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1. 140 KEE KE MEE I RE e EEN 140 Speed to switch from BLDC to FOC control I 1C0 nnn 141 Speed to switch from FOC to BLDC control IC 141 BON CUNEN CONTO EEE eeqasonenene nesenaes usdeocs Sienecs wohccenwters 141 Maximum current difference 2146 142 Fa e ge EG KA EEE E 142 a oer constant 217E REE EE EN E 143 13 12 1 lq current eontrol nennen nennen nennen nnn nnne nnn nda aanini i sanas nn anra as 143 Contigurationdg current control 2190 sedent rie arik EAE REKATE cn eue a ruat e EAEE 143 can ee Ee ig dE COMMON 20 a4 T mee 144 Time constant Tn lq current control 1213 144 Page 8 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Max output IG current control 2137 E 144 Non linear gain corner current Kp Iq ip 145 Non linear gain Kp slope Iq EAR 145 Non linear gain corner current Tn Iq L nnne nnns 146 Non linear gain Tn slope Iq 2194 rrrrrnnnnnorrennnnnnnvnnnnnnnnnvnevnnnnnennnvnnnnnsnnennnnnnsnnennnnnnsnnennnnnnsnnennnnnusenen 146 13 12 2 ld current contra 146 Configuration Id current control Dip 147 Gain Kp Id current control 21291 147 Time constant Th ld Current Control 2 199 E 147 Max output Id current control EEN EE E 148 Non linear gain corner current Kp Id 219
2. 158 Page 9 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 RS KEE Re e E 158 13 15 1 Set point factor and offset 216E rrrrnnnnrnnrnnnnnnrnrrnnnnnrrvrrnnnnnrrnnrnnnnrrrnnrnnnnrrnnnnnnnnrrnnnnnnsnsnnn 158 NTP EN 159 SEENEN 159 Reference speed filter 2126 rrrrennnnrnrrnnnnnnnnrnvnnnnnnnenevnnnnnnnnevnnnnnsnnennnnnnrnnnnnnnnnsnennnnnnnenennnnnnennennnnnuennen 159 Gain Kp of speed regulator 212 160 Gain Tn or speed regulator 219D usssocs sesuac ient hdd esu sanere need x0 En Aieiaia dana Rede ex UR pns 160 Maximum torque in speed mode 213E rrrrnnnnnnnnnvvnnnnnnnnnrrrvvrnnnrnnnnnernrrennnnnnnnnerssernnnnnnnnnersseennnnnnnnsssnee 160 Minimum Torque speed mode 2 T3F EE 161 omi eO I 161 NPE 20 T XXX 161 Bitrate 20F p 162 COB ID SWING message 100 EE 162 Communication cycle period T006l nnne 163 Gard EG P 163 ENE DN cies tncouquteaeeeasandeantedesance soasnecOeeteensaaatseaeSededeneoee 163 Delay between scope data I2OEbI nennen nennen nnns nnns nnne nnns 164 Sea PN Hr 164 Iq display filter constant 21 EI 164 Id display filter Constant 21901 164 Uq filter constant 2181 e
3. 55 Figure 34 Sin Cos Encoder Offset 57 Figure 35 Encoder angle offset calbratnon nnns 59 Figure 36 Encoder angle offset calibration without test bench 60 Figure 37 PCB Temperature Limiter Darametergs nnne 62 Figure 38 Minimum DC Link Voltage Cutback Limiter Parametere 000nnnnnn0nnnnnnoannnnnnnnnnrsnnnrrrenenna 62 Figure 39 Example for K Factor interpolation nicessarii eaen e aia 65 Figure 40 contreller SISD response ln Une DEE 66 Figure 41 ly controller step response TUNING nennen 67 Figure 42 Induced Voltage Example nnne nnne nnn nnn nnns 70 Figure 43 Field Weakening Tuning nnne nnne nnn nnns nnn nnns 72 Figure 44 Id current step with tuned and enabledN GE 73 Figure 45 Measurement of the iron saturation with O CGontrol 75 Figure 46 Example Measurement of saturation rrnrnnnnnrnrnnnrevrnnnrrvnrnnnnenrnnnnennnnnnrennnnnnennnnnnennnnnnnen 76 Figure 47 Magnetizing inductance eene nennen nnne nennen nnn nnne nnns nn nnns nnns 76 Figure 48 Field Weakening Tuning nennen nnn nnn nnn nnn nnns 79 Page 88 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 13 Appendix B Parameter Description Parameters for QUASAR Version V1 03 0 13 1 Inverter SKAI inverter specific parameters 13 1 1 Type and version
4. c 165 Be bt ee eg EE 165 131602 TPM 165 Transmission type 1600 2 eebe deed gegieeer ee ole otegCEeh eEgen gedoen 166 inhib Ume 1000 3 WE 166 19169 PRO NO 166 Transmission EA NE 167 ENO TAS OOI EEE EEE 167 19164 TXPDO 3 1909 E 167 Transmission E EE 168 eine PD BO EEE EE EEE EEE E 168 19055 PORN 168 Transmission Ate CARE E 169 Inhibit Ume O0 EE 169 CS Ka Ee 169 zelo EEE E E EE 170 EPSON Y 202 EE EET 170 Page 10 of170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Change management Version Page Section Description New version 16 11 2011 Remarks added pictures and tables replaced 15 02 2012 Applied new template 15 03 2012 Merged content of different documents 31 07 2012 Adapted for new parameter tree ACIM field weakening updated 11 09 2012 ACIM control diagram updated Brushless DC Motor removed Table 1 Change management Release Version Description Date Name 2 0 Release for QUASAR V1 03 1 12 09 2012 CDA Table 2 Release Page 11 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 1 Disclaimer SKAltek reserves the right to make changes herein without further n
5. V Figure 13 Field weakening IPM To configure field weakening behavior see the parameter group Field weakening on page 150 3 7 4 2 For ACIM For ACIM motors the induced voltage is not caused by the permanent magnets but by the magnetizing current which is the d axis current generated by the MC Therefore field weakening is done by reducing d axis current In the field weakening area the output voltage reaches its maximal amplitude at 0 97p u This value is defined in Udq absolute vector maximum length 215F Reduction of Id will be done when the filtered Udq voltage exceeds the value of parameter Voltage limit 1 2495 Greater reduction is done when Voltage limit 2 2496 has been exceeded Above the Voltage limit 3 2497 also the q axis current will be reduced Page 28 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar Version 2 0 Date modified 14 09 2012 Uq ref limited ACIM1 A 20 213 20 Torque ref M1 J 4 2 jj id ACmMi J sj d i Apeak V Udref ed GE E ER Udq ref limited length S 100 0 Sr p u lv Iq ACIM 3 L Udq ref length filtered ACIM1 3 a Ak xI re m 0 OI ep Id ref limited ACIM d le i E EE Figure 14 Field weake
6. Applied immediately Sud O O OOOO me Iq filter constant 217D Name Iq filter constant 217D Description Filter constant for acutal lq filtering Applied at start up reset needed om s H Page 142 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Id filter constant 217E Name Id filter constant 217E Description Filter constant for actual ld filtering n Applied at start up reset needed om NN AMI EE ii See 13 12 1 Iq current control Contains parameters for q axis current control Configuration Iq current control 2190 Name Configuration T current control 290 Description Defines options for the q axis current controller 0000 0001 enable non linear gain Applied at start up reset needed Unit EE LOL OG NNNM Wage IL Page 143 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Gain Kp Iq current control 2134 Name Gain Kp Iq current control 2134 Description Gain Kp of q axis current regulator Applied at start up reset needed Unit 5 LL NM Default value 0 0012 Time constant Tn Iq current control 2135 Name Time constant Tn Iq current control
7. Page 155 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek KFact FW control limit Id 2 2505 Name KFact FW control limit Id 2 2505 Description If the length ofUdq reference length filtered is greater than voltage limit 2 the field weakening control changes the slope value to this parameter Thereby the controller will be faster and Id will be reduced faster Applied immediately Unit SR me Voltage limit 1 2495 Name Voltage limit 1 2495 Description If the length of Udq reference length filtered is greater than this parameter the field weakening control starts The KFact FW control limit 1 parameter defines the slope with which Id is reduced Applied when PWM enabled Subindex Default value 0 89999998 pne cce Voltage limit 2 2496 Name Voltage limit 2 2496 Description If Id is not fast enough reduced and the Udq reference length filtered is reaching this value the slope with which Id is reduced is changed to the parameter KFact FW control limit 2 Subindex Default value 0 92000002 Page 156 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Voltage limit 3 2497 Name Voltage limit
8. Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 p u Position counter M1 0 0005 Ude ijs Uke Diagram Commands Mien File legging File logging stopped 8 screens A Idi um X O liz wb Jo Ime en er Een Nr a sene Figure 33 Negative Rotation Direction 3 pole pairs 1 index per revolution 8 2 2 Sin Cos Encoder The Sin Cos encoder delivers analogue signals indicating the absolute rotor position In order to enable QUASAR determining the position correctly the received signals have to be scaled using an offset and gain The offset correction of sine and cosine signals is used to achieve symmetrical signals The gain correction of sine and cosine signals is used to achieve a signal range of 1 1 8 2 2 1 Setup and Preconditions e No DC link voltage required e The motor is turned in forward direction using a test bench Motor speed 1 5 of max motor speed e Set Encoder delay compensation 2169 to 0 e Get Sin Cos encoder cosine gain 212C and Sin Cos encoder sine gain 2133 to 1 e Get Sin Cos encoder cosine offset 21 2E and Sin Cos encoder sine offset 212D to 0 8 2 2 2 Criteria Sine and cosine signals are called to one and do not have any DC offset 8 2 2 3 Parameters Configuration hardware 2140 0x00080000 Select the analogue inputs to which the Sin Cos encoder signals are
9. Description Gain Kp of d axis current regulator We Applied at start up reset needed LEAL Subindex Default value 0 004 Time constant Tn Id current control 2139 Name Time constant Tn Id current control 2139 Description Tn factor of d axis current regulator Applied at start up reset needed m s Subindex Default value 0 0001 pe E Page 147 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Max output Id current control 213B Name Max output Id current control 213B Description Maximum output limit of d axis current regulator Applied at start up reset needed nt r ES 0 Non linear gain corner current Kp Id 2196 Name Non linear gain corner current Kp Id 2196 Description Defines the corner point current for the Kp factor Below this value Kp factor will decrease linear Kp factor 1 0 actual current Non linear gain Kp slope Above this current value the Kp factor will remain constant Kp factor 1 0 Non linear gain corner current Kp Non linear gain Kp slope Applied at start up reset needed LL NN MM NM Deme Oo Wage IL Non linear gain Kp slope Id 2197 Name Non linear gain Kp slope Id 2197 Description Defines the slope for the Kp factor to calculate Kp for a specific operating point Appl
10. Node ID scope data 2 T Auto connect at startup Figure 24 Q Control Communication Settings 4 Open Flash tool View Flash see Figure 25 boot 28335 update bin Control 5 Read target info W Get state periodically Erase flash Progress n a 10 Program firmware verify Actual state n a Abort Lasterror n a Reset error Unlock flash __ Select password file Erase bootloader sl 13 Jump to application Forced jump to application Target information Display targetinfo V Display target info periodically Firmware signature Name n a Version n a Burn date n a Build date n a Checksum n a Version information MCU type OTP bootloader n a Part ID PARTID n a Bootloader n a Revision REVID n a Flash AFI used n a Bootloader capabilities n a Figure 25 Q Control Flash view verify you might see additional buttons Once a firmware file has been selected Q Control will remember that file even after restart 5 Check connection Click button Read target info see Figure 25 Depending on the version and configuration of Q Control on the PC SKAItek Page 47 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 6 Turn on auxiliary power supply of the SKAI 7 Confirm the popup window by pressing
11. 1802 2 Name Transmission type 1802 2 Description Defines the transmission type for TXPDO3 Synchronous transmission types 0 240 and 252 means that the transmission of the PDO shall be related to the SYNC object Preferably the devices use the SYNC as a trigger to output or actuate based on the previous synchronous Receive PDO respectively to update the data transmitted at the following synchronous Transmit PDO Asynchronous TPDOs are transmitted without any relation to a SYNC A transmission type of zero means that the message shall be transmitted synchronously with the SYNC object but not periodically For more information see the protocol description or check CANOpen specification CiA 301 Wage IL Inhibit time 1802 3 Name Inhibit time 1802 3 Description To guarantee that no starvation on the network occurs for data objects with low priorities data objects can be assigned an inhibit time The inhibit time of data object defines the minimum time that has to elapse between two consecutive invocations of a transmission service for that data object Inhibit times can be assigned by the application This time is a minimum interval for PDO 3 transmission The value is defined as multiple of 100us It is not allowed to change the value while the PDO 3 exists Wage IL 13 16 5 TXPDO 4 1803 Contains parameters for TXPDO4 messages Page 168 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332
12. 2135 Description Tn value of q axis current regulator Applied at start up reset needed unit Subindex Default value 0 00006 Gui MS Max output Iq current control 2137 Name Max output Iq current control 2137 Description Maximum output limit of q axis current regulator Applied at start up reset needed PU Unit 5 Subindex Page 144 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Non linear gain corner current Kp Iq 2191 Name Non linear gain corner current Kp Iq 2191 Description Defines the corner point current for the Kp factor Below this value Kp factor will decrease linear Kp factor 1 0 actual current Non linear gain Kp slope Above this current value the Kp factor will remain constant Kp factor 2 1 0 Non linear gain corner current Kp Non linear gain Kp slope Applied at start up reset needed Sube Deme o mme Non linear gain Kp slope Iq 2192 Name Non linear gain Kp slope Iq 2192 Description Defines the slope for the Kp factor to calculate Kp for a specific operating point Applied at start up reset needed Unit Subindex Type Default value Page 145 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User
13. Contains parameters for type and version of the SKAI inverter Inverter Type 21A0 Name Inverter Type 21A0 Description Defines the type of SKAI Important The SKAI does not provide automatic hardware detection therefore this parameter must be programmed manually 0 SKAI not yet defined no operation possible 1 Low voltage single SKAI 2 Low voltage dual SKAI 3 High voltage single SKAI Engineering sample 4 High voltage single SKAI Serie Applied at start up reset needed ER ER ES 0 Page 89 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Inverter Subtype 21A 1 Name Inverter Subtype 21A1 Description Defines the subtype The subtype is given by the voltage class designation Important The SKAI does not provide automatic hardware detection therefore this parameter must be programmed manually 0 not defined no operation possible 100V 150V 200V 600V 1200V Applied at start up reset needed C Subindex Default value 4 Inverter Release 21A2 Name Inverter Release 21A2 Description Gives information about the hardware version of the SKAI Currently not by SKAI hardware Unit 50 Subindex mmm TI 13 1 2 Hardware Contains hardware related parameters for the inverter Page 90 of 170 SKAl
14. D s Power EJ e 2 ni i Ka E e Analog in 1 Analog in 2 El angle Hall state 3 Deen i T Figure 30 Q Control Main Window 6 4 1 Start Communication After a reset or new start up the SKAI will send a boot up message and remain in pre operational state Therefore it will not communicate with Q Control To establish normal communication the following steps have to be performed These steps have to be repeated after each reset The commands can be sent either form CAN Logger window or from the Main window 1 Activate Activate node guarding 2 Activate Send SYNC interval 100 ms e The actual values in the main window will only be refreshed automatically if Send SYNC is activated 3 Press the Start Node button e After receiving the Start Node command QUASAR starts communicating over CAN Page 49 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document A 1 DO Quasar SKAI tek Version Date modified 14 09 2012 Enter pre operational CAN goes to pre operational state It is only possible to configure QUASAR Reference values over PDO are ignored Only needed after Stop Node has been sent Start Node CAN is fully operational Reset Node Resets the CPU Table 19 CAN NMT commands 6 4 2 Verify Ccommunication If the SKAI is already programmed with a firmware the TxD and RxD on the Main Window
15. Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Parameter Typical Description value Gain Kp Iq current control 2134 Start value K 0 0005 Time constant Tn Ig current control 2135 Start value T 0 003 Non linear gain corner current Kp Iq 2191 Result of this step Non linear gain Kp slope Iq 2192 Result of this step Non linear gain corner current Tn lg 2193 Result of this step Non linear gain Tn slope lg 2194 Result of this step Table 35 Ig l current control parameters PSM 10 1 1 3 Scope settings e ldCurrentController ssf e laqCurrentController ssf 10 1 1 4 Procedure The current controller for ly and will be tuned separately Therefore the procedure is split into two main steps K and T will be determined for different operating points These values can be filled into the worksheets ly and I in the Setup Calculation file see 3 Follow the steps defined in the worksheet to make a linear interpolation and to find the required configuration values After configuring the current controller verify the Encoder Angle Offset as described in chapter 8 3 and adapt it if necessary IdFaktKp m IdFaktKp calc Figure 39 Example for K Factor interpolation Procedure for I Current Controller 1 Using Automatic Test Mode refer to 2 make a step of current following the example below The initial current step should start from near zero t
16. Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 4 3 IPM Motor Control Overview Gain Kp of speed regulator 213C Torque constant 2103 Norm DC link voltage 2164 Norm DC link voltage 2164 Udq absolute vector maximum length 215F Dead ti tion 2147 Gain Tn of speed regulator 213D Generator constant 2120 Maximum value for Id FW 214D Maximum absolute value of current FW 2142 ean tme compensanon 2147 Maximum torque in speed mode 213E Ld 2165 Id reference filter constant 2155 Iq reference filter constant 2154 Dead time minimal current 2148 Minimum torque in speed mode 213F La 2166 Enable Iqref IdRef filter 0x40 Enable Iqref IdRef filter 0x40 Dead time slope 2149 Reference torque filter 2128 Ld and Lq in f f table 0x20000 Imax Limit in function of table 0x10000 Ap tor encoder FLL contrel 1ra PWM mode 2058 ti t Reference speed filter 2126 e Goes EE Tn for encoder PLL control 2174 Enable dead time calculation 0x80 ximu Speed filter constant PT2 213A i Enable speed request filter 0x200 function o table 0x400000 p l Enable overmodulation 0x800 PLL is used for encoder 0x1000 Enable S Shape Toraue reauest 0x8000 Maximum value for Id FW 214D D Factor for Iq limitation in f UdqAbs 2160 Start Iq limitation in f UdqAbs 2161 Udq absolute vecto
17. Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Veoh A ic Date modified 14 09 2012 SKAItek 2 5 References Ref Title Description Author 1 QUASAR CAN Protocol CAN protocol definition for QUASAR 0013 DO QUASAR CAN Protocol pdf 2 Q Control User Manual Detailed information about Q Control 0026 DO Q Control User Manual pdf 3 Setup calculations Excel file with useful calculations used during the setup process 0043 DO QUASAR Setup Calculations xlsx 4 Technical explanation SKAI SKAI2 HV 3 Phase IGBT Inverter System for e SEMIKRON HV Vehicle Applications Table 4 References Page 15 0f170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 Product Features 3 1 System Overview The QUASAR software together with the SKAI hardware combines to an integrated inverter system which controls the machine and its sensors and other peripherals The system can be controlled over a CAN bus using the CANopen protocol Q Control is the tool to configure the inverter to work with the connected machines and sensors and is essential for testing and improving the motor control tuning In the final customer system an overlaying controller such as an Engine Control Unit ECU or a vehicle control unit VCU will command QUASAR and will take
18. n a n a GPxo1 NEG ENC nPHA ENC nPHB ENC INDEX GPAI1_ RET MTEMP POS MTEMP NEG CAN BMS ENC 1 PWR ENC 1 PHA ENC 1 PHB n a ENC 2 PWR ENC 2 PHA ENC 2 PHB GPAI ANA n a n a CAN H CAN L n a n a GPxO1 NEG ENC 1 PHA ENC 1 PHB n a GPAI RET MTEMP 1 POS MTEMP 1 NEG Signal power on off ignition Digital position sensor power Digital position sensor track A Resolver excitation pos HV only Digital position sensor track B Resolver sinus track pos HV only Digital position sensor track Z index B Resolver cosine track pos HV only Digital position sensor power of encoder 2 Digital position sensor track A Digital position sensor track B Differential multipurpose analog input 1 pos Analogue Sin Cos position sensor 1 single ended Analogue Sin Cos position sensor 2 single ended CAN channel A high line CAN channel A low line CAN channel B high line CAN channel B low line Multipurpose digital output 1 Digital position sensor track A Resolver excitation neg HV only Digital position sensor track Resolver sinus track neg HV only Digital position sensor track Z index Resolver cosine track neg HV only Differential multipurpose analog input 1 neg Motor temperature analogue input Motor temperature analogue input neg SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31
19. 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 1 QUASAR Warning QUASAR will start progressive torque limiting through the cutback limiters and generate a warning as soon as the minimum or maximum warning level has been reached As soon as the warning zone has been left the warning is automatically cleared by QUASAR and torque limitation is stopped 2 QUASAR Software Trip QUASAR will turn off PWM and generate an error as soon as the minimum or maximum limit has been reached The overlaying system control can avoid such a situation in normal operation by correctly reacting upon reaching a QUASAR warning level If a trip condition occurs PWM will be disabled within 1ms and the error will be indicated over the CAN bus 500us later 3 Hardware Trips Hardware trips are detected by the LCU in the SKAI and should never occur if QUASAR is configured correctly After an error has been generated the error must be cleared before PWM can be enabled again Errors are not stored persistently by QUASAR therefore active errors and the error details are lost after restarting of the SKAI system Figure 17 below shows an overview of the warnings and errors reported by QUASAR Further it visualizes the minimum and maximum cutback filters with the warning and error levels Warnings and errors will not be reported for all cutback limiters please refer to Table 12 and Table 13 for details Xcur m Hardware trip XMax HW sa QUASA
20. 13 15 Speed control Contains parameters for speed control Parameters in this section are only used if speed control is used Applied at start up reset needed 13 15 1 Set point factor and offset 216E Scaling factor and offset for speed set point Will also be applied to actual values read Page 158 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Set point factor 216E 1 ame St point tr BBE OOOO Speed set point factor The set point given is transformed in this manner SetPointApplied SetPointGiven SetPointFactor SetPointOffset C Dorte me Set point offset 216E 2 ame et point ost RSET Speed set offset The set point given is transformed in this manner SetPointApplied SetPointGiven SetPointFactor SetPointOffset as EE Gs NN Reference speed filter 2126 Name Reference speed filter 2126 Description This parameter is used to set the speed filter time constant Applied at start up reset needed m s Subindex Default value 0 000125 Ke Ac Page 159 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Gain Kp of speed regulator 213C Name Gain Kp of spe
21. 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document ft 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Digital input generates an error 214E Name Digital input generates an error 214E Description Defines which signal level at the MP DI C1 input generates an error 0 MP DI C1 input error disabled 1 High at MP DI C1 input generates an error 2 Low at MP DI C1 input generates an error Applied immediately mb ES ER ESCHER PWM frequency 214F Name PWM frequency 214F Description Defines the frequency of the motor output PWMs and the motor control calculation frequency Motor control runs with twice the PWM frequency for dual inverters with limitations apply for PWM frequencies higher than 8kHz Increasing the frequency raises the switching losses Applied at start up reset needed Unit Subindex Default value 8000 4000 16000 Page 92 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 PWM mode 215B Name PWM mode 215B Description Defines the PWM mode used 0 SVM 1 DPWMA 2 DPWMB Applied immediately Unit Deme 0 Current gain phase 1 212A Name Current gain phase 1 212A Description Defines the correction factor for the curren
22. 3 2497 Description If Id is not fast enough reduced and the Udo reference length filtered is reaching this iq current is also be reduced The slope is defined Kfact FW control limit 1 Applied when PWM enabled ES mm 13 14 Dead time compensation Contains parameters for dead time compensation Applied immediately Dead time compensation 2147 Name Dead time compensation 2147 Description Defines the dead time which should be compensated It specifies the p u of the dead time to the switching time Example If the switches have a dead time of 3 us and the switching time is 30 us then this parameter would be 0 1 p u Applied immediately EA s L BL LALGGLGGGG Pen Go rIoQ ovrrr 0 Q0G0G6 Lannen KEE pem Page 157 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Dead time minimal current 2148 Name Dead time minimal current 2148 Description Defines the minimal phase current amplitude where dead time compensation will be calculated If the current is below this value dead time compensation is turned off Applied immediately Sube o mme TI Dead time slope 2149 Name Dead time slope 2149 Description Defines the slope with which the dead time compensation is done Applied immediately Subindex Default value 0 001 Go ig
