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Maximum Power Solar Converter Author: John Charais Microchip Tech
Top Searches for this datasheetAN1211 Maximum Power Solar Converter Author: John Charais Microchip Technology Inc. From these graphs, that depending illumination panel want operate panel different load points maximize output power. complicate things even further, solar panels will have negative temperature coefficient positive temperature coefficient. Figure show change curves when temperature taken into consideration. relationship between illumination temperature make difficult estimate proper point which operate solar panel order maximize output power. solve this problem, Power Point Converter continually measures adjusts power solar panel order operate panel maximum power point, independent panel's illumination temperature. need remote operation electronic devices continues increase, power these devices becomes more concern. Remote applications powered mostly batteries that either recharged changed regular basis. more remote location bigger challenge becomes replacing these batteries. Since development modern photovoltaic cell 1954, remotely powered applications that have serviced became possible. focus this application note identify maximum power solar panel power remote application. Maximum Power Point Converter essentially DC-to-DC converter, where input voltage solar panel output voltage volts. intent converter show take solar panel generate voltage capable recharging 24-volt battery. Although chemistry battery charge battery properly extremely important actual design, these details will covered this application note. Also associated with this application note file with source code Excel spreadsheet. FIGURE SOLAR PANEL ILLUMINATION CURVE Solar Panel Illumination Curve Voltage Current Full Partial High Temp 0.51 0.4335 0.561 0.47685 0.425 0.55 0.4675 0.425 0.55 0.4675 0.497 0.42245 0.5467 0.464695 0.495 0.42075 0.5445 0.462825 0.492 0.4182 0.53 0.4505 0.487 0.41 0.45 0.47 0.35 0.035 0.44 0.35 0.025 0.38 0.28 Full Partial SOLAR PANELS Solar Panels array solar cells. characteristics solar panel essentially same those solar cells, only scaled voltage current based number solar cells used arrangement array. Solar panels come variety shapes, sizes efficiencies, have similar characteristics. solar panel will generate maximum voltage when panel full sunlight with load. This voltage commonly referred open circuit voltage (VOC) panel. load solar panel increases, output voltage solar panel will decrease nonlinear fashion until maximum output current, short circuit current (JSC) panel, reached. Figure illustrates characteristic curves solar panel under different lighting conditions. maximum power panel, best operate solar panel, knee curve. Voltage FIGURE SOLAR PANEL TEMPERATURE CURVE Solar Panel Temperature Curve Current High Temperatures Temperatures Voltage 2008 Microchip Technology Inc. DS01211A-page AN1211 OVERVIEW this project will using 10-volt open circuit solar panel with short circuit current amps. With open circuit voltage volts, boost converter needed charge 24-volt battery. Figure make Maximum Power Point Converter work, functions boost converter need merged with solar panel's output load. boost converter either storing current boost inductor (switch closed) delivering current from boost inductor load (switch opened). When boost inductor storing current, current comes from solar panel. essence, boost inductor solar panel's load. making current stored boost inductor programmable, load solar panel becomes programmable. This principal Maximum Power Point Converter works. Maximum Power Point Converter combines boost converter, programmable current oscillator software algorithm maximize power solar panel. FIGURE BOOST CONVERTER Solar Panel Battery solar panel operate maximum power point, there items needed. First, order know output power solar panel, both current voltage solar panel have monitored. This will accomplished high side current monitor simple resistor divider solar panel's output voltage. There also needs control output power solar panel. This done manipulating panel's output current. lastly, software algorithm needed know which manipulate current, e.g., whether current solar panel should increased decreased. HARDWARE OVERVIEW Figure shows block diagram Maximum Power Point Converter. FIGURE Solar Panel MAXIMUM POWER POINT CONVERTER Current Sense Boost Supply Output Voltage Sense Oscillator Over-Voltage Protection Power Algorithm Programmable Voltage Reference PIC16F690 DS01211A-page 2008 Microchip Technology Inc. AN1211 CURRENT SENSE know instantaneous current boost inductor, current sense resistor been added series with boost inductor. Knowing value current sense resistor voltage drop across current inductor obtained. current sense resistor application mOhm. sense resistor kept intentionally small reduce inefficiency that introduces boost