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AFE Controller User`s Manual

1. PWM INVA ant lreactive 1 2 Figure 10 Interleaved AFE Controller Functional Block Diagram 2 4 State Sequencing A state machine is used to provide deterministic control and sequencing of the AFE hardware If a fault is detected in any of the operating states the hardware is placed into a safe condition and the state machine is latched into the Fault state Figure 11 illustrates the operating states as well as the transition logic employed in the system state machine Publication UM 0021 Functional Description Fault Detected Initialization Complete Fault Detected Calibrate Cal Complete Line out of Fault Reset Spec Fault Reset amp Cal Complete CEN gt Pre gt Fault Charge Detected Fault Detected ae Line out of Spec Fault Stand p Detected Alone or Fault DC Link Mode em Detected Charged Alone On Command amp Cal Not Complete Off Command Low DC Link Mode Change vol Pae mode along standalone mode from Stand Off Command Alone current mode Good DC Link Fault Current Detected Reaches Zero Fault Detected Figure 11 System State Machine 2 4 1 Initialize The state machine resets to the Initialize state following a power on reset POR event While in this state the power hardware is not operable the firmware is initializing hardwa
2. PID i Description Units Ge Min Max Se 0x8040 U16 Grid Fast Under Voltage Threshold 0 1 Vims 2400 0 65535 RW 0x8041 U16 Grid Slow Under Voltage Threshold 0 1 Vims 4224 0 65535 RW 0x8042 U16 Grid Fast Over Voltage Threshold 0 1 Vrms 5760 0 65535 RW 0x8043 U16 Grid Slow Over Voltage Threshold 0 1 Vrms 5280 0 65535 RW 0x8044 U16 Grid Fast Under Frequency Threshold 0 1 Hz 570 400 4500 RW 0x8045 U16 Grid Slow Under Frequency Threshold 0 1 Hz 593 400 4500 RW 0x8046 U16 Grid Over Frequency Threshold 0 1 Hz 605 400 4500 RW 0x8047 U16 Grid Fast Under Voltage Clear Time 1 ms 16 1 65535 RW 0x8048 U16 Grid Slow Under Voltage Clear Time 1 ms 2000 1 65535 RW 0x8049 U16 Grid Fast Over Voltage Clear Time 1 ms 16 1 65535 RW Ox804A U16 Grid Slow Over Voltage Clear Time 1 ms 1000 1 65535 RW 0x804B U16 Grid Fast Under Frequency Clear Time 1 ms 16 1 65535 RW Ox804C U16 Grid Slow Under Frequency Clear Time 1 ms 16 1 65535 RW 0x804D U16 Grid Over Frequency Clear Time 1 ms 16 1 65535 RW Ox804E U16 Grid Reconnect Delay Time 1sec 1 1 1000 RW 4 3 5 1 Grid Fast Slow Over Under Voltage Thresholds and Clear Times These parameters define the allowable grid voltage thresholds When the grid voltage exceeds a particular parameter the corresponding clear time parameter is used to define a period of time to wait prior to declaring a grid voltage fault condition The slow voltage thresholds and clear tim
3. ccccccsssscecccnssseccccsssscsccensscececcessscesceassceecocescesseeaeseeees 29 4 1 Register Properti S EE Sauesccsvaaseeds dE 29 CES WR H leng Tel EE 29 4 1 2 Data Types EE 29 4 1 2 1 Specifying Fixed Point barameters 29 41 3 Access Level cccscsistevenvcs teciinsuesctuvivcccutadovactevdsceaengduccestvasteuatsjetevenvdadeunaddeessbuvancegenddauevbevi ed 30 4 2 VIE III CT 30 4 2 1 Command Register 30 AD VA eier alogge Tu d E 30 4 2 1 2 Mode Control arrearen a a a dee 30 4 2 1 3 DC Link Voltage Setpoint rrnnarorrrnrrranannnnrrrnrnrsnannnnnnrnnnrnssnnnannnnrnnnssnsnnnnnnnnnsnnssnssnnnnnnnnn 31 4 2 1 4 Grid Current Setpoint Real 31 4 2 1 5 Grid Current Setpoint Reactive rarsrrrrrannrvenrennrrenssnsrrenssnsrrenssnsrnenssnsrnenssssrrnssssnvnenssns 31 4 2 1 6 POWER Factor Setpoint iers secede scenerne naana aeaea p ie ar N eaaa aiaa Ear ae 31 4 2 1 7 F Ult RESET srera EE A EAE ee 32 4 2 1 8 Configuration PassWord Gegse age ricer nesen eeeeasser head ateist 32 4 2 1 9 Configuration Reser 32 AFE Controller User s Manual Table of Contents tT 4 2 1 10 Configuration Reload sisses ientsiiniceisericeeskeniisescni niee cieaeinen re roia aikaani eote i anties eiei iakeas 33 4 2 1 11 Stand Alone Voltage Setpoint 33 4 2 1 12 Isolated Digital Output Control 33 4 2 2 Instrumentation Register 34 4 22 AFE Operating Ste ehetdege degkeet 34 4 2 2 2 AFE Operating MOde rrnnnnnnrnrnrnnsrannnnnnrvnnrrnsrnnnnnnnrvnns
4. 4 3 13 2 DC Link Pre charge Threshold This parameter defines the DC link voltage threshold to charge to This value is specified as a percentage of the nominal rectified voltage of the measured AC line voltage 4 3 13 3 Contactor Debounce This parameter is used to specify the debounce time for both the main grid connect contactor and the precharge contactor This field is used to delay reporting a change of state in the contactor prior to considering the change valid 4 3 13 4 Contactor Close Time This parameter is used to specify the actuation time for both the main grid connect contactor and the precharge contactor This field should be set to the longest expected delay from when the contactor is driven open closed by the software to when the contactor has mechanically changed state including all expected debounce time 4 3 13 5 Precharge Timeout Threshold This parameter specifies the maximum amount of time to wait before reporting a precharge timeout fault If the DC link has not charged to the DC Link Pre charge Threshold see above within this amount of time the AFE will transition to the FAULT state This parameter is only used if the DC Link Pre charge Enable parameter see above is set to TRUE i e the AFE is AFE Controller User s Manual Parameter Register Interface controlling the precharge function If the DC Link Pre charge Enable parameter is set to FALSE the AFE will simply wait indefinitely for the DC link vol
5. Mode Jumper 1 2 Jumper 3 4 Jumper 5 6 Jumper 7 8 RS422 TX Termination RX Termination DNP DNP RS485 Four Wire TX Termination RX Termination DNP DNP RS485 Two Wire Termination DNP Connect TX to RX Connect TX to RX AFE Controller User s Manual OZDSP3000 Hardware Interfacing iva VZ ISO1 ISO1 RS422 and RS485 Four Wire RS485 Two Wire Figure 14 P1 Isolated Serial Interface Pin out RS422 485 Configuration 3 1 11 P2 Isolated CAN Bus Interface Connector P2 provides an isolated CAN Bus communications interface The interface is a shielded female DB9 style connector Table 10 P2 CAN Bus Pin Assignment Pin Description 2 CAN Low 3 CAN Ground Isolated 7 CAN High e OZDSP3000 Connector Part Number AMP 747844 5 e Mating Connector Part Number Industry Standard DB9 Male 3 1 11 1 J18 19 CAN Termination Jumpers Jumper blocks J18 and J19 provide a means to terminate the CAN bus lines CAN high CANH and CAN low CANL Note that termination should only be placed at the end terminals of the CAN communication network reference Figure 15 Publication UM 0021 OZDSP3000 Hardware Interfacing ZY 7 MG Ssg 3 BH SE WLLL Da Figure 15 Multi Node CAN Network Configuration Standard 0 1 jumpers should be installed on both J18 and J19 to enable the termination With no jumpers installed the lines remain un terminated Refer to Figure 16 for the ap
6. 46 Parameter Register Interface 4 3 3 4 Inverter Current Measurement Polarity Select This parameter defines the polarity of the measured inverter currents A value of zero 0 indicates that current flowing from the power switches to the AC line is positive A value of one 1 indicates that current flowing from the power switches to the AC line is negative 4 3 3 5 Inverter Current Measurement Auto Calibration This parameter is used to determine whether the AFE controller should attempt to calibrate the AC current sensor offset errors at startup If enabled the AFE controller will measure the current sensor values at startup and store these as the sensor offset correction values All subsequent current measurements will be corrected by this offset amount This assumes that no current can be flowing through the IGBTs at startup i e if a main grid contactor is provided the AFE controller will remain disconnected during this calibration operation This parameter should be set to false for those systems where the IGBT currents are not guaranteed to be zero when the controller is powered on 4 3 4 Default Operating Parameters Table 16 Default Operating Parameter Summary PID Description Units are Min Max eet 0x8030 U16 Default Control Mode ENUM 0 0 2 RW 0x8031 U16 Default Voltage Setpoint O 1V 8000 0 65535 RW 0x8032 S16 Default Real Current Setpoint 0 1 Arms 0 32768 327
7. Active Front End AFE Controller User s Manual UM 0021 11 Continental Blvd Merrimack NH 03054 v 603 546 0090 f 603 386 6366 oztekcorp com Jo Buryuly ALJEAOUUJ UOLJEJUIWNAJSUJ pue About Oztek Oztek Corp is proven innovator of power control and instrumentation solutions for the most demanding industrial applications Oztek products include variable motor drives grid tie inverters frequency converters stand alone inverters DC DC converters and DSP based control boards for power control applications Trademarks OZDSP3000 is a trademark of Oztek Corp Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright Oztek AFE User s Manual O December 2010 Oztek Corp All rights reserved Exclusion for Documentation UNLESS SPECIFICALLY AGREED TO IN WRITING Oztek Corp Oztek A MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION B ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES DAMAGES COSTS OR EXPENSES WHETHER SPECIAL DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK C IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE
8. There are multiple scenarios in which the firmware may automatically program the configuration memory at startup with the factory default values First when the drive boots following a reset it attempts to read a predefined read only header stored in the EEPROM If the header does not match the expected value the memory is considered uninitialized and the firmware will automatically write the default factory configuration values into the memory This would be the case if a control board were just being loaded with the firmware and operated for the first time in which case the configuration memory wouldn t contain valid data The second scenario in which the firmware will automatically update the configuration memory occurs when the firmware has been updated on the control board and its associated configuration memory map is not compatible with the previously programmed version of the firmware The configuration memory contains two factory revision values a major and a minor revision At startup the firmware will read the major revision value and compare it against the default major revision for that particular build of the firmware If the two do not match the firmware will automatically reset the configuration memory to the factory defaults Differences in the minor revision will not cause the memory to be reset Using this factory configuration revision scheme the minor revision number is expected to change for minor changes that do not change
9. To Precharge 24VDC j j Optional ee 4 8 Hardware Control Pins Fault Reset S 24V RIN _ 7 6 24V RTN J4 sa 1 1 Vline A gd 2 4 Vine B 7 Vline C Figure 12 OZDSP3000 AFE Application Electrical Connections 3 1 1 J11 SKiiP Power Module Interface Inverter A Connector J11 provides an interface to SKiiP style Semikron power modules This interface complies with Semikron s required specifications The OZDSP3000 supplies 24V power to the power module via pins 14 and 15 PWM commands 15V logic level are supplied to the top and bottom switches of each of the three half bridges via signals INV TOP U V W and INV BOT U V W respectively Feedback of phase currents temperature and DC link voltage are provided on INV IOUT U V W INV TEMP INV_UDC signals respectively Error signals from the module are similarly provided via INV ERR U V W and INV ONT Please refer to the Semikron datasheet for the particular module being used for more information Publication UM 0021 OZDSP3000 Hardware Interfacing Table 1 J11 SKiiP Power Module Pin Assignment Pin Description 1 Ground 2 INV BOT U Phase A 3 INV ERR U Phase A 4 INV_TOP_U Phase A 5 INV_BOT_V Phase B 6 INV_ERR_V Phase B 7 INV_TOP_V Phase B 8 INV_BOT_W Phase C 9 INV_ERR_W Phase C 10 INV_TOP_W Phase C 11 INV_OVR_TEMP 12 n c 13 INV_UDC 14 24V
10. o None a Loi 3 255 Unknown Reserved for future use AFE Controller User s Manual Parameter Register Interface 4 3 17 Stand Alone Voltage Regulator Parameters Table 29 Stand Alone Voltage Regulator Parameter Summary PID se Description Units SE Min Max RE 0x8100 U16 Fundamental Controller Gain 1 250 0 65535 R W 0x8101 U16 Fundamental Controller Phase 1 Deg 20 0 65535 R W 0x8102 S16 Fundamental Controller Max 0 001 999 0 999 R W 0x8103 S16 Fundamental Controller Min 0 001 999 999 0 R W 0x8104 U16 3rd Harmonic Controller Gain 1 100 0 65535 R W 0x8105 U16 3rd Harmonic Controller Phase 1 Deg 54 0 65535 R W 0x8106 S16 3rd Harmonic Controller Max 0 001 999 0 999 R W 0x8107 S16 3rd Harmonic Controller Min 0 001 999 999 0 R W 0x8108 U16 5th Harmonic Controller Gain 1 100 0 65535 R W 0x8109 U16 5th Harmonic Controller Phase 1 Deg 80 0 65535 R W 0x810A S16 5th Harmonic Controller Max 0 001 999 0 999 R W 0x810B S16 5th Harmonic Controller Min 0 001 999 999 0 R W Ox810C U16 7th Harmonic Controller Gain 1 250 0 65535 R W Ox810D U16 7th Harmonic Controller Phase 1 Deg 112 0 65535 R W Ox810E S16 7th Harmonic Controller Max 0 001 999 0 999 R W Ox810F S16 7th Harmonic Controller Min 0 001 999 999 0 R W 0x8110 U16 Voltage Command Slew Limit 1 Vrms s 200 1 65535 R W 0x81
11. 15 24V 16 n c 17 n c 18 Ground 19 Ground 20 INV_TEMP 21 INV_IOUT_U_RTN Phase A 22 INV_IOUT_U Phase A 23 INV IOUT V RTN Phase B 24 INV IOUT V Phase B 25 INV IOUT W RTN Phase C 26 INV IOUT W Phase C e OZDSP3000 Connector Part Number AMP 499922 6 e Mating Connector Part Number AMP 1658621 6 e Power 24V 1 5A 3 1 2 Custom Driver Interface Considerations When attempting to use the OZDSP3000 AFE controller with a custom designed power stage the hardware must be designed to provide the appropriate signals expected at the J11 interface Generally some sort of custom printed circuit board will be required to interface the J11 signals to the gate drivers current sensors etc AFE Controller User s Manual OZDSP3000 Hardware Interfacing 3 1 2 1 Power The OZDSP3000 supplies 24V on J11 pins 14 amp 15 This 24Vmay be used to power the electronics on the interface board The supply is capable of providing 1 5A 3 1 2 2 Switch Commands The six switching commands are provided on pins 2 4 5 7 8 and 10 These switch command signals are driven off of the OZDSP3000 at 15V logic level using MC14504B level shifting devices 3 1 2 3 Error Inputs The OZDSP3000 expects three logic level error inputs one associated with each phase on pins 3 6 and 9 When active these inputs cause the AFE firmware to latch the system off into the Fault state Pull ups to 3 3V are provided on board and the signals are active high
12. Phase A 0 1 Arms R 0x4007 S16 Grid Current Phase B 0 1 Arms R 0x4008 S16 Grid Current Phase C 0 1 Arms R 0x4009 S16 AC Line Frequency 0 1 Hz R 0x400A S16 Power Factor 0 1 R 0x400B U16 PLL Status ENUM R 0x400C S16 Inverter A Temperature 1 DegC R 0x400D S16 Auxiliary Temperature 1 DegC R Ox400E U16 Contactor Status ENUM R Ox400F U32 Warning Status n a R 0x4010 U32 Fault Status n a R 0x4011 U16 Register Operation Status ENUM R 0x4012 U16 DSP Software Revision Major Integer R 0x4013 U16 DSP Software Revision Minor Integer R 0x4014 U16 FPGA Revision Major Integer R 0x4015 U16 FPGA Revision Minor Integer R 0x4016 U16 PCB Hardware Revision Integer R 0x4017 S16 Inverter A Current Phase A 0 1 Arms R 0x4018 S16 Inverter A Current Phase B 0 1 Arms R 0x4019 S16 Inverter A Current Phase C 0 1 Arms R 0x401A S16 Inverter B Current Phase A 0 1 Arms R 0x401B S16 Inverter B Current Phase B 0 1 Arms R 0x401C S16 Inverter B Current Phase C 0 1 Arms R 0x401D S16 Inverter B Temperature 1 DegC R Ox401E U32 Fault Status 2 n a R Ox401F U16 Isolated Digital Input Status ENUM R 4 2 2 1 AFE Operating State The present AFE operating state is enumerated as shown in the table below See section 2 2 3 for details on each of these operating states Value State o 0 Initializing Charge Wait AFE Controller User s Manual Parameter Register Interface Value State o 6 Fat o 8 Unknown i 9 JftowDcuink 4 2 2 2
13. The output of the PI block is then summed into the PWM modulator outputs effectively acting as a DC offset to the commanded Va 2 c voltage waveforms The current feedback signals la g c in the figure above are normalized relative to the full scale inverter current specified by the Inverter Current Measurement Full Scale configuration parameter PID 0x8022 The output of the PI controller is added to the PWM duty cycle commands effectively increasing or decreasing the overall PWM modulation index The Kp and Ki gain constants should be scaled appropriately based on this normalization In general these gains can be set to the same values as the main la lq current loops these parameters are provided to increase system level tuning flexibility Publication UM 0021 66 Parameter Register Interface 4 3 16 Modbus Parameters Table 28 Modbus Parameter Summary PID SC Description Units dr Min Max pe Ox80FO U16 Modbus Device Address Integer 10 1 257 RW Ox80F1 U16 Modbus Baud Rate ENUM 2 0 5 RW Ox80F2 U16 Modbus Parity ENUM 0 0 2 RW 4 3 16 1 Modbus Address This parameter defines the device address for Modbus messaging 4 3 16 2 Modbus Baud Rate The serial baud rate values are enumerated as follows The parity values are enumerated as follows o 2400bps_ S 1 4800bps o 38400 bps 57600 bps 115200 bps 6 255 Unknown Reserved for future use 4 3 16 3 Modbus Parity
14. at full load the THD is significantly lower than the typical value of 5 required by most industry standards such as IEEE 519 UL1741 and IEEE 1547 Table 31 Current Mode THD Current Level THD TDD Arms 10 8 0 0 7 20 4 9 0 8 30 4 1 1 0 40 3 4 1 1 50 3 0 1 3 60 2 7 1 4 70 2 4 1 4 80 2 2 1 5 90 2 0 1 5 100 1 8 1 5 110 1 7 1 6 120 1 5 1 5 During the period of time that the above current mode THD measurements were made the measured voltage THD from the grid when the AFE was OFF was 2 6 Figure 23 below shows the current waveform when operating the AFE at the rated current of 120ARMS Although not obvious the power factor was set to 1 0 and the phase difference between the current and voltage waveforms are due to the fact that the voltage is measured line to line AFE Controller User s Manual APPENDIX A 100kW Reference Design and Performance Data Figure 23 Current Mode Normal Operation 120A The figure below shows the turn on behavior of the AFE in current mode As the figure shows when turning on the AFE the controller firsts starts up with a OA turn on current and then increases the current to the user s defined turn on current level 60Arms in these plots The plots show the measured grid current on the output of the AFE i e on the grid side of the line filter The initial current shown on the left portion of each plot is the filter current
15. roughly 5 Arms when the inverter is off The AFE is then turned on right at the point that the current begins to increase The user can configure the desired current slew rate depending on their particular system needs This is demonstrated in the plots below with two different user configured slew rates This same slew rate is used when changing the current command on the fly while the AFE is already on ME E ECO ae ume erg DEET ERC Or GE PRE AA ede Figure 24 Current Mode Turn On Isiew 300A s left and 1200A s right Publication UM 0021 APPENDIX A 100kW Reference Design and Performance Data 7 3 Voltage Mode Performance Table 32 shows the measured THD and TDD when the AFE is operated in voltage mode and regulating the DC link Similar to the current mode performance above when operating in voltage mode at full load the THD is noticeably less than the typical requirement of 5 For the configuration tested the voltage loop tuning was optimized for the best load transient response For systems with less stringent load transient response requirements the voltage loop bandwidth can be reduced to significantly reduce the overall THD by more than 50 from the data shown in this table Table 32 Voltage Mode THD Current Level THD TDD Arms 60 7 4 3 7 80 5 7 3 8 100 4 7 3 9 120 3 7 3 7 During the period of time that the above voltage mode THD measurements were made th
16. 1 8 J25 Bias Power Input The OZDSP3000 requires 24VDC power input on terminal block J25 Note that there are two redundant connections for both 24V and 24V Return only one of each needs to be connected for the controller to operate Note that Pin 3 is used for SPI boot enable it should be left floating or connected to ground for normal Flash Boot operation Alternatively this pin can be tied to 24V to enable the on board SPI boot loader which facilitates in system firmware updates over the CAN interface at power up Table 7 J12 RS 485 Pin Assignment Pin Description 1 24 VDC 2 24 VDC 3 SPI Boot Enable 4 24V Return 5 24V Return e OZDSP3000 Connector Part Number Phoenix Contact 1733606 e Mating Connector Part Number n a terminal block style e Voltage 24V nominal 18V min 28V max e Current 4 5A maximum Inrush current while powering three SKiiP modules 3 1 9 J4 External Temperature Input Connector J4 may optionally be used by the user to connect an external temperature sensor for monitoring purposes such as a cabinet s internal ambient temperature This interface provides connections for a typical 10kQ thermistor Table 8 J4 Pin Assignment Pin Description 1 Temperature input pulled up to 3 0V through 2kQ 2 Ground 24V Return e OZDSP3000 Connector Part Number Molex Micro Fit 2 Position Header 43650 0215 e Mating Connector Part Number
