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11 Appendix D USER S MANUAL SEMITEACH Based Converter System for Electrical Machines Jawwad Zafar Copyright 2010 by the Université Libre de Bruxelles (ULB), Brussels, Belgium. All rights reserved. The responsibility for the use of any information provided in this document rests solely with its user. Other information may be necessary. Previous Edition D-1

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13 Contents Page 1. Introduction...D 5 2. Precautions.D 7 3. The Semiteach...D Component Description..D Terminal Description.D The Chariot..D Description of External Connections (Front Panel) D Description of External Connections (Back Panel).D Description of External Connections (Side Panel)...D Description of Internal Components D The Electronic Circuits....D TTL to CMOS Voltage Level Conversion Circuit.D The Error Handling Circuit.D The DC-link Over-voltage and Thermal Over-load Protection Circuit...D The Contactor Switching Circuit.D The Current and Voltage Measurement Circuits..D The Wiring Diagram...D 25 D-3

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15 1 Introduction This setup is based around the Semiteach converter from the manufacturer Semikron. The converter is controlled by a Digital Signal Processor (DSP) card, DS1104, from the manufacturer dspace. The necessary transducers and controlled switches for different applications have been installed in the chariot. There is protection against short circuit, overvoltage at the DC-link and over-temperature, independent of the software protections that are necessary to be included as part of application development. D-5

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17 2 Precautions The general precautions are listed below. Others should be taken as necessary. Chariot Never connect or disconnect the dspace Connector LED Panel (CLP) to the PC while the PC or any external device, connected to the CLP, is ON. The PC should always be switched ON before any of the external devices. Make sure the circuit breaker, at the front of the chariot, is switched OFF before starting work on the system. The order of switching for the components should be the following: Turn on the PC and observe that it boots normally. The LED indicators on the CLP will glow as well. Turn ON the power switch, at the front of, the chariot and make sure that no contactor has operated when this is done. Turn ON the circuit breaker. During the experiments, keep in mind never to turn ON the grid while any of the contactors involved in the charging of capacitors is operating. This is due to the fact that the resistors, that limit the capacitor charging current, are removed once the capacitor has been charged to a certain extent. dspace The default output of digital Input and Output (I/O) is logic high which must be taken into account when starting or stopping an application. The digital I/Os have Transistor-Transistor Logic (TTL) level voltages. The current limit for the digital I/Os for the Master PPC is ±5 ma while for the Slave DSP it is ±13 ma. The voltage limit for the Analog to Digital Converter (ADC) inputs is ±10 V and must not be exceeded. The output voltage and current limit for the Digital to Analog Converter (DAC) outputs is ±10 V and ±5 ma respectively and must not be exceeded. For the DS1104, the total load on the connector pins providing power supply VCC must not exceed 500 ma while for the CLP, the total load of all the connector pins must not exceed 400 ma. I/Os have alternative functions which can cause conflicts. D-7

18 If un-installation or re-installation of the dspace hardware or software is required, the Hardware Installation and Configuration guide, of dspace, must be consulted. The dspace systems require installation in a defined sequence of steps otherwise the hardware could be damaged beyond repair. If any work has to be done on the connectors to the CLP, mounted on the chariot, do not rely on the numbers written on the connectors. Consult the Hardware Installation and Configuration guide, of dspace, for proper definition of the pins. Electrolytic DC-link Capacitor Always connect the DC-link protection inputs on the chariot, Section 4.2.3, to the DC bus of the Semiteach. The maximum voltage for the DC-link capacitors is 750 V. The rms current limit is 19.1 A and 8.2 A at 40 C and 85 C respectively. The DC-link capacitors have to be charged at the beginning of operations. This must be done through charging resistors, installed in the chariot, to avoid damage to the diode bridge rectifier. I/O 06 is reserved for this. Please refer to Chapter 6 The Wiring Diagram for details.. D-8

