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Added multi string handling and balancing

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This commit is contained in:
Matthias Heisig
2025-02-13 21:26:50 +01:00
parent f9df0a5180
commit 2ded890dd4
14 changed files with 554 additions and 302 deletions
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276
PLC/POUs/MAIN.TcPOU
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@@ -134,6 +134,21 @@ VAR
_fbStringReadyTimeout : TON;
// Sum of voltage of all active strings
_rStringsSumVoltage : REAL;
_arPowerString : ARRAY[0..(GVL_CONFIG.uiNumberOfStrings-1)] OF REAL;
_ui : UINT := 0;
_xStringsReady : BOOL;
_xStringsErrorActive : BOOL;
_xStringsInSchutdownDischargeMode : BOOL;
_xStringsShutdownDischargeAllowed : BOOL;
_xStringsAllInAutomaticMode : BOOL;
_xStringsOff : BOOL;
_rMaxCurrentInverterDCVoltage : REAL;
_rMinCurrentInverterDCVoltage : REAL;
_fbModbusRead : FB_MBReadRegs;
_wLength : WORD := 49;
xDebugTest : BOOL;
@@ -286,15 +301,15 @@ _tonStartupDelay(IN := TRUE);
// Call string 1
_afbStrings[0](
stStringModuleVoltageConfig := GVL_CONFIG.stString1VoltageConfig,
xEnable := _xEnableString, //AND GVL_CONFIG.xDummy,
xStartBalancing := _xStartBalancing, // AND GVL_CONFIG.xDummy,
xEnable := _xEnableString,
xStartBalancing := _xStartBalancing,
sInverterIP := GVL_CONFIG.sInverterIpString1,
rPowerInverter := _rPowerInverter,
rPowerInverter := _arPowerString[0],
xInSafetyCheckMode := _xInSafetyCheckMode,
stHMIInterface:= GVL_SCADA.stHMIInterface[0],
xEmergencyStopOk:= _xEmergencyStopOk,
xReleaseErrors:= _xReleaseErrors AND _tonStartupDelay.Q AND _xEtherCatString1Ok,
xReleaseLimitErrors:= _xReleaseLimitsErrors AND _tonStartupDelay.Q,
xReleaseLimitErrors:= _xReleaseLimitsErrors AND _tonStartupDelay.Q AND _xEtherCatString1Ok,
xReleaseManualMode := _xReleaseManualMode,
xConfirmAlarms:= _xConfirmAlarms,
xAllToManualMode := _xAllComponentsToManualMode,
@@ -310,11 +325,11 @@ _afbStrings[1](
xEnable := _xEnableString,
xStartBalancing := _xStartBalancing,
sInverterIP := GVL_CONFIG.sInverterIpString2,
rPowerInverter := _rPowerInverter,
rPowerInverter := _arPowerString[1],
xInSafetyCheckMode := _xInSafetyCheckMode,
stHMIInterface:= GVL_SCADA.stHMIInterface[1],
xEmergencyStopOk:= _xEmergencyStopOk,
xReleaseErrors:= _xReleaseErrors AND _tonStartupDelay.Q AND _xEtherCatString2Ok AND FALSE,
xReleaseErrors:= _xReleaseErrors AND _tonStartupDelay.Q AND _xEtherCatString2Ok,
xReleaseLimitErrors:= _xReleaseLimitsErrors AND _tonStartupDelay.Q AND _xEtherCatString2Ok,
xReleaseManualMode := _xReleaseManualMode,
xConfirmAlarms:= _xConfirmAlarms,
@@ -325,12 +340,85 @@ IF _afbStrings[1].xError THEN
_xErrorActive := TRUE;
END_IF
// ===============================
// Get global string status information
// ===============================
_xStringsReady := TRUE;
_xStringsErrorActive := FALSE;
_xStringsInSchutdownDischargeMode := FALSE;
_xStringsShutdownDischargeAllowed := TRUE;
_xStringsAllInAutomaticMode := TRUE;
_xStringsOff := TRUE;
_rMaxCurrentInverterDCVoltage := 0.0;
_rMinCurrentInverterDCVoltage := 10_000;
_rHighestSegmentVoltage := 0.0;
_rSmallestSegmentVoltage := 1_000.0;
FOR _ui := 0 TO (GVL_CONFIG.uiNumberOfStrings-1) DO
// Check ready state
IF (NOT _afbStrings[_ui].xReady) THEN
_xStringsReady := FALSE;
END_IF
// Check error state
IF _afbStrings[_ui].xError THEN
_xStringsErrorActive := TRUE;
END_IF
// Check for shutdown discharge mode
IF _afbStrings[_ui].xInShutdownDischargeMode THEN
_xStringsInSchutdownDischargeMode := TRUE;
