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{{Solar menu}}


[[File:ChargingStation3.jpg|thumb|right|Sample photo caption.]]
[[File:ChargingStation3.jpg|thumb]]


The Campus Center of Appropriate Technology is a demonstration house located on the Humboldt State University campus, Arcata, California that is a resource for students and faculty. CCAT has many different technologies on display such as: solar panels, rainwater catchment, organic gardens, a greywater marsh, and an experimental composting toilet, among other things. These projects are on display as educational tools to the community and  information is provided through CCAT/Appropedia on how to recreate these technologies on your own. The Solar Charging Station at CCAT will align with the mission of CCAT to provide education and resources to the community, by clearly expressing how off-grid solar works, while being functional for cell phone/laptop charging.
{{Device data
| making_instructions = https://www.appropedia.org/File:Final_Document.pdf
}}


{{Project data
| authors = User:Akr57, User:APenny6
| status = Deployed
| completed = 2014
| made = Yes
| replicated = No
| cost = USD 268.5
| instance-of = Photovoltaic system
}}
The Campus Center of Appropriate Technology is a demonstration house located on the Cal Poly Humboldt campus, Arcata, California that is a resource for students and faculty. CCAT has many different technologies on display such as: solar panels, rainwater catchment, organic gardens, a greywater marsh, and an experimental composting toilet, among other things. These projects are on display as educational tools to the community and information is provided through CCAT/Appropedia on how to recreate these technologies on your own. The Solar Charging Station at CCAT will align with the mission of CCAT to provide education and resources to the community, by clearly expressing how off-grid solar works, while being functional for cell phone/laptop charging.


== Understanding the market ==
== Understanding the market ==


'''What we have:'''
'''What we have:'''
[[Image:TheSunSpotters.jpg|thumb|right|The Sun Spotters]]
 
[[File:TheSunSpotters.jpg|thumb|The Sun Spotters]]
 
* 10 functioning solar panels donated to CCAT
* 10 functioning solar panels donated to CCAT
* A kiosk in the center of CCAT as a space to set up our system
* A kiosk in the center of CCAT as a space to set up our system
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* Materials for making a guest book
* Materials for making a guest book
* Some materials for charge controller housing
* Some materials for charge controller housing


'''What we need:'''
'''What we need:'''
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* 8 gauge wire from battery to charge controller
* 8 gauge wire from battery to charge controller
* Fuse block, 10 - 15 Amps near battery
* Fuse block, 10 - 15 Amps near battery


<gallery>
<gallery>
Image:SunSpottersPanel.jpg|Sun Spotters with a panel
File:SunSpottersPanel.jpg|Sun Spotters with a panel
Image:SunSpotters.jpg|Sun Spotters scouting at the Wildlife Care Center
File:SunSpotters.jpg|Sun Spotters scouting at the Wildlife Care Center
Image:SolarPathfinderbyBLC.jpg|Testing sun exposure near the Bicycle Learning Center
File:SolarPathfinderbyBLC.jpg|Testing sun exposure near the Bicycle Learning Center
Image:KevinSolarChargeStation.jpg|Kevin checking out the panels on the CCAT kiosk
File:KevinSolarChargeStation.jpg|Kevin checking out the panels on the CCAT kiosk
Image:KevinJohnCableCutting.jpg|Cutting the cables to the appropriate size for installation
File:KevinJohnCableCutting.jpg|Cutting the cables to the appropriate size for installation
Image:PVCables.jpg|PV Cable challenges
File:PVCables.jpg|PV Cable challenges
Image:PVCablesStripping.jpg|Stripping the cables for installation
File:PVCablesStripping.jpg|Stripping the cables for installation
Image:SpottersWiringPanel.jpg|Attempting to attach the wiring to the panels
File:SpottersWiringPanel.jpg|Attempting to attach the wiring to the panels
</gallery>
</gallery>


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By the end of the project we want to have accomplished the '''following goals:'''
By the end of the project we want to have accomplished the '''following goals:'''


# Have a functioning solar charging station at [CCAT][http://www.appropedia.org/Campus_Center_for_Appropriate_Technology]
# Have a functioning solar charging station at [CCAT][https://www.appropedia.org/Campus_Center_for_Appropriate_Technology]
# Provide an effective demonstration of off-grid solar
# Provide an effective demonstration of off-grid solar
# Complete a step by step guide to construction here on Appropedia for those who want to build it themselves
# Complete a step by step guide to construction here on Appropedia for those who want to build it themselves
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The project location will be the roof of the CCAT demonstration wall kiosk. We measured solar insolation at this location with a Solar Pathfinder and assessed other sites at CCAT as well. We chose the kiosk for having the most solar insolation on an already constructed, available rooftop, and because it is in a centralized location at CCAT.
The project location will be the roof of the CCAT demonstration wall kiosk. We measured solar insolation at this location with a Solar Pathfinder and assessed other sites at CCAT as well. We chose the kiosk for having the most solar insolation on an already constructed, available rooftop, and because it is in a centralized location at CCAT.


