PERPUSTAKAAN UMP

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DEVELOPMENT OF POK1AELt YV UrnNr p rtiED POWER SUPPLY

MUHAMMAD FARHAN BIN ZAINUDDIN

This thesis is submitted is fulfillment of the requirements for the award of the degree of

Bachelor of Electrical Engineering (Power Systems)

Faculty of Electrical & Electronics Engineering

Universiti Malaysia Pahang

JUNE 2012

ABSTRACT

Photovoltaic or in short term PV is one of the renewable energy resources that

recently has become broader in nowadays technology. The demand or future work is

looking for high efficiency, more reliable and economical price PV charge controller

which is come in portable size has become very popular in PV system. In general, PV

system consists of a PV array, charge controller, rechargeable battery and dc load. PV

charge controller is very important in PV system because to control the voltage charging

and also to keep the battery from overcharging. In this project, microcontroller (PlC

16F688) are used to monitoring the voltage of the battery. This project used dc-dc buck

converter circuit which has been simulated using software of Proteus 7. Liquid Crystal

Display (LCD) is used to display the voltage from rechargeable battery. The benefit of

this project is an improvement of efficiency voltage change.

ABSTRAK

Photovoltaic atau dalam jangka pendek PV adalah salah satu sumber tenaga

boieh diperbaharui yang baru-baru mi telah menjadi lebih luas dalarn teknologi masa

kini. Permintaan atau kerja masa depan sedang mencari kecekapan tinggi, Iebih

dipercayai dan PV harga rnenjimatkan caj pengawal yang datang dalam saiz mudah alih

telah menjadi sangat popular dalam sistem PV. Secara amnya, sistem PV terdiri daripada

pelbagai PV, pengawal caj, bateri boleh dicas semula dan beban AT. PV pengawal caj

adalah sangat penting dalam sistem PV kerana untuk mengawal pengenaan voltan dan

juga untuk menjaga bateri dari benlebihan. Dalarn projek mi, inikropengawal EPIC

16F688) digunakan untuk memantau voltan bateri. Projek mi menggunakan dc-dc

penukar buck litar yang telah perisian sirnulasi menggunakan Proteus 7. Paparan Kristal

Cecair (LCD) digunakan untuk memaparkan voltan dari bateri yang boleh dicas semula.

Manfaat daripada projek mi adalah peningkatan perubahan kecekapan voltan.

