Harmony NG Control Boards

• Keypad Options:
• MotherBoard/ISA Bus • Additional communication boards
• CPU
• Digital to Analog
• System Interface
• Communications
• Fiber Optic
• Modulator
• Signal Conditioning
• Cell Control
• Gate Drive
Next Gen Control Hardware
Chassis with covers
Next Gen Control Hardware
Chassis with covers
 Fiber Optic Digital Modulator
Cable to Medium
Voltage Bypass
Communications Chassis less covers
System Interface
Fiber Optic Interface

Analog to Digital

CPU
Fiber Optic Cables to Cells

Power Supply
Connection

ISA Rack
 Modulator Bd Communications CPU Bd
Bd

FIBER Optic Bd
System Interface Bd Analog to Digital Bd
 Pwr
only 12 BiDir Fiber Optic Channels
Fiber Optic Board (2nd) Cells
Channels 13-24 13-24

60 Pin Ribbon Cable

Modulator Board
Bypass Fiber Optic MV
Bus Intfc. Bypass F.O. Out Bypass
Sys. Interupt, IOC, Board
Pwr & HE Fail

60 Pin Ribbon Cable

Pwr
only 12 BiDir Fiber Optic Channels
Fiber Optic Board (1st) Cells
Channels 1-12 1-12
SOP download cable & Debug port

10 Pin Ribbon Cable

Input
Communications Board
&
RS232 Output
Bus Intfc. UCS UCS Voltage
RS485 37 Pin Cable
#1 #2 &
Modbus Signal
Current
Conditioning
ISA Feedback,
Board
Pwr HE
BUS (Isolation)
Burden
only
System Interface Board resistors
& Pwr,
CR3,
50 Pin Ribbon Cable Hall Effect future
Pwr Sply +15Vdc

IP Carrier Board (Analog I/O) Hall Effect

IP C Pwr Sply -15Vdc
Bus Intfc. IP B IP A
Analog
In

WAG O Pwr
Single Bo ard Computer Fieldbus I/O Sply 120 Vac
Module 24Vdc
CompactFlash Disk (I/O System)
Comm 1 RS232 (WAGO)
Comm 2 RS485 (Keypad)
Bus Intfc.
Future Ethernet
Video Out (for Debug only)
Keypad
Keybrd In (for Debug only)
Paralell port (for Debug only)

+5, -12 Vdc & Gnd only Power Supply

Backplane
+5, +12, -12, -5 Vdc
+5, +12, -12, -5 Vdc; Gnd & Sense Wires W/Pwr Fail sig.

Card Cage
 Next Gen Control Hardware
CPU Board front view

Chipset:
Intel ® VGA
430 TX

Ethernet

User I/O

Intel
Pentium ®
MMX CPU
266 MHz Keyboard
 Next Gen Control Hardware
CPU Board rear view
CompactFlash™
Module
64MB

SDRAM
Module 64MB
 CPU Intel Pentium 266 MHz
 System memory:Two 144-pin SODIMM RAM
sockets support SDRAM memory module from 8 MB
to 256 MB
 Operating temperature: 0 ~ 70° C (32 ~ 166° F)
 CompactFlash™ disks IDE file system for storing:
 Drive Control software, System program, Configurations
files (menu text, min/max values, and defaults)
 Flash Card can be removed and installed into a PCMCIA
adapter card and then read from a PC. Drive must be off
when pulling the flash.
 Connections
 Serial port: one RS232 - Connects to User Wago I/O
 VGA Monitor port: - Connects to a monitor for debugging
 Keyboard port - Connects to a keyboard to change
monitoring menu
 Built-in Ethernet Controller: 10/100 Mbps - Connects to
Laptop in combination with Tool Suite package
Next Gen Control Connections
CPU Board
WAGO
Coupler