23. 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Hall2 down 21B1 4 Name Hall2 down 21B1 4 Description Angle for high to low transition Applied immediately Applied immediately Deme C Hall3 up 21B1 5 Name Hall3 up 21B1 5 Description Angle for low to high transition Type Default value Hall3 down 21B1 6 Name Hall3 down 21B1 6 Description Angle for high to low transition Applied immediately Unit Subindex Type Default value U Page 128 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document ft 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 13 11 Vector control Contains parameters for vector control settings Page 129 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual C Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Configuration vector control 2150 Configuration vector control 2150 Description This parameter is used to configure the vector control Each bit is used for another setting the defined bit definitions are in the following table described 0000 0001 enable field weak control part should be enabled 0000 0002 reserved 0000 0004 enable power limiter 0000 000
24. Applied at start up reset needed LL NN MEM NN Wage IL Page 108 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Generator constant 2120 Name Generator constant 2120 Description Defines the generator constant of motor which defines how much voltage is induced relative to speed Applied at start up reset needed Sube ER Default value 0 92000002 L NND Ld 2165 mme ep Description Defines the D Axis stator self inductance Applied immediately Subindex Default value 0 025 e Ed Lq 2166 tame taza Description Defines the Q Axis stator self inductance Applied immediately Subindex Default value 0 025 pene ced Page 109 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 13 5 ACIM Contains parameters for the AC induction motor characteristics Parameters of this section are only used if ACIM motor type is defined Nominal motor speed ACIM 2492 Name Nominal motor speed ACIM 2492 Description Defines the nominal motor speed Gm when PWM enabled Unit 5 ud 0 Default value 2000 e c Nominal motor torque ACIM 2501 Name Nominal motor torque ACIM 2
25. DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Maximum acceleration 216D Name Maximum acceleration 216D Description Defines the maximum motor acceleration The limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed ES o O OOOO me 1 Speed limit delta for slope 215A 1 Name Speed limit delta for slope 215A 1 Description Defines the value to calculate slope of the reference speed limit cutback limiter symetric and asymetric The slope is calculated by 1 lt value gt Applied at start up reset needed Se LC Maximum speed to switch PWMs on 216A Name Maximum speed to switch PWMs on 216A Description Defines the maximum speed at which the PWMs can still be enabled Applied immediately ud 0 Wage IL Page 133 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Iq reference filter constant 2154 Name Iq reference filter constant 2154 Description Filter time constant for Iq current reference GE at start up reset needed Unit 5 LL NM Default value 0 00625 Pes Id reference filter constant 2155 Name Id reference filter constant 2155 Description Filter time constant for Id current reference LR at start up reset needed Unit Subinde
26. FOC NMT PC PCB PDA PSM RTR Rx SDO SKAI SKAI HV SKAI LV SW SYNC TOP TX VCU Terms and Abbreviations Alternating current induction motor Motor speed where field weakening starts at rated DC link voltage Bottom IGBT Controller Area Network Communication protocol for CAN bus Device under test tuning Engine control unit or Electronic Control Unit Term used for rotor position sensing devices This applies for all types of position sensing devices Field Oriented Control vector control Field weakening Hardware Identifier e g CANopen node ID Interior permanent magnet synchronous motor Logic Control Unit Motor Control the part in QUASAR controlling the motor In this document motor is used as a general term When referencing to motor an electric machine in generator or motor mode or any other load or source is meant Non linear state feedback Cross coupling decoupling Network Management CANopen Personal Computer Printed Circuit Board Process Data Object CANopen Surface mount permanent magnet synchronous motor Remote Transmit Request CANopen Receive CAN messages Service Data Object CANopen SEMIKRON SK advanced integration 3 phase inverter with DSP controller High voltage SKAI Low voltage SKAI Software Synchronisation Object CANopen Top IGBT Transmit CAN messages Vehicle control unit Table 3 Terms and Abbreviations Page 14 of 170 SKAltek
27. Navigate to the Start Menu Q Control and start Q Control The Main Window appears Page 48 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 File View Commands Info Communication Bus load 0 00 fe 4 RDS TxD moa Open com Close com State Closed Average 0 00 Peak 0 00 CANOpen commands Start node Reset node Send SYMC Interval ms Logger Number of measurements o Actual line n a Number of values for average Logger file name Torque Speed rpm ene reference E C Speed control Maximum H Minimum NMT state Mode of operation n a Firmware version Hardware version Update PCB temp DCB1 temp DCB2 temp DCB3 temp Motor temp Digital In 1 Digital In 2 Digital out 1 Digital out 2 o Du Du IAbs Ig Id DC link voltage Speed Torque Warning Errors Clear Power module error ha System error 1 Du RE zi E pp gt E ni i B E TIT d dd d System error 2 System warning ha Error details Update Details Iq reference A Ug actual Active limitation Id reference A Udactual Actual limitation factor Iq actual A UdgAbs actual Id actual A i ni 3 E Du i 3i le E oi Ee E ni zo 3 BE ni i Torque calc 23 ni i Max av torgue 3 E z r
28. Value 0x0000009 must be set in order to disable filters for the tuning Set back to typical after completing this step Configuration Id current control 2195 0x00000000 Disable non linear gains Gain Kp Id current control 2138 n a Start value K 0 0005 Time constant Tn Id current control 2139 n a Start value T 0 003 Configuration Iq current control 2190 0x00000000 Disable non linear gains Gain Kp Iq current control 2134 n a Start value K 0 0005 Time constant Tn lg current control 2135 n a Start value T 0 003 Table 37 la l current control parameters PSM 10 1 3 Encoder Delay Compensation This step is actually a part of the encoder configuration As it is part of the fine tuning it does not make sense to carry out this step before the current controller has been tuned and the encoder offset has been adjusted again afterwards Encoder delay compensation allows compensating phase lag effects of analogue encoder systems at higher motor speeds It is important to do first the position sensor calibration described in chapter 8 4 before doing this setup In general the procedure is the same as to determine the angle offset The only difference is that the procedure is done at higher motor speed 10 1 3 1 Setup and Preconditions Test bench in speed controlled mode with maximum torque DC link voltage must be on Torque reference value 0 PWM enabled Motor rotates at NO load driven by test bench or
29. and limit values unit Torque mode with symmetric limit Reference Torque Maximum speed rpm Torque mode with asymmetric limit Reference Torque Speed rpm with high and low limit Speed mode with symmetric limit Reference speed rpm Maximum Torque Speed mode with asymmetric limit Reference speed rpm Torque with high and low limit Table 5 QUASAR Control Modes In all control modes the respective limits can be changed during operation PWM enabled The commands to be used are described in 1 Also switching between modes is allowed during operation The reference and limit values are validated by QUASAR These checks include verification that low limits are lower than high limits Further the values are limited to maximum values If problems are detected values are corrected to fit the respective range and a warning is indicated In all modes the symmetric and asymmetric limiters are implemented as normal cutback limiters see chapter 0 3 5 1 Torque Control Mode In torque control mode the reference torque is given in percent of maximum torque The maximum torque is defined by the nominal torque Nominal motor torque ACIM 2501 for ACIM motors and the maximum l current Maximum current motor 2100 for PSM motors The reference torque of IPM motors selects the required currents over tables Depending on the mode of operation limitation mode flag in Rx PDO 1 refer to 1 either symmetric or asymme
30. and the nominal flux value from the datasheet should be written into the parameter Constant for Iq to flux 2500 If this information is not available in the datasheet the flux can be calculated with the following equation A LMyom Lag v2 2 Flux optimized for torque dynamic contact local sales for more information 3 Flux optimized for efficiency contact local sales for more information 10 2 5 Reference Torque Adjustment measured Without this calibration the effective torque produced will not be the same as the reference torque This is because the torque of an ACIM motor is not proportional to the current This chapter defines how to proceed to make this adjustment using a test bench with a torquemeter 10 2 5 1 Setup and Preconditions e Previous step of ACIM setup completed e Motor is driven by test bench in speed control mode at 500 rpm e Apply a set torque of 20 with Q Control 10 2 5 2 Parameters Table 48 ACIM Reference Torque Filter Parameters 10 2 5 3 Procedure 1 Modify the parameter Adapt torque ACIM 2499 until test bench s torquemeter shows the same value as the requested torque 10 2 6 Reference Torque Filter To minimize the influence of any noise on the torque reference a torque filter can be applied The time constant for this filter can be changed by the user Page 77 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR
31. connected to Encoder type 2143 Encoder delay compensation 2169 Set 0 when starting to configure Sin Cos encoder cosine offset 212E To be determined using the procedure described below Page 55 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Sin Cos encoder cosine gain 212C To be determined using the procedure described below Sin Cos encoder sine offset 212D To be determined using the procedure described below Sin Cos encoder sine gain 2133 To be determined using the procedure described below Filter constant for sine input 2184 Filter is not active Filter constant for cosine input 2185 Filter is not active Table 26 General Encoder Parameters 8 2 2 4 Scope settings e SinCosEncoderGainOffset ssf 8 2 2 5 Procedure There are different ways to define the gain and the offset values One is to change the values of gain and offset manually until the signals are scaled appropriately The second and recommended possibility is to save the values measured in the scope to a csv file and calculate the gain and offset using the SinCos worksheet of Setup Calculation Excel file refer to 3 Measure original curves oave data to csv Open the received file in Excel Copy columns E and F into column B and C of the calculation sheet Copy the received valu
32. control of the BLDC motor Dass E immediately Unit 5 LL NM Time constant Tn BLDC 2131 Name Time constant Tn BLDC 2131 Description Time constant Tn of current control of the BLDC motor ee immediately Unit Subindex Wage IL Max output of Current regulator BLDC 2132 Name Max output of Current regulator BLDC 2132 Description Defines the maximum output limit of the BC Current regulator OO immediately Unit 5 Subindex iD 13 13 Field weakening Field weakening settings Page 150 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 8 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Udq absolute vector maximum length 215F Name Udo absolute vector maximum length 215F Description Defines the maximum absolute value for the Udq voltage If Udq reaches this limit the integral part of the PI regulator will be held on the last value Applied immediately 0x215F Subindex Default value 0 97000003 pee jd KFact FW control limit 1 214C Name KFact FW control limit 1 214C Description PSM IPMSM If the length of Udq reference length filtered is greater than Udq absolute vector length1 the field weakening control starts This parameter defines the slope with which Id will be generated ACIM If the length of Udq reference length filtered is greater tha
33. control over the complete system ECU VCU Q Control SS CAN bus DC Link Sensors Figure 1 System Overview 3 2 Supported SKAI Types Currently QUASAR has only been tested and released for SKAI HV Please contact local sales for the usage of SKAI LV QUASAR is designed to run on all available SKAI2 inverter types For each base type all available options for auxiliary power supply and DC link voltage are supported e SKAI2 High Voltage SKAI HV e SKAI2 Low Voltage SINGLE SKAI LV single SKAI2 Low Voltage DUAL SKAI LV dual Depending on the provided interface on the individual inverter type some features of QUASAR may not be available Restrictions are indicated for the respective features in this document Page 16 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 The following figures show a SKAI LV and a SKAI HV system Figure 2 SKAI2 Low Voltage Figure 3 SKAI2 High Voltage 3 3 Motor Types QUASAR implements vector control for the following motor types e Surface Mounted Permanent Magnet Synchronous Motor PSM e Interior Permanent Magnet Motor IPM e AC Induction Motor ACIM A wide range of parameters allows the tuning of the vector control for the customer s motor characteristic in order to reach best efficiency 3 4 QUASAR Motor Co
34. exceeds the defined error limit four times Applied immediately C LL 9 C ONE NN Wage IL 13 8 Resolver Contains parameters for the resolver inverface of HV SKAI Parameters in this section are only used if encoder type Resolver is configured This feature is only available for HV SKAls with resolver interface Configuration resolver 2144 Name Configuration resolver 2144 Description Resolver Configuration register 3A see Semikron technical explanation Subindex Applied at start up reset needed Wage IL Page 121 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Resolver transformation ratio 2175 Name Resolver transformation ratio 2175 Description Resolver transformation ratio 0 0 23 1 0 286 Applied at start up reset needed Sube 13 8 1 Sin Cos encoder Contains parameters for the SIN COS encoder signal filtering and processing Parameters in this section are only used if encoder type Sin Cos encoder is configured Sin Cos encoder sine gain 2133 Name Sin Cos encoder sine gain 2133 Description This parameter is used if a Sine Cosine Encoder is used It allows adjusting the sine signal of the encoder to the desired amplitude level Applied at start up reset needed mb AE KE Page 122 of 170 SKAltek Keltens
35. for PT2 speed filter at start up reset needed unit 0 Subindex Wage IL Page 118 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 13 7 1 ABZ ABZap incremental encoder and resolver Contains parameters to configure incremental encoders and resolvers Parameters in this section are only used if either encoder type ABZ ABZap encoder or resolver is configured Configuration incremental encoder 2113 Name Configuration incremental encoder 2113 Description Defines configuration options for the incremental encoder 0000 0001 Enable encoder drift check Applied at start up reset needed C LL NN MN NM Number of encoder lines 2125 Name Number of encoder lines 2125 Description With this parameter the number of encoder lines is specified Total number of rising and falling signal edges on track and B Applied at start up reset needed am Subindex Default value 4096 es Page 119 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Encoder lines drift ignore limit 2114 Name Encoder lines drift ignore limit 2114 Description This limit defines how much l
36. in f UdqAbs 2161 Name Start Iq limitation in f UdqAbs 2161 Description If Udq Absolute Vector reaches this value lq will be limited The Iq limitation is in function of Udg Absolute Vector for D Part Applied immediately P A Ll IMMER Page 154 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Minimum speed for generating Id 216B Name Minimum speed for generating Id 216B Description Defines the minimal speed at which Id will be generated With decreasing DC Link voltage QUASAR scales up speed to define the operating point of the machine Therefore the field weakening will start at lower speeds This parameter is to avoid high Id currents at low DC link voltage when speed is low The parameter should be set below the field weakeing point for to lowest expected DC Link voltage in normal operation Applied immediately uides 0 mme 0 13 13 2 ACIM Contains ACIM specific parameters for field weakening KFact FW control limit Id 1 2494 Name KFact FW control limit Id 1 2494 Description If the length of Udo reference length filtered is greater than voltage limit 1 the field weakening control starts This parameter defines the slope with which Id will be reduced Applied immediately am Subindex Type Default value Range
37. number of encoder lines 4096 Encoder delay compensation 2169 Set 0 when starting Configuration incremental encoder 2113 0000 0001 Enable encoder drift check Encoder lines drift ignore limit 21 14 Encoder lines drift error limit 21 15 Encoder lines drift error count 21 16 Indexes per mechanical revolution 2136 The encoder may generate more than one index per revolution Check its datasheet Table 23 ABZ Encoder Parameters ABZap specific Additional parameters for ABZap sensors are needed This encoder type supports clocking out the current absolute position at start up Therefore the encoder power supply must only be switched after the SKAI is ready to handle encoder signals Depending on the SKAI type this feature is supported directly by selecting this encoder type For other SKAI types this can be reached by connecting the encoder power supply to the Digital Output 1 of the SKAI Configuration hardware 2140 0x00000000 Usually Encoder power supply is used and not I O Encoder type 2143 Choose ABZap encoder type Number of encoder lines 2125 Make sure the correct value is set Some manufactures use different line definition than QUASAR Table 24 ABZap Encoder Parameters Resolver specific The SKAI implements a conversion from analog resolver signals to digital ABZap Encoder Signals Once initialized correctly the Resolver works identically to the ABZap Encoder Therefore only some special param
38. rad s Resulting kg 0 04852 Vrms rpm Table 40 Induced voltage example 10 1 5 Phase Resistance Measurement Check if the motor s stator phase resistance corresponds to the design power cables T The phase resistance shall include the resistance of the connecting 10 1 5 1 Setup and Preconditions Phase resistance with U I method Amperemeter For example Hewlett Packard 974A 4 7 Digit True RMS multi meter Voltmeter For example Fluke 289 True RMS multi meter Constant current trough motor windings supplied by a laboratory power supply 10 1 5 2 Parameters Parameter Typical Description value Stator resistance 2121 According to datasheet or measured including cabling Table 41 Motor resistance parameters Page 70 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 1 5 3 Procedure 1 Measure the values as shown in Table 42 2 Fill the values in the setup calculations excel sheet 3 and configure the respective parameter with the calculated value Example results Phases U V Phases V W Phases W U const A 4 725 4 725 4 724 U drop V 0 1485 0 14805 0 1465 R mQ 31 4285714 31 3333333 31 0118544 15 62895985 Table 42 Phase Resistance Calculation Remarks The phase resistance was specified with e 12 8mO 20 C winding t
39. should be blinking e RxD blinks green when messages are received e xD blinks when Q Control sends messages normally some SDO are sent to get a part of the actual values and settings TxD and RxD are blinking if messages are received and sent Communication o 1 3 67 ROG NOG G2 Open com state OK 3 30 100 00 Figure 31 CAN Communication Select node to communicate 6 4 3 Trouble shooting State Error BUSHEAVY is indicated Verify if SKAI is running Verify your CAN settings Make sure node l and baud rate are correct Verify that the red LED of USB PCAN Adapter is on If it is off check the driver installation or the USB port of the PC Close and Open the CAN communication and check again Open CAN communication and restart the SKAI In the CAN Logger Window you should see the boot up message of QUASAR indicating the correct Node la If this message does not appear verify the baud rate If a boot up message from node la 0x10 was received the Bootloader did not find a valid firmware Program the firmware again State OK is shown but actual values are not Select Send SYNC option to activate the updated periodic update requests Table 20 CAN communication trouble shooting Page 50 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 7 Setu
40. the DCB temperature limiter The DCB temperature limiter is implemented as a Maximum Cutback Limiter as defined in 3 9 3 1 Warning DCB temperature 210B See SKAI Maximum cutback limiter warning level datasheet Maximum DCB temperature 210C See SKAI Maximum cutback limiter error level datasheet Configuration vector control 2150 0x00080FFD All limiters active Table 32 DCB Temperature Limiter 9 4 4 PCB Temperature Limiter The electronic temperature is measured directly on the printed circuit board PCB The PCB temperature limiter is implemented as a Maximum Cutback Limiter as defined in 3 9 3 1 Warning PCB temperature 2107 See SKAI Maximum cutback limiter warning level datasheet Maximum PCB temperature 2108 See SKAI Maximum cutback limiter error level datasheet Configuration vector control 2150 0x00080FFD All limiters active Figure 37 PCB Temperature Limiter Parameters 9 4 5 Minimum DC Link Voltage Limiter The Minimum DC Link Voltage is implemented as a Minimum cutback limiter as defined in 3 9 4 The limiter is used to avoid deep discharge of a battery connected to the DC Link and for SKAI LV types it ensures that the internal DC DC converter providing the PCB power supply can operate within the specified range The minimum critical value is typically set about 596 above the absolute minimum value Warning minimal DC link voltage 2117 n a Minimum cutback limiter warning level Minimal DC lin
41. therefore this manual needs to reference them A convention for the mapping of the signals has been defined to address this problem notation as defined for SKAI2 HV T Generally the QUASAR software and user manual use the pin The figure below shows the two mapping layers used in this manual to address the variety of possible combinations Function naming QUASAR Interface Function Mapping generic Interface naming QUASAR Hardware Software Mapping fix Hardware naming SKAI HV LV Figure 3 Naming concept QUASAR Page 42 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar Version 2 0 Date modified Hardware Software Mapping SKAItek 14 09 2012 The naming for interfaces in QUASAR is based on the naming used for SKAI HV The following mapping table shows the respective interface names for SKAI LV QUASAR SKAI HV SKAI SKAI Description dk LV single LV Dual n a PS PWR PS DI A PS DI AP PS DI B PS DI BP PS DI C PS DI NP n a n a PS DI A 2 n a PS DI B 2 n a MP Al C1 MP AI C1P PS AI C1 PS AI C1 PS AI C2 PS AI C2 CANA CANA H CANA CANA L CANB CANB H CANB CANB L MP DO C1 MP DO C1 PS DI A PS DI AN PS DI B PS DI BN PS DI C PS DI NN MP AI C1 MP AI C1N TS AI MOT TS AI MOT n a n a Page 43 of 170 CAN BMS ENC PWR ENC PHA ENC PHB n a n a n a n a GPAI ANA n a n a CAN H CAN L
42. 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 12 Appendix A Tables and Figures Tables Table 1 Changemanagement nn nnnne nn nssna inr ssna sns sesa sns sana sare saa assess 11 Table E 11 Table 3 Terms and Abbreviations sseeeeesssssesseseseseee nennen nennen nennen nnn nnn nnn nnns nnn nns 14 Table 4 References NER UU uum 15 Table 5 QUASAR Control Modes rrrnnnnnnnnnnnonnnnnrrrrrrnnnnnnnnnnnnnnnnsrrrnnnnnrrrnrnnnnnnnnnnnnnnnsesennnnnnnnrrnnnnnnnnnnn 22 Table e ee 24 Table 7 Motor control feature overview eessssssssssssessee nennen nnne nnn nnns nnn nnns nnns 25 Table 8 Supported Position Sensor Tvpes nennen nnne nnns nnns 30 Table 9 Supported motor temperature sensors seeeessssessssssesseseeee nennen nnne nnns 31 Table 10 Hardware trips c cccccccccsescccceeceeceeeeeceeeeeeeceeseeecseeeeeseuaeceeseaeceeseaeeeessaueeesseaeeesseaeeeesseeeeeeas 33 jou ENN omm 33 Table 12 Maximum Cutback Limiters nnne nnne nnne nnn nnns 34 Table 13 Minimum Cutback Limiters eeesesseeesssseseeseeneeeenn nnne nnnm nenne nnne nnn nnns 35 Table 14 CANopen default node les 36 BET aa E eet 37 Table 16 Flag parameter notation rrrrnnnnrorrnnnnorrnnnnrrrnnnnronrnnnrennnnnnennnnnnrnnnnnnsennnnsnennnnssenn
43. 1 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 For IPM motor ly generated from a specific speed defined in the IPM motor characteristic tables Therefore it is possible that the field weakening effect is not visible with the test above To tune field weakening for IPM motors set the parameter of the Norm DC link voltage 2164 to a smaller value This will result in lower automatically generated l4 and allows having a similar condition as with a PSM A good approach to choose the KFact FW control limit 2 2163 is to multiply KFact FW control limit 1 214C with 8 KFact for FW Control Limit 2 KFact for FW Control Limit 10 1 6 3 Scope Settings FieldWeakening ssf 10 1 6 4 Procedure 1 Enable PWM 2 Make a torque step and record it with the scope 3 Changes of KFact should not affect the captured signals 4 Make sure the speed is just at the beginning of the field weakening region and with the torque step the motor is already in the field weakening region Uagapsriterea gt Uag Absolute Vector length1 5 If the field weakening is working Ig will be generated if Uggabsritterea IS higher than the parameter Udg absolute vector length 1 FW 214B Set KFact as high as possible without inducing oscillations in the measured currents Repeat steps 3 and 6 at different speed until the FW reacts as fast as possible without oscillations Example amp Sc
