DI Driver Rev F - National Instruments
Contents
1. 10 0A lt 572 08 200 08 Trigd M 10 34 HAN MD NAAN AA HOME Figure 11 BackBoostTime 0 100 msec Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 24 Drivven Inc DI Driver Module Kit H 20 0V g B 10 0A x 572 08 200 08 Trigd H 1034 nnm MAA AN AN j hhnnnn DEE Figure 12 BackBoostTime 0 150 msec Piezo Injector Operation The DI Driver module is capable of driving unipolar piezo injectors Unipolar means that the piezo injector is charged to a positive voltage and discharged to ground Bipolar drive means that the piezo injector can be charged to a positive or negative voltage When driving piezo injectors only channels 1 and 2 are available for this mode Channel 3 must be connected with a shorting jumper between the Inj and Inj terminals Electrically piezo injectors are a capacitive load as opposed to an inductive load from solenoid injectors Solenoid injectors require current to be driven through the solenoid in order to create the proper magnetic field within the injector body to mechanically open a valve Piezo injectors have a stack of piezo crystal elements which respond mechanically to a voltage applied across the stack The two pins of the piezo injector are connected internally across the stack As the voltage across the stack increases the stack expands and exerts a force to open a fluid valve The benefit of piezo injectors is the ability of the piezo stac2. DI Driver Module Kit charging the piezo stack the final charge will be a few volts less than the HVTarget setpoint When discharging the piezo stack the final discharge state will be 0 Volts The IPhaseArray is used differently during piezo mode The eight elements of the IPhaseArray are divided into two groups The first four elements are used for charge and the last four elements are used for discharge The BackBoostTime parameter is not used for piezo injector operation The DriveSrc Boolean for each IPhaseArray element is not applicable for piezo injector operation because the high voltage driver circuit is always used A representative simplified schematic driving two piezo injectors is shown in figure 13 below DI Driver Simplified Circuit Schematic for Piezo Injectors Internal Boost Power Supply High Side High Voltage Switch 47yH 47pH inductor Inductor Piezo Piezo Injector 1 Injector 2 Chan 1 Chan 2 Chan 3 Low Side Low Side Low Side Switch Switch Current Sense amp Comparator Circuitry Figure 13 DI driver simplified schematic for two piezo injectors The DI Driver module can also operate piezo injectors requiring an inverted charge scheme The inverted piezo mode is determined by the Piezolnvert Boolean discussed in the software section of this manual This means that the injector valve is closed when the stack is charged and the valve is opened when the stack is discharged Only a single pi
3. configuration example 1 H 500V g H 5 00A ae 084 08 200 08 Stop 4 31 3V Figure 15b Current and voltage traces from Piezo IPhaseArray configuration example 1 HVTarget 150V Charge time 148 usec Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 28 Drivven Inc DriveSre NUM IUpper A 10 ILower AJ g Dur msec 0 025 ri y IPhaseArray DriveSrc wm IUpper A 10 ILower AJ 9 Dur msec 10 025 I DriveSre DN IUpper A 10 ILower AJ g Dur msec 0 TE av IUpper A w ILower A 9 Dur msec 0 025 Figure 16a Piezo IPhaseArray configuration example 2 B 500v g B 5 00A HVTarget 150V Charge time 124 usec Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 288 05 ma IUpper A 10 TLower A g Dur msec 0 025 200 08 Figure 16b Current and voltage traces from Piezo IPhaseArray configuration example 2 DriveSrc DI Driver Module Kit DriveSrc Ts v IUpper A Upper A 10 10 ILower A ILower A 9 9 Dur msec Dur msec 0 025 Wo Stop f 31 3V 29 Drivven Inc DI Driver Module Kit IPhaseArray o DriveSre DriveSrc DriveSrc KA KD EUN IUpper A U pper A IUpper A
4. designed with components carefully selected for efficiency and compactness Still the primary source of heat within the DI Driver Module is the internal boost power supply If the internal module temperature rises above approximately 80C then the module temperature fault will be set High Voltage Limit Fault HighVoltageLimit If the charge on the internal power supply exceeds 175V then the high voltage limit fault will be set This fault could occur due to internal problems with the module or due to excessive injector solenoid back boosting Excessive solenoid back boosting can be caused by a combination of solenoids with very high inductance and using the internal boost supply very little The above faults are loosely tied together in that certain conditions can lead to two or more of the above faults For example the power supply may be loaded such that the board temperature will reach its limit before the overload integrator limit is reached Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 13 Drivven Inc DI Driver Module Kit Internal Boost Power Supply Benchmarks For a better understanding of what the power supply Is capable of in terms of driving typical common rail diesel injectors below are some bench test results Table 3 Bench Test Results Test Condition Test 1 Test 2 3 inj 3 gt RPM 25 50 AE e Injector under test Bosch P N 0445 110 072 Mercedes Benz P N 611 070 09 87 Wi