Full sun hours at location: 2.05 hrs/day
* Full sun hours at location: 2.05 hrs/day
Panel power: 100 Watts
* Panel power: 100 Watts
Balance of system efficiency assumed at: 0.8
* Balance of system efficiency assumed at: 0.8
Number of panels: 2
* Number of panels: 2
 
Edaily = full sun hours * panel power * efficiency
Edaily = 2.05 hrs/day * 100 Watts * 0.8
= 164 Wh/day / 1000
= .164 kWh/day * 2 panels
'''= .328 kWh/day'''
 
.328 kWh/day * 365 days/year = 119.72 kWh/year


Edaily = full sun hours * panel power * efficiency
Edaily = 2.05 hrs/day * 100 Watts * 0.8
equals 164 Wh/day / 1000
equals.164 kWh/day * 2 panels
'''.328 kWh/day'''
'''.328 kWh/day * 365 days/year = 119.72 kWh/year'''


<gallery>
<gallery>
Image:PV Voltage Test.jpg|Testing the IV Curve of the PV Panels
File:PV Voltage Test.jpg|Testing the IV Curve of the PV Panels
Image:RESUTestingIVCurve.jpg|Testing IV Curves with the RESU
File:RESUTestingIVCurve.jpg|Testing IV Curves with the RESU
Image:JohnRoof.jpg|Sun exposure test at the Wildlife Care Center (same test done on Kiosk)
File:JohnRoof.jpg|Sun exposure test at the Wildlife Care Center (same test done on Kiosk)
</gallery>
</gallery>


== Construction ==
== Construction ==


The panels will be positioned vertically and staggered on the kiosk rooftop, facing south, at a 30 degree angle for maximum sun exposure.  
The panels will be positioned vertically and staggered on the kiosk rooftop, facing south, at a 30 degree angle for maximum sun exposure.


'''Stabilizing the Kiosk Roof, Building the Panel Racks, Mounting the Panels, and Installing the Fuse'''
'''Stabilizing the Kiosk Roof, Building the Panel Racks, Mounting the Panels, and Installing the Fuse'''
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<gallery>
<gallery>
Image:KioskPreConstruction.jpg|Kiosk Pre Construction
File:KioskPreConstruction.jpg|Kiosk Pre Construction
Image:KioskUnderside.jpg|Underside view of the Kiosk prior to reinforcements
File:KioskUnderside.jpg|Underside view of the Kiosk prior to reinforcements
Image:KioskReinforcements2.jpg|Reinforcements being made to the underside
File:KioskReinforcements2.jpg|Reinforcements being made to the underside
Image:KioskReinforcements.jpg|Reinforcements to the Kiosk
File:KioskReinforcements.jpg|Reinforcements to the Kiosk
</gallery>
</gallery>


First, we noticed the kiosk roof has a wobble to it due the the rooftop having a centralized beam and no side support. In an attempt to stabilize the roof, we added additional screws from the main support beam to the support beams from the main wall.
First, we noticed the kiosk roof has a wobble to it due the the rooftop having a centralized beam and no side support. In an attempt to stabilize the roof, we added additional screws from the main support beam to the support beams from the main wall.


'''Building the Panel Racks:'''  
'''Building the Panel Racks:'''
 
<gallery>
<gallery>
Image:KevinSolarChargeStation.jpg|Testing out PV Placement!
File:KevinSolarChargeStation.jpg|Testing out PV Placement!
Image:KioskPlacementTest.jpg|Testing PV Placement from another angle!
File:KioskPlacementTest.jpg|Testing PV Placement from another angle!
Image:DesignSketch.jpg|Design Sketch Up
File:DesignSketch.jpg|Design Sketch Up
</gallery>
</gallery>


Second, we began constructing our own panel racks. We chose building our own over buying racks to attempt to keep within budget and recycle materials at CCAT. We built our racks out of scrap metal found at CCAT. The panels are attached to the rack with 90 degree brackets and the tools used were available at CCAT. Our priorities for the racking were that they be:
Second, we began constructing our own panel racks. We chose building our own over buying racks to attempt to keep within budget and recycle materials at CCAT. We built our racks out of scrap metal found at CCAT. The panels are attached to the rack with 90 degree brackets and the tools used were available at CCAT. Our priorities for the racking were that they be:


# Stable, attached firmly to the panels
# Stable, attached firmly to the panels
# Supporting the panels at desirable angles
# Supporting the panels at desirable angles
# Reusing materials at CCAT
# Reusing materials at CCAT


'''Rack/Panel #1:'''
'''Rack/Panel #1:'''


We addressed rack stability by experimenting with different heights of the first rack while still maintaining a close to 30 degree angle. The back legs of the panel ended up being around 2.5 feet long. We preferred the back legs being shorter versus longer to prevent the panel from picking up wind during storm events. We also included a crossbeam between the back two legs to prevent the panel from swaying. The front of the panel will rest upon two short metal supports that will attach to the roof through angled brackets. The panel front will be as low to the roof as possible to prevent swaying in the wind.  
We addressed rack stability by experimenting with different heights of the first rack while still maintaining a close to 30 degree angle. The back legs of the panel ended up being around 2.5 feet long. We preferred the back legs being shorter versus longer to prevent the panel from picking up wind during storm events. We also included a crossbeam between the back two legs to prevent the panel from swaying. The front of the panel will rest upon two short metal supports that will attach to the roof through angled brackets. The panel front will be as low to the roof as possible to prevent swaying in the wind.