44. 10 1 1 1 Setup and Preconditions Make sure that angle is correct angle offset is correct encoder has been referenced Block the motor shaft Apply nominal DC link voltage Disable lqref Filter and Dead Time Calculation in Configuration vector control 2150 Set Configuration Id current control 2195 0x00000000 Set Configuration Iq current control 2190 0x00000000 Set start values for K and T given in Table 35 10 1 1 2 Parameters Parameter Typical Description value Confiquration vector control 2150 0x00080FFD Value 0x00000009 must be set in order to disable filters for the tuning Set back to typical value after completing this step Configuration Id current control 2195 0x00000001 Disable all options and set back to typical value after completing this step Gain Kp Id current control 2138 n a Start value K 0 0005 Time constant Tn Id current control 2139 n a Start value T 0 003 Non linear gain corner current Kp Id 2196 n a Result of this step Non linear gain Kp slope Id 2197 n a Result of this step Non linear gain corner current Tn Id 2198 n a Result of this step Non linear gain Tn slope Id 2199 n a Result of this step Configuration Iq current control 2190 0x00000001 Disable all options and set back to typical value after completing this step Page 64 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual
45. 14 09 2012 Indexes per mechanical revolution 2136 Name Indexes per mechanical revolution 2136 Description The parameter defines how many numbers of indexes or periods are indicated by the position sensor for one mechanical revolution If the number of pole pairs is divided by this parameter the result must be a whole number and must be greater than one If this is not the case the position sensor cannot be used for that motor no unique or drifting electrical position information Applied at start up reset needed mb ES 0 Deme fT me Encoder delay compensation 2169 Name Encoder delay compensation 2169 ae Correction of signal delay from encoder OR immediately Unit 5 pe Page 117 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Kp for encoder PLL control 2173 Name Kp for encoder PLL control 2173 Description Kp parameter for PLL on mechanical angle GE at start up reset needed Unit 5 LL NN MEME Tn for encoder PLL control 2174 Name Tn for encoder PLL control 2174 Description Tn parameter for PLL on mechanical angle Applied at start up reset needed Unit Subindex Default value 0 0001 mee eM Speed filter constant PT2 213A Name Speed filter constant PT2 213A Description Filter constant
46. 32 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Motor temperature sensor type 214A Name Motor temperature sensor type 214A Description Defines the motor temperature sensor thermistor type Motor Temperature Sensor disabled Motor Temperature Sensor KTY16 Motor Temperature Sensor KTY81 1 Motor Temperature Sensor KTY81 2 Motor Temperature Sensor KTY82 1 Motor Temperature Sensor KTY82 2 Motor Temperature Sensor KTY83 CON O OO A UO N Motor Temperature Sensor KTY84 Motor Temperature Sensor KTY85 Motor Temperature Sensor YBB145 Motor Temperature Sensor PT100 Motor Temperature Sensor NTC10K Motor Temperature Sensor NTC33K Motor Temperature Sensor PT100 Motor Temperature Sensor PT1000 Note Depending onf the inverter type only a subset of the availble temperature sensors are supported for more informaton see the QUASAR manaual Applied at start up reset needed C Ide o Page 106 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO _ Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Warning motor temperature 2109 Name Warning motor temperature 2109 Description Defines the warning level of the maximum cutback limiter of motor temperature If motor temperature is above this value the cutback limiter starts li
47. 4 121 Resolver transformation ratio 21 l nennen nennen nnns 122 13 8 1 IIA SOS ere e ge n 122 Sin Cos encoder sine gain 31322 122 Sin Cos encoder sine offset 3 12D nennen nennen nnne nnne nnn nnns 123 Filter constant for sine input 2184 eese nennen nnnm nnns 123 Sin Cos encoder cosine gain 12 123 oin Cos eneoder cosine offset 2 2E E 124 Filter constant for cosine input 2 185 iua icsnua dt qun t ad da exti EN n um xia dd Ru Xmas be Zu na badende 124 13 8 2 PASWAN sire E E E E EE 124 DS FOWA EE 124 PE 125 Aldo PEPE 125 SEET gt 0 AN 125 PA GOWN E REE EE 126 PEN PP 126 w ll Ree e BEEN A 126 EO Le EE 126 Halt up 21B1 1 c ccccesececesescscscececececeseecevevececacecsesevevavavaveceusevevavavavaveusevevevavavaversusevevavavivereneevevevavcenenen 127 Halt down 21B1 2 ccccccecccccscesececesescecevevececececeucevevevavaceceusevevevavacaveveusevevevavavereusevevavavveneneetevevacaeenenen 127 Hall2 up le AES E 127 Hall2 down D1Bi AI retener tr tenente terrse tnter 128 palo p Z T c 128 wll GOWA FE IE EE 128 PT E e COMIC EE 129 Configuration vector control DO 130 Page 7 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Norm DC link voltage 2164 EE ss inoedda
48. 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 6 Setup guide Communication Check After the cabling of the SKAI is completed it is recommended to check the communication with the inverter system For this task the desktop application Q Control can be used 6 1 Installation The installation of Q Control is simple It includes the installation of the PCAN USB adapter and the software installation on your PC for more information refer to the Q Control User Manual 2 6 1 1 CAN Adapter Q Control supports communication over CAN using the PCAN USB adapter from Peak Systems The licensing of Q Control is based on this type of CAN adapter A specific PCAN USB adapter has to be purchased from SEMIKRON or drivetek sales Each CAN adapter includes one runtime license for Q Control PCAN USB adapters not purchased through SEMIKRON or drivetek sales will not work with Q Control because they do not contain the Q Control license The driver for the CAN interface must be installed before starting Q Control Install the driver either from the CD delivered with the PCAN USB adapter or download it from the web page of Peak oystems QUASAR only support one CAN interface of SKAI hardware Connect the PCAN adapter to the CAN A interface of the SKAI A termination resistor of 120 Ohm must be used to allow communication Either an external resistor can be used or an internal
49. 41 32 332 79 81 Title QUASAR User Manual BE Se e Date modified 14 09 2012 CSKAI tek Udq absolute vector length 1 FW 214B Name Udq absolute vector length 1 FW 214B Description If the length of Udq reference length filtered is greater than this parameter the field weakening control starts The KFact for FW Control Limit 1 parameter defines the slope with which Id is generated Applied immediately Sube oo mm TI Udq absolute vector length 2 FW 2162 Name Udq absolute vector length 2 FW 2162 Description If Id is not fast enough generated and the Udo is reaching this value the slope with which Id is generated is changed to the parameter KFact for FW Control Limit 2 Applied immediately Subindex ange Page 153 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual C Document 8 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Maximum value for Id FW 214D Name Maximum value for Id FW 214D Description Defines the maximum value of Id p u of the maximum absolute current which can be generated Applied at start up reset needed ES mre D Factor for lq limitation in f UdqAbs 2160 Name D Factor for Iq limitation in f UdqAbs 2160 Description D Factor for Iq limitation in function of Udq absolute vector Applied immediately Subindex Default value 0 002 e Ed Start Iq limitation
50. 501 Description Defines the nominal motor torque LR when PWM enabled Unit Subindex me Nominal rotor current ACIM 2517 Name Nominal rotor current ACIM 2517 Description Defines the nominal rotor current Applied immediately Unit 0 LLL LLL LLLLLLLLLLIII Wage IL Page 110 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Rotor resistance ACIM 2453 Name Rotor resistance ACIM 2453 Description Defines the rotor resistance Applied when PWM enabled Subindex Default value 0 028 peu ed Maximum slip ACIM 248F Name Maximum slip ACIM 248F Description Defines the maximum Slip allowed Applied when PWM enabled Subindex Wage IL Page 111 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Warning 1 2 t rotor protection ACIM 2513 Name Warning I 2 t rotor protection ACIM 2513 Description Warning I12 t limit value If I 2 t limiter is enabled refer to parameter Configuration vector control 2150 and cumulated rotor losses calculated by I 2 t approach is greater than this value a linear reduction of the desired torque starts Applied whe
51. 6 rrrnnnrnnnnnnnnvrnvnnrnnnvrvvnnnnnnernrnnnnnnerrennnnnnrrrennnnnnersennnnnnsneeene 148 Non linear gain Kp slope Id Sid 148 Non linear gain corner current Tn Id IS1opl nnn 149 Non linear gain Tn slope Id ioo 149 13 12 3 BLDC current control MNT 149 SK PD PN 150 Time constant Tn BEDC 213 ae 150 Max output of Current regulator BLDC 2132 errrrrrrrnnnnnnnnnnrnnnnnnnnvnnnvrvrnnnnnnnnnnnnnnrrrrrrrrnnnnnnrrnnnnnnnnnnn 150 13 13 Field weakening REENEN 150 Udg absolute vector maximum length 21BE nnne 151 sju tedagEeosiellimaaem 151 KE ACE i eost 2 aio EE 152 VET PIP enc 152 Maximum absolute value of current FW IOIAI nnn 152 Udg absolute vector length 1 FW 214B nnn 153 Udq absolute vector length 2 FW II 153 Maximum value for Id FW IAU 154 D Factor for Iq limitation in f UdqAbs 210 154 Stan id limitation In T WAGABS BEA AA seere 154 Minimum speed for generating Id IIe 155 CR AON 155 KFact FW Controllimit ld T2494 pM 155 Sms gii contol imit ld WE E 156 MOM ACS ITET KE EE 156 Vage IMEL E 156 Voltage limit 24971 157 13 14 Dead time compensation rrannnnnnnrnnnnnvovnrnnnnnrrnvrnnnnnrnnrnnnnnnrnnnnnnennennnnnnssennnnnnssennnnnnsssennnnnensennnnnnssee 157 Dead time compensation 2147 EE 157 Dead ume minimal current 2148 EE 158 Dead time slope 2149 EEE v
52. 7000000000007 mm Subindex Default value 0 0625 ee Adapt torque ACIM 2499 Name Adapt torque ACIM 2499 Description Defines an factor to scale the requested torque with the effectivly produced torque To adjust this parameter command a reference torque of 10 After that adjust the coefficient to obtain 10 of the nominal torque Use a torque meter measuer the produced torque C Subindex Default value 1 488 LAM NEEEENENEMEMEMMNEEEEEE Gain for actual torque feedback ACIM 2516 Name Gain for actual torque feedback ACIM 2516 Description Gain used to adjust actual torque feedback Torque is calculated using motor model Subindex Default value 9494 GS Page 136 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Minimal magnetizing current ACIM 2458 Name Minimal magnetizing current ACIM 2458 Description The minimum magnetizing current which will be produced Applied immediately Unit 5 LL LLLIIIILLCL Z ZIII LT LL NN MN NN Deme Oo Wage IL 13 11 2 Magnetizing current Contains parameters for the calculation of isd Parameters in this section are only used if ACIM motor type is defined Magnetizing current constant 2459 1 Name Magnetizing current constant 2459 1 Description Mapping constant T
53. 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Transmission type 1803 2 Name Transmission type 1803 2 Description Defines the transmission type for TXPDO4 Synchronous transmission types 0 240 and 252 means that the transmission of the PDO shall be related to the SYNC object Preferably the devices use the SYNC as a trigger to output or actuate based on the previous synchronous Receive PDO respectively to update the data transmitted at the following synchronous Transmit PDO Asynchronous TPDOs are transmitted without any relation to a SYNC A transmission type of zero means that the message shall be transmitted synchronously with the SYNC object but not periodically For more information see the protocol description or check CANOpen specification CiA 301 Wage IL Inhibit time 1803 3 Name Inhibit time 1803 3 Description To guarantee that no starvation on the network occurs for data objects with low priorities data objects can be assigned an inhibit time The inhibit time of data object defines the minimum time that has to elapse between two consecutive invocations of a transmission service for that data object Inhibit times can be assigned by the application This time is a minimum interval for PDO 4 transmission The value is defined as multiple of 100us It is not allowed to change the value while the PDO 4 exists B
54. 8 enable maximum speed cutback limiter 0000 0010 enable maximum motor temperarute cutback limiter 0000 0020 enable maximum electronic temperature PCB DCB cutback limiter 0000 0040 enable Iq ref ld ref filter 0000 0080 enable dead time compensation 0000 0100 enable minimum DC link voltage cutback limiter 0000 0200 enable speed request filter 0000 0400 enable maximum DC link voltage cutback limiter 0000 0800 enable overmodulation 0000 1000 enable NLSF 0000 2000 reserved 0000 4000 reserved 0000 8000 enable S Shape Torque request filter 0001 0000 reserved 0002 0000 test Id controller 0004 0000 test Iq controller 0008 0000 enable maximum acceleration cutback limiter 0010 0000 Maximum absolute current in function of table 0020 0000 Ld and Lq in function of table 0040 0000 Maximum torque in function of table 0080 0000 enable power limiter 0100 0000 reserved 0200 0000 enable I 2 t limiter Limit to the maximal I 2 t rotor losses for ACIM only Index 0x2150 ic Type DI U32 Page 130 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Default value Ox7F9 0 67108863 Norm DC link voltage 2164 Name Norm DC link voltage 2164 Description Scale base used to normalize DC link voltage Voltage with which torque la Id tables were measured
55. 907 lt M lt 0 952 Remark The coefficient 2 rr represents the fundamental amplitude which is possible to reach with a square wave This coefficient is taken as reference i Maximum amplitude per phase Fundamental amplitude Linear modulation 1 KP Se 7 Voc 0 5 Vac Vpc 0 577 Voc cs o Overmodulation 1 V3 S Vpc 0 667 Voc i Voc 0 606 i Vpc Figure 11 Modulation resume Overmodulation II is not implemented in QUASAR 3 7 3 Non Linear State Feedback NLSF for IPM PSM The feature non linear state feedback NLSF is also called d and q axis decoupling compensation It compensates the cross coupling influence given by the motors voltage equation I wandelt val o LQ R p lLa Due to cross coupling Ug f la la Ua f la la the q axis current control loop and the d axis current control loop are coupled That means d axis current effects q axis voltage and vice versa the NLSF grey box in Figure 12 does consider these factors Figure 12 NLSF Controller Page 27 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 In quasi stationary situations low dynamics the cross coupling can be compensated by the current controllers themselves and NLSF is not necessary If NLSF is activated the controllers dynamic behavior improves meaning that steps in
56. DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 3 11 4 Flag Parameter Notation Warning and error values as well as some configuration settings are defined as flag parameters Each bit of the parameter is used to indicate if an error is active or inactive or if an option is enabled or disabled respectively Example Error Option Hexadecimal value Flag binary value Feature 1 0x0000 0001 0000 0000 0000 0000 0000 0000 0000 0001 Feature 2 0x0000 0002 0000 0000 0000 0000 0000 0000 0000 0010 Feature 32 0x0080 0000 0000 0000 1000 0000 0000 0000 0000 0000 Table 16 Flag parameter notation To enable feature 1 and feature 2 calculate the sum of the hex values The result will be 0x0000 0003 The respective hexadecimal values can be summed using a calculator with hexadecimal support 3 11 5 IPM Machine Characteristics In order to tune IPM machines for best efficiency tables are used to characterize them QUASAR implements several tables that can be configured over CANopen interface Table 17 defines the dimension and units for each available table The dimensions given include one row and one column respectively which define the used scales Characteristic Columns x axis Rows y axis Value Unit Value Unit Size Value Unit Size d axis current A peak MD n 27 in T DU 52 MEINEN e d axis inductance Idabs peak Idaps Apeak 26 EES Maximum torque mE 27 Generator Motor 1 1 Se EE EE EE Tab
57. EES 13 17 Tables Contains parameters to adjust table lineartiy tolerance Page 169 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Epsilon X 2520 nnn E ve DEBUIMIIGLLLLL LGLGGGULUGI OLL floating type C Susma O O Epsilon Y 2521 Name Epsilon Y 2521 floating type 0 LL NUMEN emm C Index ann mw Deme PO Wage IL Page 170 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81
58. Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Gain for DC link voltage Ea MERO 100 Maximum OOM Cle 2 1 EEE aa getane cua tatniienianegain 101 13 2 1 S i e Terzo Me fes e PETER 101 Configuration overvoltage protection DZ 101 Overvoltage protection OFF minimal DC link voltage 217B rrrnnnnnnnnnnnnnnrnrvnnnrrnnnnnrrnrrnnnrnnnnnnerrerennnn 102 Overvoltage protection ON max DC link voltage DC 102 Ge 102 Mee HES KK t 103 PEPI AE c 103 Stator We Sle tae eS KR EEE LE AEE AE TAE a i 104 Warming SOCC 2104 EEE 104 Maximum speed 2102 E 105 MTP 105 Motor temperature sensor type DIANA 106 Warning motor temperature 100 107 Maximum motor temperature 2108 107 Motor temperature ADC offset 21 108 pom PPM 108 Torque constant 21021 108 EPP 109 Ld 2165 109 Lq 2166 109 DD FN 110 Nominal motor speed ACTIMIIDA0O2 nnne rn nnns 110 Nominal motor torque ACIM 2501 reerrnnnnrnvvnnnnnvrrvnnnnnnerrrnnnnnnerrrennnnnerrrnnnnnnersennnnnnerrennnnnnersennnnnneeeen 110 Nominal rotor current ACIM DI 110 Rotor resistance ACIM IA 111 Maximum slip ACIM P48F 111 Warning l 2 t rotor protection ACIMNIObI2 nr 112 Maximum 2 t rotor protection ACIM IObiAT nnn 112 No
59. H 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Hall2 down 21B0 4 Name Hall2 down 21B0 4 Description Angle for high to low transition OM immediately Unit 5 Deme OO mme Hall3 up 21B0 5 Name Hall3 up 21B0 5 Description Angle for low to high transition Gm immediately unit 5 Sume 3 mme 00 Hall3 down 21B0 6 Name Hall3 down 21B0 6 Description Angle for high to low transition EEE immediately unit 5 Subindex Wage IL 13 10 Backward Contains parameters that define switching angles for Hall sensors for negative sense of rotation Page 126 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Applied immediately Hall1 up 21B1 1 Name Hall1 up 21B1 1 Description Angle for low to high transition Applied immediately Deme o O O Wage 0 0000 Hall down 21B1 2 Name Hall1 down 21B1 2 Description Angle for high to low transition Applied immediately Demi o E Hall2 up 21B1 3 Name Hall2 up 21B1 3 Description Angle for low to high transition Applied immediately Beau vate 0 O mo pooo Page 127 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332
60. Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Non linear gain corner current Tn Iq 2193 Name Non linear gain corner current Tn Iq 2193 Description Defines the corner point current for the Tn factor Below this value Tn factor will decrease linear Tn factor 2 1 0 actual current Non linear gain Tn slope Above this current value the Tn factor will remain constant Tn factor 1 0 Non linear gain corner current Tn Non linear gain Tn slope Applied at start up reset needed Sube ER Deme o mme TI Non linear gain Tn slope Iq 2194 Name Non linear gain Tn slope Iq 2194 Description Defines the slope for the Tn factor to calculate Tn for a specific operating point Applied at start up reset needed Unit Subindex Type Default value 13 12 2 Id current control Contains parameters for d axis current control Page 146 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Configuration Id current control 2195 Name Configuration Id current control 2195 Description Defines options for the q axis current controller 0000 0001 enable non linear gain Applied at start up reset needed am ES O OOOO Deme OO mme 1 Gain Kp Id current control 2138 Name GamKpkdcurentconrolIZS9 TTT
61. Parameters nennen 80 Table 53 ACIM Setting ISSUES nennen nnne nnnni nnns enirn EETA 81 Table 54 Dead Time Compensation Parametere 81 Table 55 Hardware Ke E 83 Table 56 Software trips System error e 84 Table 57 Software trips System error 2 85 Table 58 System warnings cccccceeecccceecceceeeeeceeeeceeceueceeseueeceseeeecesseueceeseaeeeesseeeesseaeeessseeeeesseeeeeas 85 Figures Figure 1 System Over VEN 16 Figure 2 SKAI2 Low Voltage nnne nennen nennen nnn nsn nan n nnns nnn nnn nnns 17 Figure 3 SKAL Miom Voltage TN 17 Figure 4 Torque control mode with symmetric speed mm 22 Figure 5 Torque control mode with asymmetric speed mm 23 Figure 6 Torque limiter in symmetric speed Control 23 Figure 7 Torque limiter in asymmetric speed Control 24 Figure 8 Third harmonic injection Basic solution red optimized QUASAR solution blue 25 Figure 9 Third harmonic injection Waveform between two phases rrrrrrnnnnrnnnnnnrennnnnnennnnnnennnnnnnen 26 Figure 10 Overmodulation TO O0 5MSO Ob 27 Figure 11 Modulation resume nennen nennen nnne nnnna nnns nsn n nan n nnn ss naar nnn rss 27 Figure 12 Te ee E 27 Figure 13 Field weakening IPDM 28 Figure 14 Field weakening ACIM nnne nnn nennen nnns nsn nnn nnn sna nnn nnns 29 Figure 15 Current form with and without dead time Compensaion 29 Figu
62. Q Control on your computer Establish communication with QUASAR Set basic parameters to allow further steps Basic Settings Information about units used in QUASAR Position Position sensor settings 5 E Calibrate sensor offset and phase lag Limiter Settings Configure remaining limiters and safety parameters common Define the motor type Motor Control Basic motor settings Settings Advanced MC settings Table 18 Setup steps for QUASAR 4 1 Step instructions The following chapters will define all setup step with several sub steps Each sub step is structured in the same way Setup and Preconditions Provides information about the hardware setup the operating point and the parameters needed in order the setup step can be performed Criteria Gives information about the criteria the must be verified for successful tuning Parameter Lists all parameters involved in the setup step Further information is given how a specific parameter is to be used Page 40 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Scope Settings For some tests steps a predefined Q Control scope setting file ssf It defines a workspace that can be loaded in the Q Control scope to load the scope channels required for the test to be done For information about the values measured in each chan
63. QUASAR SKAItek User Manual Document Version Date modified Status Classification Author SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 www skaitek ch Abstract 0011 DO Quasar 2 0 14 09 2012 Released Public CDA This document is the user manual for the QUASAR motor control software It describes all features and provides extensive information about the setup and system tuning Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Table of contents TEN 12 MN Z 020209190 2Mmg nicconeaamrepsaeaseenessaieieceisesaes 13 2 1 PUDO O NS 13 2 2 Document CGonventons nnne nnnnnnnan nnn nns snnna ier n nns i ss ssesa gar n siiis inns aan nnn nnns 13 2 2 1 Son ic T 13 2 2 2 Hints and Important Information eeeeessssssssssssseeeeee enne 13 29 ended FRSC MER OU A 13 2 4 Terms NNN 14 2 FACTO LOINC EEE EE EO 15 3 Product pl E 16 3 1 SE EO EEE 16 32 Dee Ee KEE RK e 16 33 NTE 17 EE e Ree EE EE EE uU su edunt UNI UM MEE 17 3 4 1 General Motor Control 18 3 4 2 PSM Motor Control Overview eeeeeeesssessseeeeee nennen nennen nennen nnne nnns nnn naar nnn nns nnn 19 3 4 3 IPM Motor Control COve
64. R trip amp warning Warning Maximum cutback limiter X warn max PS Ss Normal operation L Warning QUASAR trip amp warning Minimum cutback limiter Error Figure 17 Safety Levels The QUASAR error limits should be set based on the respective datasheet values of the SKAI inverter The main task of the cutback limiters is to detect critical situations and to apply immediate cutbacks in order to enable the overlaying control e g the ECU VCU to react in a timely manner on the warning indicated by QUASAR Depending on the actual operation state of a system a safe reaction A on warning may be achieved in different ways Possible actions may be to turn off PWM or to reduce torque It is up to the overlaying control to decide what action is taken Page 32 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 9 1 Hardware Trips QUASAR handles all hardware trips detected by the SKAI As soon as one of the following errors is indicated by hardware maximum value Xyw tirp has been reached the PWM is turned off and a respective error is indicated over CAN In a correctly configured system HW trips should never occur Table 7 lists the HW trips propagated over CANopen Description Power module error value Desaturation Vcg detection Overcurrent or short circuit
65. Release SEENEN 90 13 1 2 LE OLE EEE EE EEE 90 Configuration hardware 2140 91 Digital input generates an error 214 E rrrnnnnnnnnnnnnnonnnnnnvnnnnnnrvnnnnnrennnnnrennnnnrnnnnnnsennnnnennnnnnennnnnnsennnnssen 92 abiere aiu 92 PAU MOOS 21B EQ 93 curenti ee T2 EN EEE EE EN NE 93 Curent gain phase 3 212B aus 93 Filter constant for analog input C1 Dibil nnne 94 Filter constant for analog input CG3D ib2l nnne 94 Filter constant for analog input CG3ID ib3l nnne nnns 94 Warning PCB temperature 210 l nnnm nnn nnne nnn annes ann rns 95 Maximum PCB temperature 31081 95 Warning DGS temperature 210B ssnssaviciusorx pu vinenkkz ditkus a resins Qva vk EKAA EREE RR rb RO eia wai 96 Maximum DCB temperature 210 96 13 1 3 Ge 0 EE 96 PWM ON time information 220 RRE 97 Motor rotating time information 2202 rrrnnnnnnnnrnnnnrnnnnnnrennnnnrennnnnnrnnnnnnrennnnnrennnnnnrnnnnnrennnnsnennnnsnsennnnssen 97 System up time information D2021 nnne nnne nnn nnn nnns 97 o5 NOI e 97 Warning minimal DC link voltage 117 98 Minimal DC link voltage 108 98 Warning maximum DC link generator voltage 21181 99 Maximum DC link voltage generator mode I210EL 99 Maximum DC link voltage 2106 lessen nnns 100 Page 5 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32
