THE PENNSYLVANIA STATE UNIVERSITY

SCHREYER HONORS COLLEGE

THE SCHOOL OF ENGINEERING DESIGN, TECHNOLOGY, AND
PROFESSIONAL PROGRAMS
DEVELOPMENT OF AN APPROPRIATE SOLAR AND WIND
HYBRID CHARGING STATION FOR ELECTRIC VEHICLES
IN DEVELOPING COUNTRIES
ERIC MICHAEL SAUDER
Fall 2008
A thesis
submitted in partial fulfillment
of the requirements
for a baccalaureate degree
in Mechanical Engineering
with honors in Engineering Design
Reviewed and approved* by the following:
Andrew S. Lau
Associate Professor of Engineering
Thesis Supervisor
Thomas H. Colledge
Assistant Professor of Engineering Design
Thesis Supervisor
Richard F. Devon
Professor of Engineering Design
Honors Adviser
*Signatures are on file in the Schreyer Honors College.
We approve the thesis of Eric Michael Sauder:
Date of Signature
_______________________________ ______________
Andrew S. Lau
Associate Professor of Engineering
Thesis Supervisor
_______________________________ ______________
Thomas H. Colledge
Assistant Professor of Engineering Design
Thesis Supervisor
_______________________________ ______________
Richard F. Devon
Professor of Engineering Design
Honors Adviser
9-3087-7017
Abstract
Mustard Seed Communities (MSC) is a faith based non-prot organization working in
Jamaica to provide care for mentally and physically disabled youth. MSC began a partnership
with Penn State to develop sustainable technologies for Jacobs Ladder a new care facility for 500
residents. Until the donation of two golf carts, the Jacobs Ladder operators were having
problems getting caretakers to travel the nal mile into the site every morning. The path is
dangerous, and taxi drivers charge exorbitantly. Jacobs Ladder operators identied the charging
of these electric vehicles as a signicant need for the development of the site.
A solar and wind hybrid charging station was designed to take advantage of seasonal
wind and sun. According to the predicted vehicle usage data, estimations of vehicle and charger
efciencies, the charger is required to generate two kilowatt hours daily. The charge demand will
be met with a wind turbine rated for 400 W, and a 260 W solar array. The charge storage is
designed to allow the vehicles to be in operation during the day, and onboard vehicle batteries
during the night. To increase the versatility of the charging station, the direct current is inverted
to 110 V alternating current receptacles.
The charing station will be constructed on the roof of the site library, built by Penn State
University in Fall 2008. The solar panels will help to shade the roof of the library, cooling the
structure. To promote the continued sustainability of the charger, the station will be installed by
Students from the University of Technology (UTech) in Jamaica, providing a local knowledge
bank capable of maintaining the energy system. After successful installation, MSC will host a
one day alternative energy conference. University students from Penn State and UTech, local
businesses, and curious neighbors will join to reassemble portions of the charger, and share
knowledge about alternative energy technologies.
Keywords
Alternative Energy Systems, Solar, Wind, Hybrid Power System, Renewable Energy,
Sustainability, Jacobs Ladder, Mustard Seed Communities, Jamaica, Charge Controller, Inverter,
Lead-Acid Batteries, Solar Panels Wind Turbine, Sustainable Community, Appropriate
Technology, Shipping Container
Table of Contents
2. Introduction 1
2.1 Project Background Information 1
2.1.1 Mustard Seed Communities 1
2.1.2. Jacob"s Ladder 2
2.1.3 Bauxite Mining: A Local Problem 2
2.1.4 Future Goals For Jacob"s Ladder 3
2.1.5 Preliminary Community Assessment of Jacob"s Ladder 4
2.2 Project Denitions 4
2.2.1 Problem Statement 4
2.2.2 Project Goals 5
2.2.3 Project Planning 5
3. Project Needs and Specications 6
3.1 Customer Input 6