converter. high side current monitor used generate voltage that common mode range comparator. After comparator enabled, positive input will greater than negative input, which causes output comparator immediately change output high. When output comparator high, following will occur: boost converter conducts. positive input comparator equals (see Equation Energy stored boost inductor. current boost inductor increases linear rate. voltage negative input comparator increases. OSCILLATOR Figure shows current sense works with comparator components boost supply make oscillator. start-up condition oscillator dictated software PIC16F690. Before comparator enabled, port holds gate boost while oscillator's reference voltage stabilizes. Once reference voltage stable, comparator enabled. This creates start-up condition with voltage negative comparator input while positive input will VOSC_REF multiplied divider ratio provided RSOURCE RHYSTERESIS. EQUATION VOSC_REF (VDD VOSC_REF) RSOURCE/(RSOURCE RHYSTERESIS) predetermined current inductor, negative input comparator becomes greater than positive input, which causes output comparator become low. This current, (for hysteresis high), calculated following formula (Equation where gain current monitor: EQUATION /(GM RSENSE) FIGURE RSENSE SIMPLIFIED DIAGRAM BOOST OSCILLATOR VOUT When output comparator low, following will occur: boost converter does conduct. positive input comparator equals (see Equation Energy taken boost inductor delivered 24-volt load. current boost inductor decreases linear rate. voltage negative input comparator decreases. Current Monitor RHYSTERISIS Osc. Output VOSC_REF RSOURCE EQUATION VOSC_REF RHYSTERESIS/(RSOURCE RHYSTERESIS) current inductor will keep decreasing until voltage negative input equals positive input comparator. This current, (for hysteresis low), calculated formula Equation EQUATION RSENSE) When this point reached, comparator's output changes high cycle repeats. 2008 Microchip Technology Inc. DS01211A-page AN1211 FIGURE CURRENT TIME BOOST INDUCTOR frequency oscillation determined combination these times: Figure shows current profile boost inductor with respect time. rate current inductor changes, slope inductor current, inversely proportional inductance. larger inductor slower current inductor changes. combination amount hysteresis size boost inductor will dictate frequency oscillation. time takes current from EQUATION EQUATION (IHH IHL)L/VIN time takes current from EQUATION (IHH IHL)L/(VOUT VIN) DS01211A-page 2008 Microchip Technology Inc. AN1211 PROGRAMMABLE VOLTAGE REFERENCE voltage reference PIC16F690's first comparator, will used current solar panel. making this reference programmable, possible increase decrease current solar panel independent solar panel's voltage. power solar panel will controlled monitoring voltage adjusting current solar panel's current. implement programmable voltage reference, filter, combination with PIC16F690's PWM, will used. Ideally, current solar panel would scalable from amps approximately 2.75 amps slightly exceed panel's full range 0-2.5 amps, hardware setup oscillator does allow this happen. Looking back equations (Equation (Equation seen that programmable voltage reference zero, will zero, determined high output resistor divider RSENSE RHYSTERESIS. This creates inherent offset current equal half ripple current boost inductor. programmable solar panel's current closer desired full dynamic range, will have decrease current hysteresis boost supply. side effect decreasing amount hysteresis current that frequency oscillation will increase. This just many trade-offs that goes into selection components boost converter. current hardware configuration Maximum Power Point Converter yields programmable current range 1-2.86 amps. This allows enough dynamic range slow enough switching frequency application hand. OVER-VOLTAGE PROTECTION With boost converter, special care needs taken make sure that output voltage does exceed desired level. provide over-voltage protection, PIC16F690's second comparator, used. comparator positive input connected resistor divider boost supply, negative input internally generated voltage VDD. When boost supply greater than volts, comparator's output high. seen Figure high output comparator used ground positive output comparator setting current boost inductor zero. FIGURE OVER-VOLTAGE PROTECTION VCURRENT_SENSE VOSC_REF Rsource RHYSTERESIS VINT_REF VBOOST 2008 Microchip Technology Inc. DS01211A-page AN1211 COMPONENT SELECTION Keeping mind that goal this project most power solar panel, would seem unwise waste power having inefficient boost power supply. order optimize efficiency boost supply, first need examine losses associated with each component. Below series power equations associated with each major component boost supply. further analysis interaction these equations, download Excel spreadsheet associated with this application note. SCHOTTKY