To find the appropriate lengths of the racking to maintain a 30 degree angle we used simple geometry:
To find the appropriate lengths of the racking to maintain a 30 degree angle we used simple geometry:
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We decided to have the second angle lay almost flat on the rooftop instead of having a 30 degree angle. This decision was made to prevent shading of the first panel on the second and also to more effectively catch summer sun. We figured since the panels will not be moved, we wanted our system to be built with one panel focused on catching winter sun and one that can catch the higher in the sky, summer sun.
We decided to have the second angle lay almost flat on the rooftop instead of having a 30 degree angle. This decision was made to prevent shading of the first panel on the second and also to more effectively catch summer sun. We figured since the panels will not be moved, we wanted our system to be built with one panel focused on catching winter sun and one that can catch the higher in the sky, summer sun.


'''Mounting the Panels:'''
'''Mounting the Panels:'''


<gallery>
<gallery>
Image:AnnettebyMonique1.jpg|Measuring Panel Placement
File:AnnettebyMonique1.jpg|Measuring Panel Placement
Image:KevinPanelScrewing.jpg|Mounting a panel in the front and back
File:KevinPanelScrewing.jpg|Mounting a panel in the front and back
Image:JohnAnnikaScrewing.jpg|Screwing the panels in place
File:JohnAnnikaScrewing.jpg|Screwing the panels in place
Image:JohnDrillingPanels.jpg|Screwing in another panel
File:JohnDrillingPanels.jpg|Screwing in another panel
Image:AnnikaSolarKiosk.jpg|Panel mounting is almost complete
File:AnnikaSolarKiosk.jpg|Panel mounting is almost complete
Image:FinalScrews.jpg|Mounting Teamwork
File:FinalScrews.jpg|Mounting Teamwork
Image:SelfieAnnetteRachaelAnnika.jpg|Being proud of our installation
File:SelfieAnnetteRachaelAnnika.jpg|Being proud of our installation
</gallery>
</gallery>


'''Building and Mounting the Charge Controller Box and Battery installation:'''
'''Building and Mounting the Charge Controller Box and Battery installation:'''
<gallery>
<gallery>
Image:AnnetteHandSaw.jpg|Cutting the Charge Controller Box mount
File:AnnetteHandSaw.jpg|Cutting the Charge Controller Box mount
Image:Tupperware.jpg|The tupperware housing for the charge controller box
File:Tupperware.jpg|The tupperware housing for the charge controller box
Image:AnnikaJohnAdjustingWires.jpg|Attaching the wires from the charge controller to the battery and the panels!
File:AnnikaJohnAdjustingWires.jpg|Attaching the wires from the charge controller to the battery and the panels!
Image:ChargeControllerBox.jpg|Completed Charge Controller Box! Blue light means go!
File:ChargeControllerBox.jpg|Completed Charge Controller Box! Blue light means go!
Image:JohnAnnikaBuryingBattery.jpg|Burying the battery to deter theft
File:JohnAnnikaBuryingBattery.jpg|Burying the battery to deter theft
</gallery>
</gallery>


'''Installing the Fuse'''
'''Installing the Fuse'''


Since our system has a current of 8.33 Amps, we chose a 10 Amp fuse for safety. We were advised to choose a fuse between 10 - 15 Amps, but we chose the lowest number as an extra precaution. The point of a fuse is to "pop" should there be a surge of current in the circuit. The fuse popping prevents the current surge from damaging something else in the system and disconnects the circuit, turning the system off.  
Since our system has a current of 8.33 Amps, we chose a 10 Amp fuse for safety. We were advised to choose a fuse between 10 - 15 Amps, but we chose the lowest number as an extra precaution. The point of a fuse is to "pop" should there be a surge of current in the circuit. The fuse popping prevents the current surge from damaging something else in the system and disconnects the circuit, turning the system off.


We put our fuse on the positive battery line. The battery is the most important place to have a fuse, due to the amount of energy batteries have stored up. If the battery were to explode, it could cause significant damage or even start a fire. Furthermore, since batteries are typically expensive, you don't want any damage to come to it. For these reasons you should always have a fuse by the battery.  
We put our fuse on the positive battery line. The battery is the most important place to have a fuse, due to the amount of energy batteries have stored up. If the battery were to explode, it could cause significant damage or even start a fire. Furthermore, since batteries are typically expensive, you don't want any damage to come to it. For these reasons you should always have a fuse by the battery.


