This blog depicts ECEP 490 group 5's investigation into the design process and hardware for grid-tied photovoltaic systems with or without battery backup. This blog aims to track our weekly progress by noting down our approach to the solution, design goals and major accomplishments.
Sunday, May 6, 2012
Wiring of the Photovoltaic System
Our team looked into the wiring of the system and formulated a table consisting of the different connections such as PV to CC, CC to Battery etc. The table consists of fields such as Connector type, connector color, wire gauge, wire type, wire color, wire length and cost.
Connection block diagram and Final 3D schematic
The 3D schematic was developed using Google SketchUp which included a potential orientation of the panels. Due to the limitations in the size of the cart and the weight of each panel, the only viable option was to place the panels horizontally. It was decided that two light sources, each capable of giving out 89000 lumens, would be directed from above utilizing separate stands.
Although initially it was decided to use just two digital ammeters and voltmeters at the charge controller and DC end of the inverter, later it was deduced that having more measuring devices would enhance the learning experience of students. Although this would incur an additional investment, this would not be that significant due to the low cost of these devices. Moreover, the type of wiring that will be incorporated in the system and methodology of implementing the connections to the various components were discussed.
Block Diagram with Electrical Connections
Final Version of 3D Schematic |
Photovoltaic System: 3D Schematic
Our design team utilized Google SketchUp 3D CAD
software to model our design in real space. Google SketchUp is a free CAD software that several of our team members
had previous experience with. We used
the dimensions found on the data sheets of all our components to create the 3D
model to scale. This was helpful to
visual our project and determine how to mount the solar panels, where to run
wire conduits, and the layout of all the devices. The following figure shows a general overview of our design setup and how it would look in a classroom
setting.
The next figure show the bottom shelf with the battery, charge controller, and inverter on it.
The
top shelf shown below supports the frame structure that will house the
four 55W solar panels.
Progress Update
Our team has been discussing, finalizing and updating the different components that we will be using to make our system. We got to see the solar panel that we will be using and realized that the panel dimensions and weight deviated from our original estimations by a large amount. Therefore, we will need to come with a different way of mounting the panels on the cart such that we can easily fit the four panels on the cart along with the mountable light source we are planning to use.
For the light source, we decided to use a 600 Watt High-pressure sodium light bulb mounted on a fixture.
For the light source, we decided to use a 600 Watt High-pressure sodium light bulb mounted on a fixture.
- 600 Watt
- 89,000 Lumens
- Covers a 6' x6' area
From the image below we can estimate the approximate coverage area of the bulb attached to a fixture.
Preliminary 3D schematic: Experiment with orientation of Panels
We started working on the 3D schematic in order to experiment with the appropriate orientation of the panels.
Sunday, April 22, 2012
Budget
Hardware Expenses
|
|||
Equipment
|
Quantity
|
Price/Unit ($)
|
Sub Total ($)
|
SunWize, 55 W
Polycrystalline Solar Panel
|
4
|
235.00
|
940.00
|
Morningstar, Charge
Controller
|
1
|
211.00
|
211.00
|
Universal Power,
Sealed Lead Acid Battery
|
1
|
109.61
|
105.00
|
Morningstar, 300W Sine
Wave Inverter
|
1
|
225.00
|
225.00
|
BK Precision, 300W
Programmable DC Electronic Load
|
1
|
1,095
|
1,095.00
|
Suntek Store, DC
Digital Ammeter
|
3
|
12.08
|
36.24
|
Suntek Store, DC
Digital Voltmeter
|
3
|
7.19
|
21.57
|
AC Digital Ammeter
|
1
|
|
0.00
|
AC Digital Voltmeter
|
1
|
|
0.00
|
600 W Dimmer Switches
|
2
|
32.95
|
65.90
|
PlanetLights, 600 W
Light Source
|
2
|
25.25
|
50.50
|
Light Fixture with
Ballast
|
2
|
205.95
|
411.90
|
Light Stands
|
2
|
47.99
|
95.98
|
Northern Industrial,
Service Cart
|
1
|
134.99
|
134.99
|
Tripp Lite, 15 A Power
Strip
|
2
|
11.99
|
23.98
|
Single Conductor
Copper Wire - Red (100 ft)
|
1
|
17.85
|
17.85
|
Single Conductor
Copper Wire - Black (100 ft)
|
1
|
14.21
|
14.21
|
Single Conductor
Copper Wire - Gray (100 ft)
|
1
|
15.81
|
15.81
|
AC/DC 10 V Power
Adapter
|
1
|
25.07
|
25.07
|
Sea Dog, Bus Bar
|
2
|
10.98
|
21.96
|
GE, 30 W Light Bulbs
|
5
|
4.99
|
24.95
|
Bulbs Fixture
|
1
|
6.90
|
6.90
|
Support Frame - Angle
6061-T6 Aluminum, Extruded
|
210
|
0.09
|
18.9
|
Support Underside - 6061-T6511
Aluminum, Extruded
|
105
|
0.2
|
21.00
|
Support Legs - Square.
Tube 6063-T52 Aluminum
|
25
|
0.13
|
3.25
|
|
|
|
|
|
|
Total
|
3,586.96
|
Sunday, April 15, 2012
Preliminary Product Description: Solar Energy System
Preliminary Product Description
ECEP 490 Group 5
Product Description
Our
design group aims to develop a low cost solar energy demonstration system for
middle or high schools. The photovoltaic (PV) system we develop will display
voltage and current of key equipment so that students can observe equipment
response to changing solar conditions like light intensity and shading.
Furthermore, the DC and AC load levels will be variable so that students can
observe system response to changing loads. Some of the constraints for our
design will be low cost, minimum storage, insulated cover for safety of
students, and a mobile cart for easy movement of the entire system. The main
features include adjustable light source and load.
Learning Goals
The PV demonstration cart will focus on:
- Brief high level description of PV system component functions
- How light intensity effects PV system performance and output
- Shading effects on PV system performance and output
- Effect of varying load level and battery interaction
- Concept of Inversion
System Graphics
The next figure depicts a block diagram of the PV system.
Component Descriptions
Solar Panel
Type: SunWize SW-S55P 55 Watt Polycrystalline Solar Panel
Type: Morningstar SunSaver
MPPT Solar Controller with maximum power point tracking
Inverter
Type: Morningstar SureSine Pure Sine Wave 300 Watt
Inverter
Type:
BK Precision 8500 300 Watt Programmable DC Electronic Load
Type: UPG UB12500 AGM Deep Cycle 12 Volt 50 Ah Battery
Light Source
- Sunmaster MH 1000 Watt, 100000 Lumens.
- Buld Life: 9,000 hours
- Cost $93.95
- Number of bulbs we will use: 1
Digital Ammeter/Voltmeter
- DC 50A Blue LCD Digital Ammeter and Shunt
- Comes with connecting wire and 50A 75m Vshunt
- Low Power Consumption
- Measuring Input Range: DC 50A
- Working Power Range: DC 6V to 15V
- Meter Dimensions(LxWxH): Approx: 7.2 x 3.6 x 2.5cm (2.9 x 1.4 x 1 inch)
- Shunt Dimensions(LxWxH): Approx: 12 x 2.5 x 1.8cm (4.7 x 1 x 0.7 inch)
- Cost: $12.08
- Mini DC 99.9V Blue LED Digital Panel Meter Voltmeter
- 3 digital bright LED, easy to read the digits
- Power Supply: DC 6V to 15V
- Type: Blue LED
- Measuring Range: 0 -99.9V
- It's easy to install, ideal for DIY
- Safe to use
- Accuracy: ± 0.2%
- Resolution: 0.1V
- Cutout Dimensions: Approx. 38mm (L) x 20mm (W) (1.5 x 0.8 inch)
- Voltmeter Dimensions: Approx. 45(L) x 25(W) x 20(H)mm (1.8 x 1 x 0.8 inch)
- Cable Length: Approx. 20 cm(8 inch)
- Cost: $7.19
Mobile Cart
- Northern Industrial Structural Foam Service Cart
- Material Type: Structural foam
- Capacity: 500 lbs
- Shelves: 3
- Shelf Capacity: 165 lbs
- Dimensions W x D x H(in) : 26 x 38 x 33 5/16
- Cost: $144.99
Activities
Varying the load is one of the
activities students can perform to interact and learn about the PV system. The load can be adjusted by using the DC
Electronic Load to adjust DC load and a small multi-speed fan, ac light bulb
bank with switches, or some other common variable AC load provided by the
demonstrator to change AC load. The
light source can be varied by students by using a dimmer switch commonly used
to adjust house lighting to vary the intensity of light.
Tuesday, April 10, 2012
Meeting 2: Choosing the Right Hardware
Every member of the group researched into a particular hardware for the photovoltaic system we plan to build.
The major components for solar PV system are solar charge controller, inverter, battery bank, auxiliary energy sources and loads.
• PV module – converts sunlight into DC electricity.
• Solar charge controller – regulates the voltage and current coming from the PV panels going to
battery and prevents battery overcharging and prolongs the battery life.
• Inverter – converts DC output of PV panels or wind turbine into a clean AC current for AC
appliances or fed back into grid line.
• Battery – stores energy for supplying to electrical appliances when there is a demand.
• Load – is electrical appliances that connected to solar PV system such as lights, radio, TV, computer,
refrigerator, etc.
Listed below is a list of the different hardware we found:
Our group decided to go ahead with the Trojan 24-AGM battery
2. Mini DC 99.9V Blue LED Digital Panel Meter Voltmeter
SureSine Pure Sine Wave Inverter 300 Watts
The major components for solar PV system are solar charge controller, inverter, battery bank, auxiliary energy sources and loads.
• PV module – converts sunlight into DC electricity.
• Solar charge controller – regulates the voltage and current coming from the PV panels going to
battery and prevents battery overcharging and prolongs the battery life.
• Inverter – converts DC output of PV panels or wind turbine into a clean AC current for AC
appliances or fed back into grid line.
• Battery – stores energy for supplying to electrical appliances when there is a demand.
• Load – is electrical appliances that connected to solar PV system such as lights, radio, TV, computer,
refrigerator, etc.
Listed below is a list of the different hardware we found:
Battery:
Light Source:
For the light source we came across two options that we could choose from:
- Bulb Type: Metal Halide
- Power Supply: AC
- Bulb Life: 12,000 hrs
- Bulb (qty.): 1
- Power Cord: 15 ft
- Dimensions LxWxH (in.): 17 x 20.5 x 24
- Bulb Life: 12000 hrs
- Cost: $30.00
We plan to use multiple bulbs to produce the desire power.
Digital or Analog Ammeter and Voltmeter:
After researching on a few digital and analog ammeters/voltmeters we found that digital ammeter/voltmeter were cheaper than analog devices. Therefore, we chose the following digital devices:
- This is a ammeter with blue LED
- Comes with connecting wire and a 50A 75mVshunt. Convenient for you to install
- Great for DIY
- Low power consumption
- Measuring Input Range: DC 50A
- Working Power Range: DC 6V to 15V
- Working Current: <60mA
- Accuracy: ±0.2%
- Resolution: 0.1A
- Meter Dimensions(LxWxH): Approx: 7.2 x 3.6 x 2.5cm (2.9 x 1.4 x 1 inch)
- Shunt Dimensions(LxWxH): Approx: 12 x 2.5 x 1.8cm (4.7 x 1 x 0.7 inch)
- Wire Length: Approx. 20cm(8 inches)
- Cost: $12
2. Mini DC 99.9V Blue LED Digital Panel Meter Voltmeter
- 3 digital bright LED, easy to read the digits
- Power Supply: DC 6V to 15V
- Type: Blue LED
- Measuring Range: 0 -99.9V
- It's easy to install, ideal for DIY
- Safe to use
- Accuracy: ± 0.2%
- Resolution: 0.1V
- Cutout Dimensions: Approx. 38mm (L) x 20mm (W) (1.5 x 0.8 inch)
- Voltmeter Dimensions: Approx. 45(L) x 25(W) x 20(H)mm (1.8 x 1 x 0.8 inch)
- Cable Length: Approx. 20 cm(8 inch)
- Cost: $7.19
Cart to keep the system on:
Inorder to keep the system together and enable easy movement of the system, we also looked into numerous carts and picked the following for our project:
Northern Industrial Structural Foam Service Cart
Northern Industrial Structural Foam Service Cart
- Material Type: Structural foam
- Capacity: 500 lbs
- Shelves: 3
- Shelf Capacity: 165 lbs
- Dimensions W x D x H(in) : 26 x 38 x 33 5/16
- Cost: $144.99
Inverter
SureSine Pure Sine Wave Inverter 300 Watts
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