development inverter stack - wattandwell...reuse external control software qualified protection to...

DEVELOPMENT INVERTER STACK FOR A MOTOR

/GENERATOR DRIVE

DIST-450-20 Datasheet

Introduction DIST is a setup for developing motor and generator control algorithms. It is composed of a dual 3-phase driver ready to be interfaced with dSPACE MicroLabBox development system. It includes 34 digital I/O (available through standard Sub-D 50 connectors) and 24 analog measurements (BNC connectors). Speedgoat interface as an option.

Some features

Dual motor driver in a single 19” rack package High power: up to 10 kW per drive Wide input voltage range: up to 750 VDC dSPACE© MicroLabBox interface Watt & Well APOLLO interface Speedgoat interface as an option Embedded hardware protections (OVLO, OCP,

Short-Circuits) with front-panel LED indicators Interface to most common sensors included:

Encoder, Hall sensor, Torque sensor, Temperature sensors

Switching frequency up to 20 kHz Separate and isolated HV and LV supplies

Development Inverter Stack Document Reference:

DOC-DISTWTC-001DST-AK

2 www.wattandwell.com

WARNING This equipment operates at voltages and currents that can result in electrical shock, fire hazard and/or personal injury if not properly handled or applied. Equipment must be used with necessary caution and appropriate safeguards employed to avoid personal injury or property damage. This board must be used only by qualified engineers and technicians’ familiar with risks associated with handling high voltage electrical and mechanical components, systems and subsystems.




Contents

1. Absolute maximum ratings ............................................................................................... 4

2. Electrical Characteristics .................................................................................................. 4

3. Safety instruction ............................................................................................................... 5

3.1. Caution ............................................................................................................................. 5 3.2. Installation ......................................................................................................................... 5 3.3. Input Rating ...................................................................................................................... 5 3.4. Live circuits ....................................................................................................................... 5 3.5. Parts substitution and modification .................................................................................... 5 3.6. Environmental condition .................................................................................................... 6 3.7. Other risks ........................................................................................................................ 6

4. Interface .............................................................................................................................. 6

4.1. High Voltage Input ............................................................................................................ 7 4.1.1. HV input filter ............................................................................................................................9

4.2. Analog interface .............................................................................................................. 10 4.2.1. Analog filters .......................................................................................................................... 11 4.2.2. Current measurement ............................................................................................................ 12 4.2.3. Voltage measurement ........................................................................................................... 13 4.2.4. Temperature measurement ................................................................................................... 13

4.3. Digital interface ............................................................................................................... 14 4.4. Sensor interface connector ............................................................................................. 19

5. Hardware protections ...................................................................................................... 20

5.1. General ........................................................................................................................... 21 5.2. Over current protections .................................................................................................. 21 5.3. Over voltage protection on HV bus .................................................................................. 22 5.4. Under voltage protection on 15V bus .............................................................................. 22 5.5. Protection signals ............................................................................................................ 22

6. Typical characteristics ..................................................................................................... 23

6.1. Test description ............................................................................................................... 23 6.2. Open Loop Test .............................................................................................................. 25

7. Maintenance ..................................................................................................................... 26

7.1. Cleaning.......................................................................................................................... 26 7.2. Cooling fan ...................................................................................................................... 26

8. Ordering information ....................................................................................................... 26




1. Absolute maximum ratings

Parameter Condition Min Max Units

HV Input Voltage (motor driver supply) VHV-VHV_RTN 0 850 Vdc

HV Input Voltage common mode (VHV+VHV_RTN))/2-Vchassis -400 400 Vdc

HV input continuous current IHV -25 25 A

HV input dV/dt 100 V/µs

LV Input Voltage (control electronics supply) VLV-VLV_RTN 0 35 Vdc

Operating Temperature 5 50 °C

Long term storage Temperature 5 85 °C

Temperature change rate 4 °C/min

Table 1: Absolute maximum ratings

2. Electrical Characteristics All specifications are given for the full temperature range unless otherwise noted.

Parameter Condition

Value

Units Min Typ Max

General

Motor Type Three phase

synchronous motor

Driver continuous output power T = 25 °C 1000

0 W

Driver instantaneous output power T = 25 °C 1300

0 W

Driver Efficiency VHV = 500V, Pout = 10 kW (LV supply excluded)

