DEVELOPMENT OF AUTOMATIC ELECTRONIC LOAD CONTROL (ELC) APPLICATION FOR PICO HYDRO SYSTEM

MOHD ABDUL HAKIM BIN MUSTAPHA 51210208327

Report Submitted to Fulfill the Partial Requirements for the Bachelor of Engineering Technology in Electricals Universiti Kuala Lumpur

NOVEMBER 2011

DECLARATION

I declare that this report entitle Development of Automatic Electronic Load Control (ELC)
Application for Pico-hydro System is the results of my own research excepts as cited in the

references. The report has not been accepted for any degree and is not concurrently submitted in candidature of any other degree.

Signature Name Date

: . : . : .....

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APPROVAL

We have examined this report and verify that it meets the program and University requirements for the Bachelor of Engineering Technology (Hons) in Electricals.

Date:

Signature: ..................................... Supervisors Name: ..................... Official Stamp

Date:

Signature: ..................................... Co-Supervisors Name: ................... Official Stamp

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ACKNOWLEDGEMENT

First and foremost, Alhamdulillah and I would like to thank God Almighty, Allah S.W.T for His consent I have succeeded to complete this final year project.In preparing this report, I was in contact with many people, researches, academicians and practitioners. They have contributed towards my understanding and thoughts. In particular, I wish to express my sincere appreciation to my main project supervisor, Madam Noor Hidayah Binti Mohd Yunus for encouragement guidance, critics and friendship. I am also very thankful to my co-supervisors Mr Ismifaizul Bin Mohd Ismail for his guidance, advices and motivation. Without their continued support and interest, this final report would not been the same as presented here. My sincere appreciation also extends to all my colleagues and others who have provided assistance at various occasions. Their views and tips are useful indeed. Unfortunately, it is not possible to list all of them in this limited space. I am grateful to all my family members that always give support to me. I hope the knowledge that gathered and the experience gained from this project will help me to face the real challenge in working environments. The support and encouragement from all the people above will always be a pleasant memory throughout my life. May God bless to all of them.

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ABSTRACT

Development of automatic electronic load control (ELC) application for pico hydro system is a project that can help to distribute the electricity automatically especially people who lived in jungle like aboriginal. Normally they live near the river so that very suitable for them to use this system so they can get electricity for their daily live. . The ELC presented here has some flexibility, but also has its limitations: It's intended for pico hydro systems that employ a single-phase synchronous alternator, working at 12V 50Hz, in a power range up to 50 watt, some or all of which can be "useful" loads, such as water boilers or room heaters. It can be built for 120V systems too, simply by using the proper power transformer, but then it will be limited to half the power. In the form presented here, four of the outputs are used in prioritized fashion, with the other four having all the same (last) priority, with power being distributed among them. This can be changed in the software too, allowing any combination from fully sequentially prioritized. The ELC in normal operation it locks the generator/turbine speed, resulting in highly accurate frequency control. However, if a heavy load change momentarily pulls the system out of lock, the resulting missing or surplus cycles will not be recovered; instead the system will try to recover the correct speed as quickly as possible. For this reason, in the presence of such transient loads it might not be stable enough to accurately run clocks that use the line frequency for reference, despite having quartz control.

TABLE OF CONTENTS
CHAPTER TITLE DECLARATION APPROVAL ACKNOWLEDGEMENT ABSTRACT TABLE OF CONTENT LIST OF TABLES LIST OF FIGURES LIST OF APPENDICES 1 INTRODUCTION
1.1 Introduction of Chapter 1.2 Background 1.3 Problem Statements 1.4 Objectives 1.5 Scope of Project/ Limitation 1.6 Summary of Chapter 1 4 5 5 6 6

PAGE ii iii iv v vi viii ix x

LITERATURE REVIEW
2.1 History 2.1.1 Previous Work 2.1.2 Present Work 2.2 Review of History 2.3 Summary 7 7 9 9 10

METHODOLOGY
3.1 Introduction 3.2 Project Overview 3.2.1 Project Block Diagram 3.2.2 Project Flow Chart 3.3 Hardware and Development 3.3.1 PIC 16F877A 3.3.2 Voltage Regulator 3.3.3 Relay 3.3.4 Push Button 3.3.5 Output LED Indicator 3.3.6 Printed Circuit Board(PCB) Fabrication 11 11 12 12 13 14 15 17 18 18 19

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CHAPTER
3

TITLE
METHODOLOGY 3.4 Software and Development 3.4.1 Programming Development Tools 3.4.1.1 C++ Programming 3.4.1.2 PCW C-Compiler 3.4.1.3 WinPic800 3.4.2 Proteus 7 Professional 3.5 Summary

PAGE

21 21 21 22 24 26 27

RESULT AND ANALYSIS

4.1 Introduction 4.2 Prototyping 4.3 Analysis 4.4 Testing and Troubleshooting 4.5 Summary 28 28 31 31 32

CONCLUSION AND RECOMMENDATION

5.1 Introduction 5.2 Conclusion 5.3 Suggestion for Future Work 33 33 35 36 37 41

REFERENCES APPENDIX A APPENDIX B APPENDIX C

42

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LIST OF TABLES
LIST OF TABLES