66. Set the parameters LA and generator constant with the correct values of the motor and activate the NLSF in parameter Configuration vector control 2150 2 Use Q Control test function current regulator set 25 5096 of maximum motor current as amplitude at 0 degrees current angle pure q axis current Modify L in order the value for Ug before NLSF adaption Variable Ud control output in NLSF ssf shows the same value as if no current is applied Increase test bench speed and repeat the procedure above to generate an array of L f omega 3 Use Q Control test function current regulator set 25 5096 of maximum motor current as amplitude at 90 degrees current angle pure d axis current Modify L in order the value for Ug before NLSF adaption Variable Uq control output in NLSF ssf shows the same value as if no current is applied Increase test bench speed and repeat the procedure above to generate an array of Ly f omega For IPM motors Ly and L are not constant Therefore the procedure A should be repeated in several operating points if the motor characteristics are not known Id filtered M1 5 Apeak Ug Control Output M1 1 0 Vpeak NLSF Vq M1 Como Con con Vpeak S annpg annm annm Hal S ll WEI SE Jee lo Lev 10 Je Pre 100 Autosave inactive lt j B gt 50 ms div Min Figure 44 Id current step wi
67. Third harmonic injection Basic solution red optimized QUASAR solution blue Figure 9 shows the resulting waveform after adding third harmonic injection on each phase leg and the waveform measured between two phases Page 25 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Waveform for Phase Leg a b and c Time s Figure 9 Third harmonic injection Waveform between two phases 3 7 2 Overmodulation The magnitude of each basic space vector is normalized by the maximum value of the phase voltages Therefore when the maximum DC link voltage is Vpc the maximum line to line voltage is also Vpc Therefore the maximum phase voltage amplitude line to neutral is SC In Figure 10 Above the circle inscribed to the hexagon green the voltage waveform of the inverter is distorted The reason is that it is physically impossible to maintain the vector size in the red zone Using this yellow area it is possible to obtain a greater fundamental 5 but the harmonics are reinforced too Page 26 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Um 1 7 N 1 0 5 0 0 1 Figure 10 Overmodulation I 0
68. Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 QUASAR SKAI HV SKAI SKAI Description Peripheral LV iin LV Dual TS AI MOT 2 n a MTEMP 2 POS Motor 2 temperature analogue input n a n a n a MTEMP 2 NEG Motor 2 temperature analogue input neg MP AI C2 MP AI C2P GPAI2 ANA GPAI2 ANA Differential multipurpose analogue input 2 pos MP AI C2 MP AI C2N GPAI2 RET GPAI2 RET Differential multipurpose analogue input 2 neg MP DI C1 MP DI C1 GPDI1 GPDI2 Multipurpose digital input 1 MP DI C2 MP DI C2 GPDI2 GPDI2 Multipurpose digital input 2 MP DO C2 MP DO C2 GPxo2 NEG GPxO2 NEG Multipurpose digital output 2 Table 5 Hardware Software Mapping Depending on SKAI LV type hardware limitations may apply Depending on SKAI LV type sensor types may not be supported scaling For some SKAI LV types use of Sin Cos encoders may not be supported due to hardware filters Please contact local sales if such interfaces are required Not listed interfaces provided by the SKAI hardware are not supported by QUASAR 5 3 Function Mapping Some functions can be mapped to different peripherals e g digital input This mapping involves an additional abstraction level SKAI Interface QUASAR Function Generic Mapping Parameter MP DI C1 Error input INX Digital input generates an error 214E TS AI MOT Motor Temperature Fixed no mapping MP AI C1 MP AI C2 Differenti
69. User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Reference torque filter 2128 Time constant for the torque filter Table 49 ACIM Reference Torque Filter Parameters 10 2 7 Slip Limit Definition To avoid that slip is greater than the pull out slip a slip limiter is implemented In normal operation the pull out slip should not be reached but in the field weakening area this pull out slip could easily be reached if operating at high speeds Maximum slip ACIM 248F Limit where the torque is set at 096 Table 50 ACIM Slip Limit Parameters 10 2 8 Field Weakening ACIM In field weakening ly current must be reduced to reduce the induced voltage of the motor to be able to still generate the requested torque 10 2 8 1 Setup and Preconditions e The test bench shall drive the motor with a speed just below the field weakening point Uug abs around 80 e Enable PWM 10 2 8 2 Parameters Configuration vector control 2150 0x020014F9 Configuration of vector control Voltage limit 1 2495 0 92 First U44 abs corner point Voltage limit 2 2496 0 94 Second Ugq abs corner point Voltage limit 3 2497 0 95 Third Ugq abs corner point KFact FW control limit Id 1 2494 0 01 Cutback factor above first corner point Id reduction KFact FW control limit Id 2 2505 0 5 Cutback factor above second corner KFact FW control limit 1 214C gp Lal Cutback factor above third
70. active in generating mode and has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed C Susma 9 mme Maximum DC link voltage generator mode 210F Name Maximum DC link voltage generator mode 210F Description Defines the error level of the maximum cutback limiter of DC link voltage If the DC link voltage is greater than this value PWM is turned off and a DC link under or over voltage error is generated The cutback limiter is only active in generating mode and has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Subindex Page 99 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 8 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Maximum DC link voltage 2106 Name Maximum DC link voltage 2106 Description If the DC link voltage is greater than this value DC link over voltage detected error will be generated Applied immediately ES ER me Gain for DC link voltage 215E Name Gain for DC link voltage 215E Description Defines the gain correction factor for the DC link voltage measurement If the DC link voltage on the Q Control display is different than the actual value this parameter can be used to adjust this Note if the indicated voltage is not correct also check the inverter type and s
71. al analog input for Enable with Configuration hardware 2140 Sin Cos position sensor PS AI C1 PS AI C2 Single ended analog input Enable with Configuration hardware 2140 for Sin Cos position sensor MP DO C1 or Angle output Configuration hardware 2140 MP DO C2 MP DO C1 or CANopen controlled output Configuration hardware 2140 MP DO C2 MP DO Ci or Error output Configuration hardware 2140 MP DO C2 Table 5 Hardware Software Mapping 5 4 Cabling Examples This chapter gives two examples of systems including SKAI inverters For further information refer to the SKAI hardware documentation Page 44 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 5 4 1 SKAI HV The basic setup of a system with a SKAI HV is quite similar to one with a SKAI LV single inverter Angle Signal SKA Motor Control Unit 39 Q Control Figure 22 SKAI HV System Setup 5 5 SKAI LV DUAL The dual system allows controlling of two motors QUASAR implements this over two separately controllable CANopen nodes During definition of a dual system limited availability of position sensor interfaces must be considered Angle Signal CE SKA I Motor Conto Unit Figure 23 SKAI LV DUAL wiring Page 45 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax
72. ccssseeceeceeeeseeeecseeeeceeeseeeeceeeeaeeseceeesseaeeeeeseaaseeeessaegeeeeseaas 37 3 11 2 Range Checks and Valldalloris eren cient prse tope ua tete Esta I Fake eser ENEE deu 37 3 11 3 ENEE ME EE EE EE EJ EE ET O 37 3 11 4 Flag Parameter Notatnon nnnm nnne nnns nnn nna nnn 38 3 11 5 IPM Machine Characteristics sseeeseeesssesseseseeeeee enne nnne nnne nnn nennen nnn 38 ME NA 39 EE ee 40 4 1 Re NUS TUC UON RR E 40 5 SetUp 1 0 ER CablNg WE 42 5 1 Signal Naming Convention errrnnnnnrvnnnnnnnnvvnnnnnnnnevnnnnnnnrennnnnnnnsrnnnnnnnnsennnnnsnsennnnnnnssennnnnnsnsennnnnnsseennnnnn 42 o2 NARR STENE 43 SC E CIC HIOM INA DOMNG ORRE EE NE EE EN 44 54 Cabling Examples E 44 5 4 1 SKAL ea yeces aeetnacuecmen sean deene seaetent basen soeceeemoneenmenenefeaeteneenenemecteemonseameneeesnesseeeaeeeeete 45 Do OKAY EEN 45 6 Setup guide Communication Check 46 6 1 TIS QNIAUION PRETI UT 46 6 1 1 enger T a 46 6 1 2 ereoi Mme 46 62 FM FEN EE 46 6 3 Downloading QUASAR Emware nenne nennen nennen nnne nar n nnn nnns nnn a nnn nnns 46 s M OE E E E E pee dsncd apiece E annie E 48 6 4 1 Ste AG ONAL FING 0 reinen ORT 49 6 4 2 Verify Ccommunication EE 50 6 4 3 Trouble Leite rue EEE EE EEE EEE m 50 7 Setup Guide Basic Settings rrrrrrnnnrrnnnnnnnnvrrnrrrnnnnnnnrrrnnnrrnnnnnnnrsrnnnnnnnnnnnsssrnnnnnnnnnsnsss
73. ce 2455 Rotor resistance ACIM 2453 Dead time compensation 2147 Magnetizing inductance coefficient O 2457 1 Rotor leakage inductance ACIM 2454 Dead time minimal current 2148 Magnetizing inductance coefficient 1 2457 2 Dead time slope 2149 Gain Kp of speed regulator 213C Gain Tn of speed regulator 213D Constant for Iq to flux 2500 Magnetizing current coefficient 0 2459 2 Maximum torque in speed mode 213E Coefficient O for Iq to flux 2490 1 Magnetizing current coefficient 1 2459 3 Minimum torque in speed mode 213F Coefficient 1 for Iq to flux 2490 2 Magnetizing current coefficient 2 2459 4 Flux filter for slip limiter 2493 Adapt torque ACIM 2499 Enable dead time calculation 0x80 Reference torque filter 2128 Reference speed filter 2126 Enable speed request filter 0x200 Enable S Shape Torque request 0x8000 Enable overmodulation 0x800 Nominal motor torque ACIM 2501 Udq absolute vector maximum length 215F Pole pairs 2124 Voltage limit 1 2495 KFact FW control limit Id 1 2494 Voltage limit 2 2496 KFact FW control limit 2 2163 Voltage limit 3 2497 KFact FW control limit 1 214 C Udq absolute vector maximum length 215F Udq abs filter ACIM 2498 Kp for encoder PLL control 2173 Misgnelizing Tn for encoder PLL control 2174 Curren Speed filter constant PT2 213A PLL is used for encoder 0x1000 Je ere Gain Kp Id current control 2138 Time constan
74. condition detected 5V supply low oecondary side undervoltage detected Overtemperature DCB or PCB DCB temperature or PCB temperature above threshold detected Auxiliary supply low The voltage of auxiliary power supply dropped below the safe value Overcurrent Positive or negative overcurrent detected n a Reserved n a Reserved DC link overvoltage DC link voltage above threshold detected Table 10 Hardware trips 3 9 2 Simple Limiters Simple limiters only define the maximum value and will directly generate an error when reached The respective value will be limited to the maximum value For these limiters no warning is generated The following simple limiters are defined Limiter input Parameter Max Maximum current difference Maximum current difference 2146 Maximum Power Maximum power 2145 Table 11 Simple limiters 3 9 3 Cutback Limiters QUASAR implements several cutback limiters to make sure that the overlaying system control can react on critical situations Minimum and maximum limiters are available Some limiters generate a warning as soon as limiting starts and an error is generated when the maximum value has been reached and the PWM is disabled In addition to the warning sent over PDO two SDO objects 0x20a8 and 0x20a7 can be requested to get information about the active limiters and the actual limitation factor refer also to 1 3 9 3 1 Maximum Cutback Limiters The maximum limiter is us
75. corner point Iq reduction Udo absolute vector maximum length 215F Hold PI controller integrator Norm DC link voltage 2164 Voltage of normal operation Table 51 Field Weakening Parameters 10 2 8 3 Scope Settings FieldWeakening ACIM ssf Page 78 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual See 20 oe Date modified 14 09 2012 SKAItek 10 2 8 4 Procedure 1 Enable PWM 2 Make a torque step and record it with the scope 3 Changes of any KFact parameter should not affect the captured signals 4 Make sure the speed is just at the beginning of the field weakening region and with the torque step the motor is already in the field weakening region Uggapsriterea gt Voltage limit 1 2495 5 If the field weakening is working lg will be reduced if Uagapsriterea IS higher than the parameter Voltage limit 1 2495 When Uagapsriterea goes higher than Voltage limit 3 2497 also will be reduced Set KFact as high as possible without inducing oscillations in the measured currents Repeat steps 3 and 6 at different speed until the FW reacts as fast as possible without oscillations Example Ch2 Y 56 9100875854492 X 15ms Ug ref limited ACIM1 100 p u Iq ref limited ACIM1 Apeak Udq ref length filtered ACIM1 H 20 p u Id ACIMI Apeak Ud
76. cutback limiter DC Link min max cutback limiter Speed max cutback limiter Acceleraction max cutback limiter m Power limiter t limiter ACIM Torque limiters SKAItek Torque Adapt torque ACIM 2499 Moor type specific Motor Control SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Id display filter constant 2180 Iq display filter constant 217F Ud filter constant 2182 Uq filter constant 2181 ld display filter lq display filter Ud display filter q display filter PasUred values Available Torque Acutal torque Calculated values Actual wal Lies CAN Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 4 2 PSM Motor Control Overview Gain Kp of speed regulator 213C Torque constant 2103 Udq absolute vector length 2 FW 2162 l Dead time compensation 2147 Gain Tn of speed regulator 213D Genewie constent P120 Norm DC link voltage 2164 ND BO Miik OE Dead time minimal current 2148 Maximum torque in speed mode 213E Ld and Lq in function of table 0x20000 Maximum absolute value of current FW lg reference filter constant 2154 Dead time slope 2149 Minimum torque in speed mode 213F 2142 Etape REES PWM mode 215B Reference torque filter 2128 Id reference filter constant 2155 Kp for encoder PLL control 2173 Reference speed filter 2126 Enable Iqre
77. d in Table 9 The range of suitable temperature sensors depends on the SKAI hardware implementation of the temperature measurement circuitry Because of different implementations not all temperature sensors supported by QUASAR can be used with all SKAI types Sensor Type Scaling KTY16 20000 at 25 C KTY81 1 1000Q at 25 C KTY81 2 20000 at 25 C KTY82 1 1000Q at 25 C KTY82 2 20000 at 25 C KTY83 10000 at 25 C KTY84 10000 at 100 C KTY85 10000 at 25 C YBB145 1000Q at 25 C PT100 100 Q at 25 C PT1000 10000 at 0 C NTC10K 10kQ at 25 C NTC33K 33kO at 0 C Table 9 Supported motor temperature sensors There are restrictions concerning the usage of these temperature sensors for SKAI LV and SKAI HV evaluation and engineering sample versions Please contact local sales for more information 3 8 3 Error Indication over GPIO The overlaying system control can indicate errors not only over the CAN bus but also over a dedicated digital input The function can be activated and deactivated according to the needs of the system see parameter Digital input generates an error 214E page 92 3 9 Warning and Error Functions QUASAR offers several safety functions on top of the safety functions provided by the SKAI hardware The safety concept is based on a model with different levels Page 31 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document
78. driven by motor Set the motor speed to reach Ugg 40 10 1 3 2 Criteria e Ugj Oiftorque reference value is 0 10 1 3 3 Parameters Table 38 Encoder delay compensation parameter 10 1 3 4 Scope Settings e PositionSensorAngleOffset ssf Page 68 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 1 3 5 Procedure with Test Bench Follow the procedure in chapter 8 4 5 but modify the Delay Compensation parameter instead of the Encoder Offset 10 1 3 6 Procedure without Test Bench Follow the procedure in chapter 8 4 6 but modify the Delay Compensation parameter instead of the Encoder Offset 10 1 4 Generator Constant k This step defines how to check for correct phase sequence and that the generator constant kg corresponds to the actual setup 10 1 4 1 Setup and Preconditions The motor is driven in forward direction using a test bench Each of the three motor phases must be connected by a 1kOhm resistor to a virtual star point GND for oscilloscope A The motor phases must NOT be connected to the inverter outputs L1 L2 L3 There must not be a connection from the motor phases to the inverter L1 L2 L3 No connection from the motor phases to the inverter Motor speed 5 10 of maximum motor speed Phase sequence checked with oscilloscope Induced voltage
79. e in dual systems will use this node ID incremented by one Applied at start up reset needed C Suoma 0 Page 161 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Bitrate 20F1 Name Bitrate 20F1 Description Defines the bit rate of the CAN bus The following rates are defined 0 deactivated 1 10 kBit s 2 20 kBit s 3 50 kBit s 4 100 kBit s 5 125 kBit s 6 7 8 9 250 kBit s 500 kBit s 800 kBit s 1 MBit s Applied at start up reset needed C LOL M MN COB ID SYNC message 1005 Name COB ID SYNC message 1005 Description For each communication object exists an individual COB ID Communication Object Identifier in the network this ID allows prioritization of messages in case of a transmission collision oet this to 40000080 to enable the sync producing bit 30 must be 1 for sync producer Applied at start up reset needed Unit a Sube O O OOO me Page 162 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Communication cycle period 1006 Name Communication cycle period 1006 Description The communication cycle period defines the interval in which
80. e on Speed reference value 1096 of maximum motor speed Torque reference value 0 PWM enabled Make sure to set parameter Norm DC link voltage 2164 to nominal DC link voltage 8 3 2 Criteria e Motor must start if the sense of the position sensor matches with the phase sequence 8 3 3 Parameters Configuration hardware 2140 0x00000000 Configure the following bits 0000 0100 motor direction 0000 0200 change phase sequence v w w v 0000 0400 change counting sequence from encoder Do only change one parameter at once Table 27 Parameters for sense of rotation Page 57 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 8 3 4 Procedure First the sense of rotation must be adjusted 1 Rotate the motor in the direction you define a forward by using the test bench or by hand 2 If the indicated speed is positive the setting is ok 3 If the indicated speed is negative change the Motor direction bit Now it can be checked if the phase sequence matches with the sense given by the position sensor There is also a more practical way to tune the phase sequence defined below At this point of setup the motor can be operated at low current and therefore to find if the rotating sense does match the motor can be started for the first time 1 Limit the speed to 1096 of maximum m
81. e phase or phase shield Check parameters for current controllers e g gain K see 10 1 2 for IPM or 10 2 2 ACIM Check the maximum current parameters Maximum current motor 2100 and Maximum absolute value of current FW 2142 Watchdog Should never happen A fatal error occurred in the firmware Please contact support Over speed Check the parameter max speed see Maximum speed 2102 Verify that encoder signals are noise free Application error Customer specific error Communication error Check correct implementation of Life Guarding on the CAN bus master Check CAN bus wiring Table 56 Software trips System error 1 Page 84 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 11 3 System Error 2 Software Trips Error Description Possible solution code reserved reserved Motor temperature Check the parameter for motor temperature sensor see sensor fault Motor temperature sensor type 214A Check the wiring of temperature sensors Error in vector control Check the parameter of maximum difference between loop reference current and actual current see Maximum current e g laRef IgAct difference 2146 difference Make sure that the motor is properly connected to the SKAI inverter Referencing motor failed Verify your position s
82. ed regulator 213C Description Defines the Kp gain of the speed regulator Applied at start up reset needed nt r Sube 0 Gain Tn of speed regulator 213D Ame sin Tn of speed ere e Description Defines the Tn factor of the speed regulator ht Applied at start up reset needed HE Subindex Default value 0 0000002 Gui MS Maximum torque in speed mode 213E Name Maximum torque in speed mode 213E Description Defines the abolute maximum torque limit of speed regulator Higher limits requested over the RxPDO 1 or 2 will be limited Applied at start up reset needed Subindex Type Default value Range Page 160 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Minimum torque in speed mode 213F Name Minimum torque in speed mode 213F Description Defines the abolute minimum torque limit of speed regulator Lower limits requested over the RxPDO 1 or 2 will be limited Applied at start up reset needed LL mme 13 16 CANOpen Contains parameters for the CANOpen communication protocol After changing these parameters the settings of the connecting device must also be adapted accordingly Node ID 20F 3 ame Node 1D TOFS Description Defines the SKAIS node ID It defines the address of the inverter on the CAN bus The second nod
83. ed to generate a warning as soon as the current value Xact rises above the warning level Xwarn max Further torque is limited progressively by a linear limiting factor If Xmin is reached QUASAR will generate a software trip Page 33 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 limiting factor X X warn max Figure 18 Maximum Cutback Limiter Maximum limiters are implemented for the following values supervised by the SKAI Limiter Parameter Parameter Max Warning Error input Warning Start Motor Warning motor Maximum motor System warning oystem Error 1 temperature temperature 2109 temperature 210A 0x04 0x04 PCB Warning PCB Maximum PCB System warning System Error 1 temperature temperature 2107 temperature 2108 0x01 0x01 DCB Warning DCB Maximum DCB System warning System Error 1 temperature temperature 210B temperature 210C 0x01 0x01 DC link Warning maximum Maximum DC link System warning System Error 1 voltage DC link generator voltage 2106 0x10 0x02 voltage 21 18 Acceleration Acceleration limit Maximum oystem warning No error generated of motor start 216C acceleration 216D Ox10 PWM not disabled Over speed Warning speed Maximum speed System warning System Error 1 2104 2102 0x10 0x20 Table 12 Maximum Cutback Limiter
84. emperature e 20mQO 160 C winding temperature 10 1 6 Field Weakening PSM IPM In field weakening ly current is added to reduce the induced voltage of the motor to be able to still generate some torque 10 1 6 1 Setup and Preconditions e The test bench shall drive the motor with a speed just below the field weakening point Uug abs around 80 e Enable PWM 10 1 6 2 Parameters Maximum absolute value of current FW Maximum absolute value of current in 2142 ech Udq absolute vector length 1 FW 214B First UggAbs corner point Udq absolute vector length 2 FW 2162 Second Ug Abs corner point KFact FW control limit 1 214C Cutback factor above first corner point KFact FW control limit 2 2163 f Cutback factor above second corner point This typically is 8 times KFact for FW Control Maximum value for Id FW 214D Max l4 value of current in of max Absolute value of current Udq absolute vector maximum length 215F Hold PI controller integrator D Factor for Iq limitation in f UdqAbs 2160 Set 0 Feature normally not needed Start Iq limitation in f UdqAbs 2161 l Ignored if D Factor for Ig limitation in f UdgAbs 2160 is set 0 Norm DC link voltage 2164 Choose values depending on motor type PSM Voltage of normal operation IPM Voltage lower than normal operation Table 43 Field Weakening Parameters Page 71 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 4
85. ennnnnnnnsssassennnnnnnnn Di 7 1 17 51 EP nn 51 7 3 Motor and Sensor Information lsssssssessssessssssseeenn nennen nennen nennen nsn nnnan nnns nnns KER 51 8 Setup Guide Position Sensor Setup ccccccseeeeceecceeseeeeeeeaeeceeeceeaseceeecsaueeeeeeeseaeeeeesssaaeeeeesssaaeeeeessaaess 52 8 1 SETE M e 52 BSS CIS SUID 52 8 2 1 Incremental Encoder ABZ ABZap and Resolver rrrnnnarnrnnnnennnnnnevrnnnnronnnnnnennnnnnennnnnnennnnnnnen 52 8 2 2 OI OBS ee EE 55 8 3 Sense of Rotation and Phase Geouence eene annees nnn nnns nnns 57 8 3 1 Se UD and 6 ere 6 Delo d EE 57 8 3 2 Se eege 57 8 3 3 PN St Page 3 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 8 3 4 xc gt EEE EN EE E 58 8 4 Encoder Angle Offset Calbraton eene nnne nnnm nn nnns nnns 58 8 4 1 SPENN 58 8 4 2 1 m 58 8 4 3 FEE cC TP 59 8 4 4 Selen ne E 59 8 4 5 Procedure with Test BENN Lunnan MER en ia ba dd eae add Spe ep SS S A ende edu dansende 59 8 4 6 Procedure without Test Bench nennen nennen nennen nnn nnn 60 PENNEN NE 61 9 1 Setup and Preconditions EE 61 PER el E 61 9 3 Acceleration Torq
86. ensor Digital error input is in An error was indicated to QUASAR over a digital input Check the error state parameter Configuration hardware 2140 You may disable the feature if the digital input is not used for error indication Encoder error Check encoder wiring In case of an incremental encoder make sure that the index line is present reserved Table 57 Software trips System error 2 11 4 System Warning Error Description Possible solution code Electronic over Check the parameters for the electronic temperatures i e temperature warning Warning DCB temperature 210B and Warning PCB temperature 2107 Cutback limiter active A cutback limiter is active Heference or limits in Check the reference values sent over RXPDO s Some value RXxPDO s were adjusted does violate validation rules to valid values DC link capacitance Feature not yet available discharge failure Cutback limiter active A minimum or maximum cutback limiter is active and reduces the requested torque Check the limitation flags to verify which limiter is active CANopen object 0x20a8 Boot up sequence not Initialization failed Should never happen contact sales finished One or more Initialization failed Should never happen contact sales initialization s failed One or more device Initialization failed Should never happen contact sales communication failed Table 58 System warnings Page 85 of 170 SKAltek Keltenstrasse