19 3 The Semiteach The Semiteach is a 20 kva setup with a diode bridge rectifier, a three-phase IGBT inverter and an IGBT chopper. The drivers for the IGBTs, the DC-link capacitor, the heat-sink temperature measurement sensor, a protective thermal switch and a fan are included in the product. Figure-3.1 shows the schematic of the system. 3.1 Component Description Figure 3.1 The schematic of the Semiteach Diode Bridge By default, the SKD 51/14, 380V, 50 A, diode bridge rectifier is not connected to the IGBT converter. To operate the rectifier with the converter, its output has to be connected to the DC-link terminals. The rectifier can also be operated as a single phase bridge DC-link Capacitors The electrolytic DC-link capacitors are each rated at 2200μF, 400 V and connected in series to provide an equivalent 1100μF, 800 V rating. The capacitor voltage balancing resistors are 22 kω each. The DC-link capacitor will discharge through the voltage balancing resistor across it, in about 46 s IGBT Modules The IGBT modules, SKM 50 GB 123 D, are rated at 1200 V, 50 A but the maximum current recommended by the manufacturer is 30 A. The input voltage signal level required to turn the IGBT on and off is +15 V and -15 V respectively. The typical turn-on threshold voltage is 5.5 V. The maximum saturation collector to emitter voltage is 3V (3.7V), for junction temperature of 25 C (125 C), at the rated current of 50 A. The turn-on and turnoff time delay is 70 ns and 400 ns respectively while the rise and fall times are 60 ns and 45 ns respectively, with a gate resistance of 27 Ω and a current of 40 A. The peak collector current can be 80 A, but with a maximum pulse duration of 1 ms. The IGBTs have a high short circuit current capability of 500 A, at full DC voltage of 1200 V, but this short-circuit must be detected within 10 μs otherwise there is a risk of thermal breakdown. A maximum of 1000 short-circuit events are allowed, which must be at least 1 s apart. When the short-circuit current reaches 10 times the nominal the IGBT starts to desaturate, the voltage between collector to emitter increases and the current is limited. D-9

20 3.1.4 IGBT Drivers The SKHI 22A drivers can provide an output peak current of 8 A and provide the +15V and -15 V required to switch the IGBT. The gate resistor value is 30Ω. The drivers require a supply voltage of 15 V and consume 160 ma per driver. The maximum switching frequency, for the driver, is 50 khz. There is interlocking to prevent the simultaneous switch-on for IGBTs in the same inverter leg. The driver inserts an interlock dead time of µs by default. The drivers also provide the error outputs for protection at faults like shortcircuits of the IGBT, by monitoring the collector to emitter voltage VCE, and driver supply under-voltage 13 V. The short-circuit is detected within 5 μs. The error input to output propagation time is 0.6 μs. In fault case the input firing pulses are ignored and the output error latch is set. In order to reset the latch, both the signal inputs should be put to zero for at least 9 μs. The absence of a fault condition is indicated by a +15 V level at the error outputs. This error output has to be included when designing an application. The driver also has an integrated short pulse suppression function, which suppresses switching pulses less than 500 ns, caused by high-frequency interference at the driver input Snubber Capacitors The MKP type snubber capacitors, rated at 22μF, 1600 V, are mounted directly between the collector and emitter terminals of the IGBT modules. They absorb the high frequency harmonics and limit the overvoltages, due to the parasitic inductances. A snubber also reduces the switching losses but this function is less important, for an IGBT, since it can be switched at full current with full rated voltage e.g V. 3.2 Terminal Description Figure-3.2 provides the top and front views of the Semiteach and indicates the terminals available. Diode bridge rectifier output Power supply input to the fan IGBT converter DC-link input Three-phase input to diode bridge rectifier Thermal switch (a) Three-phase output of the IGBT inverter Chopper load connection terminal D-10

