USER MANUAL. QNET Energy Conversion Board for NI ELVIS with NI ELVIS RIO Control Module. Set Up and Configuration CAPTIVATE. MOTIVATE. GRADUATE.

Transcription

1 USER MANUAL QNET Energy Conversion Board for NI ELVIS with NI ELVIS RIO Control Module Set Up and Configuration CAPTIVATE. MOTIVATE. GRADUATE.

2 2016 Quanser Inc., All rights reserved. Quanser Inc. 119 Spy Court Markham, Ontario L3R 5H6, Canada Phone: Fax: For more information on the solutions Quanser Inc. offers, please visit the web site at: This document and the software described in it are provided subject to a license agreement. Neither the software nor this document may be used or copied except as specified under the terms of that license agreement. All rights are reserved and no part may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Quanser Inc. Japan VCCI Notice This is a Class A product based on the standard of the Voluntary Control Council for Interference (VCCI). If this equipment is used in a domestic environment, radio interference may occur, in which case the user may be required to take corrective actions. Waste Electrical and Electronic Equipment (WEEE) This symbol indicates that waste products must be disposed of separately from municipal household waste, according to Directive 2002/96/EC of the European Parliament and the Council on waste electrical and electronic equipment (WEEE). All products at the end of their life cycle must be sent to a WEEE collection and recycling center. Proper WEEE disposal reduces the environmental impact and the risk to human health due to potentially hazardous substances used in such equipment. Your cooperation in proper WEEE disposal will contribute to the effective usage of natural resources. For information about the available collection and recycling scheme in a particular country, go to ni.com/citizenship/weee. This product meets the essential requirements of applicable European Directives as follows: 2006/95/EC; Low-Voltage Directive (safety) 2004/108/EC; Electromagnetic Compatibility Directive (EMC) Caution: This is a Class A product. This product may cause radio interference in a domestic environment, in which case the user may be required to take adequate measures. QNET ENERGY CONVERSION - User Manual 2

3 Contents Safety Information 4 1 Introduction 5 2 System Hardware System Schematic Modes of operation Hardware Components Interfaces Supervisor Environmental 19 3 QNET Energy Conversion Setup 20 4 Troubleshooting You are getting VI Missing messages The AC generator motors are not responding 22 QNET ENERGY CONVERSION - User Manual v 1.0

4 Safety Information The following symbols and definitions are interchangeably used throughout the User Manual: Symbol Description Caution: consult documentation for additional information Direct Current On (Power) [on NI ELVIS II unit] Off (Power) [on NI ELVIS II unit] Table 0.1: Symbols QNET ENERGY CONVERSION - User Manual 4

5 1 Introduction The Quanser QNET Energy Conversion Board for NI ELVIS with ELVIS RIO Control Module is pictured in Figure 1.1. It is a reconfigurable system designed to teach the fundamentals of energy conversion across the electrical and mechanical domains. The modular system supports a number of different configurations and measurements of key parameters are achievable using the resources on the ELVIS RIO. Example experiments include open and closed loop SMPS (switched-mode power supply) control, 3-phase power generation, rectification, inverters, and power system integration and applications. The main QNET Energy Conversion features include: Linear power amplifier Mechanically coupled motor assembly (3-phase generator) Rectifier SMPS with configurable buck or boost topology Inverter and transformer Linear current load Figure 1.1: Quanser QNET Energy Conversion Board for NI ELVIS with ELVIS RIO Control Module Caution This equipment is designed to be used for educational and research purposes and is not intended for use by the general public. The user is responsible to ensure that the equipment will be used by technically qualified personnel only. QNET ENERGY CONVERSION - User Manual v 1.0