5. injection quantities over a given injection duration However the boost power supplies operate less efficient at higher voltages Therefore the power supply must work harder to maintain a higher working voltage Typical times to reach 20 amps in common rail diesel injectors are on the order of 30 to 100 microseconds with a working voltage of 100V Frequency of Injection Events The frequency of injection events is directly proportional to the work required by the power supply to maintain the working voltage Injector Back Boost In many scenarios it is possible to get a significant and useful back boost charge from the Injector solenoid at the end of each injection event This back boost from the solenoid mostly depends on the hold current level during the injection event and the working voltage of the boost power supply In most cases if the current profile is correctly configured there will be a small back boost on the order of 5V to the power supply which will reduce the work required to maintain the working voltage It is possible to incorrectly configure the module to use very little of the high voltage supply for driving the peak current while also setting a high hold current level This configuration can lead to back boosting the power supply over the required working voltage The usage of the internal high voltage supply should be used to prevent this from happening If the working voltage Drivven Inc 2011 DI Driver Module Kit Us
6. internal power supply cannot meet the demands of the application However before deciding to use an external power supply consider using only two of the three available channels instead of all three For example consider using three DI driver modules for a six cylinder engine This will lighten the load on each internal power supply Connecting an External Power Supply to EXT PWR 7 An optional high voltage external power supply may be connected to EXT PWR 7 if the internal boost power supply is overheating or not able to keep up with the injection requirements Inside the module the external high voltage supply connects to the same internal capacitance as the Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 14 Drivven Inc DI Driver Module Kit internal boost supply Expect an electrical spark when connecting a live high voltage power supply to the EXT PWR 7 terminal It is strongly recommended that a good permanent connection be made before powering the external power supply When an external high voltage supply greater than 24V is detected it will cause the internal boost supply to automatically shutdown The BATT 0 terminal must still be connected and powered by 6 32V even when using an external high voltage supply connected to EXT PWR 7 A high voltage external power supply is not necessary for most applications Suggested External High Voltage Supplies TDK Lambda Genesys 100 15 Drivven Inc
7. terminal do not connect this high voltage supply to the BATT terminal The BATT terminal should still be connected to a separate supply of 7 32V The ground of the external high voltage supply should be connected to the GND terminal 8 2 The recommended maximum time at 40A is 100usec 3 Longer injection durations are possible but the duty cycle of the driver should be taken into consideration For example a single one shot pulse on an injector test stand could safely be 200msec Therefore injection duty cycle current levels and module temperature should be considered 4 This is a software limit However overall injection duty cycle current levels and module temperature should be considered Sixteen injection events per engine cycle may overload the module depending on engine speed and current levels 5 The software can be configured to have multiple injection commands which merge However the injector will need a certain amount of time to close the valve at the end of an injection command This is a property of the injector 6 If the current during an injection command does not exceed this level then an Open Circuit Fault will be reported However this does not effect the operation of the driver The Open Circuit Fault is for information only 7 These conditions will cause a critical fault and shutdown operation of the module A manual fault clearing via software must take place to resume operation Drivven Inc 2011 D
8. 14 9 7 Dur msec Dur msec Dur msec Dur msec Dur msec Dur msec Dur msec 0 25 0 25 0 25 0 25 0 25 0 25 Figure 6a Solenoid IPhaseArray configuration example 4 B 50 0V RH B 10 0A Ke 980 08 500 08 Trigd 4 EJ 10 3A W Mun ETT gt Figure 6b Current and voltage traces from solenoid IPhaseArray configuration example 4 Phase1FirstPeakEnable The DI Driver module provides a software option in the form of a Boolean control called Phase1FirstPeakEnable to transfer operation from the first phase to the second phase upon reaching the first current peak corresponding to the first phase IUpper threshold Figure 7 below shows an example of this mode of operation Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 2l Drivven Inc DI Driver Module Kit B 200v B 10 0A ze 57208 200 08 Trigd J 103A HMC IU m pee Figure 7 Current and voltage traces from Phase1FirstPeakEnable TRUE operating mode BackBoostTime A global parameter which is critical for proper solenoid injector control is the BackBoostTime This time period directly follows the end of the injection command duration and allows the back emf of the injector solenoid to be directed to the internal power supply for back boosting the internal high voltage power supply It also brings the injector solenoid current quickly to zero If BackBoostTime is set to zero then injector current would be allowed to reci