87. eration filter time constant Configuration vector control 2150 0x00080FFD All limiters active Table 29 Acceleration torque cutback limiter parameters 9 4 Power Limiter If the power limiter is enabled it is not possible to generate more power than the specified value The system will reduce torque to hold the limit Gees 4 1 Parameters ees Maximum power 2145 Configuration vector control 2150 0x00080FFD All limiters active Table 30 Simple power limiter parameters 9 4 2 Motor Temperature Limiter The Motor temperature limiter is implemented as a Maximum Cutback Limiter as defined in 3 9 3 1 Page 61 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Warning motor temperature 2109 oee motor Maximum cutback limiter warning level specification Maximum motor temperature 210A See motor Maximum cutback limiter error level specification Configuration vector control 2150 0x00080FFD All limiters active Table 31 Motor temperature cutback limiter parameter 9 4 3 Power Electronics DCB Temperature Limiter The DCB temperatures are the temperatures measured on the DCB direct copper bonded substrate close to the position of the power semiconductor switches DCB 1 temp phase 1 DCB 2 temp phase 2 DCB 3 temp phase 3 The highest temperature value is used for
88. es in the Q Control Parameter window QU du ow SY ol Reset the node 7 Verify the result and make manual tuning if necessary The excel file used the following formulas to calculate gain and offset e Calculate gain 2 V max Vmin e Calculate offset Vmax Vmin 2 The following figure shows the result that should be seen in the scope after successful calibration e Light green and orange raw signals of the Sin and Cos track e Green and red Sin and Cos track signals after gain offset correction e Blue Resulting electrical angle signal Positive rotating direction 4 pole pairs Page 56 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 TUL Ude ise St Ob co T gt Con con Conso cono Diagram Commands Jl View Fie logging File logging stopped 2sceens EEE pe SI XOT eio Jr Ini nmm 0 ome i Figure 34 Sin Cos Encoder Offset 8 3 Sense of Rotation and Phase Sequence For the motor to actually start and turn in a specific direction the sense of the rotation given by the position sensor must match with the sense of the windings of the motor Furthermore the connection sequence of the motor windings at the SKAI inverter terminals must be correct 8 3 1 Setup and preconditions DC link voltag
89. eters must be given for the initialization The rest of the setup is identical to the ABZ Encoder Page 53 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAItek Version 2 0 Date modified 14 09 2012 Encoder type 2143 6 Choose encoder type Resolver Number of encoder lines 2125 4096 This value must be set for resolver Configuration resolver 2144 0x0A29 12 bit resolution OXOAxy Resolver transformation ratio 21 75 n a Depending on transformation ratio of the resolver Indexes per mechanical revolution 2136 2p motor Enter the number of pole pairs of the resolver Table 25 Resolver Parameters 8 2 1 4 Scope Settings e EncoderLines ssf 8 2 1 5 Procedure e Before starting the setup make sure the parameters have the correct values especially the Number of Encoder Lines e Load the Scope setting file and check the angle signal If the angle is rising this means that the direction of the motor is positive e Check the direction of rotation Uke Uke Uke Diagram Commands vu view Fie legging File logging stopped 180 sreens AAA mes Ts Passes to tevp o1 Jee eeE SE EE SE Figure 32 Positive Rotation Direction 3 pole pairs 1 index per revolution Page 54 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31
90. f IdRef filter 0x40 Tn for encoder PLL control 2174 Ensbiesmead Tequ sHitbs a0 Imax Limit in function of table 0x10000 EEN STEEN PLL is used for encoder 0x1000 Enable dead time calculation 0x80 Enable overmodulation 0x800 Enable S Shape Toraue reauest 0x8000 Maximum value for Id FW 214D D Factor for Iq limitation in f UdqAbs 2160 Start Iq limitation in f UdqAbs 2161 Udq absolute vector length 1 FW 214B KFact FW control limit 1 214C Udq absolute vector length 2 FW 2162 KFact FW control limit 2 2163 Udqabs filter constant 2183 Torque constant 2103 Generator constant 2120 Ld 2165 Lq 2166 Enable NLSF 0x1000 Gain Kp Id current control 2138 Time constant Tn Id current control 2139 Max output Id current control 213B Non linear gain corner current Kp Id 2196 Non linear gain corner current Tn Id 2198 Non linear gain Tn slope Id 2199 Configuration Id current control 2195 ld filter constant 217E Gain Kp Iq current control 2134 j Time constant Tn Iq current control 2135 D Max output Iq current control 2137 Non linear gain corner current Kp Iq 2191 NLSFV Non linear gain corner current Tn Iq 2193 Non linear gain Kp slope Iq 2192 Non linear gain Tn slope lq 2194 Configuration Iq current control 2190 lq filter consan i170 Software Hardware Page 19 0f170 SKAltek
91. f the measured value of U U close to 0 is the same in both rotating directions at the same speed Page 58 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 8 4 3 Parameters Encoder angle offset 2123 n a 0 1 0 360 mech e g motor with 4 pole pairs 0 0 25 0 360 el Table 28 Encoder Offset Calibration Parameters 8 4 4 Scope Settings e PositionSensorAngleOffset ssf 8 4 5 Procedure with Test Bench 1 Load the Scope Settings File and set the parameter Encoder Delay Compensation O 2 Drive the motor in the positive rotating direction 3 Adjust the Index Angle Offset parameter until Ug 0 Diagram Commands View File logging File logging stopped 1 screen Max 0 1 RN fu gt KG pl vev Je Z Autosave inactve lt B gt 100msj v Min Figure 35 Encoder angle offset calibration Check that U has the same sign as the rotating direction If this is not the case then the angle offset is more than 180 Ug and U must not cross 0 when oscillating but must have a respective DC offset If this is not the case check the phase sequence Configuration hardware 2140 and Pole pairs 2124 4 Change motor direction at the same speed and adjust the Index Angle O
92. f variables in the Scope Configuration of parameters with import and export functions CAN Logger Supervising and logging of CAN communication QUASAR software update Control test mode supported by QUASAR For more information see the Q Control documentation 2 T Q Control is not included when purchasing a QUASAR software license Q Control is a very useful tool for tuning and testing and has to be purchased separately Please contact local sales for more information Q Control is running under Windows XP and Windows 7 32 and 64 bit versions Page 39 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 4 Setup Guide This chapter explains the steps to be performed to set up your system QUASAR supports a wide range of motor types and peripherals therefore the configuration involves several steps The following figure shows an overview of the steps to be completed Each step will consist of several actions to be performed It will be used to visualize which step is handled in each chapter Se Limiter Motor Cabling Basic Settings Settings Control anor common Settings Figure 21 Setup process The steps defined in the setup process should be carried out in the proposed order Cabling Wire up and connect the used devices such as motor DC supply and sensors D cono Install
93. ffset parameter until Us O 5 Repeat step 1 4 in the opposite direction several times For fine tuning you may also run the automatic calibration function ey provided in the Q Control main window in Command gt Start encoder offset calibration Start it several times and check the result Only working with test bench Page 59 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 8 4 6 Procedure without Test Bench The procedure without test bench is less straight forward and may not result in as accurate results as with a test bench 1 Make sure the trigger is set to the Torque ref on channel 2 with negative edge and a level of 0 1 Select single or normal mode Set the parameter Encoder Delay Compensation 0 Accelerate motor in the positive rotating direction When speed is reached where Ugg 10 change the torque reference value to 0 Scope will trigger on the falling edge of the reference value torque Qu Oe 2 Te Change the angle offset to get U4 0 V Uq filtered E Al 0 sa p u Iv Speed actual e s af pm Diagram Commands View File logging File logging stopped lsceen E Max 0 1 040 div sne B gt 96 GB tlf iei le c repo Autosave acte 4d gt 100 msj v mn S
94. for IPM Used for slip limit calculation in ACIM Applied immediately Sube me Calculation factor of time compensation 2127 Name Calculation factor of time compensation 2127 Description This parameter is used to compensate the time it takes to perform the calculations Applied immediately Unit Subindex Default value 0 00000225 pee ce Page 131 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Reference torque filter 2128 Name Reference torque filter 2128 Description This parameter is used to set the S Shape torque filter time constant Applied at start up reset needed om NN AMI EE ee See Acceleration calculation filter 215C Rune Taste eege Tor e Description The acceleration torque filter time constant Weg Applied at start up reset needed ME Subindex mm Acceleration limit start 216C Name Acceleration limit start 216C Description Defines the start of limitation for maximal motor acceleration The limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Subindex Default value 1000 EE Page 132 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 8 0011
95. ge 217B Description Minimum DC link voltage below this level BOT s are switched off feature not available for all SKAI types Applied immediately Subir Deme 5 Wage 0 00000 Overvoltage protection ON max DC link voltage 217C Name Overvoltage protection ON max DC link voltage 217C Description Maximum DC link voltage above this level BOT s are switched on feature not available of all SKAI types Applied immediately Subindex Wage IL 13 3 Motor Contains parameters characterizing the motor Page 102 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Motor type 2119 Name Motor type 2119 Description Defines the motor type 1 PSM 2 IPM 3 Reserved 4 BLDC 5 ASM vector control 6 reserved Applied at start up reset needed ES ER ES 0 seid KEE e OB Pole pairs 2124 Name Pole pairs 2124 Description Defines the number of pole pairs of the motor Applied at start up reset needed RN LL NM NN C Page 103 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Stator resistance 2121 Name Stator resistance 2121 Description Defines the stator winding res
96. ge 113 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Parameters in this section are only used if ACIM motor type is defined Nominal magnetizing inductance 2455 Name Nominal magnetizing inductance 2455 Description Defines the magnetizing inductance CR when PWM enabled Unit 0 Subindex me Magnetizing inductance coefficient 0 2457 1 Name Magnetizing inductance coefficient 0 2457 1 Description The coefficient c O mapping the magnetizing inductance to a d axis current OO when PWM enabled Unit 00 Default value 0 0113 ra Magnetizing inductance coefficient 1 2457 2 Name Magnetizing inductance coefficient 1 2457 2 Description The coefficient c 1 mapping the magnetizing inductance to a d axis current Gm when PWM enabled unit eee Page 114 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Magnetizing inductance coefficient 2 2457 3 Name Magnetizing inductance coefficient 2 2457 3 Description The coefficient c 2 mapping the magnetizing inductance to a d axis current Applied when PWM enabled mre 13 7 Position sensor Contains parameters to configure the position sen
97. ge IL Id display filter constant 2180 Name Id display filter constant 2180 Description Filter constant for filtered actual value of Id sent in PDO at start up reset needed unit 5 Subindex me IL Page 164 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Uq filter constant 2181 Name oameni OO OOOO Description Filter constant for filtered actual value of Uq sent in PDO uud Applied at start up reset needed Subindex Default value 0 005 peu d Ud filter constant 2182 Name Ud filter constant 2182 Description Filter constant for filtered actual value of Ud sent in PDO Applied at start up reset needed Subindex Default value 0 005 ra 13 16 2 TXPDO 1 1800 Contains parameters for TXPDO1 messages Page 165 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Transmission type 1800 2 Name Transmission type 1800 2 Description Defines the transmission type for TXPDO1 Synchronous transmission types 0 240 and 252 means that the transmission of the PDO shall be related to the SYNC object Preferably the devices use the SYNC as a trigger to output or actuate based on t
98. ges Section without saturation The inductance is constant until the corner la corner Section with saturation A 3 order polynomial equation can be found to approximate the behavior in this area 10 2 4 Torque or Efficiency Optimization There are three different methods available to control the flux in the motor without taking the field weakening area into account e Constant flux e Flux optimized for torque dynamic e Flux optimized for efficiency 10 2 4 4 Setup and Preconditions e Previous step of ACIM setup completed Page 76 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 2 4 2 Parameters Magnetizing current constant 2459 1 Start value 0 Values calculated by tool Magnetizing current coefficient 0 2459 2 Start value 0 Values calculated by tool Magnetizing current coefficient 1 2459 3 Start value 0 Values calculated by tool Magnetizing current coefficient 2 2459 4 Start value 0 Values calculated by tool Constant for Iq to flux 2500 Coefficient 0 for Iq to flux 2490 1 Coefficient 1 for Ig to flux 2490 2 Coefficient 2 for Ig to flux 2490 3 Table 47 ACIM Optimization Parameters 10 2 4 3 Procedure 1 Constant flux The nominal magnetizing current peak should be written into the parameter Magnetizing current constant
99. hannel 3 ly ref negative falling edge Page 66 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 Diagram Commands View File logging Fle logging stopped 1 screen max ooo Ee gt 9 GI tlf vev Je sj Pref atocaverinactve lt B gt imsiav m JI Figure 41 lg controller step response tuning After configuring the current controller verify the Encoder Offset as described in chapter 8 3 and adapt it if necessary After the current controller setup has been completed activate the Id e Filter in the Configuration vector control 2150 parameter Typical 0x00080FFD Page 67 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 1 2 Current controller without non linear gains Some motor may not need non linear gains because K and T are constant Therefore measurements only have to be done at one operating point with nominal current Therefore the Setup Calculation excel file refer to 3 is not needed The found values are directly filled in the Ky and T parameters for ly and lg 10 1 2 1 Parameters Parameter Typical Description value Configuration vector control 2150 0x00080FFD
100. he previous synchronous Receive PDO respectively to update the data transmitted at the following synchronous Transmit PDO Asynchronous TPDOs are transmitted without any relation to a SYNC A transmission type of zero means that the message shall be transmitted synchronously with the SYNC object but not periodically For more information see the protocol description or check CANOpen specification CiA 301 Wage IL Inhibit time 1800 3 Name Inhibit time 1800 3 Description To guarantee that no starvation on the network occurs for data objects with low priorities data objects can be assigned an inhibit time The inhibit time of data object defines the minimum time that has to elapse between two consecutive invocations of a transmission service for that data object Inhibit times can be assigned by the application This time is a minimum interval for PDO 1 transmission The value is defined as multiple of 100us It is not allowed to change the value while the PDO 1 exists Age 13 16 3 TXPDO 2 1801 Contains parameters for TXPDOs messages Page 166 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Transmission type 1801 2 Name Transmission type 1801 2 Description Defines the transmission type for TXPDO2 Synchronous transmission types 0 240 and 252 mea
101. he K value then the Ki value Check Adapt torque ACIM 2499 parameter and try to increase the value See 10 2 5 3 page 77 or if the torque or efficiency optimization is selected See chapter 10 2 4 and check if the torque or efficiency optimization is selected Verify the polynomial coefficients See 10 2 3 page 75 See 10 2 7 page 78 or increase the limit Verify that the SKAI type and subtype are set correctly Check Field weakening parameters see chapter O Check Adapt torque ACIM 2499 parameter and try to increase the value See 10 2 5 3 page 77 or if the torque or efficiency optimization is selected please call Drivetek to be sure that the polynomial equation is right See chapter 10 2 4 and check if the torque or efficiency optimization is selected See 10 2 2 page 74 In the parameter list Vector control Configuration control that the value 0x000007F9 is right Check Field weakening parameters see chapter O See 0 page 78 or decrease the value Check Field weakening parameters see chapter 0 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Table 53 ACIM Setting Issues 10 3 Common Settings In this chapter parameters of features available for all motor types are tuned 10 3 1 Dead Time Compensation 10 3 1 1 Setup and Precondi
102. he system 2 2 Document Conventions The following section provides information about how to use this document 2 2 1 Parameters Throughout the document parameters are referenced with their names and a unique parameter number which actually represents the CANopen object index Example Motor type 21 19 Each reference of a parameter is linked with the related parameter description in the appendix Click on the link to jump to the respective section After following a link you can navigate back to the last position in the document by pressing ALT gt 2 2 2 Hints and Important Information The following graphical notations are used to inform about hints and important notes Gives additional useful information or hints how to improve or simplify a specific task Notifies about important issues or commonly made mistakes and how to omit them 2 3 Intended Audience This manual is written to be understood by electrical engineers with know how in electric machines inverters and the related sensors Page 13 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title Document 8 Version QUASAR User Manual 0011 DO Quasar 2 0 Date modified 14 09 2012 SKAItek For advanced tuning steps advanced know how in motor control techniques will be needed to proceed with the given information 2 4 Term ACIM Base speed BOT CAN CANopen DUT ECU Encoder
103. he value to be configured must be requested at local sales Applied immediately Unit Index 0x2459 Type DI F32 Default value Page 137 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Magnetizing current coefficient 0 2459 2 Name Magnetizing current coefficient 0 2459 2 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately Unit a pref Magnetizing current coefficient 1 2459 3 Name Magnetizing current coefficient 1 2459 3 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately SS CN pee dg Magnetizing current coefficient 2 2459 4 Name Magnetizing current coefficient 2 2459 4 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately Unit me Page 138 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 13 11 3 Iq to flux ACIM Contains parameters to define Iq to Flux Function Torque calculation Parameters in this section are only used if ACIM motor type is defined Constant for I
104. hes the limit of Encoder lines drift error count 2116 an encoder error is reported System error 2 0x40 The error counter will be cleared if the detected lines reach a value within the Lines Drift Ignore Limit Position Count Configured MEE dud UE up Encoder lines arilt error limit A WEE wrong index 2115 Number of encoder lines ereer e S EEE A C A Encoder lines drift error limit 71 2115 Va cM tr SCR Erd a Se e c d 4 Wrong 360 720 t Index Error Count Encoder lines drift error count m mm nmm mmm meme bee 2116 Error condition reached t Figure 20 Encoder Error Detection Page 35 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 9 6 DC Link Overvoltage Protection This feature is only implemented for the SKAI LV single and dual The feature is used to protect the inverter against high voltages induced by PSM or IPM machine at high speed Depending on the motor characteristics i e if it is designed to deal with short circuited windings switching on all BOT switches can help in such a situation to keep the DC link voltage within safe levels The overvoltage protection is used to protect the hardware against overvoltage If the DC Link voltage is greater than
105. i Figure 36 Encoder angle offset calibration without test bench 7 Repeat step 1 6 in the opposite direction several times Please verify calibration after tuning the current controllers Page 60 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 9 Setup Guide Limits and Cutbacks Position HUE Cabling Basic Settings Settings Sensor common The system will shut down or reduce speed or torque at the limits and therefore avoid damages For safety reasons it is highly important to set the limits correctly and enable the desired limitations The safety parameters can be set in the Safety Limits parameter window of Q Control Menu View Parameters 9 1 Setup and Preconditions e Q Control is running e Communication with the SKAI is working 9 2 Procedure The procedure is to set the values of the implemented safety functions to values defined by the system 9 3 Acceleration Torque Limiter This task allows limiting the acceleration torque The limitation is activated if the torque limiter is enabled in the Configuration parameter Acceleration limit start 216C n a Set high acceleration to disable e g 10000 Maximum acceleration 216D n a Set high acceleration to disable e g 10000 9 Acceleration calculation filter 215C 0 01 Accel
106. ied at start up reset needed Subindex mm TI Page 148 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Non linear gain corner current Tn Id 2198 Name Non linear gain corner current Tn Id 2198 Description Defines the corner point current for the Tn factor Below this value Tn factor will decrease linear Tn factor 2 1 0 actual current Non linear gain Tn slope Above this current value the Tn factor will remain constant Tn factor 1 0 Non linear gain corner current Tn Non linear gain Tn slope Applied at start up reset needed Sube Deme OO mme Non linear gain Tn slope Id 2199 Name Non linear gain Tn slope Id 2199 Description Defines the slope for the In factor to calculate Tn for a specific operating point Applied at start up reset needed 1 Subindex me 13 12 3 BLDC current control Contains parameters for the current control settings for BLDC Parameters in this section are only used if BLDC motor type is defined Page 149 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Gain K BLDC 2130 Name Gain K BLDC 2130 Description Kp gain of current
107. ines drift is tolerated and therefore ignored by the software It can be activated by setting the bit in the Safety Configuration parameter The lines drift is calculated between two indexes Applied immediately LL NM NN Wage IL Encoder lines drift error limit 2115 Name Encoder lines drift error limit 2115 Description If an encoder lines drift is enabled this limit defines how much drift is allowed before an error is set In between ignore limit and error limit the QEP counter is reset to zero The drift is calculated in between two index pulses Note that this option does only make sense if the encoder counter is not reset on index by default see Configuration Hardware 2140 Applied immediately LIN MM Wage Page 120 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Encoder lines drift error count 2116 Name Encoder lines drift error count 2116 Description If the encoder has a lines drift which exceeds the defined lines drift error limit a counter is increased This parameter defines how many occurences are allowed until an error is generated The error counter is decremented by one when a line drift of less than the error limit was detected E g If the parameter is set to 3 the encoder error will be set only if the defined encoder line drift
108. ing operation PWM enabled The commands to be used are described in 1 3 5 2 Speed Control Mode Similar to the torque control mode in speed control mode the command interface provides two limitation modes In speed control with symmetric torque limits the given value of torque in RxPDPO1 refer to 1 is used as maximum value of the torque Figure 6 Torque limiter in symmetric speed control In addition to the torque limitation the speed cutback limiter see chapter 3 9 3 1 is applied to reduce motor speed to maximum allowed values The advantage of speed control with symmetric limits is that only one value has to be set for torque limitation The drawback is that the ECU VCU cannot influence the behavior in very dynamic situations For example if the vehicle has to overcome an obstacle it may need maximum torque Tmax for traction but as soon as the obstacle has been overcome the vehicle would accelerate With symmetric limits the controller would now start braking with maximum torque Tmax but this Page 23 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 time without load This behavior can lead to undesired jerking Therefore asymmetric limits were added In speed control mode with asymmetric torque limit a high and low torque limit can be defined in Rx PDO2 refer t
