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The copyright of this thesis vests in the author. No

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quotation from it or information derived from it is to be

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published without full acknowledgement of the source.

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The thesis is to be used for private study or non-
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Published by the University of Cape Town (UCT) in terms

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of the non-exclusive license granted to UCT by the author.

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 " UNIVERSITY OF (APE TOWN

DESIGN AND IMPLEMENTATION OF A

6 KW WIND POWERED WATER

REA TER CONTROLLER WITH PI

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PREPARED By Ritesh Lutchman

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Department of Electrical li:ngineering

University of Cape Town
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Department ofElectrieal Engineering

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Pru;PARED FOR
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University of Cape Town

ThesIs submitted In fulnUment of the requirements of the degree of l'tLlsters in Sd.nce in

Electrical Engineering at the lInivrrsil~' of Cape Town.
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 SYNOPSIS

Introduction

In our 'luest to usc more renewable energy to reduce our dependence on non renewable
fuds man has been harnessing wind, solar and hydro energy for many years. \¥hilc hydro
and solar energy arc well established, it is only during the last decade that serious
progress in wind energy has been made. Solar energy is widely used for water or space
heating while wind is used for pumping watcr for remote areas. This proj ect looks into
the design and development of a (; kW wind powered water heatill!:>; unit.

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SYl;tem Description

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The wind powered water heating system is powered by a 6 kW permanent magnet wind
generator, The generator produces three phase AC voltage which is rectified and fed into
~ DC to DC buck converter. Heater bars are placed at the output of the huck converter to
heal waler. Voltage and current LEMs are u<ed to tnt:asure the output voltage and output
current whilst a temperature probe is used to measure the heat sink temperature. A square
wave, signal representing generator speed is derived from the output voltage of the wind
turbine. Th~se signals are fed into a DSP through an interface card. From the above
inputs, the DSP calculates the necessary power flow in order to obtain maximum averagc
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DECLARATION ........................................................................................................................................... I

TERMS OF REFERENCE ....................................................................................................................... III

SYNOPSIS .................................................................................................................................................. IV
TABLE OF CONTENTS .......................................................................................................................... VII
LIST OF FIGURES ................................................................................................................................... IX
LIST OF TABLES ..................................................................................................................................... XI
GLOSSARY .................................................................................. ERROR! BOOKMARK NOT DEFINED.
INTRODUCTION ............................................................................................................................... 1

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1.1 BACKGROUND TO STUDY .............................................................................................................. 1

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1.2 DESCRIPTION OF MAIN PROBLEMS ................................................................................................ 2

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1.3 THESIS OBJECTIVES
1.4 THESI S OUTLINE ........................................................................................................................... 4

2 BACKGROUND RESEARCH ........................................................................................................... 5

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2.1 WIND POWER ................................................................................................................................ 5
2.2 MAXIMUM POWER POINT TRACKING ..................................... :...................................................... 6
2,2,] Constant Control & 2003: ,..................................................... " '"'''' , 7
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212 control method & 2003: 39) .................................. """ ....... " ..... ,, .... 9
2.3 EXISTING WATER HEATER SYSTEMS .......................................................................................... 12
of

2.3.1 Solar Water Heaters ............... " .................. " .............. " ......................................................... 12
2.3.2 Gas Water Heaters .................................................................................................. ,............. 15
2.3.3 Electric Water Heaters ........................................................................................ ,.. ,', .. " .. ", ... ]6
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2.3.4 Wind Powered Water Heaters ...................................................... ,......... " ........... ,... " .. " .. ", ... 16
2.4 BUCK CONVERTERS .................................................................................................................... 17
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2.4.1 Converters ............................... ,.......... ,................. "., .... .................. ,....... , 18

NEGATIVE FEEDBACK CONTROL. ................................................................................................ 21
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2.5
2.5,] PI ,.......... ,22
2 .6 IMPLEMENTATION OF PI CONTROL IN DIGITAL SIGNAL PROCESSORS ......................................... 23
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2.6. J discrete time domain Devices ...... " 23

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2.6.2 and Control/ers" ................ " ........ "",, .......... ,...... ,..... 26
2.6,3 Methods to determine P and I constant.. .................................................................... " ........ , 28
3 SIMULATION OF HEATER CONTROLLER.............................................................................. 29
3.1 SIMULATION OBJECTIVES ........................................................................................................... 29
3.2 SIMULATION SETUP .................................................................................................................... 30
3. 2,] Simulation in Matlab ................................................................... ,.. ................... , .. ,.... ,30
3.2,2 Simulation without PI control/er .............................................. ,............... ,.... ,.... ... ,.. ,', ........ ,.31
3.2.3 Simulation with PI control/er ................................................ ,....... ,... ,...... ,..... " .. ,', .... ,." .. ,.. '., 33
3 .3 SIMULATION RESULTS WITHOUT PI CONTROLLER ....................................................................... 34
3 .4 SIMULATION RESULTS WITH PI CONTROLLER ............................................................................. 42
3.5 COMPARISON OF SIMULATION RESULTS ..................................................................................... 48
3.6 CONCLUSIONS BASED ON COMPARISON OF SIMULATION RESULTS ............................................ .49

4 HARDWARE DESIGN ..................................................................................................................... 51

4.1 HC HARDWARE TOPOLOGY ........................................................................................................ 51
4,1.1 .......... 51
 4.1.2 DC Link and .......................... 52
4.1.3 IGBT .................................................. .................................................................................... 52
4. 1.4 .................................................................................................... 52
4./.5 Inductor 1995: 1997: ........................................................ 53
4.2 SIMPLIFIED PI CONTROLLER TOPOLOGy .................. " ............................. : ................................... 58
4.3 POWER SUPPLY DESIGN .............................................................................................................. 59
4.4 CURRENT AND VOLTAGE TRANSDUCERS ........................................................................ 62
4.4.1 LV25-NP .............................................................................. 62
4.4.2 LA 55-P ................................................................................. 63
5 DSP AND INTERFACE CARD ....................................................................................................... 65
5.1 TMS 320C 2407 A DIGITAL SIGNAL PROCESSOR ....................................................................... 65
5.2 INTERFACE CARD ........................................................................................................................ 65
5.2.1 ....... 66
5.2.2 ........ 67
5.2.3
6 SOFTWARE DESIGN ...................................................................................................................... 69

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6.1 HEATER CONTROLLER SOFTWARE OVERVIEW ........................................................................... 69
6.2 STARTUP PROCEDURE OF THE MAIN ROUTINE ............................................................................ 71

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6.3 OVERVIEW OF INTERRUPT SERVICE ROUTINE ............................................................................. 80
6.3.1 Data and Data .................................................................................. 82
6.3.2 ............................... 84
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6.3.3 ............................... 85
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7 EXPERIMENTAL RESULTS .......................................................................................................... 89
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7.1 LABORATORY SETUP FOR TESTING PURPOSES ............................................................................. 89

7.2 BUILDING OF HEATER CONTROLLER ........................................................................................... 90
7.3 PROBLEMS ENCOUNTERED AND SOLUTIONS DEVELOPED ........................................................... 91
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7.3.1 ................................................................................................................. 91
7.3.2 Issues ........................................................................................................ 92
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7.3.3 Noise 93
7.3.4 Final Heater Controller ................................................................................... 96
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7.3.5 Test List to ..................................................... 99

7.4 VOLTAGE FROM WIND GENERATOR ......................................................................................... 100
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7.5 CURRENT FROM WIND GENERATOR .......................................................................................... 100

7.6 EFFICIENCY OF SYSTEM ............................................................................................................. 10 I
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8 CONCLUSIONS .............................................................................................................................. 103

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9 RECOMMENDATIONS ................................................................................................................ 106

REFERENCES .......................................................................................................................................... 107
APPENDICES ........................................................................................................................................... 112
FIGURE 1-1 SCHEMATIC OF HEATER CONTROLLER .......................................................................................... 2
FIGURE 2-1 OUTPUT POWER vis WIND SPEED FAMILY OF CURVES .................................................................... 6
FIGURE 2-2 MAXIMUM POWER POINT vis WIND SPEED CURVE ........................................................................ 7
FIGURE 2-3 CONSTANT STEP CONTROL FOR MAXIMUM POWER POINT TRACKING ........................................... 8
FIGURE 2-4 CONTROL METHOD FOR MAXIMUM POWER POINT TRACKING ....................................... 9
FIGURE 2-5 MPPT LOOKUP TABLE AND APPROXIMATED MPPT CURVE ....................................................... 10
FIGURE 2-6 MAXIMUM POWER POINT TRACKING EXPLANATION ................................................................... 11
FIGURE 2-7 SCHEMATIC OF A BUCK CONVERTER ......................................................................... 18
FIGURE 2-8 INDUCTOR VOLTAGE AND CURRENT WAVEFORM FOR ONE SWITCHING PERIOD
UNDELAND & 19
FIGURE 2-9 CLOSED LOOP SYSTEM ................................................................................................................ 22
FIGURE 2-10 ZERO ORDER HOLD APPROXIMATION METHOD DEVICES ......................... 24
FIGURE 3-1 BLOCK DIAGRAM OF SIMULATION MODEL OF HEATER CONTROLLER ........................................... 31

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FIGURE 3-2 SIMULATION OF HEATER CONTROLLER WITHOUT PI CONTROLLER .............................................. 32

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FIGURE 3-3 SIMULATION OF HEATER CONTROLLER WITH PI LOOP ................................................................. 34
FIGURE 3-4 OUTPUT POWER vis TIME GRAPH WITHOUT PI CONTROLLER ...................................................... 35

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FIGURE 3-5 RIPPLE IN OUTPUT POWER WITHOUT PI CONTROLLER ................................................................. 35
FIGURE 3-6 OUTPUT VOLTAGE VIs TIME GRAPH WITHOUT PI CONTROLLER .................................................. 36
FIGURE 3-7 RIPPLE IN OUTPUT VOLTAGE WITHOUT PI CONTROLLER ............................................................. 36
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FIGURE 3-8 OUTPUT CURRENT vis TIME GRAPH WITHOUT PI CONTROLLER .................................................. 37
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FIGURE 3-9 RIPPLE IN OUTPUT CURRENT WITHOUT PI CONTROLLER ............................................................. 37
FIGURE 3-10 DUTY CYCLE vis TIME GRAPH WITHOUT PI CONTROLLER ........................................................ 38
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FIGURE 3-11 RIPPLE IN DUTY CYCLE WITHOUT PI CONTROLLER ................................................................... 38

FIGURE 3-12DC LINK VOLTAGE vis TIME GRAPH WITHOUT PI CONTROLLER ............................................... 3 9
FIGURE 3-13 RIPPLE IN DC LINK VOLTAGE WITHOUT PI CONTROLLER ......................................................... 39
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FIGURE 3-14 LINE TO LINE VOLTAGE FROM WIND TURBINE WITHOUT PI CONTROLLER ................................ .40
FIGURE 3-15 STEADY STATE LINE TO LINE VOLTAGE FROM WIND TURBINE WITHOUT PI CONTROLLER .......... 40
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FIGURE 3-16 LINE CURRENT FROM WIND TURBINE WITHOUT PI CONTROLLER ............................................ .41
FIGURE 3-17 STEADY STATE LINE CURRENT FROM WIND TURBINE WITHOUT PI CONTROLLER ...................... .41
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FIGURE 3-18 OUTPUT POWER vis TIME GRAPH WITH PI CONTROLLER .......................................................... .42
FIGURE 3-19 RIPPLE IN OUTPUT POWER WITH PI CONTROLLER .................................................................... .43
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FIGURE 3-20 OUTPUT VOLTAGE vis TIME GRAPH WITH PI CONTROLLER ...................................................... .43
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FIGURE 3-21 RIpPLE IN OUTPUT VOLTAGE WITH PI CONTROLLER ................................................................. 44

FIGURE 3-22 OUTPUT CURRENT vis TIME GRAPH WITH PI CONTROLLER ...................................................... .44
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FIGURE 3-23 RIPPLE IN OUTPUT CURRENT WITHOUT PI CONTROLLER ........................................................... 45

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FIGURE 3-24 DuTY CYCLE vis TIME GRAPH WITH PI CONTROLLER .............................................................. .45
FIGURE 3-25 RIPPLE IN DUTY CYCLE WITH PI CONTROLLER ......................................................................... 46
FIGURE 3-26 DC LINK VOLTAGE vis TIME GRAPH WITH PI CONTROLLER ..................................................... 46
FIGURE 3-27 RIPPLE IN DC LINK VOLTAGE WITH PI CONTROLLER ................................................................ 47
FIGURE 3-28 LINE TO LINE VOLTAGE FROM WIND TURBINE WITH PI CONTROLLER ...................................... .47
FIGURE 3-29 LINE CURRENT FROM WIND TURBINE WITH PI CONTROLLER .................................................... 48
FIGURE 4-1 SCHEMATIC OF THREE-PHASE, PASSIVE RECTIFIER ...................................................................... 51
FIGURE 4-2 USE OF MITSUBISHI MODULE IN BUCK CONVERTER..................................................................... 52
FIGURE 4-3 CIRCUIT OF AN INDUCTOR USED IN INDUCTOR DESIGN ........................................... 5 5
FIGURE 4-4 BASIC PI TOPOLOGY ................................................................................................................... 59
FIGURE 4-5 CIRCUIT USED TO OBTAIN SQUARE WAVEFORM FOR PMG FREQUENCY CALCULATION ............... 60
FIGURE 4-6 CONVERTING PMG SINUSOIDAL OUTPUT INTO A SQUARE WAVE ................................................. 61
FIGURE 4-7 SCHEMATIC OF VOLTAGE LEM MODULE .................................................................................... 63
FIGURE 4-8 SCHEMATIC OF CURRENT LEM MODULE .................................................................................... 64
FIGURE 5-1 OUTPUT VOLTAGE CONDITIONING CIRCUIT ON INTERFACE CARD ............................................... 66
FIGURE 6-1 HEATER CONTROLLER SOFTWARE OVERVIEW FLOWCHART ....................................................... 69
FIGURE 6-2 STARTUP PROCEDURE FLOWCHART ............................................................................................ 71
FIGURE 6-3 SYNCHRONIZING AND READING PARAMETERS FROM PIC MICROPROCESSOR ............................... 75
FIGURE 6-4 INTERRUPT SERVICE ROUTINE TIMING ........................................................................................ 79
FIGURE 6-5 INTERRUPT SERVICE ROUTINE FLOWCHART ............................................................................... 81
FIGURE 6-6 DETAILED FIRST BLOCK OF ISR FLOWCHART .............................................................................. 83
FIGURE 6-7 ERROR CHECKING FLOWCHART .................................................................................................. 85
FIGURE 6-8 DETAILED TOPOLOGY FOR PI CONTROL OF HEATER CONTROLLER ............................................. 87
FIGURE 7-1 LABORATORY SETUP SCHEMATIC OF WIND TURBINE ................................................................... 89
FIGURE 7-2 INTERIOR OF HC UNIT BUCK CONVERTER AND RIGHT INTERFACE CARD AND

FIGURE 7-3 OUTSIDE OF HC UNIT .................................................................................................................. 90

FIGURE 7-4 CLOSE LOOK AT SET POINT POWER VERSUS OUTPUT POWER WITH WAITING AVERAGE PROBLEM 91
FIGURE 7-5 EFFECT OF RUNNING AVERAGE ON PHASE MARGIN ...................................................................... 92
FIGURE 7-6 PERTURBATION CAUSED BY SMALL TON/ToFF IGBT TIME ......................................................... 93
FIGURE 7-7 REDUCED ELECTROMAGNETIC PERTURBATION WITH INCREASED TON/ToFF OF IGBT ................ 94
FIGURE 7-8 VISIBLE REDUCTION IN NOISE PERTURBATION ............................................................................. 95
FIGURE 7-9 ADC TIMING AND LIMITED ELECTROMAGNETIC PERTURBATION ................................................. 95
FIGURE 7-10 CHARACTERISTICS OF OUTPUT VOLTAGE AND OUTPUT CURRENT FROM YOKOGA WA POWER

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FIGURE 7-11 DC VOLTAGE AND OUTPUT VOLTAGE FROM FINAL HEATER CONTROLLER ............................... 97
FIGURE 7-12 OUTPUT POWER AND SET POINT POWER FROM CONTROLLER ..................................................... 98

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FIGURE 7-13 DC Bus VOLTAGEANDOUTPTVOLTAGEAT6 KW UNDER STEADY STATE CONDITIONS ........... 99
FIGURE 7-14 OUTPUT VOLTAGE FROM WIND GENERATOR ........................................................................... 100
FIGURE 7-15 OUTPUT CURRENT FROM WIND GENERATOR ............................................................................ 10 1
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FIGURE 7-16 EFFICIENCY MEASUREMENTS FROM POWER METER ................................................................ 102
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 CHAPTER 1: INTRODlICTlON

1.2 Description of the Main Problems

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experi ~oc~d wer~:
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a. Low respons~ time. This atti-'Cts thc \IPPT algorithm becau>c the system docs no!
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r~spond fast ~l1ough to WilW gusts due to lack of proper control system. As a
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r~sult. th~ p~rI(."manc~ of th~ system is reduced. Since power exU'acted fOl1n a
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WilW generator Lncrcasc> with thc c~,he of the wind sp eed, it is important to
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respoi1d t:lst to wind gll,t, to extrad ma.~imum pow~r available.

b Th ere was a 300Hz rippl~ on the output voltagc. This output voltage rippl e was
intmdueed becausc thc control system works at a fi-equ eney k'Ss than ]00 Hz.
This rippl e in th e output voltag~ intmdu~ed a rippk in the powcr being extracted
from th e generator and was relkctoo on lh~ blad~s of the wind tllmil1C in the form
01' a~ollstie noi s~. Th~ ri p pl~ power also reducc> th e Ii fe lime 0 r th e wind gen~rmor

and the blad~s through unwanted mechanical vibrations.