9. 2011 DI Driver Module Kit User s Manual D000020 e Rev F 15 Drivven Inc DI Driver Module Kit Direct Injector Drivers Injector Driver Circuit Description The DI Driver Module contains three solenoid direct injector drivers Two Piezo injectors can also be driven by this module and the details of that are discussed later in this section The driver channels share some circuitry making it impossible for injection events to overlap among channels within the same module If injection events with different injectors must overlap then multiple modules should be employed There is a high voltage circuit and a battery voltage circuit which drive current to the injector load The high voltage and battery voltage drive circuits are shown below in the simplified schematics for operating various types of injectors Solenoid Injector Operation A representative simplified schematic driving three solenoid injectors is shown in figure 2 below DI Driver Simplified Circuit Schematic Internal Boost BattV Power Supply High Side High Side High Voltage Low Voltage Switch Switch Injector 1 Injector 2 Injector 3 Chan 3 Low Side Switch Chan 2 Low Side Switch Chan 1 Low Side Switch Current Sense amp Comparator Circuitry Figure 2 DI driver simplified schematic for solenoid injectors The user can programmatically specify up to eight sequential drive phases within each solenoid injection com
10. 4VDC battery systems However the module can accept power from a range of 7VDC to 32VDC Caution You must use a UL Listed power supply with the Drivven DI Driver Module With the internal boost power supply and injector outputs disabled the module requires up to 100mA from the external supply The total power required to operate the module and drive injectors is according to the following formula Where lp A Peak current Ih A Hold current HVTarget V High Voltage Target from internal boost supply BattV V Battery voltage supplied to BATT 0 Tip sec Time of peak current phase DurAve sec Average duration of all injection pulses within an engine cycle RPMmax RPM Maximum engine speed in RPM Nchan Number of channels used Npulse Number of injection pulses per engine cycle HVTarget Ip Tip 2 0 70 RPMmax Nchan Npulse Power 2 60 BattV Ih DurAve rip The above formula assumes a 4 stroke engine cycle For 2 stroke engines multiply the result by 2 Table 2 Example power calculation Parameter Ip A Ih A HVTarget V 138 3 2 Nhan 3 Nple 2 Powr W E ComiuousCumen A 48 Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 7 Drivven Inc DI Driver Module Kit A 100W power supply is sufficient for most applications Power requirements may peak up to 150W for more demanding applications Th
11. 6 5 8 TLower A ILower A ower A ILower A Dur msec Dur msec Dur msec Dur msec Dur msec 0 04 0 04 0 0 025 Figure 17a Piezo IPhaseArray configuration example 3 B 50 0V RH H 5 00A Ke 588 08 200 08 Stop 3 SA Figure 17b Current and voltage traces from Piezo IPhaseArray configuration example 3 HVTarget 150V Charge time 188 usec Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 30 Drivven Inc IPhaseArray DrrveSrc tv IUpper A FEN TLower A 7 Dur msec 10 05 o DriveSrc NUM IUpper A p TLower A 0 Dur msec DriveSre iV IUpper A P TLower A Dur msec DriveSrc D IUpper A E ILower A 7 Dur msec 10 025 Figure 18a Piezo IPhaseArray configuration example 4 B 500v g B 5 00A 076 08 DI Driver Module Kit DriveSrc DriveSrc fe ev IUpper A Upper A 8 8 U ower A HJ ower A E 7 Dur msec Dur msec 110 025 Ilo Stop f 43 1V Figure 18b Current and voltage traces from Piezo IPhaseArray configuration example 4 HVTarget 150V Charge voltage 100V Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F Drivven Inc DI Driver Module Kit IPhaseArray DriveSrc DriveSrc DriveSre DriveSre DriveSrc Driv
12. DRIVVEN A National Instruments Company DI Driver Module Kit User s Manual D000020 Rev F July 2012 DRIVVEN WWW DRIVVEN COM Drivven CompactRIO DI Driver Module Part 4 D000020 3 Ch Peak Hold Direct Injection Driver Internal or External Power Supply Drivven Inc 12001 Network Blvd Bldg E Ste 110 San Antonio Texas 78249 USA Phone 210 248 9308 Web www drivven com E mail info drivven com Drivven Inc DI Driver Module Kit DANGER HIGH VOLTAGE HIGH VOLTAGE This device normally operates at voltages up to 175 volts Extreme care should be taken to protect against shock Even when the device is completely powered down allow approximately three minutes for the internal high voltage to dissipate Do not touch any of the module screw terminals or injector terminals while the device is powered Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 2 Drivven Inc DI Driver Module Kit Contents Jio lilo TR 4 Mod le STN 5 luii 6 Iu ENCORE O cm 6 PN vvs 7 Platrorm Compatibili yuu u P 9 Betreier 11 Dee 16 Connecting Injectors to the Module 36 Compliance and Cerin Cau Ons vern Dev Saee deudas arua nd 38 Physical Specifications and Characteristics nnne 39 Drivven Inc 2011 e DI Driver Module Kit
13. I Driver Module Kit User s Manual D000020 e Rev F 5 Drivven Inc DI Driver Module Kit Pinout BATT INJ1 INJ1 INJ2 INJ2 N J3 INJS EXT PWR GND GND Hardware The DI Driver Module Kit provides three channels for driving unipolar solenoid and piezo injectors in a National Instruments CompactRIO module An internal boost power supply is included for providing up to 175V for driving peak solenoid currents up to 40A Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 6 Drivven Inc DI Driver Module Kit Powering the Module The DI Driver module requires power from two different sources One source is from the CompactRIO backplane male high density D Sub 15 pin HD15 connector which mates with the module s female HD15 connector This power source provides a regulated 5 volts and ground to various digital logic functions within the module The CompactRIO 5V source is active whenever the CompactRIO or R Series Expansion Chassis is properly powered The module should be powered at the HD15 connector by plugging it into a CompactRIO or R Series Expansion Chassis The module s HD15 connector should not be connected to any other device Another required power connection is at the external screw terminal connector block provided with the module The main power terminals are labeled BATT 0 and GND 9 Typical power sources will be from automotive 12VDC or 2