17. 2 5 1 2 DC Link High Voltage The AFE firmware monitors the DC link voltage and will set a warning flag if it exceeds the DC Link Over Voltage Warning Threshold configuration parameter PID 0x8051 This flag will remain set until the voltage falls below the DC Link Over Voltage Recover Threshold configuration parameter PID 0x8052 2 5 1 3 DC Link Low Voltage The AFE firmware monitors the DC link voltage and will set a warning flag if it falls below the DC Link Under Voltage Warning Threshold configuration parameter PID 0x8112 This flag will remain set until the voltage rises above the DC Link Under Voltage Recover Threshold configuration parameter PID 0x8113 2 5 1 4 PLL Not Locked The AFE firmware monitors the status of the phase lock loop PLL module that is providing synchronization to the AC line The AFE will set a warning flag if the PLL is not locked This flag is cleared when the PLL regains lock AFE Controller User s Manual Functional Description 2 5 1 5 High Inverter Current The AFE firmware monitors the RMS inverter currents for each of the three phases and will set a flag one per phase if the current exceeds the Grid Over Current Warning Threshold configuration parameter PID 0x8054 It does this for both the main Inverter A and the secondary Inverter B if the Dual Interleaved Inverters Enable configuration parameter PID 0x80D0 is set to TRUE These flags remain set until the respective current falls below the
18. 99 RW Ox80A3 S32 Ki Phase Locked Loop Locked Q16 0 6 0 0 32767 99 RW Ox80A4 U16 PLL Output Range 200 105 10000 RW Ox80A5 U16 PLL Phase Detector Error Threshold 20 1 95 RW Ox80A6 U16 PLL Lock Indicator AC Line Count 0 01 800 1 10000 RW Ox80A7 U16 PLL Unlock Indicator AC Line Count 0 01 25 1 10000 RW Ox80A8 S16 PLL Phase Lag Adjustment 0 01 0 18000 18000 RW Ox80A9 U16 PLL Phase Error LPF Cutoff Frequency 1Hz 120 1 1000 RW Ox80AA S32 PLL Auto Gain Control Filter Constant Q16 500 0 0 0 32767 99 RW Ox80AB S32 PLL Capacitor Sensing Adjustment Q24 0 0 0 0 127 99 RW 4 3 12 1 PLL Controller Gain Constants Kp Ki Locked Unlocked These parameters define the gain constants for the PI controller that is used to regulate the phase locked loop Separate gains are provided for the cases when the PLL is unlocked and locked allowing for faster time to lock and improved performance when lock is achieved AFE Controller User s Manual Parameter Register Interface 4 3 12 2 PLL Output Range This parameter specifies the maximum output range of the PLL relative to the expected grid frequency For example a parameter value of 200 for a 60Hz system would result in a PLL dynamic range of 120Hz 4 3 12 3 PLL Phase Detector Error Threshold This parameter determines the phase error threshold used by the PLL s lock detector This parameter is specified in units of i e 20 is equivalent to a phase error of 36
19. ACCURACY OF THE TRANSLATION THE ACCURACY CANNOT BE GUARANTEED APPROVED OZTEK CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW OZTEKCORP COM Date and Revision October 2013 Rev N Part Number UM 0021 Contact Information USA Telephone 603 546 0090 Fax 603 386 6366 Email techsupport Qoztekcorp com Table of Contents SS Table of Contents Te ed E 1 1 1 Referenced Documents sessiun inssi irirna AEEA ANNES A RAA ENNE AESKA OPENEN ARRASAR 1 1 2 De PINIGIONS RE E E A dee 1 2 Functional Description eseu Eege ANEREN ee 2 2 1 Typical Hardware Implementation 4 21 1 Power Module cenar TAO AE A NEE OA EOT TOO EO 4 2 1 2 Isolation Transformer and Line Elter 4 2 1 3 Pre Ch rge e TE 4 ALA WE eege RT E ge EE 5 2 2 Description of Oper tibnseasmua eessen eegene deen hd edeggeeg en 5 2 2 1 DC Link and Current Control Modes ssssssssssssssssrssssserssserrssrsessstrrsstetsstennssrteesstennssttensstentsnt 5 222 Op r ting Mod s svake 5 2 2 3 Stand Alone Voltage Control Mode rarrrrrrnnnannnnnnrvrnnnssnnnnnnnnrvnnsrssnannnnrnrvnnssssnnnnnnrnnsnnssssnnnnnnrnnn 6 2 2 3 1 Current Overload Protection 6 2 3 Dual Interleaved Inverter Operation 8 2 4 State SEQUENCING 22 suditauns Anette tate haat teen Heat 9 242 Te TE 10 242 e TE 11 243 e 11 RENE EC 11 245 Elec eege dees eege eneren deeg eege 11 246 e EE 11 247 TUPI E EE 11 2 48 LOW DG bt 11 2 5 Fault and Warning Conditions sessies in
20. Factor Setpoint command 4 3 7 9 Total Line Filter Inductance This parameter is used to specify the total line filter inductance For the recommended LCL filter topology this parameter should be set to the sum of the inverter side and grid side inductor values 4 3 7 10 Nominal Grid Frequency This parameter is used to specify the expected nominal grid frequency This parameter is normally set to 60Hz or 50Hz depending on where the AFE is deployed 4 3 7 11 Inverter Power Stage Dead Time This parameter is used to specify the interlock dead time enforced by the inverter s power stage drivers This is the time between turning off one switch and turning on the complementary switch in the same half bridge In some systems particularly those with high PWM switching rates this hardware enforced dead time may add a small but noticeable distortion to the inverter s current waveforms The AFE controller provides a dead time compensator that adds a correction to the PWM output signals to remove these distortions For proper operation the value programmed in this register must match the actual dead time enforced by the power stage driver hardware For systems where the dead time distortion is not an issue or to otherwise disable the compensator in the AFE controller simply set this parameter to zero 4 3 7 12 Output Modulation Type This parameter determines whether the AFE controller uses space vector modulation SVM or sine wave modulation o
21. Locked Loop POR Power On Reset PWM Pulse width modulation SVM Space Vector Modulator Publication UM 0021 Functional Description 2 Functional Description An Active Front End AFE is used to transfer power between an AC power input and an intermediate DC circuit or Link It generally has the ability to transfer power in both directions operating as a rectifier when transferring power from the AC line to the DC link and as an inverter in the opposite direction AFEs provide very low current distortion THDI when compared to other front end rectifier solutions Advantages of the OzAFE solutions include e Low AC Input Harmonics The OzAFE controller provides low harmonic distortion to meet IEEE 519 at the AC line inputs e Improved Power Factor The OzAFE controller provides power factor correction resulting in unity power factor operation for energy savings and system efficiency e Voltage Boost Capability The pulse width modulated control scheme behaves as a boost regulator providing regulated DC voltages higher than the rectified AC line This isolates the load electronics from the effects of AC line voltage sags e Regenerative Capability OzAFE based applications achieve considerable savings in terms of power savings and the related costs The ability to transfer power from the DC link to the AC line provides a direct interface with regenerative loads transforming the kinetic energy of the inertial loads into
22. Note that the Illegal CAN Message and Configuration Response messages use the Group Module information from the sending device as the Destination Group Module when responding so this parameter is not used for those messages For more information see FS 0047 Publication UM 0021 A Parameter Register Interface 4 3 2 8 CAN Update Rate DC Link Status Message This parameter specifies the rate at which DC Link Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic periodic transmission of this message All other values ms 65 535ms are valid 4 3 2 9 CAN Update Rate Grid Voltage Status Message This parameter specifies the rate at which Grid Voltage Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic periodic transmission of this message All other values ms 65 535ms are valid 4 3 2 10 CAN Update Rate Inverter Current Status Message This parameter specifies the rate at which Inverter A and Inverter B Current Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic peri
23. OR CONSEQUENTIAL DAMAGES INCLUDING LOST PROFITS LOST REVENUES FAILURE TO REALIZE EXPECTED SAVINGS OR OTHER COMMERCIAL OR ECONOMIC LOSSES OF ANY KIND EVEN IF OZTEK HAS BEEN ADVISED OR HAD REASON TO KNOW OF THE POSSIBILITY OF SUCH DAMAGE b ANY LIABILITY ARISING IN TORT WHETHER OR NOT ARISING OUT OF OZTEK S NEGLIGENCE AND ALL LOSSES OR DAMAGES TO ANY PROPERTY OR FOR ANY PERSONAL INJURY OR ECONOMIC LOSS OR DAMAGE CAUSED BY THE CONNECTION OF A PRODUCT TO ANY OTHER DEVICE OR SYSTEM AND c ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT IF YOU ARE A CONSUMER RATHER THAN A PURCHASER OF THE PRODUCT IN THE COURSE OF A BUSINESS AND PURCHASED THE PRODUCT IN A MEMBER STATE OF THE EUROPEAN UNION THIS LIMITED WARRANTY SHALL BE SUBJECT TO YOUR STATUTORY RIGHTS AS A CONSUMER UNDER THE EUROPEAN UNION PRODUCT WARRANTY DIRECTIVE 1999 44 EC AND AS SUCH DIRECTIVE HAS BEEN IMPLEMENTED IN THE EUROPEAN UNION MEMBER STATE WHERE YOU PURCHASED THE PRODUCT FURTHER WHILE THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY FROM EU MEMBER STATE TO EU MEMBER STATE OR IF YOU DID NOT PURCHASE THE PRODUCT IN AN EU MEMBER STATE IN THE COUNTRY YOU PURCHASED THE PRODUCT WHICH MAY VARY FROM COUNTRY TO COUNTRY AND JURISDICTION TO JURISDICTION Publication UM 0021 80 Warranty and Return Return Material Authorization Policy Before retur
24. Register Interface 4 2 2 10 Auxiliary Temperature This register reports the measured auxiliary temperature input if enabled see section 4 3 9 This register will return zero when an external temperature sensor is not used 4 2 2 11 Contactor Status The Pre charge and AC Line contactors open closed status bits are mapped as follows pn AC Line Contactor 0 Open 1 Closed Pre Charge Contactor 0 Open 1 Closed Reserved for future use 4 2 2 12 Warning Status Warning bits are active when set to 1 and not present when set to 0 See section 2 4 7 for details on each warning The warning bits are mapped into the register as follows Bit Warning 0 6 Reseved 8 Inverter A High Temperature 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 27 28 29 30 4 2 2 13 Fault Status Fault bits are active when set to a 1 and not present when set to a 0 If a fault occurs the corresponding bit is set to a 1 and remains set until a 1 is written to the Fault Reset command register PID 0x0006 When a fault occurs the controller will go to the FAULT state and the AFE will stop operating The controller will stay in the FAULT state until the Fault Reset command is received See section 2 4 7 for details on each fault condition The fault bits are mapped as follows AFE Controller User s Manual Parameter Register Interface Bit Faut o 0 Inverter A
25. condition 4 3 6 14 Inverter Over Temp Pin Active High This parameter determines the polarity of the hardware over temperature input pin from the power module interface INV OVR TEMP listed in section 3 1 1 When this parameter is set to TRUE the input pin is treated as active high meaning a high input is considered a fault condition 4 3 6 15 DC Link Under Voltage Fault Threshold This parameter defines the DC link under voltage fault threshold If the DC link voltage falls below this value while operating in Stand Alone voltage source mode the application will automatically transition to the FAULT state and operation of the inverter will be disabled and forced OFF 4 3 6 16 DC Link Under Voltage Warning Threshold This parameter defines the DC link voltage threshold below which the firmware will report a low voltage warning Once below this warning threshold the voltage must rise above the corresponding recover threshold before the firmware will clear the low voltage warning 4 3 6 17 DC Link Under Voltage Recover Threshold See warning threshold description above Publication UM 0021 Parameter Register Interface 4 3 7 Converter Control Parameters Table 19 Converter Control Parameter Summary PID Se Description Units Goen Min Max PE NA 0x8060 U16 Pulse Width Modulation Frequency 1Hz 10 kHz 1kHz 25 kHz RW 0x8061 U16 Pulse Width Modulation Deadband Enable Boolean
26. cutoff frequency for the digital low pass filter used to calculate the RMS grid phase currents 4 3 14 6 Low Pass Cutoff Freq Grid Frequency This parameter defines the cutoff frequency for the digital low pass filter used to calculate the grid frequency 4 3 14 7 Low Pass Cutoff Freq Temperatures This parameter defines the cutoff frequency for the digital low pass filter used to calculate the inverter and auxiliary temperatures 4 3 14 8 Low Pass Cutoff Freq Grid Voltage Feedforward This parameter defines the cutoff frequency for the digital low pass filter used on the measured grid voltage used in the feed forward path on the output of the current controller 4 3 15 Dual Interleaved Inverter Parameters Table 27 Instrumentation Parameter Summary PID ae Description Units Gear Min Max E Ox80D0 U16 Dual Interleaved Inverter Enable Boolean FALSE FALSE TRUE RW Ox80D1 U16 Zero Sequence Current Control Enable ENUM 0 0 3 RW 0x80D2 32 Kp Zero Sequence Current Controller Q16 1 5 0 0 32767 99 RW Ox80D3 32 Ki Zero Sequence Current Controller Q16 0 6 0 0 32767 99 RW 4 3 15 1 Dual Interleaved Inverter Enable When set to TRUE this parameter enables controls for a second inverter in parallel with the main inverter for use in a dual inverter interleaved power stage When set to FALSE the AFE controller will only drive one inverter interface and all other parameters in
27. electrical energy This eliminates the need for braking resistors and saves the wasted energy instead returning it to the line to be used by other equipment e Stand Alone Voltage Mode Capability The OzAFE controller also provides the ability to operate the converter in Stand Alone Voltage Mode In this mode the inverter can be configured to produce a controlled AC output voltage This is useful in grid tie applications that require the converter to be able to produce standby power when the utility is down ATTENTION While the AFE can be used for voltage boost it cannot be used to lower the DC link voltage The minimum DC link voltage is limited by the rectified AC line voltage AFE Controller User s Manual Functional Description Typical AFE applications include renewable energy systems as well as power systems with high inertial loads such as centrifuges test benches rolling systems high power servo systems mixers etc Figure 2 Typical Regenerative Motor Drive Application Switch Gear Loads ES Figure 3 Typical Turbo Alternator Application with Stand Alone Voltage Mode Capability Publication UM 0021 SS Functional Description 2 1 Typical Hardware Implementation Figure 4 illustrates a typical AFE electrical system implementation While component values will vary from appli
28. fall below the corresponding recover threshold before the firmware will clear the high temperature warning AFE Controller User s Manual Parameter Register Interface 4 3 6 9 Inverter Temperature Recover Threshold See warning threshold description above 4 3 6 10 Auxiliary Temperature Fault Threshold This parameter defines the auxiliary temperature fault threshold If the Auxiliary Temperature Sensor Enable configuration parameter PID 0x8078 is set to TRUE and the temperature rises above this value the converter will automatically transition to the FAULT state and operation of the application will be disabled and forced OFF 4 3 6 11 Auxiliary Temperature Warning Threshold This parameter defines the auxiliary temperature threshold above which the firmware will report a high temperature warning if the Auxiliary Temperature Sensor Enable configuration parameter is set to TRUE Once above this warning threshold the temperature must fall below the corresponding recover threshold before the firmware will clear the high temperature warning 4 3 6 12 Auxiliary Temperature Recover Threshold See warning threshold description above 4 3 6 13 Inverter Error Pin Active High This parameter determines the polarity of the hardware error input pins from the power module interface INV ERR U V W listed in section 3 1 1 When this parameter is set to TRUE the input pins are treated as active high meaning a high input is considered a fault
29. if repairs have been done to it other than by Oztek or its authorized service centers hereafter ASCs d The product if it is used as a component part of a product expressly warranted by another manufacturer e The product if its original identification trade mark serial number markings have been defaced altered or removed f The product if it is located outside of the country where it was purchased g Any consequential losses that are attributable to the product losing power whether by product malfunction installation error or misuse Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY OZTEK IN CONNECTION WITH YOUR OZTEK PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTATIONS OBLIGATIONS AND LIABILITIES EXPRESS OR IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGLIGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY IN NO EVENT WILL OZTEK BE LIABLE FOR a ANY SPECIAL INDIRECT INCIDENTAL
30. it will transition back to the Idle state If the mode is changed from stand alone to grid tie operation the state machine will transition back to the Precharge to wait for a valid AC line and to perform DC link precharge if necessary 2 5 Fault and Warning Conditions The AFE provides warning indicators and fault protection in the event of conditions that may cause damage to the equipment or injure personnel The various conditions that are monitored by the AFE are listed and described in the following sections 2 5 1 Warnings The AFE provides the warning indicators listed below These warning conditions do not prohibit operation of the AFE they are merely reported for informational purposes only Each warning condition described below is reported in the Warning Status instrumentation register PID 0x400F and also reported on the CAN bus in the Alarm Status CAN message 2 5 1 1 Inverter High Temperature The AFE firmware monitors the main Inverter A temperature and will set a warning flag if it exceeds the Inverter Temperature Warning Threshold configuration parameter PID 0x8057 If the Dual Interleaved Inverters Enable configuration parameter PID 0x80D0 is set to TRUE the AFE firmware will also monitor the secondary Inverter B temperature and compare this to the same warning threshold value These flags will remain set until the temperature s falls below the Inverter Temperature Recover Threshold configuration parameter PID 0x8058
31. sent back to the factory for diagnosing and repairing of any defects see the RMA process described at the end of this document 2 5 2 9 Software Inverter Over Temperature The AFE monitors the main Inverter A temperature and will assert a fault if it exceeds the Inverter Temperature Fault Threshold configuration parameter PID 0x8056 If the Dual Interleaved Inverters Enable configuration parameter PID 0x80D0 is set to TRUE the AFE firmware will also monitor the temperature from the secondary Inverter B interface and check this against the same fault threshold value 2 5 2 10 Software DC Link Over Voltage The AFE firmware monitors the DC link voltage and will assert a fault if it exceeds the DC Link Over Voltage Fault Threshold configuration parameter PID 0x8050 2 5 2 11 Software DC Link Under Voltage The AFE firmware monitors the DC link voltage and will assert a fault if it drops below the DC Link Under Voltage Fault Threshold configuration parameter PID 0x8011 while it is ON and operating in Stand Alone voltage mode Publication UM 0021 OZDSP3000 Hardware Interfacing 2 5 2 12 PLL Lost Lock The AFE firmware monitors the status of the phase lock loop PLL module that is providing synchronization to the AC line A fault is asserted if the AFE is in the ON state the PLL loses lock This fault only occurs when the AFE is ON or if an attempt is made to turn the AFE ON when the PLL is not locked 2 5 2 13 Software Inverter O
32. the corresponding supply voltage is not within the range required by the on board hardware The various warning flags will remain set while the supply voltages are out of tolerance and will be cleared when the supply is found to be within the required limits 2 5 2 Faults The AFE provides the fault protection listed below Whenever a fault occurs the AFE will automatically turn the converter OFF open the main line contactor and transition to the FAULT state Each fault condition is latched and reported in the Fault Status instrumentation register PID 0x4010 and also reported on the CAN bus in the Alarm Status CAN message The controller remains in the FAULT state and the latched fault flags remain set until explicitly reset with a Fault Reset command PID 0x0006 This is true even if the source s of the fault s are no longer active Upon receiving the Fault Reset command the AFE will attempt to clear all latched fault bits It then examines the sources of all fault conditions and if none are active the Publication UM 0021 Functional Description AFE controller will transition to the Precharge state and attempt to reconnect to the grid If upon re examination any sources of faults are still active their respective fault flags are latched again and the AFE will remain in the FAULT state The AFE may be optionally configured to automatically recover from grid voltage and frequency faults and turn back ON if previously enabled as descri