END_IF
// Check for shutdown discharge allowed
IF (NOT _afbStrings[_ui].xShutdownDischargeAllowed) THEN
_xStringsShutdownDischargeAllowed := FALSE;
END_IF
// Check for all in automatic mode
IF (NOT _afbStrings[_ui].xAllModulesInAutoMode) THEN
_xStringsAllInAutomaticMode := FALSE;
END_IF
// Check for all strings off
IF (NOT _afbStrings[_ui].xOff) THEN
_xStringsOff := FALSE;
END_IF
// Check for max dc voltage
IF _rMaxCurrentInverterDCVoltage < _afbStrings[_ui].stInverterData.rActDCVoltage THEN
_rMaxCurrentInverterDCVoltage := _afbStrings[_ui].stInverterData.rActDCVoltage;
END_IF
// Check for min DC voltage
IF _rMinCurrentInverterDCVoltage > _afbStrings[_ui].stInverterData.rActDCVoltage THEN
_rMinCurrentInverterDCVoltage := _afbStrings[_ui].stInverterData.rActDCVoltage;
END_IF
// Calculate highest segment voltage
IF _rSmallestSegmentVoltage > _afbStrings[_ui].rSmallestSegmentVoltage THEN
_rSmallestSegmentVoltage := _afbStrings[_ui].rSmallestSegmentVoltage;
END_IF
// Calculate lowest segment voltage
IF _rHighestSegmentVoltage < _afbStrings[_ui].rHighestSegmentVoltage THEN
_rHighestSegmentVoltage := _afbStrings[_ui].rHighestSegmentVoltage;
END_IF
END_FOR
// ===============================
// Calculate sum power for string balancing
// ===============================
_rStringsSumVoltage := _afbStrings[0].rCurrentVoltage + _afbStrings[1].rCurrentVoltage;
// ===============================
// Hardware reset button part 2
// ===============================
_xShowErrorOnButton := _xErrorActive;
// HMI Feedback
(*
GVL_SCADA.stHMIInterface[0].rVoltage := _afbStrings[0].rCurrentVoltage;
IF _afbStrings[0].eStatus = E_COMPONENT_STATUS.ON THEN
IF _iState = 30 AND _rPowerInverter > 0 THEN
@@ -343,6 +431,7 @@ IF _afbStrings[0].eStatus = E_COMPONENT_STATUS.ON THEN
ELSE
GVL_SCADA.stHMIInterface[0].eStatus :=_afbStrings[0].eStatus;
END_IF
*)
// ===============================
// Read modbus request count
@@ -381,25 +470,25 @@ _fbModbusRead(
// Copy data to modbus registers
// ===============================
// Modbus current inverter values
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentActivePower := REAL_TO_DINT(_afbStrings[_uiDebugCurrentString].stInverterData.rActACPower);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentReactivePower := REAL_TO_DINT(_afbStrings[_uiDebugCurrentString].stInverterData.rActReactivePower);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase1 := REAL_TO_DINT(_afbStrings[_uiDebugCurrentString].stInverterData.rActtACPhaseACurrent);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase2 := REAL_TO_DINT(_afbStrings[_uiDebugCurrentString].stInverterData.rActtACPhaseBCurrent);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase3 := REAL_TO_DINT(_afbStrings[_uiDebugCurrentString].stInverterData.rActtACPhaseCCurrent);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentActivePower := 0;
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentReactivePower := 0;
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase1 := 0;
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase2 := 0;
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase3 := 0;
FOR _ui := 0 TO (GVL_CONFIG.uiNumberOfStrings-1) DO
