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Photovoltaic Simulator

User Manual InteGrid Lab – EECL, CSU

InteGrid Photovoltaic Simulator

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This manual was originally written by Peter Vieira from the 2009-2010 Senior Design Team. Major revisions were made by Andrew Geck from the 2011-2012 Senior Design Team. This manual is intended to provide an overview of the hardware and software associated with the Photovoltaic (PV) Simulator so that anyone unfamiliar with the system can have some understanding of how the system operates, of how to run a simulation, and of how to collect and observe the output data from the system. For more detailed information on the underlying theory and system operation, please consult the following files which should be located on the lab PC in the "C:\PV Simulator Documentation\Reports" folder: PVEmulatorDocumentation.pdf -- "Adapting King’s Model to Design a DC Bus Photovoltaic Emulator." Written by Joel Nelson. Summer 2009. InteGridFinalReport2010.pdf -- "Final Report: InteGrid ~ Photovoltaic Simulator" Written by B. Ambon, M. Fox, J. Taylor, P. Vieira. May 2010. PVFallReport2011.pdf -- "Grid Tied Photovoltaic Simulator" Written by Andrew Geck. Fall 2011. PVSpringReport2012.pdf -- "Grid Tied Photovoltaic Simulator: Final Report" Written by Andrew Geck. Spring 2012.

InteGrid Photovoltaic Simulator

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Table of Contents Safety………………………………………………………………………………………………………………… 4 Lock Out/Tag Outs…………………………………………………………………………………… 4 Circuit Breaker Safety………………………………………………………………………………. 4 Built-in Safety………………………………………………………………………………………….. 4 Warnings………………………………………………………………………………………………… 5 System Description…………………………………………………………………………………………… 6 Introduction…………………………………………………………………………………………….. 6 Hardware Components…………………………………………………………………………….. 6 Software………………………………………………………………………………………………….. 15 Setup & Configuration………………………………………………………………………………….…… 16 Bitronics Power Meter Setup ……………………………………………………………………. 16 Summit® DC Power Supply Setup ……………………………………………………………... 18 LabVIEW Program Setup …………………………………………………………………………. 19 Adding Inverters & PV Modules……………………………………………………... 19 Adding Irradiance Data………………………………………………………………….. 19 Operation………………………………………………………………………………………………………….. 20 Test Preparation/Turn-On Procedure………………………………………………………. 20 PV Simulator LabVIEW GUI ……………………………………………………………………… 21 PV Simulator Walkthrough ………………………………………………………………………. 23 System Turn-Off Procedure ……………………………………………………………………... 24 Output Data……………………………………………………………………………………………………… 25 LabVIEW…………………………………………………………………………………………………. 25 Bitronics Interface …………………………………………………………………………………… 26 Appendix: Suggested Maintenance …………………………………………………………………………… 28 Information on Electrical Schematics & Matlab codes………………………………... 28 Glossary/Abbreviations…………………………………………………………………………… 28

InteGrid Photovoltaic Simulator

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Safety The Photovoltaic Simulator is equipped with safety in all parts of the system in order to protect the system and its operators. It was built according to National Electrical Code. The photovoltaic systems section of the code, Article 690, was used to ensure adequate installation and safety measures. Lock Out/Tag Outs

• The 480VAC PV Simulator 80A Fused Disconnect fed from CBPB01 must be locked out/tagged out whenever the PV Simulator is not in use. • Lockout/tagout procedures must be adhered to on all outgoing circuit breakers connected to the power grid or InteGrid when not in use.

Circuit Breaker Safety • All circuit breaker and disconnect doors must be bolted or latched shut at all times to prevent possible harm to operators or the system. • The 24V battery supply from the InteGrid switchgear must be connected at all times for the safety circuit to work.

