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A Hybrid Solar Home Power System

04/11/2014 5:49 AM

Hi

I want to design a solar hybrid home power system.

If you can point my way towards any resource that will help me create the design or let me know of any commercial product that meets my requirements, your kindness will be greatly appreciated.

What I am looking for:

The Project:

A hybrid solar home power system.

The requirements:

A microprocessor controlled power board that will monitor the amount of load of the house and automatically switch between a solar inverter, utility power and standby DG.

The components;

1.) PV panel and charge controller.

2.) Two battery banks of 24 Volts each, flooded tubular lead acid batteries .

3.) A SMPS mains battery charger.

4.) A sine wave inverter.

5.) DG.

6.) Over charge and deep discharge protection circuits for the batteries.

The working principle:

The power board monitors the load of the house, and if the load is within the capacity of the inverter (1 KW sine wave), it will connect one battery bank to the inverter and simultaneously connect the other battery bank to the solar charge controller and PV panel.

It will automaticaly changeover to the charged battery bank when the battery connected to the inverter is at 50% discharge level

If there is no solar input and there is utility power available, it will connect the battery bank which is to charged to the SMPS mains battery charger.

In case the load is higher than the capacity of the inverter and there is utility power available, it will connect the load to the utility power.

Else it will switch to the DG.

A bypass switch that will let me bypass the board and connect the load directly to the utility power or DG will also be a part of the system.

Thanks and Regards

Anindya Dey

India

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#1

Re: A Hybrid Solar Home Power System.

04/11/2014 8:39 AM

Generally, the charge controller and inverters are a single system. They handle the charge controller, sine wave inversion, and protection. At least the better ones do.

You would be better served using glass mat batteries than lead acid. Lead acid will quickly degenerate as they do not handle deep discharges.

You should not need to switch between banks of batteries. They can be charged while discharging.

Have you performed a full energy budget for your home yet?

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#3
In reply to #1

Re: A Hybrid Solar Home Power System.

04/12/2014 4:30 AM

Don't you mean leisure Lead Acid batteries?

Glass mat is used to absorb the gases so that a LA Battery can be sealed up......they are commonly called VRLA Batteries.

I was unable to find a VRLA (mat) battery as a leisure or deep cycle....

This link may help you further:-

VRLA_battery Comparison_with_flooded_lead_acid_cells

The main differences to normal LA Batteries appear to be according to that link:-

1) Are less reliable than flooded lead acid.

2) Have shorter recharge time than flooded lead-acid.

3) Cannot tolerate overcharging: overcharging leads to premature failure.

4) Have shorter useful life, compared to properly maintained wet-cell battery.

5) Discharge significantly less hydrogen gas.

Most of these attributes are not useful to anyone wanting to use Solar energy......they are also twice the price it would seem....even leisure batteries are not that expensive, here at least.....

I found some useful facts here (some I have had better life spans than here, especially starting batteries):-

http://www.solar-electric.com/deep-cycle-battery-faq.html#Lifespan%20of%20Batteries

1.Starting: 3-12 months

2.Marine: 1-6 years

3.Golf cart: 2-7 years

4.AGM deep cycle: 4-8 years

5.Gelled deep cycle: 2-5 years

6.Deep cycle (L-16 type etc): 4-8 years

7.Rolls-Surrette premium deep cycle: 7-15 years

8.Industrial deep cycle (Crown and Rolls 4KS series): 10-20+ years.

9.Telephone (float): 2-20 years. These are usually special purpose "float service", but often appear on the surplus market as "deep cycle". They can vary considerably, depending on age, usage, care, and type.

Subs, both conventional and atomic, use/have used huge lead acid batteries that can have a useful life even beyond 30 years. Some (in the RN many years ago) could trace their complete history showing just how many boats they were used on....the boats are long gone, but the Batteries live on....so to say!

I hope this helps further....

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#4
In reply to #3

Re: A Hybrid Solar Home Power System.

04/12/2014 8:01 AM

Actually I meant absorbed glass-mat (AGM) batteries. You list them in your post.

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#5
In reply to #4

Re: A Hybrid Solar Home Power System.