33. 0 x 0 2 or 72 4 3 12 4 PLL Lock Indicator AC Line Count This parameter defines the number of AC line cycles that the phase error needs to be less than the error threshold before the PLL will indicate that it is locked 4 3 12 5 PLL Unlock Indicator AC Line Count This parameter defines the number of AC line cycles that the phase error needs to be greater than the error threshold before the PLL will indicate that it is no longer locked 4 3 12 6 PLL Phase Lag Adjustment This parameter is used to compensate for any phase delay in the AFE system between the point in which the grid voltage is sampled and the output current is injected into the grid 4 3 12 7 PLL Phase Error LPF Cutoff Frequency This parameter sets the cutoff frequency for the low pass digital filter used within the PLL to filter the calculated phase error 4 3 12 8 PLL Auto Gain Control Filter Constant This parameter defines the filter constant for the tracking filter used in the PLL s auto gain control front end The auto gain control block is used by the PLL to normalize the line sense input prior to being used by the phase detect logic 4 3 12 9 PLL Capacitor Sensing Adjustment This parameter defines an adjustment to the PLL output angle as a function of output current It can be used to null out the phase error that occurs as a function of load when line sensing is performed at the capacitors rather than the grid when using an LCL filter configuration Note t
34. 0VAC Grid EJ DC Precharge Relay Driv Line Interface Relay Drive 24V DC Precharge RelayStatus Line Interface Relay Status Control Board CAN Line Voltaae Phase A Line Voltaae Phase B Line Voltage Phase C Figure 9 Typical Interleaved AFE Electrical System Schematic From a control perspective when operating in dual interleaved inverter mode the OzAFE controller uses the same control scheme as with a single inverter with the addition of a second current controller and PWM modulator The commanded current is generated the same as the single inverter mode and is then divided by two and sent to each of the two internal current controllers With this scheme each inverter is handling 50 of the overall load The PWM pulses on the second inverter use the exact same frequency as the main inverter but are phase shifted by 180 degrees to achieve the desired current ripple cancellation benefit provided by the interleaved system Additionally to prevent a circulating DC current from developing between the two inverters the controller also uses a PI compensator to regulate the DC current to zero in each inverter This interleaved control scheme is illustrated in the following figure AFE Controller User s Manual Functional Description Fess Current Controller B Vret ee lactive F Vac ar EI x i A SVM PWM ie Mi iLabe B vabe A Voltage Controller
35. 0kbps 50kbps 1Mbps RW 0x8015 U16 CAN Status Destination Group ID Integer 1 0 15 RW 0x8016 U16 CAN Status Destination Module ID Integer 1 0 31 RW 0x8017 U16 CAN Update Rate DC Link Status 1ms 100 0 65535 RW 0x8018 U16 CAN Update Rate Grid Voltage Status 1 ms 100 0 65535 RW 0x8019 U16 CAN Update Rate Inverter Current Status 1 ms 100 0 65535 RW Ox801A U16 CAN Update Rate Grid Status 1ms 100 0 65535 RW 0x801B U16 CAN Update Rate System Status 1ms 100 0 65535 RW Ox801C U16 CAN Update Rate Alarm Status 1ms 100 0 65 535 RW Ox801D U16 CAN Broadcast Message Receive Enable ENUM 0 0 3 RW Ox801E U16 CAN Update Rate Alarm2 Status 1ms 100 0 65535 RW 4 3 2 1 CAN Automatic Alarm Transmit Enable This is a Boolean parameter that is used to enable automatic transmission of the Alarm Status message upon a change of value of any warning or fault bit Note that when enabled parameter is set to true the checks for whether or not an automatic transmission should be sent occur on 1ms boundaries so there may be up to 1ms of latency between when the offending event occurs and when the Alarm message is sent When disabled parameter is set AFE Controller User s Manual Parameter Register Interface to false a change in any warning or fault bit does not cause an automatic transmission of the Alarm Status message 4 3 2 2 CAN Timeout This parameter specifies the timeout period to use when
36. 0x8070 S32 Inverter Temperature Coefficient CO Q16 18 515 32768 32767 RW 0x8071 S32 Inverter Temperature Coefficient C1 Q16 119 94 32768 32767 RW 0x8072 S32 Inverter Temperature Coefficient C2 Q16 27 232 32768 32767 RW 0x8073 S32 Inverter Temperature Coefficient C3 Q16 5 9997 32768 32767 RW 4 3 8 1 Inverter Temp Coefficients CO through C3 These parameters define the coefficients used by the 3 order polynomial fitting routine within the firmware to convert raw ADC readings to degrees C The temperature is calculated using the normalized ADC measurements values in the range of 0 to 1 corresponding to the 12 bit ADC input range of 0x000 to OxFFF and the coefficient parameters as follows Temperature C3 X C2 X C1 X CO Where X is the normalized ADC reading in the range of 0 1 CO C3 are the coefficient parameters The factory default values for these coefficients are based on the temperature sensors contained within a typical Semikron SKiiP power module When non SKiiP based temperature sensing is employed it is left up to the user to generate these coefficients for the specific sensor s temperature to voltage transfer function As was previously mentioned the inverter temperature input to the control board is expected to be a 0 to 10V signal see section 3 1 2 8 The temperature transfer function can be derived using a common tool like Microsoft Excel in Publication UM 0021 Parameter Register
37. 1 65535 RW 0x8112 U16 DC Link Under Voltage Warning Threshold 0 1V 6000 1 65535 RW 0x8113 U16 DC Link Under Voltage Recover Threshold 0 1V 6100 1 65535 RW 4 3 6 1 DC Link Over Voltage Fault Threshold This parameter defines the DC link over voltage fault threshold If the DC link voltage rises above this value the application will automatically transition to the FAULT state and operation of the inverter will be disabled and forced OFF Publication UM 0021 Parameter Register Interface 4 3 6 2 DC Link Over Voltage Warning Threshold This parameter defines the DC link voltage threshold above which the firmware will report a high voltage warning Once above this warning threshold the voltage must drop below the corresponding recover threshold before the firmware will clear the high voltage warning 4 3 6 3 DC Link Over Voltage Recover Threshold See warning threshold description above 4 3 6 4 Grid Over Current Fault Threshold This parameter defines the grid over current fault threshold If the current rises above this value the converter will automatically transition to the FAULT state and operation of the application will be disabled and forced OFF For dual interleaved inverter operation this value is divided in half and used by each inverter s current controller If either inverter exceeds 50 of the value stored in this register the controller will transition to the FAULT state The inverter over curren
38. 14 S32 Hi Pass Filter Coefficient AO Q24 1 0 0 127 99 R W 0x8115 S32 Hi Pass Filter Coefficient A1 Q24 1 9888 0 127 99 R W 0x8116 S32 Hi Pass Filter Coefficient A2 Q24 0 988954 0 127 99 R W 0x8117 S32 Hi Pass Filter Coefficient BO Q24 1 0 0 127 99 R W 0x8118 S32 Hi Pass Filter Coefficient B1 Q24 2 0 0 127 99 R W 0x8119 S32 Hi Pass Filter Coefficient B2 Q24 1 0 0 127 99 R W 4 3 17 1 Voltage Resonant Controller Gain amp Phase Constants These parameters define the gain and phase corrections for the resonant controller used to regulate the output voltage The resonant controller is comprised of a Fundamental controller as well as 3 5 and 7 harmonic controllers Figure 22 provides a block diagram of the Resonant Controller architecture Publication UM 0021 6g Parameter Register Interface High Pass Filter Viet Fundamental Resonant Controller DC Link Feedforward 3 Harmonic Resonant Control Vieedback 5 Harmonic Resonant Control 7th Harmonic Resonant Control Figure 22 Resonant Controller 4 3 17 2 Voltage Command Slew Limit This parameter defines the slew rate to use when operating in voltage control mode and the commanded output voltage is changed This slew rate is used both at initial turn on when the output voltage is changed from the present value to the programmed set point or when the programmed set point is changed aft
39. 67 RW 0x8033 S16 Default Reactive Current Setpoint 0 1 Arms 0 32768 32767 RW 0x8034 16 Voltage Mode Current Limit Max 0 1 Arms 2500 0 32767 RW 0x8035 16 Voltage Mode Current Limit Min 0 1 Arms 2500 32768 0 RW 0x8036 S16 Default Power Factor Setpoint 0 1 1000 1000 1000 RW 0x8037 U16 Default Stand Alone Voltage Setpoint 0 1 Vrms 4800 0 65535 RW 4 3 4 1 Default Control Mode This parameter defines the default power on control mode for the converter The legal values are as follows e 0 DC Link Voltage Control Mode e 1 Grid Current Control Mode e 2 Standalone AC Output Voltage Control Mode 4 3 4 2 Default Voltage Setpoint This parameter defines the default voltage set point to use when turning on in output voltage control mode following a power on reset POR of the control board This value is used if the DC Link Voltage Setpoint command PID 0x0002 has not been issued following a power on reset of the control board Writing the DC Link Voltage Setpoint command register with a legal value will override the default value stored in this register AFE Controller User s Manual Parameter Register Interface 4 3 4 3 Default Real Current Setpoint This parameter defines the default real output current set point to use when turning on in output current control mode Once ON the real current set point can be modified by writing to the Grid Current Setpoint Real command register PID 0x0003 4 3 4 4 Default
40. AFE Operating Mode The present AFE operating mode is enumerated as follows Value Tase pn DC Link Voltage Regulation Current Regulation Stand Alone Mode 2 255 Reserved for future use 4 2 2 3 DC Link Voltage This register reports the measured voltage on the DC link 4 2 2 4 AC Line Voltage These registers report the three measured RMS phase to phase voltages 4 2 2 5 Grid Current These registers report the three RMS AC grid currents The currents are the sum of all enabled inverter currents If single inverter operation is enabled these registers will report the current from the main inverter A If dual interleaved inverter operation is enabled these registers will report the sum of the currents from both inverter A and inverter B Note that the sensors used to measure the AC currents are located on the inverter side of the grid interface filter i e between the power switches and the output filter 4 2 2 6 AC Line Frequency This register reports the measured line frequency 4 2 2 7 Power Factor This register reports the measured power factor Note that the power factor is calculated using the inverter side current sensors 4 2 2 8 PLL Status The PLL status is enumerated as follows oOo Lock status 0 not locked 1 locked Reserved for future use 4 2 2 9 Inverter A Temperature This register reports the measured temperature reported by the main Inverter A power module Publication UM 0021 Parameter
41. Controller User s Manual Parameter Register Interface expected to change for any revision of the converter firmware At startup the firmware attempts to read this value and if it does not match the expected value the firmware assumes the configuration memory does not contain valid configuration data i e not previously programmed If this is the case the firmware will automatically reset the contents of the configuration memory to the factory defaults 4 3 1 2 Factory Configuration Revision Major This is a read only value that represents the major revision of the factory configuration stored in the configuration memory Major revision changes to the default factory configuration are those that are not compatible with previous configurations such as when new parameters are added to the memory that are required for proper converter operation or if existing parameters change locations or formats At startup the firmware will read this value from the memory and compare it against the factory default for the present build of the firmware If the two values do not match the firmware will automatically reset the memory to the factory default values Updates to the major factory revision value are expected to increment the previous value by 1 4 3 1 3 Factory Configuration Revision Minor This is a read only value that represents the minor revision of the factory configuration stored in the configuration memory Minor revisions are those t
42. Depending on the features provided in the custom design these signals can be used to interface single error sources multiple protection circuits or none at all The custom interface board should drive the pin with an open collector style circuit In the case where no protection is provided the pins should be grounded to disable the faults 3 1 2 4 DC Link Voltage Sensing The OZDSP3000 expects a signal proportional to DC link voltage to be provided on J11 pin 13 with respect to pins 18 and 19 This signal should be scaled such that 0 10 V represents the measurable DC link voltage range 3 1 2 5 DC Link Hardware Over Voltage Protection When designing a custom interface it is highly recommended that hardware over voltage protection be implemented This can be implemented with a comparator using the DC link voltage sense output The output of this comparator can be used to gate off the switch commands as well as assert the Error inputs on each phase 3 1 2 6 Hardware Over Current and Desaturation Protection Semikron SKiiP power modules provide fast hardware over current and desaturation protection When designing a custom power solution these additional protection features should also be considered When including over current desaturation and over voltage protection into the design the fault flags must be logically OR d together and reported using the open collector Error signal inputs to the OZDSP3000 3 1 2 7 Current Sense Signals
43. F This parameter is only used if the Pulse Width Modulation Deadband Enable parameter PID 0x8061 is set to TRUE 4 3 7 4 Pulse Width Modulation Max Min Duty Cycle These parameters specify the minimum and maximum duty cycles allowed on the PWM outputs to the power switches The AFE controller will clamp the PWM pulses to these values preventing any pulses narrower than the minimum specified value or greater than the maximum specified value These parameters can be used to guarantee minimum pulse widths if required by the power switches The dead band time either enforced by the power module hardware or by the AFE software parameter should be taken into account when setting these parameters AFE Controller User s Manual Parameter Register Interface The duty cycle is encoded such that 1 0 is equivalent to 0 duty cycle 0 0 is equivalent to 50 duty cycle and 1 0 is equivalent to 100 duty cycle For example setting the max duty cycle parameter to 0 95 would be equivalent to clamping the duty cycle to be no greater than 97 5 4 3 7 5 Pulse Width Modulation Action This parameter determines whether the AFE controller is controlling and modulating the PWM A or PWM B output signal as follows e 0 Modulate channel A set channel B to the complement of A e 1 Modulate channel B set channel A to the complement of B The AFE application uses active high PWM outputs As such when the inverter is off all PWM output pins are held low
44. Grid Over Current Recover Threshold configuration parameter PID 0x8055 2 5 1 6 Grid Frequency Out of Tolerance The AFE monitors the AC line and will set a warning flag if the frequency is not within the tolerances described in section 4 3 5 2 This is considered a warning condition only if the AFE is presently not ON The warning flag will be cleared once the grid frequency is within the required limits 2 5 1 7 Grid Voltage Out of Tolerance The AFE firmware monitors the three RMS Phase to Phase Voltages of the utility grid It will set a warning flag one per phase to phase voltage if the voltage is not within the tolerances described in section 4 3 5 1 This is considered a warning condition only if the AFE is presently not ON The warning flags are cleared once the associated voltage is within the required limits 2 5 1 8 Auxiliary High Temperature If the Auxiliary Temperature Sensor Enable parameter PID 0x8078 is set to TRUE the AFE firmware will monitor the external temperature sensor and will set a warning flag if the temperature exceeds the Auxiliary Temperature Warning Threshold configuration parameter PID Ox805A This flag will remain set until the temperature falls below the Auxiliary Temperature Recover Threshold configuration parameter PID 0x805B 2 5 1 9 Local Bias Supply Tolerance Warnings The AFE firmware monitors the local bias supplies 24V 15V 5V 3 3V and 15V on the control board and will set a warning flag if
45. Hardware Over Temperature 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 4 2 2 14 Register Operation Status This register is updated after every parameter read or write operation and indicates whether the operation was completed successfully The status is enumerated as follows Value State s o Operation completed successfully LL Error Illegal unsupported Parameter ID was supplied by the user 2 Error A write was attempted to a Read Only Parameter _ 3 Error A read was attempted from a Write Only Parameter 4 Error User provided data is not within legal rang 5 Error Configuration Memory Hardware Error 6 Error Configuration Memory CRC Mismatch _ 8 Error Operation not allowed when the AFE is ON Publication UM 0021 Parameter Register Interface 4 2 2 15 DSP Software Revision Major Minor These values represent the major and minor revisions of the DSP Software stored in FLASH and actively running 4 2 2 16 FPGA Firmware Revision Major Minor These values represent the major and minor revisions of the FPGA on the DSP control board 4 2 2 17 Board Hardware Revision This value represents the hardware revision of the DSP control board running the application 4 2 2 18 Inverter A B Current These registers report the three measured RMS AC currents as reported by each inverter interface For single inverter operation the Inverter A currents will matc
46. Interface which the temperature vs voltage data from the device s datasheet are entered any scaling performed based on the analog signal conditioning prior to the control board connection and then normalizing the resulting voltage by diving by the 10V input range The resulting ADC to temperature curve can be plotted and a 3 order polynomial trend line can be generated to match the curve 4 3 9 Auxiliary Temperature Monitor Parameters Table 21 Auxiliary Temperature Parameter Summary PID SE Description Units Jr Min Max an 0x8078 U16 Auxiliary Temperature Sensor Enable Boolean FALSE FALSE TRUE RW 0x8079 S32 Auxiliary Temperature Coefficient CO Q16 0 32768 32767 RW Ox807A S32 Auxiliary Temperature Coefficient C1 Q16 0 32768 32767 RW 0x807B S32 Auxiliary Temperature Coefficient C2 Q16 0 32768 32767 RW Ox807C S32 Auxiliary Temperature Coefficient C3 Q16 0 32768 32767 RW 4 3 9 1 Auxiliary Temperature Sensor Enable This Boolean parameter is used to determine if the AFE should monitor an external temperature sensor provided by the user see section 3 1 9 for connection details This parameter should be set to FALSE if an external temperature sensor is not used When set to TRUE the temperature is calculated according to the user provided temperature coefficients see next section and is also monitored for possible over temperature conditions according to the A
47. MS Overload Trip Time msec 3300 1 3600000 R W 4 3 18 1 Rated RMS Current This parameter is the maximum continuous output current rating of the inverter 4 3 18 2 I T Trip Time This parameter defines the time for which the inverter should operate with a 110 overload condition For more detailed information please reference Section 2 2 3 1 Current Overload Protection 4 3 18 3 10 100 RMS Overload Trip Times These parameters define the times for which the inverter should operate with 10 to 100 overload conditions For more detailed information please reference Section 2 2 3 1 Current Overload Protection Publication UM 0021 Oztek PCC Tool 5 Oztek PCC Tool The Oztek Power Control Center PCC is a Microsoft Windows based Graphical User Interface GUI that provides the user a simple graphical interface for interacting with Oztek s embedded Power Control products The PCC provides the ability to control monitor and configure the AFE For detailed information and operating instructions please refer to UM 0036 Power Control Center GUI User s Manual 6 Maintenance and Upgrade The firmware image on the OZDSP3000 can be upgraded in system using the resident CAN bootloader For detailed information on how to upgrade the firmware or directly interface with the bootloader please reference UM 0015 Oztek TMS28x CAN Bootloader Users Manual AFE Controller User s Manual APPENDIX A 100kW Reference Design and Performan
