ST STEVAL-ISV002V2 Bedienungsanleitung

February 2011 Doc ID 18125 Rev 1 1/19

UM1016

User manual

Getting started with the STEVAL-ISV002V2, 3000 W

photovoltaic converter for grid connected applications

Introduction

This document describes the procedure and steps to follow in order to correctly operate the

3 kW STEVAL-ISV002V2 photovoltaic converter. This system consists of an isolated DC-DC

converter and a full bridge inverter used to deliver sinusoidal current at 50 Hz to the grid.

The system operates with input voltages in the range of 200 V to 400 V and is tied to the grid

at 230 Vrms, 50 Hz, through an LCL filter. The demonstration board is provided with a fully

digital control algorithm, including power management for grid-connected operation and

MPPT (maximum power point tracking) algorithm. This has been implemented on a

dedicated control board, equipped with the latest generation 32 bit STM32F103ZE

microcontroller.

Figure 1. 3 kW PV system image

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Contents UM1016

2/19 Doc ID 18125 Rev 1

Contents

1 System description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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UM1016 List of figures

Doc ID 18125 Rev 1 3/19

List of figures

Figure 1. 3 kW PV system image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Figure 2. Block scheme of hardware implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 3. Description of the STEVAL-ISV002V2 main parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 4. Coupling inductors wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 5. Connectors used to wire the filter inductors and coupling reactor . . . . . . . . . . . . . . . . . . . . 6

Figure 6. Connectors used for the sensing signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 7. Connectors used for power supply and relay command. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 8. Wiring setup of the output sensing and relay board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 9. Input and output power connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 10. First screen shot shown on the LCD display at startup . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 11. Description of the joystick commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 12. Closed loop/open loop selection window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 13. Open loop screen shot with control state in Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 14. Screen shot with control loop state in start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 15. DC-DC converter control window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 16. DC-AC converter control window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 17. LCD display screen shot after microcontroller reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 18. Calibration function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 19. LCD display showing the closed loop control is in start mode . . . . . . . . . . . . . . . . . . . . . . 15

Figure 20. Voltage probe placement to compare inverter generated voltage and gird voltage . . . . . . 15

Figure 21. Control state “Grid Insertion” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 22. Control parameters tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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System description UM1016

4/19 Doc ID 18125 Rev 1

1 System description

Figure 2 is a block scheme representing the hardware implementation adopted for the

STEVAL-ISV002V2 demonstration board.

Figure 2. Block scheme of hardware implementation

It consists of 5 PCBs electrically connected by means of suitable connectors. The 5 PCBs

are listed below and are hereafter referred to with the following nomenclature:

●Main power board

●Multi-output power supply board

●Control and signal conditioning board

●Output sensing and relay board

●Input current sensing board

The system can be completed by adding two additional boards with input and output EMI

filters which, at the moment, are not included in the final prototype, even though they are

shown in the block scheme of Figure 2.

The main power board consists of the DC-DC converter, supplied by the PV array, and a

sinusoidal PWM full bridge inverter realizing grid connection at 230 Vrms and 50 Hz. Gate

driving circuitry, input and output voltage sensors of the DC-DC converter and the high

frequency (HF) transformer are also placed on the main power board. The multi-output

power supply board and the control board are connected to the main power board by means

of 34-pin connectors. The connection/disconnection of these PCBs is very easy. This type of

connection was chosen to allow separate debug and characterization of each board,

independently from the others.

The output sensing and relays board realizes the interface between the power system and

the grid. This task is accomplished with the implementation of a proper control algorithm

which requires both grid current and grid voltage sensing. For this reason, the system is

equipped with current and voltage Hall effect sensors. Two relays, controlled by an I/O of the

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UM1016 System description

Doc ID 18125 Rev 1 5/19

microcontroller, are also placed on the same PCB to interrupt/connect phase and neutral of

the system to phase and neutral of the grid. Moreover, this board is provided with 2-way

connectors for electrical wiring of the LCL filter to the main power board.

The multi-output power supply board implements two independent offline flyback

converters, with a wide input voltage range, based on VIPer™ technology, to generate the

following output voltages:

●+5 V to supply DC-DC converter gate drivers

●+5 V to supply DC-AC converter gate drivers

●+5 V to supply the microcontroller

●+/-15 V for LEM sensor supply

●24 V for relay supply

Figure 3. Description of the STEVAL-ISV002V2 main parts

Figure 3 shows a more detailed description of the hardware implementation according to the

nomenclature used above.