DIODE boost diode, there types losses: reverse recovery losses forward conducting losses. Depending switching speed given boost supply, reverse recovery losses ignored most part, Schottky diode used. reason this because reverse recovery current will approximately mAmps 20-50 nSeconds. forward conduction losses will dominate reverse recovery calculated using following equation: SENSE RESISTOR power lost resistance sense resistor I2R. most applications, approximated average current inductor, which yields following formula: EQUATION VF*(IHH IHL)/2 VIN/VOUT Where forward voltage across diode VIN/VOUT ratio diode's conduction time. EQUATION PRES BOOST INDUCTOR more accurate power dissipation sense resistor, power equation integrated because current constantly changing. There types losses that occur inductor: winding losses, core losses resistance losses. winding core losses have with physical inductor made which core material used. best determine these losses consult inductor manufacturer. this application note, winding core losses inductor were determined using "core loss calculator" located Coilcraft's site. This calculator will also calculate resistance losses Equation EQUATION PRES (IHH IHL) IHL2) INPUT OUTPUT CAPACITOR power lost because capacitor equivalent series resistance (ESR) ripple current cap. input capacitor, equation EQUATION PIND WIND CORE EQUATION (IHH IHL)2 DS01211A-page 2008 Microchip Technology Inc. AN1211 BOOST losses boost broken into categories: conduction losses switching losses. conduction loss, resistance loss multiplied ratio FET's on/off time. EQUATION PRDS RDS*(1 VIN/VOUT) more accurate loss: EQUATION PRDS (IHH IHL)2+(IHH IHL) IHL2 *RDS*(1 VIN/VOUT) switching losses broken into different categories: gate charge, output capacitance, transition losses calculated following equations: EQUATION PGATE Fsw*QG*VDRIVE EQUATION PCOSS (COSS*VDS2*FSW)/2 EQUATION PTRAN TF)VOUT*IIN*FSW EQUATION PFET PGATE PCOSS PTRAN switching frequency boost supply, FET's total gate charge, VDRIVE voltage gate being driven TR/TF FET's turn on/off rise/fall time. total power lost switching power supply EQUATION PTOTAL PRES PCIN PCOUT PI-RES PIND PIFET With components current bill material, calculated efficiency boost supply 96.56%, when input voltage volts input current amps. Testing Maximum Power Point Converter shown that overall process converts efficiency 94%. This slightly less than what calculated, because only account efficiency boost supply, account quiescent current draw driver, PIC16F690, current monitor, etc. 2008 Microchip Technology Inc. DS01211A-page AN1211 SOFTWARE software control Maximum Power Point Converter broken into algorithms: Current Reduction dither routine, which controlled Interrupt Service Routine (ISR). Both algorithms manipulate current solar panel Programmable Voltage reference generated PIC16F690's 10-bit PWM. modifying duty cycle PWM, current solar panel will scale linearly with respect duty cycle PWM. simplify math both algorithms, only MSBs PWM's duty cycle will used, yielding discrete current settings solar panel. Using duty cycle solar panel's current benefits. first benefit that eliminates need additional hardware. exact current solar panel, analog buffer ROUT needed, well additional filter located buffer's output. second benefit that PWM's duty cycle already digital format speeding control loop, because there need perform second conversion. Figure shows curve maximum power curve solar panel Maximum Power Point Converter designed for. Starting with load output, have open-circuit voltage volts. When panel operating this voltage, panel produces power. increasing current taken panel, begin collapse solar panels voltage, gain power. current panel increased beyond certain point, supply voltage will quickly collapse power solar panel will decrease. first time through dither routine, proportional power solar panel calculated multiplying voltage solar panel minimum duty cycle PWM. After power been calculated, PWM's duty cycle increased direction flag indicate that current panel increased current panel decreased, direction flag would cleared). second time through dither routine, power again calculated compared previous power calculation. power increases, current will adjusted same manner indicated direction flag; this case, current would increased. This will continue happen until power decreases. When power decreases, current adjusted opposite manner indicated direction flag (decreased), then direction flag cleared. DITHER ROUTINE dither routine used optimize power solar panel. algorithm does exact power solar panel, rather, difference proportional power. dither routine, only relative difference between successive power calculations important. power increase power decrease? amount power changed effect algorithm. this reason, exact power solar panel required, which allows linear relationship PWM's duty cycle solar panels current. proportional power