95 97 98 %

Phase continuous output current - - 20 Arms

Phase instantaneous output current During tp≤100ms - - 25 Apeak

Nominal speed Range 2 pole pairs motor Control dependent rpm

Maximal speed Range 2 pole pairs motor Control dependent rpm

Switching frequency 10 20 kHz

HV DC input

DC Input voltage 50 450 750 Vdc

Input current 10000 W output power, 500V input voltage

- 20 - ARMS

Over Voltage Shutdown T = 25 °C -

750 -

V

LV input

Input voltage 20 24 28 Vdc

Input current - 0.3 1.5 A

Brake output




Maximum current 11 Apeak

Brake resistor inside the rack No internal brake resistor connected Ω

Maximum power for resistor Set by external resistor W

Table 2: Electrical characteristics

3. Safety instruction

3.1. Caution

The following safety instruction must be observed during all phases of operation, service and repair of this equipment. Failure to comply with the safety precautions or warnings in this documentation violates safety standards of design, manufacture and intended use of this equipment and may impair the built-in protections within. Watt & Well shall not be liable for users to comply with these requirements.

3.2. Installation

DIST product must be connected to dedicated laboratory isolated DC power supplies. These power supplies must be compliant with IEC 61010-1 safety standard. This product is a safety Class 1 instrument. To minimize shock hazard, the instrument chassis must be connected to installation protective earth (safety ground) with the dedicated ground terminal. The protective earth terminal must be connected to the safety electrical ground before another connection is made. Any interruption of the protective ground conductor, or DISconnection of the protective earth terminal will cause a potential shock hazard that might cause personal injury. Never connect DIST product to the grid.

3.3. Input Rating

Do not use power supplies which exceeds the input voltage rating of this instrument. The electrical rating of this instrument is given into the chapter 2 of this document.

3.4. Live circuits

Operating personnel are not allowed to open the case of this instrument. Internal adjustment or component replacement is not allowed by non-Watt & Well qualified personnel. Never replace components with cable connected to this instrument. To avoid injuries, always DISconnect power and remove external voltage sources before touching components.

3.5. Parts substitution and modification




Parts substitutions and modifications are allowed by authorized Watt & Well service personnel only. For repairs or modification, the unit must be returned to Watt & Well After Sale Service. Contact

After Sale Service ( [email protected] ) to obtain RMA number.

ADRESS: Watt & Well

After Sale Service 121, rue Louis Lumière

84120 PERTUIS FRANCE

3.6. Environmental condition

DIST device safety approval applies to the following operating conditions:

• Indoor use

• Maximum relative humidity : 80 % at 31 °C and 50 % at 40 °C

• Altitude up to 2000m

• Pollution degree 2

• IP degree of enclosure : IP2X

Protective ground conductor terminal

3.7. Other risks

DIST product is a flexible development tool for motor control. Typically, serves to test different motor control algorithm. DIST product returns some signals from the motor (third party) if these signals (typically hall information) are not monitored and not used correctly it could cause a failure of DIST product and cause personal injury. Always check the different connections between DIST product and external subsystems before starts a manipulation. Reuse external control software qualified protection to reduce hazards.

4. Interface DIST is packaged in a standard 3U 19” rack. All connections are available on the front and rear panel. The front panel contains:

• 2 Sub-D 50 for digital I/O.

mailto:[email protected]




• 2×12 BNC connectors for analog measurements.

• 2×3 LEDs indicators for Power, Enable signal and Fault.

• 2 Banana Plugs (4 mm) for the LV supply. LV supply should be 24V nominal.

• Earth terminal. For safety reasons, Earth should always be connected.

Figure 1: Front Panel

The rear panel contains:

• 2 Sub-D 25 for motor interface (Hall sensor, encoder sensor and 2 NTC measurements).

• 2×3 Motor phases connections (A, B and C or U, V and W).

• 4 Banana Plugs (4 mm) to access the intermediate DC bus. The intermediate bus can be externally powered through this connector. For operation above 60V, see safety notice below

• 2x2 Banana Plugs (4 mm) to connect external brake resistors.

