Funded by Workforce Central Florida

Mentor: Alan Shaffer - Lakeland ElectricPhotovoltaic MPPT

Charge Controller (PMC2)

Group 10Amber Scheurer, EE

Eric Ago, EESebastian Hidalgo, EE

Steven Kobosko, EE

MPPT Charge ControllerSolar

Array BatteryLCD Wireless

Wireless

Inverter

System Overview

We intend on designing a charge controller that will implement MPPT and demonstrate it in a fully functional stand-alone photovoltaic system.

Motivation andValue of Project

Maximize the cost return on investment for solar panels by using Maximum Power Point Tracking (MPPT) algorithmsLCD screen and wireless data transfer

Useful for testing, research, and maintenance

Potential for industrial scalingIncorporate a charge controller system with one controller per panel

GoalsCharge controller has to be inherently low powerUtilize Maximum Power Point Tracking to increase efficiencyUser/Researcher Friendly Design

LCD ScreenWireless Data Transfer to Computer StationInexpensive

SpecificationsSolar Panel delivers > 14 VTotal System Power Output > 200 W12 V Battery with > 30 AhWireless range > 20 mApproximately 90% Efficient Charge Controller ~ $200

LCD Screen

Boost Buck

Current Sensor

Voltage Sensor

Charge Controller

PV Panel

Temp. Sensor

Micro Controller

XBee XBee

MCU

Battery Inverter

Temp. Sensor

Current Sensor

Voltage Sensor

LightSensor

Solar PanelParameter SunWize SW120

Rated Power 120 W

Type Monocrystalline

Peak Power Voltage 16.7 V

Peak Power Current 7.18 A

Open Circuit Voltage 21.0 V

Short Circuit Current 8.0 A

Dimensions ~ 2 x 5 ft.

MicrocontrollerATmega328P

Parameter Arduino UNOChip ATmega328PDigital I/O 14 PinsAnalog Input 6 PinsPWM Output 6 PinsCommunication Protocols

I2C, Serial

2.7 in• Arduino Bootloader• Open Source

2.1

in

Microcontroller Peripherals

Current SensorACS711ELCTR-12AB-T

Parameter ACS711

Sensor Type Hall Effect

Operating Voltage 3 – 5.5 V

Current Sensing -12 – +12 A

Operating Temp. -40 – 85 °C4.9 mm

6 m

m

Voltage SensorVoltage Divider

Parameter Voltage Divider

Source PV panel

Sensor Type Voltage Divider

Voltage Sense 0 – 21 V

R1 3.2 KΩ

R2 1 KΩ

Output Voltage 0 – 5 V

R1

R2

Vo

Voltage SensorVoltage Divider

R1=2.7kΩ

R2=10kΩ Vo

Irradiance SensorTSL235R-LF

Parameter TSL235R-LF

Operating Voltage 5 V

Output Square wave 50% Duty Cycle

Operating Temp. -25 – 70 °C

Light Wavelength Range

320 – 1050 nm

Output Frequency 200 – 300 KHz4.6 mm

19.4

6 m

m

Temp SensorDS1624

Parameter DS1624

Operating Voltage 3 – 5V

Temp. Range -55 – 125° C

Internal Memory E2 256 Bytes

Protocol I2C8.5 mm 9 m

m

Wireless Module

24.3 mm 27.6

mm

Parameter Xbee Series 1

Protocol 802.15.4

Communication Serial

Transmitting Power

1 mW

Outdoor Range 90 m

Frequency Band 2.4 GHz

Operating Voltage 3.3 V

Sensor Data

Wireless Subsystem

Battery ComparisonsDeep-Cycle Lead Acid vs. Li-ionAGM vs. Gel vs. FloodedKey Parameters

CostOvercharge ToleranceCharge Cycles

BatterySun Xtender PVX-420T

Parameter Sun Xtender

Chemistry AGM

Nominal Voltage 12 V

Capacity 42 Ah

CCA 40 A

Number of Charges

1000

7.71 in

8.05

in

5.18 in

Battery Charging Stages

BulkAbsorptionFloat

InverterScobra CPI 1575

Parameter Scobra/1575

Max Power 1500 W

Surge 3000 W

Wave output Moderate Sine

Input Voltage 12 V

Output Voltage

110 – 120 VAC

AC Outlets 3

USB 1

83.82 mm

223.5 mm238.8 mm

LCD Screen

Parameter 20 x 4 LCD

Communication Serial

Color Black on Green

Operating Voltage 5 V

Max Current 60 mA

MPPT AlgorithmsEfficiency Programming

DifficultyPotential for “error”

Incremental Conductance Method

Highest Complex Yes

Perturb and Observe Method

High Average Yes

Constant Voltage Method

Low Low No

Voltage

Pow

er

MPPPmax

VOC

Perturb and Observe Method

Vmp

Adjust PWM

Start Sensor Read:Battery Voltage

Sensor Read:Battery Current &

Voltage

Float orAbsorption I x V > P0 I x V < P0

Increase Voltage

Decrease Voltage

Bulk

Regulated Power

Delivered to Battery

LCD: LCD.printXbee: Serial.write

H-Bridge Topology Buck-Boost DC/DC

Regulator• Single Inductor

Buck/Boost Architecture• Separate Buck and

Boost Operating Modes • Synchronous 4-Switch

Operation for Higher Efficiency

• Wide Input Voltage Range: 4.5V to 40V

• Wide Output Voltage Range: 12V to 15V

Boost Operation

Buck Operation

Distribution of Responsibilities

Eric SolarPanel

Power Electronics Simulation

Amber Algorithms LCD Screen

User Interface

Steve Micro-processor Battery Wireless

Sebastian Inverter Sensors PCB Design

Progress

Budget

Parts ListCost per

partNumber of parts

Total Cost

Solar PanelSunWize SW120, 120 Watts 12V Solar Panel $382.89 1 $382.89

Charge ControllerPrinted Circuit Board (Student Special) $33.00 2 $66.00Serial Enabled 20x4 LCD $30.00 1 $30.00Current Sensors Sampled 2 FreeTemperature Sensors $2.99 3 $11.56Irradiance Sensors (+ Shipping) $2.99 3 $11.56Solderless Plug-in BreadBoard $5.50 2 $11.00Various Circuit Components (op-amps/caps/Inductors) $20.00 1 $20.00Wire/Solder $20.00 1 $20.00Arduino Uno SMD (ATmega328) $30.00 2 $60.00Xbee Explorer Board $10.00 2 $20.00Xbee Module $23.00 2 $46.00Mosfets & Drivers Sampled 20 Free

$296.12

BatterySun Xtender PVX-420T AGM Battery $145.00 1 $145.00

Inverter/OutputsScobra CPI 1575 $189.95 1 $189.95Heavy-Duty AC Power Inverter Cable Kit $25.49 1 $25.49Fuse Holder $6.95 3 $20.85150 Amp ANL Fuses $7.06 3 $21.18AnyVolt Micro Buck-Boost Converter $20.00 1 $20.00

$190.12$1,101.48Anticipated Total:

Total Spent to Date:

Controller Subtotal:

RemainingMilestones

Critical Design Review Feb 14

All Parts Ordered Feb 20

Order PCB Feb 29

Meet with Mentor Mar 15

Done Building/Begin Testing Mar 30

Testing Complete Apr 9

Progress Energy SymposiumApr 13

Anticipated ProblemsDesigning circuit to handle high powerHeat dissipationBuck-Boost Circuitry

Questions?