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 CHAPTER 2: BACKGROUND RESEARCH

The rotor power codficielH can also I", ~xpr~s.,ed as a runc.lion 0(' tile specd o('lhc blade
tip \'ihich is proportioll3i to the wind speed_ Ther~ ar~ variolls slalislinll lechniyu e,
available to estimate the energy production ofa wind lurlline. For a delail~d and in d~plh

analysis. l'efer to Wind Energy Explaind by l,r 'v1anvdl, J.G McGowall & A,L R01!~rs,

pllblished by WILLY (-"(anwell, McGowan & Rog~rs, 2002: 2R).

2.2 Maximum Power Point Tracking

From ~'1'lalion 2,1, it can be seen tbm the po\,' el' hm'vesled from the wind t\lrhine is

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pow~r vis wi Il<l spceJ curvcs tor a particular tmbi nc' S chm'acteri stiC'_ An exampl e of lh ~
Olllput pow~r vis w,mi speeJ curvcs arc shown in fig\lre 2,1,
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from th~ wind turbine at tbat ]Xlrticlllm' wind sp"d. 11' a lin~ is Jrawn thro\lgh each of
lh.ese maximum power poims. the maximllm p'm'~r pomt curvc ''is ,,·ind speed IS
obt.1incd for the wind l\lrllillc. 111 order 10 extract m~ximum enel'gy fl'<"n (I", winJ
generator at an} gIven tim e, the opo:rating point of the wind generator mu~t lie on the
maximum power point curve given in figure 2.2 (Moor & Beuke~, 2003: 39).

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1 2 3 ~ 5 6 7 ~ 9 10 11 12 1:3 14 15 16
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Fi~u .... 2·2 M..imum Power Point

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2.2,1 Constant Step Control (Moor & Beukes, 2003: 39)

Con~tant step control is a simple metho<l used to track maximum power point of the wind
turbine (Moor & Beukes, 2003: 39). Flowchart 2.3 describes how the constant step
control opo:l""dtes.

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2 100 20 200 iii 6000
3 115 23 500 ~ 5000 +-------'-"""-......
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area on

- 16-
 to are ...."'I"'T"'n must

is "'u"'''' •. '''.... as on

n
w
To
A converter is a e are .....'.h.......'ti to
ap
C

converter is converter
of

is to :1
ty

is l'>(u.......'11 at
si

a
er

to
v
ni
U

to
is
 converters converters. converters can
as

n
w
To
e
ap
C

2-7 Schematic of a buck converter

of

converter can two

ity
rs
ve

a. is to
ni
U

stores

b. is as
current

as

- 18 -
 current two cal:egon are "' .... ,", ..'....

o t
B

n
w
To
o e t
ap

2-8 Inductor and current waveform for one "AU"""'" Undeland &
C
of

is
ity

one
rs
ve
ni

converter are
U

area is
B must
to zero

). + ).(1- =0

- 19-
 to
is

on

can

current

n
w
To
are 1
e
ap

converter
C

to
of
ity
rs
ve
ni
U

a converter can

a. to converter or
converter.

resilstalnce or
 b. IS "'''''''''''''u

to
measures are .."'ron""'.,..."....

a. to

connect

b. on a can

n
w
To
e
ap
C

are two
of
ity
rs
ve
ni
U

is

- 21 -
 Desired

2-9 Closed

are

a. to a constant

n
b.

w
To
etc.
c. e
d.
ap
to error
C
of
ity

is .... ,~.,.
rs

,.~
ve

more
ni
U

1
= +- +
I

constant I is constant IS constant.

constant is 1 to
constant is set to zero.
a is as:
 1
= +-
I

constant

n
w
To
e
ap

a '"'v .... , .... v

C

a
of
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rs
ve
ni
U

can as

=(K p + s

is
 is error

IS constant

is constant

are
zero

constant

n
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w
more accurate more

To
to
e
ap
C

we are IS

zero
of

now
ty
si
v er
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2-10 Zero Order Hold ..."" ........ In... fl method Devices

can

""'.'..."5 ......... areas curve as 10. is accurate

 is area at n, can

= +

is area at n

is u n .. " '....... "" area one ""rn..-" .. at 1)

is "lU~U""'" area 10

n
w
1

To
can
e
ap
z· = +
C

can
of
ity
rs
ve

=
ni
U

is

U("+I) = + 11)

is

at n

IS error at 1)
 is error n

is

is
a

n
w
To
are
e
ap
C

a. it
of

b.
ity

c.
rs

d. it
ve
ni

e. run prm;esses at
U

tti:>·r",r,t

some are:

a.
must

b. It son1enm as
c. A nn,,,,,,,,'T1 must
 if use is

lenlerltlnli! a a

a. is a
see "'......, .."'.
a

n
w
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e
ap
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b. rate
of

to
ity

c.
rs
ve
ni

d.
U

"t""".t" state error.

is a on
 p

are two constants.

is
z

or measurement

n
,""c'r",.""

w
can

To
e
ap
error; as
to error are as
C
of
ity

• to zero
rs

state errors at
ve

•
ni

state error is
U

to if

us measure
is
to
 OF

covers IUlU''--''',Ul to

on

n
w
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is to to
e
ap
C

a
of
ity

III converter.
rs
ve
ni

III
U

~+",.~rI" state
error ... t ...",rI" state error

state error

III

4
to
 OF

sets were

set
a lLi\J"'~l to "''''''''' ...
'1<1.'...., new

n
w
converter a

To
e
ap

as it
C
of

converter a
ity

converter was to
rs
ve

3.1.
ni
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is

to

is to

a set 4 was
 OF

n
Pout

w
3-1 Block of simulation model of heater controller

To
e
ap
C

a
of
ty

to a set set
si
ver

same is to is not
ni
U

is

- 31 -
 OF

DC

Vlood .nd 11 •• d
"" 1---101.""
Wind Generator R.mifio.tion Slag. Buck Convorto, Load

PW1\4 Gono,.I.,

Poul

n
w
Solpolnt Po... ,

To
Co.j,ol Sign.l. u

G.in
Emboddod
e
MAT LAB Fu.oIIo.
ap
C

u(n) Transport
Dol.y
of

3-2 Simulation of heater controller without PI controller

ity
rs

an y . . ", . . v . . was
ve

.................. IS
ni
U

z=w;

>v
z=z+
end

>u
Z = Z - O.
end
== u
z =z;
end

> 1024
z = 1024
 OF

end

<0
z=o
end

y=z;

it can

is cr""""".'",..." a

n
counter

w
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e
ap
to
C

a ._.,..,.... ,.., oetvveem 0 1. is

of
ity

to is
rs
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use a ......."'.Jv.
is
ni
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an emOe(lae:a a
is is
is at zero means
is a
 OF

Vi 1---fJIoiVi

DC

Vlo.d .nd lload

WI.d Go.o"lo, "o¢lIIl ..llo. SI.g. Buck Con".rI., Lo.d

\l)onl",1 I'WM
, v ""'ullipli.,

PWM Go.o,.lor

Voo.lf01 Pout

n
w
To
Control Slg .. l. u

S"u,,!lon

e
ap
C

3-3 Simulation of heater controller with PI

of

o to 1.
ty

UtJlpeJ1UI,ng on
si
er

a is to
v
ni
U

resu

current are

to
10 state error is ms to
 OF

state error is ms. on is

at a

4500

4000

3500

3000

~
t2500
~
<:I
1:1.
:; 2000
S-
"
°1500

n
w
1000

To
500

a e
0 08
ap
C

3-4 Power vIs Time without PI controller

of

Power vIs Time

.,50r--------.--------r-~----_r--------r_------_r------_.
ty
si
v er
ni
U

"""8.'::.,-------::-0.""''::::--------=-,,''=
..-----:-'::::-----::-':-:----0=-...,,'::::-----::-'0....
·

3-5 in , •..,.. _.... Power without PI controller

 OF

to
10 state error is "' .... ,,, ..,,,v 0.1 %
state error is on is
at a

2OOr------r-----,,-----,r-----.~----,_----_.------._----_.

'80

'50

140

n
w
To
e
ap
C

06 0.7 0.8
time (s)
of

3-6 vIs Time without PI controller

ty
si
v er
ni

'80
U

,...

'65

,~L.--,-~,-~~--~~--~~--~~.~,--~O.~.,~2---0~.~,.~~o~.~'e,-~O~.41~.--~
time (5]

3-7 in ....,... ~ .... ''''~'''ftft'_ without PI controller

 OF

to
10 state error is "' ....'...... I1.V to
state error is on current is
at a

Current vIs Time

n
-; 15

....I:!

w
u

To
':i
.e-
.. 10 ----------

o
e
ap
C

07 0.0
of

3-8 Current vIs Time without PI controller

ty
si
v er
ni

~ 21.5 --
U

I
u
1
<5 21

time Is)

3-9 in Klo .... _ .... Current without PI controller

 OF

3.10 3.11 10 state error is

state error is gn'''..,....v
310 ms. on at a

07r------,-----,------,-~~_.------r_----._----_,----__,

0.'

..Ii o.
C
t

n
Q 0.3

w
To
02

e
ap
0 .•
C

3-10 vIs Time without PI controller

of
ity

Duty Cycle vis Time

o 513S,.----r---,-----.-----,r----.---.,!--.,----,-~--,------,
rs
ve

0.513 ,-- ----

: I
-l---
ni

0.5125 --- - ,-- - --- --- - --- - --- - ,-- - -- -: --- - t--- ;--. 1_ ---
. Ii
U

..!:! 0.612 ~-rj: -- -- -- c- -- -- i'l- -- -- -t- -- 1--

C~
£ 05115 --- -, -~ - - --- - --- -, -- -~ - --- 1- -r'
0.611 -- ---- ----

0.6105 +--------:·_---·-----r----------r-· -----:--.--------:---- -- --_. ~--:-

06AL:
.•- - -O
,.-J.405':::---'0=-'.•::-,---:-0."o"-=-5 ---:-0.'=42:-----;O~.425::---:0:':.43::---::-oL=----='0.44:-:---;:0-7.445:;:----;:-'0.45.
time lsI

3-11 in without PI controller

 OF

3.12
on
IS

n
w
To
e
151
ap
time
C

3-12 DC Link vis Time without PI controller

of
ty
si
er
v
ni
U

time [s)

3-13 in DC Link without PI controller

 OF

3. is a
15 a
at to <>1"".",£'1" state

Line to line voltuKII: ofWT vIs Time

400.-----.-----.------.----~----_,r_----._----._----~

200 t I

n
w
To
·200

-:;00
e
ap
4000~----0~,----~0.~2----~0~.3-----+0.•~--~O.~5----~0~.e-----+07~--~0.8
time (s)
C

3·14 Line to line from Wind Turbine without PI controller

of
ty

L'me to rIDe vonage 0 fWT vs

si

I T'Ime
400
: ! ,,
,,,
er

--- i F ~ ! ,. ......
F= 1

r
v

T ! ~
!
Ii
ni

200 1---- .--_.

r+
U

1---- --- r---

ol-----L :-- \ L
r
\
I I
---_. ,-_. ;.. --- ;---- --
j I',; ':i:
-200 1------- !-~ Ii ! .-_.

I--------t= ~ m_mm

F
- ~ ~ ~
-----~---

,
400
0.'
i i
0.42 0,43 0." 0.46 0.48 0.47 0.48 0.49 0.5
time (5)

3-15 state line to line from wind turbine without PI controller

 CHAPTER 3: SIMUL.oO.TION OF HEATER CONTROllER

Figure J 16 SfIOW~ the oUlplLlline current fWIll the wind turbiL)e_ The c_urrent settles (0 a
0,1 % stcady sMc errol' within 310 l11ol. Figure 3_17 gives a doser I()o~ at the linc to line
voltagc under steady state conditions.

Un. CUlTOnt f,'om WT vi. Tin ..

1
i 'I
~.---
-----,-- -------+-

_____ ,______________________ .L
-- ,--
LI

n
----_._----------, ----------,--

w
To
e
ap

"', "
C

tiro< (_j
of

Figuro 3_16 !.iRO Curront rrom WIot! Turbine without PI controll..-

ity

Li .. eLLr,,"! (,oon wT ,-/, Tim,

"
rs
ve
ni
U

--;. ------,-
}.;
•• « ,.
""~l
.~. "

'" "" •• ,.
ri~u,-o 3.1 ~ St,,"t!~ ,Utr lino <nrront rrom wind "'r!>i.e ,,1thou{ j'{ c"ntroUor

- 41 -
 CHAPTER 3: SIMULATION OF HEATER CONTROLLER

3.4 Simulation results with PI Controller

In this ,ection the ,imulated output power, output \oitage, output current, duty cycle, I)C
Ill" voltage, line to line volt3ge ti-om wind llIrbinc 3nd lin e cutTent from wind turbine arc
,hown_ A ,tep input 01"4 kW i, used fortlJe ,imulations.

I'igure, 3.18 3nd _1 19 SI~lW tbe output power of the heater controlkr. Tim e taken to rea~h

10 'YO steady state error is approximately 45 ms and time taken to reach 0_1 % steady ,tale
~rL'or is approximately 100 ms, The ripple on the output power is 0,5 % and o,cillate, at a
freyuency oj' 300 Hz.

n
w
To
''''p'' p,,,,, ,-;. .,---
Tl,,,
"~I'

••
e ------+------

".,
ap

,, ..
~
C

,, --
'ow
of
ity

-
rs

•..L.__ .., ... .. ..

ve
ni

Figur~ 3-13 O"'PUI powor .'1< Tlmo ~I'nph ",ith PI "0"" rollo'
U

- 42-
 CHAPTER 3: SIMUATIO~ OF HEATER CONTROLLEfl

OU'p.t Po,.."vl. n ...

" •
-- , - --,-

,-
i-
L --;
-L _L
-.!"~-".,-~-"",.-~.,,,~-".,"--.'"~-".;.~-,."~-~,,
''''1-1

n
w
Figur~ 3-19 Ripple in Output I'o"' ~r witb PI cOlltTQII.r

To
Figures 3.20 and 3.21 ~how (he output power of the heater controller. Time taken to reach
e
10 % steady state error i~ approximately 45 ms and time taken to reach 0.1 % steady state
ap

error is approx imatel y 1()() ms. The ripple on the output voltage is 0.28 % and oscillates
C

at a frequency ofJOO Hz,

of

•. ____, __--,o"".'''~...". ."..'~.,',••••',~TI......~_, -------T-

ity

.
:_______~-J~::: ::::::::~ - - - - - : : : : :_:- ----'--- - --'-- ~---"- - -
rs
ve

i== --/ ------ -

ni

'-::::::::--:---:::-:-:-----------------i--
U

:. -,-- -~ -----------------1--
~ . ~- - -- i-
-------, -
",
", ,...• . •~

Fi~ur< 3-20 U"'PHt ~"I<~g< ,.-1< Tim. ~r"ph with Pt ('oI\Lrolin

- 43 -
 CHAPTER 3: SIMULAnON OF HEATER CoNTROllER

, ,
,
.

11k I ····
, .... ,
,
·I
."A
I ,

,. ,,
, V ,..
•. '.
... .. ....
o•
, , - --i

••• • .... . .
, .
1

n
,
, , , , ---;,

w
" ,~,
'",
To
Figu r< .!-21 Rippl . in Output Yflh.~.
e "ilh PI <ontroil..-
ap
Fi gure~ 3.22 ~nd 3.2] show th~ output C\lrrent of the heater controller. Time taken to
C

re<Lch 10 % steady Slale error is approximatdy 45 ms and time t~k~n to re~ch 0.1 %
steady ~taw error is approximmely 100 ms_ 111e ripple on the outptlt C\lrrent is 0_::'8 % <md
of

oscillales iLt a frequency of 300 Hz.

ity
rs
ve

- "
--..,-----
ni

-----:-- - - j ~~~,----<--
- --~-. -<-- -- t --

, /~
U

-
I-
. I
!
'!. w---i--- --------- , -----------------.--
! I
,,
, ,, ----- i-- , -------'---- --- -j -------~--
/
, L~,C",~,".,~,••~~..~~t_~~,"
,
..,. ..,
" "

Figur. 3·22 Outl"[t CUlnnt vi, Time eraph "ith Pt <ont,.<>IIo,.