109. istance including the connection cables Applied at start up reset needed Le EE L AUN See Warning speed 2104 Name Warning speed 2104 Description Defines the warning level of the maximum cutback limiter of motor speed If speed is above this value the cutback limiter starts limiting torque and an over speed warning is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Sud ER Page 104 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Maximum speed 2102 Name Maximum speed 2102 Description Defines the error level of the maximum cutback limiter of speed If the speed is greater than this value PWM is turned off and an over speed error is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed ES OO O OOOO Maximum current motor 2100 Name Maximum current motor 2100 Description Defines the maximum q axis current value set to reach 100 torque Scaling only valid for PSM IPM motors For ACIM adapt torque parameter is used for scaling Applied at start up reset needed Subindex mm Page 105 0f170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 3
110. k voltage 2105 n a Minimum cutback limiter error level Configuration vector control 2150 0x00080FFD All limiters active Figure 38 Minimum DC Link Voltage Cutback Limiter Parameters Page 62 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 9 4 6 Maximum DC Link Voltage Limiter The Maximum DC Link Voltage is implemented as a Maximum cutback limiter as defined in 3 9 3 1 The limiter is used to protect the SKAI and the power supply e g battery connected to the DC link Therefore the value of the absolute maximum is limited to the SKAls maximum voltage The maximum critical voltage is typically set about 3 below the absolute maximum value Warning maximum DC link generator n a Maximum cutback limiter warning level voltage 21 18 Maximum DC link voltage generator n a Maximum cutback limiter error level mode 210F Configuration vector control 2150 0x00080FFD All limiters active Table 33 Maximum Battery Voltage Parameters 9 4 7 Speed Limiter This feature allows limiting the speed of the motor If the limiter is activated it is not possible to run at a higher speed than the defined maximum speed in motor mode The speed limiter is not active in generator mode The speed limiter is implemented as a Maximum cutback limiter as defined in 3 9 3 1 Warning speed 2104 Ma
111. l file see 3 Details Ig reference A Ug actual Ki Active limitation n a Id reference A Udactual Actual limitation factor Iq actual A UdgAbs actual Id actual A Figure 45 Measurement of the iron saturation with Q Control 3 Repeat step 1 and 2 with a current step l4 value increased by 5 to 10 Page 75 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar Version 2 0 Proposed values for current steps are available in the excel sheet if maximum current of motor has been defined before worksheet Date modified Measurement ld A Ud V 11 54701 12 70171 17 178239 19 62391 21 24649 23 09401 24 24871 26 55811 24 94153 24 24871 24 24871 After completing the measurement follow the steps indicated in the 115 47005 122 33826 133 94526 140 87347 140 87347 150 11107 14 09 2012 SKAItek Figure 46 Example Measurement of saturation 1 000E 02 Ka nom 9000 03 8 000E 03 4 7 000E 03 4 i 4 3rd order polynomial equation 6 000E 03 Zum e 5 000E 03 3 Measure 4 000E 03 J in 3 000E 03 An 5 2 000E 03 4 1 000E 03 4 ld corner 0 000E 00 l 0 00 m 40 00 60 00 80 00 ipi 120 00 140 00 160 00 van Isd A Figure 47 Magnetizing inductance This curve can be split into two ran
112. le 17 IPM motor characterization tables Further the table must comply with the following rules Scales must start at zero and increase arithmetically linear A Negative torque means generator mode Row 26 must contain Torque 0 Row 1 contains highest generator torque smallest negative value and must increase arithmetically 9 1 defines value in generator mode 1 defines value in motor mode Generator mode must be listed first IPM motor characteristics must be either given by the motor manufacturer in a datasheet or must be measured on a test bench In case they are available the scales may need to be adapted to fit the rules defined above An example file for IPM table characteristics is provided with Q Control Page 38 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 12 Q Control Q Control is the PC based tool to configure and operate the QUASAR software on a SKAI system By using Q Control setting up of a system is straight forward because it implements the full QUASAR CANopen interface and provides a GUI to configure the system Q Control provides the following main functions e ECU Simulation QUASAR can be controlled by Q Control Torque Speed On Off command during setup or for test purposes Display of actual operation values Visualization and recording o
113. minal flux ACIM 245A E 113 Stator leakage inductance ACTMIIOAD2l nnne 113 Rotor leakage inductance ACIM 2454 rrrnnnnnnnnrrvvnrnnnvrvennnnnnervrnnnnnnervennrnnnrreennnnnerreennnnnerseennnnnereeen 113 196 tele E ue Beie ee 113 Nominal magnetizing inductance Ab 114 Magnetizing inductance coefficient 0 2457 1 114 Magnetizing inductance coefficient 1 IGAb 21 114 Magnetizing inductance coefficient 2 2457 3 elles eene nnne nnn 115 TFS nn 115 COSY Ty FA K C1 EREE 115 Page 6 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Encoder supply voltage EAR EE 116 Encoder EPP 116 Indexes per mechanical revolution 2126 117 Encoder delay compensation EA 117 Kb Tor encoder PEL COMMON 21 RE 118 Tn for encoder PLL control Di 31 nnne nnne nennen nnn nnns 118 Speed filter constant PT2 2134A E 118 13 7 1 ABZ ABZap incremental encoder and resolver rrrrrrnnrrrrrnnnnrvvrnnnrennnnnrennnnnnrrnrnnnrennnnenrnnnnn 119 Configuration incremental encoder 21 13 orti toronto enitn sonans Osee p opes Ha EEGEN 119 Number of encoder ln CEA KEE 119 Encoder lines drift ignore limit DIANA 120 Encoder lines drift error limit 211 120 Encoder lines TM PI 121 TS TEE 121 Configuration resolver 214
114. miting torque and a motor overtemperature warning is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Um e Sube Maximum motor temperature 210A Name Maximum motor temperature 210A Description Defines the error level of the maximum cutback limiter of motor temperature If the motor temperature is greater than this value PWM is turned off and a motor overtemperature error is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Subindex Page 107 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Motor temperature ADC offset 215D Name Motor temperature ADC offset 215D Description Defines the offset added to the measured motor temperature Use this offset if the value indicated does not correspond with the actual motor temperature value Applied immediately ES O O OOO Deme OO me 13 4 IPM PSM Contains parameters for PSM and IPM motors Parameters of this section are only used if IPM or PSM motor type is defined Torque constant 2103 Name Torque constant 2103 Description Defines the motor constant which defines how much torque is generated relative to the current
115. n PWM enabled ES OO OOOO ESCHER me Maximum I 2 t rotor protection ACIM 2514 Name Maximum I 2 t rotor protection ACIM 2514 Description Maximum 2 t limit value If I 2 t limiter is enabled refer to parameter Configuration vector control 2150 and cumulated rotor losses calculated by I 2 t approach is greater than this value the maximum limitation of the requested torque is reached Applied when PWM enabled Subindex Default value 1000 E UN Page 112 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Nominal flux ACIM 245A Name Nominal flux ACIM 245A Description Defines the nominal rotor flux LEE when PWM enabled Unit 5 LL NM Default value 0 38699999 pem SE Stator leakage inductance ACIM 2452 Name Stator leakage inductance ACIM 2452 Description Defines the stator leakage inductance BE when PWM enabled Unit Subindex Default value 0 23799999 i Kc Rotor leakage inductance ACIM 2454 Name Rotor leakage inductance ACIM 2454 Description Defines the rotor leakage inductance LR when PWM enabled Unit 5 Subindex Default value 0 23799999 Gai SNR 13 6 Magnetizing inductance Contains parameters defining the magnetizing inductance of AC induction motor Pa
116. n Voltage limit3 the field weakening Control starts This parameter defines the slope with which Iq will be reduced Applied immediately rt Subindex Type Default value Page 151 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 KFact FW control limit 2 2163 Name KFact FW control limit 2 2163 Description PSM IPMSM If the length of Udq reference length filtered is greater than Udq absolute vector length2 the field weakening control changes the slope value to this parameter Thereby the controller will be faster and Id will be generated faster ACIM If the length of Udq reference length filtered is greater than Udq absolute vector maximum length the field weakening changes the slope value to this parameter This parameter defines the slope with which Iq will be reduced Applied immediately C Susma 9 me 13 13 1 IPM PSM Contains IPM PSM specific parameters for field weakening Parameters in this section are only used if IPM or PSM motor type is defined Maximum absolute value of current FW 2142 Name Maximum absolute value of current FW 2142 Description Defines the maximum absolute value of current Applied at start up reset needed Subindex mm Page 152 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax
117. nd therefore some of them are unused 3 8 1 Position Sensors For efficient vector control accurate rotor position information is essential for the motor control to work correctly and with high efficiency For PSM and IPMmotors absolute position is required and therefore ABZ Encoders with absolute position ABZap Sin Cos Encoders Hall Sensors or Resolvers must be used The main issue there is that after start up QUASAR needs to be able to determine the correct angle of the motor in order to start motor operation on the desired direction For ACIM motors only speed information is required by QUASAR Therefore an ABZ incremental encoder even without Z line provides enough information During evaluation phase of the inverter system SKAI and QUASAR the definition of the sensor type to be used is very important QUASAR supports four different types of position sensors Not all sensor types are supported by all SKAI types The following table gives an overview of the available sensor types and the SKAIs supporting them For details of the electric interface refer also to the SKAI documentation Input Sensor Type Description Number of Numberof Sensors IE SKAILV SKAI HV T LV Dual Incremental Encoder Sensor provides three digital outputs ABZ including two incremental AB and one slow Z index signal Incremental Encoder In addition to normal Incremental ABZap Encoder it provides absolute position at start up Hall sens
118. nds den Jeeves File logging stopped 459 screens re max 25 m Ch 1 Pre 2 Min 25 Page 81 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 n x amp Scope ee X jJ de adi remove Iq M1 1 E D Apeak A F o U A Current phase U M1 E 1 o D U A A Current phase V M1 F i o D u A A E 1 o 0 U Bk Sai N EN Sai EN Current phase W M1 A us t e 3 O Ho tevp Jos gt Pre Autosave inactive min 25 M Page 82 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 11 Trouble Shooting 11 1 Hardware Trips Usually hardware trips should never occur in normal operation If a hardware trip level has been reached the cutback limiter configuration must be verified Error Description Possible solution code Check motor cabling for short circuits phase phase or phase shield Check parameters for current controllers e g gain K see 10 1 2 for IPM or 10 2 2 ACIM 5V supply too low Check for short circuits in encoder supply wiring Verify that encoder current consumption does not exceed the specification of SKAI in
119. needed Leen LN RN peu Filter constant for cosine input 2185 Name Filter constant for cosine input 2185 Description Defines the filter time constant for cosine input Applied at start up reset needed Deme Oo Wage IL 13 8 2 Hall switch angle Contains parameters to define corrected switching angles for hall sensor operation The angles can be defined for positive and negative sense of rotation The corrected angles defined will only be used in FOC control mode For BLDC control mode standard hall sensor switching angles apply Parameters in this section are only used if encoder type Hall Sensor is configured Applied immediately 13 9 Forward Contains parameters that define switching angles for Hall sensors for positive sense of rotation Applied immediately Page 124 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Hall1 up 21B0 1 Name Hall1 up 21B0 1 Description Angle for low to high transition Applied immediately C mm IL Halli down 21B0 2 Name Halli down 21B0 2 Description Angle for high to low transition MT ee pem Hall2 up 21B0 3 Name Hall2 up 21B0 3 Description Angle for low to high transition Applied immediately Type Default value Range Page 125 of 170 SKAltek Keltenstrasse 1 C
120. nel the address description given in Q Control can be read select the channel click on the button on the right of the Address field For further details refer to the Q Control user manual 2 Procedure The procedure defines the actual step by step tutorial to do the setup For tests steps involving measurements with the Q Control scope captures of expected results are available For some procedures calculations need to be done Templates for these calculations are provided by the setup calculations excel sheet 3 Page 41 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 5 Setup Guide Cabling Cabling QUASAR supports three SKAI inverter types four different position sensors and four different types of motors Therefore the number of possible combinations is rather big and no default wiring exists Refer to the respective SKAI specification for more information on the electrical and mechanical interface When defining the system the electrical compatibility of all peripherals must be verified to avoid problems during the configuration of QUASAR 5 1 Signal Naming Convention QUASAR motor control software supports different SKAI inverter types SKAI HV and SKAI LV use different naming of peripherals in the respective datasheet QUASAR has to use all signals provided and
121. niat istaniavesiariunatsaninectin 131 Calculation factor of time compensation 2124 131 Reference torque filter EE EE n 132 Acceleration calculation TINE 2150 E 132 Acceleration imit start 2160 EEN 132 Maximum acceleration Tel 133 Speed limit delta for slope DOi1DA 71I nennen nnne nnns 133 Maximum speed to switch PWMs on T2i16GAl nnnm 133 Ig reference fiter CONSTANT 2 154 E 134 Id reference filter constant EE Ps vista ocv dbi aaa preda 134 Uadabs filter constant 2183 ERE s 134 TE ACIN E E 135 DE PE Ped 135 Ki for FAY protection ACIM P5 18 mappene 135 Wadd abs filter ACIM 24998 E 135 iog actual Tiller ACIM 25 EN 136 Adapt torque ACIM EE 136 Gain for actual torque feedback ACIM 2516 ccecccccccccesseseeeceeeeeeaeeseeeceeeeeeeseeeeseeeeeeesssaaaeeeeeeeeeseaas 136 Minimal magnetizing current ACIM TA 137 13 112 Magnetizing Current rrnnnnnnrvrrnnnnvvrnnnnrnrnnnnrrnrnnnnrnnnnnnrnnrnnnsennnnnnrnnnnnnsnnnnnnsrnnnnnnsnnnnnssnnnnnssnnnnn 137 Magnetizing current constant 2Abo 1 nennen nnne nnns 137 Magnetizing current coefficient O An0 21 138 Magnetizing current coefficient 1 2459 3 2 lees nennen nennen nnne nnns 138 Magnetizing current coefficient 2 DGAD0o Al nennen ns 138 TE GR XD Seu m 139 Constant for PN 139 Coefficient 0 for Iq to flux DG Ao0 2 nnne 139 Coefficient 1 for Iq to flux DG Ao0 21 nnnm nnnm nnne nnns 140 Coetiicient 2 for Id 10 TUX 2490 3
122. ning ACIM 3 7 5 Dead Time Compensation An IGBT needs time to turn on or off During this time the current and the voltage do not have ideal step behavior but a linear behavior When there are two IGBTs in series a short circuit could appear if no measures are taken Therefore dead time is added between turning off one IGBT and turning on the one in series The result is that on time is decreased in the signals for the IGBT commands Without compensation With compensation Compensation value Calculation factor of time compensation 2127 Figure 15 Current form with and without dead time compensation QUASAR compensates this effect with the dead time compensation For small currents the compensation is deactivated to avoid noise amplification Compensation Dead time Dead time slope 2149 em m pm VE rn pm vm db pm pm Dead time minimal current 2148 Figure 16 Dead Time Compensation parameterization Page 29 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 To configure dead time compensation see the parameter group Dead time compensation on page 157 3 8 Peripherals Most peripherals supported by the different SKAI types are supported by QUASAR Note that not all digital and analogue inputs and outputs can be mapped to QUASAR functions a
123. nnnneennnnnsene 38 Table 17 IPM motor characterization tables nnne 38 Table 18 Setup steps for QUASAR EE 40 Table 19 CAN NMT commande nennen nennen nnn nnn nna nnn r ise na nnn r sse n aeri rris n ans 50 Table 20 CAN communication trouble ehooimg nennen 50 Table 21 Basic settings parameters nennen nennen nnns nn anne ann 51 Table 22 Position sensor setup steps essseesssssssssseseeseeeeene nennen nennen nnnn nnns na nnns nna nnn 52 Table 23 ABZ Encoder Parameters c ccccccccccsseeeceecseeeecececeaeeceeesaaaseceesssaaeeeesseaaeeeesssuageeeeessaaees 53 Table 24 ABZap Encoder E en 53 Table 25 Resolver Parametere 54 Table 26 General Encoder Parameters nennen nennen nnne nnn nnn nnns nna nnns 56 Table 27 Parameters for sense of rotation rrrrrrnnnnrvrnnnnrvnnnnnrrnnnnnrenrnnnnrnnnnnnrennnnnrrnnnnnrnnnnnnnnnnnnsnen 57 Table 28 Encoder Offset Calibration Parameters rrrnrnrnnnnnrnnnnnnnnnvrnnrnnnnnrnnnnnnnnrennnnnnsnsennnnnnsnsennnnnn 59 Table 29 Acceleration torque cutback limiter parameters ccccccceeececceeeceeteeeeeeeeeeeeeeseeeeeeseeeeeeeas 61 Table 30 Simple power limiter pDarameiers nennen 61 Table 31 Motor temperature cutback limiter pGarameier 62 Table 32 DCB Temperature Limiter lseeeeessseesssssesssseeeeennnennn nennen nnne nnne 62 Table 33 Maximum Battery Voltage Parameters rrrrrnnnnrnnnnn
124. nnonnnnnnennnnnnrnnnnnnrenrnnnnennnnnnennnnnnrennnnnnene 63 Table 34 Speed Limiter Harameierg nennen nennen nennt nnns nans 63 Table 35 ly I current control parameters PSlVIususesesussa i ctetu tee tunt tuti rure j dene 65 Table 36 Example automatic test mode file for current sten 66 Table 97 ll current control parameters PSM uvvarsamaemnskennsoad eneren 68 Page 86 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI te Version 2 0 Date modified 14 09 2012 Table 38 Encoder delay compensation parameter eene 68 Table 39 Induced Voltage Test Harameterg nennen nnne 69 Table 40 Induced voltage example nennen nennen nennen 70 Table 41 Motor resistance parametere nennen nennen nennen nnns narrar 70 Table 42 Phase Resistance Calculaton esses nennen nnne 71 Table 43 Field Weakening Parameters nennen nnn snna nnns sna nnns nass snas 71 Table 44 NESF El 73 Table 45 ACIM Basic Motor Parameters nennen nnne nnne nnne nnns 74 Table 46 ACIM Iron Saturation Parameters nennen nnns 75 Table 47 ACIM Optimization Parametere 77 Table 48 ACIM Reference Torque Filter Harameters 77 Table 49 ACIM Reference Torque Filter Harameters 78 Table 50 ACM Slip Limit GE Java vrede 78 Table 51 Field Weakening Parameters seen nennen nnn snna nnns na sns naar Ei 78 Table 52 ACIM Torque calculation
125. ns that the transmission of the PDO shall be related to the SYNC object Preferably the devices use the SYNC as a trigger to output or actuate based on the previous synchronous Receive PDO respectively to update the data transmitted at the following synchronous Transmit PDO Asynchronous TPDOs are transmitted without any relation to a SYNC A transmission type of zero means that the message shall be transmitted synchronously with the SYNC object but not periodically For more information see the protocol description or check CANOpen specification CiA 301 mme Inhibit time 1801 3 Name Inhibit time 1801 3 Description To guarantee that no starvation on the network occurs for data objects with low priorities data objects can be assigned an inhibit time The inhibit time of data object defines the minimum time that has to elapse between two consecutive invocations of a transmission service for that data object Inhibit times can be assigned by the application This time is a minimum interval for PDO 2 transmission The value is defined as multiple of 100us It is not allowed to change the value while the PDO 2 exists Wage IL 13 16 4 TXPDO 3 1802 Contains parameters for TXPDOS3 messages Page 167 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Transmission type
126. ntrol The following chapters give an overview of the motor control implementation and the parameters used to tune it Depending on the motor type a different set of parameters is needed The following notation is used for the parameters Parameter Object Filter Object Bit in the Configuration vector control 2150 parameter flag value Bit in the Configuration hardware 2140 parameter flag value Page 17 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title Document Version 3 4 1 Warning DCB temperature 210B Maximum DCB temperature 210C Warning maximum DC link generator voltage 2118 Maximum DC link voltage generator mode 210F Warning minimal DC link voltage 21 17 Minimal DC link voltage 2105 Reference torque filter 2128 QUASAR User Manual 0011 DO Quasar Date modified 14 09 2012 General Motor control Warning PCB temperature 2107 Maximum PCB temperature 2108 Reference speed filter 2126 Torque Torque reference Warning speed 2104 Maximum speed 2102 Acceleration limit start 216C Maximum acceleration 216D Maximum power 2145 Warning 192 t rotor protection ACIM 2513 Maximum I 2 t rotor protection ACIM 2514 Page 18 of 170 Torque SH reference filter speed ER Sa reference Speed CAN refererte filter SES PCB temperature m ax cutback limiter DCB temperature max
127. o 1 This allows the ECU VCU to control the drive characteristics in a suitable manner for the current situation For example maximum acceleration can be allowed while the braking torque is limited The torque limits can be freely chosen the only rule that applies is that the upper limit Tim n has to be greater than the lower limit Tim 1 Both limits can be positive or negative If low and high limits have the same sign or do not differ enough the controller may not be able to regulate all operating points Therefore A the limits must be set with caution and should normally have different signs I Nwarn Nmax 1 Figure 7 Torque limiter in asymmetric speed control In speed control mode the respective limits can be changed during operation PWM enabled The commands to be used are described in 1 3 6 Test Modes QUASAR provides some test modes that may be useful while tuning motors Test modes can be selected over the command interface described in 1 Test Mode Description D axis and q axis currents Apply specific d axis and q axis currents Can be used to make current steps for the current controller tuning after the angle offset has been adjusted Open rotating test mode voltage Apply a fixed voltage magnitude with a specific frequency Important Current is not limited Stationary vector Apply a fixed voltage magnitude with a specific angle Closed loop rotating current Apply a fixed current with a s
128. o approximately 1096 of maximum motor phase current Current A Speed Rpm Mode Current Torque 96 0x01 on Angle 0x02 Speed 0x03 Li mode 3 3 3 3 3 Page 65 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Document I E EA 8 SKAItek Version 2 0 Date modified 14 09 2012 Table 36 Example automatic test mode file for current step 2 Increase or decrease the gain K to reach 80 of reference value Repeat step 1 and 2 until K is tuned correctly Again run the same automatic test file as before Now increase or decrease T AEG Repeat step 4 and 5 until the response of the controller looks more or less as in the figure below Iq PI Control Feedback M1 5 el SE Apeak Diagram Commands View File logging File logging stopped 1 screen Max D I Te ko gt 8 O alte Jos ree osava Dini Je ZE Figure 40 I controller step response tuning 7 Now repeat step 1 to 6 for different current steps from 0 to 20 to 40 of maximum motor phase current Procedure for l Current Controller Follow the same procedure as described in the previous chapter but do it with the l4 currents Therefore set the angle value in the Automatic Test mode file to 90 and vary the value of K and T for the ly current controller parameters Instead of Triggering on channel 1 I ref trigger on c
129. oes not implement any range check for the parameter interface It is up to the user to make sure that values are consistent and in an appropriate range For most parameters no validation will be carried out There are some parameters where a validation task corrects values if they are not correct Such values will be overwritten immediately by QUASAR but the changes can only be seen if the parameter value is read back manually 3 11 3 Parameter Types The parameters are stored as variables therefore they are of a specific type The table below gives an overview of the different types DT 18 8 Bits 1 Byte signed char 128 127 2 DT 116 16 Bits 2 Bytes signed short 32768 32767 2 2 1 DT 132 32 Bits 4 Bytes signed long 2147483648 2147483647 23 29 4 DT 164 64 Bits 8 Bytes signed long long 29 295 4 DT U8 8 Bits 1 Byte unsigned char 4 25510 2 1 DT U16 16 Bits 2 Bytes unsigned short 65535 0 25 1 DT U32 32 Bits 4 Bytes unsigned long 4294967295 0 27 1 DT U64 64 Bits 8 Bytes unsigned long long 2 1 DT BOOL 8 Bits 1 Byte signed char 128 127 2 2 1 DT FALSE DT BOOL O DT TRUE DT BOOL 1 DT F32 32 Bits 4 Bytes Rational number Table 15 Variable types Page 37 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011
130. ominal motor torque ACIM 2501 Date modified SKAItek 14 09 2012 feedback Table 52 ACIM Torque calculation Parameters 10 2 9 3 Procedure Torque from datasheet 1 Change the parameter Gain for actual torque feedback ACIM 2516 to obtain the same value than the reference value 10 2 10 ACIM Tuning Issues Symptoms Oscillation of ig and ig currents compared to the reference Delay of the ig and g currents compared to the reference Torque too small compared to the reference Torque too high compared to the reference Torque oscillation before the field weakening area Torque oscillation in the field weakening area Page 80 of 170 Possible reasons 1 most probable 6 least probable Ki parameter of the current regulator Kp or Ki parameter of the current regulator Adapt value Polynomial equation ly to Flux Polynomial equation Magnetizing Current Magnetizing inductance approximated too small Slip limit too small SKAI Subtype wrong Voltage limit too small Adapt value Polynomial equation to Flux Polynomial equation Magnetizing Current Magnetizing inductance approximated too small PI regulator Filter for the current measurement not enable Voltage limit too big Kp for field weakening too big Voltage limit too big Possible solution See 10 2 2 page 74 or try to decrease this value See 10 2 2 page 74 or try to increase t