48. Molex Micro Fit 2 Position Receptacle 43645 0200 Publication UM 0021 OZDSP3000 Hardware Interfacing 3 1 10 P1 Isolated Serial Interface Connector P1 provides an isolated configurable serial communications interface Depending on the population variant of the OZDSP3000 this port may be configured one of two ways RS232 mode or RS422 485 mode e OZDSP3000 Connector Part Number AMP 747844 5 e Mating Connector Part Number Industry Standard DB9 Male 3 1 10 1 RS232 Configuration When supplied in the RS232 configuration the RS232 transceiver device U22 will be populated while the RS422 485 transceiver device U42 will be unpopulated In RS232 mode all jumpers should be removed from jumper block J15 Figure 13 illustrates the pin out of the connector in the RS232 configuration 51 2 ell A ATI 8 as RS232_RXD RS232_TXD La ONN ISO1 ISO1 Figure 13 P1 Isolated Serial Interface Pin out RS232 Configuration 3 1 10 2 RS422 485 Configuration When supplied in the RS422 485 configuration the RS422 485 transceiver device U38 will be populated while the RS232 transceiver device U18 will be unpopulated In RS422 485 mode jumper block J15 is used to select between the two protocols and configure termination if desired as detailed in Table 9 Figure 14 illustrates the pin out of the connector in the RS422 485 configuration Table 9 J15 RS422 485 Configuration Jumper Settings
49. Reactive Current Setpoint This parameter defines the default reactive output current set point to use when turning on in output current control mode Once ON the reactive current set point can be modified by writing to the Grid Current Setpoint Reactive command register PID 0x0004 Explicit reactive current set point control is only supported when the Use Power Factor Setpoint configuration parameter PID 0x8068 is set to FALSE When the Use Power Factor Setpoint configuration parameter is set to TRUE the reactive current is controlled based on the real current command and the commanded power factor 4 3 4 5 Voltage Mode Current Limit Max This parameter defines the maximum current commanded by the voltage regulator when in voltage control mode 4 3 4 6 Voltage Mode Current Limit Min This parameter defines the minimum current commanded by the voltage regulator when in voltage control mode 4 3 4 7 Default Power Factor Setpoint This parameter defines the default power factor set point to use when turning on in output voltage control mode following a power on reset POR of the control board This parameter is also optionally used in current control mode following a power on reset POR if the Use Power Factor Set Point parameter PID 0x8068 is set to TRUE This value is used if the Power Factor Setpoint command PID 0x0005 has not been issued following a power on reset of the control board Writing the Power Factor Setpoint com
50. TRUE FALSE TRUE RW 0x8062 U16 Pulse Width Modulation Deadband Time 1ns 1000 0 65535 RW 0x8063 32 Pulse Width Modulation Max Duty Cycle Q16 0 95 0 0 9999 RW 0x8064 32 Pulse Width Modulation Min Duty Cycle Q16 0 95 1 0 RW 0x8065 U16 Pulse Width Modulation Action ENUM 0 0 1 RW 0x8066 U16 Grid Voltage Line Sensing Select ENUM 0 0 1 RW 0x8067 U16 Automatic Grid Fault Recovery Boolean FALSE FALSE TRUE RW 0x8068 U16 Use Power Factor Setpoint Boolean FALSE FALSE TRUE RW 0x8069 U32 Total Line Filter Inductance 1nH 0 0 1E 09 RW Ox806A U16 Nominal Grid Frequency 1 Hz 60 30 500 RW 0x806B U16 Inverter Power Stage Dead Time 1ns 0 0 65535 RW Ox806C U16 Output Modulation Type ENUM 0 0 1 RW 0x806D U16 Hardware On Off Pin Control Boolean FALSE FALSE TRUE RW 4 3 7 1 Pulse Width Modulation Frequency This parameter defines the frequency at which the control ISR will be executed This parameter also sets the PWM switching rate for the AFE application 4 3 7 2 Pulse Width Modulation Deadband Enable This parameter enables software deadband for the inverter half bridges The deadband is implemented as a turn on delay when turning on the power device after having just turned off its complement 4 3 7 3 Pulse Width Modulation Deadband Time This parameter defines the amount of dead band time to use between switching the complementary top and bottom switches in the half bridges i e the time that both PWM outputs are OF
51. The OZDSP3000 expects to receive a current sense signal for each half bridge phase output This should be a bipolar signal where 10V corresponds to the full scale current range The current sense signals should be provided on the following pins Publication UM 0021 OZDSP3000 Hardware Interfacing Table 2 J11 Current Sense Pin Assignment J11 Pin Description 22 Current Phase A U 21 Gnd Reference for Current Phase A U 24 Current Phase B V 23 Gnd Reference for Current Phase B V 26 Current Phase C W 25 Gnd Reference for Current Phase C W 3 1 2 8 Temperature Sense Signals The OZDSP3000 expects to receive a 0 10V temperature signal on pin 20 that corresponds to the hot spot temperature of the power devices 3 1 3 J13 SKiiP Power Module Interface Inverter B optional Connector J13 provides a second interface to SKiiP style Semikron power modules This interface is identical to the J11 interface described in the previous section This is an optional interface that is only used if the OZDSP3000 AFE controller is configured to drive a dual interleaved inverter power stage if the Dual Interleaved Inverters Enable configuration parameter PID Ox80D0 is set to TRUE When this second inverter interface is enabled all of the J13 signals are used with the exception of the DC link voltage sense input INV_UDC pin 13 For dual interleaved inverter operation both inverters must be tied to th
52. When the inverter wants to connect a particular switch it will drive the corresponding PWM output pin high For typical applications PWM output channel A is used to drive the top switch in a dual switch IGBT and likewise channel B is used to drive the bottom switch For this configuration the user would set this parameter to 0 If the user s system application is wired such that PWM output channel A drives the lower switch in a dual switch IGBT then this parameter should be set to 1 to indicate to the controller that output channel B is tied to the top switch 4 3 7 6 Grid Voltage Line Sensing Select This parameter determines whether the AFE controller hardware is configured to measure the Line to Neutral grid voltage or the Line to Line grid voltage as follows e 0 Line to Neutral Grid Sense e 1 Line to Line Grid Sense 4 3 7 7 Automatic Grid Fault Recovery This parameter determines how the AFE will respond to grid voltage and frequency faults while operating in the ON state If the inverter is ON and any grid voltage or frequency fault occurs the AFE controller will transition to the FAULT state and force the inverter OFF If this parameter is set to TRUE once the grid voltage and frequency have been within tolerance for the period specified by the Grid Reconnect Delay Time configuration parameter PID Ox804E the controller will automatically clear the associated grid fault bits and transition back into the ON state Thi
53. Zero Sequence Current Control Enable sssssssessssssssenressssssrerrnsssseserennnssssesereennssno 65 4 3 15 3 Zero Sequence Current Controller Gain Constants Kp Ki 65 4 3 16 Modbus barameters rusa sS ENEAN ENOVA NENNEN EENEN EVANSS 66 Ge Deele ele 66 4 3 16 2 Modbus Baud Rate s siviscceshicsscencedcscepsiaseeersiassecleaceacuiecdsassnsdeces ncdsaasheseaesvoeedeassnededasdneea 66 4 3 16 3 MOdDUS Panty EE 66 4 3 17 Stand Alone Voltage Regulator Parameter 67 4 3 17 1 Voltage Resonant Controller Gain amp Phase Constants 67 4 3 17 2 Voltage Command Slew Umit 68 4 3 17 3 High Pass Filter Coefficients ccccssessccecccecessesseaeceeeceseeseaeaeeeeecessesesaeseeeescesseseaaeess 68 4 3 18 Current Overload Protection Parameter 69 4 3 18 1 Rated RMS e gn E 69 4 3 18 2 PT tee WU 69 4 3 18 3 10 100 RMS Overload Trip Times 69 5 Oztek PCC LE 70 6 Maintenance and Upgrade L nasaamarunneueinneiannsnareraensdundolmneeimridekdke 70 7 APPENDIX A 100kW Reference Design and Performance Data ssssccssssssececsesseeees 71 7 1 EWEN udi A A A EE E E T 74 7 2 Current Mode PerOriManCe ss scescseececesseeddesivecesvesectecsuvcucasewsselseniweedesanssttsnenseecedvseedeeasveedesdestess 74 7 3 Voltage Mode Eet Eet 76 Warranty and Product Informatlonu uuimnesmsesmenensminnnsipiasnrsnusndnnssrinsseveeien 78 Return Material Authorization POlicy rsrevvvvrnnnnvvvnvnnunvvnnnnnnuvvnnnnnnnnvennnnnnnennnnnunnnnnnnunnneen
54. are stored internally as either 16 bit or 32 bit quantities and are treated as either signed or unsigned entities The tables below indicate this information using the following abbreviations for the Data Type e U16 Parameter is an unsigned 16 bit entity e U32 Parameter is an unsigned 32 bit entity e S16 Parameter is a signed 16 bit entity e S32 Parameter is a signed 32 bit entity Parameters that are specified as Boolean are stored as 16 bit entities a value of all zeros indicates FALSE and any non zero value indicates TRUE Unless otherwise specified in the parameter description the parameters are stored and treated as 16 bit unsigned values 4 1 2 1 Specifying Fixed Point Parameters Some parameters listed in the following sections are specified as 32 bit signed numbers with the units specified as Qxx To represent a floating point number in Qxx format simply multiply the floating point number by 2 raised to the Q power and round to the nearest integer The result is a 32 bit integer value For example 10 25 Q16 format multiply 10 25 2416 671 744 or hex 0x000A4000 Q24 format multiply 10 25 2424 171 966464E6 or hex 0x0A400000 For example 0 00212 Q16 format multiply 0 00212 2416 138 936 round to 139 or hex 0x0000008B Q24 format multiply 0 00212 2424 35 567 698 round to 35 568 or hex 0x00008AF0 Publication UM 0021 Parameter Register Interface 4 1 3 Access Level The access level for each r
55. ature Sense Signals ccccccssssscecececessesssaeeeceeecesseeeaeseceescessesasaeeeeeessessessaaeess 20 3 1 3 J13 SKiiP Power Module Interface Inverter Bioptional 20 3 1 4 J8 Relay Driver Interface ccccccccccccssssssssececececesseneaecececsseeseaeaeseceesseeseaaaeceesesseeseaeaeeeeeess 20 3 1 5 J9 Isolated Digital INPUTS c cccccccccssssssssececeeecesseseesesececesessesaeaeeeeeceseesesaeseeeesesseeseaeaeeeeeess 21 3 1 6 J10 Isolated Digital Outputs rrrrrrrrrnnnnnrorvrrrrnsnrnnnnrnrvnnsrnsnnnnnnrnnnenssnsnnnnnnrnnnrnssnsnsnnnnrsnnenssnsnnnn 21 3 1 7 J23 High Voltage Line Feedback 22 308 125 Bl s POWER IN DUE enges eerste bebe ere ge eene See eege 23 3 1 9 J4 External Temperature Input 23 3 1 10 P1 Isolated Serial Interface c ccccssecscessennacsasdensceassnesenasenedenavsnnacaaedensseasenedeaarsnedceaveneaaaaetens 24 3 1 10 1 RS232 Configeuratlon enei rin r ias ATi inanin EN Ea ERR EARRAS 24 3 1 10 2 RS422 485 Configuration cccccccscccssseceescecesseeessececssecesseccsseeecsaeceeseecsseeecaeeecaaeeesees 24 3 1 11 P2 Isolated CAN Bus Interface 25 3 1 11 1 J18 19 CAN Termination Jumpers ccccccscccssscecssececscecesseecsececsaecesseecsseeecsaeeecaaeeeeees 25 3 2 Electrical INCE M a E Seo E SEAE E E E 27 3 3 Mechanical Inte rtace wiv cccccsicecccveaccctivarcccelssaccoessstecdsevaanccdeuad cccstuaancessuadcceedsaneceduuaa coceuanaadedeeanceee 28 4 Parameter Register Interface
56. bed in section 4 3 5 2 5 2 1 Inverter Hardware Over Temperature The AFE firmware provides a means to recognize a hardware based over temperature error signal from the main Inverter A interface as is present on a typical Semikron SKiiP interface If the Dual Interleaved Inverters Enable configuration parameter PID 0x80D0 is set to TRUE the AFE firmware will also monitor the over temperature signal from the secondary Inverter B interface 2 5 2 2 Inverter IGBT Error The AFE firmware provides a means to recognize a hardware based IGBT error signal from the main Inverter A interface as is present on a typical Semikron SKiiP interface If the Dual Interleaved Inverters Enable configuration parameter PID 0x80D0 is set to TRUE the AFE firmware will also monitor the error signal from the secondary Inverter B interface 2 5 2 3 Precharge Timeout Error The AFE Firmware monitors the amount of time spent in the CHARGE State A fault will be asserted if the DC Link Precharge Enable configuration parameter PID 0x80B0 is set to TRUE i e the AFE is controlling the precharge function and the elapsed time exceeds the Precharge Timeout Threshold configuration parameter PID 0x80B4 2 5 2 4 Precharge Contactor Error The AFE monitors the status of the precharge contactor feedback signal if the precharge contactor monitor is enabled in the Contactor Monitor Enables configuration parameter PID 0x80B5 If after the time specified in the Contacto
57. cation to application depending on line voltage and power level the overall system configuration will generally remain the same Pre Charge Circuitry Relay of _0 i ere oF i EMI Filter z DE J Sa 24V Relay 24V DC gt lt CAN gt Control Board Precharge Relay Drive Line Interface Relay Drive H H Precharge RelayStatus Line Interface Relay Statu Line Voltaae Phase A Line Voltaae Phase B Line Voltage Phase C 2 1 1 Power Module Figure 4 Typical AFE Electrical System Schematic R d G S The power module is a three phase semiconductor bridge which controls the power transfer from the AC Line to the DC link and vice versa Oztek control boards are designed to interface directly with Semikron SKiiP power modules In addition to the power devices these modules provide current sensing DC link voltage sensing temperature sensing and protection features including over voltage over current and de saturation protection 2 1 2 Isolation Transformer and Line Filter An isolation transformer is used to provide isolation between the AFE and the utility In addition it is usually included in the design of the line filter used to remove the high frequency switching
58. ce Data 7 APPENDIX A 100kW Reference Design and Performance Data Oztek 100kW 480Vac Active Front End Publication UM 0021 APPENDIX A 100kW Reference Design and Performance Data m PC_CONT_CTRL Main Contactor These documents are Oztet Corp property Ozet Corp maen af copyrights Al copying and Sansmitiing of tis inbenatice requires wrtien pernisskn AFE Controller User s Manual APPENDIX A 100kW Reference Design and Performance Data OZDSP3000 Control Board AFE Connections Publication UM 0021 APPENDIX A 100kW Reference Design and Performance Data 7 1 Overview Oztek has developed and tested the 100kW AFE reference design shown in the schematics in the previous section The line filter for this design was carefully chosen based on the 100kW power level and switching rate of 11 7 kHz For testing purposes two of these AFEs were assembled and wired back to back to support full load testing under various transient conditions The sections below provide some highlights of performance data measured with this reference design 7 2 Current Mode Performance The table below lists the total harmonic distortion THD and the total demand distortion TDD THD multiplied by the ratio of the commanded current to the rated current of 120A ms measured when operating the 100kW AFE in current mode These THD values were measured using a FLUKE 434 Power Quality Analyzer As the table illustrates
59. cecessesssneseeeeseessesnaeees 51 4 3 7 Converter Control Parameters sssssssssseessssrressrtssetttssrtttesttttsstttnssttttssttntssttntssttnneseentestenn 52 4 3 7 1 Pulse Width Modulation Freguency 52 4 3 7 2 Pulse Width Modulation Deadband Enable sssssssssssssssssssssressesrssssrnssrrnsserrrssrenesssrense 52 4 3 7 3 Pulse Width Modulation Deadband Time 52 4 3 7 4 Pulse Width Modulation Max Min Duty Cycle 52 4 3 7 5 Pulse Width Modulation Action c cccccssccccssssececsesneeeceeseeecseaeeecseueeecseaeeeesenaeeeeeeaaes 53 4 3 7 6 Grid Voltage Line Sensing Select 53 4 3 7 7 Automatic Grid Fault Recovern nanesen Eana eraa EEEE ta aea iere i aaae 53 4 3 7 8 Use Power Factor Setpoint asus ad 54 AFE Controller User s Manual Table of Contents 4 3 7 9 Total Line Filter Inductance eersnnrrvnrannrrenssnsrrenssnsrrenssnsrnensssennenssnennensssennrnsssennnsssssnnnsee 54 4 3 7 10 Nominal Grid Freouencn 54 4 3 7 11 Inverter Power Stage Dead Time 54 4 3 7 12 Output Modulation Tvpe 54 4 3 7 13 Hardware On Off Pin Control 55 4 3 8 Inverter Temperature Monitor barameters 55 4 3 8 1 Inverter Temp Coefficients CO through CL 55 4 3 9 Auxiliary Temperature Monitor BDarameters 56 4 3 9 1 Auxiliary Temperature Sensor Enable ccccccsesssseceeeceessssseeaeceeecesseseaeseeeeseessessaaeess 56 4 3 9 2 Auxiliary Temp Coefficients CO through C A 56 4 3 10 Voltage Regulator Parametere 57 4 3 10 1 Voltage Command Slew U
60. checking for CAN communications errors This value specifies the timeout period in terms of milliseconds Setting this parameter to zero disables checking for CAN communications timeouts When CAN timeout checking is enabled parameter is set to a legal non zero value a timeout counter is used to time the period of inactivity on the CAN bus This timer is reset upon the receipt of any of the valid receive messages supported by this application 4 3 2 3 CAN Group ID This parameter specifies the Group ID used by the firmware For more information see FS 0047 4 3 2 4 CAN Module ID This parameter specifies the Module ID used by the firmware For more information see FS 0047 4 3 2 5 CAN Baud Rate This parameter is used to configure the serial baud rate for the CAN interface The legal values are as follows e 0 1 Mbps e 1 500 kbps e 2 250 kbps e 3 125 kbps e 4 100 kbps e 5 50kbps 4 3 2 6 CAN Status Destination Group ID This parameter specifies the Destination Group ID that this firmware will use when sending the Status messages Note that the Illegal CAN Message and Configuration Response messages use the Group Module information from the sending device as the Destination Group Module when responding so this parameter is not used for those messages For more information see FS 0047 4 3 2 7 CAN Status Destination Module ID This parameter specifies the Destination Module ID that this firmware will use when sending the Status messages
61. cription Units Ge Min Max er 0x8090 U16 Current Command Slew Rate 1 Arms S 300 1 65535 RW 0x8091 32 Kp Current Controller Q16 1 5 0 0 32767 99 RW 0x8092 32 Ki Current Controller Q16 0 6 0 0 32767 99 RW 0x8093 U16 Turn Off Current Slew Rate 1 Arms S 300 1 65535 RW 0x8094 16 Iq Current Command Offset 1 Arms S 0 32768 32767 RW 0x8095 U16 Nominal DC Link Voltage 0 1V 8000 0 65535 RW 4 3 11 1 Current Command Slew Rate This parameter defines the slew rate to use when operating in current control mode and the commanded real or reactive current is changed This slew rate is used both at initial turn on when the current is ramped from OA to the configured default turn on value or when the programmed set point is changed after the converter has already been turned on AFE Controller User s Manual Parameter Register Interface 4 3 11 2 Current Controller Gain Constants Kp Ki Leet command lreactive command q measured Figure 20 Current Control PI Regulators These parameters define the gain constants for the PI controllers that are used to regulate the average real and reactive currents when the control loops are updated The integral gain Ki parameter should be entered as the continuous gain or sometimes referred to as the analog gain The firmware handles converting this to the discrete time gain by automatically dividing this by the sample frequency at which the controller is updated The PI topology use
62. d by the current controllers is similar to that used by the voltage controller in that the proportional and integral correction terms are summed together see Figure 20 above There are actually two separate PI blocks one used to regulate the real la current and one to regulate the reactive l4 current The real and reactive current commands are either commanded by the user when operating in current control mode or commanded by the outer voltage loop when operating in voltage control mode In both cases the current commands and current feedback terms are again normalized relative to the full scale inverter current specified by the Inverter Current Measurement Full Scale configuration parameter PID 0x8022 The output of each PI block is then used to command an appropriate Vg V applied voltage command to the Space Vector Modulator as shown earlier in this document in Figure 5 4 3 11 3 Turn Off Current Slew Rate This parameter defines the slew rate to use when ramping the current down to zero following an OFF command in current control mode To turn off immediately regardless of the present operating current set this parameter to the maximum value of 65535 4 3 11 4 Iq Current Command Offset This parameter is used to command a fixed reactive current offset Its purpose is to correct for the reactive current that flows through the capacitor when an LCL grid interface filter is used and inverter current is used for feedback as opposed to g
