SAFF User Manual

SAFF Sustainable Aquaponics @ Farmer Frog

Joshua Hurley, Justin Kneip, Richard Yip

Completed for UW Bothell Mechanical Engineering Senior Design Project 2016

with Dr. Pierre D. Mourad – Capstone Advisor

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SAFF - Sustainable Aquaponics at Farmer Frog

2016 Capstone Team:

Justin Kneip - Project Manager

Joshua Hurley - Communications Director / Lead Mechanical Engineer

Richard Yip - Lead Electrical Engineer

Additional Contributors:

Kelsi Martin - Junior Electrical Engineer

Donald Tran - Data Technician

Additional Researchers:

Trevin Jorgenson – Electrical Engineering

Johnny da Silva – Electrical Engineering

Special thanks to:

Joel Unruh and MT Solar

Tim Bailey and BlueFrog Solar

Jason Budgeon, Mike Dalton, Jen Olson, Wendy Wenrick and A&R Solar

John Harley and Brimma Solar

Amy Lucas at Snohomish County Parks

Cameron Whalen at University of Washington Bothell

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Table of Contents

DESIGN STRATEGY ................................................................................................................. 1

USER INSIGHTS & RESEARCH .............................................................................................................. 2

PROBLEM UNDERSTANDING & FRAMING .............................................................................................. 5

VISION EXPLORATION ........................................................................................................................ 7

TECHNOLOGY MAPPING .................................................................................................................. 11

PRODUCT PLANNING ....................................................................................................................... 13

HUMAN INTERFACE DESIGN .............................................................................................................. 14

CONCEPT DEVELOPMENT .................................................................................................... 17

CONCEPT RISK IDENTIFICATION AND MITIGATION ................................................................................. 18

REQUIREMENT DOCUMENTATION ...................................................................................................... 22

SYSTEM DESIGN & BUILD ..................................................................................................... 28

SYSTEM OVERVIEW ......................................................................................................................... 29

BUILD SCHEDULE ............................................................................................................................ 34

BUDGET ........................................................................................................................................ 35

APPENDIX A: COMPONENT SPECIFICATIONS ........................................................................ 37

APPENDIX B: COMPONENT USER MANUALS ........................................................................ 43

APPENDIX C: REQUIRED DOCUMENTATION SUBMISSION ..................................................... 81

APPENDIX D: OTHER DOCUMENTATION............................................................................... 88

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Design Strategy

User Insights & Research 2

Problem Understanding and Framing 5

Vision Exploration 7

Technology Mapping 11

Product Planning 13

Human Interface Design 14

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Figure 1: Idealized Sustainable Energy

Shows an idealized sustainable farm.

User Insights & Research

Consumer Journey Map

Zsofia Pasztor receives an emailed PDF construction

plan for the sustainable energy system at her farm. Our

team schedules solar panels to be delivered to her

farm, and has them installed at a suitable location.

Systems are connected as required by an electrical

contractor. We notify Zsofia of safety concerns and

components prone to damage during the setup,

storage and operations phases. Zsofia does not have

to worry about the function of her equipment while she

is at the farm or away from the farm as it is completely

autonomous. She merely performs periodic cleaning

and maintenance of the solar panels.

Stakeholder Framing

Stakeholders for this project include UWB and Farmer Frog as well as partnered solar

companies contributing supplies and experienced professionals. UWB has an interest in

promoting their campus’ support for sustainability and showing themselves as a leader in the

community. Dr. Pierre D. Mourad and the Community Based Learning (CBL) program of UWB

has facilitated integrating Farmer Frog with the ME capstone projects. Farmer Frog is providing

the majority of funding for this project. The client has multiple plans to improve their farm to

serve as an educational center for the community.

User Insight Report

The client is seeking a demonstration tool to show a potential method of supplying energy to an

aquaponics system pump on a somewhat remote farm. While traditional energy options could

be used such as electrical grid or gasoline generators, these options involve an output of CO2

emissions, and have a high operational cost when there is a lack of electrical grid access. The

client prefers to use technology that leaves less of an environmental impact. Current sustainable

energy technologies like solar power, or wind farms are making advances in megawatt level

generation, but less research is involved in small scale systems. Also, these energy systems

are rarely designed for portability (unlike a gasoline generator), rather they are designed for a

specific site for long term use. The lack of portability available for clean energy systems is an

opportunity for advancement in small scale power systems.

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Figure 2: Farmer Frog Barn

This shows the ~30’ tall barn nearby.

Online Data Gathering

Our research included pumps, available wind resource, available yearly sunlight, structures,

transportation, battery and power conversion set up, and turbines for the aquaponics system.

Research into the the battery and power conversion setup showed that for both a wind or solar

system, batteries will require a charge controller to reject any back flow current as well as to

acknowledge when the battery is fully charged, and an inverter, to convert power from DC to

AC. Our investigation into turbine technology included: flying helium turbines, kite turbines, and

specially designed urban turbines. The two standardized types of turbines currently in use are

Horizontal Axis Wind Turbines (HAWT) and Vertical Axis Wind Turbines (VAWT). Research into

wind resource available at Farmer Frog showed a minimal amount of wind at 50m, and from

local data at near 30’, almost no regular wind speeds recorded. The average hours of sunlight

per year in Seattle are measured as 1.6 hours a day (winter) at lowest levels.

User Scenarios

Our client will be operating on the Farmer

Frog grounds, which is a protected Heritage

Historical Farm site owned by the county.

Possible mounting locations include the roof

of a nearby barn (appx 30’ tall) as well as

ample space on the ground near

farmhouse, and on the farmhouse’s roof.

The power system must be capable of

being disassembled in the event that

Farmer Frog is forced to move to another

location. In keeping with sustainable design,

Zsofia requests designing this system for as

long life as possible (30+ years).