We bought an in-line fuse holder at Ace and the corresponding 10 Amp fuse that it will hold. We have back up fuses stored in the CCAT Greenshed, should the fuse need to be replaced. It is also recommended to have a fuse on one of the panel lines as well, but it is more necessary for larger systems that are capable of causing more damage.
We bought an in-line fuse holder at Ace and the corresponding 10 Amp fuse that it will hold. We have back up fuses stored in the CCAT Greenshed, should the fuse need to be replaced. It is also recommended to have a fuse on one of the panel lines as well, but it is more necessary for larger systems that are capable of causing more damage.
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We had a $400 budget from CCAT for this project. For a chart of supplies, their prices, and where they were from, reference our final document linked at the bottom of this page.
We had a $400 budget from CCAT for this project. For a chart of supplies, their prices, and where they were from, reference our final document linked at the bottom of this page.


'''Buyback:'''  
'''Buyback:'''


The system will save the campus around $20 each year in electricity costs and will therefore buy itself back in about 21 years. ($400/$19.12/year = 20.88 years).
The system will save the campus around $20 each year in electricity costs and will therefore buy itself back in about 21 years. ($400/$19.12/year = 20.88 years).
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http://www.phocos.com/sites/default/files/document/181802613%20CML%20final%20manual.pdf
http://www.phocos.com/sites/default/files/document/181802613%20CML%20final%20manual.pdf


If you scroll through, there is a manual in English. The manual offers some handy troubleshooting knowledge and explains which each light/series of lights on the charge controller mean.  
If you scroll through, there is a manual in English. The manual offers some handy troubleshooting knowledge and explains which each light/series of lights on the charge controller mean.


=== Possible Issue #1 ===
=== Possible Issue #1 ===


The charge controller has a red light on it in the bottom center. This means that the battery has been disconnected, because it has run low. This could mean that the battery simply needs time to recharge, or somewhere the wiring has become disconnected. If the red light is on while another light is still on, or the red light is flashing, reference the user manual.  
The charge controller has a red light on it in the bottom center. This means that the battery has been disconnected, because it has run low. This could mean that the battery simply needs time to recharge, or somewhere the wiring has become disconnected. If the red light is on while another light is still on, or the red light is flashing, reference the user manual.


If investigating the cause of a problem always disconnect and reconnect wires in the correct order and with caution.
If investigating the cause of a problem always disconnect and reconnect wires in the correct order and with caution.


'''DISCONNECTING:'''  
'''DISCONNECTING:'''


1. Disconnect load (USB)
# Disconnect load (USB)
2. Disconnect panels
# Disconnect panels
3. Disconnect battery
# Disconnect battery


NEVER cross wires or touch a live wire. Use extreme caution. Always connect positive to positive and negative to negative. The wrong polarity will cause the charging station to stop working or the charge controller may make an error noise.
NEVER cross wires or touch a live wire. Use extreme caution. Always connect positive to positive and negative to negative. The wrong polarity will cause the charging station to stop working or the charge controller may make an error noise.
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'''RECONNECTING'''
'''RECONNECTING'''


1. Connect battery
# Connect battery
2. Connect panels
# Connect panels
3. Connect load
# Connect load


NEVER cross wires or touch a live wire. Use extreme caution. Maintain polarity.
NEVER cross wires or touch a live wire. Use extreme caution. Maintain polarity.


=== Possible Issue #2 ===
''' Possible Issue #2 '''


There is NOT a green LED light on above the battery symbol on the charge controller during the day. This light should be on during the day, it indicates that the panels are generating voltage. If this light is not on, there could be a loss of connectivity to the panels or the panels are being shaded.
There is NOT a green LED light on above the battery symbol on the charge controller during the day. This light should be on during the day, it indicates that the panels are generating voltage. If this light is not on, there could be a loss of connectivity to the panels or the panels are being shaded.
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We foresee that chargers being stolen could be a continuous issue. To save CCAT money and to save resources, we have decided to try and obtain used chargers for the station. After getting in touch with the student Help Desk, I (Annika) found out that they normally have chargers that were lost and students never came back for. After two weeks of the chargers sitting in the lost and found, they are recycled at the nearby electronic waste station. Getting these used chargers from the Help Desk or other locations on campus would prevent them from entering the waste stream just yet and get more use out of them in their lifetime. The Sun Spotters encourage collaboration with other organizations on campus to ensure that the charging station will always have chargers and that we won't have to continuously buy new ones.
We foresee that chargers being stolen could be a continuous issue. To save CCAT money and to save resources, we have decided to try and obtain used chargers for the station. After getting in touch with the student Help Desk, I (Annika) found out that they normally have chargers that were lost and students never came back for. After two weeks of the chargers sitting in the lost and found, they are recycled at the nearby electronic waste station. Getting these used chargers from the Help Desk or other locations on campus would prevent them from entering the waste stream just yet and get more use out of them in their lifetime. The Sun Spotters encourage collaboration with other organizations on campus to ensure that the charging station will always have chargers and that we won't have to continuously buy new ones.