04/12/2014 8:48 AM

That is exactly the ones I meant:- costly, easily damaged and short lived......plus points are quickly charged, can be used at any angle and don't gas....unless overcharged......

Please post a link supporting your own thoughts on using them for Solar applications. I could find nothing that would convince me to either buy or use them.....

Thanks in advance.

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#6
In reply to #5

Re: A Hybrid Solar Home Power System.

04/12/2014 9:55 AM

They seem to be the standard in the industry given the price and performance. The sources are many on the internet, but I am open to something better. What is common in Germany?

I have been considering adding a PV system to my house at some point and the predominantly recommended battery system is AGM.

Golf cart LA batteries are another substitute, but not as good as AGM.

A lot of the battery performance depends how they are charged and discharged and to what levels. The 4 to 8 year duty life sounds about right for AGM.

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#7
In reply to #6

Re: A Hybrid Solar Home Power System.

04/12/2014 1:32 PM

Wiki does not seem to like them much.......

I have never used them myself, too expensive over here, which always put me off first....I am a patron of leisure batteries, which give me a great life span.......but thats just me......

Though reading around, unless some major improvements are made to AGMs, its most unlikely that I will ever want one. But each to his won preferred Type.

The killer from me would be firstly the price (here) and secondly the need I have to be able to occasionally "top-up" from a car alternator, which would damage an AGM. I stay on some campsites with no amenities at all, they are always the best ones.....

See here:-

Advantages

Spill-proof through acid encapsulation in matting technology

High specific power, low internal resistance, responsive to load

Up to 5 times faster charge than with flooded technology

Better cycle life than with flooded systems

Water retention (oxygen and hydrogen combine to produce water)

Vibration resistance due to sandwich construction

Stands up well to cold temperature

Limitations

Higher manufacturing cost than flooded (but cheaper than gel)

Sensitive to overcharging (gel has tighter tolerances than AGM)

Capacity has gradual decline (gel has a performance dome)

Low specific energy

Must be stored in charged condition (less critical than flooded)

Not environmentally friendly (has less electrolyte, lead that flooded)

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#8
In reply to #7

Re: A Hybrid Solar Home Power System.

04/12/2014 1:56 PM

Thanks. I am thinking that golf cart batteries are a better investment for my needs. I won't be hauling them around, I just thinking about backup power when we lose it due to storms.

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#12
In reply to #8

Re: A Hybrid Solar Home Power System.

04/13/2014 7:20 AM

Now that I must agree with, though they are less easy to find here....

But I am not in the Solar business, except to assist some friends from time to time. I am still of the opinion that Solar cells are simply not good enough yet....and I also believe that some breakthroughs in both price and efficiency are LONG overdue.

Though relatively recent improvements with water cooling (Solar cells do not like getting hot strangely enough!!) allows water to be heated for other uses and the Solar cells to be cooled!!! There are even cooling units designed to be added to older Solar Cell installations. These improvements alone improve efficiency dramatically!

You can read more here:-

Hybrid-solar-panels-convert- heat-stress-into-hot-water

The first sentence makes immediate sense to almost anyone:-

A new design that improves solar PV panel efficiency by turning "heat stress" into hot water is surprising, but perhaps only because we wonder why someone didn't do it sooner.

The efficiency improvements appear to be as follows:-

Water-cooled PV panels reportedly deliver efficiencies of up to 28 percent while also providing 140 to 160-degree (F) water (the normal setting on a hot water heater is between 120 °F and 140 °F).

In some countries, here for example, Solar companies are not surviving without government help, and that help is disappearing fast!!

The Chinese Solar cells are also often short lived......efficiency, never good, gets worse rapidly....but we still have fields and roofs full of them here.....

Wind and water power are still better bets to my mind, though water will not appeal to many, being impractical unless you have a lot of land.....and both work day and night, like we do......

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#14
In reply to #8

Re: A Hybrid Solar Home Power System.

04/13/2014 11:00 PM

The GC2 is ubiquitous and inexpensive because of the sales volume. I think the GC2 from Sam's or other similar retailer is probably your best A-Hr/$ going.

I switched out a Group 27 AGM on my travel trailer for a pair of GC2's. The first set (used from my Dad's boat) went six years before I needed to replace them. And we used the hell out of our trailer.