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Figure 3: Zsofia Pasztor

Personas

Zsofia Pasztor: This user is a small-scale farmer which owns a

sustainable aquaponics system. She is a 1st world

organic/sustainable farmer interested in supporting clean

energy and educating others on the subject. This 1st world

farmer has a limited budget, but has access to other support

and resources (UWB). This week she has invited a group of

college students to her farm in order to teach them about

integrating sustainable energy with sustainable farming.

Student Visiting Farm: Jill Jackson is a student from University

of Washington in her junior year of college. She is there to

enhance her learning, as part of a class she is taking at

school. Jill will learn about how an aquaponics system can be

powered by renewable resources and about the challenges of

doing so. She will also learn about the potential problems of

scaling up or down a windmill aquaponics system, difficulties

in implementing solar power systems, and the natural limitations of a small farm. This user will

come away with an understanding of the physical and electrical factors involved with powering

an aquaponics system with renewable resources and basic operational understanding of an

aquaponics system.

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Figure 4: Farm in the Forest. This photo shows the tall trees surrounding the

farm.

Problem Understanding & Framing

Product Assumptions Outline

Farmer frog is in need of a sustainable solution to

power their aquaponics system. The farm has

restrictions on ability to construct on the property

due to its status as preserved farmland owned by

the county. The low wind and tall trees nearby

makes a wind powered system highly unlikely

below 50m, nearby rivers are not powerful enough

to generate enough practical hydropower. There is

moderate to heavy cloud cover during winter,

limiting solar potential. In addition, this system will

also be used as a demonstration tool for educating

observers on the benefits of sustainably powered

aquaponics systems, and may also be used to

acquire additional funding to support an improved

system to power Farmer Frog’s entire power

needs, or to install a system on another farm.

Functional Assumptions Outline

An off grid solution will require a method of operation, activation, deactivation and energy

storage. A grid tied solution will require the same except for energy storage. For energy storage,

we anticipate a need for battery that will need to last up to 3 days without charging to power the

LEDS, and 6 days without charging if powering the pump. For a demonstration piece, the

system will need to be visible and intuitive to allow the audience to see and understand how the

system works on a basic level. Additionally, the system will need to power, at the very least, a

series of LED lights and/or a pump for the aquaponics system. We assume the pump to require

around 30W and know the LEDs require 14W.

Experience Assumptions Outline

This product will require a user manual, professional installation & maintenance, and a

demonstration of operation. It will also need to be easily disassembled should Farmer Frog

decide to not renew its lease with the county. The manual should include setup, deconstruction,

important safety notes, and basic maintenance/replacement procedures for the battery, solar

panel, and water pumps while the demonstration should include the bulk of the safety

information, detailing precise procedures to ensure safety while working with the equipment. For

simplicity and ease-of-use there should be labels on all parts.

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Figure 5: Discovery Hall This photo shows Discovery Hall at UW

Bothell

Figure 6: Goat Goats on the farm are potential hazards to

the solar panels.

Business Needs Documentation

The next iteration of this project will begin their

work from the results of this project. We assume

that the budget for next year may be no less than

half of our current budget (~$1500). We also

assume that a selected battery will not require

replacement within a year, but poor structural

components may need refurbishing. Our initial

prototype will demonstrate the ability/feasibility of

providing power to the farm with a pair of solar

panels. It will also provide insight into scalability

and into potential improvements for future

iterations of this system. What improvements

made may be specific to a program, for example,

if the team taking over is in the Electrical Engineering program they might make improvements

to the electrical components of the system perhaps by advancing monitoring systems.

User Needs Documentation

We are assuming that students in high school and beyond are the main audience of this system,

as well as potential investors and other farmers.

Additionally, the system should be portable and

buildable with limited construction resources and

volunteer construction crew. To this end, we aim

to make individual pieces weigh no more than

80lbs and ensure minimal specialized machinery

is necessary in order to install or deconstruct the

system. We also assume that the system will

require some sort of shielding to prevent

inquisitive persons and farm animals from injury

and electrocution.

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Vision Exploration

Interaction Wireframing

Figure 7: General Wireframe

This highlights the solar panels reliance on grid or battery backup to accommodate the load

requirements at low or no light times.

Visual Illustrations

Figures 8 and 9: Wind Designs.

Figure 8 (left) shows a grid tied battery backup wind design.

Figure 9 (right) shows an off grid battery wind design.

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Figures 10 and 11: Wind Design and Solar Design.

Figure 10 (left) shows a grid tied wind design.

Figure 11 (right) shows a grid tied solar design.

Figures 12 and 13: Solar Designs.

Figure 12 (left) shows a grid tied solar design with a battery backup.

Figure 13 (right) shows an off grid solar design.

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The concepts we are exploring incorporate variations of functional solar and wind powered

systems. They show the basic required equipment to create the systems as well as how they

will be connected to each other. All concepts allow for some sort of power to be provided during

a lack of sustainable energy production.

Figures 14: Wind + Solar Design.

This shows the potential for a grid tied system including both solar and wind power systems

in the design.

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Figure 16: High Level Architecture This shows in general terms components and connections for the proposed system.

Architecture Exploration

Solar panel system hooked up to an on-grid inverter with a battery backup. If we had time to

construct 3D models we would generate a scale model of the farm; this scale model would allow

us to visualize both solar panel placement, as well as wind turbine placement. This model would

also represent the grid access points, and allow for placement experimentation.

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Table 1: Interaction Table This shows in general terms how changes in the first column may affect the items in the first row.

Technology Mapping

System Planning and Thinking & Risk Analysis

The main risk of the design is the wear of the solar panels. From a user perspective, this means

the panels have to be located clear of trees and other debris that might damage them. The

electrical storage box also needs to have a container that is water resistant, easily accessible,

and is simple so that replacing the battery and components are easy for the user. Battery

leakage can cause serious damage to the container as well as the environment. Proper hazard

equipment must be worn when replacing damaged batteries. Wiring to the system also needs to

be intuitive and insulated so as to reduce damage to wires as well as prevent accidental shocks

to the user if they are trying to repair something.