solar panel calculated multiplying voltage solar panel duty cycle PWM. simplicity, Most Significant Bytes (MSBs) PWM's duty cycle multiplied MSBs reading solar panels voltage. FIGURE DITHER ROUTINE Solar Panel Curve Cells 5x10 array Solar Panel Power Curve cells 5x10 array 9.94 12.375 14.76 17.045 18.8 15.75 1.25 8.33 Full Current (Amps) Power (Watts) 0.51 0.497 0.495 0.492 0.487 0.47 0.35 2.55 2.485 2.475 2.46 2.435 2.35 1.75 0.25 0.25 0.25 0.245 0.244 0.24 0.238 0.08 9.94 12.375 14.76 17.045 18.8 15.75 Full Voltage (Volts) Voltage (Volts) DS01211A-page 2008 Microchip Technology Inc. AN1211 algorithm works independent voltage current from solar panel. dither routine whether power increased decreased change current. power increases, continues change current same manner indicated direction flag. power decreases, changes current solar panel opposite manner dictated direction flag. Figure flowchart full implementation dither routine. FIGURE FULL IMPLEMENTATION DITHER ROUTINE Clear Present Past Calculate Present Present Past Power decreased Power increased Difference Direction Inc? Direction Inc? Increase D.C. Decrease D.C. Decrease D.C. D.C. Increase D.C. D.C. Max? Direction Flag Clear Direction Flag D.C. Min? D.C. Clear Dither Flag Enable interrupt Return 2008 Microchip Technology Inc. DS01211A-page AN1211 CURRENT REDUCTION function current reduction algorithm make boost supply efficient possible. load output, part, dictates much current should taken solar panel. Ideally, system perfectly balanced, minimum amount energy would taken solar panel maintain proper voltage output load. over-voltage protection circuit becomes activated essentially tells there much energy being taken solar panel. current reduction algorithm implemented reduce energy taken solar panel, while allowing dither routine operate solar panel peak power point. This will help converter dissipate less heat power losses each component. full implementation current reduction algorithm seen flowchart (Figure 10). algorithm does nothing unless over-voltage condition occurs, which determined interrupt comparator When interrupt occurs, hardware automatically disables oscillator current reduction algorithm slightly reduces amount energy taken solar panel. When over-voltage condition longer present, oscillator will start again slightly lower current setting. This reduced current setting desired prevent over-voltage condition from happening every oscillation. next time through dither routine, current will again adjusted down operate panel peak power point. combination current reduction algorithm dither routine will optimize power solar panel given load. FIGURE INTERRUPT SERVICE ROUTINE FLOWCHART Enter Context Save Comparator Interrupt? Decrease D.C. D.C. D.C.? D.C. D.C. Comparator Interrupt? Dither Flag Disable Interrupt Return DS01211A-page 2008 Microchip Technology Inc. AN1211 ADDITIONAL SAFETY FEATURES When comparator enabled, comparator interrupt also enabled. change comparators state verifies that oscillator oscillates causes interrupt. state change comparator used conjunction with Watchdog Timer (WDT) ensure oscillator never enters state where solar panel cannot supply enough current reach threshold. this happens, PIC16F690 will reset device. Servicing comparator interrupt causes dither flag disables comparator interrupt. comparator disabled prevent unnecessary time after already been validated that oscillator oscillates. dither flag checked only main software loop. dither flag set, dither routine will clear WDT. dither routine, dither flag cleared comparator interrupt will re-enabled. CONCLUSION solar panels increase efficiency, more more applications will begin them either primary power source backup power source. applications where ambient light continually changing, Maximum Power Solar Converter very effective tool increasing total power delivered solar panel. 2008 Microchip Technology Inc. DS01211A-page DS01211A-page D100 +V_SP_UNREG ZHCS1000 R100 0.01 L100 D101 +28V B540C C101 10uF C102 100nF C103 100nF 10uH SER1360 1/4W C100 U100 C1C106 MAX4376FAUK C2RS+ SP_VOLTAGE R103 10.0K U101 +V_SP_UNREG C1OUT TC4432COA PICkit® HEADER J100 +5V_SC C2D103 C1+/ICSPDATA R107 200K Q101 2N7002 APPENDIX AN1211 P100 R104 2.74K SOLAR PANEL R102 39.2K R109 30.1K C105 1000pF C108 100nF Q100 IRF7468 nLOCKDIS ,2,31 +V_SP_UNREG ,6,7,85 R108 5.10K SYSTEM CONNECTOR C104 100nF R105 10.0K J101 TX_COM RX_COM GND_SC SYSTEM R110 27.4K C107 100nF MCLR R106 10.0K U102 OSC1 OSC2 MCLR TX_COM BAT54 C1+/ICSPDATA ICSPCLK C1OUT SP_VOLTAGE C1C2RX_COM MCLR +5V_SC C1+/ICSPDATA ICSPCLK CONNECT GND_SC ICSPDAT ICSPCLK PICkit® SOLAR POWER CONVERTER SCHEMATIC R112 27.4K C109 100nF R111 27.4K PIC16F690-I/SS C2OUT 2008 Microchip Technology Inc. C1OUT Note following details code protection feature Microchip devices: Microchip products meet specification contained their particular Microchip Data Sheet. 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