TII - Reference Designs

Test Report - PMP7647_RevC
TEST REPORT OF MPPT & LED DRIVER
PMP 7647
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Test Report - PMP7647_RevC
CONTENTS
Contents
I.
INTRODUCTION.................................................................................................................................................................... 3
II.
DESCRIPTION ........................................................................................................................................................................ 3
III.
BLOCK DIAGRAM ............................................................................................................................................................ 4
IV.
SPECIFICATIONS .............................................................................................................................................................. 5
V.
BOARD LAYOUT .................................................................................................................................................................. 5
VI.
TEST SETUP....................................................................................................................................................................... 6
VII.
TEST DATA ........................................................................................................................................................................ 7
a.
MPPT PERFORMANCE ......................................................................................................................................................... 7
b.
LED DRIVER PERFORMANCE ............................................................................................................................................ 7
c.
MPPT EFFICIENCY PLOT .................................................................................................................................................... 7
VIII.
WAVEFORMS .................................................................................................................................................................... 8
a.
Switching Node Waveforms ................................................................................................................................................ 8
b.
Gate waveforms ................................................................................................................................................................... 9
IX.
POWER GAIN WITH MPP .............................................................................................................................................. 10
a.
Test Set-up ......................................................................................................................................................................... 10
b.
Test Results ........................................................................................................................................................................ 10
X.
SCHEMATIC ......................................................................................................................................................................... 11
a.
Power Stage ....................................................................................................................................................................... 11
b.
Controller and Bias Supply ................................................................................................................................................ 12
XI.
BILL OF MATERIALS ..................................................................................................................................................... 13
XII.
CONCLUSION .................................................................................................................................................................. 13
XIII.
APPENDIX........................................................................................................................................................................ 14
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Test Report - PMP7647_RevC
I.
INTRODUCTION
The following document is a compilation of test results of the PMP7647 reference design, a 12A
MPPT solar charge controller & 700mA LED driver. The test results are taken with simulated solar
panel input corresponding to 12V panel.
II.
DESCRIPTION
The PMP7647 is developed around the MSP430F5132 controller IC. The design is targeted for low
power solar charger and LED driver solutions such as solar street lights. This design is capable of
charging 12V batteries with up to 10A output current from 12V panels. However, it can be easily
adapted to 24V systems by just changing the MOSFETs to 60V rated parts. Also, the design can
drive up to 15 LEDs in series with 700mA of current. It is possible to adapt the design for LED
currents up to 1.1A with minimum change in hardware.
The MPPT section has a typical electrical efficiency of 97% at full load. This efficiency
figure includes the losses in battery reverse protection and panel reverse flow protection MOSFETs,
which are part of the design. The high efficiency is the result of the low gate charge MOSFETs from
TI used in the design, and also the optimum layout. Another feature is the relatively small sized
components used, possible due to the high operating frequency (settable from 100 - 200 KHz). The
design has built-in battery charge profile for 12V Lead acid batteries. The design presently uses
‘perturb and observe’ algorithm for MPP tracking. This gives fast acquisition of MPP operation.
The LED driver section is a boost converter. The electrical efficiency of boost section is
about 93% while driving 12 LEDs at 700mA, and is around 91% while driving 6 LEDs at 350mA.
The section is protected with load and converter cut-off during overload, short circuit and load open
fault situations. There is also provision to dim the output after specified time intervals. Though in a
typical application the time intervals are in hours, the board is programmed for one minute intervals
of 700mA and 350mA current drive for easy demonstration of the feature. The design is also
capable of detection of ambient light based on the panel voltage, and taking appropriate decisions
to turn on LEDs, charge battery in MPPT mode or go to standby accordingly. Low battery voltage
protection by dimming the LEDs to 10% brightness and subsequently going to low power mode with
further reduction in voltage is also implemented. The voltage levels at which these actions are taken
can be set by software.
The various parameters of the circuit like battery charge current, load current, load timing
pattern, battery under voltage set points etc can be set using a GUI made for the design. This
makes customization a lot easier.
The circuit takes only under 4mA of standby current while operating from battery. This is
further reduced to under 1mA while the circuit is in battery under voltage cut-off. Software
programmable indications are provided in hardware, but are left non-configured.
Surge protection and EMI filtering components are not present on this design, and has to
be added depending upon required specification levels.