vi

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE

DECLARATION 11

DEDICATION ill

ACKNOWLEDGEMENT 'V

ABSTRACT V

ABSTRAK Vi

TABLE OF CONTENT vii

LIST OF TABLES x

LIST OF FIGURES Xi

LIST OF SYMBOLS Xlii

LIST OF ABBREVIATIONS Xiv

LIST OF APPENDICES xv

VII

INTRODUCTION

1.1 Background

1.2 Objectives

1.3 Scope of Project

1.4 Problem Statement

1.5 Thesis Overview

1.6 Thesis Outlines

1

1

2

3

3

4

4

VIII

2 LITERATURE REVIEW 5

2.1 Photovoltaic System 5

2.1.1 Photovoltaic Array 6

2.1.2 Charge Controller 9

2.1.3 Battery Ii

2.2 PlC 16F688 Microcontroller 13

2.2.1 An Overview 13

2.2.2 PlC 1617688 Microcontroller implementation 14

3 METHODOLOGY 15

3.1 Introduction 15

3.2 Hardware Development 15

3.2.1 System Design 15

3.2.2 Charge Controller 16

3.2.3 PlC I 6F688 Circuit Design 22

3.2.4 Rechargeable Battery 24

3.2.5 Liquid Crystal Display (LCD) 25

3.2.6 Photovoltaic Panel 27

3.3 Software Implementation 29

3.3.1 MikroC PRO for Pic 29

3.3.2 UPOOB USB Plc Programmer 29

3.3.3 PICkit2 30

3.3.4 Programming the PlC 16F688 35

3.3.5 Charge Controller System Operational Flow 36

ix

4 RESULT AND DISCUSSION 41

4.1 Introduction 41

4.2 PV Charge Controllers 41

4.2.1 Discussion 42

4.3 PlC 1617688 Microcontroller Circuit 43

4.3.1 Voltmeter 43

4.3.1.1 Calculation 43

4.3.2 Discussion 44

4.5 Power Circuit 44

4.5.1 Discussion 45

4.6 Liquid Crystal Display (LCD) Circuit 46

4.6.1 Discussion 46

4.7 Loads 48

4.7.1 Calculation 50

4.8 Photovoltaic Array 50

4.8.1 Discussion 52

4.9 Comparison 52

5 CONCLUSION AND RECOMMENDATIONS 53

5.1 Introduction 53

5.2 Conclusion 53

5.3 Recommendation 54

REFERENCES

Appendices A- N -

LIST OF TABLES

TABLE NO. TITLE PAGE

3.1 List of component 22

3.2 Interface Pin function 27

3.3 Measured Values at STC 29

4.1 Result of loads used 48

4.2 Result of voltage of PV panel 51

4.3 Comparison between the project and SunGuard charge controller 52

x

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 Photovoltaic system components 2

2.1 Equivalent circuit of PV cell 6

2.2 Amorphous silicon 7

2.3 Crystalline silicon 8

2.4 Solar Panel 9

2.5 Charge Controller 10

2.6 Advanced PWM Battery Charging 11

2.7 Lead-acid batteries 13

2.8 Plc 16F688 14

3.1 The ideal of the system design 17

3.2 Opto Coupler Transistor 4N35 18

3.3 Dual Operational Amplifier IC TLC2272CP 19

3.4 Quad Operational Amplifiers IC TLC27L4CN 20

3.5 Charge Controller circuit 21

3.6 14-Pins PDIP Diagram ofPICI6F6S8 23

3.7 PlC 1617688 power supply circuit 24

3.8 PlC 16F688 reset circuit 25

3.9 Front view of LCD 27

3.10 Back view of LCD 28

3.11 PV panel 29

3.12 MikroC Pro Advanced C Compilers for PlC MCU 30

A

3.13 USB Programmer 31

3.14 PiCkit 2 Connected. 32

3.15 Reading device 33

3.16 Programming successful burn 34

3.17 Verification Successful 35

3.18 Flow chart of Battery charging 38

3.20 Flow chart of load 40

4.1 Charge Controller 40

4.2 PlC voltmeter using Proteus ISIS Schematic Captur 42

4.3 Plc Power Circuit 43

4.4 LCD Display 44

4.5 LCD brightness 1 45

4.6 LCD brightness 2 45

4.7 LCD brightness 3 46

4.8 Project design 47

4.9 Example of load 47

4.10 Experiment result of PV panel voltage versus time 49

XII

LIST OF SYMBOLS

V - Voltage

R - Resistance

A - Ampere

Ah - Ampere hours

- Current

XIII

LIST OF ABBREVIATIONS

PV - Photovoltaic

LCD - Liquid Crystal Display

DIP - Dual Inline Package

DC = Direct Current

AC - Alternating Current

PlC - Peripheral Interface Controller

LVD - Low Voltage Disconnect

LED - Light Emitting Diode

IC - Integrated circuit

MPPT - Maximum Power Point Tracking

RISC - Reduced Instruction Set Code

FET - Field-effect transistor

xiv

LIST OF APPENDICES

APPENDIX TITLE PAGE

A Rechargeable Sealed Lead Acid Battery Power Sonic 56

B Photovoltaic Panel Kyocera 58

C Pure Sine Wave Inverter Cotex 60

D SunGuard Solar Battery Charge Controller 61

E Datasheet of IC TLC2272CP 65

F D4shet of IC TLC27L4CN 66

G Datasheet 1N4148 diode 71

H Zener Diode datasheet 74

I Opto Coupled datasheet 75

J Diode Rectifier datasheet 78

K NPN transistor 82

L PNP transistor 83

M Rectifier IRZ44NP 85

N Voltage regulator LM781,05 89

xv

CHAPTER 1

INTRODUCTION

1.1 Background

For many years, fossil fuel has been the primary source of energy. However,

there is a limited supply of these fuels on earth and they being used so much more

