1. Hybrid Power Controller (HPC) Final 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 System Hardware Testing 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]

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

16. DIMM 100 Breakout Board PCB Design Prototype DIMM100 Breakout Board

17. DIMM 100 Breakout Board PCB Design

19. Component PCB Design

21. Power Circuitry

22. Inputs and Voltage Dividers

23. Generator Output Circuit

24. Serial Data

25. Status LEDs

26. Enclosure

27. Finished Enclosure

28. Enclosure mounted in NEMA cabinet

29. System Hardware

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

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

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

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

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

35. Testing

36. Test Plan - Overview Technical Constraints Complete System Test

37. Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage Multi-meter: 24.365 V HPC: 24.371 Accuracy: + 6 mV Within +/- 100 mV

38. Technical Constraints -- Accuracy: +/- 100 mV on Battery Voltage Multi-meter: 24.365 V HPC: 24.371 Accuracy: + 6 mV Within +/- 100 mV

39. Technical Constraints -- Accuracy: +/- 500 mA on Battery Current Multi-meter(1mV = 1 A): -36.336 A HPC: -36.513 Accuracy: -177 mA Within +/- 500 mA

40. Technical Constraints -- Accuracy: +/- 500 mA on Battery Current Multi-meter(1mV = 1 A): -36.336 A HPC: -36.513 Accuracy: -177 mA Within +/- 500 mA

41. 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

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

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

45. 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

46. 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

47. 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

48. Complete System Test Usage CaseStatus Generator Mode UPS Mode Critical Mode

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

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

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

52. Bill of Materials

53. 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.

54. Questions?

55. 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

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

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

58. Battery Data Sheet

59. Battery Performance

61. UPS Mode - Runtime

62. "How does it accomplish this?"

63. 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

64. 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]

65. 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

66. Testing: Current Measurements with Hall Effect sensors

67. 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