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Test Report - PMP7647_RevC
III.
BLOCK DIAGRAM
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IV.
SPECIFICATIONS
Input Voltage Range: 15VDC - 22VDC
Storage: 12V battery
Charging Current: 10A, with current limit set at 12A
Output: 12 LEDs at 700mA
Board Form Factor: 100 mm x 45 mm x 32 mm
Expected efficiency: >95% for MPPT charger, and >90% for LED driver
V.
BOARD LAYOUT
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VI.
TEST SETUP
Input conditions:
Panel input: 15VDC to 22VDC
Set current limit to the short circuit current of panel when DC source is used instead of panel
Storage:
12V battery
Output:
12 LED array
Equipment Used:
1. Current limited DC source simulating solar panel
2. Digital Oscilloscope
3. Multimeters
4. LED load/LED simulator
Procedure:
1. Connect appropriate battery to the battery terminals of the PMP7647 reference board,
maintaining correct polarity.
2. Connect panel or current limited DC source to panel terminals, maintaining correct
polarity.
3. Set the output voltage of DC source to slightly above the MPP voltage of the panel being
simulated (if DC source is used instead of panel) and turn on.
4. Observe for gradual build-up of battery charge current.
5. Connect LED array to the load terminals with proper polarity.
6. Turn off the panel input to observe gradual build-up of LED current.
Connection Diagram:
-
+
+
-
A
LED
ARRAY
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-
+
A
V
A
BATTERY
V
6
V
SOLAR
PANEL
TII - Reference Designs
Test Report - PMP7647_RevC
VII.
TEST DATA
a. MPPT PERFORMANCE
Vi (V)
Ii (A)
Vo (V)
Io (A)
Pi (W)
Po (W)
Efficiency
17.04
0.44
13.04
0.50
7.43
6.56
88.29
17.38
0.81
13.11
1.01
14.13
13.18
93.25
17.18
2.01
13.33
2.50
34.53
33.33
96.51
16.87
4.17
13.68
5.00
70.28
68.41
97.34
17.01
6.35
14.03
7.50
108.00
105.23
97.43
16.62
8.93
14.39
10.02
148.42
144.19
97.15
b. LED DRIVER PERFORMANCE
Vi (V)
Ii (A)
Vo (V)
Io (A)
Pi (W)
Po (W)
Efficiency
11.23
2.775
41.23
0.702
31.16
28.94
92.88
12.15
0.708
21.55
0.365
8.60
7.87
91.44
c. MPPT EFFICIENCY PLOT
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Test Report - PMP7647_RevC
VIII. WAVEFORMS
a. Switching Node Waveforms
MPPT switch node at 10A charging current
Boost converter switch node at 12LED, 700mA load
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Test Report - PMP7647_RevC
b. Gate waveforms
MPPT gate waveforms at 10A load show dead-time implementation
Expanded view
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IX.
POWER GAIN WITH MPP
a. Test Set-up
This test was done with an earlier similar design PMP7605.
Setup Explains the Power flow from Panel to Battery during MPPT Operation.
To connect Panel directly to battery, both contactors were opened and Extra connections were connected directly
onto the battery.
b. Test Results
12 V System
Battery Voltage = 11.96
Two Panels connected
Readings Taken approximately every 5-7 mins (@ 3.15 pm) Cloudy Conditions
Sr No
Charging Currents (A)
Panel directly connected to Battery
Charging via MPPT Board
1
1.794
2.08
2
1.28
1.443
3
0.55
0.6
4
1.15
1.3
5
1.21
1.35
6
2.13
2.5
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Improvement
%
15.94
12.73
9.09
13.04
11.57
17.37
TII - Reference Designs
Test Report - PMP7647_RevC
X.
SCHEMATIC
a. Power Stage
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b. Controller and Bias Supply
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XI.
BILL OF MATERIALS
PMP7647 BOM Revision C
Item Qty Reference
1
2
3
2
3
4
2
2
1
1
1
3
5
10
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
5
1
1
1
1
1
3
1
2
1
1
1
2
3
2
3
1
1
1
3
26
5
27
28
29
30
31
32
7
1
3
1
2
1
33
34
35
36
37
38
39
40
41
42
43
44
45
46
5
1
1
2
1
1
4
2
1
1
1
1
1
1
XII.