• Earth terminal. For safety reasons, Earth should always be connected.

Figure 2: Rear Panel

4.1. High Voltage Input

WARNING For safety reasons, a Protective Earth conductor needs to be connected to the Earth terminal (available through the front and rear panel) A Residual Current Circuit Breaker with Over Current Protection (RCBO) should be used to detect any insulation breakdown




Figure 1 Capacitor pre-charge system

The total capacitance on each inverter DC bus is 49.7µF. This capacitance is composed of a 47µF film capacitor bank and four 680nF film capacitors directly on PWB. Two 47 Ω pre-charge resistor limit the inrush current at power supply turn ON. Bypass relays are connected to “Enable” signal of each inverter. These relays are automatically opened on a fault detection. DIST can be used in two modes

• Dual Motor configuration: each inverter is supplied with an external HV power supply. Both inverters can then be used as motor drivers.

• Generator/Motor: the first driver (generator) reinject power on its HV input bus and can powers the second (motor) through its HV input bus.

o In this mode an extra diode is strongly recommended to prevent damage of the HV DC power supply

o The braking chopper feature could be used and need an external resistor. High Voltage input must be connected to a DC power supply compliant with IEC 61010-1 safety standard. Minimum electrical isolation required for the main power supply is 1500Vrms minimum.




Figure 2: Typical diagram connection for Dual motor configuration

Figure 3: Typical diagram connection for Generator/Motor configuration

4.1.1. HV input filter

For EMC compliance for conducted emissions a filter is present on each inverter DC input.




Figure 4 : EMC input filter

This filter is completely shielded directly on each inverter DC input. The output of the filter is connected to the pre-charge circuit and the capacitor bank.

4.2. Analog interface

Analog measurements are available through 24 dedicated BNC connectors are single-ended (outer connection of the BNC connected to GND). Recommended connection of the 24 analog measurements is to match the corresponding channels on the AI1 port of MicroLabBox. The 12 inputs of AI2 port will be unused.

DIST Analog Interface

Pin Channel Description Type

1 AI1 ch1 Inv 1 Current Sensor Phase A Single ended

2 AI1 ch2 Inv 1 Current Sensor Phase B Single ended

3 AI1 ch3 Inv 1 Current Sensor Phase C Single ended

4 AI1 ch4 Inv 1 Voltage Sensor Phase A-Ground Single ended

5 AI1 ch5 Inv 1 Voltage Sensor Phase B-Ground Single ended

6 AI1 ch6 Inv 1 Voltage Sensor Phase C-Ground Single ended

7 AI1 ch7 Inv 1 DC Voltage Single ended

8 AI1 ch8 Inv 1 DC Current Single ended

9 AI1 ch9 Inv 1 Torque measurement Single ended

10 AI1 ch10 Inv 1 Temperature 1 (power module) Single ended

11 AI1 ch11 Inv 1 Temperature 2 (external) Single ended


13 AI1 ch13 Inv 2 Current Sensor Phase A Single ended

14 AI1 ch14 Inv 2 Current Sensor Phase B Single ended

15 AI1 ch15 Inv 2 Current Sensor Phase C Single ended

16 AI1 ch16 Inv 2 Voltage Sensor Phase A-Ground Single ended

17 AI1 ch17 Inv 2 Voltage Sensor Phase B-Ground Single ended

18 AI1 ch18 Inv 2 Voltage Sensor Phase C-Ground Single ended

19 AI1 ch19 Inv 2 DC Voltage Single ended




20 AI1 ch20 Inv 2 DC Current Single ended

21 AI1 ch21 Inv 2 Torque measurement Single ended

22 AI1 ch22 Inv 2 Temperature 1 (power module) Single ended



Inv1 refers to inverter A Inv2 refers to inverter B

4.2.1. Analog filters

All analog measurements include a low pass filter with the following characteristics:

Channel Bandwidth Gain Offset Min Max Type

Phase current 8 kHz(1) 41.67mV/A 2.5V -25 A 25 A Single ended

DC current 8 kHz(1) 41.67mV/A 2.5V -25 A 25 A Single ended

Phase voltage 8 kHz(1) 4.8798 mV/V

0 850 V Single ended

DC voltage 8 kHz(1) 4.8798 mV/V

0 850 V Single ended

Torque 1 kHz 1.0 V/V 0 TBD Single ended

Temperature 1 1 Hz Fixed(2) Single ended



(1) Fast measurements can have the low pass filter shunted with a jumper. This removes the 8 kHz filter and leaves only a first order differential filter with fc = 159 kHz. (2) See Temperature Measurement for more explanation. The filter is a regular Sallen-Key second order low pass:

Example of component values for the 8 kHz filter:

R1 = 18 kΩ R2 = 18 kΩ C1 = 0.001 µF




C2 = 0.001 µF

Transfer Function1: G(s)= 3086419753

s2+111111.1s+3086419753

Cut-off frequency: fc = 8842 [Hz] Quality factor: Q = 0.5 Damping ratio: ζ = 1

4.2.2. Current measurement

“Phase Current” and “DC Current” output have been modified on AD version. Previous versions were Differential output. New transfer function (AD versions and newer): Output voltage swing [0V; 5V]

Old transfer function (AA, AB, and AC versions): Output voltage swing [-2.5V; 2.5V]

1 Source: http://sim.okawa-denshi.jp/en/OPstool.php

𝐶𝑢𝑟𝑟𝑒𝑛𝑡𝑚𝑒𝑎𝑠𝑢𝑟𝑒 = (𝑉𝑜𝑙𝑡𝑎𝑔𝑒𝑜𝑢𝑡 − 2.5𝑉)/𝐺𝑎𝑖𝑛 𝐺𝑎𝑖𝑛 = 41.67𝑚𝑉/𝐴




4.2.3. Voltage measurement

“Phase Voltage” and “DC Voltage” output have following transfer function:

4.2.4. Temperature measurement

Three temperature channels are available. The first one is connected to the power module of phase B while the two others are available for user. A NTC thermistor can be connected through the Sub-D 25 on rear panel. Figure and table below show the evolution of the internal NTC with temperature:

Figure 7: Voltage VS Temperature of power modules (internal NTC)

Typical internal NTC characteristics:

- R25 = 50KΩ - B25/85 = 3952K

User accessible temperature output voltage characteristics:

y = -0,037x + 5,0254

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

0 20 40 60 80 100 120 140

Ou

tpu

t V

olt

ag

e [

V]

Temperature [°C]

𝐶𝑢𝑟𝑟𝑒𝑛𝑡𝑚𝑒𝑎𝑠𝑢𝑟𝑒 = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒𝑜𝑢𝑡/𝐺𝑎𝑖𝑛 𝐺𝑎𝑖𝑛 = 41.67𝑚𝑉/𝐴

𝑉𝑜𝑙𝑡𝑎𝑔𝑒𝑚𝑒𝑎𝑠𝑢𝑟𝑒 = 𝑉𝑜𝑙𝑡𝑎𝑔𝑒𝑜𝑢𝑡/𝐺𝑎𝑖𝑛 𝐺𝑎𝑖𝑛 = 4.8798𝑚𝑉/𝑉




- Use thermistor 𝑅𝑇𝐻𝑒𝑥𝑡 (Example NTC 50KΩ)

T (°C) R (Ohms) Voltage (V)

10 100982 4.549

15 79241 4.440

20 62698 4.312

25 50000 4.167

30 40172 4.003

35 32506 3.824

40 26482 3.629

45 21713 3.423

50 17913 3.209

55 14865 2.989

60 12405 2.768

65 10408 2.550

70 8777 2.337

75 7437 2.133

80 6332 1.939

85 5416 1.757

90 4652 1.588

95 4012 1.432

100 3474 1.289

105 3020 1.160

110 2634 1.043

115 2306 0.937

120 2026 0.842

125 1785 0.758

Figure 2: Table 4: Temperature 1 output for different temperatures (internal NTC)

4.3. Digital interface

DIST uses a total 44 digital I/O lines (22 per driver)

• 16 control I/O per driver (PWMs, Fault and control lines)

• 3 Hall Effect sensor inputs per driver

• 3 Encoder sensor input per driver All digital I/O are 5V single-ended.