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Feasibility Planning

The first hurdle is to have our proposals approved by our client. She must approve of either a

solar/battery system or a solar/grid system. Once one of our proposals is approved the next

step is having a certified solar professional to approve our design and make sure it will operate

efficiently. The panel installation is the next factor to be addressed. To be able to install the

solar panels we must first find an installer and request a quote from them. We have contacted

several installers but were not able to receive a quote for our power system. This led to Justin

contacting a professor from Shoreline Community College, who also is a electrician, to price out

a cost of installation. He gave us a quote of around $1000 for installing the system. This lead

into the topic of budgeting. As of right now a system that meets all of our client’s needs is not

possible. The proposed solar/grid system is priced at $3410 (including labor) which is out of the

budget range of $3000 that is provided so additional funding is required. This system will be

able to power one LED light bulb. However, this system is scalable to eventually power all of our

client’s needs with more funds.

Competitive Analysis

There are many competitors, Solterra for example does much of the same services that we

provide. They provide designs of solar systems as well as install the systems. Their services

however are more expensive than ours. This is true for all other competitors.

Component Technology Research

Solar panels, charge controllers, inverters and batteries are all well proven technologies. Our

team’s experience using these technologies is very limited and may require an experienced

professional to evaluate selected components prior to commitment.

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Product Planning

Product Roadmap

The first complete system will be a minimal system powering a selection of LEDs, with a plan for

scaling up in the future. The second iteration of this system will be upgraded to power more of

the LEDs for the aquaponics system. The third iteration of this system will power all the LEDs

for the aquaponics system. The fourth iteration of this system will power both the pump and

LEDs, and if grid connected, will add battery backup to the system. For the grid connected

system, iterations 2 and 3 may be combined depending on budget available.

Product Schedule & Budget

Acquiring the solar panels will take the longest amount of time. We must order the panels and

mount as soon possible. Once these main components are ordered then the supporting

products will be ordered. The total costs of a grid tied system (including labor) is estimated to be

$3300. Mounting the solar panels will be the first objective that will be done. Protecting the back

of the panels will be done with a short fence, and any batteries will be stored in battery storage

containers. The next step is connecting the wiring which will need help from an electrician.

Figure 17: Schedule Flow

This shows a generalized flow of scheduling from design to design review to scheduling

construction to ordering equipment to building product.

Work Breakdown

The first objective that had to be scheduled is meeting with our client Zsofia. This discussion will

be about the budget, product use, and site location of the product. After visiting the location, the

next step is to gather information of the constraints that were given to us. This included research

in wind turbines, blade orientation, local wind data, and power requirements. Rough design

brainstorming follows adequate research. The design will then go through calculations to see

the feasibility of the design and will progress through multiple iterations, evaluating many

alternatives. When the calculations are done and we determine the design is possible, we will

evaluate specific components merits and budget requirements. After selecting a set of

components we will present the design to the client and upon confirmation, will await delivery.

Construction of the design will follow in a logical order starting with grounds work and finishing

with electrical connections.

Ergonomics Studies

To improve access for maintenance and analysis electrical components such as the charge

controller and inverter will be raised off the ground to reduce stress from maintenance activities.

Additionally, battery banks would be raised off the ground to reduce lifting heights. Fencing

placed around the panels to protect from hazards will be removable to ease panel maintenance.

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Figure 18: Area Map This map shows designated areas throughout the farm and

planned improvements.

Human Interface Design

User Work Flows

The user will not interact with our system directly very often. Once the system is setup, it will be

operating autonomously. Maintenance checks will be the main interaction between user and the

system. This will require the user to check the solar panels for any cracks or other forms of

damage as well as making sure they are clean for efficient sunlight collection. Next will be the

batteries. The batteries need to be checked for any leakage and if there are any damage to the

storage container. The ground mounting is to be inspected for any cracks and erosion. If any

flaws of the system is to be found contacting a professional solar panel installer is

recommended.

Environment Analysis

Farmer Frog is located in

Western Washington State in an

area that experiences very low

amounts of wind and low

sunlight capable of being

converted into energy. For

physical construction of the

system, regulatory bodies such

as Snohomish County Planning

and Development Services must

be consulted to ensure minimal

environmental impact.

Connection of the system to the

electrical grid, would require

certification and validation from

the Public Utility District (PUD). As connection to the local electrical grid is highly recommended

if available, our proposal involves a staged integration in which net metering can occur as early

as possible.

The target environment for the far future is that of the developing world: particularly poor nations

in Africa, Asia, South America, and elsewhere. Many of these regions have widely varying

availability of renewable energy. For this reason, our product could potentially benefit from

implementing the wind turbine device in other areas of the world where faster wind speeds are

available at much lower altitudes. The possible combination of wind and solar energy collectors,

and their associated scalabilities, allow this product to be implemented in many regions across

the globe--but at varying costs. Systems implemented in areas without local electrical grid

access will require redundancy built into the system in the form of additional panels/turbines

and/or additional batteries, all for additional costs.

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Cultural Factors Mapping

The energy-collecting device lacks any sort of direct human interaction with the user apart from

installation and maintenance; rather the device allows the user to utilize other devices that

require electrical power. For installation, or in the event the device requires maintenance, the

device should be clearly marked as containing electrical components and that risk of electric

shock exists. Furthermore, this warning should also indicate the risk associated with electronic

equipment near water. As the client intends to use the system as an educational tool, this

prototype version of the device should be clearly marked with warning signs instructing children

to not play around the electrical equipment.

Information Architecture and Hierarchy

The extent of inputs required by the user for the device should be largely nonexistent; if the

device functions properly, it should only need to be “turned on” but will likely be in an “always

on” status. Rather, the only input our device receives is in the form of solar radiation energy, its

output is electricity. If there is no sunlight for the system to collect, there will be neither an input

nor output for the photovoltaic panels; instead, the grow lights and/or water pump will draw their

required energy from the electrical grid. During periods of sunlight the generated electricity will

be directed from the direct-current photovoltaic panels to the current inverter unit, allowing the

alternating-current grow lights to operate. The initial system will likely not include batteries and

will use the electrical grid as a backup energy source. Should batteries be required for true “off-

grid power” in the future, the collected energy would instead be directed to the charge

controller/batteries for temporary storage before reaching the inverter unit.

