Smart Control Panel For Synchronization of Sources
Smart Control Panel For Synchronization of Sources
Abstract—Control panel is a cabinet which contains electrical during less load. In [10] renewable source is synchronized
components to control the equipments, motors etc. A smart with utility and also with Diesel generator. The points to be
control panel performs the same operation as that of conventional considered for DG synchronization with renewable source is
panel but the difference is controlling action is performed by
the advanced technology such as programming through micro given in [11]. The specifications of Grid Tied Inverter are given
controllers. The world, especially developing countries like India in [12]. Details of the Auto Mains Failure (AMF) controller
is facing ‘Energy Crisis’. There is a significant gap in the demand is given in [13].
and supply for electricity. As country is progressing towards The basic problem is that Solar source(GTI) is not be able
development, this gap is increasing. Tackling this situation is to generate during off grid condition as it requires reference
very important to continue country’s ascending path. In order
to meet the solution, a number of options are being considered voltage and frequency for its generation. Means we are having
with a large focus on renewable energy research & development. Solar source but failing to use it during off grid. So full
This project is about the smart switching between the energy load needs to be supplied by DG, which is not economical.
sources especifically Solar, Mains and Diesel Generator(DG). To overcome this we have designed a control panel which
An inverter is required to convert Direct Current(DC) output enables solar source(GTI) to generate during off grid condition
of Solar panels to Alternating Current(AC). Here Grid tied
inverter(GTI) is used which itself does the synchronization of its
means here we using the solar source at its extend i.e. we are
output. Auto mains failure Controller(AMF) is used to automat- increasing the solar power generation. We have done it in a
ically start the DG and at the same time it does synchronization very simple way. We are using only one controller which is
of DG. The elegance of the project is that two electric energy AMF controller it is actually used to start the DG automatically
sources (solar-grid or solar-diesel) are able to be used together for but here in addition to this we are using its input and output
running big energy consumer needs. This leads to the reduction
of demand of electricity from grid and also enhances the use of
in such a way that it is synchronizing solar with DG.
electricity from solar source.
Index Terms—Mains, solar, Diesel Generator(DG), control
panel, Auto Mains Failure(AMF) controller, grid tied inverter
(GTI).
I. I NTRODUCTION
India is one of the fastest growing country in economics in
the world. Electricity plays the major role for the developing
countries and also it is used as rope to make country developed
[1]. Due to the use of fossil fuels for the generation of the
electricity which plays important role in development , they
are getting exhausted also prices are increased [2]. The ways
are found in [3] to reduce the generation based on fossil fuels.
Fig. 1. Basic block diagram of the system
Also the motivation to use renewables for the generation is
given in [4]. Solar energy is one of the most useful source. This project is about the smart switching between the energy
Electricity can be produced using photovoltaic cells. India is sources especifically solar, grid and diesel generator. The
having more sunny days so this becomes easily possible [5]. elegance of the project is that two electric energy sources
All above things motivates for the microgrid technologies and (solar-grid or solar-diesel) are able to be used together for
researches going on in that way [6]. control algorithms for running big energy consumer needs. This leads to the reduction
seamless transition between distributed systems and microgrid of demand of electricity from grid and also enhances the use
is given in [8]. In [9] parallel operation Diesel generator of electricity from solar source. The project is carried out in
with Photovoltaic(PV) with battery as hybrid system with AC Shree Engineering, Manufacturers and Trading of Electrical
microgrid is given, in this decentralized power management Goods, Katraj, Pune.
control is used for operating the DG under low power limit In section I, we have explained necessity of electricity,
978-1-5386-6159-8/18/$31.00 ©2018 IEEE demand and supply gap, effects of conventional energy sources
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on environment, motivation to use renewable energy sources fed back to the DG sets (stator of DG sets). This condition
and in the last paragraph study about how different sources can damage the vital parts of the generator so the protection
can be connected together is given. In section II proposed of generators becomes very critical and make it work as a
method is given. System description is given in section III. motor (reducing its speed). We can expect an increase in AC
Details about control panel which we have designed is given line voltage above critical level. If this happens, the condition
in section IV. Wiring diagrams are given in section V and can trip the inverter due to over-voltage/frequency protection
section VI consisting of results, conclusion, references. circuits. Now the rooftop owner cannot consume power from
the solar and therefore he is forced to operate the DG sets.