𝑅𝑇𝐻𝑒𝑥𝑡

10𝐾Ω + 𝑅𝑇𝐻𝑒𝑥𝑡∗ 5𝑉




These signals are available in two front panel Sub-D 50 connectors. Recommended connection to MicroLabBox is direct connection of Digital I/O A and Digital I/O B to their corresponding ports.


1 GND GND GND

2 DIO1 ch16 Inv 1 Phase C PWM low side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

3 DIO1 ch15 Inv 1 Phase B PWM low side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

4 DIO1 ch14 Inv 1 Phase A PWM low side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

5 DIO1 ch13 Inv 1 Phase C PWM high side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

6 DIO1 ch12 Inv 1 Phase B PWM high side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

7 DIO1 ch11 Inv 1 Phase A PWM high side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

8 DIO1 ch10 Inv 1 Brake Chopper. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

9 DIO1 ch9 Inv 1 Fan Control. Active high (‘0’ fan off, ‘1’ fan On). Variable speed can be achieved with PWM control

DIST IN, MLBX OUT

10 DIO1 ch8 Inv 1 Reset Fault. Active low (‘0’ to clear fault, ‘1’ for normal operation)

DIST IN, MLBX OUT

11 DIO1 ch7 Inv 1 Enable Driver + Precharge Driver. Active high (‘0’ to DISTable driver, ‘1’ for normal operation)

DIST IN, MLBX OUT

12 DIO1 ch6 Inv 1 Fault OCP (HV + Phases). Active low (‘0’ indicates fault, ‘1’ normal operation)

DIST OUT, MLBX IN

13 DIO1 ch5 Inv 1 Fault HV (OVLo HV) Active low

DIST OUT, MLBX IN




(‘0’ indicates fault, ‘1’ normal operation)