Analog Interface Design

Interfacing electrical components including the charge controller and inverters will be raised off

the ground by 3’ to 4’ to allow technician easier access for connections and maintenance.

Battery bank storage will also be raised off the ground by at least 6” and not more than 4”.

Electrical cabling will be laid in trenches to protect against damage.

Graphic User Interface Design

The selected inverter and/or charge controller will have a standard GUI.

Best Use Practices Report

The points of failure of our solar system will be in the wiring of the product. If the system is not

wired properly there could be a lack of efficiency or failure of the entire system. Other points of

failure include natural phenomena which cannot be planned for. For example a strong gust

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blowing the panels down or the power grid is out and the solar panels cannot provide sufficient

power. If the system is properly used and unreasonable weather conditions are avoided the

system should be operate smoothly. A regular maintenance plan should be followed to ensure

the successful operation of the solar system. This includes cleaning of the panels, inspections of

wiring and other electrical components, as well as an overall all inspection of the mounting.

Usability Requirements Documentation

The original power system was to design a wind powered system for our client, Zsofia. This

system had to be discarded due to research of local wind data. A new system that included

using solar energy was then developed to help the client’s need of electrical power. With the

new system, Zsofia will be able to demonstrate renewable energy and aquaponics systems.

For the ground mount of the solar panels we decided to go with designing our own. This will

allow us to reduce the cost of the overall system as well as give us more funds for other parts of

the project. The ground mounts will consist of 4x4 pressure treated wood posts and galvanized

L brackets. The benefits of having pressure wood is that they are durable in outdoor conditions,

this is true for the galvanized brackets as well. However a disadvantage of using wood as a

mount is that it increases the weight of the mount, making it harder to relocate.

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Concept Development

Concept Risk Identification and Mitigation 18

Requirement Documentation 22

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Figure 19: Circuit Model This shows a basic series of connections for our proposed system.

Concept Risk Identification and Mitigation

EE / Circuit Models

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Figure 20: Panel Mount Model This is a 3D rendering of a proposed ground mount system for our solar panels.

Mechanical Models

Firmware Models

No deviation from manufacturer designed firmware for selected components.

Human Interaction Models

If possible we would model attempting to optimize the system for portability and user access,

however since this system only requires a minimal level of portability and access(must be able

to move elsewhere, minimal maintenance). Then we feel this is a low risk area to avoid concern

with, also this type of model would be time intensive.

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Figure 21: System Integration Map This map shows designated areas throughout the farm and proposed locations for individual units.

System Interface Modeling, Testing, Risk Analysis

Estimation of Costs of Goods

Any system involving a functioning wind turbine has been determined to be infeasible within our

allotted budget for the given geographic location. It has been determined that approximately

$2000 of our budget would need to be spent to obtain a structure capable of reaching 60 feet--

less than half the altitude for which the National Renewable Energy Laboratory has data. Even a

Local Engagement donation of a 40-foot utility pole from Frontier would not offset our costs

enough to make wind energy more attractive for this region. Without reliable wind available, it is

our recommendation that solar energy be pursued for the current application.

Cost analysis for solar-collecting systems is hampered by a similarly high fixed-initial-cost.

Where the wind system required a $2000+ mounting structure, the solar system requires a

sizeable investment (~$1200) in a reliable electrical inverter unit. A cheap electrical AC/DC

inverter could be implemented, but it would not be able to safely support the expansion of the

energy-collecting system. This route would also require an inverter that is capable of connecting

to the active electrical grid. Following is a table outlining our estimated cost of components of

our system.

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Table 2: Estimated Cost of Components This table outlines estimated costs incurred in the construction of our solar-collecting system.

Estimated Cost of Components

Component Cost

Inverter $1200

Solar Panel (each) $190-350

Mounting Structure $800

Electrical Installation* $0

Batteries (each) $100

Battery Storage* $0

Charge Controller $200

Solar/Battery System (1 panel, 1 battery, w/ grid access)

~$2800

Solar/Grid System (1 panel w/ grid access) ~$2500

Installation costs are not to be factored into our estimations due to availability of volunteer labor,

also, as a portion of the house could be appropriated for battery storage, this cost has been

eliminated.

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Requirement Documentation

Design Decisions and Rationale

0.0 Our client desires an environmentally-friendly method of generating electricity in an effort to

reduce carbon footprint and educate visitors. The final product delivered to our client will be a

solar energy collecting system consisting of up to five photovoltaic solar panels mounted to a

support structure. The system will be capable of supplying a variable wattage, dependant on the

time of year which we will report an estimate to the client in terms of yearly wattage produced

and number of LEDs power offset per year. The system will be designed with scalability in mind,

should the client decide to upgrade/expand the system. Although the provided system will likely

not completely meet the client’s requirements in its first iteration, it will allow for electrical grid

backup and net metering of electricity usage from the local utility company; this in turn allows

the client to sell energy back to the utility company during periods of net positive energy

generation (summer months).

1.0 Tier 1 Schematics

1.1 Capturing sun energy rather than wind or hydro was selected for this system to reduce cost

and maximize energy capture while remaining a somewhat portable system. This system may

or may not be grid connected which is represented in the above schematic. If grid connected,

this system may or may not have a battery backup depending on what stage of development the

project is in.

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2.0/2.1 Tier 2 Schematics

The SolarWorld SW325 XL Silver Mono Solar

Panel was chosen for high Wattage per dollar. To

provide enough power for the entire aquaponics

system we need roughly 5 panels.