TABLE 3.0 4.0 4.1

TITLE List of components Function and Operation Table Testing and Experimental Result of Pico-Hydro

PAGE 13 29 30

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LIST OF FIGURES

FIGURE
Figure 1.0 Figure 1.1 Figure 1.2 Figure 2.1 Figure 3.0 Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5

TITLE
Basic Diagram for Pico Hydro Example of ELC Example of ELC that used in Kenya Hydro Generator Pico Hydro at Portugal Basic block diagram Project Flow Chart. Number of Pin PIC16F877A Microcontroller Chip

PAGE
1 2 3 8 12 12 14 15 17

5V Regulator LM7805
Basic Design of relay

Circuit for controlling an AC or other high-current device from a microcontroller by using a relay
18 19 20 20 22 23 23 24 24

Figure 3.6 Figure 3.7 Figure 3.8 Figure 3.9 Figure 3.10 Figure 3.11 Figure 3.12 Figure 3.13 Figure 3.14 Figure 3.15 Figure 4.0 Figure 4.1

Circuit design using Protel DXP 2005 Solvent like thinner been used to get rid green coating.
PCB Layout Programming Flowchart

Look for Winpic800.exe in the folder

Start the program

start download program into your PIC

USB PIC Programmer

Connection between USB PIC programmer and computer

Schematic Diagram Prototype of ELC

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26 29 30

Graph Output Voltage (Volt) vs Rotor Speed (rpm)

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LIST OF APPENDICES

APPENDIX APPENDIX A APPENDIX B APPENDIX C

TITLE Projects Program Poster PIC 16F877A Datasheet

PAGE 37 41 42

CHAPTER 1

INTRODUCTION

1.1 Introduction of Chapter

Nowadays, global warming is a big issue that happened to our world. So, we need to think to create something that environment friendly although in generator system field. The cleanest type of energy generator is hydro generator system. There are many types of hydro-power system which is depends to the value of energy that generated.. Definition of pico hydro is a term used for hydroelectric power generation of under 5 kW. It is useful in small, remote communities that require only a small amount of electricity - for example, to power one or two fluorescent light bulbs and a TV or radio in 50 or so homes. Even smaller turbines of 200-300W may power a single home in a developing country with a drop of only 1 meter. Pico-hydro setups typically are run-of-stream, meaning that dams are not used, but rather pipes divert some of the flow, drop this down a gradient, and through the turbine before being exhausted back to the stream.

Figure 1.0 : Basic diagram for picohydro [1]

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Examples of pico hydro power can be found in Kenya, in the towns of Kithamba and Thimba. These produce 1.1 kW and 2.2 kW, respectively. Local residents were trained to maintain the hydro schemes. The pico hydro sites in Kenya won Ashden Awards for Sustainable Energy. [2] In Vietnam, several Chinese manufacturers have sold pico-powerplants at prices as low as 20-70$ for a powerplant of 300-500W. However, the devices sold are said to be low in quality and may damage connected equipment if connected improperly. Sam Redfield of the Appropriate Infrastructure Development Group (AIDG) has developed a pico-hydro generator made from common PVC pipe and a modified Toyota alternator housed in a five gallon bucket. The generator was developed to provide power to communities without access to the electricity grid in developing countries. Envisioned as an energy source to charge cell phones, provide lighting and charge batteries, the generator is designed to be made by artisans with basic skills and can be built for less than US $150.00. The Toyota alternator used in the generator is converted to a permanent magnet alternator allowing it to generate power at low RPMs. The Five Gallon Bucket Hydroelectric Generator was the subject of a work group at the 2008 International Development Design Summit (IDDS) at the Massachusetts Institute of Technology.

. Figure 1.1: Example of ELC [3] The ELC presented here has some flexibility, but also has its limitations: It's intended for pico hydro systems that employ a single-phase synchronous alternator, working at 220-240V, 50Hz, in a power range up to 5 kilowatts, some or all water boilers or room heaters. It can
2

be built for 120V systems too, simply by using the proper power transformer, but then it will be limited to half the power. It can also be configured for 60Hz (or any other reasonable frequency) simply by setting a parameter in the software. In the form presented here, four of the outputs are used in prioritized fashion, with the other four having all the same (last) priority, with power being distributed among them. This can be changed in the software too, allowing any combination from fully sequentially prioritized, to fully "democratic" among all outputs. The ELC in normal operation it locks the generator/turbine speed, resulting in highly

accurate frequency control. The software allows fine tuning of the frequency. However, if a heavy load change momentarily pulls the system out of lock, the resulting missing or surplus cycles will not be recovered; instead the system will try to recover the correct speed as quickly as possible. For this reason, in the presence of such transient loads it might not be stable enough to accurately run clocks that use the line frequency for reference, despite of which can be "useful" loads, such as having quartz control.

Figure 1.2 : Example of ELC that used in Kenya Pico hydro Generator

1.2 Background

An automatic electronic load controller is connected to the Pico hydro generator.