II. P ROPOSED M ETHOD How to custom design a smart power management system
With grid tied Solar power, if utility grid goes off, the Solar to use the solar generator during the condition 2 and also
power will cease operation, as the solar power cannot operate protect the DG sets? We also foresee very high requirement
as a standalone energy source. [9] The DGs will become for an effective control system, which can handle all the above
active and start serving loads(Industry load whose name is conditions such as DG protection.
given in introduction). In general, the grid tied solar power is Control Panel which we have designed is meeting all the
not designed to operate in off grid mode with DGs to share above conditions maintaining the spinning reserve of DG
the loads. This will eventually increase the fuel consumption system to avoid intermittency. This will be the ideal solution
and cost of energy, as the entire load to be served by DGs for installations with 20 to 60% Solar penetration and with
until mains supply restoration. To make the grid tied solar the diesel cost is > 1 per litre. If the DGs are running contin-
power to operate along with DGs in off grid mode, we have uously, then PV source has significant potential to reduce the
designed control panel where ‘AMF Controller’ is doing all diesel consumption. The DG has to be operated always with
the functions, which will detect the absence of main grid and minimum load, accordingly the PV generation to be curtailed
communicate with both DG and solar power to synchronize as per equation(1).
both the sources and ensure the reliable operation of grid by
SolarP owermax = T otalLoad − DGmin (1)
providing proper reference voltage and frequency parameters
over the grid network. The Control panel which we have designed satisfies all
The grid inverters are usually connected to a common above conditions. Important considerations are taken that are
distribution bus bar (India 3phase/1phase, 415V/230V). In 1)Whenever mains goes off DG will start automatically
this proposal all sources such as grid, diesel generators and and supply is fed by DG. 2)Upto 40% of capacity of DG
solar grid inverters can be connected along with the load on a load will be on DG only. When load crosses 40% of DG’s
common bus bar. What usually happens during power failure capacity Solar contactor i.e. DGSC contactor get closed hence
is, the grid inverters trips sensing loss of reference parameters Inverter gets reference voltage and frequency and it get
and stops generation, now the DG sense this situation and started. Thus it starts generating power. Hence two sources
switches ON to support the load automatically with help of get synchronized. 3)When load goes below 15% of DG’s
AMF panels. Once the generator switches on, this creates a capacity solar contactor i.e.DGSC contactor gets open and
reference voltage and frequency on the common bus bar and losses synchronization. 4)For the Safety purpose at a time one
this starts up the solar grid inverters. Once the inverter is ON, contactor is operated i.e.mains contactor and DG contactor, as
the load will be supplied by both GT inverter and DG sets (at interlocking is provided between both. 5)Interlocking is also
low RPM). provided for synchronizing contactors which are DGSC and
Is it practically possible to synchronize a grid tie inverter MSC.
with a diesel generator (DG sets) and make it work? That is
during a power failure or when grid power is not available? III. S YSTEM D ESCRIPTION
Following are the conditions at which it is possible.
1)We have a stable/good quality generator which gives good
steady voltage and frequency.
2)The generator should not sag, dip or create any surge cur-
rent when the inverter turns ON during the above mentioned
condition.