Watts (W) Amps Volts (DC) Weight (lbs) Size (in) Cost ($)

325 9.48 37 47.6 78.46 × 39.4 × 1.3 300

The UPG UB12500 AGM battery are used to back up the

pump in case the panels do not provide enough power.

The absorbed glass mat (AGM) is a technology that

provides safe reliable power. They do not produces any

fumes, shock and vibration resistance, and is resistant to

freezing temperatures. A charge controller will be needed

to regulate the current to prevent damage of the batteries.

Volts Amp-Hours Cost ($) Type

12 50 103 AGM

The mounting system for the solar panels will be custom made using pressure treated wood and

galvanized brackets. We will be using 4x4x10 pressure treated wood and galvanized L brackets

and plates. The mount itself will be roughly 2 feet tall and 22 feet long. This mount will allow 3

panels to be attached to it. For design illustrations please check appendix. If the system is to be

mounted onto the roof of the barn, the mounting will have to be bought commercially as a kit

and installed by a professional contractor. Ideally the roof mounting will be made of aluminum to

ensure that it will be light enough for the rooftop.

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Schneider C60 12/24V Charge Controller is used to

regulate current from our solar panels. This specific

component was chosen because it will fit in with the 12

Volt DC system. The controller is silent, durable, and

has automatic overload protection.

Battery Bank Voltage (DC) Max Current Output (Amp) Cost ($)

12/24 60 199

The inverter will allow us to convert the DC power

produced from our batteries to AC power which will allow

the pump to be plugged into the power system. The pump

is going to be a AC power pump so it can be backed up by

the grid system as well.

Watts (W) Input Voltage (VDC)

Output Voltage (VAC)

Type Cost ($)

2000 12 120 Pure Sine Wave 1,844

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3.0 Tier 3 Schematics

Simulation of solar panels, charge controller and inverter

Simulation of inverter

Simulation of a solar panel

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3.1

Off Grid

Solar panels will be connected to a charge controller. The charge controller controls electric

back flow to the solar panel. The connection also prevents batteries from overcharging. The

charge controller is then hooked to a battery as to have a backup of energy incase the solar

panels cannot provide enough electricity. Batteries are then hooked to an DC to AC inverter.

The power generated by the solar panels is DC so inorder to run basic household appliances

you need to convert your energy to AC. Thus you have a fully functional off grid system.

On grid

The solar panels will be connected to an on grid inverter. Which will prevent backflow of energy

as well as convert the energy being produced from DC to AC. The inverter is then hooked to a

metering system which measures the amount of energy that your system is producing. This

reduces your electricity bill. The inverter also has the capability to store backup energy by

attaching batteries and a charge controller to the inverter.

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Draft Schedule

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System Design & Build

System Overview 29

Build Schedule 32

Budget 33

Operations & Maintenance 35

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System Overview

Key Components

SolarWorld Sunmodule Plus SW280 Mono Black Panels

These panels were selected for low cost per watt, made in USA,

availability online, lack of minimum panel order, and manufacturer’s

reliable history. Two panels were purchased and shipped to UW

Bothell.

APSystems YC500a Microinverter

A microinverter was selected for its scalability, and designed operation with a small number of

panels. This model can support two modules per inverter, and up to 7 inverters can be tied

together in a single string. We were also able to source this item locally from BlueFrog solar at a

discount and have it shipped to UW Bothell.

MT Solar 4-TOP4 Racking

This racking system is designed to accommodate 2-4

solar panels, and has a unique hoisting system for ease

of installation. Our team was able to source this item for

free from MT Solar and drove out to meet a company

representative in Moses Lake to pick up the equipment.

14’ Stainless Steel Pipe (4.5” OD)

A pole mount was ultimately selected by Farmer Frog as ideal for their needs. This pipe was

specified by MT Solar as required for our height needs (to avoid goat hazards) and by their

racking design. Least expensive and most convenient purchase was from OnlineMetals.com,

shipping out of Seattle took nearly 3 weeks as it was a custom size and unusual shipment

location, but shipment arrived at Farmer Frog without difficulty.

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Completed System

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Future Work

Our team suggests initial improvements to the system will upgrade from a 2 module solar pole

mount system to a 4 module pole mount system of two rows, two columns. This will require the

purchase of 2 additional solar panels (recommend Sunmodule Plus SW280 Mono Black panels)

and another APSystems YC500a microinverter (required if connecting to existing line,

recommended if used for a new mounting location). Racking and rails for additional 2 modules

were included in MT Solar 4-TOP4 racking donation.

An interesting analysis of our designed solar system would be achievable with the purchase of

BlueFrog Solar’s ECM monitoring system (farm internet connection required). This monitoring

system would record detailed production data from individual inverters and solar panels’ input &

output. This may be a potential computer science/mechanical engineering/electrical engineering

analysis and optimization research project.

34

Build Schedule

SAFF: Basic Project with G

antt & Dependencies

Exported on M

ay 24, 2016 7:53:45 PM PD

T

35

Budget

Category $$$ Comments

Solar Panels $1012 2x Sunmodule Plus SW280 Mono (includes freight)

Inverter $257 APSystems YC500a microinverter, trunc cable, end cap

Pole Racking $0 MT Solar 4Top4 Donation includes rails and end clamps

Hoist $66 1 ton hand chain hoist (for raising pole mounting)

Pole Foundation $190 Concrete, wood supports, stakes, gravel

Wiring $443 150’ 10ga THHN wire (R,W,Blk), PVC conduit, fasteners, etc

Permit $98 L&I permit

Total Budget $3000 $2000 from FarmerFrog, $1000 from UW Bothell

Remaining Funds

$322 10% buffer budget

36

Operations & Maintenance

1) Operations

a) System will function automatically as long as breakers and disconnect switches are in

the on position.

b) Panels are designed to handle expected snow loads.