This

controller control the load based on our instruction that programmed in the circuit. This matches the electrical power that is produced to the electrical loads that are connected, and stops the voltage from changing as devices are switched on and off. Back in the age of our grandfathers, micro hydro systems were implemented without an ELC. Typically these systems had a mechanical or hydraulic speed governor, which in some cases controlled the water supply via a spear valve or similar device, or it acted upon a deflector that moved the jet away from the turbine, and some systems even had the speed governor act on a mechanical brake. In any case, this resulted in a reasonably constant speed (and thus frequency), and the voltage was set by manually adjusting a rheostat controlling the generator field current. Often the load current was coupled back to the field, which resulted in increasing the field current when there was more load, so that the output voltage was pretty constant. The basic concept any ELC uses is to let the turbine and generator run at their full power, or possibly a manually set partial power, and keep the electric load just right to attain the correct speed. It's very similar to the old mechanical speed governor that acts on a mechanical brake, only that an ELC uses electrical braking: Dump loads into which excess electric power can be put. So an ELC will measure turbine speed, and control the power delivered to one or more dump loads, to keep the speed correct. So, each system has its weak points and its strengths. You can buy ELCs using any of these different systems, from several manufacturers, but some are of poor quality, many are very expensive, and a few are both! The problem is that pico hydro is a niche market, and ELCs are typically hand- made in very small quantities. [3]

1.3 Proble m State ments Malaysia is such a developing country and everyone really needs the electricity. However, there are still exists some people who live without electricity in their house or their places. This people are aboriginal group that usually live in the jungle. Malaysias government had been help some of this aboriginal group by provided them solar system energy. This is very good step that taken by Malaysians government, so this aboriginal people start to have electricity in their house and make them easy. However, what will happen to them when rainy season? The solar system need sunlight to operate so there is no sunlight in this season and the solar system cannot operate. By using pico hydro system, this system can operate constantly because the river always flows. Normally, Pico hydro power system is found at rural or hilly area. This system will operate using upper water reservoir which is a few meter high from ground. From the reservoir, water flows downhill through the piping system. This downhill distance is called head and it allows the water to accelerate for prime moving system. Thus, the turbine will rotate the alternator to produce electricity. Normally, pico-hydro used for only one task which is supply electricity to light up peoples life. So, how to use the electricity that had generated for many tasks. The flow of water is constantly, so the electricity also always generated. Sometimes, people do not used electricity, so what will happen to electricity that had been generated? From that questionnaire, this project will solve those problem statements.

1.4 Objectives The objectives of this project are to develop automatic electronic load control for pico hydro system. After that, need to make sure the output is fully useful and prevent energy waste and overload. Lastly, to distribute the load automatically.

1.5 SCOPE OF PROJECT/LIMITATION The processes involved in order to produce this project are divided into two categories, which are developing electronic load control circuit and research. 1.5.1 Electronic Load Control The electronic load control (ELC) is an electronic device that automatically control the load that been generated from pico hydro generator. 1.5.2 Research Some research on electronic load control had been done and information gain about this project had been collected to be use as the data. Some of the references also give examples, guidelines and also suggestions.

1.6 Summary of Chapter The overall project is to design and construct the electronic load control for Pico-Hydro System. This project will be focus on mechanical and electrical system. The output of the project is hoped be beneficial to the public in general in providing renewable energy.

CHAPTER 2

LITERATURE REVIEW

2.1 History

2.1.1 Previous Work Since the early 1990s, pico-hydro has been used to deliver electricity and mechanical power to remote mountainous areas of the world. Pico-hydro projects are hydroelectric schemes with a power generation capacity of up to 5 kilowatts (kW). The energy in water flowing down a slope is converted into electrical energy. Pico- hydro schemes have low power outputs, but require little water and are simple to install. They typically provide energy for lighting and battery charging. Experts from the Energy Programme of ITDG East Africa, based in Kenya, in collaboration with Nottingham Trent University in the UK are working to develop the pico-hydro power sector in Kenya. The project demonstrates that pico- hydro technology is a sustainable and affordable technology for community electrification. Contributing to the establishment of hydro power infrastructure in rural Kenya and sub-Saharan Africa as a whole, the project benefits two rural communities in Kirinyaga District, central Kenya. [4]

Back in the age of our grandfathers, pico hydro systems were implemented without an ELC. Typically these systems had a mechanical or hydraulic speed governor, which in some cases controlled the water supply via a spear valve or similar device, or it acted upon a deflector that moved the jet away from the turbine, and some systems even had the speed governor act on a mechanical brake. In any case, this resulted in a reasonably constant and the voltage was set by manually adjusting a rheostat controlling the generator field current. Often the load current was coupled back to the field, which resulted in increasing the field current when there was more load, so that the output voltage was pretty constant.

These systems usually worked quite well, but they had their problems. First of them was that they reacted slowly. Slowest of all was the one that controlled the water valve, because it had to be slow, in order to avoid water hammer effects. The others could be faster, but were still limited by the inherent limitations of mechanical systems. To make up for the slow response of the mechanical speed governors, large, very heavy flywheels were used to stabilize the speed by force.