Let us now consider that the inverter has turned ON using
the DG sets reference voltage and frequency from the gener-
ator. There are two possible conditions now,
1)The load is always more than the Solar Power supply
2)Load can be less than Solar power supply
During the condition 1, no issues will occur, if everything
works fine. But during the condition 2, the power generated
from Solar will be greater than the load requirements and
hence there is a possibility that this excess power will be Fig. 2. Solar Panels on the rooftop of given industry
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TABLE I
In this system Solar panels are used for the generation of 30 T ECHNICAL SPECIFICATIONS OF GTI
kW electrical power. There are 8 strings of solar Panels, each
consisting of 12 panels. In total 94 panels are required which Fronius Eco 25.03-S 27.0-3-S
Input Data
is installed on the rooftop. Fig.2 Shows the installation of the MPP voltage range 580-850 V DC 580-850 V DC
Solar Panels on the rooftop of the industry where project is Max. input voltage 1000 V DC
carried out. Min. input voltage 580 V DC
Max.Input Current 44.2 A 47.7 A
Output data
Nominal output power(Pnom) 25,000 W 27,000 W
Max.Output power 25,000 W 27,000 W
Nominal Grid Voltage 3∼NPE 400/230 V or 3∼NPE 380/220
Min.grid voltage 150 V /260 V
Max.grid voltage 275 V/477 V
Max.output current 42A
Nominal frequency 50/60 Hz
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two sources solar-Mains supply or Solar-DG on the basis of diodes (LEDs) provide are used as visual indicators. Most
requirement of the load. relay boards have 2, 4, 8 or 10 channels.
The AMF controller which we have used is ComAp’s
V. W IRING D IAGRAMS
InteliLite-NT AMF 25. The Terminal diagram of InteliLite
AMF 25 is as shown in Fig.4. It has input terminals for A. Power Wiring
generator voltage and generator current. Also there is input A power circuit is defined as any circuit used to carry
for sensing Mains voltage. Any Binary input or output can electricity that operates a load. This may seem like a simplistic
be configured to any IL-CU controller terminal or changed definition but it is important to distinguish power circuits from
to different function by LiteEdit software. There is fix 1 sec control circuits since they serve different purposes.
delay when any binary input is configured as protection.
The switching time of AMF controller is few seconds. Here
AMF controller is doing all the tasks listed below:
1)It is sensing mains off condition. POWER WIRING
SUPPLY FROM MAINS SUPPLY FROM DG SUPPLY FROM SOLAR
R
Y
Y
B
B
N
N
R Y B N R Y B N
4 POLE MCB
R Y B N
YL
RL
YL
TO LOAD TO LOAD
NL
BL
NL
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are given to the 8 channel relay board through which it is
connected further. Whenever Mains supply is off it is sensed
by AMF controller and binary output of AMF controller ’O1’
CONTROL WIRING ( AMF CONTROLLER & B.C. WIRING)
is given to ’R1’ relay through start coil of the start stop relay.
SUPPLY FROM GENERATOR SUPPLY FROM MAINS
R
Y
Y
B
B
N
N
R
R
Y
Y
B
B
N
N
NOTE :- Start stop rely card is used for obtaining high current to start
and stop the DG set. As shown in Fig.8 while starting DG set
3 POLE MCB` 3 POLE MCB` NEUTRAL LINK
1) B.C. - BATTERY CHARGER
GR1 GY1 GB1 GN1 MR1 MY1 MB1 MN1 2) C1 - BATTERY CHARGING CONTACTOR
GR1
3) RL - R PHASE ON LAMP
in Auto mode the sequence would be like this Ax1 contactor
TO AMF COTROLLER
GY1
4) YL - Y PHASE ON LAMP
GB1
MR1 MN1 5) BL - B PHASE ON LAMP
GR1
GR1 GY1 GB1 GN1
GN1 2 PLOE MCB
coil get energized - NO Ax1 contact would get NC- R1 NO
CONTACTOR FOR C1 BL
MR2 MN2 SYMBOL :-
contact of relay board would get NC-GC1 NC contact of
RL YL
TO AMF CONTROLLER
BATTERY CHARGING
C1
MCB
GN1 MR3 MN3
AMMETER
+VE
A
B.C.
-VE
CONTACTOR COIL
NEUTRAL LINK
Generator contactor Would remain closed-Start Coil would get
+VE -VE
2 PLOE MCB A DC AMMETER energized - generator would get started.
+VE -VE
When generator starts running and comes in the desired
speed AMF controller gives binary output O4 and it is further
given to R4 relay From their it is given to coil of the DG
Fig. 7. Battery Charger Wiring of DG
contactor ’GC’. Thus supply is fed to the laod from DG.