14 DIO1 ch4 Inv 1 Fault Driver (UVLo LV) Active low (‘0’ indicates fault, ‘1’ normal operation)

DIST OUT, MLBX IN

15 DIO1 ch3 Inv 1 Hall sensor C/3 DIST OUT, MLBX IN

16 DIO1 ch2 Inv 1 Hall Sensor B/2 DIST OUT, MLBX IN

17 DIO1 ch1 Inv 1 Hall sensor A/1 DIST OUT, MLBX IN

18 GND GND GND

19 GND GND GND

20 GND GND GND

21 GND GND GND

22 GND GND GND

23 GND GND GND

24 GND GND GND

25 GND GND GND

26 GND GND GND

27 GND GND GND

28 GND GND GND

29 GND GND GND

30 GND GND GND

31 GND GND GND

32 GND GND GND

33 GND GND GND

34 DIO1 ch32 GND GND

35 DIO1 ch31 Unused NC



38 DIO1 ch28 GND GND















50 GND GND GND

Figure 3: Table 5: DIST Digital I/O A pin out


1 GND GND GND

2 DIO1 ch48 Inv 2 Phase C PWM low side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

3 DIO1 ch47 Inv 2 Phase B PWM low side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

4 DIO1 ch46 Inv 2 Phase A PWM low side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

5 DIO1 ch45 Inv 2 Phase C PWM high side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

6 DIO1 ch44 Inv 2 Phase B PWM high side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

7 DIO1 ch43 Inv 2 Phase A PWM high side. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

8 DIO1 ch42 Inv 2 Brake Chopper. Active high (‘0’ IGBT open. ‘1’ IGBT closed)

DIST IN, MLBX OUT

9 DIO1 ch41 Inv 2 Fan Control. Active high (‘0’ fan off, ‘1’ fan On). Variable speed can be achieved with PWM control

DIST IN, MLBX OUT

10 DIO1 ch40 Inv 2 Reset Fault. Active low (‘0’ to clear fault, ‘1’ for normal operation)

DIST IN, MLBX OUT

11 DIO1 ch39 Inv 2 Enable Driver + Precharge Driver. Active high (‘0’ to DISTable driver, ‘1’ for normal operation)

DIST IN, MLBX OUT

12 DIO1 ch38 Inv 2 Fault OCP (HV + Phases). Active low (‘0’ indicates fault, ‘1’ normal operation)

DIST OUT, MLBX IN




13 DIO1 ch37 Inv 2 Fault HV (OVLo HV) Active low (‘0’ indicates fault, ‘1’ normal operation)

DIST OUT, MLBX IN

14 DIO1 ch36 Inv 2 Fault Driver (UVLo LV) Active low (‘0’ indicates fault, ‘1’ normal operation)

DIST OUT, MLBX IN

15 DIO1 ch35 Inv 2 Hall sensor C/3 DIST OUT, MLBX IN

16 DIO1 ch34 Inv 2 Hall Sensor B/2 DIST OUT, MLBX IN

17 DIO1 ch33 Inv 2 Hall Sensor A/1 DIST OUT, MLBX IN

18 GND GND GND

19 DIO2+ ch12 Inv 2 Encoder Z (+) DIST OUT, MLBX IN

20 DIO2+ ch11 Inv 2 Encoder B (+) DIST OUT, MLBX IN

21 DIO2+ ch10 Inv 2 Encoder A (+) DIST OUT, MLBX IN

22 GND GND GND

23 DIO2+ ch9 GND GND



26 GND GND GND




30 GND GND GND

31 DIO2+ ch3 Inv 1 Encoder Z (+) DIST OUT, MLBX IN

32 DIO2+ ch2 Inv 1 Encoder B (+) DIST OUT, MLBX IN

33 DIO2+ ch1 Inv 1 Encoder A (+) DIST OUT, MLBX IN

34 GND GND GND

35 DIO2- ch12 Inv 2 Encoder Z (-) DIST OUT, MLBX IN

36 DIO2- ch11 Inv 2 Encoder B (-) DIST OUT, MLBX IN

37 DIO2- ch10 Inv 2 Encoder A (-) DIST OUT, MLBX IN

38 GND GND GND

39 DIO2- ch9 Unused NC



42 GND GND NC







46 GND GND NC

47 DIO2- ch3 Inv 1 Encoder Z (-) DIST OUT, MLBX IN

48 DIO2- ch2 Inv 1 Encoder B (-) DIST OUT, MLBX IN

49 DIO2- ch1 Inv 1 Encoder A (-) DIST OUT, MLBX IN

50 GND GND GND

Figure 4: DIST Digital I/O B pin out

4.4. Sensor interface connector

Each motor inverter has a sensor interface connector. Each connector is a standard Sub-D 25 with the pinout given in Erreur ! Source du renvoi introuvable.. All the signals are inputs (except for the 5V supply). The corresponding outputs are found on the front panel Analog and Digital Interfaces.

Pin Description Comments

1 Temp_Meas2_P Spare temperature input 2(1)

2 Temp_Meas2_N Spare temperature input 2(1)

3 Temp_Meas3_P Spare temperature input 3(1)

4 Temp_Meas3_N Spare temperature input 3(1)

5 HA/1 Hall effect position sensor input A/1

6 HB/2 Hall effect position sensor input B/2

7 HC/3 Hall effect position sensor input C/3

8 Torque Torque sensor input

9 A Encoder input A. Non inverting

10 A\ Encoder input A. inverting

11 B Encoder input B. Non inverting

12 B\ Encoder input B. inverting




13 Z Encoder input Z. Non inverting

14 Z\ Encoder input Z. inverting

15 5V Precision(2) 5V supply generated from a low noise LDO. 10mA max

16 5V(2) 5V supply. 100mA max

17 NC Unused

18 NC Unused

19 Gnd Ground

20 Gnd Ground

21 NC Unused

22 NC Unused

23 NC Unused

24 NC Unused

25 NC Unused

Figure 5: Sensor Interface Connector (applies to Inv 1 / Genrator and Inv 2/ Motor)

(1) See Temperature Measurement section 4.2.3 (2) Never short circuit or degrade these outputs. It will cause damage to the product

Parameter Condition Value Units

Min Typ Max

Hall effect sensors input

Compatibility Open collector output compatible. Internal 1K pull up connected to 5V

Input voltage range 0 5 Vdc

Vih Logic input gate datasheet 1.1 2.0 Vdc

Vil Logic input gate datasheet 1.9 3.1 Vdc

Encoder input

Compatibility Open collector output compatible. Internal 1K pull up connected to 5V