B2, B3
C1, C2
C6
C7
C8
C9, C18, C28
C10, C14, C16, C17,
C21, C22, C23, C24,
C25, C31
C11, C26, C27, C29,
C30
C12
C15
C19
C32
D1
J1, J2, J3
J4
J5, J6
L1
L2
Q1
Q5, Q6
Q2, Q3, Q4
Q7, Q11
Q8, Q9, Q10
R1
R2
R3
R4, R18, R22
R5, R12, R14, R17,
R19
R6, R8, R10, R15,
R20, R31, R33
R7
R11, R13, R16
R21
R23, R24
R25
R26, R28, R36, R37,
R38
R27
R29
R9, R32
R34
R35
R30, R39, R40, R41
R42, R43
U1
U2
U3
U4
U5
U6
Value
Description
Part Number
Manufacturer Size
1200 uF
470 uF
220 uF
470 uF
1nF
Bead, Ferrite, 500mA, 600ohms
Capacitor, Aluminium Electrolytic, Low ESR, 35V
Capacitor, Aluminium Electrolytic, Low ESR, 35V
Capacitor, Aluminium Electrolytic, Low ESR, 35V
Capacitor, Aluminium Electrolytic, Low ESR, 63V
Capacitor, Ceramic, 50V, X7R, 10%
7427920415
EEU-FM1V122L
EEU-FR1V471L
UHE1V221MPD6
UPW1J471MHD
Std
Wurth Elektronik
Panasonic
Panasonic
Nichicon
Nichicon
Std
805
12.5 x 30 mm
8 x 22 mm
10 x 12.5 mm
12.5 x 25 mm
603
1uF
Capacitor, Ceramic, 25V, X7R, 10%
TMK107B7105KA-T
Taiyo-Yuden
603
0.1uF
560pF
220pF
100 uF
10uF
SS26
OSTTC022162
PEC36SAAN
PEC36SAAN
6.8uH
47uH
CSD18533Q5A
CSD18534Q5A
CSD17553Q5A
MMBT3906
MMBT3904
2m
0.68
5.1
2.05K
Capacitor, Ceramic, 50V, X7R, 10%
Capacitor, Ceramic, 50V, NPO, 1%
Capacitor, Ceramic, 50V, NPO, 1%
Capacitor, Aluminium, 10V, 20%
Capacitor, Aluminium, 10V, 20%
Diode, Schottky, 2A, 60V
Terminal Block, 2-pin, 15-A, 5.1mm
Header, Male 3-pin, 100mil spacing, (36-pin strip)
Header, Male 4-pin, 100mil spacing, (36-pin strip)
Inductor, SMT, 18.5-A, 4.1-milliohm
Inductor, SMT, 3.6-A, 60-milliohm
MOSFET, N-Chan, 60V, 103A, 5.9 mOhm
MOSFET, N-Chan, 60V, 50A, 9.8 mOhm
MOSFET, N-Chan, 30V, 23.5A, 2.7 mOhm
Trans, PNP, 40-V, 200-mA, 225-mW
Trans, NPN, 40-V, 200-mA,225-mW
Resistor, 2 milliOhm, 3W, 1%
Resistor, 0.68 Ohm, 2W, 1%
Resistor, 5.1Ohm, 1W, 5%
Resistor, Chip, 1/16W, 1%
Std
Std
Std
EEU-EB1A101
50YXM10MEFC5X11
SS26-TP
OSTTC022162
PEC36SAAN
PEC36SAAN
7443556680
7447709470
CSD18533Q5A
CSD18534Q5A
CSD17553Q5A
MMBT3906LT1G
MMBT3904LT1G
LRMAP2512-R002FT4
CSRN2512FKR680
Std
Std
Std
Std
Std
Panasonic
Rubycon
MCC Semi
OST
Sullins
Sullins
Wurth Elektronik
Wurth Elektronik
TI
TI
TI
On Semi
On Semi
TT/Welwyn
Stackpole
Std
Std
603
603
603
5 x 11 mm
5 x 11 mm
SMA
0.40 x 0.35 inch
0.100 inch x 3
0.100 inch x 4
18 x 18 x 9 mm
12 x 12 x 10 mm
QFN-8 POWER
QFN-8 POWER
QFN-8 POWER
SOT23
SOT23
2512
2512
2512
603
33.2K
Resistor, Chip, 1/16W, 1%
Std
Std
603
10K
100K
7.5
681
10
100K
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/10W, 5%
Resistor, Chip, 1/4 watt, ± 5%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/10W, 1%
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
Std
603
603
805
1206
603
805
205
154K
14K
14.7K
7.5K
2.49K
5.11K
1K
LM25101C
UCC27517DBV
MSP430F5132IDA
TLV70433DBV
INA199A2
uA78L10A
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/10W, 1%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/16W, 1%
Resistor, Chip, 1/16W, 1%
1A 80V Half-Bridge Gate Driver
IC, 4A Single Channel High-Speed Low-Side Gate Drivers
IC, Mixed Signal Microcontroller
IC, 24-V Input, 150 mA, Utralow IQ LDO Regulator
IC, Current shunt monitor, Bi-Directional Zerø-Drift Series
IC, 3 Pin 100mA Fixed 10V Positive Voltage Regulator
Std
Std
Std
Std
Std
Std
Std
Std
LM25101CMAX
UCC27517DBV
MSP430F5132IDA
TLV70433DBV
INA199A2DCK
UA78L10ACLPR
Std
Std
Std
Std
Std
Std
Std
Std
TI
TI
TI
TI
TI
TI
603
805
603
603
603
603
603
603
SO8
SOT23-5
MSOP-38
SOT-23
SC-70
TO-92
CONCLUSION
The board is tested for the given specifications and found to meet them. Further optimization of
software can be done depending on specific system requirements.
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XIII. APPENDIX
EVALUATION BOARD/KIT/MODULE (EVM) WARNINGS, RESTRICTIONS AND DISCLAIMER