14. NJ Open Circuit This condition is detected when the current during the injection event does not exceed 1 5A The OpenCircuit non critical fault is reported for the appropriate channel and is automatically cleared upon the next pulse if the condition is removed Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 35 Drivven Inc DI Driver Module Kit Connecting Injectors to the Module 16AWG wire A recommended p UL Listed Automotive 20A fuse DI Module Connector Figure 22 Connecting solenoid injectors to the driver module Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 36 Drivven Inc DI Driver Module Kit 16AWG wire recommended UL Listed Automotive 20A fuse BATT INJ1 INJ1 INJ2 INJ2 INJ3 INJ3 EXTPWR 7 GND short Ch 3 GND 9 DI Module Connector Figure 23 Connecting piezoelectric injectors to the driver module Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 37 Drivven Inc DI Driver Module Kit Compliance and Certifications Safety This product meets the requirements of the following standards of safety for electrical equipment for measurement control and laboratory use e IEC 61010 1 EN 61010 1 e UL61010 1 CSA 61010 1 Electromagnetic Compatibility This product meets the requirements of the following EMC standards for electrical equipment for measurement
15. User s Manual D000020 Rev F 3 Drivven Inc DI Driver Module Kit Introduction The Direct Injector Driver Module Kit provides a CompactRIO cRIO module for driving a wide variety of diesel and gasoline direct injectors including many piezo actuated injectors The kit includes LabVIEW FPGA and RT Vis for controlling the driver channels Each DI driver channel is individually controlled for timing and duration but channel operation may not overlap The module cannot control piezo and solenoid actuator types simultaneously When configured for piezo mode channel 3 is not available and must have its terminals shorted together Features 3 channel solenoid injector drivers 2 channel piezo injector drivers in piezo mode Up to 175V internal boost power supply Up to 40A peak current drive Operates from 6V to 32V battery Optional external input for high voltage supply up to 175V o Internal boost supply automatically shuts down when external high voltage is applied gt 24V Circuit protection and diagnostics Protected against INJ short to battery high voltage Protected against INJ short to GND Internal power supply overload protection Internal power supply over charge protection Module temperature protection Open circuit detection Fault flags reported for all above conditions gt LabVIEW FPGA and RT Vis for engine synchronous multi pulse injection control strategies o Upto 16 pulses per injection cycle Engine Speed Limited o Co
16. acement and Disposal Battery Directive This device contains a long life coin cell battery If you need to replace it use the Return Material Authorization RMA process or contact an authorized National Instruments service representative For more information about compliance with the EU Battery Directive 2006 66 EC about Batteries and Accumulators and Waste Batteries and Accumulators visit ni com environment batterydirective Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 38 Drivven Inc DI Driver Module Kit Management Methods for Controlling Pollution Caused by Electronic Information Products Regulation China RoHS D Chinese Customers National Instruments is in compliance with the Chinese policy on the Restriction of Hazardous Substances RoHS used in Electronic Information Products For more information about the National Instruments China RoHS compliance visit ni com environment rohs_china HS im ie NA HERoHS G HEE National Instruments PSHE TEE RES RoHS XFNational Instruments HERoHS SIIPHESE HAS ni com environment rohs china For information about China RoHS compliance go to ni com environment rohs china Physical Specifications and Characteristics Weight 170 grams Maximum Altitude 2000 m Maximum Ambient Temperature 45 C Operating Humidity 1096 to 9096 RH noncondensing Pollution Degree 2 Ingress Protection IP30 For Indoor Use Only If you need to clean the module wip
17. control and laboratory use e EN 61326 1 IEC 61326 1 Class A emissions Industrial immunity e EN 55011 CISPR 11 Group 1 Class A emissions e AS NZS CISPR 11 Group 1 Class A emissions e FCC 47 CFR Part 15B Class A emissions e CES 001 Class A emissions Caution When operating this product use shielded cables and accessories CE Compliance C This product meets the essential requirements of applicable European Directives as follows e 2006 95 EC Low Voltage Directive safety e 2004 108 EC Electromagnetic Compatibility Directive EMC Environmental Management NI is committed to designing and manufacturing products in an environmentally responsible manner NI recognizes that eliminating certain hazardous substances from our products is beneficial to the environment and to NI customers For additional environmental information refer to the NI and the Environment Web page at ni com environment This page contains the environmental regulations and directives with which NI complies as well as other environmental information not included in this document Waste Electrical and Electronic Equipment WEEE EU Customers At the end of the product life cycle all products must be sent to a WEEE recycling center For more information about WEEE recycling centers National Instruments WEEE initiatives and compliance with WEEE Directive 2002 96 EC on Waste Electrical and Electronic Equipment visit ni com environment weee Battery Repl