3.2 Determination of Design Specications 8
4. Preliminary Research 8
4.1 Solar Photovoltaic System Sizing Research 8
4.1.1 Science of Solar Photovoltaic Cells 8
4.1.2 Types of Solar Modules 8
4.1.3 Solar Insolation 9
4.1.4 Array Orientation 9
4.1.5 On-Grid and Off-Grid Systems 10
4.1.6 System Components 10
4.1.7 System Sizing 11
4.2 Charge Storage Research 12
5. Concept Development 12
5.1 Existing Product Search 12
5.2 Problem Decomposition 14
5.3 Preliminary Design Concepts and Ideation 14
5.4 Charge Storage Design Concepts 15
5.4.1 Description of Concepts 15
5.4.2 Option 1: DC to AC 15
5.4.3 Option 2: DC With Storage 16
5.4.4 Option 3: Onboard Storage 16
5.5 Charge Storage Concept Selection 17
i
6. System Level Design 18
6.1 System Sizing 18
6.1.1 Vehicle Usage 18
6.1.2 Estimated Vehicle Efciency 19
6.1.3 Available Energy: Local Solar Insolation 20
6.1.4 Anticipated System Efciencies 20
6.1.5 System Load Sizing Calculations 21
6.2 Available Charge Sources 21
6.2.1 Meeting the Power Needs with Photovoltaics 21
6.2.2 Available Wind Energy Production Resources 22
6.2.3 Advantages and Disadvantages of Hybrid Power Systems 22
6.2.4 Mustard Seed Wind Development Plans 23
6.2.5 Wind Availability at Jacob"s Ladder 23
6.3 Station Location Concepts: Finding the Optimum Placement 23
6.3.1 Option 1: Site Entrance 23
6.3.2 Chapel 24
6.3.3 Demonstration Village 25
6.4 Station Location Selection 25
6.5 Station Conguration Concepts: A Functional Design 26
6.5.1 Mounted on Existing Building 26
6.5.2 Mounted on Proposed Library 26
6.5.3 Ground Mount 27
6.6 Station Conguration Selection 27
Detailed Design 27
7.1 Station Design: The Charge Sources 28
7.1.1 Solar Array 28
7.1.2 Solar Integrated Green Roof 28
7.1.3 Solar Array Mounting Conguration 29
7.1.4 Wind Turbine 31
7.1.5 Wind Turbine Placement 31
7.2 Station Design: Processing Electronics 33
7.2.1 DC Breaker Box 33
7.2.2 Wire Sizing Calculations 33
7.2.3 Charge Controller 34
7.2.4 Battery Bank 35
7.2.5 Inverter 36
ii
7.3 Station Design: The Charger - User Interface 38
7.3.1 Benets of an AC Receptacle 38
7.3.2 Golf Cart Charger 38
7.4 Station Overall System Design 38
7.4.1 Charging Unit Placement 38
7.4.2 Electrical Component Arrangement 39
7.4.3 Solar Charging Station Rack Mount 40
7.5 Project Budget and Cost Analysis 41
Implementation: Jamaica Design-Build 41
8.1 Overview of Design Build Week 41
8.2 Murphy"s Law 41
8.2.1 Weather 41
8.2.2 Where are the Solar Components? 42
8.3 Revised Plans 42
8.3.1 Theory of Appropriate Technology 42
8.3.2 Installation and Instruction Manual 43
8.3.3 Developing Local Connections 43
8.3.4 Future Alternative Energy Conference 44
8.4 Results of Design-Build Week 44
8.4.1 Placement and Finishing of Container Library 44
8.4.2 Completed Library Interior 45
8.4.3 Identication of Electrical Vehicle Specications 46
Conclusions 46
9.1 Experiences and Lessons Learned 46
9.2 Improvements: A Marketable Design 46
9.2.1 A Justication for Alternatives: The Cost of Power 46
9.2.2 An Analysis of the Project Costs 47
9.2.3 The Redesign 48
9.3 Feasibility of Implementing Design in Developing Nations 50
9.4 Personal Impact of Development Work 50
10. Acknowledgments 51
Appendix 1
iii
2. Introduction
2.1 Project Background Information
2.1.1 Mustard Seed Communities
Mustard Seed Communities (MSC) is a faith-
based non-prot organization working in central Jamaica
to care for mentally and physically disabled young
adults.
1
Although care facilities for the disabled exist in
Jamaica, they do not continue care for individuals after
reaching the age of 18. MSC operates seven sites on the island, striving to build a community of
caring, sharing, and training.
2
The goals of MSC are to provide exceptional care for disabled
individuals, present them with opportunities to develop skills, and to live in an encouraging
community setting.