Monitor DI, DO, AI, AO

Laptop
Lpptop
Keyboard

Keypad

Ribbon
Cable

VGA Adaptor Bd

Ethernet for
ToolSuite

CPU Board

CPU Board
 Next Gen Control Hardware
System
Interface
Board
Signal Conditioning board
Inhibit Relays
Connector 120V and
24VDC

Isolation CT’s
for Input
currents and
Output filter
Discrete currents
Wiring
Terminal
Block
 Next Gen Control Hardware
Signal Conditioning board
 DIN rail mountable
 120VAC or 24VDC Inhibit relay inputs
 Feedbacks
 Secondary CT’s for Input currents and Output currents
CT’s
 Hall Effects which give a Current feedback scaled with
burden resistors.
 Input Voltage and Output Voltage
 Terminal block for sensor and burden resistors connections
Signal Conditioning Board

System Interface
Board
Analog
Test Points on this Input/Output
Board Board

P4

Signal Conditioning Board

Input V & I feedbacks Inhibit

Output V & I feedbacks FB
 Next Gen Control Hardware
System Interface board
Interface to
Analog I/O
Board
Interface to
Signal
Conditioning
Board

Interface to
Digital
Modulator
Board
 Next Gen Control Hardware
System Interface board
 Provides all analog signal conditioning of sensor measurements
 Receives signals from the Analog Input/Output Board
 Drive input voltages (line)
 Drive input currents (line)
 Integrated and actual motor voltages
 Motor currents and output filter currents
 IOC current level output
 Control Power Supply Failure detection Circuitry
 Hall Effect Power Supply Failure detection circuitry
 No ISA data bus interface only power
 All Analog components
 Next Gen Control Hardware
System Interface board
 Test points for all voltages and currents
 TP4, TP9, TP14, TP18, TP20, 24 - Agnd - Ground connections
 TP1, TP2, TP3 - VIA, VIB, VIC - Voltage input
 TP5, TP6, TP7 - VMA, VMB, VMC - Motor Voltage
 TP8 - VON - Not used at this time
 TP10 - AI - Not used at this time
 TP12, TP13, IIB, IIC - Input Current for B & C
 TP15, TP16, TP17 - IFA, IFB, IFC - Output I filter - typically not used
 TP19 - IOC - Instantaneous Over Current Feedback
 TP21, TP22, TP23 - IMA, IMB, IMC - Average Motor I Feedback
 Board Interface

System Interface
Board CPU
Analog
Test Points on this Input/Output
Board Board

P4 Modulator Board
Signal Conditioning Board

Input V & I feedbacks Inhibit

Output V & I feedbacks FB
 Next Gen Control Hardware
ISA Carrier
Board
Analog I/O board

ADC Module
 Next Gen Control Hardware
Analog I/O board
 Receives signals from Signal conditioning board
 A/D: 12 bit inputs for signal conversion
 Input Voltage
 Input Current
 Output Voltage
 Output Current
 Output Current Filter - Only with output filter CT’s
option.
 Additional Circuitry
 Control Power Supply Fail feed through
 Hall Effect Power Supply Fail feed through
 Inhibit Feeds through this board
 Next Gen Control Hardware
Analog I/O board
 Options
 ISA bus carrier board can accommodate up to 3
Industry Pack modules.
 Module #1 DAC:6 D/A channels used for
monitoring system parameters (menu selectable) Is
not being utilized
 Module #2:not populated
 Module #3 ADC:40 ADC channels, 12 bit, 10Sec
conversion time, 5 signals sample
simultaneously.Measures input/output currents.
Measures input/output voltages
 Next Gen Control Hardware Medium
Digital Modulator Board Voltage
Bypass Board
Modulator Bypass Interface
FPGA’s Controller (Fiber Optic)
FPGA

Fiber Optic ISA Bus System Interface Board

Board Connector (Timing, IOC,
Interface’s Power Supply fail signals)
 Modulator Connections
F
O
T
B

CPU

F
O
Modulator T
Board B

Inhibit Input
Bypass Board

System Interface
 Next Gen Control Hardware
Digital Modulator Board
• Controls timing for Control and Power Electronics
– Timing for the controls is controlled from the modulator