21 Driver error outputs 1 4 Firing pulse inputs to top level IGBTs 1 3 Firing pulse inputs to bottom level IGBTs 1 3 Firing pulse input to the chopper IGBT Temperature sensor output Driver supply inputs 0/+15 V (b) Figure 3.2 Semiteach terminals description (a) the top (b) the front. The input BNC connector shields and the temperature sensor reference are connected to the driver 0 V. The temperature probe is LM3352 with a gradient of 10 mv/ C. It measures the temperature of the heat sink, at its hottest point. D-11

22 4 The Chariot Two chariots, each complete with all the measurement, signal conditioning, protection, control and power handling components, have been especially fabricated. Connections can be made in a number of ways depending on the requirements for the electrical drive and power electronic courses taught at the university. Each chariot can be operated independently or used together to have a back-to-back converter topology. Special features included allow for safe operation. 4.1 Description of External Connections (Front Panel) Figure-4.1 describes the terminals present at the front of the chariots. Single-phase PWM outputs Three-phase PWM outputs ADCs, DACs Master PPC Digital I/O Current sensor outputs 1 5 Voltage sensor outputs 1 5 Single-phase power ON/OFF switch Driver error inputs Encoder input Slave I/O PWM Serial interface I/Os 17, 18, 19 DC voltage output DC-link voltage indicator Three-phase power circuitbreaker Indication lamp Threephase power Figure 4.1 Front panel view of the chariot and terminal description PWM Outputs The 3-phase and 1-phase PWM outputs are provided at the front panel, after signal conditioning from +5 V generated by the dspace card to +15 V required by the IGBT drivers ADC Inputs The ADC inputs are present to interface with the transducers. They consist of 8 channels. ADCH1 to ADCH4 are multiplexed, 16-bit resolution, to a single ADC while ADCH5 to ADCH8 are four independent ADCs, each with 12-bit resolution. D-12

23 The input voltage limit is ±10 V. The conversion time for the multiplexed channels is 2μs while for the parallel channels it is 800 ns DAC Outputs The DAC outputs are present to interface with actuators. There are 8 independent DAC channels. DACH1 through DACH8 have a 16-bit resolution and voltage output limits of ±10 V. The output current limit is ±5 ma Master PPC Digital I/Os Inputs and outputs controlled by the master processor PPC are indicated as Digital I/O Current Transducer Outputs Five current measurement outputs are provided. The instantaneous value transducers have a bandwidth DC 150 khz and an output of ±9.8 V for a ±50 A current input (DC/ AC/pulsed). The response time at 90% of the nominal current is less than 1 μs while the accuracy and linearity are ±0.5% and less than 0.1% respectively Voltage Transducer Outputs The instantaneous value voltage transducers provide ±7.5 V output for an input of ±860 V (DC/AC/pulsed). The response time at 90% of the nominal voltage is 20 μs to 100 μs while the accuracy and linearity are ±0.7% and less than 0.1% respectively Power Supply Switch The ON/OFF switch is for single-phase power supply to the chariot. The power is required for fans, DC power supplies for the IGBT drivers, contactors, transducers Circuit Breaker The 25 A three-phase circuit breaker, at the input of the chariot, protects the Semiteach diode bridge rectifier against short circuit on the DC-link Indicator Lamps Three 220 V lamps, marked as R, S and T indicate the availability of all the three phases from the grid Driver Error Inputs The driver error inputs, at the front panel, should be connected to the error outputs on the Semiteach; see Figure Incremental Encoder Interface The 24-bit digital incremental encoder interfaces (02 Nos.) are present for speed and position measurement. They are single-ended TTL or differential RS422, input selectable, with a maximum input frequency of 1.65 MHz. D-13