Figure 2.1: Pico Hydro at Portugal [5] Another problem was, of course, maintenance and wear. Mechanical systems need to be lubricated, cleaned, adjusted, and even then they break down rather easily. Specially the mechanical brake system produced a lot of friction, heat and wear. Add to this an assortment of problems like the tendency of spear valves to clog with small debris, and the tremendous
8

spray in the turbine housing when a deflector is used. Also, the lack of real voltage regulation made it hard to use some of these systems with sensitive loads. The basification of electronic devices made it possible to radically change the approach. It soon became standard practice to provide generators with built- in, highly accurate and reliable electronic voltage regulators, usually called "AVR" (automatic voltage regulator, to differentiate it from the old manual field current adjustment!) by the generator manufacturers. At that time, pico hydro builders became interested in using electronic speed control too, that works without any mechanical actuators.

2.1.2 Present work Lately, IEEE Power and Energy Society launch a paper work that about analysis and design of an electronic load controller (ELC) for three-phase self-excited induction generators (SEIGs) suitable for stand-alone pico-hydro power generation with constant input power.[6]
The proposed ELC consists of an uncontrolled rectifier and chopper with a series "dump" load. Proper design of rectifier, chopper, and dump load is very important for trouble free operation of ELC.

2.2 Review of History

Nowadays, automatic Electronic Load Controller (ELC) is an important device that used for many tasks because from usage of this thing the quantity of work and worker is decreased. So, from usage of this device can make the cost of worker is decreased. The basic concept any ELC uses is to let the turbine and generator run at their full power, or possibly a manually set partial power, and kept the electric load just right to attain the correct speed. It's very similar to the old mechanical speed governor that acts on a mechanical brake, only that an ELC uses electrical braking: Dump loads into which excess electric power can be put.

2.3 Summary Many research and experiment had been done from the earlier history of electric power system till today. All of the research are only had one objective that is to make better electric power system for the use of mankind. Along with this research also will discover the greatness of Distributed Generation when it is applied to electric power system.

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CHAPTER 3:

METHODOLOGY

3.1 Introduction

This chapter will discuss on the hardware and software development including the hardware design and software programming design. The hardware design including the charging circuit, selection of generator, design turbine, piping design, and its application. As well as to discover on how to control the speed of motor to produce the maximum output voltage from generator and planning to estimate the output power and considering the type of electrical load will be used. The software design will discuss on how to des ign the project schematic, PCB circuit design and the programming part.

3.2 Project Overvie w The main focus of this project is to control the load that generate from pico hydro system. After the electricity been generated, the output control by Programmable Integrated chip (PIC) that can control many output. For the software, the programming need to install in this PIC so this PIC can operate based on instruction that had been installed. This project programming used C++ while the circuit design using Protel and Proteus. For the hardware, the tools that needed are PCB board, PIC chips, rectifier, and LED to display.

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3.2.1 Project block diagram

Figure 3.0 : Basic block diagram

3.2.2 Project Flow Chart

Figure 3.1: Project Flowchart

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3.3 Hardware and Development The whole system consists of the following parts and components: Table 3.0 : List of components Description Microcontroller IC Socket Crystal Capacitor Voltage Regulator Capacitor Capacitor LED Resistor Diode Switch Photo PCB Etching Powder PCB Developer Battery Resistor LED Resistor array Relay Transistor Resistor Resistor array Switch Value PIC16F877A 40 pin 20MHz 18pF LM7805 0.1uF, 50V 1000uF, 16V 5mm 1KR 1N4007 On/Off 300mm*150mm 1Kg 50g 12VDC, 1.2AH 1KR 5mm 1K, 5 pin SPDT NPN, C9013 10KR, 1/4W, 5% 10K, 5 Pin Push button, big Quantity 1 2 1 2 2 1 1 1 1 5 1 1 1 1 1 4 8 1 4 4 1 1 3

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3.3.1 PIC 16F877A microcontrolle r PIC16F877A-I/P microcontroller is used to control the whole system. It is designed using flash technology. So the PIC can read/write program for more than 100,000 times. The PIC 16F877A has 8 K words or program memory. Since each word in the midrange family is 14 bits long the program memory can also be expressed as 14 Kbytes. The unit has 368 bytes of data ram and 256 bytes of EEPROM. It has 8 channels of A/D with 10 bit resolution. The unit has 2 8 bit Timer/Counters and a single 16 bit Timer/Counter. In addition to this it has several different types of serial communication functions such as SPI, I2C, and normal pc type serial communications functions.

Figure 3.2: Number of Pin PIC16F877A Microcontroller Chip OSC1 and OSC2 pins are connected to 20MHz crystal to execute every single program line in the system. 20MHz crystal is used because this is the maximum frequency that the PIC can support. If over frequency the PIC will burn. Else if crystal speed less tha n 20MHz then PIC response speed will slower. The MCLR pin of the PIC is pull up to 5V through a 10KR resistor. The PIC can operate using 4.5V to 6.0V DC voltage. In the project is operating at 5.0V (by using 7805). It is DIP layout (dual in line package) and suitable for student project. It has 40 pins but only 33 I/O pins can be set as digital input or digital output. The digital output of the PIC is 5V (for signal 1) and 0V (for signal 0) these signals will be directly connected to actuators for control purpose.