2) Maintenance

a) Maintenance should be performed by a licensed electrician or solar installer.

b) Ensure breaker and disconnects are switched off prior to work.

c) Cover modules with a small tarp or blanket if possible to ensure they are not supplying

current to the connections.

d) Racking system may be lowered with provided 1-ton chain hoist for ease of access at

ground level.

e) Prior to lowering racking system, disconnect microinverter from junction boxes, and

remove junction boxes from U-bolt assemblies on pole.

f) At designed angle (40∘) cleaning will occur naturally by rain, if necessary, spray only top

of solar panels lightly with a hose.

g) If excessive snow (+10”) builds up on modules, brush lightly with a clean, soft bristled

broom.

37

Appendix A: Component Specifications

Microinverter Specifications 38

Solar Module Specifications 40

Pole and Racking Specifications 42

Microinverter Specifications

38

Microinverter Specifications

39

Solar Module Specifications

40

Solar Module Specifications

41

Pole and Racking Specifications 42

43

Appendix B: Component User Manuals

MT Solar 4-TOP4 Installation Manual 44

SolarWorld SW280 Mono Manual 54

APSystems YC500a Microinverter Manual 57

MT Solar 4-TOP4 Installation Manual

44

4” Series Top of Pole Mount

Installation Manual

2016 V2.5

www.mtsolar.us

844-MT-SOLAR (687-6527)


45

2

Thank you for choosing MT Solar Pole Mounts.

It is the installer’s responsibility to determine foundation parameters based on local site conditions, such as wind speed, snow load, soil type, exposure category, etc. Installations also must comply with local building regulations and requirements.

We recommend consulting an engineer for a recommendation on foundation dimensions and pipe size and thickness. MT Solar can also provide a stamped drawing engineered for site-specific requirements for an additional fee. Please contact us to find out more.

Tips for Conventional Pipe Installation:

Dig hole according to recommended depth and diameter.

Set pipe in hole and use a level to ensure it is plumb and vertical to the ground.

If installing multiple poles, use a string to line up pipes.

Brace pipe to prevent it from moving while pouring concrete.

Proper compaction of backfill around sonotube or form is recommended, unless pouring so that con-crete is in direct contact with the soil.

Allow concrete to cure for recommended length of time.

Tools Required:

3/4” Socket

9/16” Socket

Crescent Wrench

Torque Wrench

Tape Measure

Angle Finder

Compass

Ladder


46

3

103 104 A

Installation Guide

102 B 102 A

104 B

The 4” Series Top of Pole Mount does not come standard with the lifting bracket and chain hoist. If you choose to add this option, follow steps 101 to 104 to install the lifting assembly.

101: With the 4" Sch 40 or Sch 80 steel pipe installed in the ground, slide the pole cap over the pipe.

102: Place the lifting insert into the top of the pipe until it sits flush. Place the lifting bracket into the lifting insert with the eye facing south.

103: Hang a 1 ton or greater chain fall hoist from the lifting eye.

104: Hang the U-Bracket Assembly on the Chain Hoist.

101

105: If you do not have a chain fall hoist, install pole cap at the top of the pole, in-sert the 5/8” x 7” bolt, two 5/8” fla

t washers and 5/8”nut

and four 1/2” x 1” set screws. Tighten all. Proceed with in-stallation of all components at the top of the pole.

107

106: Attach the Tilt Adjuster Handle to the tab on the Back Plate with the 1/2” x 1 1/2” Bolt, two 1/2” flat washers and 1/2” Nylock Nut.

105 106


47

4

107 109

108

110: Ensure that the MT Solar lette

r

i ng is upright, and atta

c

h one of the 2x3” rectangular tubes to the 2” pipes using the 1/2” x 3 1/2” bolts with 1/2” flat washers and split washers.

111: Install the remaining 2x3” rectangular tube. Snug up all 4 bolts, but leave loose enough to allow for some play when installing Angle pieces. Adjusting the Tilt Adjuster as necessary, level the array in prepa-ration for the installation of the 2” x 3” angle.

110

107: Slide one of the 2” pipes through the tilt adjuster and the other 2" pipe through the U Bracket Assembly sleeve.

108: Center pipes in sleeves. There should be equal length of pipe on either side of the sleeve.

109: Slide collars on 2” pivot pipe and tighten with 1/2” x 1” square head set bolts. Hold collar firm against the sleeve when tightening.

111


48

5

112 A 113

112 B

112: Install the first two 3x2 Angle sections to the 2x3 Tube using the 1/2" x 1 1/2” bolts, flat washers and split washers. Use the 1/2” x 1 1/4” bolts and 1/2” flan ge nuts to splice the two angle sections together.

113: Install the second two 3x2 Angle sections but DO NOT TIGHTEN at this step.

4 Module Installation

For 4 Module installations, follow steps 112 thru 117 below. For 2 or 3 Module installations, skip to step 118.

114 A 114 B

114: Standing on the North Side of the array with the Tube to Angle bolts started but not tightened, sight the Angle pieces to ensure they are parallel. If not, twist the array until they are then tighten the bolts between the Rectangular Tubes and the Angle.


49

6

115 B

115 A

115 C

115: Plan the layout of your rails according to your module width. Install the Beam Clamps on the I-beam using the 3/8” x 1 1/4” carriage bolts and 3/8” flange nuts.

Remember to leave a 5” gap in the center to allow for the 4” diameter pipe to protrude through, if you wish to put all the modules on at ground level.

117

116: Install the Mounting Rail into the beam clamps slot as per Mounting Rail instructions. Use 3/8” x 1” stainless steel bolts and 3/8” serrated flange nuts. Tighten beam clamps once the rails are in position for modules.

117: Center rails over Angle pieces, keeping equal length of rail off the end of each angle.

116


50

7

2 & 3 Module Installation

For 2 & 3 Module installations, follow the steps 118 thru 119 below. For 4 Module installations, see steps 112 through 117 above.

118 A

118 B

118: Install the Rail Attachment brackets to the ends of the 2x3 rectangular tube using the 1/2” x 1 1/2” bolts.

119 B 119 C

119: Install the Aluminum Rails to the Atta

c

hment brackets using the 3/8” x 1” stainless bolts and 3/8” fla

nge nuts.