18. e external battery ground is isolated within the module from the CompactRIO 5V supply ground However the external battery ground and the CompactRIO ground may be connected externally The module will not be recognized by software without both power supplies active at the HD15 connector and the external screw terminal block Warning The external battery supply input terminals are not reverse voltage polarity protected Connecting power to the module in reverse polarity will damage the module This event is not covered by warranty Please refer to the DrivvenReverseBatteryNotice pdf document available on the website for a recommended solution for protecting a system from reverse battery polarity There is an optional power input to the external screw terminal connector block The terminal is labeled EXT PWR 7 The ground reference for EXT PWR 7 must be the same ground as GND 9 This power input can range from 6V to 175V and is optionally used to provide the boost voltage in place of the internal boost supply Since the internal boost power supply is a significant contributor to the internal module heat generation this external power input may be necessary if the injector drive requirements in combination with maximum engine speeds cause the internal module temperature to exceed the limit This topic is discussed in detail later in this manual When a voltage above 24V is applied to the EXT PWR 7 terminal then the internal boost power s
19. e it with a dry towel Safety Guidelines N Caution Do not operate this module in a manner not specified in these operating instructions Product misuse can result in a hazard You can compromise the safety protection built into the product if the product is damaged in any way If the product is damaged return it to National Instruments for repair D000020 UM Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 39
20. eSre D ww EE v EE v EE u Ee IUpper A IUpper A Upper A Upper A Upper A Upper A 8 8 qa uis 8 8 ILower A ILower A ILower A ower Al Tower Al ILower A SEH 7 7 7 Gr Dur msec Dur msec Dur msec Dur msec Dur msec Dur msec Dur msec 0 0 025 0 025 0 025 0 0 05 0 3 Figure 19a Piezo IPhaseArray configuration example 5 A 500v g H 5 00A A 988 08 200 08 Stop 31 3V Figure 19b Current and voltage traces from Piezo IPhaseArray configuration example 5 HVTarget 150V Charge voltage 100V step then 150V Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 32 Drivven Inc IPhaseArray DriveSre pm iv wow IUpper A Upper A 8 E I ower A ower A 7 7 Dur msec Dur msec Dur msec 0 025 0025 Figure 20a Piezo IPhaseArray configuration example 6 B 500v B 532 08 B 5 00A DI Driver Module Kit DriveSre Dur msec 0 025 Dur msec 200 08 Stop 31 3V d Figure 20b Current and voltage traces from Piezo IPhaseArray configuration example 6 HVTarget 150V Inverted piezo operation Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 33 Drivven Inc DI Driver Module Kit IPhaseArray TT DriveSre Drive5rc v BE u ME uv IUpper A IUpper A Upper A s D ll COE TL
21. enoid IPhaseArray configuration example 2 Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 19 Drivven Inc IPhaseArray Upper A 15 ILower 14 Dur msec 0 1 0 Drive Sre wv IUpper A 10 ILower A 9 Dur msec DriveSre mm IUpper NNI ILower A 0 Dur msec 0 DriveSre tv IUpper A ILower AJ 0 Dur msec Figure 5a Solenoid IPhaseArray configuration example 3 B 200v g ANN du A B 10 0A CB MAMA 368 05 II DriveSrc ul IUpper A 5 UI ower A 0 Dur msec 200 08 Trigd E B TENIS D DI Driver Module Kit mm IUpper A D Lower 0 Dur msec IO DriveSrc iv IUpper A re ILower A Dur m sec 0 10 3A Figure 5b Current and voltage traces from solenoid IPhaseArray configuration example 3 Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 20 Drivven Inc DI Driver Module Kit IPhaseArray PU T l Ei 7 0 DriveSrc DriveSrc DriveSrc DriveSrc DriveSre DriveSrc iw ev Jg ow Je Upper A IUpper A IUpper 4 IUpper 4 IUpper A IUpper 4 Upper A as E d 20 WWE D D UL ower A ower A Tower OAI ower A ILower i Lower 4 ower A 34 29 24 19
22. er s Manual D000020 e Rev F 12 Drivven Inc DI Driver Module Kit exceeds 175V then it will generate a fault and shut down automatically Power Supply Faults and Protections There are a few critical faults related to the operation of the internal power supply which will cause all operations of the module to shutdown automatically The internal boost power supply and injection control can be re enabled by manually clearing the faults via software Power Supply Charge Fault PSCharge If the power supply is actively attempting to recharge and detects that the voltage is not rising then the charge fault will be set This fault would most likely occur if there was an internal problem with the module such as a capacitor failure Power Supply Overload Fault PSOverLoad The DI driver module maintains an integrator of power supply usage An internal counter increments with each power supply voltage boost and decrements according to a fixed time interval If the integrator winds up to 3 800 counts then an overload fault will be set This is an indication that the module temperature would soon rise beyond its maximum operating temperature if not stopped The module temperature fault may be tripped before the overload fault depending on the actual conditions Module Temperature Fault ModuleTemperature Due to the standard CompactRIO module enclosure design there is limited ability for heat to escape the module The power supply circuitry was
23. ezo injector may be operated by channel 1 when operated in inverted mode Channel 2 must be left disconnected while channel 3 must be connected with a shorting jumper between the Inj and Inj terminals When Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 26 Drivven Inc DI Driver Module Kit Piezolnvert mode is enabled the first four IP haseArray elements are used for discharge and the last four elements are used for charge representative simplified schematic driving a single piezo injector in inverted mode is shown in figure 14 below DI Driver Simplified Circuit Schematic for Single Inverted Piezo Injector Internal Boost Power Supply High Side High Voltage Switch 47yH Inductor Piezo Injector 1 Chan 1 Low Side Low Side Low Side Switch Current Sense amp Comparator Circuitry Figure 14 DI driver simplified schematic for a single inverted piezo injector Figures 15 21 below are oscilloscope images showing examples of current and voltage waveforms for seven different IPhaseArray configurations for piezo injectors Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 27 Drivven Inc DI Driver Module Kit IPhaseArray DriveSre Drive5rc iv MRE v IUpper A Upper A CE e UI ower A Lower A 7 7 Dur msec Durimsec Dur msec Dur msec 10 025 0 025 0 025 0 Figure 15a Piezo IPhaseArray