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentActivePower := GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentActivePower + REAL_TO_DINT(_afbStrings[_ui].stInverterData.rActACPower);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentReactivePower := GVL_MODBUS.stModbusEMSComm.stModbusReg11.diCurrentReactivePower + REAL_TO_DINT(_afbStrings[_ui].stInverterData.rActReactivePower);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase1 := GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase1 + REAL_TO_DINT(_afbStrings[_ui].stInverterData.rActtACPhaseACurrent);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase2 := GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase2 + REAL_TO_DINT(_afbStrings[_ui].stInverterData.rActtACPhaseBCurrent);
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase3 := GVL_MODBUS.stModbusEMSComm.stModbusReg11.diTotalACCurrentPhase3 + REAL_TO_DINT(_afbStrings[_ui].stInverterData.rActtACPhaseCCurrent);
END_FOR
// Set Modbus mirror values
GVL_MODBUS.stModbusEMSComm.stModbusReg11.diSetpointActivePowerMirror := GVL_MODBUS.stModbusEMSComm.stModbusReg12.diSetpointActivePower;
GVL_MODBUS.stModbusEMSComm.stModbusReg11.rSetpointCosPhiMirror := GVL_MODBUS.stModbusEMSComm.stModbusReg12.rSetpointCosPhi;
// ===============================
// Calculate highest and lowest
// segment voltage
// ===============================
_rSmallestSegmentVoltage := _afbStrings[_uiDebugCurrentString].rSmallestSegmentVoltage;
_rHighestSegmentVoltage := _afbStrings[_uiDebugCurrentString].rHighestSegmentVoltage;
// ===============================
// State machine
// ===============================
@@ -464,6 +553,16 @@ CASE _eBMSControlMode OF
_eBMSControlMode := GVL_SCADA.eRequestedControlMode;
END_IF
SM_BALANCING();
E_BMS_CONTROL_MODE.CYCLING:
_xAllComponentsToManualMode := FALSE;
_xInSafetyCheckMode := FALSE;
_xReleaseManualMode := FALSE;
_rAutoPowerRequest := DINT_TO_REAL(GVL_MODBUS.stModbusEMSComm.stModbusReg12.diSetpointActivePower);
IF (GVL_SCADA.eRequestedControlMode <> _eBMSControlMode) AND (GVL_SCADA.xCanChangeControlMode) THEN
_eBMSControlMode := GVL_SCADA.eRequestedControlMode;
END_IF
SM_AUTO();
END_CASE
GVL_SCADA.xCanChangeControlMode := _xCanChangeMode;
@@ -514,13 +613,13 @@ END_IF]]></ST>
10: // Wait for string to be ready
_fbStringReadyTimeout(IN := TRUE, PT := GVL_CONFIG.timStringReadyTimeout);
IF _afbStrings[_uiDebugCurrentString].xReady AND (NOT _afbStrings[_uiDebugCurrentString].xError) THEN
IF _xStringsReady AND (NOT _xStringsErrorActive) THEN
_fbStringReadyTimeout(IN := FALSE);
_rPowerInverter := 0.0;
_iState := 30;
END_IF
IF _afbStrings[_uiDebugCurrentString].xError OR _fbStringReadyTimeout.Q THEN
IF _xStringsErrorActive OR _fbStringReadyTimeout.Q THEN
_fbStringReadyTimeout(IN := FALSE);
_xEnableString := FALSE;
GVL_SCADA.stAutomaticModeHMI.diSetpointAutomatic := 0;
@@ -528,6 +627,7 @@ END_IF]]></ST>
_iState := 45;
END_IF
IF (ABS(_rAutoPowerRequest) < DINT_TO_REAL(GVL_CONFIG.diMinimumAbsPowerForEnable)) THEN
_fbStringReadyTimeout(IN := FALSE);
_xEnableString := FALSE;
@@ -574,51 +674,65 @@ END_IF]]></ST>
END_IF
// Shutdown triggered by battery fully charged
IF GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus = E_CHARGE_STATUS.CHARGING AND ((_afbStrings[_uiDebugCurrentString].stInverterData.rActDCVoltage >= GVL_CONFIG.rStringFullyChargedVoltage) OR _rHighestSegmentVoltage >= GVL_CONFIG.rMaximumUnitVoltage) THEN
_tonBeginShutdown(In := FALSE);
IF GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus = E_CHARGE_STATUS.CHARGING AND ((_rMaxCurrentInverterDCVoltage >= GVL_CONFIG.rStringFullyChargedVoltage) OR _rHighestSegmentVoltage >= GVL_CONFIG.rMaximumUnitVoltage) THEN
// Send message
_fbBatteryFullMessage.Send(0);
IF (_eBMSControlMode = E_BMS_CONTROL_MODE.CYCLING) THEN