119 A


51

8

120: Install Solar Modules as per Mounting Rail and module manufacturer instructions using top clamps. See last page of manual for Iron Ridge Rail and Clamp instructions.

120 A 120 B

121 A 121 B

122

121: For the TOP-2 and TOP-4, if you are installing modules at ground level, leave a 5” gap to allow for the 4” pipe to protrude through the array. If you are installing at the top of the pole, you do not need to provide this gap.

122: For the TOP-3, if installing at ground level, leave the middle module out until array is hoisted to the top. It is ok to temporarily install the outer two modules with just 2 end clamps each.


52

9

123 124

123: Once module installation is complete, raise and or tilt the array to facilitate module wiring and wire management as needed. When wiring is completed, raise the array to the top of the pole.

124: If necessary, installing remaining module.

125

126

125: Insert the 5/8" x 7” bolt over the top of the pole with the 5/8” fla

t

washers and 5/8” nut. Securely tighten the 4 tension bolts in the back of the pole cap to 200 ft-lb.

126: Remove the chain hoist and lifting bracket and place the 1 3/8” diameter round cap in place.

Using an angle finder, adjust array to proper tilt.

Installation is complete.


53

10

SolarWorld Sunmodule SW280 Mono Manual

54


55


56

APSystems YC500a User Manual

57


58


59


60


61


62


63


64


65


66

APsystems YC50 0 -A Installat ion/ User Manual 8

YC50 0 number per branch

2 3 4 5 6 7* 8 9

EXTERNAL W IRE

SIZE (AW G) MAXIMUM EXTERNAL CABLE LENGTH (f t )

12 370 .7 237.1 167.9 124.3 93.6 70 .2 51.4 35.7

10 593.1 379.4 268.6 198.9 149.7 112.3 82.3 57.1

8 926.8 592.9 419.6 310 .7 233.9 175.5 128.6 89.3

6 1482.8 948.6 671.4 497.1 374.3 280 .8 20 5.7 142.9

*7 is the maximum number / branch w ith a 20 amp br eaker

Step 2 – Attaching the APsystems microinverters to the

racking or the PV module frame

A. Mark the location of the microinverter on the rack, keeping in

mind the PV module junction box or any other obstructions.

B. Mount one microinverter at each of these locations using

hardware recommended by your module racking vendor.

C. GROUNDING WASHER: If using the appropriate grounding

washer (check with a licensed electrician), attach the grounding

washer between the PV racking frame and the microinverter.

WARNING: Prior to installing any of the microinverters, verify that

the utility voltage at the point of common connection matches the

voltage rating on the microinverter label.

Figure 5

AB


67


WARNING: Do not mount the microinverter in a location that allows

exposure to direct sunlight. Allow a minimum of 3/4” (1.5 cm.) between

the roof and the bottom of the microinverter to allow proper air flo

w

.

NOTE: Connecting cables (steps 3-5) can be done in any order but DO

NOT energize the utility power grid until all the steps are completed.

Step 3 – Connecting APsystems microinverters to the PV module

Connect the DC cables from the PV modules to the microinverter per the

diagram below:

Note: When plugging in the DC cables, the microinverter should

immediately blink red then green three times. This will happen as

soon as the cables are plugged in and will show that the microinverter

is functioning correctly. This entire check function will start and end

within 5 seconds of plugging in the unit, so pay careful attention to

these lights when connecting the DC cables. This only occurs when DC

voltage is fir

s

t appl ied. The LED wi ll not flas

h

whe n t he second panel

is connected.

9

Figure 6

Photovoltaic panels

and microinverter DC

input cable connection

MC4 Connectors

AB


68


WARNING: Ensure that all AC and DC wiring is correct. Check that

none of the AC and DC wires are pinched or damaged. Be sure that

all junction boxes are properly closed.

Step 4 - Ground the system

NOTE: If you already used grounding washers (WEEB) to ground the

microinverter chassis to the PV module racking as described in Step

2C, skip this step.

Each APsystems microinverter comes with a ground clamp that can

accommodate a single #6 awg strand and #4 awg solid conductor.

Check your local electrical code for grounding conductor sizing

requirements. Connect the grounding electrode conductor to the

microinverter ground clamp.

NOTE: The AC output neutral is not bonded to ground inside the

microinverter.

Figure 7


69


Step 5 - Connecting the APsystems microinverter to the PV module

A. Check the microinverter datasheet for the maximum allowable

number of microinverters on one AC branch circuit.

B. Plug the AC female connector of the fir

s

t mi croi nverter int o the

male connector of the next microinverter, and so on, to form a

continuous AC branch circuit.

C. Install a protective end cap on the open AC connector of the last

microinverter in the AC branch circuit.

WARNING: Do NOT exceed the maximum number of microinverters

in an AC branch circuit, as displayed on the unit label.

Figure 9

A B

FigureFigure 8


70


M icro inve rte rse ria l n u m b e rs

AB AB AB

1 0 11 2 34 5 80 4 4 1 01 12 3 45 8 04 5 1 01 1 23 4 58 0 54 ……

Step 6 - Completing the APsystems installation map

Fill in the APsystems registration cards, which provide system

information and the installation map. Feel free to provide your own

layout if a larger or more intricate installation map is required. The

layout map provided is designed to accommodate labels in vertical or

horizontal orientation to meet all fie

l

d PV conf igu

r

ati ons.

1. Each APsystems microinverter has a removable serial number

label. Peel each label off, and affix

it to the respective locat ion

on the APsystems installation map.

2. Fill out the warranty cards. The warranty card and installation

map are needed to register the site in the EMA.

3. Complete the EMA Installer Account Registration form found

on the APsystems website. APsystems will create the EMA

account and email you the account information. Then you can

use the EMA website to view detailed performance data for the

PV system.