For Feasibility Evaluation Only, in Laboratory/Development Environments. The EVM is not a complete product. It
is intended solely for use for preliminary feasibility evaluation in laboratory / development environments by technically
qualified electronics experts who are familiar with the dangers and application risks associated with handling electrical /
mechanical components, systems and subsystems. It should not be used as all or part of a production unit.
Your Sole Responsibility and Risk. You acknowledge, represent and agree that:
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limited to Food and Drug Administration regulations, if applicable) which relate to your products and which
relate to your use (and/or that of your employees, affiliates, contractors or designees) of the EVM for
evaluation, testing and other purposes.
2. You have full and exclusive responsibility to assure the safety and compliance of your products with all
such laws and other applicable regulatory requirements, and also to assure the safety of any activities to be
conducted by you and/or your employees, affiliates, contractors or designees, using the EVM. Further, you
are responsible to assure that any interfaces (electronic and/or mechanical) between the EVM and any
human body are designed with suitable isolation and means to safely limit accessible leakage currents to
minimize the risk of electrical shock hazard.
3. Since the EVM is not a completed product, it may not meet all applicable regulatory and safety compliance
standards (such as UL, CSA, VDE, CE, RoHS and WEEE) which may normally be associated with similar
items. You assume full responsibility to determine and/or assure compliance with any such standards and
related certifications as may be applicable. You will employ reasonable safeguards to ensure that your use of
the EVM will not result in any property damage, injury or death, even if the EVM should fail to perform as
described or expected.
Certain Instructions. Exceeding the specified EVM ratings (including but not limited to input and output voltage,
current, power, and environmental ranges) may cause property damage, personal injury or death. If there are
questions concerning these ratings please contact a TI field representative prior to connecting interface electronics
including input power and intended loads. Any loads applied outside of the specified output range may result in
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Please consult the EVM User’s Guide prior to connecting any load to the EVM output. If there is uncertainty as to the
load specification, please contact a TI field representative. During normal operation, some circuit components may
have case temperatures greater than 60°C as long as the input and output ranges are maintained at nominal
ambient operating temperature.
These components include but are not limited to linear regulators, switching
transistors, pass transistors, and current sense resistors which can be indentified using the EVM schematic located
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Agreement to Defend, Indemnify and Hold Harmless. You agree to defend, indemnify and hold TI, its licensors
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Safety-Critical or Life-Critical Applications. If you intend to evaluate TI components for possible use in safetycritical applications (such as life support) where a failure of the TI product would reasonably be expected to cause
severe personal injury or death, such as devices which are classified as FDA Class III or similar classification, then
you must specifically notify TI of such intent and enter into a separate Assurance and Indemnity Agreement.
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