GVL_MODBUS.stModbusEMSComm.stModbusReg12.diSetpointActivePower := GVL_MODBUS.stModbusEMSComm.stModbusReg12.diSetpointActivePower * -1;
// Change of charge discharge should be handled in next cycle by sasme state
// GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.DISCHARGING;
ELSE
_tonBeginShutdown(In := FALSE);
// Send message
_fbBatteryFullMessage.Send(0);
// Set inverter to zero power
_rPowerInverter := 0.0;
// Set local remote to zero power
GVL_SCADA.stAutomaticModeHMI.diSetpointAutomatic := 0;
// Start string shutdown
_xEnableString := FALSE;
// Change battery status
GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.FULL;
GVL_MODBUS.stModbusEMSComm.stModbusReg10.uiActiveParallelMembers := 0;
_iState := 35;
END_IF
// Set inverter to zero power
_rPowerInverter := 0.0;
// Set local remote to zero power
GVL_SCADA.stAutomaticModeHMI.diSetpointAutomatic := 0;
// Start string shutdown
_xEnableString := FALSE;
// Change battery status
GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.FULL;
GVL_MODBUS.stModbusEMSComm.stModbusReg10.uiActiveParallelMembers := 0;
_iState := 35;
END_IF
// Shutdown triggered by battery empty
IF GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus = E_CHARGE_STATUS.DISCHARGING AND ((_afbStrings[_uiDebugCurrentString].stInverterData.rActDCVoltage <= GVL_CONFIG.rStringEmptyVoltage) OR _rSmallestSegmentVoltage <= GVL_CONFIG.rMinimumUnitVoltage) THEN
_tonBeginShutdown(In := FALSE);
IF GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus = E_CHARGE_STATUS.DISCHARGING AND ((_rMinCurrentInverterDCVoltage <= GVL_CONFIG.rStringEmptyVoltage) OR _rSmallestSegmentVoltage <= GVL_CONFIG.rMinimumUnitVoltage) THEN
IF (_eBMSControlMode = E_BMS_CONTROL_MODE.CYCLING) THEN
GVL_MODBUS.stModbusEMSComm.stModbusReg12.diSetpointActivePower := GVL_MODBUS.stModbusEMSComm.stModbusReg12.diSetpointActivePower * -1;
// Change of charge discharge should be handled in next cycle by sasme state
// GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.CHARGING;
ELSE
_tonBeginShutdown(In := FALSE);
// Send Message
_fbBatteryEmptyMessage.Send(0);
// Set local remote to zero power
GVL_SCADA.stAutomaticModeHMI.diSetpointAutomatic := 0;
// Set inverter to zero power
_rPowerInverter := 0.0;
// Start string shutdown
_xEnableString := FALSE;
// Change battery status
GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.EMPTY;
GVL_MODBUS.stModbusEMSComm.stModbusReg10.uiActiveParallelMembers := 0;
_iState := 35;
// Send Message
_fbBatteryEmptyMessage.Send(0);
// Set local remote to zero power
GVL_SCADA.stAutomaticModeHMI.diSetpointAutomatic := 0;
// Set inverter to zero power
_rPowerInverter := 0.0;
// Start string shutdown
_xEnableString := FALSE;
// Change battery status
GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.EMPTY;
GVL_MODBUS.stModbusEMSComm.stModbusReg10.uiActiveParallelMembers := 0;
_iState := 35;
END_IF
END_IF
// Check for errors
IF _afbStrings[_uiDebugCurrentString].xError THEN
IF _xStringsErrorActive THEN
_xEnableString := FALSE;
_tonBeginShutdown(In := FALSE);
GVL_SCADA.stAutomaticModeHMI.diSetpointAutomatic := 0;
@@ -627,7 +741,7 @@ END_IF]]></ST>
END_IF
35: // Wait for string to be in shutdown discharge mode
IF _afbStrings[_uiDebugCurrentString].xInShutdownDischargeMode THEN
IF _xStringsInSchutdownDischargeMode THEN
// Check if we are allowed to discharge during shutdown with inverter
IF GVL_CONFIG.xShutdownDischargeWithInverter THEN
_iState := 40;
@@ -641,12 +755,12 @@ END_IF]]></ST>
END_IF
// Check for errors
IF _afbStrings[_uiDebugCurrentString].xError THEN
IF _xStringsErrorActive THEN
