Contract for:<br/><br/>SPECIFIC TARGETED RESEARCH OR INNOVATION PROJECT<br/>WP3: Developing Appropiate Technologies DELIVERABLE D11: 2 Power conditioning station prototypes adapted to the requirements of MSGs in target countries (P1) Project acronym: CRESMED Project full title: Cost efficient and reliable rural electrification schemes for South Mediterranean countries based on multi user Solar Hybrid grids Proposal/Contract no.: 015286<br/><br/>Contract 015286 (INCO) - CRESMED Document: D-11 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries WP 3 Task 3.1 Final use- I Date: 17/02/2008 Description: Language English Responsible: Antoine Graillot Co-authors Revised by:<br/><br/>Version:01 Level: PW Nº pages:29<br/><br/>Author: Antoine Graillot Date Comments<br/><br/><br/>I. Technical background of the existing device ................................................................ 3 1. Introduction............................................................................................................... 3 2. General rules ............................................................................................................. 3 3. Inverter controller module ........................................................................................ 3 4. Inverter power modules ............................................................................................ 3 5. Battery supervisor and energy management system................................................. 3 6. PV charger modules with MPP tracking .................................................................. 3 7. 12VDC supply .......................................................................................................... 4 8. External battery chargers .......................................................................................... 4 9. Peripherals for load management (optional)............................................................. 4 10. Special rules for systems with several racks........................................................... 4 11. Exceptions of the rules............................................................................................ 4 II. Functional description of the power conditioning unit ................................................ 5 1. GENERAL performance .......................................................................................... 5 2. THE MODULAR POWER CONDITIONING RACK TApS ................................. 5 2.1 THE INVERTER (D+C) .................................................................................... 6 2.2 THE pv CHARGER MODULE (B) ................................................................... 6 2.3 THE 12V CONVERTER.................................................................................... 6 2.4. MAIN INDICATORS ....................................................................................... 6 2.5. THE INTELLIGENT SYSTEM MANAGER (A) ............................................ 7 3. Accesories ............................................................................................................... 11 3.1 THE REMOTE VISUALIZATION PANEL ................................................... 11 3.2 THE LOAD MANAGEMENT SWITCH........................................................ 12 4. THE GENSET ........................................................................................................ 13 III. Technology adaptation.............................................................................................. 15 1. HARDWARE ......................................................................................................... 15 2. SOFTWARE........................................................................................................... 28 2.1 OPERATIONAL IMPROVEMENTS .............................................................. 28 2.2 IMPROVEMENT OF THE EFFICIENCY OF THE BATTERY CHARGING AND VOLTAGE LIMITATION ........................................................................... 28 2.3. Solutions to the STRATIFICATION AND THE SULFATION OF THE BATTERY.............................................................................................................. 28 2.4. New: INTELLIGENT ALGORITHM FOR BATTERY CHARGING .......... 28 2.5. MANAGEMENT OF THE LOAD DISCONNECT....................................... 29<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 2/29<br/><br/><br/>I. Technical background of the existing device<br/>Design Rules for Autonomous Energy Supply systems with centralita TapS<br/>1. Introduction<br/><br/>The centralita is an universal rack system for autonomous power supply. It houses different modules, which may be combined according to rules described here. Thus there are many possibilities to adapt the configuration of the centralita to the needs of the installation. The only power cables to be wired are for the battery, PV field, inverter output, and an connection to earth.