63. d voltage or frequency fault This parameter is only used if the Automatic Grid Fault Recovery configuration parameter PID 0x8067 is set to TRUE and the AFE was previously turned on using the On Off Control command register PID 0x0000 4 3 6 Fault and Warning Parameters Table 18 Fault and Warning Parameter Summary PID SE Description Units SC Min Max E 0x8050 U16 DC Link Over Voltage Fault Threshold 0 1V 8750 0 65535 RW 0x8051 U16 DC Link Over Voltage Warning Threshold 0 1V 8600 0 65535 RW 0x8052 U16 DC Link Over Voltage Recover Threshold 0 1V 8500 0 65535 RW 0x8053 U16 Grid Over Current Fault Threshold 0 1 Arms 2500 0 65535 RW 0x8054 U16 Grid Over Current Warning Threshold 0 1 Arms 2350 0 65535 RW 0x8055 U16 Grid Over Current Recover Threshold 0 1 Arms 2250 0 65535 RW 0x8056 U16 Inverter Temperature Fault Threshold C 85 20 150 RW 0x8057 U16 Inverter Temperature Warning Threshold C 75 20 150 RW 0x8058 U16 Inverter Temperature Recover Threshold C 70 20 150 RW 0x8059 U16 Auxiliary Temperature Fault Threshold C 85 20 150 RW Ox805A U16 Auxiliary Temperature Warning Threshold C 75 20 150 RW 0x805B U16 Auxiliary Temperature Recover Threshold E 70 20 150 RW Ox805C U16 Inverter Error Pin Active High Boolean TRUE FALSE TRUE RW 0x805D U16 Inverter Over Temp Pin Active High Boolean TRUE FALSE TRUE RW 0x8111 U16 DCLink Under Voltage Fault Threshold 0 1V 5800
64. de Control This register is used to indicate the desired operating mode The default mode following a power on reset is specified in the configuration memory see Section 4 3 3 3 for details The mode may not be changed while the AFE is ON AFE Controller User s Manual Parameter Register Interface 0 DC Voltage Control In this mode the DC link voltage is regulated 1 Current Control In this mode the grid current is regulated 1 Standalone Mode In this mode the AC output voltage is regulated 3 to 255 Not Supported 4 2 1 3 DC Link Voltage Setpoint This register is used to adjust the desired DC link voltage set point when the AFE is operating in voltage control mode The default voltage following a power on reset is specified in the configuration memory see Section 4 3 3 3 for details The value sent in this command does not change the default voltage stored in the configuration memory rather it merely provides a dynamic and temporary override from the default value 4 2 1 4 Grid Current Setpoint Real This register is used to adjust the desired real grid current set point while the AFE is operating in current control mode The default real current set point used when turning on the AFE is specified in the configuration memory see Section 4 3 3 3 for details The value sent in this command does not change the turn on value stored in the configuration memory rather it merely provides a dynamic and temporary override whi
65. de Transient Response F ster 77 Publication UM 0021 vii Table of Contents Table of Tables Table 1 J11 SKiiP Power Module Pin Assignment rorrrrrnnnnannnnrnrvnnrrnsnnnnnnrnrvnnssnsnnnnnnrnrsrnssnsnnnnnnrnnsrnssnsnnnn 18 Table 2 J11 Current Sense Pin Assignment rrrrnrnannnnnnrvrrrrsrnannnnrnrvrnrrnsnnnnnnrnrvrnrsrsnnnnnnrnnsrnssnsnnnnnnrnnsenssrnnnnn 20 Table 3 J8 Relay Drive Pin Aeslenment nar nnsrnssnsnnnnnnrnnsrnssnsnnne 20 Table 4 J9 Isolated Digital Input Pin Assignment sessnssesessseesnsssseserressssssrrernrssssesrrernnssssesereennssssesereena 21 Table 5 J10 Isolated Digital Output Pin Assignment sssssssssssssssissssserssssrrssrsrrsstrnsserrssrernsseenrssttnnsseetet 22 Table 6 J23 High Voltage Sense Pin Assignment rrnnorrrrrnnnnannnnrnrvvnrnnsnnnnnnrnrrrnrrnsnnnnnnrnrvrnssnsnnnnnnrnnsrnssrnnnnn 22 Table 7 J12 RS 485 Pin Asslgnment 23 Table 8 J4 Pin ASSISNIMENE ccc iiss secicsccesssasseensiacecsesssosnenniscaedessiosncnnissaesvsdsvsnennsiesedessssnanad esenesbeovnensaeesedesse 23 Table 9 J15 RS422 485 Configuration Jumper Settings ccccccscccssscesssecssreecssecesseecesseeesseesesaeeeeaseeeees 24 Table 10 P2 CAN Bus Pin Assignment sssssssesnnssssesrerrrssssesnreernssssrerretnassssererntsnssnnenernnsnssrnernnnnssssernennnna 25 Table 11 Command Register Set 30 Table 12 Instrumentation Register Set 34 Table 13 Configuration Control Parame
66. e measured voltage THD from the grid when the AFE was OFF was 2 6 The figure below shows the turn on behavior of the AFE when starting up in voltage mode The blue trace Ch2 shows the DC link voltage with an offset of 850V As the figure shows the AFE first turns on with a DC link voltage equal to the rectified grid voltage or about 695V in this case The voltage is then increased to the user s configured setpoint 850V as shown in these plots Like current mode the user can configure the slew rate for changing voltages and this is illustrated in the plots below with two different slew rate settings This same slew rate setting is used when changing the voltage command on the fly while the AFE is already on Figure 25 Voltage Mode Turn On Vsiew 1500V s left and 5000V s right AFE Controller User s Manual APPENDIX A 100kW Reference Design and Performance Data The next set of plots Figure 26 shows the transient load response when operating in voltage mode For this test case the DC voltage was set to 800V and the load was changed from 100 Arms to 0 Arms and vice versa As can be seen in the plots the load was programmed to change across three AC line cycles In this case the overall voltage deviation was less than about 10V Figure 26 Voltage Mode Transient Response The next figure shows the response for a faster load change this time in less than one line cycle In this case the resulting DC link voltag
67. e Command Slew Limit This parameter defines the slew rate to use when operating in voltage control mode and the commanded output voltage is changed This slew rate is used both at initial turn on when the output voltage is changed from the present value to the programmed set point or when the programmed set point is changed after the converter has already been turned on 4 3 10 2 Voltage Controller Gain Constants Kp Ki lreal command lim min Figure 19 Voltage Control PI Regulator These parameters define the gain constants for the PI controller that is regulating the output DC link voltage when the converter is operating in voltage control mode The integral gain Ki parameter should be entered as the continuous gain or sometimes referred to as the analog gain The firmware handles converting this to the discretized gain by automatically dividing this by the sample frequency at which the controller is updated specified by the Pulse Width Modulation Frequency parameter PID 0x8060 As Figure 19 above illustrates the PI topology used by the AFE application sums the proportional and integral correction terms and then clamps the output to the specified current limits based on the Voltage Mode Current Limit Min Max configuration parameters PIDs 0x8034 0x8035 It is important to note that the voltage setpoint and measured feedback voltage used in the AFE application software are actually normalized relative to
68. e USA or Canada In addition to the above you MUST include return freight funds and you are fully responsible for all documents duties tariffs and deposits Out of Warranty Service If the warranty period for your product has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your unit may be serviced or replaced for a flat fee If a unit cannot be serviced due to damage beyond salvation or because the repair is not economically feasible a labor fee may still be incurred for the time spent making this determination To return your product for out of warranty service contact Oztek Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee will be charged If applicable you will be contacted by Customer Service once your unit has been received AFE Controller User s Manual
69. e same DC link and therefore only the voltage sense input from Inverter A is used The J13 interface is not used when the second inverter interface is not enabled In this case it is safe to leave connector J13 unconnected 3 1 4 J8 Relay Driver Interface The AFE firmware automatically controls both a pre charge relay as well as a line interface relay intended to drive the coils of higher power contactors Table 3 J8 Relay Drive Pin Assignment Pin Description 3 Line interface relay 24V drive 7 Line interface relay drive return 4 Pre charge relay 24V drive 8 Pre charge relay drive return e OZDSP3000 Connector Part Number Molex Micro Fit 2x4 Header 43045 0824 AFE Controller User s Manual OZDSP3000 Hardware Interfacing e Mating Connector Part Number Molex Micro Fit 2x4 Receptacle 43025 0800 e Output Range 24V 2A continuous 5A inrush 3 1 5 J9 Isolated Digital Inputs The AFE controller may be configured to use the isolated digital inputs for monitoring contactor status or for optional hardware On Off and Fault Reset control of the inverter When configured to monitor contactor status see parameter 0x80B5 Contactor Monitor Enables the AFE firmware expects switch closure feedback from the pre charge and or the line interface contactors These switch closure status feedback signals should be wired to the optically isolated inputs on J9 as illustrated in Figure 12 When the configu
70. e variation was approximately 15V Figure 27 Voltage Mode Transient Response Faster Publication UM 0021 Warranty and Return Warranty and Product Information Limited Warranty What does this warranty cover and how long does it last This Limited Warranty is provided by Oztek Corp Oztek and covers defects in workmanship and materials in your OZDSP3000 controller This Warranty Period lasts for 18 months from the date of purchase at the point of sale to you the original end user customer unless otherwise agreed in writing You will be required to demonstrate proof of purchase to make warranty claims This Limited Warranty is transferable to subsequent owners but only for the unexpired portion of the Warranty Period Subsequent owners also require original proof of purchase as described in What proof of purchase is required What will Oztek do During the Warranty Period Oztek will at its option repair the product if economically feasible or replace the defective product free of charge provided that you notify Oztek of the product defect within the Warranty Period and provided that through inspection Oztek establishes the existence of such a defect and that it is covered by this Limited Warranty Oztek will at its option use new and or reconditioned parts in performing warranty repair and building replacement products Oztek reserves the right to use parts or products of original or improved design in the repair or replac
71. eat E EE EEEREN EEES 12 251 W rningsaasartqavsgssarsesesattarsdeeteaarete seeren 12 2 5 1 1 Inverter High Temperatureunserser rama dekee sneket 12 2 5 1 2 DC Link High Voltage EE 12 2 5 1 3 DC Bio e TT 12 2514 PLE Not Locked unnsette eide 12 2 5 1 5 High Inverter Current sisesma eseese ds tude Aerer egegdteN eet 13 2 5 1 6 Grid Frequency Out Of Tolerance rrrrrnnnnnrvrnnnnnvvrnnnnnvnrnnnnnvnrnnnnnnnrnnnnnnnnnnnnnnnnnsnnannnnsnne 13 2 5 1 7 Grid Voltage Out of Tolerance eneee E ee e EAE NEE Eea RERE aeia EREA 13 2 5 1 8 Auxiliary High Temp rat r rase eeestis norte er iE EE E ERR 13 2 5 1 9 Local Bias Supply Tolerance Warnings rerrrnrnnsnannnnnnvvnnrnnsnnnnnnnnvvnnsrnsnrnnnnrnrsnnssnssrnnnnnnnn 13 252 FaU eeraa eE AEO EA O A OREA OAA NOE OEREO 13 2 5 2 1 Inverter Hardware Over Temperature 14 2 5 2 2 Inverter IGBT Error c siccevescesssecsatcesteacwesia want aE RE EE ENdedE E EN R tele 14 2 5 2 3 Precharge Timeout Error eerren eeaeee enaena EREE eave css se ae 14 2 5 2 4 Precharge Contactor Erroruussasaadtattede rekene annen 14 25 25 Grid Contactor d 14 2 5 2 6 Relay Driv r Hardware Error uuunosadssrresak sea 14 2 5 2 7 Communications Timeout ikeen serieak eNEAN REAKTE EK dka 15 2 5 2 8 Configuration Memory de 15 2 5 2 9 Software Inverter Over Temperature 15 2 5 2 10 Software DC Link Over Voltage cccccccccesssssssssecececeesesecesaecececeseesesaeaeeeescessessaeaeeeeeens 15 2 5 2 11 Software DC Link UnderVohtage icenian ieena d
72. egister is defined as follows e W writeable the parameter is writable by the user e R readable the parameter is readable by the user e P password protected the parameter may only be accessed by supplying a password 4 2 Volatile Registers 4 2 1 Command Registers Table 11 Command Register Set PID Data Description Units Min Max Access Type Level 0x0000 U16 On Off Control ENUM 0 1 R W 0x0001 U16 Mode Control ENUM 0 2 R W 0x0002 16 DC Link Voltage Setpoint 0 1 V 0 32767 R W 0x0003 S16 Grid Current Setpoint Real 0 1 Arms 32768 32767 R W 0x0004 S16 Grid Current Setpoint Reactive 0 1 Arms 32768 32767 R W 0x0005 S16 Power Factor Setpoint 0 1 1000 1000 R W 0x0006 U16 Fault Reset ENUM 0 1 R W 0x0007 U16 Configuration Password n a 0 65535 R W 0x0008 U16 Configuration Reset ENUM 0 1 R W P 0x0009 U16 Configuration Reload ENUM 0 1 R W Ox000A S16 Stand Alone Voltage Setpoint 0 1 Vims 0 32767 R W 0x000B U16 Isolated Digital Output Control ENUM 0 7 R W 4 2 1 1 On Off Control This register is used to turn the AFE ON or OFF as follows 0 OFF This turns the AFE OFF 1 ON This turns the AFE ON 2 to 255 Not Supported If the Hardware On Off Pin Control configuration parameter PID 0x806D is enabled this command register will be ignored Instead the AFE is turned ON or OFF using a digital input pin as specified in section 3 1 5 4 2 1 2 Mo
73. ement If Oztek repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaired products become the property of Oztek Oztek covers both parts and labor necessary to repair the product and return shipment to the customer via an Oztek selected non expedited surface freight within the contiguous United States and Canada Alaska Hawaii and locations outside of the United States and Canada are excluded Contact Oztek Customer Service for details on freight policy for return shipments from excluded areas How do you get service If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Oztek directly at USA Telephone 603 546 0090 Fax 603 386 6366 Email techsupport oztekcorp com Direct returns may be performed according to the Oztek Return Material Authorization Policy described in your product manual What proof of purchase is required In any warranty claim dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Oztek Proof of purchase may be in any one of the following forms e The dated purchase receipt from the original purchase of t
74. er on reset is specified in the configuration memory see Section 4 3 3 3 for details The value sent in this command does not change the default voltage stored in the configuration memory rather it merely provides a dynamic and temporary override from the default value 4 2 1 12 Isolated Digital Output Control This register is used to set the output state for three general purpose open collector digital outputs located on connector J10 The three output pins are controlled using the lower 3 bits in this register as shown in the table below Writing a 0 to a particular bit will result in a high impedance output i e open collector output is off Writing a 1 to a particular bit will result in the open collector output being asserted i e OV from collector to emitter J10 Pin J10 Pin Collector Emitter 0 povo 5 1 i oom 6 1 3 fopon 7 3 Publication UM 0021 Parameter Register Interface 4 2 2 Instrumentation Registers Table 12 Instrumentation Register Set PID Data Description Units Access Type Level 0x4000 U16 AFE Operating State ENUM R 0x4001 U16 AFE Operating Mode ENUM R 0x4002 16 DC Link Voltage 0 1V R 0x4003 S16 AC Line Voltage Phase A to B 0 1 Vims R 0x4004 S16 AC Line Voltage Phase B to C 0 1 Vims R 0x4005 S16 AC Line Voltage Phase C to A 0 1 Vrms R 0x4006 S16 Grid Current
75. er the converter has already been turned on 4 3 17 3 High Pass Filter Coefficients These parameters configure the digital high pass filter used to remove DC offsets from the voltage controller The filter is implemented as a Second Order Direct Form Il Infinite Impulse Response IIR digital filter The difference equations are implemented as follows Output y n BO v n B1 v n 1 B2 v n 2 where v n AO x n A1 v n 1 A2 v n 2 AFE Controller User s Manual Parameter Register Interface CE 4 3 18 Current Overload Protection Parameters Table 30 Current Overload Protection Parameter Summary PID ai Description Units p Min Max p 0x8120 U16 Rated RMS Output Current Amps 90 1 65535 R W 0x8121 U16 IT Trip Time 0 1 msec 1000 1 65535 R W 0x8122 U32 10 RMS Overload Trip Time msec 240000 1 3600000 R W 0x8123 U32 20 RMS Overload Trip Time msec 200000 1 3600000 R W 0x8124 U32 30 RMS Overload Trip Time msec 67000 1 3600000 R W 0x8125 U32 40 RMS Overload Trip Time msec 34000 1 3600000 R W 0x8126 U32 50 RMS Overload Trip Time msec 10000 1 3600000 R W 0x8127 U32 60 RMS Overload Trip Time msec 8300 1 3600000 R W 0x8128 U32 70 RMS Overload Trip Time msec 6700 1 3600000 R W 0x8129 U32 80 RMS Overload Trip Time msec 5000 1 3600000 R W 0x812A U32 90 RMS Overload Trip Time msec 4000 1 3600000 R W 0x812B U32 100 R
76. es are intended to be used to check for moderate voltage deviations from the nominal grid voltage and to define an appropriately slow time to wait prior to declaring a fault The fast voltage thresholds and clear times are intended to be used for checking for gross voltage deviations from the nominal grid voltage and to define a relatively fast fault assertion time Grid voltage fault conditions are only asserted when the AFE is ON or an attempt is made to turn the AFE ON If the AFE is OFF and a voltage threshold has been exceeded a warning bit s will be asserted corresponding to the violating phase voltage measurement If the AFE is AFE Controller User s Manual Parameter Register Interface a ON and a voltage threshold has been exceeded and the corresponding clear time has not yet been met a warning bit s will be asserted for the violating phase 4 3 5 2 Grid Fast Slow Over Under Frequency Thresholds and Clear Times These parameters are similar to the voltage thresholds described above except that they pertain to the measured grid frequency Grid frequency faults are only asserted when the AFE is ON otherwise when the grid frequency exceeds one or more of the thresholds an associated warning bit will be asserted 4 3 5 3 Grid Reconnect Delay Time This parameter is used to define the period of time to wait when automatically reconnecting to the grid and turning ON following a gri
77. h the reported Grid Current and the Inverter B currents will return all zeros For dual interleaved inverter operation each inverter s currents are reported separated in their respective registers Note that the sensors used to measure the AC inverter currents are located on the inverter side of the grid interface filter i e between the power switches and the output filter 4 2 2 19 Inverter B Temperature This register reports the measured temperature reported by the optional secondary interleaved inverter B power module If dual interleaved inverter operation is disabled this register will return zero 4 2 2 20 Fault Status2 Fault bits are active when set to a 1 and not present when set to a 0 If a fault occurs the corresponding bit is set to a 1 and remains set until a 1 is written to the Fault Reset command register PID 0x0006 When a fault occurs the controller will go to the FAULT state and the AFE will stop operating The controller will stay in the FAULT state until the Fault Reset command is received See section 2 4 7 for details on each fault condition The fault bits are mapped as follows Oo Inverter A RMS Current Overload Phase A Inverter A RMS Current Overload Phase B Inverter A RMS Current Overload Phase C 6 31 4 2 2 21 Isolated Digital Input Status This register reports the state of the four isolated digital inputs located on connector J9 The input state for each pin is mapped to t
78. harmonics from the line current An L C L filter architecture is typically employed with damping provided by series resistive elements 2 1 3 Pre Charge Circuit A pre charge circuit is used to limit the inrush current associated with charging the DC link capacitance when applying line voltage to the AFE Lack of a pre charge circuit can result in extremely high potentially damaging inrush currents AFE Controller User s Manual Functional Description 2 1 4 Control Board The control board is used to generate the gating signals to the power switches in order to control either line current or DC link voltage The control board also provides instrumentation and user control functions 2 2 Description of Operation 2 2 1 DC Link and Current Control Modes Figure 5 presents a simplified block diagram of the control scheme employed in the AFE firmware The DC link voltage controller is a PI type regulator whose reference sets the value of the DC link voltage to be maintained This reference is compared to the measured DC link voltage providing the DC voltage error input to the PI regulator The output of the DC link voltage controller serves as the active current reference while the reactive current reference is used to maintain power factor PI regulators are used to control both the active and reactive current components using current feedback calculated from the three phase current measurements Ita lib lic The current regulators are