24. ge up to 175V The boost power supply can be enabled or disabled at any time via software It is disabled automatically whenever critical faults occur and can only be enabled thereafter by clearing the faults The high voltage is stored within internal capacitors and used to drive the high voltage phases of the injector current profile HIGH VOLTAGE HIGH VOLTAGE This device normally operates at voltages up to 175 volts Extreme care should be taken to protect against shock Even when the device is completely powered down allow approximately three minutes for the internal high voltage to dissipate Do not touch any of the module screw terminals or injector terminals while the device is powered Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 11 Drivven Inc DI Driver Module Kit Internal Boost Power Supply Performance There are six critical factors which determine how well the internal boost power supply will perform for a particular injector solenoid application Those factors are Injector solenoid resistance Injector solenoid inductance Peak current required to open the injector valve Working voltage requirement HVTarget Frequency of injection events Injector solenoid back boost time BackBoostTime vy v Vv v v v We will discuss each of these factors one at a time Injector Solenoid Resistance Typical common rail diesel injector solenoids will have a resistance of 1 ohm or less This re
25. k to respond mechanically quicker than a solenoid operated injector It is difficult to estimate the fuel quantity injected while the injector valve is in the process of opening Therefore achieving a shorter time from the beginning of energizing the injector to fully opening the valve is an advantage because the fuel injection quantity can be metered more precisely over the entire injection command Since a piezo stack is electrically like a capacitor it requires current in one direction to charge up to a specified voltage and current out in the opposite direction to discharge The typical charge voltage required for piezo injectors ranges from 100V to 200V Most piezo injectors in production today require up to 165V and will vary based on desired fuel rail pressure A piezo stack must be charged up to the specified voltage at a rate which will not damage the stack If the charge and discharge rate is too fast the stack will not last very long Therefore the charge and discharge current must be controlled This can be done practically with an inductive element in series with the piezo stack and treated similar to an inductive load as far as current control is concerned However the DI Driver module has a special piezo mode of operation which utilizes the same IPhaseArray interface to control current to the piezo stack for charge and discharge rates When Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 25 Drivven Inc
26. mand pulse via an 8 element IPhaseArray Each phase is implemented sequentially Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 16 Drivven Inc DI Driver Module Kit and can specify upper and lower current dithering setpoints phase duration and drive circuit high voltage or battery voltage The high voltage drive circuit should be used only as much as necessary so that the internal boost power supply energy Is conserved and not overloaded The solenoid current is controlled using a dual comparator feedback circuit for upper and lower dithering thresholds Other current and voltage sensing circuits are used for fault detection Figures 3 6 below are oscilloscope images showing examples of current waveforms for four different IPhaseArray configurations Three of the examples show waveforms that are common in the direct injection industry The fourth waveform is for the purpose of showing the flexibility of the IPhaseArray interface The software interface to the DI Driver including the IPhaseArray is described in the software section of this manual however some things are worth noting here The total duration of the injection command is not determined by the total durations of the IPhaseArray elements The total duration is determined by the Boolean command delivered to the DI Driver FPGA express VI Generating command pulses to the express VI is described in the software section of this manual If the Duration para
27. meter of an IPhaseArray element is set to 0 then the current levels for that element will be carried out for the remainder of the injection command Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 17 Drivven Inc IPhaseArray DriveSre mr Upper A I 15 ILower A 14 Dur msec DriveSrc wv IUpper o ILower AJ 0 Dur msec HU DriveSre mm IUpper AJ O ILower AJ 0 Dur msec 0 DriveSre Dur msec 0 Figure 3a Solenoid IPhaseArray configuration example 1 A 200v g B 10 0A III III m nnnnnrmnnnnnnnm i 1 I L i xt 584 08 DriveSrc une IUpper A ILower A 0 Dur msec reg a NAP i DI Driver Module Kit DriveSre mm IUpper A rg ILower A Dur msec masmi 200 08 Trigd B DriveSrc Dur msec 0 9 00A Figure 3b Current and voltage traces from solenoid IPhaseArray configuration example 1 Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 18 Drivven Inc DI Driver Module Kit IPhaseArray DriveSrc NUM IUpper A TLower A o Dur msec Dur msec Dur msec 02 EE Figure 4a Solenoid IPhaseArray configuration example 2 B 20 0V B 10 0A Ke 584 05 200 08 Trigd EJ 5 00A Figure 4b Current and voltage traces from sol
