1. Hybrid Power Controller (HPC) Mid-Semester Presentation Senior Design I

2. HPC Team Members Stephen AllardDavid DukeBrandon KennedyKevin Roberts Dr. Mike Mazzola Electrical Engineer Website Design System Integration Testing Controller Design Electrical Engineer System Integration Enclosure Integration Research Controller 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

3. Outline Problem Solution System Overview Constraints – Practical – Technical Approach – Components – Software Progress – Timeline Questions

4. Problem In the event of a catastrophic power outage, people lose contact with the outside world and suffer the loss of everyday necessities.

5. Solution Design and build a controller that autonomously manages a personal solar panel array, battery bank, and generator to supply reliable power during a power outage.

6. System Overview Solar Array MPPT Charger DC Distribution Panel Battery Bank Mobile Inverter/ Charger AC Outlet (load) Generator Hybrid Power Controller OEM Device

7. Mobile Solar Generator

8. MPPT Charger

9. Mobile Inverter

10. Grid-tie Inverter (unused)

11. AC Outlet (load)

12. Solar Panel Bus

13. DC Bus

14. Technical and Practical Constraints

15. Technical Constraints NameDescription AccuracyThe Hybrid Power Controller must have an accuracy of +/- 100 mV on inputs. InputThe Hybrid Power Controller must accept inputs up to 50 Volts DC. OutputThe output of the device must provide a signal to operate a 12 volt relay for start/stop generator operation. Sampling RateThe device must take samples from Hybrid Power System components 3 times per second. Supply PowerThe device must accept 24 Volts DC for supply power.

16. Practical Constraints NameDescription EconomicThe parts must cost less than $200. ManufacturabilityThe device must fit into available space in the NEMA enclosure.

17. Economic Cost Considerations Price of competition: $420 [1] Estimated cost of parts for HPC: <$200 Choosing a microcontroller to meet Dr. Mazzola’s future needs

18. 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

19. 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”

20. Approach

21. Powering the Microcontroller RegulatorCost Max Current Output VinVout Require External Components Through- hole compatible ? Our Choice Linear Technology 1076 [2] $82.0 A8-45V Yes Dimension Engineering SW050 [3] $151.25 A Up to 30V 5VNoYes Linear Technology 3742 [4] $42.0 A 4V- 30V.8V- 30V YesNo The micro-controller must be powered from the 24VDC battery bank. A regulator is needed with an input of 20-28VDC, and an output of 5.0 VDC. Due to the large difference between the input and output voltage, a linear regulator will not suffice, due to excess heat. A switching regulator will be needed.

22. Powering the Microcontroller RegulatorCost Max Current Output VinVout Require External Components Through- hole compatible ? Our Choice Linear Technology 1076 [2] $82.0 A8-45V Yes Dimension Engineering SW050 [3] $151.25 A Up to 30V 5VNoYes Linear Technology 3742 [4] $42.0 A 4V- 30V.8V- 30V YesNo The micro-controller must be powered from the 24VDC battery bank. A regulator is needed with an input of 20-28VDC, and an output of 5.0 VDC. Due to the large difference between the input and output voltage, a linear regulator will not suffice, due to excess heat. A switching regulator will be needed. ✓

23. Microcontroller Micro Cost/per +1000 Familiarity Potential for further development with HPC ADC Our Choice PIC24HJ32GP202$2.90[5]YesNo10/12-bit “Piccolo” F28027$1.85 [6]No 12-bit “Concerto” F28M35H $11.76[7]NoYes12-bit

24. Microcontroller Micro Cost/per +1000 Familiarity Potential for further development with HPC ADC Our Choice PIC24HJ32GP202$2.90[5]YesNo10/12-bit “Piccolo” F28027$1.85 [6]No 12-bit “Concerto” F28M35H $11.76[7]NoYes12-bit ✓

25. “Concerto” Peripherals : Easy Setup RJ-45 Ethernet Jack USB-ISO JTAG Control Suite Example Projects

26. Software Approach Check Batt. Voltage No Yes Sample Solar and Load Power Solar >= Load V Batt. Critical Voltage Low No Turn on Generator Yes Generator on No Turn Off Load No Yes

27. Approach HPC [8]

28. Approach HPC

29. Progress

30. Research

31. Data for Emulation [9]

32. Data for Emulation [9]

33. Data for Emulation [9]

34. Data for Emulation [9]

35. Data for Emulation [9]

36. System Emulator

37. PV_VOUT Solar Array Voltage

38. System Emulator B_BANK_VOUT Battery Bank Voltage

39. System Emulator B_BANK_SENS Battery Bank Current Sensor

40. System Emulator SHUNT_OUT1 through SHUNT_OUT5 Solar Array Shunt Current Sensors

41. System Emulator PV Voltage Battery Bank Voltage

42. System Emulator PV Voltage Battery Bank Voltage Adjustment

43. System Emulator Battery Current Sensor PV Shunt Sensor

44. System Emulator Battery Current Sensor PV Shunt Sensor Adjustment

45. System Emulator

46. Next Steps

47. Timeline AugustSeptemberOctoberNovemberDecember Research of Hybrid Power System Components, Design of System Emulator Manufacture of System Emulator, Finalize Design Constraints of Controller Construct Prototype of Controller, Testing of Prototype with System Emulator Complete Testing, Debugging, Finalize Prototype

48. References [1] Outback Mate 3 System Control and Monitor. [2012, Sept. 12]. Available: http://www.solarhome.org/outbackmate3systemcontrolandmonitor.aspx http://www.solarhome.org/outbackmate3systemcontrolandmonitor.aspx [2] Digi-Key Corporation: LT1076CT#PBF. [2012, Oct. 10]. Available: http://www.digikey.com/product- detail/en/LT1076CT%23PBF/LT1076CT%23PBF-ND/888671 [3] Dimension Engineering: 5V 1A Switching voltage regulator. [2012, Oct. 10]. Available: http://www.dimensionengineering.com/products/de-sw050 [4] Linear Technology: LT3742 - Dual, 2-Phase Step-Down Switching Controller. [2012, Oct. 10]. Available: http://www.linear.com/product/LT3742 http://www.linear.com/product/LT3742 [5] Digi-Key Corporation. [2012, Sept. 24]. Available: http://www.digikey.com/product- detail/en/PIC24HJ32GP202-I%2FSP/PIC24HJ32GP202-I%2FSP-ND/1635696http://www.digikey.com/product- detail/en/PIC24HJ32GP202-I%2FSP/PIC24HJ32GP202-I%2FSP-ND/1635696 [6] C2000 32 bit 28x Piccolo™ Series. [2012, Sept. 26]. Available: http://www.ti.com/mcu/docs/mcuproductcontentnp.tsp?sectionId=95&familyId=919&tabId=2883 [7] Texas Instruments, Microcontroller (MCU). [2012, Sept. 12.] Available: http://www.ti.com/mcu/docs/mcuproductcontentnp.tsp?sectionId=95&familyId=2049&tabId=2743 http://www.ti.com/mcu/docs/mcuproductcontentnp.tsp?sectionId=95&familyId=2049&tabId=2743 [8]WattMetrics. [2012, Sept 26]. Available: http://www.wattmetrics.com/support/connectingtoinverters/OutBack.aspx http://www.wattmetrics.com/support/connectingtoinverters/OutBack.aspx [9] Mate Serial Communications Guide. Rev. 4.04., OutBack Power Systems, Arlington, WA, 2008.

49. Questions?