rapidly than they are being created. Eventually, they will run out. In addition,

because of safety concerns and waste disposal problem, renewable energy is

definitely the solution. Photovoltaic or in short term PV is one of the renewable

energy resources that recently has become broader in nowadays technology. The

demand or future work is looking for high efficiency, more reliable and economical

price PV charge controller which is come in portable size has become very popular

in PV system. PV has many benefits especially in envirotmental, economic and

social. In general, a PV system consists of a PV array which converts sunlight to

direct-current electricity, a charge controller which regulates battery charging and

operation of the load, the inverter for convert dc to ac, energy storage in the form of

batteries and loads or appliances.

A charge controller is one of functional and reliable major components in PV

systems. A good, solid and reliable PV charge controller is a key component of any

PV battery charging system to achieve low cost and the benefit that user can get from

I

2

it. The main function of a charge controller in a PV system is to regulate the voltage

and current from PV solar panels into a rechargeable battery. The minimum function

of a PV charge controller is to disconnect the array when the battery is fully charged

and keep the battery fully charged without damage. A charge controller is important

to prevent battery overcharging, excessive discharging, reverse current flow at night

and to protect the life of the batteries in a PV system. A power electronics circuit is

used in a PV charge controller to get highest efficiency, availability and reliability.

The use of power electronics circuits such as various dc to dc converters topologies

like buck converter, boost converter, buck-boost converter and others converter

topology as power conditioning circuitry to provide a desired current to charge

battery effectively.

I' : Inveiter

PV array ,/ C> controllerc> i::::

S---------

Batteiy

Figure 1.1: Photovoltaic system components

1.2 Objective

i. To develop prototype portable power generator based on photovoltaic

technology.

ii. To simulate voltage reading simulation by using Proteus 7 software.

iii. To develop battery voltage reading by using PlC 16F688.

3

1.3 Scope of Project

L The scope of project is to developed portable generator by using

photovoltaic (PV).

ii. To make the portable PV generator that can use at least for two hours by

used 12V 7.2AH battery with load of 18W lamp.

iii. To develop voltmeter using PlC 16F688 for monitoring voltage storage.

1.4 Problem Statement

Most of portable generators nowadays just use gas or fuel as a source of

energy to generated power. By using that kind of source will cause harm to

environment. For example, by using gas it will produce carbon dioxide (CO 2) but if

using renewable energy it will not produce that kind of waste. Besides that, the price

of gas or fuel is very expensive and also the maintenance cost also high. So to

overcome this problem, PV generator was develop by using renewable energy.

4

1.5 Thesis Overview

The project is about to development portable generator by using solar as a

source of energy. The portable generator must in simple design and easy to use in

everywhere. It using photovoltaic (PV) array to convert solar energy to electricity.

The battery storage used to storage energy that can use at least for two and half hours.

1.6 Thesis Outlines

Basically this thesis is about to development of portable PV generator power

supply. These theses contain five of chapter which is introduction, literature review,

methodology, result and discussion and conclusion and recommendation.

For the introduction part, it contains the background of the IV technology,

the objectives of project, the scope of project, the problem statement and the thesis

overview. In chapter of literature review, it consist the review of the journal that

relates to the project like about the photovoltaic, the battery and so on.

Next is the methodology part. In this part is about hardware development

design such as equipment procedures and method design for charge controller and

inverter. The relevant information is gathered from the literature review.

In chapter result and discussion, it Consist the hardware and software result

and the discussion about every part of project hardware and software. Lastly is the

chapter conclusion and recommendation of the project development.

