Phase Converter Simulator AKA Voltron Group 8 Anthony McCorvey Ronnie Lalchan Chris Beck George Thompson

Problem The power companies are converting the old mechanical meters to Smart meters. Wireless Communication Accurate Readings KWH every hour Power Factor Connect/Disconnect No jobs for meter readers Hiring untrained contractors Cheaper Looking for a cost efficient method to train contractors

Goals To design a product that the power companies can use for their renovations Cost efficient Safe User Friendly Test and Train

Design Requirements Hardware Meter Cans Potential Transformers Variable Transformer Toggle Switches/Relays Fuses Control Box

Thinking about the Design 2 Phase Configurations Delta Wye Single Phase Three Phase How can we convert single phase to three phase? Rotary motors etc Too expensive Defeats our goal “Trick the Voltage” That’s when Simulator was added to the name Phase Configuration Phase to Ground Phase 1 to Phase 2 Phase 2 to Phase 3 and Phase 3 to Phase 1 *Power leg to Ground Single Phase Delta 120 Volts 240 Volts Three Phase 208 Volts Wye

Meter Cans (2) Three Phase Meter Cans (3) Single Phase Meter Cans 2 Wire Delta Junction Meter 3 Wire Delta 3 Wire Wye LED Lights (3) Single Phase Meter Cans 2 Wire Delta 3 Wire Delta 3Wire Wye LED Lights (Safety Precautions)

Potential Transformers 6 total potential transformers 3 Step-down PT’s “Configuration” 115:50 (Phase to Phase - Delta) and (Phase to Ground – Delta and Wye) 115:80 (Stinger leg Delta) 115:42 (Phase to Phase – Wye) 3 Step-Up PT’s “Multiplier” 2.4:1

Step-Up PT Schematic Variable Transformer Secondary Primary 115 50 11580 11542 S3 Variable Transformer

Voltage Calculations Phase to Ground for Wye and Delta (115:50) 50 x 2.4 = 120 Volts Power leg to Ground (Delta) (115:80) 80 x 2.4 = 192 Volts Specific to needs Found a solution Phase to Phase for Wye to Delta Subtractive Polarity Delta 50 x 2.4 = 120 volts Different terminals 120 <0 – 120 <180 = 240 Volts Wye (115:42) 42 x 2.4 = 100.8 Volts 100.8 <0 – 100.8 <180 = 201.6 Volts

Control Box Variable Transformer 4 Fuses ON/OFF switch (1) 5 Amps (3) 2 Amps ON/OFF switch Safety Precautions 5 toggle switches for selection of configuration 3PDT

Delta Switching Sequence Delta Single Phase Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Phase 1&2 to Ground Up Down Phase 1 to Phase 2 Delta Three Phase Power Leg to Ground Phase 1 to Power Leg Phase 2 to Power Leg

Wye Switching Sequence Single Phase Switch 1 Switch 2 Switch 3 Switch 4 Switch 5 Phase 1&2 to Ground Up Down Phase 1 to Phase 2 Wye Three Phase Phase 1,2,&3 to Ground Phase 1 to Phase 3 Phase 2 to Phase 3

Phase Converter Simulator Hardware 1

Changing Switches to Relays Mechanically changes configurations Allows microcontroller to control switching A lower voltage device can now control the voltages of the meter cans Eliminates need for the user to know list of combinations

Relays - Type Impedance Input voltage Voltage Required to operate Current Required Triple pole double throw (3PDT) 120 Ω 6 – 240 VAC 8 - 14V Min of .2 A -

Schematic of Relay Connection

Testing Tested relays by realizing the schematic For the microcontroller, we applied a steady voltage. Connected to relays to microcontroller. Replaced switched with relays.

Building First attempt: Diode parallel with relay Purpose: Protect circuit from feedback current when relay switched Diode shorted out the transistors Solution: Remove diode

Building Second attempt: 1K resistor Limited current to microcontroller Too much impedance on breadboard Switch to 100 ohms Blew transistors 2n2222 2n2222 didn’t have a high enough rating Solution: Changed transistor to TIP120

Software Objective Create a Interface to compliment the Training Simulation To allow the user to interact with the system. To give a visual reference to the user of his or her actions Control Relays for Configuration Purposes Approve or Decline Users Certification

Software Components Microcontroller Voltmeter Circuit LCD Screen 2 line X 20 characters

LCD System Flow Chart Push Button Voltmeter Circuit

Switches to Switching Relays Microcontroller changes configurations Eliminates need for the user to know switch combination Configurations can switch when required or prompted automatically

LCD/system Code

Voltmeter Circuit(Feedback) Input Voltage (120-240) | Probes Transformer Full Wave Rectifier w/ Capacitor Voltage Divider A/D converter(microcontroller) Problems….

A/D Converter -5(A/D) Voltage +5(A/D) 115V-.284V(53) 120V

PCB 2 Layer PCB .10” Traces Ground Plane Using PCB Express Schematic PCB Board

Schematic

PCB Board

Microcontroller Vs. FPGA PIC16F876A ATmega168 FPGA Basys

ATmega168 Features ATmega168 I/0 Pins 23 Memory Type FLASH Program Memory (KB) 16 EEPROM (Bytes) 512 SRAM (KB) 1 Operating Voltage 5.5 Volts

PIC16F876A Features PIC16F876A I/0 Pins 22 Memory Type FLASH Program Memory (KB) 14 EEPROM (Bytes) 256 SRAM (KB) 0.359 Operating Voltage 5.5 Volts

FPGA Basys Features FPGA Basys I/0 Pins 24 Memory Type FLASH Program Memory (KB) 72 EEPROM (Bytes) - SRAM (KB) Operating Voltage 3.3 Volts

Microcontroller Vs. FPGA Features ATmega168 PIC16F876A FPGA Basys I/0 Pins 23 22 24 Memory Type FLASH Program Memory (KB) 16 14 72 EEPROM (Bytes) 512 256 - SRAM (KB) 1 0.359 Operating Voltage 5.5 Volts 3.3 Volts ATmega168

Budget Part Development Immediate Cost Prototype Total: $565.00 Switches $10 Fuses Enclosure $30 Three Phase Meter Box $140 Single Phase Meter Box $75 Potential Transformer $60 Wiring $0 Microcontroller Interface Volt Meter A/D converter $40 Variable Transformer $100 User Interface $50 Keyboard Total: $565.00 $725.00

Budget Analysis

Budget Current Cost $550 Development Budget $565 Prototype Budget $725

Thanks Family Faculty Friends