Built-in Safety Any of the following actions will activate the safety circuit, triggering the shunt trips on all of the Eaton/Cutler-Hammer AC breakers, thereby powering down and isolating the system from the 480V and 240V sources: • Pressing the Emergency-Stop button on the outside of the control cabinet. • Pressing the Emergency-Stop button on the LabVIEW front panel while the program is running. • Removing the DC or AC connection covers on the Summit® DC Power Supply while power to the 24V circuit is connected. • If the 120V power to the PV Simulator control cabinet fails. • If the 480V AC input voltage to the Summit® DC Power Supply drops below 354VAC. • If the Bitronics power meter is configured to activate a digital output when the AC current exceeds a given limit, it will activate a relay. This limit should be set to the maximum AC output current for the inverter being operated to improve the safety of operation.

InteGrid Photovoltaic Simulator

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Warnings

• The fan switch to the Preload Resistor Bank must always be on while DC output power is on in order to cool the resistors and prevent overheating. • Each Preload Resistor Bank (5 resistors each) contains an inline fuse which is located in their respective DC disconnect box. These fuses must be open and the DC disconnect must be open to conduct maintenance on the Preload Resistor Banks. • Check for latent voltage before conducting maintenance on any device. The DC supply and inverters contain large capacitors which store charge and could be dangerous for several minutes after power is removed. • A common ground runs from the 480V Main Distribution Panel to the entire PV Simulator, including the frame, boxes, cabinet, conduit and devices. Do not touch any hot lines to any of these pieces of metal or a short will occur. • Do not operate the output of the Summit® DC Power Supply above 600V nominal. This would exceed the voltage rating of the cables used for the DC connections and the inverter maximum input limits. • The Bitronics power meter must be configured to trip its output relay to the shunt trip circuit at the max AC output current of the inverter under test to ensure maximum safety of operation. • The Bitronics power meter measures non-scaled voltage, therefore caution must be taken when around the voltage terminals on the meter or possible injury could result. These terminals will have 480V or 240V on them when live.

InteGrid Photovoltaic Simulator

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System Description Introduction The Photovoltaic Simulator is an advanced PV emulator that allows for the testing of solar generation systems with the use of simulated photovoltaic arrays and physical grid-tied solar inverters in the range of 2 – 25kW. It is adaptable to inverters with 208VAC, 240VAC, and 480VAC output connections. The controls for the simulator use measured current and voltage signals, and a pre-recorded solar irradiance profile to operate the DC power supply. The response of the DC supply is made to behave as though it were a PV array. Each half of the power supply can be connected to a different inverter and can operate independently at up to 25kW. The inverters have their own stand-alone control systems to monitor their DC inputs, convert the DC to AC power, and push the AC power onto the grid connections. The LabVIEW front panel user interface provides a means to setup, initiate, and observe a simulation. The behavior of the DC supply is recorded by the program and saved to a file at the end of the test. The system is also equipped with a Bitronics AC power meter to observe and record the AC output properties of the system. The information from this device can be used to observe the effect of the AC output from the PV Simulator on the rest of the grid to which it is attached. Hardware Components This section describes all the major components of the PV Simulator. An image and some basic information are provided for reference. For more detailed information on the components, manuals and spec sheets can be found on the control PC in the "C:\PV

Simulator Documentation\Manuals & Datasheets" folder. If files are available for a component, the file name(s) will be given in the description.

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LabVIEW Program Setup There are two LabVIEW programs written to operate the DC supply. Both are available through shortcuts located on the control PC desktop. The first is a manual operator, which can be used to operate the supply as a constant source. It requires manual operation of all digital and analog controls, and should only be used for special testing by someone familiar with the system. It uses no information about the inverters or potentially simulated PV modules. More detailed information will not be provided here. The primary program is the PV Simulator LabVIEW program. It uses inverter and module data, predetermined irradiance values, and measured current and voltage values during the simulation to automatically operate the DC supply as though it were a real PV array. Listings of inverters, modules, and irradiance profiles already exist in the program, but additional information can be added if desired. Adding Inverters & PV Modules Inverter and PV module models that do not exist in the lists in the simulator program can be added manually. This is done by adding a row for each in the “Inverter&Module Data.xls” excel file. Navigate to C:\PV Simulator\Inverter&Module Data.xls and open the file. Click on the Inverter Data sheet and add a row containing all known data for the new inverter, entering data under the appropriate column header. Click on the Module Data sheet and add a row containing all known data for the new module, entering data under the appropriate column header. Save the file. When the LabVIEW PV Simulator program is reopened the lists will be updated.

