Photovoltaic system controller

• US 4,888,702 A
• Filed: 08/20/1987
• Issued: 12/19/1989
• Est. Priority Date: 08/20/1987
• Status: Expired due to Term

• Current Assignee: Westinghouse Electric Company LLC (Brookfield Asset Management Incorporated)
• Original Assignee: Integrated Power Corporation
• Inventors: Gerken, Kenneth F., Sullivan, Robert A.
• Primary Examiner(s): Bovernick, Rodney B.
• Assistant Examiner(s): Callaghan, Terry S.
• Application Number:
  US07/087,314
• Time in Patent Office: 852 Days
• Field of Search: 364/492, 364/493, 364/494, 320/39, 320/40, 320/61, 320/62, 323/906
• US Class Current: 700/295
• CPC Class Codes: H02J 7/35 with light sensitive cells
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers

Abstract

A photovoltaic system controller particularly adapted for utilization with a photovoltaic power system including a photovoltaic array, system battery, load and, optionally, an auxiliary generator. The controller utilizes a microprocessor to monitor various parameters of the system and to perform system control functions. The microprocessor is provided with a plurality of setpoints corresponding to desired system parameters for utilization as reference points for the conducting of control functions. The setpoints are adapted to be easily field adjustable to cover a wide range of parameters. The controller is particularly suited for adaption to an entire spectrum of system designs merely by replacing the programmable memory component of the controller. The controller derives its power from a tap off the system battery and is designed to withstand the harsh environment associated with remote site locations. All of the control functions are temperature compensated. The controller is provided with timing control means which allows the controller to be inactive between operating cycles so as to reduce power requirements.

Claims

1. A photovoltaic system controller for utilization with a photovoltaic power system including at least a photovoltaic array, a system battery adapted to be charged by said array and a load adapted to be powered by said battery, said controller comprising a microprocessor having an erasable programmable memory, said microprocessor having means to receive input data from said array, said battery and said load, said microprocessor having means to evaluate said input data in relation to at least one predetermined setpoint, said microprocessor in response to said evaluation being adapted to disconnect said battery from said array or to disconnect said load from said battery, said setpoint being adapted to be adjusted to a second setpoint by adjustment means, said erasable programmable memory being adapted to be changed whereby said evaluation performed by said microprocessor is also changed.

2. The photovoltaic system controller recited in claim 1, wherein said adjustment means comprises a plurality of adjustable DIP switches.

3. The photovoltaic system controller recited in claim 1, wherein said disconnections are accomplished by means of mercury displacement relays.

4. The photovoltaic system controller recited in claim 1, wherein said controller is powered by means of a 12 volt tap off said system battery.

5. The photovoltaic system controller recited in claim 1, wherein said photovoltaic system further comprises generator means, said microprocessor being adapted to effect starting and stopping of said generator means, said starting and stopping being accomplished by means of a relay.

6. The photovoltaic system controller recited in claim 1, wherein said microprocessor is adapted to actuate a visual alarm indicator.

7. The photovoltaic system controller recited in claim 1, further comprising a display panel, said display panel being adapted to visually display the voltage and current of said battery, the current of said load, the current of said array and ambient temperature.

8. A photovoltaic system controller for utilization with a photovoltaic power system including at least a photovoltaic array, a system battery adapted to be charged by said array and a load adapted to be powered by said battery, said controller being adapted to be powered by tapping from said battery, said controller comprising a logic unit, said logic unit including an input/output board, a logic board and a display board, said input/output board and said logic board being separated from each other by isolation means, said logic board including a microprocessor, said microprocessor having means to receive input data at least from said battery, said microprocessor having means to compare said input data to at least one predetermined setpoint provided to said microprocessor, said setpoint being adapted to be adjusted to another second setpoint, said input data being temperature compensated.

9. The photovoltaic system controller recited in claim 8, wherein said isolation means comprises a metal plate electrically isolating said logic board from said input/output board.

10. The photovoltaic system controller recited in claim 8, wherein said input data comprises the voltage and current of said battery, and the current of said load, said microprocessor being adapted to calculate the voltage for said system based upon said input data.

11. The photovoltaic system controller recited in claim 10, wherein said microprocessor is provided with an array disconnect setpoint, an array reconnect setpoint, a load disconnect setpoint and a load reconnect setpoint, said microprocessor being adapted to effect disconnection of said array from said battery when said system voltage reaches said array disconnect setpoint, reconnection of said array to said battery when said system voltage reaches said array reconnect setpoint, disconnection of said load from said battery when said system voltage reaches said load disconnect setpoint and reconnection of said load to said batter when said system voltage reaches said load reconnect setpoint.

12. The photovoltaic system controller recited in claim 11, wherein said logic unit is provided with timing control means to delay disconnection of said load for a brief time after said system voltage reaches said load disconnect setpoint.

13. The photovoltaic system controller recited in claim 10, wherein said photovoltaic system further comprises an auxiliary generator and said microprocessor is provided with a generator start and a generator stop setpoint, said microprocessor being adapted to effect starting of said generator when said system voltage reaches said generator start setpoint and stopping of said generator when said system voltage reaches said generator stop setpoint.

14. The photovoltaic system controller recited in claim 10, wherein said microprocessor is further provided with a high voltage alarm setpoint and a low voltage alarm setpoint, said microprocessor being adapted to actuate a visual indicator when said system voltage reaches said low voltage alarm and high voltage alarm setpoints.

15. The photovoltaic system controller recited in claim 8, wherein said at least one setpoint is adapted to be adjusted by means of a plurality of DIP switches.

16. The photovoltaic system controller recited in claim 8, further comprising an analog backup controller, said analog backup controller being adapted to be operated in the event said microprocessor fails.

17. The photovoltaic system controller recited in claim 8, further comprising an expansion bus.

18. A method of using a photovoltaic system controller in a photovoltaic power system comprising a PV array, a system battery and a load, said controller being characterized by a logic unit enclosed in a casing, said logic unit having a logic board and an input/output board, said logic board having a microprocessor, an erasable programmable memory component and adjustment means for providing at least one predetermined setpoint to said microprocessor, said input/output board having a terminal strip, said controller having a main terminal block, a plurality of shunts and a plurality of relays, said method comprising the steps of:

opening said casing to gain access to said logic board;

adjusting said adjustment means to a desired setpoint;

closing said casing;

electrically connecting said battery, said load and said array to said main terminal block;

electrically connecting said load to one of said shunts and to one of said relays;

electrically connecting said array to another of said shunts and to another of said relays; and

electrically connecting said main terminal block to said terminal strip.

19. The method recited in claim 18, further comprising the steps of:

opening said casing to gain access to said logic board;

removing said erasable programmable memory component from said logic board;

placing a new erasable programmable memory component on said logic board; and

closing said casing.