28. mpactRIO modules are not compatible with the National Instruments CompactDAQ chassis Drivven CompactRIO modules REQUIRE one of the hardware support systems described above in order to function The modules may not be used by themselves and or interfaced to third party devices at the backplane HD15 connector These efforts will not be supported by Drivven or National Instruments Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 9 Drivven Inc DI Driver Module Kit You can use Drivven C Series modules with NI cRIO 911x NI cRIO 907x and NI R Series Expansion systems under the following conditions Leave one empty chassis slot between Drivven and NI modules Maintain an ambient system operating temperature of 0 to 45 C Typical specifications of NI modules may not apply when used in a system with Drivven modules Warranted specifications are guaranteed for all NI modules except thermocouple modules when used in a system with Drivven modules The NI 9214 is recommended for thermocouple measurements in cRIO systems using Drivven modules Scan Interface mode auto detection and ID mode are not supported for Drivven modules Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 10 Drivven Inc DI Driver Module Kit Internal Boost Power Supply The DI Driver Module contains an internal boost power supply which can be commanded to maintain a voltage level from battery volta
29. ndition will immediately cause a ShortCircuit critical fault Since current is flowing through the injector solenoid current rise times are limited by the load inductance and the short will typically be detected at about 20A if the channel is off and 45A if the channel is on INJ shorted to battery This condition will immediately cause a ShortCircuit critical fault Since current is bypassing the injector solenoid current rise times are extremely fast and could peak as high as 200A before detection However the module can handle this current spike and shutdown appropriately INJ shorted to ground This condition will cause a HighVoltageDriver critical fault or LowVoltageDriver critical fault during an injection event The fault reported depends on when exactly the short condition occurs during the high voltage or low voltage portion of the current profile INJ shorted to ground This condition will cause a HighVoltageDriver critical fault or LowVoltageDriver critical fault during an injection event The fault reported depends on when exactly the short condition occurs during the high voltage or low voltage portion of the current profile INJ shorted to INJ This condition will cause a HighVoltageDriver critical fault or LowVoltageDriver critical fault during an injection event The fault reported depends on when exactly the short condition occurs during the high voltage or low voltage portion of the current profile INJ I
30. nfigurable for any combination of angle and time triggering o Current control profile Upto 8 phases K Each phase provides settings for upper and lower current dithering setpoints Duration and drive voltage battery or boost specified for each phase First phase can be configured to end after first peak gt Drivven s DI Calibrator application assists with firing injectors on a test bench for configuring the injector current voltage profile gt Piezo injector operation for unipolar drive o Inverted piezo drive supported Discharge ON Charge OFF vy v v v v v Y O O O O O O O Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 4 Drivven Inc DI Driver Module Kit Module Specifications Table 1 Module Specifications Parameter Description ae ute Number of Channels for Solenoid Injectors 3 o Number of Channels for Standard Piezo Injectors 2 Z Number of Channels for Inverted Piezo Injectors III Main Battery BATT Input Range External Power EXT PWR for Boost Power Supply E Replacement Maximum Module Internal Power Dissipation Maximum Current Drive to Injectors Maximum Recommended Injection Command Duration Maximum Injection Events Per Engine Cycle Minimum Time Between Injection Events n n 3 Maximum Single IPhase Element Duration Maximum BackBoostTime 5 Notes 1 When using an external high voltage power supply connected to the EXT PWR
31. ower A Lower A ower A 7 7 7 Dur msec Dur msec Dur msec Dur msec 0 025 0 025 loo Figure 21a Piezo IPhaseArray configuration example 7 50 0V g B 5 00A ne 088 08 200 08 Stop 44 31 3V Figure 21b Current and voltage traces from Piezo IPhaseArray configuration example 7 HVTarget 175V Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 34 Drivven Inc DI Driver Module Kit Injector Types Supported Many different types of solenoid and piezo injectors can be driven with this module including gasoline direct injectors Drivven will help customers determine the appropriate settings and operating limitations for any type of injector at no cost if the setup parameters can be re used for other customer projects Drivven does not verify injector operation on a fuel flow bench Instead Drivven will determine the optimum software settings to achieve a specified current voltage profile Injector Driver Circuit Faults and Protections There are several scenarios which can lead to short circuits with the DI driver module Each possible short condition is detected by the module and a critical fault is reported Each short circuit fault will cause all power supply and injection control operations to shutdown automatically The power supply and injection control can be re enabled by manually clearing the faults via software Short Circuit Fault Conditions INJ shorted to battery This co