Adding Irradiance Data Three options exist to simulate irradiance data from days not already saved on the control PC: Go to http://www.nrel.gov/midc/research/ and download desired irradiance csv files to C:\PV Simulator\Irradiance Data\RecordedProfiles. The files being used on the system are from the "SRRL 10Hz Direct Normal" section of the site. Use the IRModifierGUI.m Matlab program, located at C:\PV Simulator\Irradiance

Data\ . This program can modify existing recorded profiles, generate new simple profiles, select a shortened portion of a profile, or join two profiles together. It saves its output to the ModifiedIR.txt file. It is recommended this file be copied into the TestingProfiles folder and then renamed with an appropriate description.

Manually place a generated file in the RecordedProfiles or TestingProfiles folders. Be sure to conform to the format of the other existing text files. When the simulator program is reopened these new data files will be selectable.

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Operation Test Preparation/Turn-On Procedure The following procedure must be performed every time a simulation is conducted: 1. Determine whether or not either of the Preload Resistor Banks will be used. If so, open the appropriate DC disconnect box and close the 10A fuse located below the positive terminal on the output side of the disconnect. Also, be sure to turn on the

fan switch located to the side of the upper DC wireway. If the Preload Resistors will not be used, open the fuses and close the DC disconnect doors. 2. Open PV Simulator.vi located at C:\PV Simulator\PV Simulator.vi, or select the shortcut icon on the control PC desktop. Special Note: Since the simulator program uses some embedded Matlab scripts, the control PC must have access through the Ethernet hub to the CSU campus network in order to retrieve a license from the servers before the PV Simulator.vi will load. 3. Make sure all circuit breakers and disconnects are open. 4. The Load Bank or InteGrid AC grid connection should be turned on by an experienced operator in the lab following the InteGrid lock-out/tag-out procedures. 5. Hit the "Run Program" arrow icon in the LabVIEW PV Simulator program. This will activate the safety circuit relay so that the AC breakers in the system can be closed. 6. Remove lockouts and close the AC breakers and disconnects to the devices being attached to InteGrid for the simulation. 7. Close the DC disconnects and switches to the devices being used in the simulation. 8. Turn on the Summit® Power Supply by closing the main circuit breaker, then removing the lockout from, and then closing, the main fused disconnect. Once the DC supply has powered up, the status indicators on the LabVIEW interface should show that they are ready, and a simulation can begin. From this point, follow the directions for running a simulation with the PV Simulator program. See the descriptions of the interface and walkthrough in the following sections.

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5. A & B Tab control and Status window: Selecting one tab or the other will move between the windows for Side A or Side B of the simulator. Each side can run a simulation independently, and has identical controls and indicators. The large text "A" or "B" towards the top middle of the screen provides a quick reference of which tab is currently open. A tab does not have to remain open for the simulation to continue to run. The Status window provides the user some quick instructions during the start of a test, and an indicator of the state of the simulation during and after a test. 6. The upper four buttons are for starting, stopping, or resetting the sides of the simulator program independently. The 250 Ohm Preload Resistor? button changes DC current calculations for the measurements so that only the current flowing to the inverter is used in the voltage setpoint calculations. The default setting for this button is to be enabled. 7. Inverters and Modules: The two lists on the right show all the inverters and modules loaded into the simulator. The default inverter for Side A is the PVP3500, and the default inverter for Side B is the PVP30kW. After selections are made, the three boxes on the right display some of the important properties associated with the inverters, modules, and calculated array that will be used for the simulation. 8. Irradiance Graph: Clicking the folder icon will open a dialog box to select an irradiance profile text file to use for the simulation. The selected irradiance will be displayed on the graph after the file loads. As the simulation runs, a green tracking dot will display where the simulator is in the irradiance profile. The Start and End Time boxes can be used to select a shortened section of the loaded profile. The Elapsed Time box displays how much real time has passed since a simulation was started, which should be useful for determining if the five minute warm-up period of the inverters has elapsed. 9. PV Array I-V Curve: This graph displays the I-V curve for the calculated array at the present level of irradiance. The red dot shows the Maximum Power Point, and the green tracking dot displays the actual measured voltage and current. 10. Data Recording: These buttons control if, and at what rate, data from the simulator is collected. The default rate is 10 Hz. Selecting "Fast Data" changes the rate to 1 kHz. This information is only the DC behavior related to the supply. 11. Display of values: This graph displays some of the measured and calculated values for the simulator as it runs. The legend below the graph explains which values are displayed.