24 PWM Slave Digital I/Os The digital I/Os controlled by the slave DSP are marked as Slave I/O PWM. These I/Os are reserved for functions related to the PWM generation Serial Interface Two serial Universal Asynchronous Receiver and Transmitter (UART), one with RS232 and the other, selectable, RS422/RS485 transceiver mode are also present I/Os 17, 18 and 19 These I/Os are taken from the digital I/Os, Section 4.1.4, controlled by the Master PPC and provided at the front to interface with any external devices. They can be used as interrupts or to turn devices ON and OFF. The current limit is ±5 ma DC-link Voltage Output The measured DC voltage, for protection, is always available at this connector. This is done to avoid using an additional voltage transducer, Section 4.1.6, to measure the DC link voltage DC-link Voltage Indicator The DC-link voltage is continuously indicated by the moving coil panel meter. This is a safety feature for the user since dangerous voltage levels, at the capacitors, can be present for a couple of minutes after the experiment. This panel meter is operational even if the power supply to the chariot is OFF. The indicated value is to be multiplied by Description of External Connections (Back Panel) Figure-4.2 describes the terminals present at the back of the chariot Thermal Switch Inputs The thermal switch inputs present are, internally, connected in series. Two thermal switches can therefore be connected. If any one of the switches becomes open, the power supply to the drivers is blocked and an alarm is sounded. The thermal switch of the Semiteach must be connected to one of these inputs. This is a protection feature against over-temperature due to fan failure. The other switch can be from the brake resistor, also provided with the chariot Driver Supply Output The 15 V driver supply output is for the Semiteach IGBT drivers DC-link Protection Input The provided DC-link protection input must always be connected to the DC-link bus bar to protect against over-voltage that can destroy the DC-link capacitors. This measurement is also used to provide the DC-link voltage output mentioned in Section D-14

25 Thermal switch inputs Driver supply output DC-link protection input Three-phase output to Semiteach Fan Current sensor inputs 1 5 Voltage sensor inputs 1 5 Fuse Three-phase input from Semiteach Fan Three-phase input to the chariot Three-phase output to the machine Figure 4.2 Back panel view of the chariot and terminal description Three Phase Output to Semiteach The three-phase output to Semiteach can be connected to the diode rectifier inputs. This output is indirectly connected to the three phase input, Section 4.2.6, through the series connection of the input circuit breaker, Section 4.1.8, and capacitor charging contactors installed internally, Section Fans The two fans provide forced cooling for the internal components of the chariot. There main purpose is to cool the capacitor charging resistances, Section , filter inductances to be installed inside the chariot Three Phase Input to the Chariot The three-phase input to the chariot is the primary grid input to the whole system Three Phase Output to the Machine The three-phase output to the machine is the final output of the system for use Current Sensor Inputs The current transducer inputs are numbered in a descending order from left to right. This makes them correspond to the numbering order for the outputs of the transducers at the front of the chariot. The colour coding allows positive output voltage from the sensors, for DC inputs. D-15

26 4.2.9 Voltage Sensor Inputs The voltage transducer inputs are numbered in a descending order from left to right. This makes them correspond to the numbering order for the outputs of the transducers at the front of the chariot. The colour coding allows positive output voltage from the sensors, for DC inputs Fuse The 10 A fuse is at the input of the single-phase supply to the chariot Three Phase Input from the Semiteach The three-phase input from the Semiteach should be connected to the output of the IGBT converter. 4.3 Description of External Connections (Side Panel) Figure-4.3(a) shows the placement of the audible alarm generator, on the left side, and Figure-4.3(b) shows the placement of the brake resistor, on the right side, of the chariot. Audible alarm Brake resistor (a) (b) Figure 4.3 Side views of the chariot (a) left (b) right Audible Alarm Generator The audible alarm is sounded for over-voltage, at the DC-link and overtemperature at the converter heat sink or the brake resistor Brake Resistor The brake resistor, SACE 15 RE 22 from ABB, is rated at 22Ω, 2 kw. It is used to dissipate the energy while braking the motor and thereby avoid the increase of the DC-link voltage. 4.4 Description of Internal Components Figure-4.4 shows the internal functional distribution of the components. The top level has the control circuits, to direct the power flow, and protection circuits. D-16

