Test Report - PMP7605_RevA
April 10
th
, 2013 1 TII - Reference Designs
TEST REPORT OF MPPT CHARGE CONTROLLER
PMP 7605
Test Report - PMP7605_RevA
April 10
th
, 2013 2 TII - Reference Designs
CONTENTS
Contents
I. INTRODUCTION .................................................................................................................................................................... 3
II. DESCRIPTION ........................................................................................................................................................................ 3
III. BLOCK DIAGRAM ............................................................................................................................................................ 3
IV. SPECIFICATIONS .............................................................................................................................................................. 4
V. BOARD LAYOUT AND ASSEMBLY ................................................................................................................................... 4
VI. TEST SETUP ....................................................................................................................................................................... 5
VII. TEST DATA ........................................................................................................................................................................ 5
a. 12V SYSTEM PERFORMANCE ............................................................................................................................................ 5
b. 24V SYSTEM PERFORMANCE ............................................................................................................................................ 6
c. PLOTS ..................................................................................................................................................................................... 6
VIII. WAVEFORMS .................................................................................................................................................................... 8
a. Switching Node Waveforms ................................................................................................................................................ 8
b. Gate waveforms ................................................................................................................................................................... 9
c. MPP Acquisition ................................................................................................................................................................ 10
IX. SCHEMATIC .................................................................................................................................................................... 12
a. Power Stage ....................................................................................................................................................................... 12
b. Controller and Bias Supply ................................................................................................................................................ 13
X. BILL OF MATERIALS ......................................................................................................................................................... 14
XI. CONCLUSION .................................................................................................................................................................. 15
XII. APPENDIX ........................................................................................................................................................................ 16
Test Report - PMP7605_RevA
April 10
th
, 2013 3 TII - Reference Designs
I. INTRODUCTION
The following document is a compilation of test results of the PMP7605 reference design, a 20A
MPPT solar charge controller. The test results are taken with simulated solar panel input
corresponding to 12V and 24V panels.
II. DESCRIPTION
The PMP7605 is developed around the MSP430F5132 controller IC. The design is targeted for
small and medium power solar charger solutions. The present design is capable of operating with
12V/24V panels and 12V/24V batteries with up to 20A output current. However, it can be easily
adapted to 48V systems by just changing the MOSFETs to 100V rated parts. Also, it is possible to
increase the current to 40A by using TO-220 package version of the same MOSFETs used in the
design. The design has an operating efficiency of above 97% at full load in a 24V system. For 12V
systems the efficiency is above 96%. This efficiency figure includes the losses in battery reverse
protection MOSFET and panel reverse flow protection MOSFET, 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 the
interleaved buck topology used. The interleaved buck topology reduces the component stresses by
a great extent. Another feature is the relatively small sized components used, possible due to the
high operating frequency (~200 KHz per stage). The design has built-in battery charge profiles for
12V and 24V Lead acid batteries. The circuit takes only under 10mA of standby current while
operating from battery. There is also a provision to connect a load to the battery with overload and
short circuit cut-off built in. The design presently uses ‘perturb and observe’ algorithm for MPP
tracking. This gives fast acquisition of MPP operation. Software programmable alarms and
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.
III. BLOCK DIAGRAM
Test Report - PMP7605_RevA
April 10
th
, 2013 4 TII - Reference Designs
IV. SPECIFICATIONS
Input Voltage Range: 15VDC - 44VDC
Output: 12V or 24V battery
Output Current: 20A max.
Board Form Factor: 130 mm x 84 mm x 22 mm
Expected efficiency: >95%
V. BOARD LAYOUT AND ASSEMBLY
Test Report - PMP7605_RevA
April 10
th
, 2013 5 TII - Reference Designs
VI. TEST SETUP
Input conditions:
Panel input: 15VDC to 22VDC for 12V system or 30VDC to 44VDC for 24V system
Set current limit to the short circuit current of panel when DC source is used instead of panel
Output:
Electronic load in CV mode to simulate battery or 12/24V battery
Equipment Used:
1. Current limited DC source simulating solar panel
2. Digital Oscilloscope
3. Multimeters
4. Electronic load
Procedure:
1. Connect appropriate battery or electronic load in CV mode to the BAT+ and BAT-
terminals of the PMP7605 reference board, maintaining correct polarity.
2. Connect panel or current limited DC source to PANEL+ and PANEL- terrminals,
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 output current.
VII. TEST DATA
a. 12V SYSTEM PERFORMANCE
Vi (V) Ii (A) Vo (V) Io (A) Pi (W) Po (W) Efficiency (%)
17.70 0.01 0.00 0.00 0.14 0.00 0.0
17.01 0.76 12.01 0.99 12.93 11.93 92.3
17.16 2.19 12.05 3.00 37.58 36.17 96.2
17.27 3.61 12.09 5.00 62.34 60.46 97.0
17.52 5.40 12.15 7.57 94.61 91.98 97.2
17.42 7.20 12.20 10.00 125.42 122.03 97.3
17.33 11.00 12.32 15.00 190.63 184.79 96.9
17.19 15.06 12.44 20.00 258.88 248.70 96.1
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