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14. To end the simulation and download all the simulator data to the “MEASURED DATA” folder, press the Program Stop Output and Save Data button. The files will be generated and saved to the folder located at C:\PV Simulator\MEASURED DATA\Y-M-D HH:MM. A few of the buttons can be pressed at any time during a simulation: 1. Press the Record Bitronics button to record AC output data on the Bitronics meter. It is recommended to hold this in for a few seconds so the meter has a chance to register the input. Refer to the Setup & Configuration section to configure the triggered recording on a digital input on the Bitronics meter. 2. Press the Stop button or the Stop A&B button to turn the DC power supply output off. This pauses a simulation. The simulation can be resumed, but the inverters will go through another five-minute warm-up period. Enter the elapsed time into the "Reset Simulation Time" box while the Stop button is still latched in, release the Stop button, and then press the Run button to resume a simulation from the entered elapsed time. 3. Press the Emergency Stop button while a simulation is running to trip all the circuit breakers and isolate the system if an emergency situation develops. This completely stops a test, and no output data files are generated. 4. After manually stopping a simulation, press the Restart Program button to start over from the very beginning of a simulation. 5. Press the Record Fast Data button to record data at 1kHz instead of 10Hz.

System Turn-Off Procedure The following procedure should be performed when turning the system off after the test is complete and the LabVIEW program has stopped: 1. Ensure DC supply output is off, and allow the unit some time to run the cooling fans. 2. Open the 480V main circuit breaker and disconnect to the DC supply and lockout/tagout the disconnect. 3. Open the AC circuit breaker connections to InteGrid that were in use and lockout/tagout. 4. Open the remaining AC disconnects or DC disconnects that were closed for the test. 5. Open the main tie breaker to InteGrid in the switchgear downstairs, and open the main InteGrid breaker & lockout/tagout upstairs. 6. Turn off the preload resistor cooling fan switch.

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Appendix: Suggested Maintenance The filters on the front of the preload resistor box should be cleaned occasionally to ensure adequate air flow for cooling the resistors. The cooling fins of the heat sinks on top of the small inverters should also be cleaned occasionally. Information on Electrical Schematics & Matlab codes Please see the printed electrical schematics located in the pocket of the main control cabinet door. Current versions of the Matlab codes used in the simulator can be located on the control PC at C:\PV Simulator\MATLAB Glossary/Abbreviations AC …………… Alternating Current ADC ………… Analog-to-Digital Converter CBPB01 …… Circuit Breaker Panel Board 01 cDAQ ……….. Compact Data Acquisition CSU …………. Colorado State University csv …………… comma separated value CT ………….… current transformer DAC …………. Digital-to-Analog Converter DC …………… Direct Current DNP3 ………. Distributed Network Protocol EECL ……..… Engines and Energy Conversion Lab E-stop ……… Emergency Stop FTP ………….. File Transfer Protocol GUI …………... Graphical User Interface IR ……….…… Irradiance I-V …………… Current - Voltage kS/s ………… kilo-samples per second NC …………… Normally Closed N.I. …………... National Instruments NO …………... Normally Open PC …………… Personal Computer PTs …………. Potential Transformers PV ……….…… Photovoltaic SG3B ………... Switch Gear 3B UPS ………….. Uninterruptable Power Supply VFP ………….. Virtual Front Panel VTs ………….. Voltage Transformers

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User Notes: Use this area to write down any desired additional information: