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

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 following diagram depicts the single line diagram of the PV system. 

The next figure depicts a block diagram of the PV system.

Component Descriptions

Solar Panel

Type: SunWize SW-S55P 55 Watt Polycrystalline Solar Panel

Charge Controller

Type: Morningstar SunSaver MPPT Solar Controller with maximum power point tracking

Inverter

Type: Morningstar SureSine Pure Sine Wave 300 Watt Inverter

DC Load

Type: BK Precision 8500 300 Watt Programmable DC Electronic Load 

Battery

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.

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:

Battery:

Our group decided to go ahead with the Trojan 24-AGM battery

Light Source:

For the light source we came across two options that we could choose from:

1. Designer's Edge Goliath Power Light: 100 Watt, 100,00 Lumens, Model# L-4210

• 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

2.  Industrial Performance 1000 Watt, 71,000 Lumens BT56 Mogul Screw (E39)

  

     

• 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:

1.  DC 50A Blue LCD Digital Ammeter and Shunt

•        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

• 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