Vih Logic input gate datasheet 1.1 2.0 Vdc

Vil Logic input gate datasheet 1.9 3.1 Vdc

Torque input


Internal input gain 1.0 V/V

Figure 6: Sensors interface electrical characteristics




5. Hardware protections The following hardware protections are available on each inverter:

• Over current protection on HV bus and phases A,B,C (signal Fault OCP (HV + Phases)*)

• Over voltage protection on HV bus (signal Fault HV (OVLo HV) *)

• UVLO on 5V bus

• UVLO on 15V bus (signal Fault Driver (UVLo LV) *)

• Short-circuit protection for each transistor (signal Fault Driver (UVLo LV) *)

• UVLO on isolated gate driver power supplies (signal Fault Driver (UVLo LV) *)

• Minimum Deadtime protection for each leg PWMs (set to 232 ns) A thermal protection is included on each inverter. Thermal sensors of IGBT module N°2 is monitored. If internal temperature of IGBT module reach 125°, the system is automatically shut down.

* Signals available on each digital connector DB-50 for each inverter.

5.1. General

DIST product is dedicated to function with laboratory power supplies. Use current limitation or electronic fuse feature of the laboratory power supply to protect the overall system in case of major failure of the equipment.

5.2. Over current protections

Internal overcurrent protection stops the internal PWM signals and keep open the IGBT modules. The following thresholds are implemented on each inverter:

Signal protected

Theoretical threshold

Measured threshold

Measured threshold

Note: Minimum DeadTime ensured by the board (232ns) may be too aggressive. Given the switching characteristics of the APTGT50A120T1G IGBT modules, a more conservative dead time will be give by

𝑡𝑑𝑒𝑎𝑑 = ((𝑡𝑑(𝑜𝑓𝑓)𝑀𝐴𝑋

− 𝑡𝑑(𝑜𝑛)𝑀𝐼𝑁

) + 𝑑𝑟𝑖𝑣𝑒𝑟 𝑝𝑟𝑜𝑝𝑎𝑔𝑎𝑡𝑖𝑜𝑛 𝑗𝑖𝑡𝑡𝑒𝑟) ∙ 1.2

Resulting in tdead = (420-90 + 4)*1.2 = 400ns (to be ensured by software)

WARNING No current protection in rectifier mode.




– Inverter 1

– Inverter 2

HV 25 A 24.7 A 24.7 A

Phase A 25 A 24.7 A 24.7 A

Phase B 25 A 24.7 A 24.7 A

Phase C 25 A 24.7 A 24.7 A

Figure 7: Over current protections thresholds

Overcurrent protection is not functional in rectifier mode.

5.3. Over voltage protection on HV bus

The following threshold for the HV bus is implemented on each inverter:

Signal protected

Theoretical threshold

Measured threshold – Inverter

1

Measured threshold – Inverter

2

HV 750 V 749 V 749 V

Figure 8: Over voltage protection on HV bus thresholds

5.4. Under voltage protection on 15V bus

The following threshold for 15V UVLO is implemented on each inverter:

Signal protected

Min threshold

Typical threshold

Max threshold

15V 11.3 V 12 V 12.7 V

Figure 9: Under voltage protection on 15V bus thresholds

5.5. Protection signals

Each time one of the protections listed above triggers, the fault signal is triggered, and the front panel LED named “Fault” is powered. The following graph shows the sequence to send to the inverter to restart:




Figure 10: Fault event and restart condition

As soon as a critical fault is triggered, PWMs are inhibited and the pre-charge relay is opened. The fault led on the front panel becomes red and the system stays in a fault mode, whatever the state of the Enable_In signal. To clear the fault state, the user must give a transition from high state to low state (falling edge event) on the signal ResetFault_In. In this case, the fault led becomes unpowered and the system can work properly if the signal Enable_In is pulled high and no-fault conditions are detected. Output LED “Fault” still ON even after a fault clear. The LED “Fault” is OFF, when the fault is cleared AND the “Enable” signal is ON.

6. Typical characteristics The typical characteristics are given for one motor drive block. Each driver is based on 3 power IGBTs from Microsemi APTGT50A120T1G (rated 1200V, 50A).