32. rculate through the injector until the energy dissipates which would lead to unpredictable injector valve closing Therefore BackBoostTime should be calibrated long enough for the energy within the injector solenoid to be fully discharged to the internal boost power supply If BackBoostTime is greater than zero but too short you will see the injector current bump up and recirculate until the energy is fully dissipated BackBoostTime should be extended until the current recirculation cannot be seen on the scope solenoid current trace A typical BackBoostTime is approximately 0 2 milliseconds Injectors with higher inductance will have more energy to dissipate at the end of injection and require a longer BackBoostTime Figures 8 12 below show five different values for BackBoostTime applied to the same solenoid injector Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 Rev F 22 Drivven Inc DI Driver Module Kit H 200v B B 10 0A x 572 08 200 08 Trigd H 1034 NANNA On be Figure 8 BackBoostTime 0 0 msec H B 20 0V B BM 10 0A zz 972 08 200 08 Irigd R 10 3A II HA 2 lil MI l I AIP rind Mt JI N Figure 9 BackBoostTime 0 025 msec Drivven Inc 2011 e DI Driver Module Kit User s Manual D000020 Rev F 23 Drivven Inc DI Driver Module Kit H 200v B B 10 0A x 572 08 200 08 Trigd H 1034 Annar MESE pee Figure 10 BackBoostTime 0 050 msec H 200v B B
33. sistance will waste as heat a portion of the energy supplied to the solenoid It also affects the maximum current achieved in the coil which depends on the drive voltage applied In general lower solenoid resistances are better for common rail solenoid injector applications Injector Solenoid Inductance Typical common rail injector solenoids will have an inductance of 1mH or less Inductance acts to resist current change through the coil The higher the inductance the longer it will take to achieve the required peak current level given a constant drive voltage When the internal high voltage is used as a current drive there is a transfer of energy from the internal high voltage capacitance to the injector solenoid Longer drive times mean more energy will be depleted from the internal high voltage capacitance This causes the internal boost supply to work harder to maintain the high voltage target However inductance is not a bad thing because it is proportional to the magnetic force generated for opening the injector valve Peak Current Requirement Higher peak currents require more energy from the internal boost power supply because the internally stored high voltage will be depleted at a higher rate Working Voltage Requirement A higher working voltage maintained by the internal boost power supply will be able to drive the peak current level in a shorter amount of time thereby providing quicker valve opening times and more predictable fuel
34. th air flow over the module the duration of operation at heavy loads can be extended The internal power supply requires approximately 10 milliseconds to charge from 12V to 100V and approximately 20 milliseconds to charge from 12V to 150V This charge up process will occur immediately when enabling the power supply As long as the power supply is enabled the requested working voltage will be maintained while injection events are not commanded Depending on the working voltage the user may hear a slow frequency of faint clicks from the module This is normal noise from the power supply The above table is a guide to the capability of the internal boost power supply There are many different possible solenoid current profiles that are required by as many different injector solenoids The DI Calibrator application can assist in determining whether the internal power supply will meet those requirements Drivven will determine calibration parameters for customer s injectors at no cost if the calibration data can be re used This does not include fuel flow measurements Drivven must be provided with current profile information and a test solenoid or injector When the internal supply is disabled the high voltage will bleed down to battery voltage from 175V in approximately 2 minutes While it is not ideal for packaging considerations to use an external high voltage power supply there is a screw terminal to the module for this purpose in case the
35. upply will automatically shut off even if it is enabled via software Even when EXT PWR 7 is connected to an external high voltage power source BATT 0 must still be connected to 6V to 32V in order for the module to be properly powered for general functions In most applications the EXT PWR 7 terminal is not necessary and should be left unconnected Drivven Inc 2011 DI Driver Module Kit User s Manual D000020 e Rev F 8 Drivven Inc DI Driver Module Kit Platform Compatibility CompactRIO modules from Drivven are compatible within two different platforms from National Instruments One platform is CompactRIO cRIO typically consisting of a CompactRIO controller and CompactRIO chassis as shown in Figure 1a below Integrated cRIO chassis and some SbRIO boards are also included in this compatible platform Please contact Drivven for the latest cRIO family compatibility information Jm f mmm mx Figure 1a CompactRIO platform compatible with Drivven CompactRIO modules The other platform is National Instruments PXI which consists of any National Instruments PXI chassis along with a PXI RT controller and PXI 78xxR R Series FPGA card An R Series expansion chassis must be connected to the PXI FPGA card via a SHC68 68 RDIO cable The CompactRIO modules insert into the R Series expansion chassis This platform is shown in Figure 1b below Figure 1b PXI platform compatible with Drivven CompactRIO modules Drivven Co
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