79. hat do not require reloading the memory to the factory default values This could be a result of a minor value change to the default value for a particular parameter or the addition of a new parameter that is not needed for proper converter operation Updates to the minor factory revision value are expected to increment the previous value by 1 4 3 1 4 Application Configuration Data Revision This value is used to represent the revision of the application specific configuration data as programmed by the factory This field is meant to store the revision of any custom configuration settings programmed at the factory for a specific end user application The factory default prior to customization for this field is zero indicating that no custom settings have been made to the configuration memory Application specific updates to the configuration data are expected to increment this parameter by 1 This parameter is password protected to prevent accidental modification by the end user 4 3 1 5 Hardware Configuration This read only register is provided for future use only It is presently not used by the AFE application and will return a value of zero when read 4 3 1 6 User Configuration Revision This is a generic parameter that is provided to allow the user or a higher level controller to maintain revision information for custom settings to the configuration memory The firmware does not use this value The protocol for numbering and maintaining c
80. hat the units of this parameter are degrees Amp Publication UM 0021 Parameter Register Interface 4 3 13 Pre charge Parameters Table 25 Pre charge Parameter Summary PID SC Description Units GEN Min Max EEN 0x80BO U16 DC Link Pre charge Enable Boolean TRUE FALSE TRUE RW Ox80B1 U16 DC Link Pre charge Threshold 90 0 100 RW 0x80B2 U16 Contactor Debounce Time 1 ms 10 1 10000 RW Ox80B3 U16 Contactor Close Time 1 ms 500 1 10000 RW Ox80B4 U16 Pre charge Timeout Threshold 1 ms 20000 10 65535 RW 0x80B5 U16 Contactor Monitor Enables ENUM 3 0 3 RW Ox80B6 U16 Grid Contactor Enable Boolean TRUE FALSE TRUE RW 4 3 13 1 DC Link Pre charge Enable This Boolean parameter enables the use of the precharge contactor control in the AFE If this parameter is set to FALSE it is assumed that the precharge function is performed by another piece of equipment attached to the same DC link as the AFE In this case the AFE will not attempt to close the pre charge contactor when first starting up Instead it simply monitors the DC link voltage and waits for it to reach the configured DC Link Pre charge Threshold see below before it will transition from the CHARGE state to the IDLE state If this parameter is set to TRUE the AFE will attempt to close the precharge contactor prior to entering the CHARGE state and will then open the contactor when the precharge operation is complete
81. he lower 4 bits in this register according to the table below When a voltage is applied across the input pins the corresponding bit in this register will return a 1 When OV is applied across the input i e the optically isolated input is OFF the corresponding bit in this register will return a 0 AFE Controller User s Manual Parameter Register Interface Note that the isolated inputs INO and IN1 may be configured to monitor contactor state and may therefore be unavailable as general purpose inputs See the Contactor Monitor Enables configuration parameter PID 0x80B5 for further details Similarly isolated inputs IN2 and IN3 may be configured for hardware On Off and Fault Reset control and may therefore be unavailable as general purpose inputs See the Hardware On Off Pin Control configuration parameter PID Ox806D for further details J9 Pin J9 Pin Input Return 0o mo 1 5 1 m 2 6 3 m 4 8 4 3 Non Volatile Configuration Registers Many operating parameters in this application have been made configurable so as to support the various Active Front End product variants as well as to support other similar products in the future As such the software contains provisions for storing these configuration parameters in an external non volatile EEPROM device CAUTION EEPROM devices have limited write cycle capability While they can handle 1 million write cycles care should be taken not to continuo
82. he product at point of sale to the end user e The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status e The dated invoice or purchase receipt showing the product exchanged under warranty AFE Controller User s Manual Warranty and Return What does this warranty not cover Claims are limited to repair and replacement or if in Oztek s discretion that is not possible reimbursement up to the purchase price paid for the product Oztek will be liable to you only for direct damages suffered by you and only up to a maximum amount equal to the purchase price of the product This Limited Warranty does not warrant uninterrupted or error free operation of the product or cover normal wear and tear of the product or costs related to the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and Oztek will not be responsible for any defect in or damage to a The product if it has been misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b The product if it has been subjected to fire water generalized corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Oztek product specifications including high input voltage from generators and lightning strikes c The product
83. his parameter defines the full scale value of the voltage sensor used to measure the DC link voltage This full scale value is relative to the signal at the DSP s ADC input that would cause a full scale ADC reading i e ADC reading of OxFFF 4 3 3 2 Line Voltage Measurement Full Scale This parameter defines the full scale value of the 3 line voltage measurements This full scale value is relative to the signal at the isolated high voltage ADC input that would cause a full scale ADC reading i e ADC reading of OxFFF If the Grid Voltage Line Sensing Select configuration parameter PID 0x8066 is set to Line to Line voltage sensing by the hardware then this full scale measurement parameter should be set to the peak not peak to peak line to line voltage that would result in a full scale ADC reading If the Grid Voltage Line Sensing Select configuration parameter is set to Line to Neutral voltage sensing by the hardware then this full scale measurement parameter should be set to the peak to peak line to neutral voltage or in other words twice the peak line to neutral voltage that would result in a full scale ADC reading 4 3 3 3 Inverter Current Measurement Full Scale This parameter defines the full scale value of the 3 inverter current sense measurements This full scale value is relative to the signal at the DSP s ADC input that would cause a full scale ADC reading i e ADC reading of OxFFF Publication UM 0021
84. implemented in the voltage oriented synchronous DQ reference frame A digital phase locked loop PLL provides synchronization with the AC line voltage The outputs of the active and reactive PI regulators are then used to control a space vector modulator SVM which generates the gating commands to the power switches Space vector operation may optionally be disabled and replaced with sine wave modulation see PID 0x806C Current Controller SSSA SR SSS Sa SS a a SS SS SS EE SR SSS lactive ILabe Voltage Controller ot lreactive Figure 5 AFE Controller Functional Block Diagram 2 2 2 Operating Modes Typically an AFE is used to regulate the DC link voltage as previously described In order to maintain the desired DC link voltage the voltage regulator will command an active current either into or out of the AC line as necessary In certain applications there may be a separate Publication UM 0021 6 Functional Description controller responsible for regulating the DC link in which case it may be desirable to operate the AFE as a current controller as opposed to a voltage controller By properly setting the Mode Control command register PID 0x0001 the user may disable the voltage controller and directly command the active current CAUTION Operation in current control mode assumes there is an external means to control the DC link voltage DC link voltage control is absolutely necessary when com
85. l Functional Description configured by setting the desired trip time for a 110 overload i e 210 rated output current The following figure illustrates the time to trip as a function of overload Figure 7 Stand Alone Mode I T Protection Characteristic The RMS algorithm works similarly in that it integrates the difference between the RMS load current and the rated output current If the function integrates beyond a trip threshold a fault is asserted The function is configured by setting the desired trip time for ten overload conditions 10 20 30 30 50 60 70 80 90 and 100 overload The following figure illustrates the time to trip as a function of overload 0 100 200 300 400 500 600 700 800 trip Times Figure 8 Stand Alone Mode RMS Protection Characteristic Publication UM 0021 SS Functional Description 2 3 Dual Interleaved Inverter Operation The AFE controller provides support for an optional second inverter interface to be used when driving a dual interleaved inverter power stage Note that this option is not available if the controller is intended to be operated in Stand Alone voltage mode This system would look very similar to the single inverter system shown in Figure 4 with the addition of a second IGBT bridge and inverter side filter inductors as shown in the figure below Pre Charge Circuitry Zs K1 ON v i gek K EMI FF e Filter 48
86. l Function Specification for more details on the use of broadcast messages The legal values for this parameter are encoded as follows e 0 Do Not Accept Broadcast Messages e 1 Accept Group wide Broadcast Messages Module ID 0 AFE Controller User s Manual Parameter Register Interface e 2 Accept System wide Broadcast Messages Group ID 0 e 3 Accept both Group wide and System Wide Broadcast Messages 4 3 2 15 CAN Update Rate Alarm 2 Status Message This parameter specifies the rate at which Alarm 2 Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic periodic transmission of this message All other values ms 65 535ms are valid 4 3 3 System Measurement Scaling Parameters Table 15 System Measurement Scaling Parameter Summary PID Description Units AA Min Max Seen 0x8020 U16 DC Link Voltage Measurement Full Scale 0 1V 10109 0 65535 RW 0x8021 U16 Line Voltage Measurement Full Scale 0 1V 10005 0 65535 RW 0x8022 U16 Inverter Current Measurement Full Scale 0 1A 6250 0 65535 RW 0x8023 U16 Inverter Current Measurement Polarity ENUM 0 0 1 RW 0x8024 U16 Inverter Current Measurement Auto Calibration Boolean TRUE FALSE TRUE RW 4 3 3 1 DC Link Voltage Measurement Full Scale T
87. le the converter is on 4 2 1 5 Grid Current Setpoint Reactive This register is used to adjust the desired reactive grid current set point while the AFE is operating in current control mode The default reactive current set point used when turning on the AFE is specified in the configuration memory see Section 4 3 3 3 for details The value sent in this command does not change the turn on value stored in the configuration memory rather it merely provides a dynamic and temporary override while the converter is on Explicit reactive current set point control is only supported when the Use Power Factor Setpoint configuration parameter PID 0x8068 is set to FALSE When the Use Power Factor Setpoint configuration parameter is set to TRUE the reactive current is controlled based on the Grid Current Setpoint Real command and the Power Factor Setpoint command 4 2 1 6 Power Factor Setpoint CAUTION Care should be taken when commanding low power factors Lowering the power factor will increase the total current in or out of the AFE which could eventually result in an over current fault condition This register is used to indicate the desired power factor set point when the AFE is operated in voltage control mode This set point is also optionally used in current control mode if the Use Power Factor Setpoint configuration parameter PID 0x8068 is set to TRUE The default power factor following a power on reset is specified in the configurati
88. mand register with a legal value will override the default value stored in this register As indicated in the table above the power factor is commanded in units of 0 1 For example a power factor of 0 95 would be entered as 950 decimal or 0x03B6 hexadecimal A power factor of 0 98 would be entered as 980 decimal or OxFC2C hexadecimal A positive number less than 100 indicates grid currents lagging grid voltage i e inductive load a negative number indicates grid currents leading grid voltage i e capacitive load CAUTION Care should be taken when using a low power factor setpoint Lowering the power factor will increase the total current in or out of the AFE which could eventually result in an over current fault condition Publication UM 0021 ag Parameter Register Interface 4 3 4 8 Default Stand Alone Voltage Setpoint This parameter defines the default RMS phase to phase voltage set point to use when turning on in Stand Alone output voltage control mode following a power on reset POR of the control board This value is used if the Stand Alone Voltage Setpoint command PID Ox000A has not been issued following a power on reset of the control board Writing the Stand Alone Voltage Setpoint command register with a legal value will override the default value stored in this register 4 3 5 Grid Monitor and Protection Parameters Table 17 Fault and Warning Parameter Summary
89. manding currents into the AFE Lack of control can result in catastrophic over voltage conditions on the DC link 2 2 3 Stand Alone Voltage Control Mode Figure 6 presents a simplified block diagram of the stand alone voltage mode control scheme employed in the AFE firmware A reference angle and quadrature a AC voltage reference waveforms are generated by the software The output voltage is sensed by the A D converter and converted to quadrature a B format Resonant controllers are then employed to provide closed loop regulation by controlling the modulation index of a space vector modulator Generator Figure 6 Stand Alone Voltage Controller Functional Block Diagram 2 2 3 1 Current Overload Protection When operating in stand alone voltage control mode the AFE firmware provides two types of current overload protection fast I T limit and a slower RMS limit The I T algorithm is intended to protect the inverter for gross overloads exceeding 200 rated while the RMS protection functions for overloads between rated and 200 rated The I T algorithm integrates the sample by sample difference between the absolute value of the current waveform and the overload threshold As such it integrates up during the time when the current is greater than the threshold and down while the waveform is lower than the threshold If the function integrates beyond a trip threshold a fault is asserted The function is AFE Controller User s Manua
90. mit 57 4 3 10 2 Voltage Controller Gain Constants Kp Ki 57 4 3 10 3 Voltage Droop Control Gain K seenl 58 4 3 11 Current Regulator Parameters cccccccccccsssssssssecececessessaeseceescsssesssaesecesscessesaaeseeeesenssessaaees 58 4 3 11 1 Current Command Slew Rate 58 4 3 11 2 Current Controller Gain Constants Kp Kl 59 4 3 11 3 Turn Off Current Slew Rate rrrnrannrnrnrannvrvnrsnsrvrnssssrrnnssnsrvenssrsrnnnssnsnnrnssssnnrnssssnnnnssssnnnsee 59 4 3 11 4 Iq Current Command Offset 59 4 3 11 5 Nominal DE Link arreirar enara OAOA IEO AOE ONAF 60 4 3 12 Phase Lock Loop PLL Darameters 60 4 3 12 1 PLL Controller Gain Constants Kp Ki LockediUnlocked 60 43 12 22 PLL Output RAMBO rr ra ra araea e ae rra e a saededdensestagseeesaieeasiecbdncteniadssstiten 61 4 3 12 3 PLL Phase Detector Error Thresbold A 61 4 3 12 4 PLL Lock Indicator AC Line Count 61 4 3 12 5 PLL Unlock Indicator AC Line Count 61 4 3 12 6 PLL Phase Lag Adlustment EEN 61 4 3 12 7 PLL Phase Error LPF Cutoff Freouency 61 4 3 12 8 PLL Auto Gain Control Filter Constant 61 4 3 12 9 PLL Capacitor Sensing Adjustment ssssssssssesenresnssssrerrrssssssrrernnssssrsrrennessssesereennssne 61 4 3 13 Pre charge Paraime ters iecis ccc ccvsscs cecceceddcnxstasudenaced usa e a heed Gvaessveadectteudeassdodudenededee 62 4 3 13 1 DC Link Pre charge tnable eriosiirisssirdsiss encsi eoirce dearie ainne suea 62 4 3 13 2 DC Link Pre charge Threshold rrrrrrnnnnrrrrrn
91. n first powering up the control board the AFE software attempts to calibrate the controller s internal ADC This error is asserted if the controller is unable to perform the required calibration There is likely an issue with the control board hardware if this error occurs in which case the board should be sent back to the factory for diagnosing and repairing of any defects see the RMA process described at the end of this document 3 0ZDSP3000 Hardware Interfacing The OZDSP3000 is a highly integrated DSP control solution for power control applications Typical applications include voltage output inverters grid tie inverters AC induction motor controllers brushless DC motor controllers and Active Front End regulators This section describes how to utilize the OZDSP3000 along with the AFE control firmware in a typical AFE system application AFE Controller User s Manual OZDSP3000 Hardware Interfacing 3 1 Application Interfaces SKiiP Power Module Inverter A Send SKiiP Power Module Inverter B optional CANH CANL L1 L L3 GND 24VDC SM FAULT S To MAA Filter Optional DOUT2 7 Open Collector 3 OZDSP3000 L2 Output Pins DOUT1 6 Li L3 Doutro 2 4 x A A 24VDC 24V RTN 1 Nola EA
92. n the PWM outputs as follows e 0 Space Vector Modulation e 1 Sine Wave Modulation AFE Controller User s Manual Parameter Register Interface 4 3 7 13 Hardware On Off Pin Control When this parameter is set to TRUE the AFE is turned ON and OFF using the isolated digital input pin located at connector J9 pins 4 input and 8 signal return This input is an optically isolated input that may be driven with 24V The AFE will be turned ON when this input is driven high 24V and will be turned OFF when this input is low OV or not connected Additionally when using hardware On Off control i e this parameter is TRUE a second isolated digital input pin located at connector J9 pins 3 input and 8 signal return may be used for resetting any fault conditions that may have turned the AFE off and caused the controller to go to the Fault state An attempt will be made to clear all faults when this input is transitioned from a low input OV or not connected to a high input 24V When using hardware On Off pin control the On Off Control command register PID 0x0000 and the On Off Control CAN command message are not used and will have no effect When this parameter is set to FALSE the On Off and Fault Reset digital input pins are not used and will have no effect 4 3 8 Inverter Temperature Monitor Parameters Table 20 Inverter Temperature Parameter Summary PID Se Description Units Geh Min Max Jer
93. nable rrrrnnnrorrnnrrnanonnnnrnrvrnsrnsnnnnnnrvnvnnssnnnnnnnnrsnsener 44 4 3 2 15 CAN Update Rate Alarm 2 Status Message 45 4 3 3 System Measurement Scaling Parameters r rrrnnrnnnsnnnnrvrvrnssnnnnnnnnrvnnenssnnnnnnnnrsnnenssnnnnnnvnvsnssnne 45 4 3 3 1 DC Link Voltage Measurement Full Scale rrrrnronnrnrnnonnvrnnrrnnvnvsnennvrrsernnvnnsrennvsssesnnnsee 45 4 3 3 2 Line Voltage Measurement Full Scale rrrrrrrnnnnnnnnnrrnnrrnsnnnnnnrnrvnnrrnsnnnnnnrnrsnnssnsnnnnnnnens 45 4 3 3 3 Inverter Current Measurement Full Scale rrrarannrnrnronnvnrnrrnnrrvrrrnnrresernnrnrsrensrnssssnnnse 45 4 3 3 4 Inverter Current Measurement Polarity Select 46 4 3 3 5 Inverter Current Measurement Auto Calbration 46 4 3 4 Default Operating Parametere 46 4 3 4 1 Default Control Mode Langaririh suse Ee enker AARAA 46 4 3 4 2 Default Voltage Setpoint rrrnnarrrrrnnarannnnnnvnvnrnnsnannnnnnrnnnsrssnnnnnnnnrnnnssnssnnnnnnnnsnnssnssnnnnnnnnn 46 4 3 4 3 Default Real Current Setpoint rrrrrrrannnnnnrnvnrrnsnannnnnnvvnnrnnsnnnnnnnnrnnnssnsnnnnnnnnrsnnssnssnnnnnnnnn 47 4 3 4 4 Default Reactive Current Setpoint 47 4 3 4 5 Voltage Mode Current Limit Man 47 4 3 4 6 Voltage Mode Current Limit Mim 47 4 3 4 7 Default Power Factor Setpoint rrrrannnnnnrvvnrnnsrannnnnnrvnnernsrnnnnnnnrnnnssnsnnnnnnrnrsnnssnssnnnnnnnnn 47 4 3 4 8 Default Stand Alone Voltage Setpoint 48 4 3 5 Grid Monitor and Protection Parameter 48 4 3 5 1 Grid Fa
94. ning a product directly to Oztek you must obtain a Return Material Authorization RMA number and the correct factory Ship To address Products must also be shipped prepaid Product shipments will be refused and returned at your expense if they are unauthorized returned without an RMA number clearly marked on the outside of the shipping box if they are shipped collect or if they are shipped to the wrong location When you contact Oztek to obtain service please have your instruction manual ready for reference and be prepared to supply e The serial number of your product e Information about the installation and use of the unit e Information about the failure and or reason for the return e A copy of your dated proof of purchase Return Procedure Package the unit safely preferably using the original box and packing materials Please ensure that your product is shipped fully insured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging Include the following e The RMA number supplied by Oztek clearly marked on the outside of the box e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e A brief description of the problem Ship the unit prepaid to the address provided by your Oztek customer service representative If you are returning a product from outside of th