6 2 System Hardware 2.1 System Schematic The QNET Energy Conversion provides an integrated communication interface with the NI ELVIS RIO Control Module. The interaction between the different system components on the QNET Energy Conversion is illustrated in Figure 2.1. The NI ELVIS RIO Control Module is interfaced to the PC or laptop via USB link. The NI ELVIS RIO Control Module provides command signals to the QNET Energy Conversion components. An on board supervisor is used to safeguard the hardware and to set the mode of operation. Figure 2.1: Interaction between QNET Energy Conversion components QNET ENERGY CONVERSION - User Manual 6

7 2.2 Modes of operation The QNET Energy Conversion may be configured to represent the modes that are outlined below. This is accomplished over a communications interface between the ELVIS RIO and the supervisor. After selecting a mode, the supervisor will automatically connect the appropriate modules on the board Phase Power This mode includes the linear amplifier, as well as the 3-phase AC generator components (no rectifier). Figure 2.2: Three phase power configuration Boost Converter This mode includes the linear amplifier, switched mode power supply (in boost) and the variable load components. Figure 2.3: Boost converter configuration Buck Converter This mode includes the linear amplifier, switched mode power supply (in buck) and the variable load components. Figure 2.4: Buck converter configuration QNET ENERGY CONVERSION - User Manual v 1.0

8 2.2.4 Inverter This mode includes the linear amplifier and the single phase inverter components. Figure 2.5: Inverter configuration Rectifier This mode includes the linear amplifier, 3-phase AC generator and rectifier components. Figure 2.6: Rectifier configuration Generator-to-Boost This mode includes the linear amplifier, 3-phase AC generator, rectifier, switched mode power supply (in boost) and variable load components. Figure 2.7: Generator to Boost configuration QNET ENERGY CONVERSION - User Manual 8

9 2.2.7 Generator-to-Boost-to-Inverter This mode includes the linear amplifier, 3-phase AC generator, rectifier, switched mode power supply (in boost) and single phase inverter components. Figure 2.8: Generator to boost to inverter configuration Generator-to-Buck This mode includes the linear amplifier, 3-phase AC generator, rectifier, switched mode power supply (in buck) and variable load components. Figure 2.9: Generator to buck configuration QNET ENERGY CONVERSION - User Manual v 1.0

10 2.2.9 Buck-to-Inverter This mode includes the linear amplifier, switched mode power supply (in buck) and single phase inverter components. Figure 2.10: Buck to inverter configuration Boost-to-Inverter This mode includes the linear amplifier, switched mode power supply (in boost) and single phase inverter components. Figure 2.11: Boost to inverter configuration QNET ENERGY CONVERSION - User Manual 10

11 2.3 Hardware Components The main components comprising the QNET Energy Conversion board are labelled in Figure 2.12, and are listed in Table 2.1. ID# Description 1 NI ELVIS RIO Control Module 2 USB connector port to PC 3 24V 2A power connector 4 Status LEDs for the supervisor, 24V-2A supply and system enable 5 Brushed DC motor used to drive AC generator 6 Brushless DC motor used as AC generator 7 Single phase inverter capacitors 8 Isolated step down power transformer Table 2.1: QNET Energy Conversion component nomenclature Figure 2.12: General layout of QNET Energy Conversion Caution Exposed moving parts near the AC-generator assemble. QNET ENERGY CONVERSION - User Manual v 1.0