<br/>2. General rules<br/><br/>· Nominal battery voltage: 48V · For each system, one or two racks may be installed · each rack has seven slots, which may be occupied with following modules: · inverter controller · inverter power modules · PV charger modules with MPP tracking · battery supervisor and energy management system · No external fuses and sectioning devices needed, they are all integrated in the rack<br/>3. Inverter controller module<br/><br/>· required for inverter control · comes with a low power inverter (20VA) for stand-by appliances<br/>4. Inverter power modules<br/><br/>· AC-power of one module 1.25kVA · at least one inverter controller module has to be installed<br/>5. Battery supervisor and energy management system<br/><br/>· · · · · · ·<br/><br/>required for MPP-tracker modules, recommended for any system comes with monitoring system with data dealing with energy flows (PV, genset, wind, AC-consumption, DC-consumption) solar irradiance and other data provides system state signals for energy dispenser and load management relays external sensor only work together with the battery supervisor module Comes with the GIFA programme for data download / analysis and system configuration<br/><br/>6. PV charger modules with MPP tracking<br/><br/>· PV-power of one module: 2.0kW<br/>D 11 Project: CRESMED<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 3/29<br/><br/><br/>· At least one battery supervisor module has to be installed · PV fields have to be connected separately to each PV charger module, maximum three modules per series · Fuses and sectioning devices integrated in housing<br/>7. 12VDC supply<br/><br/>· Up to one 12V DC supply (10A) may be installed (without occupying a slot)<br/>8. External battery chargers<br/><br/>· · · ·<br/><br/>Two different external battery chargers possible Power of each external battery charger may not exceed 10kW. Fuses or sectioning devices integrated in housing Number and power of external battery chargers to be specified when ordering centralita<br/><br/>9. Peripherals for load management (optional)<br/><br/>· Remote visualisation panel: battery supervisor required · Load management relays: battery supervisor required · Energy dispenser/meter: no requirements; battery supervisor required only for the additional features (restriction and benefaction modes) .<br/>10. Special rules for systems with several racks<br/><br/>· Controller rack with battery supervisor and up to six PV charger modules ==&gt; Maximum PV power: 12kW · Inverter rack with inverter controller and up to six inverter modules ==&gt; Maximum Inverter power: 7.5kVA · No additional fuses or sectioning devices needed · Special connection cable between the racks required (included)<br/>11. Exceptions of the rules<br/><br/>On request, offers may be elaborated which are beyond these rules. (Extension of inverter power, etc.)<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 4/29<br/><br/><br/>II. Functional description of the power conditioning unit 1. GENERAL performance The PV stand-alone micro power plant consists of: - PV array to convert the solar energy, - the back-up genset and/or other renewable energy sources with battery charger, - the electrochemical storage battery, - the modular power conditioning rack TApS to control the battery, to convert the electricity to usual voltages and to inform about the system status, - the electrical protection gear, - the user's consumption installation. The performance characteristics in the specifications are: - EDA. Energy Deliverability Assurance (daily average) corresponding to a given average solar radiation. - AUT. Days of battery autonomy at rated consumption (EDA). - POT. Max. power to loads.<br/><br/>2. THE MODULAR POWER CONDITIONING RACK TApS<br/><br/>The power station is made of the following modular elements: - Intelligent manager of the system (A), - PV MPPT charger (B), - pilot inverter (D) and inverter power modules (C), - DC power supply (internal, optional).<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 5/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>2.1 THE INVERTER (D+C)<br/><br/>The inverter converts the battery DC voltage into a common AC voltage. To start up: Green button (2) The green light of the inverter control (11) comes on pressing the green button (2) with symbol «I». Consumptions lower than 25W are supplied by the pilot inverter (D), this fact avoids the inverter power modules start up. These ones start automatically as the consumption increases (10). To stop: Red button (1) Press the red button (1) with symbol «0».<br/>2.2 THE pv CHARGER MODULE (B)<br/><br/>The charger tracks for the PV Maximum. Power Point and, when the battery voltage is high enough, it limits the energy in flow to protect it.<br/>2.3 THE 12V CONVERTER<br/><br/>The converter is designed to supply devices in 12V. Please ask to your installer when the devices have internal battery. Start up and stop the 12V converter in menu FUNCTIONS.