== Cisco Speaker ==
== Cisco Innovator (Speaker) ==


CCAT will be receiving a mini speaker donated by Cisco for the Solar Charging Station. The speaker can be connected to via Bluetooth and uses a USB charger. Therefore, we can charge the speaker from our station and use the charging smart phones to play music through it. This will be an excellent resource for CCAT volunteer days so that we can play music off of renewable energy.  
CCAT will be receiving a mini speaker donated by Cisco for the Solar Charging Station. The speaker can be connected to via Bluetooth and uses a USB charger. Therefore, we can charge the speaker from our station and use the charging smart phones to play music through it. This will be an excellent resource for CCAT volunteer days so that we can play music off of renewable energy.


The speaker should be kept INSIDE in a safe location when not in use. Preferably somewhere upstairs where it can be locked up at night, but still accessible for Volunteer Fridays or other work days.
The speaker should be kept INSIDE in a safe location when not in use. Preferably somewhere upstairs where it can be locked up at night, but still accessible for Volunteer Fridays or other work days.
<gallery>
File:CiscoInnovator.jpg|The mini speaker with USB charger attached.
File:CiscoInnovator2.jpg|The mini speaker and protective case.
</gallery>


== Documents ==
== Documents ==
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Here is the final document for our project:
Here is the final document for our project:


[[File:Final Document.pdf]]
[[File:Final Document.pdf|600px]]


Here are the hours spent on the project for each team member:
Here are the hours spent on the project for each team member:


[[File:Annika's_Hours.pdf]]
[[File:Annika's Hours.pdf|600px]]
[[File:Annette's_Hours.pdf]]
 
[[File:Annette's Hours.pdf|600px]]


Here is the solar math breakdown for the project:
Here is the solar math breakdown for the project:


[[File:Energy Calculations.pdf]]
[[File:Energy Calculations.pdf|600px]]


[[File:Energy_Cost Buyback.pdf]]
[[File:Energy Cost Buyback.pdf|600px]]


[[File:Carbon Intensity.pdf]]
[[File:Carbon Intensity.pdf|600px]]


== Contact ==
== Contact ==


Annika can be contacted about this project at akr57@humboldt.edu
Annika Ragsdale can be contacted about this project at akr57@humboldt.edu
 
== References ==


We would like to acknowledge and express our gratitude to members of our community who served as references for us:
== Related projects ==


Campus Center for Appropriate Technology, Humboldt State University, Arcata
{{Gallery
| instance-of = Photovoltaic system
}}


Lonny Grafman, Engineering Professor, Humboldt State University, Arcata
== References ==
 
Dr. Richard Hansis, Humboldt State University, Arcata
 
Monte Merrick at the Humboldt Wildlife Care Center, Bayside 
 
Dan Moyer at Appropriate Solar, Sun Frost Refrigeration, Arcata


Bryan Norkunas at PV Cables, Redway
We would like to acknowledge and express our gratitude to members of our community who served as references for us:


Kristin Radesky at Schatz Energy Resource Center, Humboldt State University, Arcata  
* Campus Center for Appropriate Technology, Cal Poly Humboldt, Arcata
* Lonny Grafman, Engineering Professor, Cal Poly Humboldt, Arcata
* Dr. Richard Hansis, Cal Poly Humboldt, Arcata
* Monte Merrick at the Humboldt Wildlife Care Center, Bayside
* Dan Moyer at Appropriate Solar, Sun Frost Refrigeration, Arcata
* Bryan Norkunas at PV Cables, Redway
* Kristin Radesky at Schatz Energy Resource Center, Cal Poly Humboldt, Arcata
* Renewable Energy Student Union (RESU), Cal Poly Humboldt, Arcata


Renewable Energy Student Union (RESU), Humboldt State University, Arcata
<references />


{{Page data
| keywords = Solar, renewable, energy, Cal Poly Humboldt, demonstration, photovoltaic, solar array, solar panels, charging station, appropriate technology, design, battery, USB, current, voltage, cellphone, laptop, tablet, Campus Center for Appropriate Technology, off-grid, stand alone, CCAT, Wood, Metal, Charge Controller, Battery
| sdg = SDG07 Affordable and clean energy, SDG04 Quality education, SDG09 Industry innovation and infrastructure, SDG11 Sustainable cities and communities, SDG12 Responsible consumption and production, SDG13 Climate action
| published = 2014
| organizations = Category:Campus Center for Appropriate Technology (CCAT), Cal Poly Humboldt
| license = CC-BY-SA-3.0
| language = en
}}