- 44-
 CHAF'TER 3: SI\1UL;TIO.~ Of HEATER CONTROLLER

oU'pu, c.,... ~, ,'I. T;,..

"'~- --,- ------ ,-----
,,,. ,--
_______ _, __________ , __________ ' __________ v __
"
~
---- -----, - ,-

, ---+ -i
---i-- ------------------- ------! ----------f-, -- --1
--,- --f-- -, ------- -,-- -j-
" ~~--
"J
"L ,-
_. • •. ,__~~~ __l

n
.,,, " . . _ n ,'", "

w
To
Fi~urc 3-13 Ripple;" U"'PUi Currem wilhom PI rontrollor
e
figures 3.24 and 3.25 8how the duly cycle. Time taken to reach 10 % ste:ldy state error is
ap
approximately 45 inS and time lak en 10 reach 0.1 % 8\eady state error is apprllximalely
C

100 ms. Th e rippl e on the duty cycle is 0.18 % and oscillates at a frequency "f300 Hz.
of

Du,y '-"yd, vi, 10m,

ity

,, -- --- --'-- --- -~

/~~ ,
rs

..L //
ve

.'j ,I
ni

b ~_
! . ,:I
U

,,~-- --c-- ------------, --

":, -- - ---,-- ,
-l-J, ~,.~,~.-,i,br-- ,.. ,,' .';;--- -. ~',-=-~,'.~-!"

Fi~" "0 J_24 Duty eye!. "~I. Tim. graph wl!h PI rontrnllor

- 45-
 CHAPHR 3: SIMULATION OF HEAHR CONTilOLI.ER

I .1, Tim.

~l

n
w
To
Figuce 3_25 Ripple ill Dn!y Cyrl. with PI eonlrolle,'
e
ap
Figures 3.26 and 3.27 sho", the DC Link Voltage. There is a 5.8 % overshoot which
C

settles to 0.1 % steady slate error level after 100 ms. Maximum ripple on the DC link
voltage is 0,23 °4 and it also oscillates at 300 Hz.
of
ity
rs
ve
ni
U

"" --------_.-

-- -----, ---------~-
"
~
,
,. '" ,., ,.
0."
" tim. ['1
• ." '.k
" "
~-i~u,,' 3-26 He Link Vallaz. vi. Ti .. . graph wilh PI cunlrollor

- 4(i -
 CHAPTER 3: SIMULATION OF HEATER CONTROLLER

• ~.,". ,
, . ~

• ••••
_. , - ---,-- : .
,
· , , ......

A
' ~A K
"
, I ,
••
JI
'. .., '.
w< ' .
,

n
, :
•

w
,,~',.,

To
Fi, uro 3-27 R'l'plt in DC Link Volt.ge ",itb PI cont",llore
ap
Figure ),28 shows the output line lo lin~ voltag~ Ii-orr! th~ wind turbine. Th~L"~ is a 5,g '~"i>
C

()v~rshoot which s~ttlc, to ,,0_1 '/0 >leady stale ~rror within 100 nJs
of

Lin. 10 lino VoUOt ' orWi.d '] .roino,-!, Til..

ity

~, - , ,

t
___ J,c_
rs

• r
I
----f-

I '\ j l f I I
I
n I
ve

,
c, • J f it
, r
ni

--- --
i~
! ,1 ,J
I ,
U

,"'- l.._ _J_ I

,j"
) -"', ,
, -I ,

I, I'I:. lJ 1111 I
I:
•• -''''-
• I
".- I
•• J
U
,
U UL \
"
I
- -=C

,
" .- - , . ... ~ -~~-i'.~~~L,-~~
,,~, '" ". ... L;"" 1>1
."
L
."

Fi t ure 3_28 Lino ta line '-oU'go f",nl Wind TUI-bioo "ilb PI <ollirall""

- ·17 -
 CHAPTER 3: S,MULATION OF HEATER CONTROlLER

Fig\lre 3.29 ,h,.)\\,s the (lutput line current fn~n the wind lurbillc, Thc current sdtks wa
0_1 % ~teady slale err(lr wi lh ill 100 m S

l h'e Currenl QfWin~ Turl>in • • ;, Tim.

- --r-
"

f
, • f
I

1
!
it! -r . . . ...

1
,fl,'. 'on .

n
--- -'1',1"[-- :~--- j--I(.'\ -l P:'\- Tff'~- f'- -("-'1

w
------rr--- ---:.--- u--:·-~ <I 'I) ,,'" "':ll_\IY __ ~ '.'1'-'

To
~ - - - ' ---u - .' -.~ ~ - .- ', 1_ "~.~ '" . . '------, .1-
, ~ ~
',_J ~
~ . V

-.[ --\".- " ••-,.'.-•.,.- •.,.--/•••-",.--/•.,.--1",.--/"

e
ap
'1"'1'1
C

I'iann 3-H v"" Curr,,,{ frum Wino! Tur!>;n, w;lh PI (onl...-.II",

of

3.5 Comparison of Simulation Results

ity
rs
ve

Table },I compare, the rcwl\> (lhtaineJ rrnm lhe ;;imulalion;; using lhe lWO ~(JIllrol

methods i,e, with al1d withOUllhe PI ~(lIllr(llleL'. The peri(xmance spcciticaliolls lhat ha,'c
ni

he"" ~ompared ar~;

U

• 10% steady ,tate elTor ~lllill S (ime.

• 0_1 % sleady Slale error seUlillg time,
• Pcr~cnl"ge overshool,
• O;;~illation fnoquency,
• PcrcClltage rippk.
 OF

is not

Table 3-1 ofsimulation results

With PI Controller Without PI Controller

DC DC
Link Link
Power Current Power Current

n
10 % Steady State Error
45ms 45ms 45ms 45 ms 45 ma 290 ms 290 ms 290 ms 290 ms 290 ms

w
Settling Time

To
0.1 % Steady State
100 ms 100 ms 100 ms 100 ms 100 ms 310 ms 310 ms 310 ms 310 ms 310 ms
Error Settling Time

% Overshoot 0 0 0 5.8 0 0 0 0 20.5 0

e
ap
Main Oscillation Freq 300Hz 300 Hz 300Hz 300Hz 300 Hz 300 Hz 300Hz 300Hz 300Hz 300Hz

% Ripple 0.5 0.28 0.28 0.23 0.18 6.5 3.5 2.5 0.57 0.49
C
of
ity
rs
ve

it can use
ni

use
U

310 ms to 1
more
PI
7.1.

on current
to
to is to a
 means
on

U
ni
ve
rs
ity
OF

of
C
ap
are

e
To
w
n
on
 1

IS

converter. converter is
to IS

n
w
to current

To
see
e
ap

.1
C
of

4.1
ity

IS
rs
ve
ni
U

4~1 Schematic of rectifier.

- 51 -
 .2

currents . is a

.3

n
w
To
IS as
converter. e
ap
was was
as converter as
C
of
ity

IGBT Module IGBT Module

rs
ve

Vdc Vdc
ni

c Load Load
U

4-2 Use of Mitsubishi module in buck converter.

was at
It was .... """1<,11"'" to
 not

' ' ' V I . . ,,,,,", 15

to 15

zener uses an
to ..''''.l.....''

n
w
To
It ael:eC'[S over current a it is on.
ae
ap
C

IS is
of

or on
ity

is an over current is
rs

sets to zero
ve

on
ni
U

1 1

current is " ..."" ........' "',...

current is
4.1.

8
=L· (4.1)
8t
 to a converter on is
can as

is is

fs is a is

n
w
converter.

To
e
ap
C
of

• (max)} =
ity

}=
rs

• =
ve

• a= 5
ni
U

In(]LUCrarlCe L was to
a

to cores
turns H'-" ......'.... to
 an we IS on
IS core is
to

Rg

Flux
Rc

n
w
To
Ni

e
ap
4-3 circuit of an inductor used in inductor
C

core
of

IS i is current
ty
si

to "'''''v,",''"',,,,, core are

er

.... ,.....'''V'~ ...

v
ni
U

19 is meters
= xl
IS cross area

=
Ie is meters
is core.
is core.

can

r/J=---

core is

n
w
To
=
e
ap
IS core.
C

to
of

is as
ity
rs

+ ]=--=--..:::....
ve
ni

Lcan
U

L =----"--=-
i

to use 2 cores or 3 cores was pn~aalsnleet was

to
an is F.
 constants are core are as

• =

• =1
•
•
• Ie = 1 mm
•

n
• i=

w
To
spreadlshc:!et. two were "'11<,,,,,.
,111. are:
e
ap
• 2 core "n............,.
C

19 = 4.1 mm
40 turns
of

L=
ity
rs

• 3 core
ve

Ig = mm
= turns
ni

L=
U

two was
IS

=--..:;.::...

=
 = = 11)

is cross """"''''''1 to
is a constant 2 was
"'o..1U ......... as as
3 core was
to

are as

n
w
• 3

To
• mm e
•
ap
• 10
C

... ", ..... ",,,", is IS was

of
ity
rs
ve
ni

current I "n""'''''''' U is to
U
 TMS320L.F2407

n
w
4-4 Basic PI

to I is
To
at 10 I
e
ap
are
to
C
of
ity

to
rs
ve

converter is COlnITI:11 to at
ni
U

measurement
over a
 on at

one to
on
are:

II

n
w
To
I 1
v 11 e
ap

same .."'t'-.....'~... r'''' 0 are to

C

measurement
of

1, 2 or 3. 4 is to
to "''''''''''>T'''
ity
rs

was a
ve

at at IS is
ni
U

PMG frequency detect/on test circuit

4-5 Circuit used to obtain square waveform for PMG t-.... n .. '''n~·v calculation
It can seen a

is to convert

is ... a ....... at....... is

Generation of squara wew from sine WIIW

n
w
To
2
r---l
I
e I
ap

-2
C
of
ty

tlme[s]
si

4-6 'nnv ....yil1.... PMG sinusoidal into a square wave

v er
ni
U

is

it is two to
 to measure currents

over

n
•

w
•

To
• e
•
ap
• is current
C
of
ity

measurement
rs
ve

is 0-
ni

measurement
U

111'-''-'\.1.'''';:) IS

is
 +15V

Is r---~----~--, Im Vm
LV 25-P
Is=(2.5 KIm) Rm
VRef

4-7 Schematic of LEM Module

n
is measurement must

w
To
so as to use to measure
e
to are
ap
C
of
ity

:::: X 14)
rs
ve

is
current is '"'....... ..,..'u current Is to 10
ni

measurement
U

a v
on

current an~;aucer is
 +

1m
Is LA P Vm

lout 1m = ( Is I 00) Rm

4-8 Schematic of Current LEM module

n
w
To
current is are
measurement current are e
ap

=
C
of
ity

=
rs
ve

It was
ni

at
U

to to V at ."...~~ ..'" current.

is
 AND .lUT .. . , . " ,

A is a 16

it a

n
w
costs.

is
To
to
e n."rfnrrn
ap
C

measurement
of
ity

are not """'''''''1-'''

rs
ve

to
ni

nrc',,, .. , ... ,, at
U

"'I--'V"'.IlUllh J.

is a means to
is
 AND

to
are:

a.
b.
c.
d. to measure

n
w
To
.....,.... ''' ...... .., to converter o to
e
ap

to measure
C

measurement on at
of
ity

Cl
rs

22nF

+HT
ve

R3 R6
27k +15V
Potentiometer used 1----''''''
ni

IIl1<
LV25-P ·15V for Inaccuracy 5.6k
A compensation
U

Rll B
loll toADC
·HT 3.3Vlor
4.35Vlor
U-266V U-266V

Measurement R15· 51<

Resistor for 2
LEM low pass
filter

5-1 cOlulItionil1lg circuit on Interface card

A to
measurement
measurement are to remove
measurements
 AND NTE~RFJI).CE

A
1.

measurement

n
w
To
o to
e is a 10
ap
o IS as
C
of

= xl 1)
ity
rs

must
ve

to convert
ni
U

4.16 5.1 Is can

 AND ...,TI::O.'"

is to convert

current

measurement
is

n
w
To
5.1 IS rI"'l~"''''rn as
e
ap
C

=
of

'''''HAl'"r... to convert to
ty
si
ver

1
ni
U
 IS ....,.,na... ~'m

to
was "',"''''1",,11'''"''''

n
w
Initialization Routine

To
memory addresses
Declare variables e
ap
C

Main Routine

Procedure
of

RAni"... r Initialization
Vl'Illil'li'1IIAlI: initialization
ity

-
rs

,.-----"-----,..........
Continuous
As Continuous
ve

Requi d
Write Data to
repeat
ni
U

100 usee

6-1 Heater Controller Software Overview Flowchart

6.1
starts to
 to
nrrHTr<lTn is run,

or error
Cf()Dr'oces~)or runs a c"""<>r<>t,,,

n
w
IS

To
to
is to store e
ap
C

it
of

a
ity
rs
ve

to 2
ni

at 10
U

......,''''"'''' at

next more
 DrlDceaure

Ensure ports for PWM are zero

1 3,,, ....,,,"'"""'" with Pic to read

Table

Tum on Clocks

1 Calculate of Power Curve

n
w
1
To
Read Parameter Tables

SPI port setup for DACs e

1
ap
Initialise Timer T1
C

External switch setup IOPC6

of

1 Initialize vriables
ity

ADC
rs

1
ve

Start Timer T1
ni

Serial Port
U

I
6-2 Procedure Flowchart

..,..."h ..,,,, is as

to to

- 71 -
 are to set to
zero.
on
or cause .....AU~.F.'" to

1* switch PWM setup "/

"MCRA 1= OxOOCO;

are set to IS

uses a . U ' U H...., .... on

n
w
To
/" code timer setup IOPB2 */
*MCRA &= OxFBFF; e
*PBDA TDIR 1=
ap
*PBDA TDIR &= OxFFFB;
C

1* on elks */
of

*SCSR I = OxOOEC;
ity

IS set are
rs
ve
ni
U

is run

/* setup */

*IMR = Ox0023;
*IFR OxFFFF;
*EVAIMRA = Ox020 1;
eire
 to to are
are to

I" SPI port setup for DAC corns "I

·SPICCR &= OxOFF7F;

*MCRB 1=
*SPICCR 1= "'''''"lln:
"SPICTL Ox0006;
*SPIBRR 1= Ox0003;
·SPICCR 1= Ox0080;

n
w
·PCDATDIR 1= Ox2020;

to are
To
set
e
ap
set
are to
C
of
ity

1* for ADC *1
rs

*ADCTRLI = OxOF90;
ve

*ADCTRL2 = OxOOOO;
*MAXCONV OxOOOF;
ni
U

is set to

1* Serial port setup "I

*MCRA 1= Ox0003; 1* IOPAO SCITXD & IOPAI = SCIRXD *1

*SCICCR Ox0007; 1* I stop bit, no 8 bit char IOOIJba<:k enabled *1
*SCICTLI = Ox0003;
*SCIHBAUD = OxOOO I; 1* Baud rate set to 9600 *1
 ·SCILBAUD == OxOOFF;
*SCICTL2 == Ox0002; /* enable RXRDY */
*SCICTLl = Ox0023; /* from reset "/

set is to

a to

n
to

w
to it wants to is

To
e
ap
C
of
ity
rs
ve
ni
U
 DSP sends 200 to PIC

No
Keep checking for 200 from DSP

PIC sends 201 10 DSP

n
w
No

To
Keep checking for 201 from PIC

e
ap
DSP sends 202 to PIC to say Hwants to
read EEPROM
C
of

DSP sends 131 then EEPROM address to

PIC
ity
rs
ve

PIC replies with dala stored on EEPROM

address
ni
U

DSP sends 203 to PIC when all data has

been read

6-3 ..n . . " . . . . . . and from PIC

is
at
 is a 16 bit is an 8
on two Setlarate on

... rlrI~<>,,,.. it

wants to
it wants to
are

are

n
w
To
e
ap
same
C
of

it a to to it
ty
si
er

can
v
ni
U

reset to new Dalrarrletl~r or

/'" Start of communication pre,cedlure between PIC and DSP "'I

for m<20000; I'" Short to clear the serial bus""

{}

'''' DSP 200 until it receives a 201 from the PIC

"'SCITXBUF 200;
 &

"'SCITXBUF = 202; I'" Once it receives 201 from the DSP sends 202 and waits "'I
&

for
{}

I'" Read table *1

&

n
& 0;

w
To
e
ap

0;
C
of
ity
rs

0;
ve
ni
U

&
0;

1* Calculate curve*1

for ; i<10;
 /" Read Parameter Table */

for (i=O; i<9;

*SCITXBUF 131
"SCITXBUF=
while
Value = rcvd«8;
*SCITXBUF = 13 =OxOOOO) 0;

n
*SCITXBUF= & 0;

w
while

To
Value = Value +
e
ap

IMax = 100;
C

VMax = Value;
< VMax = 200;
of

> VMax=
ity

< PMax = 10000;

rs
ve

= Value;
<0) =0;
ni

> 1) = 1;
U

if (i=7) PMaxHz = Value;

m";'-'uu~, < TimeConst = 100;

m"; ..... u'U~, > TimeConst = 2000;
1* TimeConst = 400; *1
1* *1
':Hi1l,;lU.IO"1I,1H = 8;

*SCITXBUF= & 0; I*DSP sends 203 when it has finished

table and parameter table from Pic mic:rojJlfoceSS4Jf */
 IS counts to

IS to
a counter is set to count to a set

counter is set to count

to zero.
to

n
w
f" .. ",·"h"./1 at 10

To
it " ... "... "1",,,,, at 10
e
ap
1024
C
of
ity

o
rs
ve

6-4 nt,,'rrUint Service Routine

ni
U

counter is as

/* up of clocks and of timers "'I

swfr = 1024;
"'Tl PR = swfr; 1* Period = 1024 "'25nsec*2 = 51 usee: approx 20kHz "'I
*Tl CNT = OxO;
*Tl CON OxA802; I" the nre!;cal.er "'I
"'nCON OxA842; 1* the timer "'I
 are
to
to .., ... ,'u ....., are .... jJ~. . . .~, ...

n
w
are is

To
e
ap
C
of
ity
rs
ve
ni
U
 Yes
Standby or Errors? >----'...:c:.--------r-----------------.