6.1. Test description

Validation test are run with:

• Digital Signals o Phase PWM generation

SVM (Space Vector Modulation) generation with amplitude control (0-100%) Fixed frequency (10 kHz)

o Brake Chopper:




PWM with fixed frequency (1 kHz) and variable amplitude o Fan Control

PWM with fixed frequency (1 kHz) and variable amplitude o Control lines management

Enable signal Fault reset

• Analog signals o Use scope.

Notes: Inverters are tested separately. Apollo DSI/DSO connections are done with specific harness. Assembly current consumption

Independence Test

Measurement Name Measured Inv 1 Measured Inv 2 Expected value

HV impedance 103.9 kΩ 100kΩ >100kΩ

LV impedance 43.6 kΩ 43.6 kΩ 40 kΩ ± 10%

Impedance Leg A – HV_RTN

623 kΩ 602 kΩ >500kΩ

Impedance Leg B – HV_RTN

623 kΩ 601 kΩ >500kΩ

Impedance Leg C – HV_RTN

623 kΩ 600 kΩ >500kΩ

Figure 12: typical impedances

Measurement Name

Acceptance Threshold

Measured value Inverter 1

Measured value Inverter 1

Current at power supply - 24V - Driver OFF

220 mA ± 20% 210mA 210 mA

Current at power supply - 24V - Driver ON

500 mA ± 20% 290mA 290 mA

Current at power supply - 24V - Driver ON – Fan ON (DutyCycle=100%)

1 A ± 25% 410 mA 410 mA

Figure 11: Typical power consumption on LV input




6.2. Open Loop Test

Setup configurations: Low voltage power supply: HAMEG HM7042-5 High voltage power supply: ELEKTRO AUTOMATIK EA-PS8720-15 Current probes used for screening phase current are from HIOKI (typically HIOKI 3276) The multimeter used to screen current on HV voltage is AGILENT U1252B The resistors used for passive load are 100Ω = TE1500B100RJ and 220Ω = TE1500B220RJ 3 Differential voltage probes placed to screen Phase_A-Phase_B; Phase_B-Phase_C; Phase_C-Phase_A HV voltage from 0V to 600V LV = 24V

• No load: Phase cables are left open

• Passive load: 220Ω//100Ω//100Ω =40.7Ω with star connection

Table 3: Power versus input voltage – Inverter 1 (40,74Ω star connection - Torque target 0,45Nm - Speed Command=2000 rpm - T=25°C)

0,00 W

500,00 W

1000,00 W

1500,00 W

2000,00 W

2500,00 W

3000,00 W

3500,00 W

4000,00 W

4500,00 W

5000,00 W

5500,00 W

6000,00 W

0,00 V 100,00 V 200,00 V 300,00 V 400,00 V 500,00 V 600,00 V 700,00 V




Table 4: Power versus input voltage – Inverter 2 (40,74Ω star connection - Torque target 0,45Nm - Speed Command=2000 rpm - T=25°C)

To test with passive load, the average duty cycle on each phase is set at 40%. All the results are presented in the Acceptance Test Results (ATR).

7. Maintenance

7.1. Cleaning

Use a soft cloth for cleaning the device. Do not use cleaning agent. Internal dust could be removed with hoover or dry air cleaning.

7.2. Cooling fan

Cooling fan is controlled by user. Please always turn ON fan control at maximum level to ensure normal performance of DIST. Do not obstruct apertures on the case side.

8. Ordering information [email protected] Engineering Center: 129 avenue de Paris à Massy (91300) France Production Facilities: 121 rue Louis Lumière à Pertuis (84120) France USA Subsidiary: one riverway, Suite 1700, 770 South Post Oak Lane Houston (Texas) USA

0,00 W

500,00 W

1000,00 W

1500,00 W

2000,00 W

2500,00 W

3000,00 W

3500,00 W

4000,00 W

4500,00 W

5000,00 W

5500,00 W

6000,00 W

0,00 V 100,00 V 200,00 V 300,00 V 400,00 V 500,00 V 600,00 V 700,00 V

Typical DC input Voltage Power

DIST-450-20 750 V 2 x 10 kW

Table 5: Product reference

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