27 The next two are the current transducer and voltage transducer levels respectively. The level below the transducer levels has the components which handle the main power flow through the chariot. Control and protection circuits Voltage transducers Current transducers Power handling components Figure 4.4 Internal functional distribution of the components The Control and Protection Level Figure-4.5 indicates the placement of different components in the top level of the chariot, which is the control and protection level. DC-link + Thermal overload protection board (Card 2) DC power supply Protection relay (R2) DC power distribution DC-link voltage transducer Current limiting resistance Field termination panel (Card 3) +5 V to +15 V conversion board (Card 1) Error handling board (Card 5) Figure 4.5 Layout of components in the control and protection level. D-17

28 Protection Circuit Board (Card 2) The protection circuit board Card 2 protects against DC-link over-voltage and thermal overload. The voltage is sensed by the transducer, Section The over-voltage limit is 720 VDC. The thermal overload protects against over heating and damage to the semiconductors and the brake resistor DC Power Supply The 175 W DC power supply provides the different voltage levels required to power the circuit boards, the contactors and the transducers in the chariot. The voltage levels provided are +24 V, ±15 V, +5 V and 0 V Protection Relay (R2) The protection relay R2 works with the DC-link protection circuit of Section The power supply to the contactors, the IGBT drivers is directed through it; See Section 5.3. It has a latched response which ensures that the system does not toggle abruptly or go back to immediate operation once the voltage goes below the 720 V trigger level. This is justified since the voltage required at the DC-link for most applications is around 600 V, for the rated 380 V at the grid. The absolute maximum voltage limit for the capacitors is 750 V DC Power Distribution The different voltages of the DC power supply, Section , are conveniently distributed by a multi-terminal connector DC-link Voltage Transducer The DC-link voltage transducer works with the protection circuit; See Section Its output is further provided at the front panel, See Section Current Limiting Resistance This is used to select the measurement range of the DC-link voltage transducer of Section Field Termination Panel (Card 3) The Field Termination Panel Card 3, from Analog Devices, is used to provide a terminal interface with dspace I/Os provided by the system. It is connected through a 50 channel band cable to the Master Digital I/O, Section 4.1.4, and Slave I/O PWM, Section , connectors available at the front of the chariot. See also Chapter 6 The Wiring Diagram Voltage Conversion Circuit Board (Card 1) The +5 V to +15 V conversion board Card 1 has been made to convert the PWM signals generated by the dspace card to the level required by the Semiteach driver modules Error Handling Circuit Board (Card 5) The error handling circuit board Card 5 is required for the user-interrupt feature that is used in the software for fault monitoring of the system. This circuit makes it possible to adjust the voltage level, from +15 V to +5 V, and use only one user- D-18

29 interrupt input, from the four provided by dspace DS1104, so that the other inputs can be used for their alternate function as I/Os. An error signal from any one of the four drivers will cause an interrupt, which has to be acknowledged The Current and Voltage Transducer Levels Figure-4.6 shows the layouts of the current and voltage transducer levels. There is space to add more transducers, if necessary. Current transducer 1 5 Measurement resistor 1 5 DC voltage distribution (a) Current limiting resistor 1 5 Voltage transducer 1 5 Measurement resistor 1 5 (b) Figure 4.6 Layout of components in transducer levels. (a) current level (b) voltage level Current Transducers The five current transducers are provided with shielded power cables to reduce interference. D-19