No
Set
Set
Check which error been activated and
display that error on LCD

ExitlSR

n
PsetFreq:> 100 Yes

w
and ~~=-------,
Vout:> 30 v?

To
No
e
ap
C
of
ity

Yes
rs

74 < Temp < 81

ve

Derate the system

Calculate new Pset
No
Display o,.ert.,moeralure
ni
U

selpolnt
array

Calculate New
Duty Cycle

10

6-5 In1"tI>lI':I'IUlt Service Routine Flowchart

- 81 -
 can are

II
is

II

are met.
II

n
w
more

To
e
ap
C

,,,,,oT .. ,rn to

10
of
ity

is
rs

is al~icusse:a 1.
ve
ni
U

vuu". . current is to a
 Convert Vout, lout
and Vtemp to real
values

Muiliply Voul and

lout 10 calculate
Poul

flag

n
Yes to zero
Both standby buttons off?

w
To
No

e Determine which error

Yes Sat PWM 10 zero
ap
Errors?
Exlt
Display error massage on LCD
C

No
of
ity
rs
ve
ni

6-6 Detailed first block of ISR Oowchart

U

measurement
is a
to
current or tprnn,prl'lltl
 current
are

IS

centre

n
It is

w
To
e UI;;\~L1\JU;) are
ap
cannot reset are
C

if are not on ",,,.'T,,,,',,,,, is

to op€~rate.
of
ity

"".'.."...... is on are set to zero

rs
ve
ni
U

""" .. "'""... is not on ",L<lU1\.j,U errors

are are
is set are
is set
an error IUI..;);)'"j:l;'" to error nH~Ke~a

is

case an error, are set to zero,

to zero.
 lout> (Imax + 3) A

Voul> (Vmax + 20) V : > - - - - - - - - - ,

Temp> 80 degrees

n
w
To
Impedance < 5 Ohms >---------,
e
ap
C
of

Implfldslnce > 30
ity
rs
ve
ni

6-7 Error """""0;""'11.11: Flowchart

U

is

see is to one
 uses

at
use

to COIltr() I

n
w
To
e an
ap

IS
C

6.1, is set
of

user
ity
rs

::::::------ 1)
ve
ni

set current IS
U

is current set user

= x

uses to
 =---'-----=--

to uses

is
current are

.... nu'I'.r to watts to

n
w
To
e
ap
C
of
ity
rs
ve
ni

Healll(llk temp.
U

PMG frlllquency

6-8 Detailed "'''''un",;.y for PI control of Heater Controller

set
set

IS
 IS oe··ralceo IS

::: x

is set

set is set is

n
w
uses a IJ,.,,,,\r\". to £'nl"ln'n

To
is
e
ap
error
C
of

1.
ity
rs

a new is a
ve

..., ....,..., .... 1......' . ,

is ,..n'........ "' ..".rt

ni

is to 0
U

sent to

on next to
occur.
 CKAPTER 7: EXPERIMENTAL RESULTS

7 ExPERIMENTAL RESULTS

This chapter d~als with the t~sting of the heater controller, probl ems encountered and
solutions developed. Measurements don~ on the heater controller have been included to
complement the discussions. Videos have heen induded in the CD accompanying this
thesi. showing the heater controller during the final phase, of te.ting.

7.1 Laboratory setup for testing purposes

n
w
To
For testing purposes, the wind generator ,>"as mounted on a test bench and coupled to a
DC machine through a gearbox. The speed of the DC machine is controlled by using a
e
ap
DC drive. The DC machine and the DC drive were used to emlliate the wind tumine.
Controlling the speed of th e DC machine meant that the frequency of rotation of the wind
C

turbine could be changed and therefore the output power from the wind generator altered.
of

The wind generator and the IX: motor were coupled through a gearbox to match the high
speed of rotation of the dc machine to the low speed of rotation of the wind generator.
ity

Thi, is illustrated in figure 7.1 below. Starting from the left. is showll the wind turbine
rs

follow ed by the gearbo,," and finally the DC machine. On the following picture, the DC
ve

drive used (in omnge) is illustrated.

ni
U

- 89·
 CHAPTER 7: EXPERIMENTAL RESULTS

7.2 Building of Heater Controller

Three heater controll er unit~ were built according to the specifications discussed in
chapla- 4. Tho: interior of th e box is divided into two pans. The buck converter demenlli
have been mounted on the heat ~ink. The power supply, DSP and interface carll ha,'e
been mount~d 00 the dividing paneL The display. keypad., din raih and AC breaker have
been mounted in th e lower part ofthe box.

n
w
To
e
ap
C

Fi~u", 7_2 J~terinr nf HC U~it (I~ft Buok Convelior and r1v.t DSP, Imorfa.. card ud Di.ptay)
of

The heat sink i~ on the front of the heater controller unit since the unit is to bt: wall
ity

mounted (see App endix A). Parameters of the heater controller Can be changed via the
rs

keypad. The errors and heater controll er variables are displayed on the LCD .
ve
ni
U

.
••• iIIJII,
• ••

l'lgun 7-3 OUIStde ofHC Uail

• 9<J •
 CHAPTER 7: EXPERIMENTAL RESULTS

7.3.2 Running Average Issues

One way of lIvoiding lh~ wailing a"emge i,"u~ i, lO u,~ a running a,~mg~. An array
contoining ~ elenlents is slor~d. TI", ~1~Ol~nl' in Ihe amLY r~pr~'~lll oulpul p'''''er. Th~

oldesl clement in the array is l'epillc ed by H new elenlent, Every second interrupl. the
av~rage oflhe 5 clements in ttle "ITily is used as the vollag~. cun'~nt or power \'alue in th"
other caicublions involved in the interrupt.

CnforlUlllllely, Ihis sy'lem also tntroduced pllase lag ill the systeOl and tllerefore affects
tile response linl e oflhe PI comroll~r, This is illuslraled ill figure 7.5, The top \'iavefonn

n
w
is til e duty cycl e (which is slill affected by noise as call be seen) amI ttle ooltom

To
waveform is the OUlp\l1 vollag~. Th~ dUly cycle is alxlill lms Olll ofpllase witll the OIltP\lt
"ol!age. Tilis can be explai n~d hy car~ I,dl y ~xam Lning the runnillg average pl'oced\lre
e
ap

Th~ elements in the mTaY al' e refl'esh ed lit 0.1 ms. 11'11", array is initially filled wiih zeroes
C

and are to be tilled wilh '1', lo get a 9{l % re'p,ms" un" willlla;'" to wlIit at kast 0,7 OlS
of

all~r a p"rlurbariun i,e. fill at lellst 7 ofll", eI~Ol~lllS in Ihe army, The signal conditioning
~mplili,'r inlroduc~
ity

un the interf"ce bctal'd a delay 01' G.I mS, The b\lck convenel' itself
inlmducc, a delay mainly because of ii, oUlput capacitur estimated at III ms, Therefore,
rs

lhe IOlal delay between 1I pelturbmion 'll1d a r~'pons~ in the duty cycle is approximmely
ve

0.9 ms which correspollds to an angl~ of ~pprQximately 100° at 300 Hz. This means not
ni

~nullgh phase margin is pres~nl at 300 Hz 10 reject the ripple on the outpo.lt V()llag~.
U

lii ::u,'" ~_5 Eff«t uf r"nDin~ ",",.~,·"It ph"," mor~in

- 92 -
 CHAPTER 7: EXPERIMENTAL RESULTS

7.3 Problems Encountered and Solutions Developed

7.3.1 Wailing Averages

Th~ lirsl change made (0 the SYSlClll was the indusion of the PI algorithm in the s.oftw~re

from the older version ol·lhe heater corllrnllcr. The formula for (he PI loop has been
dis.cussed in more details in s~clion 2..1.1 A ,tel' lesl 01·4 k\'i was lhen performed on lhe
SYSlem. The resllits are illuSlraled in In., ligures hdow. The lop ,,~,,·eliln[] in li gme 7.4
repres. en(s the set point po\'v"~r. The hOllom wavclilrm shmvs lhe OUlplll power. One can
clearly see (h~t the output power chall!,~S every 3.40 ms whi~h corr.spond In

n
w
approximately 64 interrllpt cycles.

To
The Ol[lpUt power is calculated by mulliplying: e lh~ olilpul vollage and lhe Olllpul curren!.
To avoid nois~ dislurbance, the Olilput power is. averaged over 64 ~ycles. Tn., waiti,,!'
ap

average illlroJUC.S "phase lag in lhe s.ystem whkh delays the response of the 1'11001'
C
of

------
ity

I
rs

,, J
ve

•
ni
U

Figul·' 7-4 Clo •• luuk .1 ,et point power HI~U. output po" <r ,..ilh "."ilin~ ",·cnlge problem

The operating I're'l"ency oflhe PI loop decreases to "pproximaldy 29+ Hz. The waiting
averal<e limils Ihe puwer bandwidth of the PI ~onlrolleL

- 91 -
 CHAI'l[R 7: E~P(RlM £IH""L R t:SULTS

Ii "a' ihcrclorc dccid~>d 10 reduce Ihe number of cJemcms in Ihc runn ing ", ero)le IIormy LU
a minim llm or 1"0 ' If eliminme the II~ uJ runnlll)l army" allo~e!h"r .

7.3.3 Methods of Reducing Noise Pickup

The implementation or averag.,,; i~ done l<I reduce the enOCI of noi<'c on the ~~,tem.
A«"II'-C averaging coold not be implemented in lhe ~yslem, ti,e noi~e in (h" ~~~I""l had
III he rcJuccd fin the hardware 1C\'cl nnd signal c"nditiuning:.

n
I i ' s[l~', all conditionin)! amp li fiers OIl Ihe interface c..rd "'"'' ch"t~cd .n make 'un: Iha!

w
'In·

To
til e cuI offfr~qucncics "ere c"' r~~1. h was found lhm Ihe dcsigns a~ well a~ (he cut
treqllCllcics wcre appropriate e
ap
Seeomll)" ~ ll the O1e~s urem"nl cabl~ were careful!) posit ioned 50 a~ to O1jnimi/e Ih", ,.
C

lel\~\h. [u rcdllCc /wisc pickup Shidrl~ cable.1 were u.oo and the shield:. weill !.I""'lnldo:d
The lenllth oflhe IwiSlCd pair of"i ..e~ li·nm floc: ICS T driver to the Icu r &,te-cmiucr
of

"a) ~ept in a strict minimllm.

ity
rs

After 1e:.1;1I)!, ;1 ,,"as found l h~ 1 nobc "'a~ ).Iill bein)! picked up in the mca~un:menl $i!Vl~I,
ve

nnd \'-J.~ aOeclin)! (he response of the PI In.,p. Furl l,er inve stigat ion showed th.. t th~ IGRT
ni

"a~ being \"iICil eci on/off too fa~1. Thil il illuslralN in figure 7," bel,,,, .
U

,'
--";1, ''1
,j.~I'~
_. _-- - - I'~!. ,.
-,-
,
-
~-----

~;~",. 7_6 l' ,"'urh~tkln <"">0,1 by on,,11 I .... .rroff IG BT Ii ...

 CHAPHR 7: EXPEFlIMENTAL RESULTS

n,~ top waveform shows the PW.\1 sign~l ooing sem from the DSP to the JCMI driver
board. The bottom wavefoml shows the voltagc wavet"rm across the nywheel diode. The
voltage across the flywheel diode rises within 40 n~ and also falls within 4 0 ns which
indicate that the Ton and Tofftimes ofthc IGBT are 40 ns. n,~ Ton and jofftimes ~re

sct by a gate fCsistor on the driver board. From the lGFlT data sheet (Appendix D) the

rallg~ of r~sistor valu~s that Can he us~d is R.3fl to R3fl. The gate l" esistor used 011 the
driver board was 2.2 fl. This was causillg th~ J(iRT to swilch on and off too fast. 'I hi s

resulted in large changes in current flowing through the inductor, df/,d ' ihus cr~alin g , ,
el~ctromagnetic pt'rturbation which is cl~arl)' visible on lh~ PWII,-I wav~form ill r;gm~

n
7.6.

w
To
To reduce th e perturbalion the TOll ailli Tolf tim~
e of the ICiBT was changed to 200 ns

which correspondcd to ~ gate resis/ol" of22~1. 'Ihis reduced df/:;t ~nd as a result redllced
ap

the pertlLrbation as shown in Ilgurc 7.7 below.

C
of
ity
rs
ve
ni
U

fi~ur~ 7-7 R.duc.d .t.<lroma~n.ti< perturb.,i"" with i"<I'o •• ~rl To"IT"ff of Ie BT

Th~ dlcct of the rlJduction in perturb~tion can be seen by comparing the wal,- eR",ns
shown in figure 7.H. The Sigllals being measur~d ar~ lh~ PWJ\l output and the gal~ cminer
voltage of the ICUT. The l"educt;o" ill lloise Call he clearl) visible by comparing th~ two
measurements, beror~ and atlcr thc IGI3T driver g~te l"csistor w~s changed.

- '14 -
 CHAPTER 7: EXPERIMENTAL RESULTS

Fi~UI-' 7_8 Vi,ibl< ,-. ducliun in Mis. I)"'tll rb'lion

n
rurthcl'lnol'~, 10 r~ducc the eJ1cct of noisc 'spikcs'. lhe mcasured HlI'iabl~s w~re '>ampl ~d

w
four tim~' Hl1d ayeraged. The incremcnt or dccrcmcm on th~se variahl~s cycl~ \\·a.< also

To
luniteJ 10 at ma~imum of 4 10 avoiJ large sudden changcs which could dcstabili1c the
systcnl.
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ap
C

Thcse measures improved the noise redllClion in the system bclow but did not I'~mov~ \h~

clectromagnetic pcrtUl'bHtiol1 el1tirdy a.< ,h{mn ligure 7.9 below. To prevcnt thc limit~d
of

r~rturbalion Ii-om affccting the PI r~spo".<~, the sollwarc waS rcarrangcd to makc sure
ity

thal thc analogue to digital COl1vcl'sion orlile yariahl ~s used 1(1[ thc PI loop arc not done
rs

during the limilcd limc that pelturoHtiol1 occurs_ Figurc 7.9 lhc ADC liming t<',1' the
ve

'mall~SI dUlj' cycle and the larg~st duty cycle, i.e. 29 % and 47 % re sjA'Clively. Thcy do
ni

not coincide with the electromagnctic perturbation causeJ by s\\·itching th~ IGRT on or
U

off.

Fi :" '" 7_9 ADC timin~ and limi{,d .Io<tn,,"a~n <l i< porturbaHun.