• Sampling Frequency -> 3KHz-6KHz timing engine

– Generates IGBT PWM Firing Information

– Synchronized, Bi-Directional s 60 pins flat cable interface to Fiber
Optic Boards

 Can support up to 24 cells

 Each FPGA can control 6 cells
• digital modulatorsPC-ISA Bus interface to CPU
 Next Gen Control Hardware
Digital Modulator Board Overview
 Built-in bypass controller
– Interface to Mechanical Cell Bypass system ( Board)

 On board battery backed RAM (60KB). Used for storing historical

logger, fault logger, KWHRS, and other variables that need to be
maintained after power loss. @ this time, in future in flash

 Contains the power supply fail and IOC detection logic

• Real-Time 3 phase reference angle interface
• Complete status provided
– modulator/protection input status
– power cell status
– bypass system status
 Fiber Optic Link Board

• There are 11 bits of data in each serial

string.
• 2 bits are start bits.
• 8 bits are data bits.
• 1 bit is a stop bit.
• There are 4 transmit and 4 receive
modes.
 Fiber Optic Link Data
Transmit Data
Bit mode 00 mode 01 mode 10 mode 11
Q0 0 1 0 1
Q1 0 0 1 1
Q2 /enable Reset Reset TstEn1
Q3 left pole not used not used test a
Q4 right pole “ “ test b
Q5 not used “ “ /TstEn2
Q6 not used “ “ not used
Q7 “ “ “ “
 Master Link Data
Receive Data
Bit mode 00 mode 01 mode 10 mode 11
Q0 Link faults ------------------------------------------------
Q1 0 1 0 1
Q2 0 0 1 1
Q3 fault out of sat /Q1OOS VQ1<50
Q4 Vavailable overvoltage /Q2OOS VQ2<50
Q5 Overtemp NA /Q3OOS VQ3<50
Q6 Pwr Okay Cap share /Q4OOS VQ4<50
Q7 not used Comm fault Blown fuse
 Next Gen Control Hardware
Digital Modulator Modulation
• Adjustable Carrier Frequency -> 200-1200 Hz Triangle
waveform

• CPU fast loop updates voltage and step change to Interpolator

on Modulator

• IGBT LP/RP Firing signals generated by PLD

every 9-11 sec

• Configuration defined by CPU based on number

of Power cells and desired carrier frequency
 Next Gen Control Hardware
Digital Modulator Power Cell Interface
• 24 Dedicated bi-directional serial ports to and from each cell
– Synchronized serial communications
• Communicating to and from each cell
– Up Message to cells:
• Output Enable, RP/LP firing data, Temperature circuit sync
– Down Message from Cell:
• Faults, DC Bus Low, Modulated temperature feedback
• Diagnostic Communication
– Processor selects diagnostic communication mode to
independently test and monitor each power cell
 Next Gen Control Hardware
Digital Modulator Power Cell Diagnostic
Messages
• CPU can interrogate cell status
• Modulated Temperature feedback with 600 Hz carrier
– Overtemperature Warning: > 20% to < 80% duty cycle
– Overtemperature Fault:  80% duty cycle
• Control Power Fault
• DC Bus Status
– High Fault (> 125% rated)
– Low Fault (< 55% rated)
– Low Warning (< 65% rated)
• OOS (any device)
• Capacitor Sharing
• Communication Error
 Next Gen Control Hardware
Digital Modulator System protection
• Modulator board inhibits Output Enable signal to all power cells immediately
upon detection of any of the following conditions:
• Power Cell Fault (any cell)
• Inhibit Signal (CR3)
• IOC (Instantaneous Over Current)
• Mechanical Bypass Fault
• CPU Watchdog Fault
– 3 consecutive unacknowledged system interrupts
• CPU/Hall Effect Power Loss
• Each of these signal conditions are latched to ensure CPU can properly
determine fault conditions
 Next Gen Control Hardware
Digital Modulator System Status
• Bypass System status
– Bypass problems with no active bypass contactors are classified as
warnings