30 Measurement Resistors The measurement resistors are used to convert the output current signal to an equivalent voltage for both types of transducers. The 1 % precision resistance values are 100 Ω and 150 Ω for current and voltage respectively; See Section DC Voltage Distribution It has been provided to distribute power to the transducers Current Limiting Resistors The current limiting resistors in Figure-4.6(b) are for measurement range selection of the voltage transducer since it requires a current signal at its input. The rated conversion ratio from primary to secondary is 10 ma/50 ma. The resistance value selected gives a measuring range upto 860 V for a 10 ma input current Voltage Transducers Five voltage transducers have been provided The Power Handling Component Level Figure-4.7 shows the layout of components in the power handling level. The power handling components carry the three-phase power that passes through the chariot. Contactors output power connector DC-link charging resistor 1 3 Semiteach output contactor Semiteach input contactors DC power supply Contactor switching card (Card 4) Figure 4.7 Layout of components in the power handling level The Contactor Output Power Connector This connector is used to connect the output of the two contactors, which are involved in the charging of the DC-link capacitors, at one point. It is rated at 50 A DC-link Charging Resistors The HS Ω, 75 W capacitor charging wire-wound resistors operate with the input contactors of Section They are provided at the input to the rectifier for two reasons. The first reason is to avoid long cables that would otherwise be D-20

31 required to take the rectifier output to the resistor, installed in the chariot, and back to the converter DC input. This would add large cable inductance to the DC bus-bar. The second reason is the provision to simulate grid voltage dips. When mounted on a heat sink, not done here, the rating of the resistor is 300 W Semiteach Output Contactor This contactor is used to switch the output of the Semiteach converter to the machine. The output of the converter, Section , is sent to the machine, Section 4.2.7, via this contactor Semiteach Input Contactors Two contactors are present. One of the two contactors removes the charging resistors, once the capacitor has enough voltage to limit the charging current, to avoid losses during normal operation DC Power Supply The DC power supply is used to power the electronic components of the contactor switching circuit and its relays Contactor Switching Circuit Board (Card 4) The contactor switching circuit board Card 4 makes it possible to operate the contactors from the digital I/Os which have a current limit of only ±5 ma. D-21

32 5 The Electronic Circuits 5.1 TTL to CMOS Voltage Level Conversion Circuit The dspace card provides a PWM signal of 0/+5 V that needs to be converted to 0/+15 V to be able to be used with Semiteach IGBT drivers. A circuit based on GD74LS07 is used which provides 6 non-inverted buffers with open-collector outputs. The schematic of one such buffer is shown in Figure-5.1. The typical propagation delay from input to output is 12 ns. Figure 5.1 Schematic of +5 V to +15 V conversion circuit. 5.2 The Error Handling Circuit The error inputs to the chariot are provided to a 4-input CMOS AND gate CD4082BMS shown in Figure-5.2. The supply voltage VDD, +15 V, is referenced to VSS which is 0 V. The propagation delay is 90 ns. Figure 5.2 CD4082BMS D-22

33 5.3 The DC-link Over-voltage and Thermal Over-load Protection Circuit The DC-link over-voltage protection circuit is shown in Figure-5.3. It is based on the comparison of the output of the DC bus voltage measurement transducer, Section , against a voltage reference and subsequent operation of an auxiliary relay R1 that switches a higher current capacity relay R2 mentioned in Section R1 +24V +15V + INPUT 72 k LV 100 LEM +15V k 39 k 6.4 k 5.8 k OP07 +15V 8.2 k 3.9 k +15V OP07 ICL V R2 TS Contactors Drivers R3 Figure 5.3 DC-link over-voltage and thermal over-load protection circuit In case of a fault, the relay R2 disconnects the three-phase power to and from the chariot by disabling all the contactors, blocks the power supply to the drivers and sounds an alarm. It has a latched response to avoid further operation unless the cause of the alarm is determined and dealt with. The thermal switch TS, of the Semiteach and the brake resistor, in Figure-5.3 is a normally closed switch. It is in series with the power supply to the drivers and the coil of relay R3. In an over-temperature condition of 71 C, the thermal contact opens and disconnects the power supply to the drivers and relay R3 which causes an audible alarm. The thermal switch has a hysteresis response and only closes again at around 50 C. The integrated circuit OP07 serves as a voltage comparator and a buffer while ICL7667, which is a power MOSFET driver, converts the TTL level signals to high current outputs at 15 V to drive relay R The Contactor Switching Circuit The contactor switching circuit is used to switch the power contactors and is commanded by the dspace card. It has active low inputs since the power-up default output of I/Os is logic high. This circuit is based on the integrated circuit 74LS04 and the dual power MOSFET driver ICL7667. The LEDs at the output indicate if the relay is energized. This circuit is powered by a separate DC power supply and the schematic is given in Figure-5.4. D-23