- 95 -
 CHAPTER 7: EXPERIMENTAL RESULTS

7.3.4 Results from Final Heater Controller

11lG simulalions done on the heater control IeI' gave a guide line ahoutthe propo rt ional all d
illlegral constams. They pl'ovided a staning point to find th~ proportion al and integral
con,tant through lhe trial and error method. see ~ection 2,S.}. After extensive testin g
lhes~ ,mllllal~d valu es w~re chan ged accordingly l{l meet the ~pecifi cation, of th e heater
controller. Th~ Jinal valu~s ()rlh~ PI controller are:

• Proportional Gain = 476:56 = 0.1640625

n
Int~gral Gain

w
• = 76:56 = 0.0078125

The proponional and illt~gral constants used in the

To
~im\llation~ are 0,00005 and 0, 007
e
ap
re~pe~l.iyely, COl11par~d lo the actual valu~, ~s~d ill the Heater Controller given aho\'~.

lh~ integl'al gam has changed slightly whiIG a bigger change is ohserved in the
C

proportional gain, Illis can be ~xplaind by lh~ fact thaI the PI contl'Oll~r u,ed in the llSI'
of

is a digilally implemented PI controlb wh~r~a, lh~ PI controller m~d in the simulations

ity

was a continuous PI controller.

rs

""'ith the noise pickup reduc.xllo a minimum and the COlTeCl PI colllfolier constants. :he
ve

heater comroll~r was lC~l~d and the final I'e,~h obl.ain~d m~l all the spccifl~ations that
ni

\wre 'd. This" illustrated through ll", Jigme, giv~n below,

U

- 96-
 CHAPTER 7: EXPERIMENTAL RESULTS

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Fl2Urt 7-10 Cha .... cttrl.t!cs of outplU voltage and output CUrrtllt from Yokega"a po""r md.r

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From the data obtained, the ac cornp0l1ent in tre de voltage is 2.73 volts which represents
ap
1.12% of the r.m.s de voltage. The ac component in the de current is 0.239 arnp~r~s
C

which repr~s""t 0.992% of Ih~ r.m.S de eurr""t. It can clearly be 8e"" that the 300 liz
ripple is nO longer present in the output de voltage and the de eurr""t and therefore from
of

the output power. This climinates the rippl~ torqu~ on Ire g~nerator therefore also
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eliminating the audible noise created by the ripple torque.

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FI\:ure 7-11 DC Volta~e and Output Voltag~ from !lnal b~atrr <oJUrollrr

- 97 -
 CHAPTER 7: EXP ER IMENTAL R ES ULTS

The lop waveform in figure 7.11 illustrates the DC bus and the boltom waveform
displays the output voltage of the HC unit for a 4 kW step test. ConfOfming 10
specification~. the output voltage reaches 90 % of steady state value within 50 m~ and
there is also minimum overshoot with no visible 300 Hz ripple.

The Olltput voltage corresponds 10 the set point power being calculated by the controller.
This is illllstrated in the figure 7.12 below. The top waveform displays the output power
as being measured by the healer controller "hile the bottom waveform displays the step
set point power. The noise on the signal~ are picked up from lhe oscilloscope leuds and
do not alTect the healer controller perfonnance.

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F j~lLl" ~lId . ct puinl pm' or frolll "0,,1"011,-,.

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Under Meady state condition, the percentage ripple on the DC bus voltage and output
voltage is minimal. Thi s is illustrated in figure 7.13. The top waveform shows the DC
Bus voltage and the oouom waveform shows the OlltPllt voltage while running the heater
controller at maximum power under steady state conditions.

- 98 -
 CHAPTER 7: EXPERIMENTAl RESUlTS

Fi~ur < ~_13 I), Bu, ,ullag. and uul pt voltag. at 6 j,\\, under 'to"d~ ,tal. oundilion,

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l'h ese results show lhal lh~ main objective of this t~sis was successfully met. lhis
consisted of improving lhe h~al~r conlrolb-', r~spon,e time and incre~sing the opelming
e
ap
bandwidth of the C(N1lrolier 10 remOve voltage rippl e from the output of the buck
converter. This w~s achieved by implem~nling a Proportional Integral controller to
C

control til<: sySlem

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7.3.5 Test List to check pelformance and specifications of He

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A lisl or le,t, was created together wilh ;1,.lr. Jacques Souquet to thoroughly te,;t all
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as])Ccts of th e heater COnlrol kr ami to make sure that all th e spec; fi~alions havc kcn mel.
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Thi, list togeth er wilh lhe results has been :ncluded ill Appendix I. All the (es(s w~re

performed (Nl ~a~h of the heater controller ullils ill lh e laooratory using the selUp
des~ril""d in section 7.1.

From the te,;l r~,;ulls, il can be concluded lhal all the spccific~tions for the h~mer

controller have h;,~n successfully met

~ 99 ~
 CHAPTER 7, EXPERIMENTAL RE3UL T3

7.4 Voltage from Wind Generator

From lh~ wind g~"nalOr poml or ,-i~w, th~ \'Ollag~ wavd'oml being extral'led from tile
gL,,~rator wlwn the ompul power WaS S<:l to 6 kW is shown in Jigure 7.14. Thi, ",-a"e/ill111
IS con.",km to the outpul "ollag~ wavdonn linn lh~ simulations as shown in figure
3.28, The vollag~ wavdonn is th~ qllasi squar~ wavc/ol'ln.

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hUI phase shifted by 30 degrees as tile voltage wavetann. being measured are the line to
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line voltages.

7.5 Current from Wind Generator

/lle current wave/arm extracted ti'om the wind gener~tor when fUnning ~t 6 k. W is al.o
consistent with simulations result,. The simulation resulls are illustrated in figure 3.2'),
Figure 7.15 shows the Currml wa"donn.

- 100-
 CI-lAPTER 7: EXPERIMENTAL RESUL T8

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ri ~ m< 7_15 Ootput <u,n.t frum wind 2<n<rOlOT

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Since (he syslcm is a balanccll syslcm, (he linc currenl wave!imns being lira",,, from each
e
phase are equal in magnitude but also phasc shiftcd by 30 dcgrc~s ,
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7.6 Efficiency of system

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The efficiency ofdlC systcm wa s mcasurell at flLll power using a digital pow~r meter. Th e
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total input power into the system was measured as wel! as the (olal oulpul pow~r. The
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efficiency of the system at full power is then calculated by dividing to total oulpul pown
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by lhc lOlal inpul pOW~T,

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Perccnlag~
"= Iolal Oulpul Powe~ x 100
Totall~p\lt power

Th~ measm~ments captured irom the digital power meter arc illustrated in fIgure 7.16,

• WI -
 CHAPTER 7: EXPERIMENTAL RESULTS

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Elements 1, 2 and 3 represent the three phase inputs while dement 6 rcpresenls Ihe output
To
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of jhe heater controller. represents the total three phase inpul power into th e
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system. 'Jbe total input power into the system is 6.757 kW and the total output power
from element 6 is 6.099 kW. These measurements were taken at different time intervals
of

during a 2 hour long test session and the tlnal elTlciency avemge<l to make sure that Ihe
ity

effect of temperature ofthe system is also included in the ellicierwy measurem ents.
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The average efliciency of the heater controller units was ~al~lIla!cd to be gSA % at
maximum outplll power.
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2003 - Version A 1 - 17 November 2003 - Version - 12 November 2003
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02 - Simplified scheme:
6JcW Heaw Cootro/,'or simplified schematic (ver')1dj Pm"'~~O/IJW
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DSP boar(!

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03 _ Housing, fixing and display:
• Bottom sids of the box will be removable for input-output COOMCtiOOS ( term in ai connsdors hed on back door)
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_ThB cooiroller is intended to be fixed on a wall (4 r.crews).

_ MLT-Eoltec l>"1iv~rsal di,play/keypad module will b~ used as user intBrface and for param~i~~lsi!!ttingsireccrds
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 60V to 280V AC between hases
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15 A per
6350 W

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8.8 ohms

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4 mA
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 a
curve is stored in a F

the the
- The of the converter.
content. The to is

the converter.
maximum

Sclrocco's Heater Controller Look up table

(P measured at resistor output)
7000r----------r----~------~----_r------_,

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1
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4 140
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5 160
6 180
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 07- Keyboard functions

, -
K,y Function Remark
--- --- - - -
11 the devk:e is in working mode, after action too output 15 cancelled A< power ,", devk:e \'\oill
ONIStby
"'

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(with ramp) automat",ally start working!
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(with ramp)
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will be c~nce!led ,
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Reset Reset the microconlroller in case of e"ror
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Menu Go to "Menu" display whatever is the cu'rent display
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Enter If a meml lis~ is displayed go to the sel~cied rr,enu

, If a parameter lIS! is displayed. go to the selected parameter
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If a paramet~' value is displayed, v~lkjate the v~lue and ed

- - ,-, -'-

• if a list is dIS
"" scroll u the list

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p the value (irtc"""m"'"'""'_______+___ _____ _
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If a value is displayed, decrease the value ,,'"'"'"'~"'"'"","'___ _ ___'_ _ _ _ _ _ _ _ _ _..J
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L,d Function Remark

I ON Led 100% activated when too dev",e is in workirY;J mode

Blink 50/50 if the OUtput is cancelled (stan-dby mode or rerr,ote input
corrJnand)

I Error Led 'I Blink 50~'.50 wh~n the devic~ is in Error

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1 -OOOW 10 to Hz

19.0Hz - 10 to 1 Hz

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28.0Hz - 1000W 10 to

32.0Hz - 10 to Hz

36.0Hz - to Hz Hz

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Appendix B: Semikron rectifier block

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SKD30

coo ,~ ;;;;",
'00 SKD 300<1<1
I;Q SKD3;,'J.!IAI
12;0 SKD:)'~"M' o TS
"00 SKI)3o."1,~1

1'l'l'l SKD3(1',M,

C6~d!tr. ,.};_,;:'- ~:
T, •• ~ 'C, ;500;«'i
Valuu
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Units

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T••• ~ 'C, ,"",.~,1)
T, • • 5 < C, """"",,1) ~,S
Power Bridge Rectifiers" c.'lo""'" ,S
' , ' 45 'C,
T,·'C. ,
T,,'::5 'C, '0""
T.,""·C.'0rm
SKD 30
i" T."~·8,~,3. "m,
T,"SC'C,~,3 10m.
'. '2~· C,~·'~A " "iX.2.2
tn'''. OM

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T,' l~C'C
Features
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T, ' lSO-C """.12

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• 1""laled mellli ~as" ·,.·~th screw , T.,' 2S'C, v~. v_ ,m

To
l<>rmilais T., ' 'C, V"C>"Y""" ~ \'
• Blockbg va.age up tp ,1 600V ~. '''G'C, Y",,'\'eRIJ
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• "",11 surge cur""n\s
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• UL recognized, fil<t m. E 63 532
....,od" 1,5 K'H
Typical Applications cl'." ,'.' U ,"'M
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Th~e phaY: rec\l~ers fur IX'Wer ~'" ., toto ; 0,7 ~W

supplies "';,., ; tolo-l 0,' <W

+-
_.:. + 150 'C
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of

Inp"t ,,"ctifiers 1m variable

freq""n'Cy doves _ '., " '.0.$ .. SCHz;r.m.""ilrrin
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• Ra!:tifiers rarOC molm field ,-

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Appendix C: Data sheets for input and output capacitor

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 M----.....N -
innovation +servICe
Aluminium electrolytic capacitors

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To ~
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• fiJterin'g
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- switched mode power supplies

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(~F)
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(mm) : Typ
(100 Hz)

M" l'" "'.ax 1 ..·C as'c 1(IS'C

Code

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350 '3300 I 76,5 x 10-4 25 30 20 25 1e,D 1o,e , SKC3M3·35a-~

400 , 1500

12200
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Leakage cUmin! (I~ 3 200 pA ( after 5 min (Ullllt
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Mounting torque for Mllscrevn 2 Nm (Max vailltl)

Vleratlon T•• t: 10·55 Hz 0,75 mm (10 II - 98 mltl)

Ufe expectancy lit ripple G!Jrrent:

at 105· C :. 10 000 hours

at6S·C :. 40 000 hOtl~
 s~~rKRON I?TY! LTD

P.O. BOX 3621J

ARCADIA, PRETU~lA
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Appendix 0 : Mitsubishi IGBT module

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 MITSUBISHIIGBT MODULES

CM7SDU-12F
HIGH POWER SWITCHING USE

CM75DU·12F

."
_ VCES.
.75A
""".6IJOV
_I nsulated Type
• 2·elemenls in a pack

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General purpose inverters & Servo controls, etc
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OUTliNE DRAWING & CIRCUIT DIAGRAM
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• MITSUBISI-I
"'aECTOC
 MITSUBISHI IGBT MODULES

CM7SDU-12F

HIGH POWER SWITCHING USE

MAXIMUM RATINGS (TI_' H '

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. . . ELECTRIC
 MITSUBISHIIGBT MODULES

CM75DU-12F

HIGH POWER SWITCHING USE

PERFORMANC~ CURVES
COLLEGTOR_'MITIER SAT\JRAT<ON
OUTPUT G~ A RACTERI " TIC" VOLTAGE CHARACTER,"T>CS
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, (TY>'ICAL)

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• MITSlIBISHI
. . . . ELECTPJC
 MITSUBISHIIGBT MODULES

CM75DU·12F

HIGH POWER SWITCHING USE

R"IIERS" ReCOVERY CHARACTER,"TIC ' TRAN Sle~T TH~RMAc

0' 'R~e .WH~El DIOD" l""e"A~E CH ARA CT ~RlSTICS
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Appendix E: IGBT Driver Module

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Appendix F: Ferrite core used for inductor and spreadsheet
used to calculate Nand Ig Appendix G: Data sheets for LV 25 NP
and LA 55 P

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Core Dimensions Imm) -: F :_ J E 70/32
ID D!e 32·250·

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Core Parameters

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Electrical Specification
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~30/ 20%
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F5!l. I ;112E +30/-20% !I ;-8,,0--- 32-250-49
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gap leng'h (mm) t'.Jms (core) turns (Eap) turns (tota ) ind>.Jctance (uH)
1 core 2 core 3 wre
0.419307459
0 0 0.419307459 2.00405005 ~,OO81001 6.012150151
0,419307459 099213471 1.411442169 6,745887031 1349177406 20,23766109
"
" 0.419307459
00 0.419307459
0419307459
1.98426942
2.97640~13
3,96653884
2403576B79 11.4B772401 22.97544802 34.46317203
3.39571159 1622956og9 3245912193 ~3.63863293
4,3678463 20,97139797 419427g594 62.91419392
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0; 0.419307459 496067355 5.3799810' 25,71323495 5142646991 77.13970486
0.; 0.419307459 5,95280B26 6.37211572 30455071g3 60.910'4387 91,3652158
0,419307459
"" 0.419307459
6.94494297
7.93707768
736425043 35,'0090891 70.39331783 105.5907267
8.358385141 3gg3874589 79~7749179 119,3162377
,
0.' 0,419307459
0.419307459
3,92921239
gg2t3471
9,34851965' 4~,630532B8 89.36116575 1340417486
10.34065456 49422419B6 98,8~~83971 148.26725%
0.41930H59 11,33278927 54.16425684 108.3285137 1624927705
" 10,913~3'8

"" 0,4'9307459
0.419307459
0419307459
11M56'65
12.89775'2
13B896359
1232492398 58,906093B2 1178121876 176.71828'5
13,3170586g 63.6479308 127.2956616 190,9~37924
68,33976778 136.7795356 205.1693033
"" 14.3og193 ~

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041930745g 14.8820207 1530132B1, 73,13160476 H6.2632095 2'9.3948H3

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o 41930745g
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0419307459
0,41930745g
17.8584243
18,B505595
19.6426942
18.27773224 87.3571'57 1747'42314 262,0713~71
19,26986695 92,09895268 184.1979054
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276.200858
290,522369
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" 0.41930H59 21.6269636 2224627108 106,3244636 212.6489272 3'8,9733909
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22.81g0983 232384057g 1110663006 2221326012 3331980018

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,; 0419307459 246033678 25.22267521 120.5499746 2410999491 3616499237
of

0,419307459 25,7955025 26.21480992 125,2918115 250,5836231 315.8754346

0.419307459 26,7876372 27.20694463 1300336485 2600672971 3901009456
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n 0419307459 27.7797719 23.19907934 134.7754855 269.550971 404.3264565

", 0.419307459 287719066 2919'2'405 1395173225 279,034645 418,5519675

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0419307459 29.7640413 30.18334876 144.2591595 288.5183189 432.7774784

31,17546347 H9,0009964 293,00'9929 4 ~ 7.0029893
" 0.419307459 30.758176
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31.7483107 32.16761818 153.7428334 3074856669 461.2285003

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0.4'9307459 32.7404~54 33,1597529 158.4646704 316,969340B 4754540' 12
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0.4'9307459 34,7247149 35.14402232 167.%83444 335g366887 503.905033'

0.419307459 35.7168~96 3613615703 172.7101814 3454203627 5181305441

"'"n 0.4'9307459
0419307459
367089843
37,701119
37.12329174 1774520'83 3549040367
38.12042645 '82.1938553 364.3671'06 546.5315659
532.356055