CHAPTER 2

LITERATURE REVIEWS

2.1 Photovoltaic System

A standalone system does not have a connection to the electricity "mains"

(aka "grid"). Standalone systems vary widely in size and application from

wristwatches or calculators to remote buildings or spacecraft. if the load is to be

supplied independently of solar insolation, the generated power is stored and

buffered with a battery. In non-portable applications where weight is not an issue,

such as in buildings, lead acid batteries are most commonly used for their low cost. A

charge controller may be incorporated in the system to avoid battery damage by

excessive charging or discharging and to optimizing the production of the cells or

modules by maximum power point tracking (MPPT) [4]. However, in simple PV

systems where the PV module voltage is matched to the battery voltage, the use of

MPPT electronics is generally considered unnecessary, since the battery voltage is

stable enough to provide near-maximum power collection from the PV module. In

small devices (e.g. calculators, parking meters) only direct current (DC) is consumed.

In larger systems (e.g. buildings, remote water pumps) AC is usually required. To

convert the DC from the modules or batteries into AC, an inverter is used.

5

rol

The proposed system consist of Photovoltaic array, charge controller, battery,

inverter, load the single line diagram is shown in Figure 2.1, the description of each

block as follows:

2.1.1 Photovoltaic Array

1phja

IF

Load

Figure 2.1: Equivalent circuit of PV cell

Photovoltaic (PV) is the field of technology and research related to the

application of solar cells for energy by converting sun energy (sunlight or sun ultra

violet radiation) directly into electricity. Due to the growing demand for clean

sources of energy, the manufacture of solar cells and PV arrays has expanded

dramatically in recent years.

Semiconductor material, typically silicon, is used in thin wafers or ribbons in

most commercially available cells. One side of the semiconductor material has a

Positive charge and the other side is negatively charged. Sunlight hitting the positive

side will activate the negative side electrons and produce an electrical current. There are two types of cells which is crystalline silicon and amorphous silicon. Crystalline

cells have been in service the longest and exhibit outstanding longevity. Cells

7

developed almost 40 years ago are still Operating and most manufacturers offer 10-

year or longer warranties on crystalline cells.

Figure 2.2: Amorphous silicon

There are two sub-categories of crystalline cells - single crystal and

polycrystalline. They both perform similarly. The efficiency of crystalline cells is

around 13%. Amorphous silicon is a recent technology for solar cells. It is cheaper to

produce and offers greater flexibility, but their efficiency is half Of the crystalline

cells and they will degrade with use. These types of cells will produce power in low

light situations. This technology is expected to improve application possibilities far

exceeding crystalline technology. Currently, the best choice for solar cells will be the

crystalline variety.

Figure 2.3: Crystalline silicon

The diode equation usually describes the operation of the solar PV cell. Sun

light exposure of a solar PV cell results in the creation of an electric current as

excited "electrons and the remaining holes are swept in different directions by the

built in electric field of the depletion region". [1]. Figure 2.1 shows a simple

equivalent circuit for a PV cell. The circuit consists of an ideal current source

(representing the current generated due to photon interaction) and an ideal diode

which is given by

1 'ph -

Where I h=Short-circuit current due to sunlight, Id--Current shunted through the

diode, R= Load resistance, I=Current through the load, V= Voltage across the

load.