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When the PIC pin is set as digital input, it will detect input voltage 5V as signal 1 and 0V as signal 0. Any voltage less than 0V or more than 5V will damage PIC.

3.3.2 Voltage regulator module

Figure 3.3: 5V Regulator LM7805

The voltage regulator module is used to protect PIC and other connected sensors / actuators from over voltage. This is because PIC and all other connected sensors, actuators all support 5V DC only. Over voltage will cause any of the module burn. LM7805 is used to regulate voltage in the system and output 5V DC (max output current: 1000mA). It supports input voltage from 7V DC to 18V DC. If the input voltage is over, the LM7805 will burn or auto shutdown due to overheat. The generated 5V from LM7805 will be noise filtered by 0.1uF ceramic capacitor and a 1000uF electrolytic capacitor. This is to avoid high frequency oscillation on the outputs which may cause system hang or unstable. A diode is connected at the input of the LM7805. This is to avoid voltage connected reversely. An on/off switch is used to turn on/off the system and a LED (5V, 5mA) is used to indicate the system is power on/off. The LED is connected through 1KR resistor to limit current pass through LED is 5mA.

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Advantages The 7805 series has several key advantages over many other voltage regulator circuits which have resulted in its popularity:

7805 series ICs do not require any additional components to provide a constant, regulated source of power, making them easy to use, as well as economical, and also efficient uses of circuit board real estate. By contrast, most other voltage regulators require several additional components to set the output voltage level, or to assist in the regulation process. Some other designs (such as a switching power supply) can require not only a large number of components but also substantial engineering expertise to implement correctly as well.

78xx series ICs have built- in protection against a circuit drawing too much power. They also have protection against overheating and short-circuits, making them quite robust in most applications. In some cases, the current- limiting features of the 78xx devices can provide protection not only for the 78xx itself, but also for other parts of the circuit it is used in, preventing other components from being damaged as well.

Disadvantages

The input voltage must always be higher than the output voltage by some minimum amount (typically 2 volts). This can make these devices unsuitable for powering some devices from certain types of power sources (for example, powering a circuit which requires 5 volts using 6- volt batteries will not work using a 7805).

As they are based on a linear regulator design, the input current required is always the same as the output current. As the input voltage must always be higher than the output voltage, this means that the total power (voltage multiplied by current) going into the 78xx will be more than the output power provided. The extra input power is dissipated as heat. This means both that for some applications an adequate heat sink must be provided, and also that a (often substantial) portion of the input power is wasted during the process, rendering them less efficient than some other types of power supplies. When the input voltage is significantly higher than the regulated output voltage (for example, powering a 7805 using a 24 volt power source), this inefficiency can be a significant issue.
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Even in larger packages, 78xx integrated circuits cannot supply as much power as many designs which use discrete components, and therefore are generally not appropriate for applications which require more than a few amps of current.

3.3.3

Relay

A relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism, but other operating principles are also used. Relays find applications where it is necessary to control a circuit by a low-power signal, or where several circuits must be controlled by one signal. Figure 1 shows the basic design of relay.

Figure 3.4: Basic design of relay. The output of each PIC pin is 5V with max output current of 20mA or 0V with 0mA output. The voltage is not enough to run high power device e.g. motor, solenoid. Thus we need a relay to control these high power items. A simple switching circuit (using NPN transistor, C9013) will be used to energize / de-energize the input coil of the relay. The relay output is single pole double throw (SPDT). And its coil can be energized using 5V and de-energized using 0V. Normally the relay output NC and COM will be connected. When the input coil of relay is energized, output NO and COM will connect. The switching can be used to control item which is less than 250Vac and 10A.

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A reverse diode (1N4007 is connected with input of relay to avoid reverse spike or over current flow back from the load. And a LED indicator is used to show relay is now on/off. When relay is on, LED is on. When relay is off, LED is off.

Figure 3.5 : Circuit for controlling an AC or other high-current device from a microcontroller by using a relay

3.3.4 Push button: The push buttons are connected to 5V when no pressed. Thus PIC gets 1 when button no pressed. Whenever button is pressed the PIC pin is shorted to ground and thus PIC get 0. 3.3.5 Output LED indicator: A normal LED use 5V and 5mA to operate. And through LED the current status of the system can be known. A 1KR resistor is connected series with the LED to limit the current pass through LED is 5mA.

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3.3.6 Printed Circuit Board (PCB) Fabrication

Step to create circuit PCB are like below: 1. PCB Drawing: PCB drawing is designed using Protel DXP 2005, this software can automatically convert schematic file to PCB automatically.

Figure 3.6: Circuit design using Protel DXP 2005

2. Film Printing: After PCB file is generated, use laser printer to print it on transparency. 3. PCB Cutting: Cut photo PCB size according to the film size. 4. PCB Photo Etching: Expose the photo PCB in photo etching kit for 8-10minutes. 5. PCB Developing: Wash the PCB using PCB developer (white powder) for 2 min. 6. Acid Etching: After PCB is developed, put it in Ferric Chloride liquid. Add in hot water (80C) and shake the water until you see unused part is washed and left only the tracks. The etching process takes around 30 min. 7. Solvent Washing: Wash the PCB with thinner to get rid the green coating. Refer figure 3.7:

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Figure 3.7: Solvent like thinner been used to get rid green coating.