", 0419307459 36.6932537 39,11256116 1869356923 3736713B46 5608070769

0.419307459 396853884 40.10469587 '91.6775293 333,3550585 5750325678
0419307459 406775231 4109683056 1964193683 392.83B7325 589.2580983
" 0419307459 41.6696578 42,08896529 20',1612032 ~02,3224065 6034836097
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OA 19307459
~2,6617925
436539212
43.0811 205.M~0402 4118060804 617,7091206
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0419307459
4~,646062
45.6331967
45.06536942 215.3867142 430.7734234 646,160'425
~6,05750413 220.'285512 440.2571023 660.3856535
" 466303314 470496388~ 224,8703381 ~~9,7407763 674.6111644
"" 0.419307459
04'9307459
OA,9307459
47.622~661
48.6146008
48.04177355 229.6122251 459,2244502 688,8366754
49,03390826 234354062' 468.7081242 703062'863
"
Appendix G: Data sheets for LV 25 NP and LA 55 P

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 -_
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Voltage Transducer LV 25-P I" 10 rnA

For the electronic measurement of voltages: OC, AC, pulsed
with a galvanic isolation between the primary circuit (high voltage)
VpN - 10 .. 500 V
and th~ secondary circuit (<!Ieclronic circuit)_

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~Iectrical data

'- Pm,,"'y nominal '.m.' ou,,-,, nt ~, Features

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Accuracy _ Dynamic performance data primory e "cu~ 01 tll o tronod ucer
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G'meral data I Applications
Ambient operating !emperature u .. + 70 "
"" Ambienl oto'age ~empera'_"re _2,_ +85 " • AC vocilible speed drlv.. and ",V O

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"A li.t of oorre"ponding te.t. io ava:iable 981125114

LEM Components www.l om.oom

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Dimensions LV 25-P Ii" mrn. 1 rnm· 0.0394 inch)

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• F. .te<1ing '" connectiOn of pnm.;Iry 2piM • fhlS i. a ot. nd,rd mod ol F", (!tNere nt """"",,, (""PPly
0.635.0.635 mm vo~ages, turn. ratio;. unidirect,,,,, .. me,,",.m. "!•... ),
• fostenir>;j & cOMecnon o( ,,",c<>ndor, 3pin;01 mm pie;;" """tact us.
• Recommended PCB hoI~ 1.2 men

'0"""01100 ' lor uu "' th o voltog. ".n.o"c.. .....,0 01 LV 25_P

P:im.Cj' '''isl''~, I~ < """"",,,,,(, opt;"'um ,w"""1 ~ ooi,j ""d.l If'oe no"",,", P"'""Y """'"!. .....
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<",,,, "t of 10 rnA

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')R, _ 2"niB W.),_1DmA
~)R,'~Q'''11.l ! W,I • • ~mA

10k'"'> ;"10 ",eount t~

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1.S '" of V~ (@r," 2~'C)
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bI<) .n<J '" _Jon, hi. ~."",.,."oc '"~,"'" I", ""''''''''' ",.",",1 "",_, fr"'" 10 '0 GOO v,
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 ...-..-_.-
-_ - .....
--
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---
Current Transducer LA 55-P - 50A
For the electronic measuremerl! of currents, DC, AC, pulsed ... ,
with a galvanic isolation between the primary circuit (high power)
and the secondary circuit (electronic circuit)

CE:
Electrica l data
I" Prim. ry comic. 1r.m. ' ourrect 50 A Features
,'. Prim.ry curr""!, rne • • urln~ r>c~
M•• • urin~ rg' ''t. nco ~
0 .. ,70
T, = I'l'e T, = 85'C
A
• C,,""O loop (comp"o'"t~d) c"rront
f\. _ R". _ f\. _ R". ~ lranod"c&< ".iog the H. II eff~ ct
,CO eo • Prinled circuit bOard mounlin~

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aooordiog to UL 94NO
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Socond ary nominol rm.s. curr.", "' Advantages
Ie-
'.'. Com"rsio" ,.tio "
1 ' 1000
e "', o £xoe l ent . ccuraC'/
S~p<'y Yoltoge (i 5 'hI
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o Ve ry good , nearl y

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Curmo! coos"mption 10(@.'SV)+I,
R.m.'_ \loli.ge for AC isol.l:on ie,l, 50Hz, I mn "'" • Low \em~r.tu", drift
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AoosaC'/@I",
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f!I±I2,I5V(±5'h)
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R.sidu . 1ClJrront ~ @ I, = 0, abr . n ovorload of 3 xl"" ±0.3 "'
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• '00
React"" tme@IO "' ofl ..
' , • Battery . uppr" d a ppli ""tioc"
U

RespOose lime@gO ',-, of""

,"dUdt Mdt aO:;\Jral~Y fo l ow06 • '00 A'~s"' • Uninterruptibl " Powe rSuppl le.
(UPS)
FreqlJ'Ol1cy baoo\";dth (- I dB) DC ,200 ~,
• Switc:,ed Mode Power SUpplie"
(SMPS)
General data • Powor . uppli .. lor \Widing
a ppli""tioe , _
'. i'.mbieot operating temperaiu,e
Ambiert .ior.9" t"mpe'"itJr~
- 25 " . " ,
,,~ ~O ""''
.,'""
To
'. S.roMary coil r,,, iotae,,," f!I T, = 70'C 0

m Mass
T, = B5'C

"
EN 501 78(97_ 1001)
0
,
Staedard. ')

!iilltl -, M" ",ur'''g range lit1lited to ~ 60 A_ ,

~ Me",""og range limit06 to ± 55 A_ ,
" R.. ult cf t"" coo,,;i'e ~old of th. mage. tic drClJil
') A 1st of corr.. poedieg te, t, i, ••• iI.ble

LE M Co m pone n ts wwwlem.rom
Dimensions LA 55-P (in mOl. 1 mOl ~ 0.0394 inch)

Left view I
Bottom view ,-----e---~_o,T

• t 1----:-...+-1 ."'-"
R --:"+
':;;
!
!

• •

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Connection

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Front view
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Mechanical characteristics Remarks

ni

• General tol eranc . ±O.201m • I, i. po. ilive wf1"" ~ fiowo in the direclion of the " crow
U

• pr.m3rj l'tOL>1h-hol~
• F3sten"g & connec:ion of
Recomm~nded PCB hol e
12.Tx7m01 • Temper. ture of the p'mory conductor ,houk! not exceed
.ecood~ry ~ pin, 00"
0.63 x 0.560101 • DyMmic performonoe. (dildt . nd respo" '. t'me) ore be.t
0.9 mm ll.ith , ~ngl . b3r completely fill,nq the prim3'j hol e
• In orde< 10 .chieve lhe be"t m3gn e'.ic coupl n g, the prm 3rj
wn dn g. h~.G b b~ wound O'/~r toe top Mge of th~ d"";c,,
• Thi . i•• , 1. nd . Td mod el. For different ve<oion . (. UPpll
voll"ll e. , lurn . ratio " un·<1irectional me • • urement • .),
pl . as . contoct uS

LEM r~s~"e . th~ 'ightto Ca"1 out modification" on it" trMSQUce rs . in order to improve lhem. without pre'io" , not;oe
Appendix H: Data sheet for Viper 50 chip and power supply
design

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 VIPer50/SP
VIPer50AlASP

SMPS PRIMARY I.e .

• ADJUSTABLE SWITCHI!-;G FREQUENCY UP PEtlTAWATTHV PENTAWATIHV

TO 200 kHz IOl:IYj
• CURRENT ~10DE C()t.;TROL PawerSo-tO"'"
• SOFT START AND SHUT DOWI\ CONTROL

n
. AUTOMATIC BURST MODE OPERATION II-; DESCRIPTION
STAND-BY CONDITION ABLE TO MEET

w
VIPar50'"I50A, mad ~ u'I119 V)Power MO
"BLUE ANGEL" !>;ORM «lW TOTAL POWER Tectvoorogy, combine. on the Same silicon CNP 0
CONSUMPT!Ot»

. INTER!-;ALL Y TRIMMED lE!-;ER REFEREr-;CE
• UKOERVOl lAGE LOCK-OUT WITH
HYSTERESIS
ap
• INTEGRATED START·UP SUPPLY
. AVALANCHE RUGGED
. OVERTEMPERA1URE PROTECTION
C
To
state-{JI-the-art PWM circuit logeth .". ".,;th an
optmize<:l high voililQG avalanche rugged Ve<1ical
power MOSFET (620V or lOOV i 1.SA) .
Typ<cal app l catiOOs cover offline power supplies
e
,.,;th a s""ondary power capallillt)l of 25W in wide
ran<}e condition and SOW in single r""9" or ,.,;th
dC>Ubler cDrlli(lll"ation. It is compatible from both
primary r:x """ondary r9Qulation ioop oo~pite

lISir>;) around 501'. IG.~ compor><mt. when

• LOW STAND-BY CURRENT compared "';Ih " d"ccGtG ","uti on, B~~t rmd e
. ADJUSTABLE CURRENT LIMITATION oparation .. "n auu',tio",,1 fa"ture of this ""vi ",
offertng .,~ po''''bility to op e r~l e in .t"nd.by
of

mode with""t extra C<Jmp<lnents.

BLOCK DIAGRAM
ty

.. -------~
si
er

! I03CUAlQ
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1.'21
 VIPer50/SP - VIPer50AlASP

ABSOLUTE MAXIMUM RATING

Sym bo l ~. ramet. r V, lo o
; C""""."" Dr"' ,,-Sol.<Ct VCj I... . IT i - 2~ 10 1 2~· C)
Yo, IJr VIPer50,'SP -'0 .3 ' 0620
lor VIPer50AIASP

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THERMAL DATA
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C

CONNECTION DIAGRAMS (Top View)

PENTAWATIHV P~NTAWAn HV{Q22Y) Powe.sO·1Q'·

of

/
. -....
-
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ve

CURRE~T A~D VOLTAGE CONVE~TIO~S _ _ __ __ __ __ _ __

.
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"- c
-
I

ft'>~i1'-~<> ---E
1.'..;
,."

I,- !:J / ...

1
1
w, '-- ",.,. v",,
_k_ I
I
I I 1-
.
~., --
.-
2123
VIPer50/SP - VIPer50AlASP
ORDERING NUMBERS
PE~TAWATTHV PENrAWAn HV (C22Y)
VlP " r~O VlPe6~ (0221)
VIPorooo.
PINS FUNCTIONAL DESCRIPTION
DRAIN PIN:
Inl~g,ateu Power MOSFET d,ain pin It proviue;
iot,.,-""I 1><0' Ol..nnt during start-lIP ;ia on
iot"ll'oted high voltoge Cl1Teot .0urCG whk;h i.
switched off during normal operation, The dev ,"~
is aUe to handle an UfIClOO1pOO c,..-rent du~r.g ils
norm.1 ap"'ation, as.urir.g self ptotoction against
.o l ag~ .u'g~ . , PCB ' I,ay ir-duti'r-ce, and
alklwing a snLObbGrles. operation lor law oulput
pow,..-,
SOURCE Pin:
Power MOSFET sOurCG pin Prim...-y ;iue circuil
common grout>d connGction,
veo Pin:
C
This pio pro.ides two foocton"
of
- II oO'"responus to IhG low voltage ;uppl}' of lhe
control port ofthG c~ouit. If VOJ go~ belo..... BV,
ity
the .tort-up cum""t .Ource i. acti''''ed and the
oulput power MOSFET is switchGd off unlil the
rs
VOL' >'C l age reaches ltV, During thi. pha8G,
!he intern.1 currMt consumption is reducoo.
ve
Ihe YOJ pin . ou,c~s a ClYre", of about 2mA
and the COMP pin is shated 10 ground, Aner
ni
that, Ihe curreot sOLYce i. shut down, and thG
de."" triGs to .Iort I.IP by .wilchi~ agoin
U
_ Thos pin i• • 1. 0 tonMd~d 10 th~ error amplifier,
in Ortle' to allow primary as well as sacondary
regu l.tion ton~gurations, 10 case of primary
regulabon, an internal 13V trimmed rGference
vollage is used to mainla" Yoo at 13V, For
' ecanu"y 'egul'l,on, a .oIlage between 8,5V
ond 12.5Y will b<; put 00 Voo p<n bytransformef
ue;'Jn, '" ..-der to sticK the outjl<Jt 01 the
Iransconductance amplfier to tho t"Hgh oto lG,
The CaMP pio behoves a8 a oon,tanl OllfTenI
3.'.3
~--------------------------
PoworSO_l C'~
VlP. r50SP
V1P.~ O ASP
"OUlCe, and cao easily be ConMtiOO to th~
output 0/ an opIocauple' Nale t hat any
overvo l age due to '''Yulation loop foilu'~ i• • ti~
det~tI~d by Ih ~ e'Ta, 'mplifi~r Ihrough the Y JO
.oIloge, wh ith connO! o'e'po"" '3V, The
oUlput V<)ltag~ wil be .0mGwho l higher thon the
n
nemin ol onG, but stiH undGr control
w
COMP PIN:
To
This pio proooes twa fur-clioos'
_ II i. tM output of th e er"O, t,anscandutlar-ce
e
omplif"", ond al ows fa, the tonnech;)n of a
ap
oomP"""otion ne1werk to provkje tm d~si'ed
tronsfer lunction 01 th e rGgulation lOOp. It.
band\l;kjth can ea.ily 00 a~u'ted to the
needed va lue with u.ual compooonts value, As
stated above. socondary regulatioo
conf'.l ",.tbns are "iso m plemeoted through
Ihe COMP pin
- When IhG COMP voltaqe qOGS ~ow O.SY, the
shut-down 0/ the circuit OCCLr"S. with a ~ero
duty cycle for the power MOSFET, This feature
tan be used to switch oII'the con.erler, and is
automotic"ly activa100 by the r~gulatiOn loop
(whatever i. the oonfiguration) Ie pro.iJa a
bu~l mode cp~'alian in ta'~ of ne~ligibl~
output powe' 0'" open "adcondition.
OSC PIN:
Ao RrG, network must bG oonnGtled en Ihat pin te
oofinG the swl ohing frGquency, Not~ thot uespito
the connect;oo of R, tc V DO ' no s~nifitant
frequency ch ""II~ OCCllf. lor Yoo varying from By
to 1SV, It also prOVide. 0 synohran',,,olion
capability, when oonnected to on exte'naI
frequenoy",uroe.
""'!I
 VIPer50/SP - VIPer50A/ASP

M.. VaiIJ. Unit

,
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Is .., I g. '2)
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ELECTRICAL CHARACTERISTICS (Tj _25 "C; VOC~, 3V, un!',.. othllfWl ... specified)
PQ'NER SECTION
Symbo l P... mot ... T•• , C"-nd~i"".
10"' rnA; '0'00''''-0'0'
""
fof VIP&r~O!SP
be ViI' . r~O"'ASP 1..,0 r",.5)

n
VcC*.,,~~V; T ·~l25"C
; Of_S,at. O",jn C"""", '0'0,.,20'0' tJi VI?r~o/SP
,

w
,
" 00-700'0' fof VIP&r~OA!ASP
---- - .'

To
,, ----
io='A ,
Ior VIP.rWISP
, " ," I,
0
,
'" "
SM" Dr.'n-Sou,," rorVIPorW",ASP e 0
Ros<on)
! On Rool,t"""" 10='" T,~' OO"C
ap
for VW'.iSOISP
I f", VlPor5olA/ASP
" , D_3 ,
0

2" "
C

'l.,- ]O~V I') "0

t-
foil Tm o
10-0
IS .. 'iQ_ 3) "'
"
L.__ -- .
~
-
10"1 A; V,."- :lOO'l I')
"'
of

, Ri,. Tlmo
" -- OutOut-ti i>ooit'=
h;"
I

;
ISo< f".])
Vc,"2~'l
-
,
,~ 1.::-- .,.-'
ity

" ) Cn I"'-'" .. C,"" . c.,.".,.;

rs

SUPPlY SECT!ON
-_.- - - -- -----
"" ",
---- ~- -
Symbol Paramot. r To. t Condition.
., I On .,
Unit
ve

----- .- - -- - ,
Sl, ,,-Up Ch'~inIl Voo - ~; Vo.-3~V
,~
~urr . nt I''''' fii_ 2 ....-.:l fig. 1~) I I
ni

-
~
O.
0p""""" Sup;jy CL<ro"'- Voo~'2V; F,w
""' " "
U

I... fig. 2)
,'4 -,-----
0", OpOf. tlng SUW1 Curro"' Voo "'2V: F,~"'OOI<Hz . _. ~
-
Opoor . tln~ Suppy Cur"",t, ~ooE'2V: f, .• "_2IlO1<Hz ~
'00' l)nd""" I"'le ShlJtro.on ISe.fii.2) " -
"~
--- " " " "
",
~-

Uno ...... o'",. R....