34 +12V +5V +24V 3-Phase Input Relay Contactor +5V +12V 1/0 1/0 74LS04 ICL Phase Output Figure 5.4 The contactor switching circuit. 5.5 The Current and Voltage Measurement Circuits The current and voltage measurement circuits are given in Figure-5.5. (a) (b) Figure 5.5 Measurement circuits (a) current (b) voltage. D-24

35 6 The Wiring Diagram The wiring diagram of the chariot is given in Figure-6.1. The 50-pin field termination panel Card 3 provides access to all the 37 pins of the Slave DSP PWM connector of the CLP but access to only the selected 13 pins of the Bit I/O connector. The connections are described in Table-6.1. Please refer to dspace DS1104 Hardware Installation and Configuration guide for more details. The contactor switching relay logic, implemented in one of the chariot, is shown in Figure-6.2. Table 6.1 Field termination panel connection description. Field Termination Slave I/O PWM Panel Connector Digital I/O Connector Terminal No. Pin Signal Pin Signal 1 1 GND 2 2 SCAP1 3 3 SCAP3 4 4 GND 5 5 ST2PWM 6 6 GND 7 7 SPWM1 8 8 SPWM3 9 9 SPWM SPWM SPWM GND GND GND GND SSIMO SCLK VCC(+5V) VCC(+5V) GND SCAP SCAP ST1PWM ST3PWM GND SPWM SPWM SPWM SPWM GND GND GND GND D-25

36 34 34 SSIMO SSTE GND GND Field Termination Slave I/O PWM Panel Connector Digital I/O Connector Terminal No. Pin Signal Pin Signal VCC(+5V) VCC(+5V) GND GND I/O I/O I/O I/O I/O I/O I/O I/O I/O 02 NOTE: I/O 16 has been wired as a user-interrupt for error signal output acknowledgement from the Semiteach drivers. Contactors 1 and 2 are operated from I/O 06 and I/O 08 respectively while Contactor 3 is operated from I/O 10. D-26

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38 10 A L N G 1-PHASE INPUT TO THE CHARIOT PHASE PWM PHASE PWM DIGITAL I/O 16 ERROR INPUTS ON/OFF 230 V DC-LINK VOLTAGE 1 SLAVE I/O PWM METER 500 k ERROR INPUTS CARD 5 FANS +15V 0V TORQUE METER LAMBDA +12V 0V PC SUPPLY +5V 0V +12V -15V 0V +15V +24V +5V ON/OFF 230 V CIRCUIT BREAKER 25 A METER LAMPS DC-LINK VOLTAGE DIGITAL I/O 50 LAMPS CIRCUIT BREAKER 25 A 3-PHASE PWM OUTPUTS PHASE 10 PWM 29 OUTPUTS 11 CARD V 0V +15V CARD CARD 2 BUZZER 0V +24V +15V 0V R14 +5V +24V +15V 0V -15V +24V +15V A1 R11 R31 R22 A2 0V R12 R34 +15V -15V LV k +15V PROTECTION RELAY R21 R2 0V N R S T DC-LINK PROTECTION THERMAL SWITCH DRIVER SUPPLY 3-PHASE INPUT TO THE CHARIOT 2 4 ENCODER COUPLE +12V 0V CARD 4 +5V 0V +12V CON1 FROM TORQUE METER 330R 300W CON3 CON2 R S T R S T R S T 3-PHASE OUTPUT TO THE SEMITEACH 3-PHASE INPUT FROM THE SEMITEACH 3-PHASE OUTPUT TO THE MACHINE M 3 Figure 6.1 The wiring diagram of the chariot. D-28

39 Figure 6.2 Relay logic for contactor switching. D-29

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