8. Drilling: Drill PCB after alcohol washing, use drill bit 0.8mm, 1.0mm and 1.2mm. 9. Soldering: Place all components on the PCB, use tape to stick all components tightly on the PCB and then solder the components using soldering iron and lead.

Figure 3.8: PCB Layout

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3.4: Software and Development

3.4.1 Programming Development Tools

Programming tools are used to implement the task between hardware and software. These tools of programming are selected based on the chip products that are used in the project.

3.4.1.1 C++ Programming Language

C++ is an object oriented language, which combines the best of the structured programming techniques of C, thus making it a very powerful language. C++ is based on C and Simula 67 language. C was inverted by Bjarne Stroustrup. Since C++ is a superset of C, therefore most of C language constructs apply in C++ as well. A program in C++ can be written in both C style and Object Oriented style. As one of the most popular programming languages ever created, C++ is widely used in the software industry. Some of its application domains include systems software, application software, device driver, embedded software, high performance server and client applications, and entertainment software such as video games. 27 Several groups provide both free and proprietary C++ compiler software. C++ is also used for hardware design, where design is initially described in C++, then analyzed, architecturally constrained, and scheduled to create a register transfer level hardware description language via high- level synthesis.

3.4.1.1.1 Programming flowchart

Firstly, the flowchart was build to plan the program structure and to make programming writing become easier. For the flow chart, refer to the figure 3.7

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Start Detect push button

Button 1 pressed?

Yes

Toggle bulb 1

No Button 2 pressed? Yes

Toggle bulb 2 on/off

No Yes

Button 3 pressed?

Toggle bulb 3 on/off

No Detect bulb status

Motor turn on

No

Any bulb on?

Yes

Stop motor

Figure 3.9: Programming flowchart

3.4.1.2.a PCW C-Compiler: Edit and compile C-language program. It will generate .hex file for downloading application. The trial version of C-compiler can download from www.ccsinfo.com. Step to use this software are like below: 1. Open PCW C-Compiler Start->All Programs->PIC-C->PIC C Compiler. 2. File -> New to start a new file. 3. Save the file as .c file, it is advisable to put the main file name within 8 chars length, extended file name must be .c, e.g. myprog1.c. 4. Type / Edit your program. 5. Save program before compile. 6. Compile your program using F9. 7. If any error occurs, please check your program and compile again. Otherwise you wont get your .hex file. 22

3.4.1.2. b Application

1. Connect PIC programmer to computer via serial port / USB port. 2. Insert PIC into the programmer socket. 3. Copy Winpic800 folder to Desktop. 4. Look for Winpic800.exe in the folder.

Figure 3.10: Look for Winpic800.exe in the folder

5. Double click Winpic800.exe to start the program.

Figure 3.11: Start the program 6. Select proper PIC name in the top right combo box.

7. Open the .hex file which you want to download into PIC e.g. if your .c filename is abc.c, suppose you need to download abc.hex into PIC. 8. Go to Device -> Program All to start download program into your PIC.
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Figure 3.12: start download program into your PIC

3.4.1.3 Winpic800 USB Downloader Software: This software is used to download program to PIC.

Figure 3.13 : USB PIC Programmer

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3.4.1.3.1 Step to Use : Figure below show connection PIC programmer to computer via serial port/USB port.

Figure 3.14: Connection between USB PIC programmer and computer

PIC will insert into the programmer socket. Winpic800.exe will double click to start the program. The language will change to English by using menu on top Idoma English. PIC will select the proper name in the top right combo box. Menu will click by follow Device Detect PIC. If PIC model is detected and show on screen mean connection success. Else if Unknown display on the screen mean connection fail caused by PIC, driver or programmer itself. File Open will click to open the .hex file which you want to download into PIC e.g. if .c filename is abc.c, suppose you need to download abc.hex into PIC. Device Program All will select to start download program into your PIC. Download time is around 3-5 sec. If download success, the PIC can be removed from the programmer and plug back to the I/O board.

3.4.1.4 Universal PIC Programmer: It is an electronics device used to download PIC

program into PIC. Through Winpic800 USB downloader software, this programmer can download PIC program (machine code, .hex file) into PIC.

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3.4.2 Proteus 7 Professional Proteus PCB design combines the ISIS schematic capture, Proteus Virtual System Modeling (VSM) and ARES PCB layout programs to provide a powerful, integrated and easy to use suite of tools for professional PCB Design. ISIS lies at heart of the Proteus system, and is far more than just another schematics package. It combines a powerful design environment with the ability to define most aspects of the drawing appearance. ISIS provides ultimate control of the drawing appearance in terms of line widths, fill styles, colors and fonts. It enables the designer to produce attractive schematics like in the magazines rather than thin- line diagrams associated with other CAD software. Once drawing is complete, the designer can export it as a graphics file or copy it to the clipboard for incorporation in other documents. This makes ISIS ideal for use in technical documentation, academic papers and project reports in addition to being an excellent front and design tool for PCB Design.