<br/>2.4. MAIN INDICATORS<br/><br/>Charger module (Light 9). The PV array is generating energy. Inverter power module on (Light 10). The inverter power module is on. Inverter activated (Light 11). There is service in AC. Overload in alternating current (Light 12). The red light indicates that the maximum power of consumption has been exceeded. This alarm goes with an<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 6/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>acoustic warning and, if this situation remains for more than 30 seconds, the inverter stops. To resume operation, disconnect the load and stop the inverter (1) , then start it up again (2). (Light 13) Not operative in this version. Low battery voltage (light 14). The inverter has disconnected itself since the battery voltage is too low. Wait until the battery is charged. Afterwards, to resume operation, the inverter should be stopped (1) and started again (2).<br/>2.5. THE INTELLIGENT SYSTEM MANAGER (A)<br/><br/>The card controls the operation of the whole system. This is the &quot;brain&quot; of the power station. It has a display (8) where the messages appear. This can be the start screen, warnings or menu screen. Start display The display (8) shows the date, the solar hour and the remaining energy. If the consumption control is by Energy Deliverability (ED) the screen shows the remaining energy until the sunset. When the ED is 0, the service is stopped.<br/>dd/mm/yy ED 99.9d hh:mm 99999Wh Energy deliverability in Wh and in days of nominal consumption<br/><br/>If the consumption control is by Battery (BAT) the screen shows the total remaining energy of the battery. When this is 0, the service is stopped.<br/>dd/mm/yy hh:mm BAT 99% 999.9kWh Remaining energy of the battery in kW.h and in %<br/><br/>Control keys There are four buttons that allow to access to menus: - ACCEPT (5): green symbol key to read an spontaneous warning, to enter into a submenu, to change a value, or to confirm a value change. - EXIT (3): red symbol key to exit the spontaneous warnings, a submenu or not saving a change. - RIGHT ARROW (6), LEFT ARROW (4): To change among menus or modify values. Menus All the manager information is organised in three menus:<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 7/29<br/><br/><br/>READINGS PARAMETERS FUNCTIONS<br/><br/>To check the system's operation To see the parameters of operation and control Allow to operate the power station<br/><br/>To see the menus, follow this steps: 1. If there is spontaneous warnings, press EXIT (3) and the start screen appears with the date and solar hour. 2. Press ACCEPT (5), the main menu appears with the words READINGS. (Now it would be also possible make the selection with the PARAMETERS ARROWS OR FUNCTIONS). 3. Press ACCEPT (5) to enter in the selected menu. 4. The screens among menus change with the ARROW. Warnings of the intelligent manager (Light 7) Red light shows any abnormal situation and green light a positive situation. If the warning is flashing, it suggests an action to be taken by the user. Check the spontaneous warnings of the screen and do the actions described in the table. Once the notice is read, press ACCEPT (5) to see the next one. To skip the warnings and return to the start screen, press EXIT (3).<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 8/29<br/><br/><br/>Spontaneous warning BATTERY DEGRADED VOLTAGE ERROR STOP AND RESTART (14 + 28 + 27, red) COURT-CIRCUIT ARRÊTER et DEM. (12 + 28) SURINTENSITE ARRÊTER et DEM. (12 + 28) BAT. EXHAUSTED CHARGE (27, red) NO ENERGY AVAILABLE WAIT (32, all stop) BATTERY LOW (27, red) EQUALIZATION CHARGE NEEDED (27, yellow) RESTRAIN LOADS EXCESS ENERGY USE IT NOW! (22) EQUALIZATION COMPLETED (26)<br/><br/>Description and recommended action The battery is in bad condition. Inform to the maintenance service. Battery voltage too low. Charge urgently the battery!. Stop and start the inverter. Short-circuit in the receiving installation. Find it and eliminate it. Stop the inverter and start it up. Too much consumptions at the same time. Disconnect the most powerful consumption. Stop the inverter and start it up. End of the battery autonomy. The consumptions are disconnected. Charge urgently the battery! The energy deliverability is totally consumed. Active the ED reserve or wait until the manager allows more energy. There is little autonomy left in the battery. Reduce consumptions or charge the battery. Reduce consumptions to allow an equalizing charge of the battery. Battery at medium state of charge. The battery can not store all the energy generated at this moment. Good time to consume. Today batteries have reach equalization.