Test Report - PMP7647_RevC TEST REPORT OF MPPT & LED DRIVER PMP 7647 th December 12 , 2013 1 TII - Reference Designs 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 th December 12 , 2013 2 TII - Reference Designs 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. th December 12 , 2013 3 TII - Reference Designs Test Report - PMP7647_RevC III. BLOCK DIAGRAM th December 12 , 2013 4 TII - Reference Designs Test Report - PMP7647_RevC 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 th December 12 , 2013 5 TII - Reference Designs Test Report - PMP7647_RevC 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 th December 12 , 2013 - + 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 th December 12 , 2013 7 TII - Reference Designs 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 th December 12 , 2013 8 TII - Reference Designs Test Report - PMP7647_RevC b. Gate waveforms MPPT gate waveforms at 10A load show dead-time implementation Expanded view th December 12 , 2013 9 TII - Reference Designs Test Report - PMP7647_RevC 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 th December 12 , 2013 10 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 th December 12 , 2013 11 TII - Reference Designs Test Report - PMP7647_RevC b. Controller and Bias Supply th December 12 , 2013 12 TII - Reference Designs Test Report - PMP7647_RevC 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. th December 12 , 2013 13 TII - Reference Designs Test Report - PMP7647_RevC 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: 1. 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