8

ze

Figure 2.4: Solar Panel

2.1.2 Charge controller

The charge controller regulates the flow of electricity from PV modules to the

battery and the load [2]. The controller keeps the battery fully charged without

overcharging it. When the load is drawing power, the controllers allow charge to

flow the modules into the battery, the load, or both. When the controller sense the

battery fully charged, it stops the flow of charge from the modules. Many controllers

will also when loads have taken too much electricity from batteries and will stop the

flow until sufficient charge is restored to the batteries. This last future can greatly

extend the battery's lifetime. However, controllers in stand-alone photovoltaic

system are more complex device that depends on battery state-of-charge, which is

turn, depends on many factors and is difficult to measure. The controller should

ensure that no current flows from the battery to the array at night or not use.

j

10

Figure 2.5: Charge Controller

When the storage batteries of a PV solar panel array installation becomes

fully charged, the array will continue to produce additional power as long as the sun

is present, unless some control circuitry is used to shut down the power generation

process. If power continues to be applied to the storage batteries, it will overcharge

them creating a potentially dangerous situation. Overcharged batteries can overheat

and possibly explode. The additional power being generated is also being wasted.

An open circuit regulator monitors the balance of voltage in the charging

system and creates an open circuit condition to separate the PV array from the

charging system. When the battery voltage falls off to a predetermined level, the

regulator closes the circuit so the PV array can start charging the storage batteries

again. The drawback to this type of regulator is that the PV array will continue to

provide energy as long as light is present-the energy generated while the regulator is

in the open circuit condition is simply wasted.

Charging 14

volts12

4

amps2

11

r!4Y1A':A BULK CHARGING

Charging Current

6 8 10 NOON 2 4 6 AM AM AM PM PM PM

Figure 2.6: Advanced PWM Battery Charging

2.1.3 Battery

Car batteries are not suitable for PV applications as they cannot handle the

deep discharges that can occur with PV systems. "RV" or "marine" batteries can

handle a deeper discharge than car or starter batteries and can be used in a beginning

system. They will last 2 to 3 years. Geli cell sealed batteries can be used in limited

conditions, but also will not handle deep discharges. Because they are sealed, they

are suited to marine applications.

Deep cycle batteries are available for golf carts, and include Industrial

Chloride batteries. These batteries are the best choice for PV systems as they can be

discharged 80%. The golf cart batteries will last 3-5 years. There are some larger

capacity deep cycle batteries that will last 7-10 years. Industrial Chloride batteries

will last 15-20 years.

Non lead-based batteries such as nickel-cadmium batteries are costly but can

last a very long time if they are not discharged excessively. A new type of nickel-

cadmium battery, fiber-nickel-cadmium, has outstanding longevity at a 25%

12

discharge rate. Nickel-cadmium (NiCad) batteries have different operating and

maintenance characteristics than lead-acid batteries that must be considered. For

example, it is difficult to measure the depth of discharge that is occurring with a

NiCad battery since its Output is constant right up to the last moments before being

completely discharged. Check with the suppliers in the Resources section about the

operation and maintenance characteristics of the NiCad batteries they offer.

For large systems, the best battery choices will be the "true" deep cycle types.

Caution in using batteries must be observed along with recognition of their

characteristics in response to temperature changes (lead-acid batteries operate less

efficiently in cold temperatures) and ventilation requirements.

Batteries are device that produce DC electricity through a chemical reaction

process. The chemicals in the battery react with its terminals when external path for

current flow is provided. The process causes free electrons to gather at the negative

terminal of the battery while a depletion of electron occurs at the positive terminal.

This provides the push and pull to create current flow through an external circuit.

When an external pathway is provided the electrons flow from the negative terminal

through the external circuit and back into the positive terminal of the battery. It is

very low resistance load is placed across the terminals, a large flow of electron

current will occur. Larger resistive loads draw lower levels of current flow from the

battery, as described by the basic Ohm's Law fonnula for current, voltage and

resistance.

Batteries are often used in PV systems for storing energy produced by the

PV array during day time and supplying it to electrical loads as need during night

time or cloudy weather. Moreover, batteries are also needed in the tracker system to

keep the operation at MPP in order to provide electrical loads with stable voltage

Nearly most of the batteries used in PV systems are deep cycle lead acid. These

batteries have thicker lead plates that make them tolerate deep discharges. The

thicker the lead plates, the longer the life span. The heavier the battery for the given

group size, the thicker the plates and the better the battery will tolerate deep

discharges.