12 Caution Components can get hot near the upper right corner of the board Linear Amplifier The QNET Energy Conversion uses a power op amp to supply either the DC motor or the SMPS, depending on the mode of operation. It has a voltage compliance of 0 to 20V phase AC Generator and Rectifier The QNET Energy Conversion uses the Anaheim Automation BLWR11D-24V brushless DC Motor as a 3-phase AC Generator. The specification sheet can be found at: Anaheim Automation BLWR11D-24V The generator is driven using a Micro-drives M2232U-24-GS-050 brushed DC Motor. The specification sheet can be found at: Micro-drives M2232U-24-GS-050. The rectifier can be dynamically configured for 3-phase or single phase operation with or without bulk capacitors of 1µF and 10µF Switched Mode Power Supply The switched mode power supply can be configured as a buck or a boost. A maximum switching frequency of 25MHz is enforced for both topologies. The boost configuration is limited to a duty cycle range of 0 to 50 % and an On-time of 150 µs. The maximum boost output voltage is 30 V Variable Load The variable load on the QNET Energy Conversion board is a current sink. It is capable of sinking 250 ma or more, given a source above 7V with a low output impedance. Attempting to command loads in excess of 250 ma will cause the load to saturate near 300 ma Phase Inverter This includes an isolated step down power transformer to a resistor load. The maximum input voltage is 30 V, which is the maximum output from the switch mode power supply. The inverter needs a minimum voltage of 10.5 V to operate. Once enabled, a minimum input voltage of 8.5 V must be maintained. QNET ENERGY CONVERSION - User Manual 12

13 2.4 Interfaces Control SPI Interface This SPI interface operates with 16-bit data at 5 MHz or lower, with CPOL = 0 (clock polarity) and CPHA = 0 (clock phase). Data is transmitted MSb (most significant bit) first. The NI ELVIS RIO Control Module acts as a master. This interface is used to set the board mode, clear the watchdog and set the values of user controlled switches. The pin definitions are defined in Table 2.2. Def CSn CLK MOSI MISO Pin MXP_A_DIO4 MXP_A_DIO5 MXP_A_DIO7 MXP_A_DIO6 Table 2.2: Control SPI Interface pin definitions The data input contains the raw supervisor code, as described above, as well as a board ready bit as shown in Figure 2.13a. The board ready bit is set after the board is ready to be used after changing the mode from reset. The board ready bit is cleared after the board is put into reset or if it enters the supervisor state. (a) Input Data format (b) Output Data format Figure 2.13: Control SPI 16-bit data configuration The data output is split into two bytes. The upper byte is a preamble and the interpretation of the lower byte depends on the value in the preamble. The format is as shown in Figure 2.13b. The preamble and lower byte behavior are as described in Table 2.3. QNET ENERGY CONVERSION - User Manual v 1.0

14 Preamble Lower Byte Description 0x9A 0xAA Clear the watchdog 0x00 Set the board mode to reset 0x01 Set the board mode to 3 phase inverter 0x02 Set the board mode to boost converter 0x03 Set the board mode to buck converter 0x04 Set the board mode to generator-to-boost 0xA0 0x05 Set the board mode to inverter 0x06 Set the board mode to rectifier 0x07 Set the board mode to generator-to-boost-to-inverter 0x08 Set the board mode to generator-to-buck 0x09 Set the board mode to buck-to-inverter 0x0A Set the board mode to boost-to-inverter 0bxxxxxxx1 Connect the transformer load switch 0bxxxxxxx0 Disconnect the transformer load switch 0bxxxxxx1x Connect the 10 µf rectifier bulk capacitor 0xA1 0bxxxxxx0x Disconnect the 10 µf rectifier bulk capacitor 0bxxxxx1xx Connect the 1 µf rectifier bulk capacitor 0bxxxxx0xx Disconnect the 1 µf rectifier bulk capacitor 0bxxxx1xxx Connect the BLDC num_phases switch 0bxxxx0xxx Disconnect the BLDC num_phases switch Table 2.3: Preamble and lower byte behavior QNET ENERGY CONVERSION - User Manual 14

15 2.4.2 Inverter SPI Interface This interface is reserved exclusively for commanding the inverter voltage. The pin definitions are as described in Table 2.4. Def CSn CLK MOSI Pin MXP_B_DIO6 MXP_B_DIO5 MXP_B_DIO7 Table 2.4: Inverter SPI Interface pin definitions This interface only contains data output. The inverter voltage command is signed and corresponds to the percentage of the amplitude being commanded to the inverter driver. For example commands the maximum negative voltage and 1023 commands the maximum positive voltage. This uses the 2 s complement via 11 bits, as shown in Figure 2.14 Figure 2.14: Inverter SPI 16-bit data configuration QNET ENERGY CONVERSION - User Manual v 1.0