_iState := 1000;
END_IF
40: // Wait for inverter discharge done
IF _afbStrings[_uiDebugCurrentString].xShutdownDischargeAllowed THEN
IF _xStringsShutdownDischargeAllowed THEN
_rPowerInverter := GVL_CONFIG.rAbsShutdownDischargePower;
ELSE
_rPowerInverter := 0.0;
@@ -657,29 +771,30 @@ END_IF]]></ST>
END_IF
// Check for errors
IF _afbStrings[_uiDebugCurrentString].xError THEN
IF _xStringsErrorActive THEN
_iState := 1000;
END_IF
// Restart if possible
IF (ABS(_rAutoPowerRequest) > DINT_TO_REAL(GVL_CONFIG.diMinimumAbsPowerForEnable)) AND (NOT _afbStrings[_uiDebugCurrentString].xError) AND _afbStrings[_uiDebugCurrentString].xAllModulesInAutoMode THEN
IF (ABS(_rAutoPowerRequest) > DINT_TO_REAL(GVL_CONFIG.diMinimumAbsPowerForEnable)) AND (NOT _xStringsErrorActive) AND _xStringsAllInAutomaticMode THEN
_iState := 5;
END_IF
45: // Wait for shutdown of string to be done
IF (NOT _afbStrings[_uiDebugCurrentString].xInShutdownDischargeMode) AND _afbStrings[_uiDebugCurrentString].xOff THEN
IF (NOT _xStringsInSchutdownDischargeMode) AND _xStringsOff THEN
GVL_MODBUS.stModbusEMSComm.stModbusReg11.eBatteryStatus := E_BATTERY_STATUS.OFF;
GVL_MODBUS.stModbusEMSComm.stModbusReg11.eChargeStatus := E_CHARGE_STATUS.UNDEFINED;
_iState := 0;
END_IF
// Restart if possible
IF (ABS(_rAutoPowerRequest) > DINT_TO_REAL(GVL_CONFIG.diMinimumAbsPowerForEnable)) AND (NOT _afbStrings[_uiDebugCurrentString].xError) AND _afbStrings[_uiDebugCurrentString].xAllModulesInAutoMode THEN
IF (ABS(_rAutoPowerRequest) > DINT_TO_REAL(GVL_CONFIG.diMinimumAbsPowerForEnable)) AND (NOT _xStringsErrorActive) AND _xStringsAllInAutomaticMode THEN
_xCanChangeMode := FALSE;
_iState := 5;
END_IF
// Check for errors
IF _afbStrings[_uiDebugCurrentString].xError THEN
IF _xStringsErrorActive THEN
_iState := 1000;
END_IF
@@ -691,7 +806,7 @@ END_IF]]></ST>
_iState := 1010;
1010: // Wait for reset from error state
IF (_rAutoPowerRequest = 0.0) AND (NOT _afbStrings[_uiDebugCurrentString].xError) AND _xConfirmAlarms THEN
IF (_rAutoPowerRequest = 0.0) AND (NOT _xStringsErrorActive) AND _xConfirmAlarms THEN
// Reset modbus error register
GVL_MODBUS.stModbusEMSComm.stModbusReg11.lwErrorBitmap := 0;
@@ -703,7 +818,28 @@ END_IF]]></ST>
_xCanChangeMode := TRUE;
END_IF
END_CASE]]></ST>
END_CASE
// Calculate string power balancing
IF _rStringsSumVoltage <> 0 THEN
FOR _ui := 0 TO (GVL_CONFIG.uiNumberOfStrings-1) DO
// Discharging
IF _rPowerInverter > 0 THEN
_arPowerString[_ui] := _rPowerInverter * (_afbStrings[_ui].rCurrentVoltage / _rStringsSumVoltage);
// Charging
ELSIF _rPowerInverter < 0 THEN
_arPowerString[_ui] := _rPowerInverter * (1.0 - (_afbStrings[_ui].rCurrentVoltage / _rStringsSumVoltage));
// Nothing
ELSE
_arPowerString[_ui] := 0.0;
END_IF
END_FOR
ELSE
FOR _ui := 0 TO (GVL_CONFIG.uiNumberOfStrings-1) DO
_arPowerString[_ui] := 0.0;
END_FOR
END_IF
]]></ST>
</Implementation>
</Action>
<Action Name="SM_BALANCING" Id="{f1f90032-de29-468d-899c-50bfb54e48e0}">
@@ -760,6 +896,11 @@ END_CASE]]></ST>
<ST><![CDATA[_xCanChangeMode := TRUE;]]></ST>
</Implementation>
</Action>
<Action Name="SM_PRECHARGE" Id="{b84aedc8-0039-40a2-8abe-a166eca7bebc}">
<Implementation>
<ST><![CDATA[]]></ST>
</Implementation>
</Action>
<Action Name="SM_SAFETY_CHECK" Id="{6d8e5993-cf32-4980-9ea3-c1fbfa4b8601}">
<Implementation>
<ST><![CDATA[// Start on start button pressed
@@ -796,6 +937,7 @@ CASE _iStateSafetyCheck OF
IF NOT _xStartSafetyCheck THEN
_xEnableString := FALSE;
_iStateSafetyCheck := 0;
_xCanChangeMode := TRUE;
END_IF
// Check for errors