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

2. 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

3. Outline Problem Solution System Overview Constraints Technical Practical PCB Design Enclosure Testing Timeline Questions

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

5. 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

6. "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

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

8. Hybrid Power System [1]

9. Technical and Practical Constraints

10. 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.

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

12. Sustainability Vibration Resistance Located within an enclosure mounted on a mobile trailer Need reliable connections Easy to connect Solution Use locking connectors [3] [2]

13. 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

14. 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”

15. PCB Design

16. DIMM100 Breakout Board DIMM Connector Placement Header Placement

17. DIMM100 Breakout Board DIMM Connector Placement Header Placement Top View Bottom View

18. PCB Design

19. Header Connection

20. PCB Design Sensor Input Header

21. PCB Design Voltage Regulator and Power Switch

22. PCB Design Serial Data Header and Level Shifter

23. PCB Design Status LEDs

24. PCB Design Generator Start/Stop Transistors and Header

25. Enclosure

27. PCB Placement

28. Header Placement

29. Controller Placement

33. Connector Placement

34. Connector Access

35. Test Plan

36. Test Plan - Overview Completed Unit Test Cases (emulated system) Sampling and measurement accuracy Generator Stop/Start functionality Load cut-off control Controller Logic and Status Indicator behavior Pending 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

37. Testing: Input Measurements Compare HPC measurements (voltage and currents) with multimeter measurements

38. Testing: Generator Test Generator Start/Stop function. [1] [5] Make connections with generator Modify software to reflect recommended starter timing

39. Testing: Load Cutoff [4] Send serial “DD” to OEM Interface to Drop load when Battery Voltage reaches critical level

40. Total System Test Once subsystem tests are complete, test entire system Test Sunny and Rainy day usage cases

41. Timeline JanuaryFebruaryMarchAprilMay Hybrid Power System Software Integration Improvements to Battery runtime algorithm Design and order PCB and any additional parts. Place components, package and test final product. Complete Testing and Debugging. Complete the integration of HPC into Hybrid Power System.

42. References [1] Inverter Generator with CMD Triple-Fuel System. [2012, Nov. 28]. Avalable: http://www.generatorsales.com/order/Honda-EU3000iS-Tri- fuel.asp?page=EU3000iS_Tri_Fuel [2] US Digital. [2012, Noc. 28]. Available: http://www.usdigital.com/products/cables- connectors/cables/5-pin/ca-fc5-sh-lc5 [3] Digi-Key Corporation. [2012, Nov. 28]. Available: http://www.digikey.com/product- detail/en/C091%2031W107%20100%202/361-1317-ND/1647574 [4] Mate Serial Communications Guide. Rev. 4.04., OutBack Power Systems, Arlington, WA, 2008. [5] Owner’s Manual Generator EU3000is. Rev. 1.0., Honda Motor Co., Printed in Japan.

43. Questions?

44. Battery Data Sheet

45. Battery Performance

47. UPS Mode - Runtime

48. "How does it accomplish this?"

49. 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

50. 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]

51. 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

52. Testing: Current Measurements with Hall Effect sensors

53. 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