Figure 3.15: Schematic Diagram Proteus Virtual System Modeling (VSM) combines mixed mode SPICE circuit simulation, animated components and microprocessor models to facilitate co-simulation of complete microcontroller based design. ARES features a state of the art layout database capable of representing the most comple x of PCB designs. It include Netlist & Ratnest Handling, Auto Placer, Shape Based Autorouting, Manual Route Placement, Power Planes, Design Rule Checking, 3 D Visualization and many others.
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3.5 Summary

This chapter are about the software and hardware that been used for this project. Some software are familiar and been used during my studies while there are software that I just learn like Protel and Eagle. Hardware development more focuses on circuitry while the software development more focuses on programming. Hardware must be carefully handled because it the most important part of the project. Without hardware, the project is not complete and analysis cannot be run. It is important to know the function of each component involved to make sure the project well functioned. Meanwhile, the program written is also same important as the hardware. The program is the main part and act as a brain to give the instruction to the hardware to determine the functionality. The interfacing between hardware and software is very important in determining whether the project is functioning or not.

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CHAPTER 4

RESULTS AND ANALYSIS

4.1 Introduction This chapter will define the final result of the development of electronic load controller (ELC) from starting of the block diagram to the end. It will be discussing on the results obtained and analysis of the result of the circuit.

4.2 Prototyping In general, the major concern in the development of ELC for pico-hydro system are the supply voltage, value of power and how to manage the load. For hardware construction and interfacing, tests have been carried out to verify that the circuit functions perfectly. Figure 4.1 shows the proposed ELC for pico-hydro system that has been developed.

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Figure 4.0 Prototype of ELC

Table 4.0: Function and Operation Table

PIC I/O Pin Connected To Sensor / Actuator RB5 RB6 RB7 RC4 RC5 RD2 RD3 RD4 RD5 RD6 RD7 Yellow push button (switch 3) Green push button (switch 2) Red push button ( switch 1) Relay on/off Relay on/off Relay on/off Relay on/off Blue LED Yellow LED Green LED Red LED Function On/off bulb 3 On/off bulb 2 On/off bulb 1 To control bulb To control bulb To control mini motor( dummy load) To control bulb On when motor run ( dummy load) On when load 3 turn on On when load 2 turn on On when load 1 turn on

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Table 4.1: Testing and Experimental Result of Pico-Hydro Rotor Speed (RPM) 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 Voltage (V) 6.00 7.60 7.01 8.12 8.60 9.50 10.20 10.60 10.70 11.32

12 11 10 9.5 8.6 8.12 10.6 10.7

11.32

10.2

Voltage(V)

9 8 7.01 7
6 6 5

7.28

Voltage (V)

1800 1900 2000 2100 2200 2300 2400 2500 2600 2700

Rotor Speed (RPM)

Figure 4.1: Graph Output Voltage (Volt) vs Rotor Speed (rpm)

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4.3 Analysis This part is the most critical stage in this research project as it determines the feasibility and achievability of the proposed pico-hydro system. There are many factors that determine the feasibility and achievability of the system. This includes: i. The amount of power supply. Depends on speed of the water flow then spin the turbine and generate power. ii. iii. iv. The quantity of load that been used. The types of motor to generate power need to choose rightfully. The cost of developing the project and operating the system

4.4 Testing and Troubleshooting

Testing and troubleshooting part explain the process of circuit testing that will solved the problem. Troubleshooting is needed to develop and maintain complex systems where the symptoms or failure of a problem can have many possible causes. Troubleshooting is the important process in developing the Pico-Hydro Electric System.. In troubleshooting the PCB circuit for the project, the first step is to check the placement of PIC16F877A Microcontroller is in the right condition. By using digital multimeter, the input supply of +9V from battery or +12V from the adopter was measured as the input of PCB circuit. Then the input for PIC must be +5V since it was regulated by using LM7805. The placement of LM7805 in wrong condition cannot regulate the +12V/+9V input supply. It is important to know the programming setting. The connection between component to component, component to ground and component to supply needed to check again to make sure that it has the connection.

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4.5 Summary In this chapter show the result of this project. This part needs to solve any problem to make the project is success. After that needs to analyze and identify the problem by find out the root cause of the problem before fix the problem. It will guide to so lve this problem. The main problems in this project are due to the hardware part and software part.

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CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 Introduction

This chapter will discuss the conclusion of the project according to the aim set out in the earlier chapter and also recommend the idea or method that will upgrade the system in future and achieve a better application.

5.2 Conclusion In conclusion, ELC is an important device that must be applied especially when doing distribution of electricity generation. It is because this ELC will operate all time to control the load anytime day and night. Furthermore, dummy load will operate when there are no load been used like during a day when nobody used electricity. This dummy load functions as an output to prevent overload because the power from pico hydro continuous generated.

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In addition for generation part, the selection of turbine and generator in terms of their type and size or capacity is also important in designing and developing the proposed pico- hydro power system. Improper type and sizing of these components would cause the system to operate at undesirable performance. This project is a combination of hardware and software development.