16 2.4.3 I/O channels The outputs are defined in Table 2.5. The inputs are defined in Table 2.6. Name Source Min Max Conversion Source Voltage MXP_A_A01 0 V 22 V DAC_raw = SourceV oltage 0.24 ADC_LSB_weight Source Voltage MXP_B_A01 0 A 0.3 A DAC_raw = SourceCurrent 18 ADC_LSB_weight SMPS PWM MXP_A_DIO10 0% 100% N/A Inverter Command Transformer Load Switch BLDC num_phases Switch 10 µf Rectifier bulk capacitor 1 µf Rectifier bulk capacitor Inverter SPI Interface Control SPI Interface Control SPI Interface Control SPI Interface Control SPI Interface -100% 100% [ ] mapped to [-1 1] ON OFF N/A ON OFF N/A ON OFF N/A ON OFF N/A MXP_A_ADC_MUX_A MXP_B_DIO N/A MXP_A_ADC_MUX_B MXP_B_DIO N/A MXP_B_ADC_MUX_A MXP_B_DIO N/A MXP_B_ADC_MUX_B MXP_B_DIO N/A Table 2.5: Output pins defined in the custom FPGA code QNET ENERGY CONVERSION - User Manual 16

17 Name Source Mux Value Conversion Hall A Sensor MXP_A_DIO0 N/A Hall B Sensor MXP_A_DIO1 N/A Hall C Sensor MXP_A_DIO2 N/A Linear Sink Temperature MXP_B_AI0 00 = ADC_raw ADC_LSB_weight BLDC B2C Voltage MXP_A_AI2 00 = (ADC_raw 2048) 5 ADC_LSB_weight BLDC Phase B voltage MXP_A_AI1 00 = (ADC_raw 2048) 5 ADC_LSB_weight Source Current MXP_A_AI3 00 = ADC_raw ADC_LSB_weight Rectifier Diode Current MXP_A_AI0 00 = ADC_raw ADC_LSB_weight SMPS Output Voltage MXP_B_AI2 00 = ADC_raw 11 ADC_LSB_weight BLDC Phase A Voltage MXP_A_AI1 01 = (ADC_raw 2048) 5 ADC_LSB_weight BLDC Phase A Current MXP_A_AI2 01 = (ADC_raw 2048) ADC_LSB_weight BLDC Phase C Current MXP_A_AI3 01 = (ADC_raw 2048) ADC_LSB_weight SMPS Output Current MXP_B_AI3 01 = ADC_raw ADC_LSB_weight Linear Sink Current MXP_B_AI0 01 = ADC_raw 18 ADC_LSB_weight BLDC A2B Voltage MXP_A_AI1 10 = (ADC_raw 2048) 5 ADC_LSB_weight BLDC Phase C Voltage MXP_A_AI2 10 = (ADC_raw 2048) 5 ADC_LSB_weight BLDC Phase B Current MXP_A_AI3 10 = (ADC_raw 2048) ADC_LSB_weight Transformer Output Voltage MXP_B_AI0 10 = (ADC_raw 2048) 10 ADC_LSB_weight SMPS Input Voltage MXP_B_AI3 10 = ADC_raw 11 ADC_LSB_weight Source Temperature MXP_A_AI0 11 = ADC_raw ADC_LSB_weight BLDC C2A Voltage MXP_A_AI2 11 = (ADC_raw 2048) 5 ADC_LSB_weight Transformer Input Voltage MXP_B_AI0 11 = (ADC_raw 2048) 10 ADC_LSB_weight Source Voltage MXP_A_AI3 11 = ADC_raw 7.49 ADC_LSB_weight SMPS Input Current MXP_B_AI3 11 = ADC_raw ADC_LSB_weight SMPS Inductor Current MXP_B_AI3 00 = ADC_raw ADC_LSB_weight Table 2.6: Input pins defined in the custom FPGA code QNET ENERGY CONVERSION - User Manual v 1.0