The main power board is highlighted in yellow and clearly shows the way it hosts two

ancillary boards: the multi-output power supply board and the control board with

STM32F103ZE. They are both highlighted in red in Figure 3. Also the output sensing and

relay board is highlighted in red and placed near the two filter inductors highlighted with a

grey circle and the coupling inductor highlighted by a blue circle. The coupling inductor is

also connected in series with a circuit breaker providing fault protection.

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System description UM1016

6/19 Doc ID 18125 Rev 1

Figure 4. Coupling inductors wiring

Figure 4 shows how the filter and coupling inductors are actually wired, between the middle

point of each leg of the full bridge inverter and the output relay and sensing board.

Figure 5. Connectors used to wire the filter inductors and coupling reactor

In Figure 5 the three 2-way screw terminal connectors are highlighted. The filter inductors

are connected to J8, placed on the main power board and to J7 which is placed in the output

sensing and relay board. The coupling reactor is also connected to the output sensing and

relays board through J9. It is important to underline that while the filter inductors have the

two wires connected between J7 and J8, both the wires of the coupling inductor are

connected to J9.

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UM1016 System description

Doc ID 18125 Rev 1 7/19

Figure 6. Connectors used for the sensing signals

●Connect J15 (relay board) with J11 (control board)

●Connect J14 (relay board) with J9 (control board)

●Connect J14 (relay board) with DC input current sensor

The microcontroller board and the output sensing and relay board are also equipped with

mini BNC connectors. These connectors are used to carry the current and voltage

measuring signals by means of shielded wires, running from the sensing device to the

microcontroller board, where they are then conditioned and properly filtered to be acquired

through the ADCs. In particular, on the microcontroller board, J14 is used to connect the

wire carrying the signal proportional to the input DC current. The second terminal of this

wire is connected on the input current sensing board. The wire carrying the signal

proportional to the line voltage is connected to J11 at one end, on the microcontroller board

and, on the other end, to J15 which is placed on the output sensing and relay board. The

wire carrying the signal proportional to the grid injected current is connected to J9, placed

on the microcontroller board, and to J14 which is soldered on the sensing and relay board.

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System description UM1016

8/19 Doc ID 18125 Rev 1

Figure 7. Connectors used for power supply and relay command

●Connect J6 (multi-output power supply board) to VDC (relay board)

●Connect 24 V (multi-output power supply board) to J11 (relay board)

●Connect J1 (control board) to J12 (relay board)

The output sensing and relay board is also equipped with additional screw connectors used

for the power supply cables and also the signal provided by the microcontroller to command

the operation of the relay. The voltage sensor needs a +/-15 V supply voltage which is

provided by means of a multi-wire cable running from J5 on the power supply board to the 3-

way screw terminal connector, called VDC, on the output sensing board. The +15 V is also

used to obtain the +5 V supplying the Hall effect current sensor.

The relay coil is supplied with 24 V provided by the multi-output flyback of the power supply

board and running on a multi-core shielded wire connected between the 24 V connector of

the power supply board and J11 on the output sensing board. The relay command cable is

connected between J1 and J12, placed on the microcontroller board and output sensing

board respectively.

Figure 8 shows a close-up of the output sensing board and provides clear instructions on

how to correctly carry out the wiring of this part of the system.

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UM1016 System description

Doc ID 18125 Rev 1 9/19

Figure 8. Wiring setup of the output sensing and relay board

●Connect J6 (multi-output power supply board) to VDC (relay board)

●Connect 24 V (multi-output power supply board) to J11 (relay board)

●Connect J1 (control board) to J12 (relay board)

Open loop operation

The control firmware can operate either in open loop or closed loop mode. The open loop

mode of operation has been included to allow debugging and component evaluation when

the system is not connected to the grid and therefore delivering power to a suitable external

load. The open loop function and hardware configuration allows also to independently test

both the DC-DC converter and the DC-AC converter. In this case, connector J9 shown in

Figure 9, can be used to either connect an electrical load when testing the DC-DC converter

or to connect a DC power supply when testing the DC-AC inverter.

Figure 9. Input and output power connectors

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System description UM1016

10/19 Doc ID 18125 Rev 1

After having connected the AC voltage to connector J1, the LCD display on the control

board lights up and shows the screen shot in Figure 10, indicating the firmware version:

Figure 10. First screen shot shown on the LCD display at startup

The control board is equipped with a miniature joystick that can be used to scroll the menu

for functions included in the firmware. The joystick has five commands as detailed in

Figure 11:

Figure 11. Description of the joystick commands

The test procedure detailed below can be followed in order to test the system with the open

loop control firmware:

1. Connect a suitable electrical load to connector J7. Keep the filter inductors wire

connected on J7 as well.

2. Move the joystick up to select the next window on the LCD display. The screen shot of

Figure 12 appears.

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