The objective of this project has complete achieved to develop a small scale hydro generation system using consuming water distributed to houses as an alternative electrical energy source for pre-commercialization. During the period of project development, there are a few things that have been familiarized. The time that been spent in this project development has exposed students with a great practical and theoretical knowledge about electronics characteristics and circuits. With the help of supervisor, technician and stude nt effort, the project had been work pretty successful.

This Electronic Load Controller are suitable been implement in pico-hydro power system or micro-hydro power system. This is because there will be no storage system which is expensive for a small power output. Though the use of ELC is existent in micro- hydro systems these days also, the present ELCs face different problems such as getting damaged very soon, inconsistent in repairing. The selection of ELC in this final year project is to make an effort to mitigate the problems stated. Replacing thyristor with triac makes ELC more efficient as triacs are less prone and damage. The costs of ELC is much lower compared to existing ELC. All these things lead to the conclusion that, with some minor modifications, this ELC can be a good replace ELC. This project overall is quite struggle and tough, but all of the progress has run smoothly until the project complete successfully.

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5.3 Suggestion for Future Work The project has been successfully developed and implemented. However, it can be improved to target more advance and better application in the next stage of research. For future improvement, there are several suggestions stated below can be continued: i. Use AC type of generator to produce high voltage will be generate. ii. Add storage system to store the generated power iii. An electronic controller is connected to the generator. This matches the electrical power that is produced, to the electrical loads that are connected. This is necessary to stop the voltage from going up and down. Without a load controller, the voltage changes as lights and other devices are switched on and off.

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REFERENCES [1] P. Maher and N. Smith, Pico hydro for village power: A practical manual for schemesup to 5 kW in hilly areas, 2nd ed., Intermediate Technology Publications, May 2001.

[2] The Ashden awards for sustainable energy,(2004) Kenya,Pico scale hydro power. http://www.ashdenawards.org/winners/itdg

[3] Jan Portegijs, (2001) Electronic Load Control for Micro hydro. Retrieve on 2010 http://ludens.cl/Electron/picelc/picelc.html

[4] P. Maher, (2002) Kenya Case Study1 at Kathamba and Case Study 2 at Thima. Retrieve on 14 April 2010 http://www.eee.nottingham.ac.uk/picohydro/documents.html#kenya

[5] Wendy, Permaculturing in Portugal generating hydro power: Powered. Retrieve on 9 December 2010 http://permaculturinginportugal.net/blog/powered/

[6] Analysis and design of electronic load controller for self-excited induction Generators http://ieeexplore.ieee.org/Xplore

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APPENDIX A Projects Program

#include <16f877a.h> #use delay(clock=20000000) #fuses hs,noprotect,nowdt, nolvp

//use pic16f877a //clock 20mhz //default setting

#byte porta=5 #byte portb=6 #byte portc=7 #byte portd=8 #byte porte=9

//port a address //port b address //port c address //port d address //port e address

void main() { int bulb1=0; int bulb2=0; int bulb3=0; int bt1_en=1; int bt2_en=1; int bt3_en=1;

//set io for each pin set_tris_a(0b00000000); set_tris_b(0b11100000); set_tris_c(0b00000000); set_tris_d(0b00000000); set_tris_e(0b00000000);

output_low(pin_c5); output_low(pin_c4); output_low(pin_d3); output_low(pin_d2); output_low(pin_d7);

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//off bulb1 //off bulb2 //off bulb3 //off motor /off red led

output_low(pin_d6); output_low(pin_d5); output_low(pin_d4);

//off green led //off yellow led //off blue led

do { if(input(pin_b7)==0 && bt1_en==1) { if(bulb1==0) { bulb1=1; output_high(pin_c5); output_high(pin_d7); //on bulb1 //on red led //if bulb1 button pressed

else { bulb1=0; output_low(pin_c5); output_low(pin_d7); } //off bulb1 //off red led

bt1_en=0; } else if(input(pin_b7)==1) { bt1_en=1; } //if bulb1 button released

if(input(pin_b6)==0 && bt2_en==1) { if(bulb2==0) { bulb2=1; output_high(pin_c4); output_high(pin_d6);

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//if bulb2 button pressed

//on bulb2 //on green led

} else { bulb2=0; output_low(pin_c4); output_low(pin_d6); } //off bulb2 //off green led

bt2_en=0; } else if(input(pin_b6)==1) { bt2_en=1; } //if bulb2 button released

if(input(pin_b5)==0 && bt3_en==1) { if(bulb3==0) { bulb3=1; output_high(pin_d3); output_high(pin_d5); } else { bulb3=0; output_low(pin_d3); output_low(pin_d5); }

//if bulb3 button pressed

//on bulb3 //on yellow led

//off bulb3 //off yellow led

bt3_en=0; } else if(input(pin_b5)==1) { bt3_en=1;

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//if bulb3 button released

if(bulb1==0 && bulb2==0 && bulb3==0) { output_high(pin_d2); output_high(pin_d4); } else //if other cases { output_low(pin_d2); output_low(pin_d4); }

//if no bulb on

//on motor //on blue led

//off motor //off blue led

delay_ms(200); }while(1); }

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APPENDIX B POSTER

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APPENDIX C PIC 16F877A DATASHEET

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