131. ope ea ka SP Add Remove 5 Y 5 14892160892487 X 30 625ms Iq ref M1 1 e Apeak Iq filtered M1 m Als iiio st mt Ute Sie Ute e Apeak Id ref M1 1 Apeak Id filtered M1 oe Apeak UdgAbs filtered M1 100 30 p u Gg Es oO TS Es ON gt a O H gt Es Ei Tn gt e Diagram Commands View Fie logging File logging stopped 1sceen EEE Max 20 55986 ETE Ht ch Jeck Pos Jee Autosave inactive Odium Min i Figure 43 Field Weakening Tuning 10 1 7 Non Linear State Feedback NLSF In this step non NLSF is configured If the feature is not used it can be disabled using the respective parameter 10 1 7 1 Setup and Preconditions e Activate the NLSF in the Configuration vector control 2150 parameter Page 72 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Veoh A pes Date modified 14 09 2012 SKAItek e Enable PWM e Set test bench speed to 10 of maximum motor speed 10 1 7 2 Parameters Configuration vector control 2150 0x00080FFD Enable NLSF flag 0x00001000 Ld 2165 Value of the Ld Lq 2166 Value of the Lq Generator constant 2120 Value of the generator constant Table 44 NLSF Parameters 10 1 7 3 Scope Settings e NLSF ssf 10 1 7 4 Procedure 1
132. or Encoder type 2143 Name Encoder type 2143 Description The encoder type is defined with this parameter Encoder type not yet defined Incremental encoder ABZ Sin Cos Encoder Encoder with update function Incremental encoder with absolute position ABZap Hall Sensor not valid for ACIM Resolver Applied at start up reset needed C Subindex Type Default value Range Page 115 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Encoder supply voltage 2176 Name Encoder supply voltage 2176 Description Encoder supply voltage 0 5V 1 12V Applied at start up reset needed C Susma NNNM Dorun vae o pref Encoder angle offset 2123 Name Encoder angle offset 2123 Description Offset between mechanical and electrical system It is important to tune this parameter when the motor is turning forward Definition of forward turning Forward turning means the angle is rising and the speed display in Q Control shows positive values ME S G aeo eoeMLLLILLUGLGLGiui an LLL G eBu 49 LOVL L oe eee Page 116 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO _ Quasar u SKAI tek Version 2 0 Date modified
133. order to be able to choose the appropriate SKAI type This will facilitate and shorten the setup time considerably Values in datasheets of components may not be given in the same units as required by QUASAR Especially values of motor parameters may be given in different units or may be provided as RMS values rather than peak values Page 51 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 8 Setup Guide Position Sensor Setup This chapter defines the procedure to configure the position sensors supported by QUASAR 8 1 Overview The different sensor types require different setup steps The following sections define the steps needed for each encoder type Each of the steps is then described in the following chapters The following table shows which steps have to be completed for a given position sensor type 1 Type specific setup see chapter 8 2 Sin Cos Encoder ABZ Encoder ABZap Encoder with absolute position at start up Resolver 2 Signal Offset Gain Calibration see chapter 8 2 2 o Scale signals for optimal use 3 Sense of rotation see chapter 8 3 4 Angle Offset Calibration see chapter 8 4 o Configure difference between mechanical angles from Encoder depends on mounting and electrical angle given by windings of the motor Table 22 Position sensor se
134. ors Hall sensors do not have high enough resolution for vector control but can be used for BLDC mode Interpolation will be used at high motor speed if used for PSM IPM Resolver Provides a two channel analogue signal An output providing SEN voltage is available in the SKAI one type selectable Sin Cos Encoder Provides two channel analogue signals that allow absolute position detection at any time di differential se single ended Table 8 Supported Position Sensor Types Page 30 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 The resolver interface is only implemented in the SKAI HV serial production versions It is not available in the SKAI HV evaluation and engineering sample versions or in the SKAI LV versions For SKAI LV filters may be implemented depending on the hardware version Please check SKAI specification to verify if analogue inputs are suitable for Sin Cos encoder signals Please contact local sales for further details To configure the position sensors please refer to the parameter group Position sensor on page 115 The different power supply voltage levels if supported by the SKAI hardware can be parameterised refer to the respective SKAI datasheet 3 8 2 Motor Temperature Sensors Motor temperature sensors supported by QUASAR are liste
135. otice to improve reliability function or design Information furnished in this document is believed to be accurate and reliable However no representation or warranty is given and no liability is assumed with respect to the accuracy or use of such information SKAltek does not assume any liability arising out of the application or use of any product or configuration parameter described herein Furthermore this technical information may not be considered as an assurance of product characteristics No warranty or guarantee expressed or implied is made regarding delivery performance or suitability This document supersedes and replaces all information previously supplied and may be superseded by updates without further notice The QUASAR software has been developed and tested with the highest possible diligence but nonetheless the occurrence of defects cannot be completely eliminated SKAI tek will not be liable for any defects that occur by the usage of this software Furthermore the change of parameters is done at the users own risk SKAltek will not be liable for any damage defects or errors that occur with the change of any parameter SKAltek products are not authorized for use in life support appliances and systems without express written approval by SKAltek Page 12 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Da
136. otor speed by setting the speed reference value 2 Enable PWM 3 Set the torque reference value to 2 gt If the motor starts the sequence is OK 4 Ifthe motor does not start increase the torque set point to 4 gt If the motor starts the sequence is OK 5 Ifthe motor does still not start change the phase sequence in the parameters With the actual setup QUASAR may not be able to control the motor correctly If the motor starts it may accelerate to speeds above the value given as maximum reference Be ready to turn off the system manually or make sure the maximum motor speed is set to 10 of maximum motor speed or 500rpm respectively 8 4 Encoder Angle Offset Calibration The purpose of this step is to find the angle difference between the magnetic field of the rotor and the encoder zero position For the ACIM motor the absolute position is not needed Therefore the angle offset calibration described in this chapter can be skipped 8 4 1 Setup and Preconditions Make sure to set parameter Norm DC link voltage 2164 to nominal DC link voltage Set Encoder delay compensation 2169 to O DC link voltage must be on Torque reference value 0 PWM enabled Motor rotates at NO load driven by test bench or driven by motor Set the motor speed to reach Ua 10 increase speed and verify Ug actual value given in Q Control e he Cooling system must be on 8 4 2 Criteria e The found angle offset is correct i
137. p Guide Basic Settings This chapter defines some configurations to be done to proceed with the step by step tutorial These steps are prerequisites for the position sensor tuning 7 1 Overview Some basic motor and system parameters have to be defined and set in order the following steps give accurate results Manufacturers use different conventions in their motor specifications QUASAR uses the following values e Resistance and inductance values of a single phase winding e Peak values for voltages and currents unless otherwise specified Parameters Parameter Typical Description value Inverter Type 21A0 Inverter Subtype 21A 1 Motor type 21 19 Norm DC link voltage 2164 Provide the DC link voltage on which all p u indications will be based on Warning minimal DC link voltage 21 17 Minimal DC link voltage 2105 Warning maximum DC link generator voltage 21 18 Maximum DC link voltage generator mode 210F Maximum DC link voltage 2106 Maximum current motor 2100 Configuration hardware 2140 Select interfaces to be used Inputs outputs Sin Cos Encoder input Motor temperature sensor type 214A Verify if correct motor temperature is indicated after configuring Table 21 Basic settings parameters 7 3 Motor and Sensor Information To be able to use QUASAR information about the connected components is very important During evaluation it is important to define a system concept in
138. pecific frequency Table 6 QUASAR test modes Test modes must only be used within safe environment for test purposes Some control and safety mechanisms can be disabled All test functions are provided without any warranty 3 7 Motor Control Features QUASAR supports a wide range of state of the art motor control features to reach best efficiency for all supported motor types Page 24 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Motor Type Vector Control Features Parameter iul ein on X X X Third harmonic injection Always active Overmodulation I Confiquration vector control 2150 Non linear state feedback NLSF Configuration vector control 2150 Field weakening Confiquration vector control 2150 Dead time compensation Dead time compensation PWM modes SVM DPWMA DPWMB PWM mode 215B Table 7 Motor control feature overview 3 7 1 Third Harmonic Injection The maximum modulation index of a three phase inverter PWM system can be increased by including a common mode third harmonic term into the target reference waveform of each phase leg With the standard method it is possible to obtain a gain on the fundamental waveform of 11 red curve QUASAR implements further optimizations to obtain a gain of 15 blue curve Figure 8
139. q to flux 2500 Name Constant for Iq to flux 2500 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately am ES 0 Deme OO mme Coefficient 0 for Iq to flux 2490 1 Name Coefficient 0 for Iq to flux 2490 1 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately Unit Lol MEM NN Page 139 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C i Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Coefficient 1 for Iq to flux 2490 2 Name Coefficient 1 for Iq to flux 2490 2 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately si Coefficient 2 for Iq to flux 2490 3 Name Coefficient 2 for Iq to flux 2490 3 Description Mapping coefficient The value to be configured must be requested at local sales Applied immediately rt pe 13 11 4 Switch BLDC to FOC Contains parameters for the block commutation BC control Parameters in this section are only used if Hall sensors are configured as position sensor type Applied immediately Page 140 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual BE Se e Date modified 14 09 2012 CSKAI
140. r length 1 FW 214B KFact FW control limit 1 214 C Udq absolute vector length 2 FW 2162 KFact FW control limit 2 2163 Udqabs filter constant 2183 Torque constant 2103 Generator constant 2120 Ld 2165 Lq 2166 Enable NLSF 0x1000 Gain Kp Id current control 2138 Time constant Tn Id current control 2139 Field weakening Max output Id current control 213B Non linear gain corner current Kp Id 2196 Non linear gain corner current Tn Id 2198 Non linear gain Tn slope Id 2199 NLSFV Configuration Id current control 2195 ld filter constant 217E Con acu iss NLSFV JU Pali Gain Kp Iq current control 2134 x i Time constant Tn Iq current control 2135 Kp Tn sci deser Max output Iq current control 2137 Wm Non linear gain corner current Kp Iq 2191 i Non linear gain corner current Tn lq 2193 NLSFV Nonlinear gains Non linear gain Kp slope lq 2192 Non linear gain Tn slope Iq 2194 Configuration Iq current control 2190 lq filter DEE SE Software Hardware constant 217D Page 20 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAItek Version 2 0 Date modified 14 09 2012 3 4 4 ACIM Motor Control Overview Minimal magnetizing current ACIM 2458 Magnetizing current constant 2459 1 Ja Maximum slip ACIM 248F Nominal magnetizing inductan
141. rated speed e Reference torque 0 10 2 3 2 Parameters Parameter Typical Description value Configuration vector control 2150 0x000007F9 Enable the set torque filter Minimal magnetizing current ACIM 2458 n a Make several measurements with the current step values proposed in the excel sheet Nominal magnetizing inductance 2455 Nominal magnetizing inductance before saturation Calculated by excel sheet Magnetizing inductance coefficient 0 2457 1 Polynomial coefficient 0 Co Calculated by excel Magnetizing inductance coefficient 1 2457 2 Polynomial coefficient 1 C4 ig Calculated by excel Magnetizing inductance coefficient 2 2457 3 Polynomial coefficient 1 C isd Calculated by excel Table 46 ACIM Iron Saturation Parameters 10 2 3 3 Procedure The goal is to take several measurement points to obtain a good representation of the saturation characteristics For this test the user can increase the g current up to the nominal current of the motor Before doing this test the following parameters must be changed To measure the saturation follow these steps 1 Use the parameter Minimal magnetizing current ACIM 2458 to define a current lj reference Start with about 596 of nominal phase current 2 Take note of the voltage U and U4 as well as l4 Fill in the values for each measurement in the respective field in the worksheet ACIM Lm in the Setup Calculations Exce
142. re 16 Dead Time Compensation parameterization ccccccecccccssecceceseceeceeeceesseeeeesseeeeeseaeeeeeas 29 mie uM Er 32 Page 87 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI te Version 2 0 Date modified 14 09 2012 Figure 18 Maximum Cutback Lumter nennen nennen nennen nnne nnn nnns 34 Figure 19 Minimum Cutback Limiter esee nenne nnne nnn nnns 34 Figure 20 Encoder Error Detechon nennen nnne nnn nnn nnn nnn nnn nns 35 ENN NN 40 Figure 22 SKAI HV System Getup nennen nenne nhan nnns sss n na SEAKS 45 Figure 23 SKAI LV DUAL wg 45 Figure 24 Q Control Communication Gettngs nennen nnne nnne 47 Figure 25 Q Control Flash view very 47 Figure 26 Quit QUASAR and jump to Bootloader sss 48 Figure 27 Tagel IR T m 48 Figure 28 Q Control flash date time window cccccecccseesseceeeeeeeaaeeeeeeceeeeeseaeeaseceeeeeessaaaaeeeeeeeeeseaas 48 Figure 29 Programming and Erasing progress nennen nnn 48 Figure 30 e EE Coren Wid EE 49 Figure 31 CAN Communication Select node to communicate rrnnnnnnnrnnnnnnvnnnnnnnnrrrrrnnnnnnnnnrrnnnnnnnn 50 Figure 32 Positive Rotation Direction 3 pole pairs 1 index per revolution 54 Figure 33 Negative Rotation Direction 3 pole pairs 1 index per revolution
143. ref limited ACIM1 Du Udg ref limited length ACIM1 1 da Ate ih ih e NE Viel Pr I ei Op ug AAT TER pu Iq ACIM1 Apeak Id ref limited ACIM1 5 5 5 Di DI G eo eo Di G o Di SEI Adj dal be Xie SEI Ude Wide ib Apeak e mun Diagram Commands Si View File logging stopped lsceen IS T gt x OLEE Jak BE ke z pr 20 autosave inactive 4d D gt 123 75 msjdv Figure 48 Field Weakening Tuning 10 2 9 Torque Calculation Adjustment Without this calibration the torque calculation will not be adjusted and depending on the machine the torque calculation could have a constant error This chapter defines how to proceed to make this adjustment using a test bench with torque meter Make sure that the steps defined in chapter 10 2 5 are carried out before doing the steps in this chapter 10 2 9 1 Setup and Preconditions e Previous step of ACIM setup completed e Motor is driven by test bench in speed control with 50 of the rated speed e Apply a set torque of 50 with Q Control 10 2 9 2 Parameters Gain for actual torque feedback ACIM Gain used to adjust actual torque Page 79 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar Version 2 0 2516 N
144. resistor in the SKAI can be if available refer to the SKAI hardware documentation for details 6 1 2 Q Control Double click the installation wizard download from www quasar skaitek ch and follow the instructions By default the application will be installed in the program file folder Program FilesVSKAltek Q Control and will create some registry keys 6 2 Programming QUASAR Firmware If you have purchased a SKAI with QUASAR software only the QUASAR Bootloader is installed on the device You will have to install QUASAR firmware before being able to use the SKAI If the QUASAR Bootloader is installed on the SKAI the flash of the ey DSP is locked Therefore it is not possible to install any other firmware than QUASAR 6 3 Downloading QUASAR Firmware 1 Connect the PCAN adapter to the PC and the SKAI 2 Start Q Control 3 Configure the CAN interface View gt Communication Settings a Select 250kBit s b Node ly MC 1 must be 0x10 default setting Page 46 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar Version 2 0 Date modified 14 09 2012 amp Communication settings Baudrate and sample point Full control 250 kBit s 87 5 sample point Sjw 0 1 sampling Bir Btri DxO11C fa 11 Bit ID standard f 29 Bit ID extended Node ID MC 1 CAN Interface Node ID scope data 1 Peak PCAN USB Node ID MC 2
145. rms value can measured with a multi meter Ambient temperature 25 C 10 1 4 2 Criteria e Sinusoidal open terminal voltages on all motor phases with similar amplitudes e Phase sequence U V W L1 L2 L3 when turning in forward direction otherwise phase sequence has to be changed by using the respective flag in parameter Configuration hardware 2140 e Find or verify number of pole pairs by comparing test bench speed and fundamental frequency of induced voltage 10 1 4 3 Parameters Parameter Typical Description value Configuration hardware 2140 0x00000000 Change phase sequence if needed Use flag 0x00000200 Generator constant 2120 n a Calculated in this step Pole pairs 2124 n a According to motor datasheet Table 39 Induced Voltage Test Parameters Page 69 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 1 4 4 Procedure Example results Bild speich Taste Druck Figure 42 Induced Voltage Example e Chi Voltage phase U V Ch2 Voltage phase V W Ch3 Voltage phase U W The measured value is added in the worksheet k in the Setup Calculations Excel file see 3 to calculate the generator constant correctly Voltage between Result Unit PhaseU PhaseV 24 26 Vrms PhaseV PhaseW 24 26 Vrms PhaseU PhaseW 24 26 Vrms Resulting kg 0 3783 Vpeak
146. rview nennen nnne nennen nnns nnn nnn nna enirn 20 3 4 4 ACIM Motor Control Overview eeessssessseeeeeeene nennen nennen nnne nnn nnn nnns nnn nnn nnns 21 S MEER Go ele 22 3 5 1 Toe COMO Bio o ve 22 3 5 2 Speed Control MOGQO aeuo eaten esten a qne keen oen peras inan tnid ienkear eeneg Eeeeg ee eeeg egf 23 Sr Nu Oe le EE 24 SW ZEN ee E aire hl 24 3 7 1 Tord Harmonie re D 25 3 7 2 Overmodulation EE 26 S MES Non Linear State Feedback NLSF for IPM PSM nnn 27 3 7 4 FE OA VY Be WE 28 3 7 5 Dead Time Compensation cccccceceeseeeeeeeeeeeeeeeeeseeeeeeeeesaeeeeeeeeeeeessaaseeceeeeesesaeaeeeeeeeeeeaaas 29 SE GE le 30 3 8 1 Poe ECCE TE 30 3 8 2 Motor Temperature Sensors eene nennen nnns nna nnns enar nnns sina ann 31 3 8 3 Error MCC ATION Over ee Eee 31 39 Warning ang Error FUNCTIONS savaessmmsvmsnomnsammidst apie d ende 31 3 9 1 EON ETA EN EN NM 33 3 9 2 MEL rn 33 3 9 3 TUNER E 33 3 9 4 Minimum Cutback Limiters rrrrnnnrrnnnronrrrnnnnnnnrorrrnrrnnnnnnnnrrnnnnrnnnnnnnnssnnnnnnnnnnsnnsssnnnnnnnnnsnnaseennn 34 3 9 5 Encoder Error Detection E 35 3 9 6 DEC LINK Overvollage PoledliMm uauvvva lt vqasansosaduaadmamnmuaadanoisemvsaereuaqdvssdei 36 Page 2 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 TD NNN 36 S PT on 36 3 11 1 Parameter Groups Overview cccc
147. s 3 9 4 Minimum Cutback Limiters The minimum limiter is used to generate a warning as soon as the actual value X44 drops below the critical value Xwarn Further torque is limited progressively by a linear limiting factor If Xmin is reached QUASAR will generate a software trip limiting factor X min Awarn Xact Figure 19 Minimum Cutback Limiter Only one minimum cutback limiter is available Page 34 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Parameter Critical Parameter Warning Critical Error Minimum Minimum DC link Warning minimal Minimal DC link System warning System Error 1 voltage DC link voltage voltage 2105 0x10 0x00000020 2117 Table 13 Minimum Cutback Limiters 3 9 5 Encoder Error Detection For ABZ and ABZap encoders error detection is implemented The error is generated when the signals on AB lines do not match with the index received on the Z line Figure 20 shows an example for a situation when an error is generated In this situation the configured number of lines is greater than the effective lines detected before receiving an index signal For this reason the error counter is incremented whenever an index is received If the Encoder lines drift error limit 2115 is reached an error counter is incremented If the error counter reac
148. scription Defines the error level of the maximum cutback limiter of DCB temperatures If any DCB temperature is greater than this value PWM is turned off and an error is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Subindex 13 1 3 Information Contains parameters with information about operation times Page 96 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 PWM ON time information 2201 Mame PHRF ON ine formation BT Gives the time in seconds since the inverter was switched on PWM enabled Fac 6 LLLLLL CDD m Motor rotating time information 2202 Name Motor rotating time information 2202 Gives the time since the motor started motor speed gt 0 is saved in the motor rotating time Leen EE Beete EECH System up time information 2203 name Syse uptime formatene 00000000007 amm Subindex mm IL 13 2 DC link Contains parameters related with the DC link Page 97 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO _ Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Warning minimal DC link
149. scription Defines the warning level of the maximum cutback limiter of PCB temperature If the PCB temperature is greater than this value the cutback limiter starts limiting torque and a warning is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed LL CNN NE Maximum PCB temperature 2108 Name Maximum PCB temperature 2108 Description Defines the error level of the maximum cutback limiter of PCB temperature If the PCB temperature is greater than this value PWM is turned off and an error is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Subindex Page 95 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Warning DCB temperature 210B Name Warning DCB temperature 210B Description Defines the warning level of the maximum cutback limiter of DCB temperatures If any DCB temperature is greater than this value the cutback limiter starts limiting torque and a warning is generated The cutback limiter has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Um e Sube o Maximum DCB temperature 210C Name Maximum DCB temperature 210C De
150. synchronization objects are sent Applied at start up reset needed om pu Subindex Default value 250000 pee Ed Guard time 100C Name Guard time 100C Description Defines guard time in ms for node guarding The time used for node guarding is Time Guard time Life time factor Applied immediately Subindex mme Scope node ID 20F4 Name Scope node ID 20F4 Description Defines CANOpen node ID used for Q Control scope The second node in dual systems will use this node ID incremented by one The scope node ID must be different to the normal inverter node ID Applied at start up reset needed Unit Subindex Page 163 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar u SKAI tek Version 2 0 Date modified 14 09 2012 Delay between scope data 20F5 Name Delay between scope data 20F5 Description Defines the delay between scope data update Set a delay between SDO 22KS202 2 200mmn Gives a lower priory CAN message a chance to be sent Unit 5 Subindex Wage IL 13 16 1 PDO data filters Defines filters for actual values sent through PDOs Iq display filter constant 217F Name Iq display filter constant 217F Description Filter constant for filtered actual value of Iq sent in PDO BEEN UOI at start up reset needed unit 5 Subindex Wa
151. t measured ccccseeeecccccseeseeeeceeeeeeeeecseaeeeeesesaaeeeeeseaageeeesenas 77 10 2 6 Reference Torque EE EE EE TUTTI 77 10 2 7 Slip Limit Definition rrnnnnnnrrnnnnnnvnvnnnnvnnnnnnrnnnnnnnrnvnnnnsnnnnnnssnnnnnnsnnnnnnsnnnnnnsrnnnnnsnnnnnnssnnnnssennnnn 78 10 2 8 Feld Weakening AGIN Nr rc 78 10 2 9 POROUS Calculato n SBN 79 10 2 10 ATEN een 80 Page 4 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 103 NENNE EE 81 10 3 1 Dead Time Compensation nennen nennen nnn nnne nsn ann nnns nna n inris n anne 81 A FOU ee e RR E EE EAE EAE 83 TT FEN EE 83 11 2 System Error 1 Software Trips cc cccccccccccccscsccsssenceccestccceseceeceeecesccessaceecercosteesseeceseecenceesseeeeeeeseest 84 11 3 System Error 2 Software Trips eeeeeissssssssssesssesssesseenn nnne nennen nnne nnns nnn nnns nnns nna 85 DE ME rubias EDEN Um 85 12 Appendix A Tables and Foures nennen nennen nnn nennen hann nnns naar nnns nnn nnn nnns 86 Tables 86 FOUE 87 13 Appendix B Parameter Descrpton eene nennen nennen nnne nennen nnne nnns nnns 89 130 MONT Si EE 89 13 1 1 MVS IG VST SI 0 EE EE EE EE A E 89 In PE ZIA E 89 Inverter Subtype 21A EEEMMEEEEEEMMEEEEEEEEEEEEEEEMEEEEEMMMM 90 ENEE