To Start the DG in auto mode sequence would be like this
Single phase supply is taken and it is given to the battery Ax2 coil would get energized -Ax2 NO contact would become
charger followed by Single phase(SP) MCB’s and Normally NC -after pressing start push button which is on the door of
Closed (NO) contacts of the contactor for battery charging. Control Panel so its get closed-GC1 contact would also remain
From the battery charger further it is given to the Double pole closed-Start relay coil would get energized starts the DG set.
(DP) MCB and given to battery(Having capacity 99AH which To on the DG contactor in manual mode seperate relay is
is of DG set). used which is ’D1’ relay. The operation would be like this Ax2
It is also shown that DG supply and Mains supply is also coil get energized-DGc is closed manually by push button DGc
given to the AMF controller. CT’s are also used to take the open remain NC - D1 coil get energized - contacts of the D1
current of the DG supply and it is given for measuring purpose relay would become NC and coil of DG contactor would get
also to AMF controller. energized and thus DG supplies the load. To stop DG in auto
B. Control Wiring
A control circuit is a special type of circuit used to control CONTACTOR CONTROL WIRING
NOTE:-
the operation of a completely separate power circuit. GR MR GC - GENERATOR CONTACTOR
GSC - GENERATOR-MAINS CONTACTOR
MSC - MAINS-SOLAR CONTACTOR
SELECTOR S/W
-
mode sequence would be like this Ax1 coil get enegized -
R4
Ax1 contact would become NC-O2 output of AMF controller
would give signal to R2 relay and R2 contact get closed-GC1
D1
GR2
SUPPLY FROM
GR3 contact would get closed - Stop coil would be energized and
GENRATOR
DG get stop signal.
In Manual mode sequence is Ax2 Coil-Ax2 contact would
Fig. 8. Control Wiring 1
become NC - DG Stop would get closed - GC1 NC - stop
Above Fig.8 shows the Control wiring of the Control Panel relay coil get energized-DG get stoped here.
of the system. Control wiring is of 24V DC. From the selector In the above control wiring diagram main contactor’s of the
switch we can select Auto mode or Manual Mode of the system that are DG contactor (GC),DG-Solar contactor (GSC),
system and accordingly control wiring operates. For this two Mains Contactor (MC), Mains-Solar contactor (MSC) comes
contactors are used one is for auto mode and one is for manual in the picture.
mode. If the circuit is in auto mode AMF controller comes To on DG contactor sequence would be like this R phase
in the picture. The binary output’s of the AMF controller is taken fromDG supply -SP is connected in series-R4 relay
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contact is in serires, parallel to this D1 relay contact is used
- whenever one of this two contacts get closed GC contactor
coil would get energized and supply is fed to load.
GSC contactor would come in the picture when DG set is
running and supply on the DG set becomes greater than 25kW
this would be sensed by AMF controller and it gives output
by giving signal through O5. Which is further given to R5
relay and from their output is taken and it is given to GSC
which supply power to the busbar lines where Solar lines are
also connected .This gives reference input to the Solar or GT
inverter which is the important need of GTI and it would start
generating Solar Power. Thus load is fed through two sources
Solar and DG. energy is fulfilled as well as uninterrupted supply becomes
The sequence of operation would be like this R phase of DG available. The energy sources can be operated individually or
supply -GC NO becomes NC-R5 relay contact would become in synchronisation with others. Thus the efficiency of usage
NC (after satisfying all conditions)-GSC would get energized- of energy sources has improved. The proposed method has
GSC starts. extended the usage of solar source. This reduces the cost of
Whenever mains supply is available GC contactor would generation of electricity by diesel generator as well as the
become open and supply is fed from Mains. At this time charges required to pay to MSEB.
reference input to the GTI is given by Mains and it starts
generating power and thus load is fed by both the sources. R EFERENCES
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