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 9/29<br/><br/><br/>The more useful readings are:<br/>SUBMENU ENERGY Screen Description -99.999kWh Consumptions of the current day +99.999kWh (negative) and generation of the current day (positive). -99999.9kWh Cumulative counter of consumptions +99999.9kWh and PV energy generated. +99999.9kWh Cumulative counter of the generated +99999.9kWh energy by other renewable sources or by the auxiliary external or internal charger. SUBMENU POWER -99999W Power in the inverter and in 12V DC +99999W and internal. +99999W Instantaneous PV generation and other +99999W energy resources. +99999W Input of the external or internal auxiliary charger.<br/><br/>TODAY<br/><br/>Cons. PV AUX1 AUX2<br/><br/>INVERTER CC PV (99%) AUX1 AUX2<br/><br/>VOLTAGE MAX 99.9 CURRENT Temp. T1 BAT. CYCLES HISTORICAL EQ.<br/><br/>SUBMENU BATTERY 99.9 V Instantaneous battery voltage and MIN 99.9 extreme values of the current day. ±999.9A Battery voltage (positive = charge 99.9ºC input). Battery temperature. 9999 99% State of charge of the battery. Cycle normalised to nominal capacity. 99% The historical average index of the days in the last month that the battery equalization has been completed. Days of complete equalization (+) or not ( ). Yesterday is the last in the second row.<br/><br/>+++-++--++++-+++ -++--++-+-+--+++<br/><br/>For a complete description of all the available menus, see the manual of reference.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 10/29<br/><br/><br/>Functions are:<br/>EXTRA RESERVE On/Off CONVERTER 12V On/Off CHARGER On/Off SUPERCHARGE On/Off MESSAGES SEQUEN. To activate the reserve after the ED is totally consumed. To start and stop the 12 V power supply. To start and stop the auxiliary charger. To activate or deactivate the forced charge of the battery. To activate the display of sequential messages.<br/><br/>DATE, SOLAR TIME To change date and hour. The hour should be dd/mm/yy hh:mm solar time! LANGUAGE English To change the language of the messages<br/><br/>Example: change of language of the messages: a. Select menu FUNCTIONS and enter pressing ACCEPT (5). b. Press ARROW (3) (6) until the screen with the language appears. c. Press ACCEPT (5) and the word flashes. With the ARROW select amongst the ones available. d. Press EXIT (3) to save changes and exit.<br/>3. Accesories<br/><br/>3.1 THE REMOTE VISUALIZATION PANEL<br/><br/>Allows the query about the micro power plant from a frequent place (corridor, kitchen, etc.) (21) &quot;Day&quot;. On when the PV modules receive day light. (22) Limiting the energy input. The regulator is limiting the energy coming in. Good time to use deferrable consumptions; washer machine, water pump, vacuum cleaner, etc. So, the energy overflow is well-spend. (23) Electricity production. Generated by the PV modules or any other generator (genset). (24) Charge-discharge. Indicates the battery is charging (green lights on the right) or discharging (orange lights on the left). (25) State of charge. If the whole file is on it means 100%. (26) Equalizing charge. Indicates it has been reached during the day. Try to reach it every week in order to extend the battery life.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 11/29<br/><br/><br/>(27) Warnings about the battery state: · yellow: Historic low. Try to allow an equalizing charge of the battery (light 26). · red: The charge state of is very low. Advisable to disconnect the most consumptions or use a genset. If the consumptions are not disconnected, the power station will shortly cut the service. (28) Inverter alarm. The inverter has stopped. See the inverter lights and proceed as described in chapter 2. (29) Hot water tank temperature. (Range from 30° to 65°C, for hot water tank). (30) The temperature of the tank is enough for consumption (only for installations with solar water heating). (31) Circulation pump of the solar water heater. Pump on. (32) Availability of energy. For installations with EDA load control. When all the file is off, the service stops. (33) Positive warning. Good time to consume.<br/>21 23 28<br/><br/>22 24<br/><br/>26 30 25 27 33<br/><br/>31<br/><br/>32<br/><br/>29<br/><br/>34<br/><br/>3.2 THE LOAD MANAGEMENT SWITCH<br/><br/>Automatically when certain conditions are fulfilled, it allows to manage consumptions. In this case the rely yellow lights on. The table shows the available conditions.<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 12/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>If more than one selection is selected they need to be on simultaneously.<br/><br/>ELECTRIC SAFETY All the distribution circuits should remain protected by the protection mains. Do not connect consumptions directly to the battery or the power station. Num. 1 1 2 3 4 5 6 7 8 Switch condition DAY (in case of normal relay ED0-R) NIGHT (in case of twilight relay ED1-R) Today the battery has been charged until the equalization voltage In this moment the controller is limiting the generation There is energy generation, can be photovoltaic or from any auxiliary source The temperature of the solar collector is enough high to activate the circulation pump The temperature of the water is hot enough The battery has an energy reserve above the minimum The total power of consumptions is below limit of the inverter<br/><br/>4. THE GENSET<br/><br/>The genset is used for direct supply and, at the same time, if we have a charger, it can charge batteries. The direct use of the genset Usually, the installation has a commuter switch that connects the receiving installation directly to the genset, instead of the inverter. This could be necessary when: 1. there are bigger consumptions, than the inverter power one. 2. the battery state of charge is low and an important consumption is needed. The best time for the direct use of the genset is that with maximum consumption and less PV generation (by night, for example).