: V""""
r-~_ H"..ter.~ , S'"~"'-'P
j ISee f" 2)
IS "" ng. 2)
"
" "
"
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SHUTDOWN AND OVERTEMPERATURE SECTION

,,,
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Symbol P.... m<>'or

i (,,,,, n, , Too' COMMlons
""
,~

e, ,
, ""'
U

Yeo_, R",,,~ ~",,~oil

i (,,,,, n, u
1O"",

T."
D~obI. Sel Up T",.
~." r,~o::::~ ,d "'"
T.~", o tur .
'(S« fi" 8)
" "e , no .," ,
~efrnalStw\do'ltn ,
'r,~" (s •• fig, 8) I
HY".r."I,
" ·C ,
 VIPer50lSP. VIPer50A'ASP

Figure 1: Vee Ra~ulati"" Point Figure Z: UndccvO:la;Jc Lockout

'~" ·J~ V
f,"'- - .J

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,." - --------------------"""""";
( ~,)'l
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BV",

,"I-----"",,----1
"-
, -----',,---1
:t--~-'--!=
'" .0 "" '"
T""","''''' ("C)
" II) '20

L.'. "
. _ "
_ _"_ T.",,,,,-.!...
8J : 'C',
,0( 110 1'0

6123
VIPerSO/SP· VIPerSOAIASP

Figur. 7: Start-Up Wa.elorms_ _ _ __ _ _ _ _ _ _ _ _ _ _ __ _ __ _ _ __ _ _

".'lJ •,
0
~
,
"
"' ~ I: ;,
,
,
,
, +
, •,
~!'IIW_

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--
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1. _ __, ., ...
C

FlglJl"' i: O"""Olnoo:. tm P:atoctoo

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 VIP(!r50/SP. VIP(!r50AlASP

Figure 9: O,ci:lokr

.--~

,
'0""
For R,"1 .2Kn

'osc
,"
n ~
C, 15nF it Fsw ~ 40KH~

OV m "(1 - RI '~)
FSW - RtC, 150

1" ,L,I
~

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,=~
-- -_ .
. ~.,'-,
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,,
".,-,~

,, '«~~~
..... ..

, , t-..
, , ,
RI (ldl) '"""
4"'-________________________________________ ~W"'
VIPer50ISP. VIPer50A/ASP

Figur. 10, ErrQr Amplilier Frequency Response

-------

re"",
60

40
•
"•
0

0 20 ,
,• 'I
•
g 1

n
0 !I

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To
(28\)lJ1 0-01 0' 1,000
Frequency (kHz)
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Frequency (kHz)

L --~
 VIPer50lSP - VIPer50AlASP

Figure 12: AvalarlChe T es1 Circuit

k
,
'--
! ,
L.
,
, ",
.r.!
,
"".... ,,", . ,.".
~
" "., , , L--C,>-----< .,
-
-
i
I,
,
.
,
,.
• " "",,If"-""
,~~
...""
"-'"
r~
t'
n
.,...
" ·"wm
; 'M

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" '"

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 VIPer50ISP. VIPer50A/ASP

Figure 13, Off Une Powor Supply With Au, liary Supp~ Feedbac,

"
: -,-----------,~=~-~ ~~ 'r- --:\
~- M
I - :>---r-r-,----;"; r-l!-r-~'" -_.-=- ~

==~~-it!} "

'"

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VDo " .. ~ ,

"'~~C.' ~"'J '

w
t----
~ ~~

To
oow ><l"'"''
, gOO
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111'23

OPERATION DESCRIPTION:
CURRENT MODE TOPOLOGY
l na W!T ...... mode eonllui methOd, li<e III.. un..
inlegralfld ,n lIIe VIPet50150A ~ tNt> "",,!to!
Ioopl - ~n mner cune", oon uolloop .... d an outer
klop "" vtIl1¥,jC <;aWol When lIle Powor
MOSFEl outpul tranMIO< I. on, th<> induClOl
currenl (P'rnary "de 01 \he Iranslormer) Is
mOMorad . ""1~ a SenllllFEl I.,<imique and
COi"I\'ort~d IrtiO a vol,ge Va p'o"orlknallo I~ ,"
curronl Who-> Vs ~"""H Veo ,.'? (1"0 amplifi od
output v d lag~ 9rror) t~ t powe r switch'", switcMd
ofT. Thu ., the outgr vc>tagt cootrd Ioe>p define ,
tM lovd at whicl1 tho 'n~QI' lugp 'ogul,to. pc.,
OJ'fCnt IIl....,.q. ll>e j)<JWe' IIW1tet. ur'Kl 1M pfim<ry
.,nding of tho> U.. ",forme'
E'-WIlerti D C open loop and dynamIC line
llI\lulallon is en ..... C<I Que to thc "he.cn! input
vo.~a fee<lfolwarQ ch""CICrlal~ Q/ the currcnt
mOde """"01, lljs 'Huh. In an i"""""oo _
.es;;ylahon, ins tant~ ntoo' corrccttun to 1m
ch,,,,,,,,,, aM bene. s ta~llty for tl'>; Wlltatl ~
'6gYlat lu n toop
C.... ,e!lt mode 1<>;)O Io:lY 01'0 c,,"uro" ~m
IImh too in tl1e ca.e 01 5/I~rt ~,..,.,t DIlrir>; lh~
rnl pn.s~ IIle output OO,,"lI'It iO<:rlJa..,. slowly
rgllOwro'J the d~namlC of the r.gulation loop. Then
it ~ lIIe maolm ... m ~m,tatoo culra,'It
inlomally 5'>1 and finally 'IO~ Decau"" the POW'"
of
IUpPly' on VII) is no longer correct. Fo. spocif"lC
apphcabons tM maJ<mum pca. curren! internally
11&' can 00 wernddcn by ~m,hn<; 'he ,,<,"age
ity
• ,t»..."" 0"I;tnalI1 on I~e COM? pin An
Int.,. ,.t"," «an .. '.... !il!9t nt;b~. tho PWM
rs
comporol", W!pJl fol I aMr1 time aHe.' thoe
Int6Y'o led Powe, M05FEl II switched an, T~ II
ve
lunCUon ,..-events ""am.l~ue '" plemotlre
t8lmin.t.,., ~I the switch",\! pul" n the case of
CUtftOt ....1<00 cauoed by poi'".,- lido ... padt.....".
ni
Of IC ....... dao:y .d~ r<>abe' ' ...."'" recOllery b1M,
U
SlANO-BY MODE
SraM./;>y opcrat>on In n&¥ly ",pen load wnd,U""
'~lOm.t""'lIy lead. to & Dur.1 mO<k ope<ation
illlOwr>;l wlti>gc '~9~t,Uan on thol le.:und ory ",d~.
Th e trons~lon Irom no,m &1 operati oo 10 tu"s.t
mode operation ",ppc:,,"
IQ" puw"," P STllY given
>,
, ,
PSTBY - 2lp l STB yF sw
"',"Ill.. pnm.ry
lp 0& 'ndoJQan~ of II'HIlransf0rm9.
VIPer~O/SP _ VIParSOA/ASP
FSW II the normal switching frequency
ISTSV • tho min'm ll"T1 1;0ntr« lal:>le curr9nt.
C<lIt&lpOM ing t~ lho monmum on tim e that II'HI
ooice. _ to providQ in """", at opem",,_This
CUff'" can be computed u;
(t D - tdWIN
ISl ey - C,
1., ..... the ...... fA 11>0 blan'"ng I,m. and 01 II'>;
propfg.tiQn lime of the n!e'~1 currcm ' ","0 aM
c;um~"IO', and rougN~ ropre ,onill Iho nmmum
on tlrTHI Col too dev ice , Note Ihlll PSHY may be
aff&CI1)(j by 1M efficiency of th e coov&r!or at 101'1
Io;td, and must indw . the P<lWor d'awn 00 the
~I ry au><.l""Y voltage,
Ai. loon u the power GOOIJ below this ~m~. tl>:!
ao.lUlary ie~ondafY voltage ..altt 10 ...",asc
n
_e
above IIle 13V rcSUlabon h;v"t",CftG the <nqIUI
w
"",trag. 01 the tr .... sconQ.H::I .. n(;6 ampllie. to low
(VCOJ.Ip < VcmoPtJ. n ....cu~t>un Ic~d~ tu
To
III, ,""ul"""'" mode where lIIe PQ<vc ••wlet. 'S
malntaiM(! in 1M off .tille, '"lntln~ in mo'''1l;l
~1d" aM LCfO duly c~cle, A, ,!>On M "CD ~ot.
e
biICk I~ Ihe reyulatiun love l ond the VC()!.'I?t~
tl'teShOld l~ reached, th e device op9(31es aQain
ap
lh e at»<. c~cle 'ep4!at9 ~lIeIf Illdefin~ely,
jlflMdin~ a bu,..t mooe 01 whlcll the e!f&dt.e d il.y
C
~ ,I mudl lower IIlan IIle m,nimum "" .. ..non ,n
n<.rmal upcra~",, _ The c<IU""lont ....1dI .. g
lR:quCrKy • ~150 Iowor III.... lIIe n<,ll'lTlal one,
lep,g to a ..,duced consumphon on ..... "'Put
rna..., hnes. 11Is modi! of opera""n "",,"s "'"
VIPer50/50A 10 meel lIIe n.... German "Blue:
~r Norm WIth low. ~n 11',' 100at po .......
oc,""umptloo lor II>:! ' )'SI~m ",,~en .QI'kln~ in
8Iand-by. The outptlt vult_ge 'emol ... 'os"ated
iW'Oulld the n",mal I ~ v~, WI!" ~ lul'l Ile(JJ<lr'ICy
ripple corN.pond lng to the OtrfSl mode, Tho
IImpliludc gl !hi. rip\>o i. low, bccau'~ <)/ tho
o utt),lt c.apaQta.-s and bQcause orthe lew oo4>ut
Q.A".ent 1!aw<! in .... ch c;ond.d""l Tn. 00""",1
upe,.,iQn ",.umM al<tofno,toeally .... n.n 1M power
g~ bed< Iovels which aro h'ghQ' lIw> PSTllV-
HIGH VOLTAGE START-U P CURRENT
SOURCE
An inl&\j",led hl(;l'l vult..;Je eY"ent SOU 'ce prov:cles
a bl.a9 C\mefll Ifom th9 DRAIN pin dU,lng the start-
up phOU TM, current i& partially abiO'"ood b)'
'nte 'nat oo ntrol ct cuit. whict1 lire pacod into a
5I<Indby mud. WIth ,;duco::J COIlumpu"" and aN!
ajso Pf",,;:r.d to the ellOlfl1al capaCllO( conncdoo
to tM VDQ pm, A. soon n lIIe ..onag. on Ius pm
.eacl>n the hllOh vtIltar""" IIlffihold VOo.n of tOO

UVLO Ioo}c, the 09vHoe tums into activa moC9 arid
,tart, ,witchir.g,
The SlM up CU'1'Mt generalor;, sw~ch e d aff and
the cooverter '"'auld rormally prov;"a the I\9adad
current on the Voo pin thrDUgh the aux'j j",y
"';r.o"g of th e t'anMormer. a, shown on f':lure f5
In ca.e o! abnormal condit;"n whare the auxiliary
v,;n0'n\l is unable to pravi"" IhG low voltage .upply
current ta tha Voo pin (i.a, .Ilort circuit ar, th e
autput of Ih e convert",!. the exte'Ml capacitor
dischar~e. rtself dawn!o the "WI thresholo "'Ita~e
V[)[)o'f r:i tha UVLO kogio, and th e devioe get. ba ok
to the "aotiva .tata whare 1I1G Intarnal circUIts are
in standby mOOe and the start up current source is
acnvated, The converter enters an erodess sta<t
up cycle, with ft ,Ia<t.up <illy cycl e de "n ed by the
rat>o at cl13rging current lowards discl13rgir,g I'II",r,
Ille VIPerSOiSOA tries to start, This ratio is nxed by
des';ln from <ta 15, whioh 9ives a 12~. start up
dUty cycl9whila tha power cii .. ipatlor, at sta<t up i,
app'aximat .. y 0,6 W, for a ZYl Vrm s i~put voltage,
This "1'1 val"" of start-up duty cycle prevents the
"",ss at th e oulput rectifiers and of lhe
Iransform er wl"'n in ,mrt circuit
The external capacitor CV[)O an the Voo pin must
be sizoo according to the tima naeded by the
canvenar to start up, whe ~ the device starts
s",;tchir.:) , Thi, lime tss depenos 00 many
C
para mete,", amor'll wh;"h tran,-.lormer dasigr"
outP<' capacHo," ,a~ 'Iart realure and
campensatian nelworl< implemented on the COMP
of
pin, The ralklwin~ formula can bu used Iordafining
the m'l ri mum capacitor needed'
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C , ","',,",c
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FigLJre 15: Beha,;or r:i Ihe high vollaga ctxrGnt,-.C>lrCe at .,',"".,"",_ _ _ _ _ _ _ _ _ _ _ _ __
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-.-----+-~
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VIPer50lSP - VIPer50AlASP
wha-u;
100 is tl'" consumptior, cur-ent an the V OD pi:",
when .wilching_ Rerer to 'peciliood 1001 ....,d 1002
valuas,
tss i, tha ,tart up lime or IhG oon".rtar wher1 the
device begins ta switch Worst CaS e i, g""",ally at
full 1000,
VO(lIO'" i, tha voitag.e hy,teresis of too UVLO
logic. Rerer ta the minimum sp"clfi ed value,
Son siart feature Ga~ be implem erlted on the
COMP pin throu~h a simple capacilor which-MII
"Iso be used as the comp ensatian M tworl_ In thi s
ca'e, Ille regul3tion loop bandv.idth i. rather >Ow,
bec"u' e of the large valu e af thi, capacltor_ Ir,
case of a laV" reQul.t>On loop baroCY';OIh is
mandatory, the .ch9lT1.tics in (i gure 1S oan be
used_ It mixes a h>:Jh performance campensaoon
n
netwo," to\lether with a s€parate hf;jh value son
w
start capacitor_ 8ath $ofl start time and r"9-'latOO
loop band'widtll can be a~usled separat e ~
To
If the de,;cG is inlantiar.al~ shul COwn by puttifl!J
t he COMP pin ta ground, the dG,;ce is aM
pertarmng start-up CYCl es, and th e V[)O voltage is
e
osc l lali"" between V [)[)oc and Voo.~'
ap
ThO; voltaQG can be usad (ar wpptying axlernal
runeli""s, provided that their consumption doesnl
exceed Q,5mA. Figure 17 smws a ty~cal
applioattan at this functior" with a lalchad .h ut
dowr,_ Once Ih e -Shutdawr,- ,;gna l I"" been
acti.aled, the device remains in Ille off Slate urli
tha input voltage is ",maved_
'",A DRAIN
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-
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 VIPer50lSP - VIPer50AlASP

TRANSCONDUCTANCE ERROR AMPLIFIER ~c"e"" diff,.,-enl compeMation laws. A oapar:ilor

The VIPer5OlS0A irooludes a lransconductance "";1 provide an irtegrator luoctkon, lhu~ eliminating
error amp l f..,-. T,anscond\..<;tanoe Gm is to.. tr-e DC slatic error, and a resistarooe in _les
chaf'l9'l in olltIXA cU'renl (LeQ"?) versus change in lead! to ~ fial gain ~l high"'- freqLJeOCY, insurin~ a
i<1)llt vdt","e (V,,~) nus' c""eel pr.aso maf~il1, This confi!1-'raton is
ilkJstrated in figure 18
JI
COMP
As shown in figure 18 an "dditiOl1a1 noise fillering
capacitor of 2.2 nF i; generally need ~ d lo a.dd
The ootpur impedance lCCMP at the output or this am high /requem:y inlerference,
ampiff...- (COMP pn) oan be c!efi ne d a~
It can also be intere,ting to implem ~ nl a Skop"
iJV COMP 1 av COMP compenMticn whel1 working in conh,uou~ mode
ZCOMP - JI
COMP
- G-m '--i,~~o"'oC w i h du ly C)lcle h",herthal15(i ',; Fgure 19 shows
suoh a configLM"ation. Note thal R1 and C2 buikj
the classkoat compensatiOl1 ootl'lorl;, an d OJ is
;"ectin ~ t r-e slope compensation w~h the correct
Thi:'llast "Guah:ol1 sr,ows that the "Pen loop gain
polarKy from th ~ oscillator sawtooth.
Ava. can be ,elated to Gill and l~o"?;