Figure 10


71


72


73


74


75


76


77


78


79


Figure 11

Sample W iring Diagrams

Sample W iring Diagram - 120 V/ 240 V Split Phase

Sample Wiring Diagram - 120V/ 240V Split Phase

AC

JUN

CT

ION

BO

X

EN

ER

GY

CO

MM

UN

ICA

TIO

N U

NIT

ET

HE

RN

ET C

ON

NEC

TIO

NT

O B

RO

AD

BA

ND

RO

UT

ER

12

0 VA

C P

OW

ER C

AB

LE

AC

BR

AN

CH

EN

D C

AB

LE

RE

D - L1

BLA

CK

- L2

WH

ITE - N

ME

TE

R

BR

AN

CH

EN

D C

AP

INS

TA

LLE

D O

N T

HE

OP

EN A

C C

ON

NE

CT

OR

UP

TO 7

YC5

00 P

ER

BR

AN

CH

CIR

CU

IT

Ap

system

s Y

C5

00

-NA

20

AM

P C

IRC

UIT

BR

EA

KE

R PE

RB

RA

NC

H C

IRC

UIT

TO

ME

TE

RO

R A

CD

ISTR

IBU

TIO

NPA

NE

L

NEU

TR

AL

GR

OU

ND

DIS

TR

IBU

TION

PAN

EL

120

V/2

40

V S

PLIT PH

ASE

SOLA

RPA

NEL

EC

U


80


Sample Wiring Diagram - 120V/ 208V Three Phase

AC JU

NC

TIO

N B

OX

AC

BR

AN

CH

EN

D C

AB

LE

RE

D - L1

BLA

CK

- L2W

HIT

E - N

ME

TER

BR

AN

CH

END

CA

PIN

STA

LLED

ON

TH

EO

PE

N A

C C

ON

NE

CT

OR

UP T

O 6

YC5

00

PE

RB

RA

NC

H C

IRC

UIT

20

AM

P CIR

CU

ITB

RE

AK

ER

PE

RB

RA

NC

H C

IRC

UIT

TO M

ETE

RO

R A

CD

IST

RIB

UT

ION

PAN

EL

NE

UT

RA

LG

RO

UN

D

DIS

TR

IBU

TIO

N PA

NE

L1

20

V/ 2

08

V T

HR

EE P

HA

SE

SO

LAR

PAN

EL

ET

HER

NE

T CO

NN

EC

TIO

NTO

BR

OA

DB

AN

D R

OU

TE

R

Ap

system

sY

C5

00

-NA

12

0 VA

C P

OW

ER

CA

BLE

EN

ER

GY

CO

MM

UN

ICAT

ION

UN

IT

EC

U

NOTE: The ECU should function properly when connected to L1, L2

or L3.

Sample wiring diagram - 120 V/ 20 8V Three Phase

Figure 12

81

Appendix C: Required Documentation Submission

PUD Site Diagram 82

Initial Wiring Diagram 83

As-Built Wiring Diagram 84

Grounds Preparation Diagram 85

Warranty Information 86

PUD Site Diagram

82

Solar arrays on pole mount Modules 40”x65”

Micro inverters under modules

PUD meter & solar meter grouped on side of home panel in electrical room

Job: Farmer Frog 23210 Paradise Lake Rd Woodinville, WA 98077

Initial Wiring Diagram

83

560 W SOLAR PHOTOVOLTAIC SYSTEM

GENERATOR

Solar PV Array Module: SolarWorld 280 Mono Power Output: 280 W DC Quantity: 2 Modules Total Max Output: 560 W DC Location: Pole mount

INVERTERS

Qty 1: APS YC – 500A Max Power Output: 500 W AC Output Voltage: 240 V AC Max Amps Out: 2.08 A AC Location: Co-located with modules

MAIN SERVICE PANEL

Rating: 200 A / 240 V AC Main Breaker: 200A SERVICE METER

1 String of 1 panel 2 conductors #10 in 3/4“ PVC

1 String of 1 panel 2 conductors #10 in 3/4“ PVC

2 conductors #10 in 3/4“ PVC

#10 EGC

Total System Voltage Drop: 0.11%

Customer: Address: Designer:

Zsofia Pasztor 23210 Paradise Lake Rd Woodinville, WA 98077 S.A.F.F

As-Built Wiring Diagram

84

560 W SOLAR PHOTOVOLTAIC SYSTEM

GENERATOR

Solar PV Array Module: SolarWorld 280 Mono Power Output: 280 W DC Quantity: 2 Modules Total Max Output: 560 W DC Location: Pole mount

INVERTER

Qty 1: APS YC – 500A Max Power Output: 500 W AC Output Voltage: 240 V AC Max Amps Out: 2.08 A AC Location: Co-located with modules

MAIN SERVICE PANEL

Rating: 200 A / 240 V AC Main Breaker: 200A

SERVICE METER

1 String of 1 panel 2 conductors

1 String of 1 panel 2 conductors

3 conductors #10 in 3/4“ PVC

Total System Voltage Drop: 0.11%

Customer: Address: Designer:

Zsofia Pasztor 23210 Paradise Lake Rd Woodinville, WA 98077 S.A.F.F

#6 GEC

15 A

Grounds Preparation Diagram

85

30’onhouse 50’underground

2’dia

Sch40PVC&10gaTHHN

Sch80PVC&10gaTHHN

Warranty Information

86

87

88

Appendix D: Other Documentation

Contact Information 89

Initial PUD Interconnect Application

Net Metering Agreement

Contact Information

89

Company Topic Representative Email

BlueFrog Solar APSystems YC500a

Microinverter Tim Bailey [email protected]

MT Solar MT 4-TOP4 Joel Unruh [email protected]

SolarWorld SW 280 Mono Customer Support [email protected]

Technical Support [email protected]

A&R Solar Marketing Jen Olson [email protected]

Project Administrator Wendy Wenrick [email protected]

Electrician Mike Dalton [email protected]

Electrician Jason Budgeon [email protected]

mailto:[email protected]








Documents

SAFF User Manual