18 2.5 Supervisor On power-up, the QNET Energy Conversion goes into a reset mode. In this mode, all outputs from the NI ELVIS RIO Control Module are disabled, the external 24 V supply is electronically disconnected from the circuit and all switches go to safe values. The SPI interface can be used to change the mode from reset to one of the modes identified in subsection 2.2. Depending on the mode that is selected, some of the supervisor conditions in Table 2.7 will be enforced. The purpose of this is to prevent the user from accidentally damaging the hardware. If any of the supervisor conditions are violated, the QNET Energy Conversion will go into a supervisor state. The supervisor state is similar to reset mode in that the external 24 V supply is electronically disconnected, all outputs are disabled and switches are set to safe states. The only way to get the QNET Energy Conversion out of the supervisor state is to put the device back into reset mode, or cycle the power. Error Name Always Description/Cause Code Active? 0x0000 None Yes No supervisor violations detected. 0x0001 Power Good Yes External 24 V power supply brownout or not detected at all. 0x0002 Watchdog Expired Yes A watchdog must be cleared every 25 ms (cleared over SPI interface). 0x0004 Boost over-voltage Yes The voltage at the output of the SMPS exceeds 30 V. 0x0008 Boost ON-time limit No Boost switch was conducting for more than 150 µs. 0x0010 Boost max duty cycle No PWM Duty Cycle exceeded 50 % for boost switch. 0x0020 Inverter No The inverter needs to be supplied with a minimum voltage under-voltage in order to operate. It will be enabled when it s supply voltage crosses around 10.5 V. After it has been enabled, this supervisor condition is violated if the inverter supply voltage ever dips below around 8.5 V. 0x0040 DC Motor Stall No If the DC motor is driven with more than 14 V, the Hall sensors will be monitored by the supervisor to determine whether the motor is stalled. 0x0080 Buck under-voltage No The buck converter needs to be supplied with a minimum voltage in order to operate. It will be enabled when it s supply voltage crosses around 6.5 V. After it has been enabled, this supervisor condition is violated if the buck supply voltage ever dips below around 5.5 V. 0x0100 SMPS maximum No SMPS PWM frequency exceeds 25 khz. frequency 0x0200 Source Yes Linear Amplifier temperature sensor exceeds around 45 C. over-temperature 0x0400 Sink over-temperature Yes Variable Load temperature sensor exceeds around 70 C. Table 2.7: QNET Energy Conversion supervisor conditions QNET ENERGY CONVERSION - User Manual 18

19 2.6 Environmental The QNET Energy Conversion is designed to function under the following environmental conditions: Standard rating Indoor use only Temperature 5 C to 40 C Altitude up to 2000 m Maximum relative humidity of 80 % up to 31 C decreasing linearly to 50 % relative humidity at 40 C Pollution Degree 2 Mains supply voltage fluctuations up to ±10 % of the nominal voltage Maximum transient overvoltage 2500 V Marked degree of protection to IEC 60529: Ordinary Equipment (IPX0) QNET ENERGY CONVERSION - User Manual v 1.0

20 3 QNET Energy Conversion Setup The procedure to install the QNET Energy Conversion module on the NI ELVIS RIO Control module is detailed in this section. The NI ELVIS II + and NI ELVIS RIO Control module components used in the installation procedure are located and marked by an ID number in Figure 3.1, and described in Table 3.1. Note: The NI ELVIS RIO Control Module and QNET Energy Conversion are compatible with both the NI ELVIS II and NI ELVIS II +. Caution If the equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. Figure 3.1: Components on NI ELVIS II + and NI ELVIS RIO Control module QNET ENERGY CONVERSION - User Manual 20

21 ID# Description 1 NI ELVIS II + 2 NI ELVIS RIO Control Module 3 Power Cable for NI ELVIS II + 4 USB Connection between ELVIS RIO CM and PC 5 Active LED 6 Prototyping Board power switch 7 Prototyping Board power LED 8 NI ELVIS RIO Control Module power LED 9 MXP Connector (male end) Table 3.1: NI ELVIS II + and ELVIS RIO CM components Caution Do NOT make the following connections while power is supplied to the hardware! Caution The unit is provided with a grounded cord to be used with a properly grounded outlet only, this is a safety feature, do not disable it. Follow these instructions to setup a QNET Energy Conversion board on an NI ELVIS II + : 1. Position the handle of the QNET Energy Conversion over the bracket at the front of the NI ELVIS II + to ensure proper mechanical support. Slide the female MXP connector of the QNET Energy Conversion module into the male MXP connector on the NI ELVIS RIO Control Module. Make sure it is connected properly. 2. Connect the USB cable from the NI ELVIS RIO Control Module to the PC. Note that a USB connection to the NI ELVIS II + is not required. 3. Connect the NI ELVIS II + power cable. 4. Connect the supplied QNET power supply to the 24V power connector for motors on the QNET Energy Conversion, as labeled in Power the NI ELVIS II + by turning ON the System Power Switch on the rear panel, and the Active LED should turn orange in under 2 s. 6. Turn ON the Prototyping Board Power switch, and the Prototyping board power LED as well as the NI ELVIS RIO Control Module power LED should turn green in under 2 s. QNET ENERGY CONVERSION - User Manual v 1.0

22 4 Troubleshooting Most hardware/software errors are reported through the Supervisor. See 2.5 for more details. Please review the following before contacting Quanser s technical support. 1. Verify the connections outlined in Section 3 in this guide. 2. Make sure all cables are firmly connected. 4.1 You are getting 'VI Missing' messages 1. Make sure you installed all the LabVIEW add-ons listed in the Quick-Start Guide. 2. Verify that the correct LabVIEW version is installed (2016, as the VIs are not backward compatible). 4.2 The AC generator motors are not responding 1. Ensure that the 2-pin cable to the brushed DC motor is connected. 2. Ensure that the 8-pin 3-phase AC connector coming out of the AC generator is connected. 3. Ensure that the supervisor isn t reporting any errors and that the 24V power is connected. 4. Ensure that the DC motor - AC generator assembly is freely moving. If problems still persist, obtain support from Quanser by going to and click on the Tech Support link. Fill in the form with all the requested software and hardware information as well as a description of the problem encountered. Also, make sure your address and telephone number are included. Submit the form and a technical support person will contact you. QNET ENERGY CONVERSION - User Manual 22

23 QNET boards to teach introductory controls, mechatronics and physics concepts using NI ELVIS QNET Mechatronic Interfacing Board teaches fundamentals of microcontroller IO and inter-device communication QNET Mechatronic Actuators Board teaches functions of actuators QNET Mechatronic Sensors Board teaches functions of sensors QNET 2.0 DC Motor Control Board teaches fundamentals of DC motor control QNET 2.0 HVAC Board teaches temperature (process) control QNET 2.0 Rotary Pendulum Board teaches classic pendulum control QNET 2.0 VTOL Board teaches basic flight dynamics and control QNET Physics and Dynamics Board teaches fundamental concepts in physics and engineering dynamics QNET Myoelectric Board teaches control using principles of electromyography (EMG) Quanser QNET add-on boards for the NI ELVIS platform teach introductory control topics in undergraduate labs cost-effectively. All QNETs are offered with comprehensive courseware that have been developed to enhance the student learning experience. To request a demonstration or quote, please info@ni.com 2016 Quanser Inc. All rights reserved. LabVIEW is a trademark of National Instruments. INFO@NI.COM INFO@QUANSER.COM