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#10
In reply to #1

Re: A Hybrid Solar Home Power System.

04/13/2014 3:58 AM

There are Lead Acid batteries specifically designed for solar applications.

Please have a look at this link,

http://www.exide4u.com/exide/JSP/masters/apnpro/solar.htm

Both VRLA and flooded batteries are produced for solar power purposes.

So I not sure why you infer Lead Acid batteries will degenerate.

If the battery bank is on float charging mode, will it get fully charged?

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#11
In reply to #10

Re: A Hybrid Solar Home Power System.

04/13/2014 4:18 AM

Really depends on the load and the capacity/current limit of your rectifiers.....but assuming the rectifiers are capable of supplying both the load and charging the batteries then float charging will eventually fully charge a battery if the juice is not interrupted. It's done on every cell site, telephone exchange, datacentre, diverse UPS, and other mission critical installations on the planet (assuming they are correctly designed, implemented and maintained that is) There are other examples.

A common eg.. the battery in your car is float charged and eventually fully charged when the engine is running even with all your lights and other electrical accessories turned on.....providing you do not exceed the alternator's current limit and you give the battery enough time to charge.

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#13
In reply to #10

Re: A Hybrid Solar Home Power System.

04/13/2014 7:24 AM

Fully charging every time, can age many types of battery.....faster than NOT fully charging......also, fully charging some batteries will drive off water and or chemicals....

You must read the manufacturers infos fully and compare types.....it is not safe to generalise too often though.....

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#15
In reply to #1

Re: A Hybrid Solar Home Power System.

05/13/2014 5:26 PM

Exactly. Economics would dictate the priorities as follows:

  1. as much solar power as possible via the battery storage
  2. utility to top-up the solar
  3. generator if neither of the above is available.
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#2

Re: A Hybrid Solar Home Power System.

04/11/2014 10:42 PM

Add a wind powered generator too.

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#16
In reply to #2

Re: A Hybrid Solar Home Power System.

05/13/2014 5:28 PM

...with the wind having the same priority as the solar in #15 above. Good point.

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#9

Re: A Hybrid Solar Home Power System

04/12/2014 11:11 PM

Hello Anindya,

Here is a sample system.

1.) 4 or 6-250 watt 60-cell modules (depending on budget) and 1 Midnight Solar Kid MPPT 30A. (Two Kids can run in parallel for a larger array.)

2.) One battery bank up to three series strings.

3.) Battery charger output included in inverter. #4 below.

4.) Outback Power GFX International Series Grid Tie Inverter/Charger, 24(or 48)VDC 120 Vac/60 Hz.

5.) Gen-set with auto start. Inverter with generator support like #4 above.

6.) Over charge protection is in charge controller, discharge protection is in inverter. These are both highly configurable.

This sample system is grid-tie (sell), with battery back-up, and generator support. It would work well with a net-metering interconnection agreement. Consult your local utility and read their renewable energy interconnection agreement before buying any equipment.

In this scenario the array would charge the batteries and maintain them, then excess power would be made available to the loads attached to the inverter to either be consume by the loads or (if sell is enabled) sold back through the meter (or consumed by other loads on the service panel). In the event of a power outage the loads on the inverter would be powered by batteries, if the batteries drop below 50%, the gen-set would start and run until they were charged.

The technology is available to accomplish what you are asking but using different methods. You will have to carefully select what loads will be powered by the inverter.

Start with your battery pack. This is the single most important component of your system. With a gen-set you can use a smaller pack. Size it based on how long you want to run your loads, during an outage, before the gen-set comes on.

A $2,500 USD battery bank example:

16-6 volt Interstate deep cycle FLA Batteries (6V, 216AH)

2 strings, 8 batteries each

216 amp hours at 48 volts nominal per string.

Total capacity: 432 amp hours at 48 volts. 20,736 Watt-Hours.

Usable capacity (50%): 10,368 Watt-Hours.

Size your inverter based on the loads you want to run on the system. Size your battery bank by how long you want to run the loads (without gen-set). Size your array based on how much you want to produce (PVWatts is a good tool to estimate production) and size your charge controller based on your array's voltage and amperage.

Hope this helps a little.

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