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EXTERNAL CLOCK SYNCHRONIZATION
where G". value flY VIPer50150A i~ 1.5 mAN

typkoally,
G,,-i:'I well defined by ~pecilication, but lCC"? and
therefore A.,.x are subjeello lar>l'" tolerances, An
impedance Z can be connected betNeel1 to..
CQMP pin and g'OOnd in IYder to define more
accurately the tranMer luncti"" F of the enar
ampifier. acconJir>;l 10 l~ e fo l owing equati"", very
To
The QSC pin pro.ide~ a 'yllChrorisation
capability, whel1 cOl1nected to an external
frequeocy SOurce. Fi]ure 20 ~how~ one p"'sibl ~
~cr.amatic to 00 adapted depending on the
e
sp ~ cHko ne ~ ds, If th ~ pr"Pos ~ d sch ~ matic is used,
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th ~ puioe duration rrM.!,t be kept at a low value
(500ns is suffK'ient) lor minimizinQ consumption,
n", optocoupler must 00 able 10 pro'<ide 2DmA
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simi .., to lhe ooe above'

tr.rcugh the Oplotransi;tor
F(s: ~ Gm r liS)
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The ",ror amplifier frequency respor1oe is rep"""'d PRIMARY PEAK CURRENT LlMtTATION
in liQure 10 for d ffere nl values of a simple
rMistance connected on the CaMP pin The T"-' ~imary IOPEAK current and, a, re~ultir>;J
ity

unloaded transconduelance error amplifie' shows efiecl th ~ outIXA power oan b ~ limit ~ d using lh ~
an inle'nallcOMP of aboot 330 KD., More complex simpl ~ oi",uit sr.own in figure 21. The circuil ba~&d
impedance can be connected 011 lr", COMP pin to on af, R, and R2 clamps the .oItaQe on the
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Figure 16: Mixed Sofl Sta~ and CampenMtion F~ure 11: Latched Shut Down
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 VIPer50lSP - VIPer50AlASP

COMP pin in order to Imit the prim.ry peak curront OVER-TEMPERATURE PROTECTION:
or the de"koe to ~ ".Iu o Over_temperature prat&Ctian i, based an ch ip
V 05 temp<l<ature ;ens'rlg TM minim'-'" junctioo
COMP temp<l<ature at whkoh over-temperatcre cut-oc.<
'CPEAK
Dec,n i. HO'C wnl e the typk:.1 ".'ue is 17O"C
The device is automatk:ally restarted wh ~ n the
jwction temp!ll"Htcre docrea"e; to the r""tart
tamparature thresl1ald that is ty>,cally 40"C baklw
O,6~ -'',"c-'" the . hutdown yalue ( ..... figu ", 8),
"
Th<: sugg estad ."'u ~ b, R,~R, i; in the range '"
220Kl.1

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Figure 22: Input Volta 9<' Surg e!; P ro l ~ ction

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, I Auxilliary wi:1dng

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The VIP", may be .oomittecl to "ectrical over
C

can overpass the V[)O pin absolute ma"m um

.tress caused ~y =Ioot input voltage surge. or rati,.... 'Ioltoge valu e_Such events may Ir>gger t ""
Ilghtr>ng. Following the .oocosw Layoot V D:> Inte<n<1l protection CirCUitry wri ch aou d be
Cens i<;jo, r~ ' oos chapter rules IS tr.. .",ost of l h ~ d~""' 9<' d by th e strong disch~r9<' ourr9'1t of Ihe
of

time sufficient tQ pr""Mt cataslro ph e damages, Voo bulk capociter. The simp " RC fdt~ .hewn In
how ~ ver in sam ~ eas ~ s the "" Ita g ~ surges fLgur~ 22 can be. Im ~ m e nl ed to .,.,pro~e I""
coupled Ihrough the transformer auxiliary ", in ding appl>:::at"n Immunl"! to such sur9<'s_
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 VIPer50l SP - VIPe r50AlASP

Fig u", 23: Recon'lrl'1ended LaylXlt

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S,,",e 'imple ",Ies ins"", a com;ct running of power one •. The intorfe",,,,,es due to a miXl1g
,wilchng power supp'e" They may be classified of signal and power may resuli in in'Iab'li lies
C

into 11'0'0 c.teWle" and/or anomalous be",.i", 01 the dev>:::e in

• To mitlimiza power oops t~a way the s...-itched case of'liolenl powe r ,urge (Inpu t o.erw:-i tages
power current must be carefuMy analyzed and output short cr cuil,,,.).
of

thG correspmOng path. mu.t pr. sent the In case 01 VIPer, lhese ",Ies apply as ,howtl ill
smollG,t po.. ible inner koop area. Thi, a.ods fi7Jra 23. T.'" loops C1- n-u 1, C5-02-T 1, C7 -01 -
ty

radiated EMC noises, conducted EM C Mises T1 mu,t be mitlimizod. C6 mlJSt bQ os c" .. as

by magnetic CO<lpling, and pro'lides a better possiblQ to T1. Tho oi,!7'al compon""ts C2_ IS01,
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erricier;cy by elminatinQ parasitic Muct.nCG., C3.nd C~ use a dedi""ted track to be connected

esp.d.llyon secondary sde diractly to Ihe SOUrce oltne device
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 VIPer50!SP - VIPerSOA!ASP

PowerSO_10 nt MECHANICAL DATA

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PENTAWATT HV 02 2Y (VERTICAL HIGH PITCH) MECHANICAL DATA

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 Y Roltec EO.tee SAS - ABS, Pooe de L' ~nas, Holl C _00299 N"", Code, 3 _
T~ 00.33.(0)6.63.73.2461 Fax: 00.33.10).4.94_30.82.35
Em,,;l: contact@ooIt"".com www.ooi!ec.CQ!!J
Fr~r,ce

Allthor: Jacques $ollquel

Dale; 25 october 2003

• WIDE RANGE POWER SUPPLY PROTOTYPE -

BASED ON VIPER50

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• The prd:otype 01 power ~l.IPply (PS) is intended to supply the Heatef Cootroll8' electronic boards and display
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• It i5 intended to be rlirectly powered frOOl the ,,"nd turbine generator voltage (PMG).
• The P$ is based on a VIPER50 compooerlt (Stmlcrooiectronicsj and a ~yback traMfafmar.
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• A 24Vdc-C.5A ~tyegulated output has been added. This output is intended to ~upply power relays, like
s)mchrrn;ze relay for other power electrooics like the IPC.
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• A b~ttery i~t has been aclded. It is intended to allow the ~imultaneous connection or AC (main or PMGj 6lI1d
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DC (batter>es) supply to the l>oord

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Power supply Input:

Valtege input range will be: 0 to 280Vac
FrequellCy of input vot:age will 00 0 to 5ct1z
Output power "7W" should be ava.~ble from 30Vao to 2SOVac, or 35Vdc to 400Vdc
Output power" 18W shotAd be available from 60Vac to 280Vac

Power ~upply output:

Output 1 , +5Vdc I 500mA
Output 2 _+15VdcI100Il1A
Output 3 : _15Vdc I l00mA
(Output 1,2_3 shares the s~me OV reference)

Output 4 + 15Vdc I lOOmA - no~ referred to ttle ether oulputs

Output 5 '+24Vdc I SOOmA unregulated and oot referred to other OlJtput~ (available from 60Vac at input)

Transform~r : (S!emens-Matsuschita I Epcos)

Core RMB # B6581 IJR67
Material , N67
Coil former 12 pins #B65812C1512T1
Cip, #B65812A2203

Page liS
Switcher-controller, Vlper50
60 kHz ~xed switching frequency (internal oscillator)
62OV-l,5A irtegrated Mosfet
Integrated aver voitage-current-temperature protection
Integrated high voltage current SOUrCe for startin<;!
Integrated voltag e reference
Pentawatt pockage

. Preliminary Test Results .

Due to oor lack of mean . and time, the prototype hasn't been tested an it'. whole expected wor1<ing range (0_
280Vac" O-50hz),

Test cond-!io"s ,

Input voltage: 0 to 24DVac

Input frequency: 50hz

Output load (15V) 1 ODrnA (1 50 ohm.)

Output load (5V) :333mA(ISohms)
Oulput load (24V) , 333mA (75 ohms)

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Tem pe rllture : +1- 25C'

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Preliminary resull$; e
Under 7V/load. oulpul power is available from less than 3DVac (at 50hz)
ap
Under 7W load, oulput power is available from les . than 35Vdc
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Under 15W load, output pOwe r is avail8bl e from less thoo 60Vac (at 50hz)
The device start even with a smooth voltag e ramp
of

Depend " g of the output load, there i. a range of k:lw voltage where the device try to start, switch, stop, start
etc_,_ Lang lerm behavior in this area must be les:ed.
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From 60Vac to 230Vac and under I 5W crolinuous resistive load, temperature increase (Viper-transformer)
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seem . reasonable (after 2 hour . )

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Measurement. and test. must be reaized with actual PMG voltag e. and frequencie. _Due to low PMG
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frequ encies, law input voltage performance" will be negatively affecled by the voltage ripple around the
1 OO~F-400V inpul capacitor
Max, i1pul voltage hasn't been tested (280Vac)
Lan<;! term be havior a: transitioo voltage (de pends w load) must be explored
Starting behavior with PS connected to Ihe real boards (DSP, data acq.) must be ch ecked
Output noise and stability on v",ioo . loads musl be checked
A sma~ heatsink musl be added to the oolpul regulalor" (nale that excess of voltage is limited and i. very
stabl e, aroond 2,7·3_DV)
The transform er is gapped (0, 13mm) 00 both internaLiexternal paths, with a 0, 13mm film
Price (1+,'- euras 3--4) and availabi~ty to be checked
ViperSOA inlerestiav;:oilabiity to be cI1ecked (700V-5. m masfet in place of 62DV-5,(Xl)

Pag~ 2i5
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WIde Input range Power Supply Prototype with Vi~r5(J
VersiIIrJ B" opIiootJJ 24V..().~ ocr/pUI
S"*"OJ§I f~/: 6O:tIl.I
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COI3 it-IOI ;ST- ()1$trto\
0uI4 411-121. III • D.2Sfr.m
 Recommendod layout: (ViperSO datasheet)

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-1- Voltages surges Immunity Improvements (In red)
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-2- Low vollage starting cancenation (in blue)

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_1_ Voltages surges Immunily improvement (in red)
It is a ST r..commendalion (ftg 22 of datasheetj to improve the immunity to large input voltage surges

_2_ Low voltage starting cancellation (in blue)

Most of the time the wind turbine wil st...-t relatively quickly and even allow wind sr>"ed the PMG outpLJt
volt"ge will qUickly reach at least 60Vac,
However, it is possible th"t the WT stays for some time at a speed where tne output voltage;s just equal to
the PS board sl<lrting Voltage, say +/-30Vac.
In that case the PS board will st"rt/stop cyclically.

As" possible improvement, the idea of the proposed additioni!ll drcllitry around COMP pin (in blue) is,
The COMP rwn C<ln be used to cancel the output. When the COMP voltage goes below O.5V the shut-
down <J the circuit occurs, with a zero duly cycle lor the power Mosfet
With the proposed circuit (not tested, to be checked) ,
When VDD pin Voill reach +/-5V, n Voill pull COMP down to ground, c"nceling tI,e output.
When the DC bus will reacl1 +1- 35V, T2 will open n, enab~ng Viper starting.

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Appendix I: Final test list for heater controller

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 Eolt..c SAS - ABS, Porte de l'Arenu , Hal C _06299 Nice Cedtix 3 _ Frar>Ge
Tel. 00.33,(0)6,63,7324,61 Fax: 00,33 {O).494,30 8235
Ema~: info@~oltec,com \'MW,eoK~,,,,-,,,,m

Heater Controll er

ntro u~tlOn :
The test list i a reliab le and safe method to validate HC's software,ltlardw","e modifi,ations,
The list is , ,
~'~'~
but are not present in the followi ng list
~ II Ii,

,
Results

1 Lookup table verifK;atlon Wire 8,1 ohms o ad Passed

Ctleck output power on entire range
Ctled output ripp,e «3Vpp) on entire range

Place partICular attention to:

,
0- 200W range (check output voltage)
,
Max, power (5050W)
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2 I Transieot response test Che,k that step response is about 100ms or tess Passed

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Low impedance test Che<;k that with about 5 o11ms load impedan,e Passed
, current is well limited to 30Adc
-
4 ,, High impedance test
e
Check that with about 20 o11m5 load impedance the
output voltage is wetllimited to 250Vdc
Passed II
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Cl\eck that nov max output voltage limit is well
,; Over voltage detection test Tested at
C

detected (broken wire test) ower voltage

and passed
.
. ---,--
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6 Over CLrrent detection test Cl\eck that

'" m" output current limit
detected (short ,ircuit test) " Tested at
ower cu rrent
ty

and passed
si

7 Remote control input test (NO) Set the remote input to NO, w'lre a switch and 'l\eck OC - disabled
er

ttlat output is enabledldisab led , CC - enabled

test Set the remote input to NC, wire a switch and che,k OC - enabled
7~~te
9 control output
v

that the is enabledld'lSabled

,
OC disabled
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9 Standby logic test
Note:
Pic = Pic Standby Statu5
Dsp = Dsp Standby sta:us
- Set the remote input to NO and wire a switch
• run the device with medium power
• disable the output using too ONlstdby button 00
keypad (Pic = 1)
- switch OFFiON the remote swit,h
i Too output must stay disabled (OFF pri or ity) i Passed

The HC works il and only if ' - set ttle swit'h to OFF (output disabled) (Osp" 1)
both s:.>nd by st atus are se: to - push on the Stdby button (Pic" 0)
I
3 The output must stay disabled (OFF pr Ority ) Passed

- set the switch to ON (Pic = 0 and Dsp = 0) Output enable

- push on too Stdby button (Pic = 1 Dsp = 0) Output disable
Too output must be enabled Faied

Redo the same with remote input set to NC Passed

10 Tl\erm~1 deratltog test (75- ' Check thermal derating Passed

80C)
11 Over tempera~u re test (>8OC") Cl\eck over temperature detection
.. '-.-'.--.--_.

Pag e 1,12
~
2 Pmax set~rog test (if th is fixtu re Wire a j ohms ~
is Implement ed? ) Set Pmale to :il OOOW
Chec~ trlat Petit Is wel l Iom lted to 2000W
.-f---- __j_ --------'-
I

1- Look up ubi" vllrification

Check In st the lookup tablfl is well updated (1, -:il0 04)

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Appendix J: Schematic of DSP Card and Interface Card

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Appendix K: Specifications of the Sci rocco 6 kW permanent
magnet wind generator

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·gtoneralcr
Ifaiable speed riPF'T operalicon
ov!r speed centrifuga l stall
con:rol
... fully se:lhd desl']n
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S,i,ooc; "';',:1 :U'~;ne ;, c",..acto,ilOG by , very hgh

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wOid!' ;; orc'iait:rg ,-,0,1 of t"C I':r~ (>8D%i_ Tois is
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r':',"'; c-'lici~'lt dire~t ~;;YC PM gO""'"tor comb'flcG wil"
11~ mnima oo ..... s, poi,1 Irack,ng conlrcl '[jI(Jl'.in,. 111~
ccmt .."fy ,,'~ryirg '/-.',";C ~c~d
< ,<\1 Il1gh ,",':nd sp<!ocs, :h~ \,'>'1 ,:crlir _e 1-: opel.le ~, ils

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lis sUp"J'icr low':m-Jc'um "ifld portor,-,J'l"~S opO'lS 'lOW
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'~sl'<)nd 10 a ""'Y wide rl"'98 of al'-pli-:,t,,_os as ~att9CY

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st"n~J."e~
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-'-,a:Y 0, ;;ortro iee c" mp-motor dri'''-''
,:,~)~ slectric jIj,1'ci-l[; p..,-rnl\s to ~xpl':il well r~"es 0\'5r
1z),.. cep;~ Ic' cr;flk' ng Gr i,"goli':r watoe ou'p':5~S,
Or 0'r:ica! r""'oto w.tor IX""r:i'9 srtos with ,.',o"g~ '.",,:nc
SO~CG ~s k'.'i NS 5".':s, trc Sc:r:coo 'NT '.'ii:' sa\'% up:o
5 f GO ~') e,.- 0' fuel, t"u. e_oJ ~::ng 5,<csll._o! oa;ha,:k
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Due la 110,: uncompromis'ng des'£c, maxi;',l!m rClaror .
speeo i, HI"ileo [t, 245q::m, ;,wt~"ing a o"axitTllrf, 1',:
speed of ,'Cmfs, nat's one at he ke'l :a gel a CU'G
ruc~'ng on !he en: ~ e 'Nino range, It",.' nt, se, Ie,'.'.' pia,:\<
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PNlorlTl~nccs
R~ted C<.9'~ pO'Ne" ".Jk'N:§:' 12 m:S
SCI! in +in" $:;./I d Z 7 tTl,'S
CII o,~ ".'IOa I~Ged NL,no;
$llr'.,j,;1 '.... irod speec ,SO 'r,:" f,:fe.;ign tccor':!i~1:¢'

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T)',o~ $ 'InCh or', 0 l1 ,C~: ',~:'! ",,' ,
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Miscellaneous
v~" '.. ;nB 'yste'T1 Pa"I."e, ~p'.'."in,j '<! .. :&~~ ee, I
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CV8COoe(}j ooctro AG-o,:'ymT,iG 'ull
8r~,e OO!'L,na,O' I .Ir
e''Jer~ror~1 .. :

Weigl,l : 202 kg fCt'O",,~ete

TOWG" , S - 24 _20 T ii:~ne,~r:1 TO" yeo
Ba~lery cl1arg er : /,3
~'''l!;ng o"t"je foc t'OI 0"$1 ai'
Grid im e rter

'AnnL~, inspecton

Eollec SAS
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