<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 13/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>¿How to charge the batteries with the genset? To start the genset and its corresponding charger, follow the next steps: 1. Start the genset. 2. Follow the charger instructions to start it. 3. In the second screen of the menu READINGS/POWER you can verify the instantaneous power of the charger in AUX1.<br/><br/>RATIONAL USE OF THE ENERGY Energy management is a key point to have a good service. In order to obtain the maximum advantage of the energy deliverability here you are some advices: * Illumination with high efficiency lamps. * Do not leave lights on. * Use of efficient devices, specially fridges and freezers (class A+). * Consume in hours with sun, when the controller limits, specially machines of a certain power (washing machine, vacuum cleaner, water pump, etc.). * Do not use electric heaters, nor electric water heatings or similar devices. * Always keep the battery in a high state of charge (six lights in the scale (25) of the visualization panel). * Try to allow the equalization charge at last once per week (see light 26). * For the automatic management of energy according the advices given, there are the load management switches, that allow the control of consumptions connected according to certain conditions.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 14/29<br/><br/><br/>III. Technology adaptation<br/><br/>This report will present the improvements made on the hardware and software to adapt the existing technology for the application in the target countries.<br/>1. HARDWARE<br/><br/>The first part deals with the hardware improvements which includes the following parts: a. b. c. d. e. Fun cooler control Radiator on Charge Controller MPPT Radiator on Inverter Power Module Redesign of the Pilot Inverter board Redesign of the fuse support and shunt measure resistance on Inverter Power Module and Charge Controller MPPT. f. Change input fuse protection for automatic protection. g. Case and filters. h. Inductance.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 15/29<br/><br/><br/>a. Fan cooler control. On the previous version the fan cooler was automatically switch by hardware on with the first Inverter Power Module.<br/><br/>Original placement of the power supply fan by the first Inverter Power Module.<br/><br/>Actual connection by the power supply fan on the Input-Output board, software controlled. Turns on by inverter power, charge controller power, generation auxiliary power and temperature.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 16/29<br/><br/><br/>b. Radiator on Charge Controller MPPT.<br/><br/>Original board without protection neither radiator.<br/><br/>Actual radiator and protection. The radiator improves the board dust protection either the temperature evacuation.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 17/29<br/><br/><br/>c. Radiator on Inverter Power Module.<br/><br/>Original board without protection neither radiator.<br/><br/>As the Charge Controller MPPT protection, the function on the Inverter Power Module becomes more important because it could be working all day and the temperature must be evacuated.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 18/29<br/><br/><br/>d. Redesign of the Pilot Inverter board. In order to have the possibity of a mount a radiator on the Pilot Inverter too, it was necessary a redesign of the board.<br/><br/>Original Pilot Inverter board without possibility of the radiator's integration.<br/><br/>Re-designed board. Take a look at the holes on the bottom's board and the slided components. We used to change the MOSFET transistors, not only in the Pilot Inverter, but also in the Charge Controller MPPT and the Inverter Power Modules, to allow more capacity and decrease the heating effect.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 19/29<br/><br/><br/>Final Pilot Inverter board with a radiator.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 20/29<br/><br/><br/>e. Redesign of the fuse support and shunt measure resistance on Inverter Power<br/><br/>Module and Charge Controller MPPT.<br/><br/>Previous fuse base and measurement shunt.