95. nnnee 80 AFE Controller User s Manual Table of Contents Table of Figures Figure 1 Typical Renewable Energy PV Solar Application rnnarorrrnrnnanonnnnrnrvrnnrnannnnnnrnvsrnssnsnnnnnnrsnsnnssnnnnnn 3 Figure 2 Typical Regenerative Motor Drive Application cccsscccccecessesesseceeeeecesseseaeeeceeeeessessaeaeeeeeens 3 Figure 3 Typical Turbo Alternator Application with Stand Alone Voltage Mode Capability 0 3 Figure 4 Typical AFE Electrical System Schematic 4 Figure 5 AFE Controller Functional Block Diagram ccccccecssccecessneeeceesneeeceeseeecseaeeecseaeeeceeseeeceeeeeeeeees 5 Figure 6 Stand Alone Voltage Controller Functional Block Diagramm 6 Figure 7 Stand Alone Mode I T Protection Characteristic ccccccccccsccsccsscssccsscssssescsscscsesssssesssesseuserseasas 7 Figure 8 Stand Alone Mode RMS Protection Characteristic ccccccccccsssssssssseceeecessesssseseeeeecessesssseaeeseeens 7 Figure 9 Typical Interleaved AFE Electrical System Schematic r rrrnnrnnnnnnnnvnvvrnnrnsnrnnnnvnvsrnssnsnnnnnnrnnvenssnnnnnn 8 Figure 10 Interleaved AFE Controller Functional Block Diagramm 9 Figure 11 System State Machine 10 Figure 12 OZDSP3000 AFE Application Electrical Connections ccceseesssseceeeeesseseseaeeeeecessesenaeaneeeeens 17 Figure 13 P1 Isolated Serial Interface Pin out RS232 Configuration rerrrnrrnnnrnnnnvnvvrnnnnsnnnnnnrsn
96. nnrannnnrnrvnnrrnsnnnnnnrnrrnnssnsnnnnnnrnnsnnssnnnnnnnnnsnsenee 62 4 3 13 3 Contactor DEDOUNCEC sic osiers srera ENNAN AASE ANEA 62 4 3 13 4 Contactor Close Time serisine anaa Naaa NNa 62 4 3 13 5 Precharge Timeout Threshold rrrrnnnorrrrrrnnronnnnrnrvnnrrnsnnnnnnrnrsnnssnsnnnnnnrnnsnnssnnnnnnnnnsnsenee 62 4 3 13 6 Contactor Monitor Enables eassnrrvnrannrrvnnsnsrrenssnerrenssnernenessennenssnennenssnsnnrnssnennnssssnnnnee 63 4 3 13 7 Grid Contactor Enabl iicsescccccasscccsssiacccssansiechesaicdseanccecdasdeccdasaucceceesseccdusvisccesastiiecaaaetee 63 4 3 14 Instrumentation barameters 63 4 3 14 1 Instrumentation Interrupt Rate 63 4 3 14 2 Low Pass Cutoff Freq V DC Link Instrumentatlon 64 4 3 14 3 Low Pass Cutoff Freq V DC Link Feedback 64 4 3 14 4 Low Pass Cutoff Freq Grid Voltage ccccccccssssssseceeeceesesseneaeceeecessesssaeseeeeseesseseeaeees 64 4 3 14 5 Low Pass Cutoff Freq Grid Current c ccccccccssssssseceeeceesssecnsaeceeecessesesaeseeeessessesesaees 64 4 3 14 6 Low Pass Cutoff Freq Grid Freouency 64 4 3 14 7 Low Pass Cutoff Freq Temperatures 64 4 3 14 8 Low Pass Cutoff Freq Grid Voltage Feedforward ccccesssscececessesscseeeeeeseessesenaeens 64 4 3 15 Dual Interleaved Inverter Parameters rrsrnnnnannrannrannrrvnrennrrverennrsensennrsversnnrsvssennrsnssennrsessennnn 64 Publication UM 0021 Table of Contents 4 3 15 1 Dual Interleaved Inverter Enable A 64 4 3 15 2
97. nnrnrvrnssnsnrnnnnrnrsrnssrnnnnn 67 Table 30 Current Overload Protection Parameter SUMMALY rerrrrrrnnnnnnnnrnrvnnrrnsnannnnrnrrrnssnsnnnnnnrnnsrnssrsnnne 69 Table 31 Current Mode THD EE 74 Table 32 Voltag Mode THD su excised ceeds cosessncdasegedd en dude EES eE ORERE ERE ne ea EEEa 76 AFE Controller User s Manual Introduction 1 Introduction This document is intended to provide instruction on how to employ the Oztek AFE firmware application on a standard Oztek OZDSP3000 controller in an actual hardware system It describes the electrical connections as well as the scaling of the various signals required by the control firmware 1 1 Referenced Documents pa peme ees gt UM 0018 OZDSP3000 Users Manual FS 0046 OzCan Protocol Function Specification 3 5 6 um 0036 Power Control Center GUI User Menu 1 2 Definitions AFE Active Front End CAN Controller Area Network DSP Digital signal processor EEPROM Electrically Erasable Programmable Read Only Memory EMC Electro magnetic compatibility EMI Electro magnetic interference GND Ground low side of input power supply GTI Grid Tied Inverter GUI Graphical User Interface HMI Human Machine Interface IPM Intelligent Power Module N C Not connected PCB Printed Circuit Board PCC Power Control Center PI Proportional and Integral Compensator PLC Programmable Logic Controller PLL Phase
98. odic transmission of this message All other values ms 65 535ms are valid 4 3 2 11 CAN Update Rate Grid Status Message This parameter specifies the rate at which Grid Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic periodic transmission of this message All other values ms 65 535ms are valid 4 3 2 12 CAN Update Rate System Status Message This parameter specifies the rate at which System Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic periodic transmission of this message All other values ms 65 535ms are valid 4 3 2 13 CAN Update Rate Alarm Status Message This parameter specifies the rate at which Alarm Status CAN messages will be automatically transmitted by the firmware This value specifies the period between message transmissions in terms of milliseconds Setting this parameter to zero disables automatic periodic transmission of this message All other values ms 65 535ms are valid 4 3 2 14 CAN Broadcast Message Receive Enable This parameter determines whether or not the AFE controller will accept broadcast messages from the host controller See reference document FS 0046 OzCan Protoco
99. on memory see Section 4 3 3 3 for details The value sent in this command does not change the default value stored in the Publication UM 0021 Parameter Register Interface configuration memory rather it merely provides a dynamic and temporary override from the default value As indicated in the table above the power factor is commanded in units of 0 1 For example a power factor of 0 95 would be entered as 950 decimal or 0x03B6 hexadecimal A power factor of 0 98 would be entered as 980 decimal or OxFC2C hexadecimal A positive number less than 100 indicates grid currents lagging grid voltage i e inductive load a negative number indicates grid currents leading grid voltage i e capacitive load 4 2 1 7 Fault Reset This register is used to reset any latched fault conditions and to return the controller to the STANDBY state if no further faults exist 0 NOP No reset action requested 1 RESET Request to attempt a fault reset register is auto cleared to 0 2 to 255 Not Supported 4 2 1 8 Configuration Password This register is used to supply a password for those configuration operations that are password protected The password is cleared to zero at the end of the next parameter read or write operation 4 2 1 9 Configuration Reset This register causes the system to restore its non volatile configuration memory to the factory default configuration 0 NOP No reset action requested 1 RESET Re
100. onfiguration Control Parametere 40 AB VA EEPROM Header eegend 40 4 3 1 2 Factory Configuration Revision Major sssssssssssssssssesrrsssseserersrssssesrreennssssreereennssno 41 4 3 1 3 Factory Configuration Revision Minor 41 4 3 1 4 Application Configuration Data Revislon 41 4 3 1 5 Hardware Configuration ie cosis aiie eese inane iiaee aek iE iet 41 4 3 1 6 User Configuration Revision ssssssssssesressssssrrenressssssrrennrsssseserersnssssenereennsssserereennssno 41 4 3 1 7 Configuration Password srarorvrnnsnannnnnnrvnvrnnsnannnnrnrrnnsrnsnnnnnnrnrrnnssnsnnnnnnnnnsrnssnannnnnnnsnnsee 42 4 3 2 CAN Interface ParaMeter cc c scecdecsseccendesveecssstdeccuessevedunadeccduledavedusasdeceiuedevedsnedccessedaneaeensdt 42 4 3 2 1 CAN Automatic Alarm Transmit Enable 42 4 3 2 2 CAN TIMEOUT sveket 43 4 3 2 3 CAN Group 1D EE 43 4 3 2 4 CAN Module ID nannestad eee eneeier 43 4 3 25 CAN Baud Rate eieiei EES daa 43 4 3 2 6 CAN Status Destination Group ID 43 4 3 2 7 CAN Status Destination Module ID 43 4 3 2 8 CAN Update Rate DC Link Status Message 44 4 3 2 9 CAN Update Rate Grid Voltage Status Message 44 4 3 2 10 CAN Update Rate Inverter Current Status Message 44 4 3 2 11 CAN Update Rate Grid Status Message 44 4 3 2 12 CAN Update Rate System Status Message 44 4 3 2 13 CAN Update Rate Alarm Status Message 44 Publication UM 0021 Table of Contents 4 3 2 14 CAN Broadcast Message Receive E
101. output pin assignments are shown in the table below as well as in Figure 12 Table 5 J10 Isolated Digital Output Pin Assignment Pin Description 1 DOUTO Emitter GND reference DOUTO Collector signal output DOUT1 Emitter GND reference DOUT1 Collector signal output DOUT2 Emitter GND reference DOUT2 Collector signal output FAULT Emitter GND reference FAULT Collector signal output COJ HR IN WID NIM e OZDSP3000 Connector Part Number Molex Micro Fit 2x4 Header 43045 0824 e Mating Connector Part Number Molex Micro Fit 2x4 Receptacle 43025 0800 e Input Range Logic high OV or floating Logic low 3V 25V 3 1 7 J23 High Voltage Line Feedback The AFE firmware expects to sense AC line voltage for the purposes of line synchronization on J23 The standard hardware variant is designed to accept 480VAC voltages directly Interfacing to other AC voltages may require a modification to the gain of the sense amplifier consult Oztek for more information Table 6 J23 High Voltage Sense Pin Assignment Pin Description 1 Line Voltage Phase A 4 Line Voltage Phase B 7 Line Voltage Phase C 10 Neutral eave unconnected for 3 phase systems e OZDSP3000 Connector Part Number Waldom Molex 26 60 4100 e Mating Connector Part Number Tyco 4 644465 0 AFE Controller User s Manual OZDSP3000 Hardware Interfacing 3
102. plicable interface circuit J19 J18 1 1 2 2 Se 60 4 60 4 4700 pF ISO1 eee E p gt gt CANH E vvvyte d gt gt CANL 51 uH 5A 100 pF 100 pF Lo ISO1 Figure 16 CAN Interface Circuit AFE Controller User s Manual OZDSP3000 Hardware Interfacing 3 2 Electrical Interfaces The approximate location of the connectors jumper blocks LEDs and test hooks are illustrated in Figure 17 ORRE SSG CI CIC O J12 10741 REV C ww OUTER com Figure 17 Approximate Connector Jumper LED and Test Hook Locations Publication UM 0021 OZDSP3000 Hardware Interfacing 3 3 Mechanical Interface w 330 OUTER PAD 189 DRILL HOLE 5 PLACES 00 7 000 6 7 2 PLACES O 1 D i L ECH 300 2 PLACES 2 PLACES 5 665 a 8 700 2 PLACES 9 000 Figure 18 OZDSP3000 Mechanical Dimensions AFE Controller User s Manual a Parameter Register Interface 4 Parameter Register Interface The AFE is controlled monitored and configured via a parameter register set This register set can be accessed through several different interfaces including RS 485 and CAN bus serial communication links 4 1 Register Properties 4 1 1 Parameter ID The Parameter ID PID listed in the tables below represents a numerical identifier for each parameter 4 1 2 Data Types The actual parameters
103. quest to reset the configuration register is auto cleared to 0 2 to 255 Not Supported Successful execution of this command requires the following conditions be met e The Configuration Password register PID 0x0007 must have been previously loaded with the correct password e The system must be in a non operation state i e the AFE must be OFF CAUTION Upon execution all currently stored configuration data will be permanently destroyed and over written with the factory default configuration data AFE Controller User s Manual Parameter Register Interface 4 2 1 10 Configuration Reload This register causes any modifications to the configuration register space to be loaded from the non volatile configuration space 0 NOP No reload action requested 1 RELOAD Reload the operational parameters from the configuration space register is auto cleared to 0 2 to 255 Not Supported Successful execution of this command requires the following conditions be met e The system must be in a non operation state i e the AFE must be OFF CAUTION Either execution of this command or a Power On Reset POR is required before changes to the configuration space are used for operation 4 2 1 11 Stand Alone Voltage Setpoint This register is used to adjust the desired RMS phase to phase AC output voltage set point when the AFE is operating in Stand Alone voltage control mode The default voltage following a pow
104. r Debounce Time configuration parameter PID 0x80B2 has passed the precharge contactor is not in the state commanded by the AFE a fault will be asserted 2 5 2 5 Grid Contactor Error The AFE monitors the status of the main grid contactor feedback signal if the grid contactor monitor is enabled in the Contactor Monitor Enables configuration parameter PID 0x80B5 If after the time specified in the Contactor Debounce Time configuration parameter PID 0x80B2 has passed this contactor is not in the state commanded by the AFE a fault will be asserted 2 5 2 6 Relay Driver Hardware Error The AFE monitors the status of the relay drive circuit on the control board that is used to drive the precharge and main line contactors This hardware circuit provides the ability to detect open load short circuit over voltage and over current conditions A fault is asserted if any of these conditions are reported AFE Controller User s Manual Functional Description 2 5 2 7 Communications Timeout If the CAN bus interface is used and the CAN Timeout configuration parameter PID 0x8011 is set to a non zero value the AFE will monitor the amount of time elapsed between received CAN messages A fault will be asserted if the specified timeout threshold is exceeded 2 5 2 8 Configuration Memory Error This fault occurs any time a read from the configuration memory is performed and the CRC for the block being read does not match the CRC stored in the memor
105. re peripherals configuring variables and performing self health tests Upon successful initialization the state machine will auto transition to the Calibrate state AFE Controller User s Manual Functional Description 2 4 2 Calibrate The Calibrate state is used to calibrate system hardware as applicable Power hardware is not operable while in the Calibrate state Following successful calibration the state machine will auto transition to the Precharge state 2 4 3 Precharge The Precharge state is used to wait for a valid AC line interface before attempting to begin the DC link charging process As long as the operating mode is not stand alone voltage mode the state machine will remain in the Precharge state indefinitely transitioning either on a fault or upon detecting a valid AC line Power hardware is not operable while in the Precharge state If stand alone voltage mode is selected the state machine will transition directly to the Idle state 2 4 4 Charge The Charge state is used to charge the DC link capacitance in a controlled manner before directly connecting to the AC line Once the DC link is charged the state machine will sequence to the Idle state Power hardware is not operable while in the Charge state 2 4 5 Idle Once in the Idle state the AFE is ready for use The state machine will remain in the Idle state indefinitely transitioning either on a fault a turn on command or upon detecting an invalid AC line If
106. red for hardware On Off and Fault Reset control see parameter Ox806D Hardware On Off Pin Control the AFE is turned On Off and faults are cleared using the pin assignments below and also shown in Figure 12 Table 4 J9 Isolated Digital Input Pin Assignment Pin Description 1 Pre charge contactor status switched 24V 24V Return Line contactor status switched 24V 24V Return Fault Reset OV to 24V transition clears faults 24V Return On Off Control OV Off 24V On 24V Return O AIN IQGIO NJ UT e OZDSP3000 Connector Part Number Molex Micro Fit 2x4 Header 43045 0824 e Mating Connector Part Number Molex Micro Fit 2x4 Receptacle 43025 0800 e Input Range OV 25V 3 1 6 J10 Isolated Digital Outputs The AFE controller provides 3 general purpose isolated output pins DOUTO DOUT1 and DOUT2 that can be controlled using the Isolated Digital Output Control command register PID 0x000B The controller also reports the AFE fault status using a 4 isolated output pin FAULT on this connector These pins are open collector optically isolated outputs For the FAULT output a high impedance output i e open collector output is off indicates that no fault conditions are Publication UM 0021 OZDSP3000 Hardware Interfacing present When a fault occurs and the AFE controller is driven to the Fault state this output will be asserted i e OV from collector to emitter The specific
107. rid current By setting this parameter Publication UM 0021 60 Parameter Register Interface equal to the capacitor current the resulting grid side current and power factor will better correspond to the commands 4 3 11 5 Nominal DC Link This parameter defines the nominal DC link voltage for which the control loop compensation has been designed It is used to perform DC Link voltage feed forward correction 4 3 12 Phase Lock Loop PLL Parameters The table below summarizes the configuration parameters that affect the operation of the AFE s phase lock loop PLL module that is used to synchronize the AFE output to the utility line The factory default values have been carefully chosen to optimize the performance of the AFE for low THD and robust immunity to grid voltage disturbances CAUTION It is highly recommended that the user not adjust the default PLL parameters listed below These parameters are provided for flexibility when the AFE is employed in atypical non utility based systems Contact Oztek for further information regarding possible modifications to these PLL settings Table 24 PLL Control Parameter Summary PID SE Description Units den Min Max E Ox80A0 S32 Kp Phase Locked Loop Unlocked Q16 0 03 0 0 32767 99 RW Ox80A1 S32 Ki Phase Locked Loop Unlocked Q16 6 0 0 0 32767 99 RW Ox80A2 S32 Kp Phase Locked Loop Locked Q16 0 003 0 0 32767
108. rnsnnnnnnrnrsnnssnsnrnnnnnnnsesssnnnannnnnnnnssee 35 4 2 2 3 DE Dine Voltage 35 42 24 AC LINE Voltage seiner rear EE E sui ise seksti 35 42 25 Grid Tu EIN A A A A T E N A E T 35 4 2 26 A e E E En e EE 35 4 2 2 7 Power Factor usa 35 4 2 2 8 BE Eege ee eege 35 4 2 2 9 Inverter A TEM pPGrature sic csi scishcSescccasscveetendsssccun EErEE EEE E EErEE EEEE EEEE 35 4 2 2 10 Auxiliary Temperature 36 42 211 Contactor St tus suansis pa Geunes aaa E E RAE EEE eeennauscudhebdsstargacveatencs 36 Der e Sak NEEN TT 36 42 213 e EE 36 4 2 2 14 Register Operation Status cccccccccccccccececececeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeseeeess 37 4 2 2 15 DSP Software Revision Malor Minor 38 4 2 2 16 FPGA Firmware Revision Major Minor s sss ssssssssssssssssssnssnessrrssrnssrresrresrnnsrrnsrreseresne 38 4 2 2 17 Board Hardware Revision ccccccsssecessennececseneececseeececeeaaececeeaueeeeseaaeeesseaaeeeeseaeeseneaaes 38 4 2 2 18 Inverter A B Current ttnn antenner rE nn tanen ninnan nn nesne nn nannat 38 4 2 2 19 Inverter B Temperature 38 4 2220 Fault STIS A oo ed ekesasavenscdlecdhsaaseadeiapscebntceasescasacchsseses Uosdesavehnsesavenncesaudsaaa lenis 38 4 2 2 21 Isolated Digital Input Status r rrrrrnnnnnnnrrrrrrrsrannnnrnrvnnrrnsnrnnnnrnrvnnssnsnrnnnnrnnnerrsrnnnnnnnnnnsssee 38 4 3 Non Volatile Configuration Registers cccssscccsessnsecesseeeceeseeeecesseeeecseseeaeceeseeeecseeeaaecessenaeess 39 4 3 1 C
109. s Cutoff Freq V DC Link Instrumentation 1Hz 2 1 10000 RW Ox80C2 U16 Low Pass Cutoff Freq V DC Link Feedback 1 Hz 1000 1 10000 RW Ox80C3 U16 Low Pass Cutoff Freq Grid Voltage 1 Hz 5 1 10000 RW Ox80C4 U16 Low Pass Cutoff Freq Grid Current 1 Hz 5 1 10000 RW 0x80C5 U16 Low Pass Cutoff Freq Grid Frequency 1 Hz 10 1 10000 RW Ox80C6 U16 Low Pass Cutoff Freq Temperatures 1 Hz 2 1 10000 RW 0x80C7 U16 Low Pass Cutoff Freq Grid Voltage Feedforward 1 Hz 5 1 10000 RW 4 3 14 1 Instrumentation Interrupt Rate This parameter specifies the rate at which the instrumentation interrupt is executed in the AFE controller This is the rate that the various measurements are read and filtered by the AFE software Publication UM 0021 64 Parameter Register Interface 4 3 14 2 Low Pass Cutoff Freq V DC Link Instrumentation This parameter defines the cutoff frequency for the digital low pass filter used to calculate the DC link voltage for instrumentation purposes 4 3 14 3 Low Pass Cutoff Freq V DC Link Feedback This parameter defines the cutoff frequency for the digital low pass filter used to calculate the DC link voltage for feedback in Voltage Control mode 4 3 14 4 Low Pass Cutoff Freq Grid Voltage This parameter defines the cutoff frequency for the digital low pass filter used to calculate the RMS phase to phase grid voltages 4 3 14 5 Low Pass Cutoff Freq Grid Current This parameter defines the
110. s is only true if no other fault conditions exist and if the converter was left ON i e the last On Off Control command PID 0x0000 sent was the ON command If this parameter is set to FALSE then any grid voltage or frequency related faults will be latched and the AFE controller will remain in the FAULT state with the converter OFF until the faults are explicitly cleared using the Fault Reset command PID 0x0006 Publication UM 0021 Parameter Register Interface 4 3 7 8 Use Power Factor Setpoint This parameter determines whether or not the Power Factor Setpoint command PID 0x0005 will be used when the AFE is operating in current control mode If this parameter is set to FALSE the Power Factor Setpoint command will be ignored when operating in current mode Instead the real and reactive current levels are explicitly set according to the corresponding Grid Current Setpoint Real Reactive commands PIDs 0x0003 0x0004 If this parameter is set to TRUE the Grid Current Setpoint Reactive command will be ignored Instead the reactive current will be set based on the Grid Current Setpoint Real and the Power Factor Setpoint commands This parameter is not used when operating in voltage control mode Instead the output of the voltage controller will always control the real current command to the inner current loop and the reactive current level will be based on the real current command from the voltage controller and the Power
