Hybrid Power Controller (HPC) Final Presentation Senior Design II

HPC Team Members Stephen Allard David DukeBrandon KennedyKevin Roberts Dr. Mike Mazzola Electrical Engineer Website Design System Integration Testing Generator Controller Circuit Electrical Engineer System Integration Enclosure Integration Research PCB Design Electrical Engineer Website Design Programming Controller Design Component Research Electrical Engineer Programming Test Circuit Design Controller Design Debugging Advisor Andy Lemmon, GRA Co-Advisor

Outline Problem Solution System Overview Constraints Technical Practical PCB Design Enclosure System Hardware Testing Questions

Problem Existing residential backup power solutions are not adequate for long-term power outages which follow large-scale natural disasters.

Solution A hybrid power system that can address residential long-term power needs. This system requires an autonomous controller which manages: solar panel array tri-fuel generator battery bank

"What does the HPC do?" The HPC efficiently manages the Hybrid Power System to accomplish the following objectives: 1- Keep the batteries healthy 2- Supply the load when traditional backup power supplies cannot

System Overview Solar Array Battery Bank Inverter Load Generator Hybrid Power Controller OEM Device

Hybrid Power System [1]

Technical and Practical Constraints

Technical Constraints NameDescription Accuracy The Hybrid Power Controller must have an accuracy of +/- 100 mV on the battery bank voltage input and +/- 500 mA on the battery bank current input. Input The Hybrid Power Controller must accept inputs up to 50 Volts DC. Output The output of the device must provide signals to operate a 12 volt relay for start/stop generator operation. Response Time The device must take samples from Hybrid Power System components and respond to changes within 1 second. Supply Power The device must accept 24 Volts DC for supply power.

Practical Constraints NameDescription Sustainability The device must be vibration resistant. Manufacturability The device must fit into available space in the NEMA enclosure.

Sustainability Vibration Resistance Located within an enclosure mounted on a mobile trailer Need reliable connections Easy to connect Solution Use locking connectors [3]

Manufacturability Size Limitation Controller enclosure must fit inside existing NEMA enclosure Limited spacing around other components, such as fuses and distribution panels The maximum available space is 10” x 10” x 5” HPC

Manufacturability Size Limitation Controller enclosure must fit inside existing NEMA enclosure Limited spacing around other components, such as fuses and distribution panels The maximum available space is 10” x 10” x 5”

PCB

DIMM 100 Breakout Board PCB Design Prototype DIMM100 Breakout Board

DIMM 100 Breakout Board PCB Design

Component PCB Design

Power Circuitry

Inputs and Voltage Dividers

Generator Output Circuit

Serial Data

Status LEDs

Enclosure

Finished Enclosure

Enclosure mounted in NEMA cabinet

System Hardware

Generator Modification In order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.

Generator Modification In order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.

Generator Modification In order to transfer from the breadboard emulator to the real system, the generator needed extra hardware.

Current Sensing Battery Current Hall Effect Solar Array Hall Effect Calculated an Offset and Conversion Factor in Software

System Assembled After the necessary hardware was completed, we began to test each subsystem and our constraints

Testing

Test Plan - Overview Technical Constraints Complete System Test

Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage Multi-meter: V HPC: Accuracy: + 6 mV Within +/- 100 mV

Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage Multi-meter: V HPC: Accuracy: + 6 mV Within +/- 100 mV

Technical Constraints -- Accuracy: +/- 500 mA on Battery Current Multi-meter(1mV = 1 A): A HPC: Accuracy: -177 mA Within +/- 500 mA

Technical Constraints -- Accuracy: +/- 500 mA on Battery Current Multi-meter(1mV = 1 A): A HPC: Accuracy: -177 mA Within +/- 500 mA

Technical Constraints -- Inputs -- HPC must accept up to 50 VDC HPC reads inputs up to 50 VDC using voltage divider circuits Sensor Inputs up to 50 VDC

Technical Constraints -- Outputs The output of the device must provide signals to operate a 12 volt relay for start/stop generator operation.

Load Cutoff [4] Send serial “FF” to OEM Interface to Drop load when Battery Voltage reaches critical level Send “OO” to reconnect load

Technical Constraints -- Response Time HPC must respond to system changes within 1 second: o Protects Batteries o Increases Runtime for customer HPC responds within allotted time

Technical Constraints -- Response Time HPC must respond to system changes within 1 second: o Protects Batteries o Increases Runtime for customer HPC responds within allotted time

Technical Constraints -- Supply Power -- Controller must accept 24 VDC for power 24 VDC is stepped to 5 VDC using switching regulator Controller is successfully powered by battery bank Board Power Indicator LED

Complete System Test Usage CaseStatus Generator Mode UPS Mode Critical Mode

Complete System Test Usage CaseStatus Generator ModeFully Functional UPS Mode Critical Mode

Complete System Test Usage CaseStatus Generator ModeFully Functional UPS ModeFully Functional Critical Mode

Complete System Test Usage CaseStatus Generator ModeFully Functional UPS ModeFully Functional Critical ModeFully Functional

Bill of Materials

References [1] Inverter Generator with CMD Triple-Fuel System. [2012, Nov. 28]. Avalable: fuel.asp?page=EU3000iS_Tri_Fuel [2] US Digital. [2012, Noc. 28]. Available: connectors/cables/5-pin/ca-fc5-sh-lc5 [3] Digi-Key Corporation. [2012, Nov. 28]. Available: detail/en/C091%2031W107%20100%202/ ND/ [4] Mate Serial Communications Guide. Rev , OutBack Power Systems, Arlington, WA, [5] Owner’s Manual Generator EU3000is. Rev. 1.0., Honda Motor Co., Printed in Japan.

Questions?

Test Plan - Overview Unit Test Cases (emulated system) Sampling and measurement accuracy Generator Stop/Start functionality Load cut-off control Controller Logic and Status Indicator behavior Sub-System Integration Testing Sampling and measurement accuracy including hall effect sensors Generator Stop/Start functionality with generator hardware Load cut-off control with OEM controller Complete System Testing

Practical Constraints Sustainability -- Vibration Resistance Vibration resistant connections needed during transport Locking connectors were used

Practical Constraints Manufacturability -- Device must fit in NEMA enclosure Device fits in available space in NEMA enclosure

Battery Data Sheet

Battery Performance

UPS Mode - Runtime

"How does it accomplish this?"

Generator Mode Continually monitors battery voltage Takes action when the batteries drop below a threshold voltage Attempts to start the generator via a relay Stops the generator when the batteries recover to a sufficient voltage Uses the generator only when needed to supplement PV array power Upon failure of generator, transfers to UPS Mode

UPS Mode Functions as an Uninterruptible Power Supply Utilizes the solar panel array and battery bank to power the load Estimates the state of charge of the batteries at present conditions Alerts the user when load cut-off is imminent Uses all possible energy before dropping the load 11.7 Volts (Recommended Cutoff Voltage) 0% State of Charge [4]

Critical Mode A "last resort" mode Drops the load when the battery voltage drops below a critical voltage Prevents the batteries from being damaged Controller continues to monitor battery voltage after disconnecting load Reconnect the load after the batteries have returned to a stable level

Testing: Current Measurements with Hall Effect sensors

Test Plan - Overview Unit Test Cases: Sampling and measurement accuracy Generator Stop/Start functionality Load cut-off control Controller Logic and Status Indicator behavior Sub-System Integration Testing Complete System Testing