152. t Tn Id current control 2139 Max output Id current control 213B Non linear gain corner current Kp Id 2196 Non linear gain corner current Tn Id 2198 Non linear gain Tn slope Id 2199 Feld weakening Configuration Id current control 2195 Id filter constant 217E o Li o Gain Kp Iq current control 2134 Time constant Tn Iq current control 2135 H Max output Iq current control 2137 PERSER Non linear gain corner current Kp Iq 2191 Geet torte curan rez nr Non linear gain corner current Tn Iq 2193 Non linear gain Kp slope Iq 2192 Hardware Noi fines gaia Trslope a 21041 ITT Gees SE EE cane UU Sm um Configuration Iq current control 2190 lq filter Ea mm ONE DNE SEU DNE ENG EN mm mm mm HN mm OUR pm OUR OR mp rm GNU ER ERAS UH mm UNE OUS pm pp OUR OR AU rm HH NO UH mm mm mm pm UN OUR CURED rm GA rm mm mm mm mm mm pm UR mm SR e RS EH GAS GN EO mm UH pm UNT OUR UNS SUUS UNS mr UA mm NH HH pm CONS e OUR rm NUS SUN mm mm ml emm mm USO pm EE OUN ON OE OM CUM UR OUS URS DESEE DU mm EC pm OUR ON OH OUS OU OU ON OS SR DH mmm mm constant 217D Page 21 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 5 Control Modes QUASAR can operate in different modes The mode can be selected by the ECU VCU over the CANopen command interface Reference
153. t be carried out using the Automatic Test Mode of Q Control because the magnetizing current ly is calculated by the ACIM controller The gains K and T parameters of the controllers are adjusted until the step response has a fast rise without overshoot Non linear gains can also be deactivated if not needed Please refer to chapter 10 1 2 10 2 2 1 Procedure for Current Controller Follow the same procedure as for the IPM motor type as described in chapter 10 1 1 Instead of using the automatic test mode to generate the current step do it as follows 1 Set the value for the current step to be done in parameter Minimal magnetizing current ACIM 2458 directly apply the full step value 2 Turn on PWM 3 Wait 2 seconds until Scope has triggered 4 Turn off PWM First do the tuning of the Id current controller When finished copy the values of all the parameters found for Id to the respective Iq parameters Page 74 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 2 3 Iron Saturation The saturation behavior of the magnetizing inductance depends on the current which flows through it Reminder Voltage equation Usp la R Lm aao la ue ug iq R Magnetizing inductance Lm Omec P ld 10 2 3 1 Setup and Preconditions e Constant speed at 50 of the
154. t measurement gain of phase U Applied immediately Subindex 0 98 1 02 Current gain phase 3 212B Name Current gain phase 3 212B Description Defines the correction factor for the current measurement gain of phase W Applied immediately Supine NN Page 93 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Filter constant for analog input C1 2151 Name Filter constant for analog input C1 2151 Description Defines the filter constant for analog input MP Al C1 Applied at start up reset needed om EMEN Deme OO me Filter constant for analog input C2 2152 Name Fite constant for analog input c2 215 O O O O O O OO Description Defines the filter constant for analog input MP_AI_C2 weg Applied at start up reset needed NN Subindex mm Filter constant for analog input C3 2153 Name Filter constant for analog input C3 2153 Description Defines the filter constant for analog input MP Al C3 Applied at start up reset needed om Subindex Wage Page 94 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Warning PCB temperature 2107 Name Warning PCB temperature 2107 De
155. te modified 14 09 2012 2 Introduction QUASAR is the motor control software designed and implemented to run on SEMIKRON SKAI high voltage HV and low voltage LV inverters It can be used for traction applications with Permanent Magnet Synchronous Machines PSM Interior mounted Permanent Magnet Synchronous Machines IPMSM or Alternating Current Induction Machines ACIM QUASAR supports a wide range of system setup functions It provides a set of parameters that allows customizing the motor control software Thus correct configuration of those parameters is essential This document gives an overview of the features supported by QUASAR and defines the steps needed to get the fully configured QUASAR software running 2 1 Purpose This document contains information for experienced engineers to work with the QUASAR motor control software With the given step by step instructions QUASAR can be set up and tuned to be used in a system with a SKAI inverter Information about the SKAI hardware cabling and system design is not part of this document The document is split into three main parts Product Features The first part provides general information about the product features Setup Guide The second part is a step by step setup and configuration tutorial This part includes all chapters starting from chapter 4 Parameter Description The last part in the Appendix of the document is a detailed description of all parameters available in t
156. tek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C Document 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Configuration hardware 2140 Name Configuration hardware 2140 Description Defines several hardware related options 0000 0001 MP DO C1 for angle output 0000 0002 MP DO C1 for general purpose output controlled over CAN 0000 0004 MP DO C1 for ABZap Encoder supply or Encoder update 0000 0008 MP DO C1 for error signal 0000 0010 MP DO C2 for Angle output 0000 0020 MP DO C2 for general purpose output controlled over CAN 0000 0040 MP DO C2 for ABZap Encoder supply or Encoder update 0000 0080 MP DO C2 for error signal 0000 0100 motor direction inverted 0000 0200 change phase sequence V W W V 0000 0400 change counting sequence from encoder 0000 0800 If set QEP counter is reset on detection of every index If not set QEP counter is always reset at first index after startup or when within drift line ignore and error limit see drift line error 0000 1000 only one calculation per PWM 0000 2000 reserved 0000 4000 reserved 0000 8000 reserved 0001 0000 Invert PWM outputs 0002 0000 PLL is used for encoder 0004 0000 reserved 0008 0000 If set PS Al C1 resp PS Al C2 inputs are used for Sin Cos Encoder otherwise MP Al C1 resp MP AI C2 are used 0010 0000 reserved Applied at start up reset needed um Sides 0 Linne KEE Page 91 of
157. tek Speed to switch from BLDC to FOC control 21C0 Name Speed to switch from BLDC to FOC control 21C0 Description Defines the speed value where FOG starts If speed is greater than this value motor control switches from BC to FOC Applied immediately Sube pe Speed to switch from FOC to BLDC control 21C1 Name Speed to switch from FOC to BLDC control 21C1 Description Defines the speed value where BC control starts If speed is less than this value motor control switches from FOC to BC Applied immediately Subindex Default value 0 025 ewe jq A 13 12 Current control Contains parameters for the current control settings Applied immediately Page 141 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Maximum current difference 2146 Name Maximum current difference 2146 Description Defines the maximum current difference allowed between the reference current and the actual current The maximum difference is verified for Id and Iq currents Maximum Current difference IqRef Iq resp Maximum Current difference IdRef Id If the actual difference is greater than the value defined in this parameter a system error 2 will be generated Large differences may occure if current controllers are not tuned correcly i e if they overshoot or are too slow
158. th tuned and enabled NLSF Page 73 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 2 ACIM Settings This chapter defines the specific steps to configure QUASAR to control an AC induction motor 10 2 1 Basic Motor Parameters Using the datasheet of the motor manufacturer the different parameters like Rs Rr Los can be inserted in the Q Control parameter editor If these parameters are unknown the conventional tests can be done to try to obtain a good approximation of them n a Pole pairs 2124 Stator resistance 2121 0 02 Rotor resistance ACIM 2453 0 03 Rotor leakage inductance ACIM 2454 0 00025 Nominal magnetizing inductance 2455 0 003 Nominal flux ACIM 245A 0 28 Nominal motor speed ACIM 2492 n a Nominal motor torque ACIM 2501 n a Norm DC link voltage 2164 aa DC link voltage which is used for the application Table 45 ACIM Basic Motor Parameters If the saturation behavior of the magnetizing inductance is unknown refer to chapter 10 2 3 Use the default values as 1 approximation Nominal magnetizing inductance 2455 Refer to the motor datasheet 10 2 2 Current Controller To configure the current controller a current step has to be generated with the lg part of the current In difference to the IPM motor these steps canno
159. the OK button Warning e Closing communication in application Do not open it while working with the flash tool Figure 26 Quit QUASAR and jump to Bootloader 8 If no information similar to Figure 27 is shown press the Reset error button and repeat from step 5 If this does not help check your setup press the Reset error button and repeat from step 1 Version information MCU type OTP bootloader nya Part ID PARTID Ox00EF Bootloader Revision REVIO 0x0001 Flash APT used V02 10 Bootloader capabilities 0x00000007 Figure 27 Target Info Depending on the SKAI type and version you are using a different Bootloader version will be indicated 9 Press the button Select firmware file and choose the binary file of the firmware 10 Click on Program firmware button and confirm in the pop up window by clicking the Yes button 11 Click on the Program firmware button in the second pop up window d Enter burn date Use actual system date time Uncheck checkbox for user defined burn date Program firmware Figure 28 Q Control flash date time window 12 Wait for the programming to complete Erase flash Progress 100 00 Program firmware Figure 29 Programming and Erasing progress 13 Press the button Jump to application to start the uploaded firmware QUASAR is now running After restarting the SKAI QUASAR will automatically start from now on 6 4 Main Window
160. the reference value of the torque can be regulated better and faster To use NLSF Lg L and the generator constant need to be known If NLSF is activated the stability of the system should be checked again because the factors of the coupling are dependent on the speed and current If any of them is oscillating the output will be affected and will be injected in the input again which may lead to unstable system behavior 3 7 4 Field Weakening 3 7 4 1 For IPM PSM At higher speed a motor will induce a higher voltage than the q axis voltage set by the controller Therefore the torque generating q axis current cannot flow and the requested torque cannot be delivered The induced voltage can be limited by adding a d axis current This is called field weakening Field weakening allows the generation of d axis current as soon as the Ug absolute vector reaches the value of Udo absolute vector length 1 FW 214B At this point d axis current will be generated so that the Ug absolute vector is limited to this value Iq filtered M1 1 D D Apeak InvPsmCtriSlow 32 1 o Apeak Id filtered M1 p 0 Apeak UdqAbs filtered M 1 L 100 o p u Iq limitation factor lojme Ude gl Wey Wa Wa Wa EI Ie p u Id ref M1 p 0 Apeak Iq limitation factor p o p u Udc DC link D o
161. the specified value in parameter Overvoltage protection ON max DC link voltage 217C all the BOT switches will be turned on and therefore protect the inverter from excessive overvoltage The BOT switches are afterwards turned off again as soon as the DC Link voltage is lower than Overvoltage protection OFF minimal DC link voltage 217B Depending on the LCU version of the SKAI LV this feature may not be available For further information contact local sales 3 10 Communication The configuration and operation of QUASAR is controlled over CAN bus communication running the CANopen protocol The profile used in QUASAR has been derived from DS301 More information about the interface to QUASAR can be found in CAN protocol definition 1 For SKAI LV dual system QUASAR implements a separate node ly for each motor Depending on which node is addressed the corresponding motor is addressed This applies for the whole CANopen interface Table 14 shows the default node IDs of QUASAR They can be configured Entity Default node I Parameter Motor 1 Node ID 20F3 Motor 1 Scope Scope node ID 20F4 Motor 2 SKAI LV dual system Node ID 20F3 only in parameter set for node 2 Motor 2 Scope SKAI LV dual Scope node ID 20F4 system only in parameter set for node 2 Table 14 CANopen default node IDs Some SKAI types feature two CAN interfaces QUASAR only supports one CAN interface CAN A 3 11 Parameters QUASAR implemen
162. tions The current control is well adjusted Apply nominal DC link voltage Motor is driven by test bench at NO load with 1 5 of maximum motor speed PWM are enabled Activate the Dead Time Compensation in the parameter Configuration vector control 2150 The typical value is 0x000007F9 e Testin both directions e Cooling system must be on 10 3 1 2 Criteria The phase currents do not show a dead time anymore 10 3 1 3 Parameters Confiquration vector control 2150 0x000007F9 Enable Dead Time Compensation Dead time compensation 2147 Dead time minimal current 2148 0 01 Dead time slope 2149 0 001 Table 54 Dead Time Compensation Parameters 10 3 1 4 Scope settings e DeadTimeCompensation ssf 10 3 1 5 Procedure 1 Open the motor test function Current regulator in Q Control and apply current at 0 pure Start with small values and increase to higher currents Verify the phase currents in the Scope window Adjust the parameter Dead time compensation 2147 until the phase current has an acceptable sinusoidal shape see Figure 15 4 Repeat the test in other sense of rotation E amp Scope cg X SF Add Remove Iq M1 0 Apeak Current phase U M1 oe Current phase V M1 Ha EL Uke fe iure o gt Current phase W M1 Cons Com Com con 0 A comma
163. trasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual C e Document 8 0011 DO Quasar Version 2 0 Date modified 14 09 2012 SKAItek Sin Cos encoder sine offset 212D Name Sin Cos encoder sine offset 212D Description This parameter is used if a sine cosine encoder is used It allows adjusting the sine signal of the encoder to the desired offset level Applied at start up reset needed a ES ER mme IL Filter constant for sine input 2184 Name Filter constant for sine input 2184 Description Defines the filter constant for sine input Applied at start up reset needed Subindex Wage IL Sin Cos encoder cosine gain 212C Name Sin Cos encoder cosine gain 212C Description This parameter is used if a Sine Cosine Encoder is used It allows adjusting the cosine signal of the encoder to the desired amplitude level Applied at start up reset needed Unit EE Lo IE C NN Page 123 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Sin Cos encoder cosine offset 212E Name Sin Cos encoder cosine offset 212E Description This parameter is used if a sine cosine encoder is used It allows adjusting the cosine signal of the encoder to the desired offset level Applied at start up reset
164. tric limits are used for speed limitation If torque control mode with symmetric speed limit is selected the torque will be limited with a factor p u in order to limit speed as shown in Figure 4 Figure 4 Torque control mode with symmetric speed limit When regenerating see quadrants II and IV in Figure 4 the speed limiter is not active because the torque would have to be increased in order to limit the speed but the motor control shall never produce more torque than requested In torque control mode with asymmetric speed limit a high and low speed limit can be defined For example the motor can be forced to accelerate in forward direction by setting the low limit to O rpm and the high limit to the maximum speed requested Page 22 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 The speed limits only apply in motoring mode and will be ignored in generator mode Therefore the following range for the limits applies NimH20 Nim SU The speed limiters are implemented as normal cutback limiters see chapter 0 The start of the limitation is given by the limit The slope of the cutback limiter is given by Speed limit delta for slope 215 1 Figure 5 Torque control mode with asymmetric speed limit In the torque control mode the respective limits can be changed dur
165. ts a set of parameters to configure the system They are grouped in different categories Depending on the parameter the value is applied immediately or a reset is required for the new value to be applied Information about this behavior is given in the parameter description The full parameter list can be found in Appendix B Parameter Description While tuning a system it is very handy to work with parameters that apply directly without restart Nevertheless it is advised for safety reasons to always store parameters to EEPROM and restart the SKAI to apply them Page 36 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 3 11 1 Parameter Groups Overview The parameters for the QUASAR software are organized in different groups Each group holds a number of parameters which are described in the following group description Parameters Inverter DC link Motor Position sensor Vector control Current control Field weakening Dead time opeed control Dual System CANopen Tables Manufacturers use different conventions in their motor specifications QUASAR uses the following values e Resistance and inductance values of a single phase winding e Peak values for voltages and currents unless specified otherwise tteettre t 3 11 2 Range Checks and Validations QUASAR d
166. tup steps The number of indexes per revolution must not be greater than the number of pole pairs of the motor The number of pole pairs of the motor divided by the number of indexes per revolution must result in a whole number Both conditions must be true otherwise the position sensor is not suitable to be used with the motor 8 2 Type Specific Setup 8 2 1 Incremental Encoder ABZ ABZap and Resolver 8 2 1 1 Setup and Preconditions The motor is turned in forward direction using a test bench The DC link voltage is switched off Motor speed 1 596 of maximum motor speed Set Encoder delay compensation 2169 to O The phase cables must be connected and the phase sequence has to be in the correct order u v w 8 2 1 2 Criteria Verify the saw tooth signal on the scope Rising saw tooth positive direction see Figure 32 Page 52 of 170 SKAltek Keltenstrasse 1 CH 2563 lpsach Phone 41 32 332 79 32 Fax 41 32 332 79 31 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 8 2 1 3 Parameters Confiquration hardware 2140 0x00000000 Configure the following bits 0000 0800 resets QEP counter on index if set to 1 Encoder type 2143 1 incremental encoder Number of encoder lines 2125 Total number of rising and falling signal edges on track A and B Example Encoder with 1024 periods revolution gt 2048 edges on track A 2048 edges on track B gt
167. ubtype settings Applied at start up reset needed Unit Subindex Default value Page 100 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Maximum power 2145 Name Maximum power 2145 Description Defines the maximum power of the motor If power is greater than this value the system will reduce torque to limit the power Note power is estimated out of actual set torque theoretical value and motor speed The limiter has to be enabled in parameter Configuration vector control 2150 Applied immediately LIN MN C 13 2 1 Overvoltage protection Contains parameters for the overvoltage protection of the DC link feature only available for specific LV SKAI versions Contact sales for more information Configuration overvoltage protection 217A Name Configuration overvoltage protection 217A Description Defines option for the DC link overvoltage protection 0000 0001 BOT s are switched on at overvoltage Applied at start up reset needed C LIN MM Deme Page 101 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Reeg 20 emt Date modified 14 09 2012 CSKAI tek Overvoltage protection OFF minimal DC link voltage 217B Name Overvoltage protection OFF minimal DC link volta
168. ue mier 61 ga POWE ur UE 61 9 4 1 FETE 1 cC RTT 61 9 4 2 Motor Temperature Limiter eese nnne nnne nnn nnns 61 9 4 3 Power Electronics DCB Temperature Limiter ccccceccceeeceeeeceeeeeeeeeeeeseaeeeeeeeseaeeeeeeeas 62 9 4 4 PCB Temperature lun VE 62 9 4 5 Minimum DC Link Voltage Limiter esses nnn 62 9 4 6 Maximum DC Link Voltage Limiter rrrrnnnnnrnnnnnnnvnrnnnnnnnnnnnrvnnnnnnennnnnnennnnnnsnnnnnnsennnnenennnnssennnnn 63 9 4 7 SPESA MIRI MNT Tm 63 10 Setup guide Motor Control Settings nennen nennen nennen nnn nnn nnn nnns 64 vi PENE TT A M 64 10 1 1 eigen M 64 10 1 2 Current controller without non linear game 68 10 1 3 Encoder Delay Compensation nennen nennen nennen nnns nna nnn nnn 68 10 1 4 erus dere ici Ee re 69 10 1 5 Phase Resistance Measurement eene nenne nnns nn nnns nni sn nnns 70 10 1 6 Field Weakening FER gege ege hiere ie Eege 71 10 1 7 Non Linear State Feedback NLSF rrrrrrnnnnnnnrronnrrnnnnnnnnrrrnnrrnnnnnnnnsrnnnnnnnnnnnnnssennnnnnnnnsnnasennnn 72 EG ESS EE sconce et we andetecease sb aeeseceeeeceksbaseecaetacees 74 10 2 1 Basic Motor Parameters saiiieiaienstccanevensiisncainavecveVbaiaduvedeXesevauedisusreerasiertdedaiecededasveaquleceaiencanuveons 74 10 2 2 C rrent Ee te UNE 74 10 2 3 Fe AU OO OE 75 10 2 4 Torque or Efficiency Optimization nnne nenne nnn nnne nnn annees 76 10 2 5 Reference Torque Adjustmen
169. verter OT over temperature Check for sufficient cooling of the SKAI power module PCB or DCB Auxiliary supply low Check the auxiliary power supply Over current 1 12 or Check motor cabling for short circuits phase phase or phase I3 shield Check parameters for current controllers e g gain K Check the maximum current parameters Maximum current motor 2100 and Maximum absolute value of current FW 2142 DC link voltage high Check the battery voltage and the parameters for the DC Link voltage DC link parameters Table 55 Hardware Trips Page 83 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 11 2 System Error 1 Software Trips Error Description Possible solution code PCB over temperature Check the parameters for the electronic temperatures i e Maximum DCB temperature 210C and Maximum PCB temperature 21 068 Check for sufficient cooling of the SKAI power module DC link under voltage or Check the parameters for the DC Link voltage DC link over voltage detected parameters Motor over temperature Check the parameters for the motor temperatures max temperatures sensor type Maximum motor temperature 210A Check for sufficient cooling of the SKAI power module Over current Check motor cabling for short circuits phas
170. voltage 2117 Name Warning minimal DC link voltage 2117 Description Defines the warning level of the minimum cutback limiter of DC link voltage If the DC link voltage is less than this value the cutback limiter starts limiting torque and a warning is generated The cutback limiter is only active in motoring mode and has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed C LL NM NN me IL Minimal DC link voltage 2105 Name Minimal DC link voltage 2105 Description Defines the error level of the minimum cutback limiter of DC link voltage If the DC link voltage is less than this value PWM is turned off and a DC link under or over voltage error is generated The cutback limiter is only active in motoring mode and has to be enabled in parameter Configuration vector control 2150 Applied at start up reset needed Subindex Page 98 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Warning maximum DC link generator voltage 2118 Name Warning maximum DC link generator voltage 2118 Description Defines the warning level of the maximum cutback limiter of DC link voltage If DC link voltage is above this value the cutback limiter starts limiting torque and a warning is generated The cutback limiter is only
171. x Default value 0 00625 mee eS Udqabs filter constant 2183 Name Udqabs filter constant 2183 Description Filter constant for Udqabs filtering at start up reset needed unit 0 Subindex Default value 0 003 Ge Page 134 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 8 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 13 11 1 ACIM IFOC Contains parameter for AC Induction Motor ACIM in Indirect Field Oriented Control IFOC Parameters in this section are only used if ACIM motor type is defined Flux filter for slip limiter 2493 Name Flux filter for slip limiter 2493 Time constant for the flux filter Unit Subindex Default value 0 0008 eee cR Ki for I 2 t protection ACIM 2518 Name Ki for I 2 t protection ACIM 2518 Defines the integration rate of I 2 t protection used for rotor loss limitation Unit Subindex Default value 0 00001 Beet EE Udq abs filter ACIM 2498 Name Udo abs filter ACIM 2498 Time constant for the udq actual filter Unit Subindex Wage IL Page 135 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document X 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 Idq actual filter ACIM 2515 nome F acua ter RCD RBIS
172. ximum cutback limiter warning level Maximum speed 2102 n a Maximum cutback limiter error level Speed filter constant PT2 213A 0 05 Speed filter time constant Confiquration vector control 2150 0x00080FFD All limiters active Table 34 Speed Limiter Parameters Page 63 of 170 SKAltek Keltenstrasse 1 CH 2563 Ipsach Phone 41 32 332 79 32 Fax 41 32 332 79 81 Title QUASAR User Manual Document 0011 DO Quasar SKAI tek Version 2 0 Date modified 14 09 2012 10 Setup guide Motor Control Settings Position Limiter Motor Cabling Basic Settings Settings Control SE common Settings If the previous steps have been completed the SKAI with QUASAR is almost ready for operation What is missing is the tuning of the motor control for the motor to be used This will make sure the motor will run at high efficiency in every operating point 10 1 PSM IPM Settings 10 1 1 Current Controller This procedure provides setup of the current controllers This test is done with step responses at different current values The gain K and KI parameters of the controllers are adjusted until the step response has a fast rise without overshoot The gains for K and T may decrease in function of the current and reach a minimal value at a certain limit Therefore the ly and controller have some parameters to adjust this non linear gain behavior Non linear gains can also be deactivated if not needed To do so see chapter 10 1 2

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