111. sni ieee aiaa 15 Publication UM 0021 SS Table of Contents 25217 PLU LOSULOCK TEE 16 2 5 2 13 Software Inverter Over Current cccccccsssececeessececeesneeeceeneeecseaeeeceesaeeessesaeeeeseneeeeeees 16 2 5 2 14 Grid Frequency Fault rorrrnrnnnnnnnnnrnvvvnrnnsnnnnnnrnrrnnssnsnnnnnnrnnsnnssnsnnnnnnrnnsrnssnsnnnnnnrnnsenssnnnnnn 16 2 5 2 15 Grid Voltage Fault cccs ccseccsdceescsstececcssecetucctesezeccsdcezecccdeetbecsbactacetndentecuicsbecdsisedbecstacdacetndend 16 2 5 2 16 Software Auxiliary Over Temperature rrrnnnrnrsnnnrnnnnnnnnrnrvnnsrnsnnnnnnrnnsnnssnsnnnnnnrnnsrnssrnnnnn 16 25 217 Galibr tion TE 16 3 DZDSP3000 Hardware Interfacing vu masaresminasneseneiasnmuni jvniannonidsidii 16 3 1 Application Intertarces isnin seerneissietse insense ne neiere reee EE EES ERER Enoia EREE EEEa 17 3 1 1 J11 SKiiP Power Module Interface Inverter A 17 3 1 2 Custom Driver Interface Considerations ssssssssssssssssrrssesrrssrrrsstterssrtrrssttnnssrtnnsstennssreetet 18 3 1 2 1 POWER 19 3 122 Switch Rull E 19 3 1 2 3 Error INPUtS ange ee ENE 19 3 1 2 4 D Link Voltage Sensing rerrrrrnraranannnnrvrvrrrsnnnnnnnnrvnrerrsnnnnnnnrnnrrrrsnrannnnnnnnsssssnannnnnnnsssee 19 3 1 2 5 DC Link Hardware Over Voltage Protechon 19 3 1 2 6 Hardware Over Current and Desaturation Protectlon 19 3 1 2 7 Current Sense Signals ccccccccccscsssssssecececessesssaeseceeecesscseeaeeeceesessseaeaeseeeessseseneaeeeeeens 19 3 1 2 8 Temper
112. st Slow Over Under Voltage Thresholds and Clear Times ss nsssnssnssnssnss11 48 4 3 5 2 Grid Fast Slow Over Under Frequency Thresholds and Clear Times 49 4 3 5 3 Grid Reconnect Delay Time 49 4 3 6 Fault and Warning Parameters c ccccccccssssssssecececessessaeseceescesseseeaeseceeecesseeaaeeeeeeseessesenaees 49 4 3 6 1 DC Link Over Voltage Fault Thresbold 49 4 3 6 2 DC Link Over Voltage Warning Threshold ccccsssssecececeseseesseaececeeeseesecssaeeeeeesseseees 50 4 3 6 3 DC Link Over Voltage Recover Thresbold 50 4 3 6 4 Grid Over Current Fault Thresbold A 50 4 3 6 5 Grid Over Current Warning Thresbold 50 4 3 6 6 Grid Over Current Recover Thresbold 50 4 3 6 7 Inverter Temperature Fault Tbresbold 50 4 3 6 8 Inverter Temperature Warning Thresbhold 50 4 3 6 9 Inverter Temperature Recover Threshold ssessssssssessrsssseserensrssssesereennsssseeerensessns 51 4 3 6 10 Auxiliary Temperature Fault Thresbhold 51 4 3 6 11 Auxiliary Temperature Warning Threshold c cccccccsssssesssecececessessceeseeeeseessessaeees 51 4 3 6 12 Auxiliary Temperature Recover Thresbold 51 4 3 6 13 Inverter Error Pin Active High 51 4 3 6 14 Inverter Over Temp Pin Active Hieb 51 4 3 6 15 DC Link Under Voltage Fault Threshold sssssssesnssssseenresssssserennrsssseserennnssssesereennssee 51 4 3 6 16 DC Link Under Voltage Warning Thresbhold 51 4 3 6 17 DC Link Under Voltage Recover Threshold cssssccccccsssssesscece
113. t fault condition is latched and reported separately for each inverter in the Fault Status instrumentation register PID 0x4010 4 3 6 5 Grid Over Current Warning Threshold This parameter defines the grid current threshold above which the firmware will report a high grid current warning Once above this warning threshold the grid current must fall below the corresponding recover threshold before the firmware will clear the high grid current warning For dual interleaved inverter operation this value is divided in half and used by each inverter s current controller If either inverter exceeds 50 of the value stored in this register the controller will indicate a warning condition for the corresponding inverter The inverter over current warning condition is reported separately for each inverter in the Warning Status instrumentation register PID Ox400F 4 3 6 6 Grid Over Current Recover Threshold See warning threshold description above 4 3 6 7 Inverter Temperature Fault Threshold This parameter defines the inverter temperature fault threshold If the temperature rises above this value the converter will automatically transition to the FAULT state and operation of the application will be disabled and forced OFF 4 3 6 8 Inverter Temperature Warning Threshold This parameter defines the inverter temperature threshold above which the firmware will report a high temperature warning Once above this warning threshold the temperature must
114. tage to rise above the DC Link Pre Charge Threshold 4 3 13 6 Contactor Monitor Enables This parameter is used to determine if contactor feedback monitors are enabled The enumerated values for this parameter are as follows e 0 No monitoring i e no contactor feedback is provided or checked e 1 Monitor Precharge Contactor only e 2 Monitor Grid Contactor only e 3 Monitor Both Contactors 4 3 13 7 Grid Contactor Enable This Boolean parameter is used to enable control for a main grid contactor This parameter defaults to TRUE the AFE controller will attempt to close the main contactor when connecting to the grid and open the contactor when entering the FAULT state or when the grid voltages fall out of tolerance This parameter should be set to FALSE for those systems in which there is no main grid contactor or if the AFE is not responsible for controlling this contactor 4 3 14 Instrumentation Parameters The table below summarizes the filter cutoff values for the various measurements reported to the user as well as the rate at which these measurements are updated by the AFE controller Unless a clear need exists it is recommended that the user not change these values from the factory default values Table 26 Instrumentation Parameter Summary PID spe Description Units Ge Min Max ER 0x80C0 U16 Instrumentation Interrupt Rate 1Hz 2000 500 5000 RW Ox80C1 U16 Low Pas
115. ter SUMMALY cccseessssececeeecesssseaecececeseeseaeaeeeeecesseseasaeeeesens 40 Table 14 CAN Interface Parameter Summary 42 Table 15 System Measurement Scaling Parameter Summary 45 Table 16 Default Operating Parameter SUMMALY cccccccecessssssseceeececeesesesecececeseeseaeaeeeeecessessnasaeeeesens 46 Table 17 Fault and Warning Parameter Summary 48 Table 18 Fault and Warning Parameter Summary 49 Table 19 Converter Control Parameter Summary cccccccecesssssssecececesessesssaececeesseesenaeaeeeeesessesenaeaneeesens 52 Table 20 Inverter Temperature Parameter SUMMALSY ccccesecssssececececessesseaeceeecesesseaaeaeeeeecessussneaeeeesens 55 Table 21 Auxiliary Temperature Parameter Summary 56 Table 22 Voltage Regulator Parameter SUMMALY c cccccccecsssessssecececscessessaeceeeceseeseaeaeseeeeesseseneaeeeesens 57 Table 23 Current Regulator Parameter Summary cccccccscssssssssececeescessesssaecececeseesesaeaeeeeeeessesesaeaeeeeeens 58 Table 24 PLL Control Parameter Summary 60 Table 25 Pre charge Parameter Summary 62 Table 26 Instrumentation Parameter Summary 63 Table 27 Instrumentation Parameter Summary 64 Table 28 Modbus Parameter SUMMary cccccccccecssssssssesecececessesseaeeecececeeseeeseeeeecsseesesaeaeeeeecessesseaeaeeeeeens 66 Table 29 Stand Alone Voltage Regulator Parameter Summary rrrnrrrnnnnrnvvrrrrnsnrnn
116. the full scale measureable value specified by the DC Link Voltage Measurement Full Scale configuration parameter PID Publication UM 0021 Parameter Register Interface 0x8020 Similarly the resulting current command output is also a normalized current relative to the full scale inverter current specified by the Inverter Current Measurement Full Scale configuration parameter PID 0x8022 The Kp and Ki gain constants should be scaled appropriately based on this normalization 4 3 10 3 Voltage Droop Control Gain Karoop This parameter is used to simulate a higher impedance on the regulated DC link voltage output As the figure above shows the droop control is achieved by multiplying the measured current in this case the real grid side current la by this gain Kdroop and then adding this offset to the DC link voltage feedback The affect of doing this is that as the load current goes up the regulated voltage will decrease slightly For example if the user wants a 2 drop on a DC link of 800V or 16V at a rated load of 100Arms this parameter would be set to 800 0 02 100 0 16 This feature is useful for assisting in load balancing between multiple voltage mode AFEs operating in parallel This feature is disabled by setting the Karoop gain to the factory default value of zero 4 3 11 Current Regulator Parameters Table 23 Current Regulator Parameter Summary PID Des
117. the layout and format of the data in the configuration memory i e a simple change to a default value for a particular parameter or its legal data range The major revision number is required to change any time new parameters are added or parameter locations or formats are changed The user must take care when updating the firmware to understand whether or not the configuration memory will be reset so as not to lose any custom settings previously stored The present factory revision of the configuration memory is stored in the Factory Configuration Revision registers PIDs 0x8001 0x8002 4 3 1 Configuration Control Parameters Table 13 Configuration Control Parameter Summary PID e Description Units Ge Min Max DECH 0x8000 U16 EEPROM Header Integer Ox1AFE 0 OxFFFF R 0x8001 U16 Factory Configuration Revision Major Integer 8 0 OxFFFF R 0x8002 U16 Factory Configuration Revision Minor Integer 0 0 OxFFFF R 0x8003 U16 Application Configuration Data Revision Integer 0 0 OxFFFF RWP 0x8004 U16 Hardware Configuration ENUM 0 0 OxFFFF R 0x8005 U16 User Configuration Revision Integer 0 0 OxFFFF RW 0x8006 U16 Configuration Password Integer Ox1111 0 OxFFFF RWP 4 3 1 1 EEPROM Header This is a read only header word that is used to indicate whether or not the configuration memory contains valid configuration data This header word is a fixed constant and is not AFE
118. the operating mode is switched from stand alone to either DC Link voltage regulation mode or current regulation mode the state machine will transition back to the Precharge state 2 46 On While in the On state the AFE is processing power and controlling either the AC line current or the DC link voltage depending on the configuration The state machine will remain in the On state indefinitely transitioning either on a fault or a turn off command When a turn off command is received the state machine will immediately go to the Idle state if in voltage regulation mode or to the Turn Off state if in current regulation mode 2 4 7 Turn Off The Turn Off state is only used when the AFE is operating in current regulation mode and was commanded to turn off This state is used to wait for the current to ramp down to zero based on the user specified rate set in the Turn Off Current Slew Rate configuration register PID 0x8093 Once the current reaches zero the state machine will then transition to the dle state 2 4 8 Low DC Link If the controller is in the Idle state and configured for stand alone operation the state machine will transition to this Low DC Link state if the measured DC link voltage falls below the value Publication UM 0021 Functional Description specified in the DC Link Under Voltage Fault Threshold configuration register PID 0x8111 It will wait in this state until the DC link rises above this fault threshold at which point
119. this section are ignored AFE Controller User s Manual Parameter Register Interface 4 3 15 2 Zero Sequence Current Control Enable This parameter is used to enable a PI regulator to be used to force the zero sequence current to zero on one or both of the inverters as follows e 0 zero sequence control disabled for both inverters e 1 zero sequence control enabled only for inverter A e 2 zero sequence control enabled only for inverter B e 3 zero sequence control enabled for both inverters The zero sequence controllers are intended to prevent a DC current offset from developing and circulating when running multiple inverters in parallel 4 3 15 3 Zero Sequence Current Controller Gain Constants Kp Ki Vasc Offset la measured 3 IB measured Ic measured Figure 21 Zero Sequence PI Regulator These parameters define the gain constants for the PI controller that is used to regulate the zero sequence current The integral gain Ki parameter should be entered as the continuous gain or sometimes referred to as the analog gain The firmware handles converting this to the discrete time gain by automatically dividing this by the sample frequency at which the controller is updated The PI topology used by the zero sequence current controller is the same as that used by the real reactive current controllers in that the proportional and integral correction terms are summed together see the figure above
120. usly write to Configuration Registers Poorly designed HMI and master controller applications that needlessly update configuration registers in a continuous fashion serve no purpose and will result in premature EEPROM failure Once one or more configuration parameters have been updated by writing to the applicable configuration register the actual operating configuration variables remain unaffected until one of two events occur either the user cycles power on the control board or the Configuration Reload command register PID 0x0009 is written to In the second case the reload is only allowed if the AFE is not enabled Attempts to reload the system configuration while the converter is in operation will result in the command being ignored and an error being reported in the Register Operation Status register PID 0x4011 The Configuration Reset command register PID 0x0008 is used to reset the EEPROM back to the original factory default values The user should take care when using this command as any custom configuration settings will be lost when the entire contents of the configuration memory is overwritten with the specified factory defaults This command is only allowed if the converter is not enabled Attempts to reset the EEPROM data while the converter is in Publication UM 0021 40 Parameter Register Interface operation will result in the command being ignored and an error being reported in the Register Operation Status register
121. ustom configurations is left up to the user Publication UM 0021 Parameter Register Interface 4 3 1 7 Configuration Password This parameter defines the configuration password stored in the configuration memory To access any parameter that is marked as password protected the user must provide a password that matches the value stored in this parameter See the Parameter Read Write messages described in FS 0047 OzCan AFE Device Profile for further details on providing this password value Note that this parameter is password protected as well The firmware has its own unpublished master password that can be used to override the password stored in this register In the event that the password is changed from the factory default listed then subsequently lost contact Oztek for the master password or for other alternatives to reset the value in the configuration memory 4 3 2 CAN Interface Parameters The following set of parameters are provided to allow for customizing the CAN interface for the end user s application Table 14 CAN Interface Parameter Summary PID Description Units can Min Max ee 0x8010 U16 CAN Automatic Alarm Transmit Enable Boolean TRUE FALSE TRUE RW 0x8011 U16 CAN Timeout 1ms 0 10 65535 RW 0x8012 U16 CAN Group ID Integer 2 1 15 RW 0x8013 U16 CAN Module ID Integer 1 1 31 RW 0x8014 U16 CAN Baud Rate ENUM 25
122. uxiliary Temperature Fault Warning Threshold configuration parameters PIDs 0x8059 0x805B 4 3 9 2 Auxiliary Temp Coefficients CO through C3 The auxiliary temperature is calculated using the same techniques as the inverter temperature as described in the previous section It is left up to the user to generate these coefficients for the specific sensor s resistance to voltage transfer function As described section 3 1 9 the thermistor is treated as the lower resistor in a resistor divider with an upper resistor of 2kQ tied to a 3 0V reference The temperature transfer function can be derived using a common tool like Microsoft Excel in which the thermistor resistance vs temperature data is entered the resulting voltage from the resistor divider is calculated and then normalized by diving by the ADC s 3 0V reference The resulting ADC to temperature curve can be plotted and a 3 order polynomial trend line can be generated to match the curve AFE Controller User s Manual Parameter Register Interface 4 3 10 Voltage Regulator Parameters Table 22 Voltage Regulator Parameter Summary PID ae Description Units GN Min Max oe 0x8080 U16 Voltage Command Slew Limit 1 V s 100 1 65535 RW 0x8081 32 Kp Voltage Controller Q16 1 8 0 32767 99 RW 0x8082 S32 Ki Voltage Controller Q16 33 5 0 32767 99 RW 0x8083 S32 Voltage Droop Control Gain Q16 0 0 32767 99 RW 4 3 10 1 Voltag
123. venssrnnnnn 24 Figure 14 P1 Isolated Serial Interface Pin out RS422 485 Configuration ccccccscccesssecsseeeeseceesseeeees 25 Figure 15 Multi Node CAN Network Configuration cccccccsssssssscececsseesesseaecececeeseseaeaeeeeseessessssaneeesens 26 Figure 16 CAN Interface Circuit 26 Figure 17 Approximate Connector Jumper LED and Test Hook Locations 27 Figure 18 OZDSP3000 Mechanical Dimensions s sssssssesssessnssssesrretsrsssserrrntnnssssrrennrsnssnernnnnsnssrnennennssno 28 Figure 19 Voltage Control PI Regulator 57 Figure 20 Current Control PI Regulators nesnseesennnssssesnneernsssseerrresnsssnrrrnnrnnsssnrrennrssssnnernnnnssssneennnnsnno 59 Figure 21 Zero Sequence PI Regulator sesnssssessresrrssssesrreernssssrsrrrtsnsseserrrnennsssnrrrnntssssnnerennnsnssnennnnesnno 65 Figure 22 Resonant Controller r rrrrrrrnnnnnnnrvrrrnrsrannnnnnnnnnernsnnnannnnnnnnssnsnnnnnnnnnnnnssnsnnnnnnrnnnenssnsnnnnnnrnnnenssnnnnnn 68 Figure 23 Current Mode Normal Operation 1204 75 Figure 24 Current Mode Turn On Isiew 300A s left and 1200A s right cccscccesseessseeesseeeeseeeees 75 Figure 25 Voltage Mode Turn On Vsiew 1500V s left and 5000V s right cccescccsssceesseeeeseeeeees 76 Figure 26 Voltage Mode Transient Response scssssscccececessesseaececeesceeseseaecesecsesesesaaaeeeseeesseseaeaeeeeeees 77 Figure 27 Voltage Mo
124. ver Current The AFE firmware monitors the RMS current for each of the three phases on the main Inverter A and asserts a fault if any phase exceeds the Grid Over Current Fault Threshold configuration parameter PID 0x8053 If the Dual Interleaved Inverters Enable configuration parameter PID 0x80D0 is set to TRUE the AFE firmware will also monitor the currents from the secondary Inverter B interface and check these against the same fault threshold value 2 5 2 14 Grid Frequency Fault The AFE will assert a fault the measured AC line frequency is not within the tolerances described in section 4 3 5 2 This fault only occurs when the AFE is ON or if an attempt is made to turn the AFE ON Otherwise this is only reported as a warning condition 2 5 2 15 Grid Voltage Fault The AFE firmware monitors the three RMS Phase to Phase Voltages of the utility grid A fault is asserted if any of these voltages are not within the tolerances described in section 4 3 5 1 This fault only occurs when the AFE is ON or if an attempt is made to turn the AFE ON Otherwise this is only reported as a warning condition 2 5 2 16 Software Auxiliary Over Temperature If the Auxiliary Temperature Sensor Enable configuration parameter PID 0x8078 is set to TRUE the AFE will monitor the external temperature sensor and assert a fault if the temperature exceeds the Auxiliary Temperature Fault Threshold configuration parameter PID 0x8059 2 5 2 17 Calibration Error Whe
125. y This may occur if the data was corrupted in transmission during the read or this may occur if the data stored in memory was corrupted Unlike all other fault sources this fault condition is not cleared with the Fault Reset command PID 0x0006 as the fault condition indicates the possibility that the control parameters are not as intended Instead this fault is considered a major system fault and needs to be addressed as follows 1 Attempt to reload the system configuration using the Configuration Reload command PID 0x0009 or cycle power to the control board Either of these actions will reset the CPU on the control board which then forces a re initialization of the application including reading the configuration parameters from the external configuration memory If this completes without error this implies the previous error occurred while the data was being read 2 If after executing step 1 above a configuration error is still present this may indicate bad data in the configuration memory In this case the memory will need to be reset to the factory defaults using the Configuration Reset command PID 0x0008 Once the memory contents have been reset and any values changed to their customized settings step 1 above should be executed to force a reload of the system variables 3 If neither of the above result in clearing the configuration error then there is likely an issue with the control board hardware At this point the board should be

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