– Bypass problems when any contactor is engaged is a System Fault

 Next Gen Control Hardware
Fiber Optic Interface board
 Single board provides fiber optic interfaces for up to 12 cells

 > 12 cells requires 2nd FOIB

 Input/Output signals are buffered

 Differential signals

 Boards can be remotely located

 Power up protection to prevent false light pulses until system is ready

 Fiber Output enable signal provided via Modulator board

 Next Gen Control Hardware
Modbus
Coupler Power Supply Input User I/O Modules

End
Terminator

Digital Inputs

Digital Outputs Analog Inputs

Next Gen Control Connections
CPU Board
WAGO
Coupler

Monitor DI, DO, AI, AO

Laptop
Lpptop
Keyboard

Keypad

Ribbon
Cable

VGA Adaptor Bd

Ethernet for
ToolSuite

CPU Board

CPU Board
 Next Gen Control Hardware
User I/O Modules
• What is required
– Modbus Coupler
– Power supply Modules feed the other modules
• Various options available, Standards listed.
• 24 volts Modbus Coupler
– DI, DO, AO, AI
• 120 volt coupler required to interface if modules to Digital
inputs
– DI, RO
• Must use the correct module with the correct power supply
source
• Can use combination of module supplies
• Must use a separator between one supply and another supply
• Must use an End Module at the end of the system
 Next Gen Control Hardware
User I/O Modules
• Color Codes of Modules
• Red -Digital Output Module, Relay Output
• Yellow - Digital Input Module
• Green - Analog Input Module
• Blue - Analog Output Module
• Clear - Supplies and special function modules
 Next Gen Control Hardware
User I/O Modules
 All user I/O supported via Wago® I/O system.
 Wago® system interfaces to the CPU via a high speed
serial connection Modbus 115Kbaud
 System supports:
 Analog I/O
 Digital I/O
 Relay I/O
 I/O modules easily added to system by simply
plugging them into the DIN rail.
 Modbus
Wago Layout
Coupler Seperation Power
Module Supply
120 vac

Power
Supply
24 vdc Seperation/End
Module

RO -120
AO - 24 2 inputs
2 outputs

AO - 24 DI - 24 DI -120
2 outputs 4 inputs 2 inputs

AI - 24 AI - 24 DI - 120
2 inputs 2 inputs 2 inputs
 Cell Control Board
• Communicates to the devices and the
controls through the fiber optic link
board
• Communications are optically coupled
to maintain 5 kV class rating
(8.7 kV class in high voltage cells).
• Switch mode power supply is
operational
between 250 and 510 VAC. Each cell
is self-powered as to achieve 100%
isolation from control cards.
 Cell Control Board Faults
• If a fault is detected, it is fed back to the
controls via the cell control board.
– Communications fault - the controls could not
establish communications with the cell control
board.
– VDC Undervoltage - detected from bus caps.
 Cell Control Board Faults

• Blocking failure - IGBT

• Switching failure - IGBT
• Device out of saturation failure - an IGBT failed
to fully conduct when turned on.
• Q1 through Q4 - individual identification of the
device.
• Cap share fault - the voltage difference between
the + or - cap banks is greater than 50 VDC.
 Cell Control Board Faults
• Overvoltage - the bus voltage has exceeded
800 VDC on the low voltage cells, and
1200 on the high voltage cells.
• AC fuse blown - the cell control board detects
that the cell input power fuse has blown.
• Cell overtemp - indication that a cell is running above design
temperature.
• Control power fault - one or more of the local supplies are out of
specification (+24, +15, +5, -15, VDC).
• Cap Share - Voltage across capacitors is unbalanced
• Link fault - communications has been lost between FOLB and CCB.
 Gate Driver Board

• Receives control signals from the

cell control board to provide firing
pulses to the IGBTs.
• Out of Saturation is detected and fed
back to the cell control board.