<br/><br/>Actual redesign of the fuse base and measurement shunt. All the current passes by these two devices, and this increases the temperature. This could cause a breakdown for over<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 21/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>heating. The fuse base is changed and the shunt is doubled and enlarged. With this improvements the board can resist and evacuate heat. f.<br/><br/>Change input fuse protection for an automatic protection.<br/><br/>Original Fuses of battery (100A) and photovoltaic array (50A).<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 22/29<br/><br/><br/>Actual magnetothermic protection of battery and photovoltaic array.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 23/29<br/><br/><br/>g. Case and filters<br/><br/>Previous case.<br/><br/>Non filtered grid.<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 24/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>New case.<br/><br/>New filtered-grid. Detail.<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 25/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>Original back grid.<br/><br/>New back filtered grid.<br/><br/>Back filtered grid detail.<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 26/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>General view of the actual case. h. Inductance. Improves of the inverter response with an Addition of an inductance to reduce high peaks of cur rent when some appliances start.<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 27/29<br/><br/><br/>2. SOFTWARE<br/><br/>2.1 OPERATIONAL IMPROVEMENTS The following points represant the improvements made by TTA from the operational point of view. They concern the menu of the user interface and also the accurancy of the measurements of voltage and energy in order to improve the management and the information to the user: Order of appearance in the `readings' menu Order of the messages of spontaneous alarms Logging of the serial number of the equipment Measurement of instantaneous voltage Improvement of the measurement of the DC energy<br/><br/>2.2 IMPROVEMENT OF THE EFFICIENCY OF THE BATTERY CHARGING AND VOLTAGE LIMITATION Another important issue for the power conditioning unit is teh efficiency of the charge controller and especially the MPP Tracker. Some improvements have been made in this sense: Higher stability in the control loop for the MPP search. Quicker control loop for limiting the voltage of the MPP Tracker at 61V if there is disconnection of the battery at full charge<br/><br/>2.3. Solutions to the STRATIFICATION AND THE SULFATION OF THE BATTERY In a stand-alone PV application, the battery is one of the most critical part and definitely the highest part of the total cost of an installation taking into account the life cycle. The battery management is important and TTA improved it to avoid typical problems which occur on the battery, which are: Stratification: density of the electrolyte lower in the upper part of the battery o Solution: periodic gasification of the battery Sulfation: Irreversibility of the crystals of lead sulfate in the plates of the battery o Occurs after long periods with a status of low charge o Almost irrevrsible. o Solution: keep the battery charged<br/><br/>2.4. New: INTELLIGENT ALGORITHM FOR BATTERY CHARGING In order to solve the problems previously mentionned, it was importrant to improve the algorithm of charge of the battery. The purpose was:<br/>D 11 Project: 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED Responsible: Antoine Graillot Page 28/29 Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/><br/>-<br/><br/>To assure the complete charge: Floating voltage with adaptative levels To assure the gasification and equalization: Equalization voltage as a variable duration.<br/><br/>2,6<br/><br/>2,5 180min<br/>VB [V/el.]<br/><br/>HBI=9%=&gt;SC HBI=10%, SOC&lt;50%<br/><br/>2,4 120min 2,3 60min 1min 2,2 0 100 200<br/>t [min]<br/><br/>HBI=50%, SOC=68% HBI=70%, SOC=83%<br/><br/>HBI=100%, SOC=100%<br/><br/>300<br/><br/>400<br/><br/>500<br/><br/>Illustration of the Floating voltage ADAPTS as a function of the HBI (Historical Battery Index) and the VARIABLE duration at the Equalization voltage in function of the State of Charge. 2.5. MANAGEMENT OF THE LOAD DISCONNECT 3 OPTIONS: By EDA (ENERGY DELIVERABILITY ASSURANCE) based on the Demand Design. (New and very recommended) By Battery INDEX. (recommended and used until now) By BATTERY VOLTAGE. (not recommended)<br/><br/>NEW ALGORITHM EDA - Assures the daily energy available (ED) according to the Demand Design. - The energy is availble at sunset or when a cycle of equalization has been completed - It is possible to increase the ED as bonus until a maximum of twice the DD in function of the HBI<br/><br/>D 11 Project:<br/><br/>2 Power conditioning stations adapted to the special requirements of MSGs in the target countries CRESMED<br/><br/>Date: 28/02/2008 15:39:00<br/><br/>Work Package : 3 ­ 2 Power conditioning stations adapted to the special requirements of MSGs in the target countries<br/><br/>Responsible: Antoine Graillot<br/><br/>Page 29/29