<!-- This code is for placing the citation you included above.  If you did not use the <ref> code, please delete this. -->
[[Category:CCAT|S]]
<references/>
[[Category:Solar]]
[[Category:Energy]]
[[Category:Cal Poly Humboldt]]
[[Category:Appropriate technology]]
[[Category:Design]]
[[Category:Wood]]

Latest revision as of 18:34, 29 January 2024

FA compass icon.svgAngle down icon.svgSolar menu
Main topics
Technologies
ChargingStation3.jpg
FA info icon.svg Angle down icon.svg Device data
Hardware license CERN-OHL-S
Certifications Start OSHWA certification
FA info icon.svg Angle down icon.svg Project data
Authors Annika Ragsdale
Annette Penny
Status Deployed
Completed 2014
Made Yes
Replicated No
Cost USD 268.5
Instance of Photovoltaic system
OKH Manifest Download

The Campus Center of Appropriate Technology is a demonstration house located on the Cal Poly Humboldt campus, Arcata, California that is a resource for students and faculty. CCAT has many different technologies on display such as: solar panels, rainwater catchment, organic gardens, a greywater marsh, and an experimental composting toilet, among other things. These projects are on display as educational tools to the community and information is provided through CCAT/Appropedia on how to recreate these technologies on your own. The Solar Charging Station at CCAT will align with the mission of CCAT to provide education and resources to the community, by clearly expressing how off-grid solar works, while being functional for cell phone/laptop charging.

Understanding the market[edit | edit source]

What we have:

The Sun Spotters
  • 10 functioning solar panels donated to CCAT
  • A kiosk in the center of CCAT as a space to set up our system
  • Scrap metal and wood
  • High quality 2 x 4s
  • CCAT tools/hardware
  • Materials for making a guest book
  • Some materials for charge controller housing

What we need:

  • A sealed battery
  • Charge controller
  • Waytek USB plug for load
  • USB split plug for multiple chargers
  • Copper wire #8 bare, 20 feet
  • Ground rod, 8 feet
  • Acorn nut
  • Panel wire, 8 feet
  • MC 4 branch 10 gauge PV wire
  • MC 4 wire 60 inches cut in half
  • Conduit
  • Battery box
  • Lock for battery box
  • 8 gauge wire from battery to charge controller
  • Fuse block, 10 - 15 Amps near battery
  • Sun Spotters with a panel

    Sun Spotters with a panel

  • Sun Spotters scouting at the Wildlife Care Center

    Sun Spotters scouting at the Wildlife Care Center

  • Testing sun exposure near the Bicycle Learning Center

    Testing sun exposure near the Bicycle Learning Center

  • Kevin checking out the panels on the CCAT kiosk

    Kevin checking out the panels on the CCAT kiosk

  • Cutting the cables to the appropriate size for installation

    Cutting the cables to the appropriate size for installation

  • PV Cable challenges

    PV Cable challenges

  • Stripping the cables for installation

    Stripping the cables for installation

  • Attempting to attach the wiring to the panels

    Attempting to attach the wiring to the panels

Project goals[edit | edit source]

By the end of the project we want to have accomplished the following goals:

  1. Have a functioning solar charging station at [CCAT][1]
  2. Provide an effective demonstration of off-grid solar
  3. Complete a step by step guide to construction here on Appropedia for those who want to build it themselves
  4. Complete a project report with a cost, buyback time, and energy return on investment analysis
  5. Create a prototype and precedent for future such stations on the HSU campus

Design[edit | edit source]

Energy calculations:

The project location will be the roof of the CCAT demonstration wall kiosk. We measured solar insolation at this location with a Solar Pathfinder and assessed other sites at CCAT as well. We chose the kiosk for having the most solar insolation on an already constructed, available rooftop, and because it is in a centralized location at CCAT.

  • Full sun hours at location: 2.05 hrs/day
  • Panel power: 100 Watts
  • Balance of system efficiency assumed at: 0.8
  • Number of panels: 2
Edaily = full sun hours * panel power * efficiency
Edaily = 2.05 hrs/day * 100 Watts * 0.8
equals 164 Wh/day / 1000
equals.164 kWh/day * 2 panels
.328 kWh/day
.328 kWh/day * 365 days/year = 119.72 kWh/year
  • Testing the IV Curve of the PV Panels

    Testing the IV Curve of the PV Panels

  • Testing IV Curves with the RESU

    Testing IV Curves with the RESU

  • Sun exposure test at the Wildlife Care Center (same test done on Kiosk)

    Sun exposure test at the Wildlife Care Center (same test done on Kiosk)

Construction[edit | edit source]

The panels will be positioned vertically and staggered on the kiosk rooftop, facing south, at a 30 degree angle for maximum sun exposure.

Stabilizing the Kiosk Roof, Building the Panel Racks, Mounting the Panels, and Installing the Fuse

Stabilizing the Kiosk Roof:

  • Kiosk Pre Construction

    Kiosk Pre Construction

  • Underside view of the Kiosk prior to reinforcements

    Underside view of the Kiosk prior to reinforcements

  • Reinforcements being made to the underside

    Reinforcements being made to the underside

  • Reinforcements to the Kiosk

    Reinforcements to the Kiosk

First, we noticed the kiosk roof has a wobble to it due the the rooftop having a centralized beam and no side support. In an attempt to stabilize the roof, we added additional screws from the main support beam to the support beams from the main wall.

Building the Panel Racks:

  • Testing out PV Placement!

    Testing out PV Placement!

  • Testing PV Placement from another angle!

    Testing PV Placement from another angle!

  • Design Sketch Up

    Design Sketch Up

Second, we began constructing our own panel racks. We chose building our own over buying racks to attempt to keep within budget and recycle materials at CCAT. We built our racks out of scrap metal found at CCAT. The panels are attached to the rack with 90 degree brackets and the tools used were available at CCAT. Our priorities for the racking were that they be:

  1. Stable, attached firmly to the panels
  2. Supporting the panels at desirable angles
  3. Reusing materials at CCAT

Rack/Panel #1:

We addressed rack stability by experimenting with different heights of the first rack while still maintaining a close to 30 degree angle. The back legs of the panel ended up being around 2.5 feet long. We preferred the back legs being shorter versus longer to prevent the panel from picking up wind during storm events. We also included a crossbeam between the back two legs to prevent the panel from swaying. The front of the panel will rest upon two short metal supports that will attach to the roof through angled brackets. The panel front will be as low to the roof as possible to prevent swaying in the wind.

To find the appropriate lengths of the racking to maintain a 30 degree angle we used simple geometry:

Rack/Panel #2:

We decided to have the second angle lay almost flat on the rooftop instead of having a 30 degree angle. This decision was made to prevent shading of the first panel on the second and also to more effectively catch summer sun. We figured since the panels will not be moved, we wanted our system to be built with one panel focused on catching winter sun and one that can catch the higher in the sky, summer sun.

Mounting the Panels:

  • Measuring Panel Placement

    Measuring Panel Placement

  • Mounting a panel in the front and back

    Mounting a panel in the front and back

  • Screwing the panels in place

    Screwing the panels in place

  • Screwing in another panel

    Screwing in another panel

  • Panel mounting is almost complete

    Panel mounting is almost complete

  • Mounting Teamwork

    Mounting Teamwork

  • Being proud of our installation

    Being proud of our installation

Building and Mounting the Charge Controller Box and Battery installation:

  • Cutting the Charge Controller Box mount

    Cutting the Charge Controller Box mount

  • The tupperware housing for the charge controller box

    The tupperware housing for the charge controller box

  • Attaching the wires from the charge controller to the battery and the panels!

    Attaching the wires from the charge controller to the battery and the panels!

  • Completed Charge Controller Box! Blue light means go!

    Completed Charge Controller Box! Blue light means go!

  • Burying the battery to deter theft

    Burying the battery to deter theft

Installing the Fuse

Since our system has a current of 8.33 Amps, we chose a 10 Amp fuse for safety. We were advised to choose a fuse between 10 - 15 Amps, but we chose the lowest number as an extra precaution. The point of a fuse is to "pop" should there be a surge of current in the circuit. The fuse popping prevents the current surge from damaging something else in the system and disconnects the circuit, turning the system off.

We put our fuse on the positive battery line. The battery is the most important place to have a fuse, due to the amount of energy batteries have stored up. If the battery were to explode, it could cause significant damage or even start a fire. Furthermore, since batteries are typically expensive, you don't want any damage to come to it. For these reasons you should always have a fuse by the battery.

We bought an in-line fuse holder at Ace and the corresponding 10 Amp fuse that it will hold. We have back up fuses stored in the CCAT Greenshed, should the fuse need to be replaced. It is also recommended to have a fuse on one of the panel lines as well, but it is more necessary for larger systems that are capable of causing more damage.

Costs[edit | edit source]

We had a $400 budget from CCAT for this project. For a chart of supplies, their prices, and where they were from, reference our final document linked at the bottom of this page.

Buyback:

The system will save the campus around $20 each year in electricity costs and will therefore buy itself back in about 21 years. ($400/$19.12/year = 20.88 years).

Troubleshooting for Future CCATers[edit | edit source]

Here is a link to the user's manual for our Phocos charge controller:

http://www.phocos.com/sites/default/files/document/181802613%20CML%20final%20manual.pdf

If you scroll through, there is a manual in English. The manual offers some handy troubleshooting knowledge and explains which each light/series of lights on the charge controller mean.

Possible Issue #1[edit | edit source]

The charge controller has a red light on it in the bottom center. This means that the battery has been disconnected, because it has run low. This could mean that the battery simply needs time to recharge, or somewhere the wiring has become disconnected. If the red light is on while another light is still on, or the red light is flashing, reference the user manual.

If investigating the cause of a problem always disconnect and reconnect wires in the correct order and with caution.

DISCONNECTING:

  1. Disconnect load (USB)
  2. Disconnect panels
  3. Disconnect battery

NEVER cross wires or touch a live wire. Use extreme caution. Always connect positive to positive and negative to negative. The wrong polarity will cause the charging station to stop working or the charge controller may make an error noise.

RECONNECTING

  1. Connect battery
  2. Connect panels
  3. Connect load

NEVER cross wires or touch a live wire. Use extreme caution. Maintain polarity.

Possible Issue #2

There is NOT a green LED light on above the battery symbol on the charge controller during the day. This light should be on during the day, it indicates that the panels are generating voltage. If this light is not on, there could be a loss of connectivity to the panels or the panels are being shaded.

If taking apart the system, refer to the instructions above and the charge controller manual.

Chargers[edit | edit source]

A mini USB to USB charger and ipod to USB charger were purchased at the HSU campus marketplace for the Solar Charging Station. They are stored in a Tupperware for waterproofing at the station and are readily accessible for all students to use. After about 3 months of use, the mini USB charger disappeared from the station.

We foresee that chargers being stolen could be a continuous issue. To save CCAT money and to save resources, we have decided to try and obtain used chargers for the station. After getting in touch with the student Help Desk, I (Annika) found out that they normally have chargers that were lost and students never came back for. After two weeks of the chargers sitting in the lost and found, they are recycled at the nearby electronic waste station. Getting these used chargers from the Help Desk or other locations on campus would prevent them from entering the waste stream just yet and get more use out of them in their lifetime. The Sun Spotters encourage collaboration with other organizations on campus to ensure that the charging station will always have chargers and that we won't have to continuously buy new ones.

Cisco Innovator (Speaker)[edit | edit source]

CCAT will be receiving a mini speaker donated by Cisco for the Solar Charging Station. The speaker can be connected to via Bluetooth and uses a USB charger. Therefore, we can charge the speaker from our station and use the charging smart phones to play music through it. This will be an excellent resource for CCAT volunteer days so that we can play music off of renewable energy.

The speaker should be kept INSIDE in a safe location when not in use. Preferably somewhere upstairs where it can be locked up at night, but still accessible for Volunteer Fridays or other work days.

  • The mini speaker with USB charger attached.

    The mini speaker with USB charger attached.

  • The mini speaker and protective case.

    The mini speaker and protective case.

Documents[edit | edit source]

Here is the final document for our project:

Final Document.pdf

Here are the hours spent on the project for each team member:

Annika's Hours.pdf

Annette's Hours.pdf

Here is the solar math breakdown for the project:

Energy Calculations.pdf

Energy Cost Buyback.pdf

Carbon Intensity.pdf

Contact[edit | edit source]

Annika Ragsdale can be contacted about this project at akr57@humboldt.edu

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References[edit | edit source]

We would like to acknowledge and express our gratitude to members of our community who served as references for us:

  • Campus Center for Appropriate Technology, Cal Poly Humboldt, Arcata
  • Lonny Grafman, Engineering Professor, Cal Poly Humboldt, Arcata
  • Dr. Richard Hansis, Cal Poly Humboldt, Arcata
  • Monte Merrick at the Humboldt Wildlife Care Center, Bayside
  • Dan Moyer at Appropriate Solar, Sun Frost Refrigeration, Arcata
  • Bryan Norkunas at PV Cables, Redway
  • Kristin Radesky at Schatz Energy Resource Center, Cal Poly Humboldt, Arcata
  • Renewable Energy Student Union (RESU), Cal Poly Humboldt, Arcata


FA info icon.svg Angle down icon.svg Page data
Keywords solar, renewable, energy, cal poly humboldt, demonstration, photovoltaic, solar array, solar panels, charging station, appropriate technology, design, battery, usb, current, voltage, cellphone, laptop, tablet, campus center for appropriate technology, off-grid, stand alone, ccat, wood, metal, charge controller, battery
SDG SDG07 Affordable and clean energy, SDG04 Quality education, SDG09 Industry innovation and infrastructure, SDG11 Sustainable cities and communities, SDG12 Responsible consumption and production, SDG13 Climate action
Authors Annika Ragsdale, Megan Moore, Annette Penny
License CC-BY-SA-3.0
Organizations Category:Campus Center for Appropriate Technology (CCAT), Cal Poly Humboldt
Language English (en)
Related 0 subpages, 28 pages link here
Impact 2,066 page views
Created November 27, 2014 by Annika Ragsdale
Modified January 29, 2024 by Felipe Schenone
Cite as Annika Ragsdale, Megan Moore, Annette Penny (2014–2024). "CCAT Solar Charging Station". Appropedia. Retrieved April 25, 2024.
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