3
Funding for MSC comes primarily from donors and supporting congregations abroad.
To build this funding base, and to decrease the operation costs of their sites, MSC attempts to use
sustainable technologies in their communities. These technologies are able to reduce the nancial
strain on operation costs by replacing previously
outsourced tasks with local products.
2
At the
Jerusalem! site in Spanish Town, MSC is cultivating
sustainable agriculture programs to feed the
residents. At the My Fathers House site in
Kingston, MSC raised chickens to provide a source
of protein for the residents, and used the manure to
provide energy for cooking.
4
Figure 1: MSC Logo
A
Figure 2: Jerusalem! resident participating in
MSC sustainable agricultural development
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2.1.2. Jacobs Ladder
Mustard Seed approached Penn State in
the Fall of 2007 to design and implement
sustainable technologies at the newest MSC site,
Jacob's Ladder. The new site will be the largest
care community operated by MSC when fully
developed. Five-hundred residents will live in
one-hundred cottages, and as many as one-
hundred caretakers and staff will work at the site daily.
5
Jacobs Ladder will require more
planning, and conscious design than MSC has needed on previous projects.
2.1.3 Bauxite Mining: A Local Problem
MSC hopes to develop technologies on the one-hundred acre Jacobs Ladder site that can
be replicated for surrounding poor Jamaicans. Like many areas in Jamaica, Jacobs Ladder once
had large deposits of Bauxite, the primary aluminum ore. Although mining operations
terminated at the site in the 1970s, the site remains pocketed with deep depressions.
2
Jamaican
legislation species a maximum slope for mined bauxite pit walls and requires the land to be
returned to a grazing pasture, however, these lands are often lack fertility.
6
Jacobs Ladder is located in a remote area of the Blue Mountains of Central Jamaica, just
north of Moneague, and approximately ten miles South of Ocho Rios. This mountainous area
contains the largest deposits of bauxite on the island, and is also home to many of the nations
poorest people. For many, the reclaimed mines are the only affordable lands for their farms and
homes. As a result, the problems existing at Jacobs Ladder: poor soil for crops, limited energy
resources, and scarce water supplies, are very real and practical problems for many Jamaicans.
2
Figure 3: Homes at Jacobs Ladder
-2-
2.1.4 Future Goals For Jacobs Ladder
As a service to their community, MSC hopes to make the Jacobs Ladder site a facility
where local community members can learn about the sustainable technologies that helped relieve
these problems. Through conversations with Mustard Seed planners, site operators, and staff,
Penn State is hoping to develop solutions that promote sustainability and increase the quality of
life for the residents and workers at the Jacobs Ladder site.
2
Figure 5: Jacobs Ladder Site - Developmental Concept Plan
C
Figure 4: Location of Jacobs Ladder Site
B
Jacobs Ladder
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2.1.5 Preliminary Community Assessment of Jacobs Ladder
Penn State students traveled to Jacobs Ladder on two community assessment trips in the
Spring of 2008. After conducting a community survey and customer needs analysis at the Jacobs
Ladder, it was determined that the energy demands of transportation was a signicant problem
facing further development of the site. Access
is provided by a one mile long, pothole lled,
dirt haul road used during mining. Staff
workers can afford the taxi fares from the
nearby towns to mine entrance; however, taxi
drivers charge exorbitant amounts to travel the
nal mile into the site. Workers do not feel safe
walking this road, as people have been robbed and mugged there in the past, but are forced to
because no transportation is available. Inclement weather can also make the long walk a
miserable experience for the staff. MSC was nding that these factors would occasionally keep
staff from coming to work. At a care facility, where all workers are needed to take care of the
residents, MSC must make every effort to assist their workers in coming to work. To do this,
MSC has purchased electric powered golf carts to shuttle workers from the entrance. Power has
been provided, but the service is not regular. Site operators expressed the need for a reliable
means to charge the electric transport vehicles at Jacobs Ladder.
7
2.2 Project Denitions
2.2.1 Problem Statement
To incorporate alternative energy and improve the transportation at the Mustard Seed
Communities Jacob's Ladder site, design an appropriate charging station to power existing
electric golf carts. The design must allow for the carts to be operated for transportation
throughout the day.
Figure 6: Students Conducting Site Assessment
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2.2.2 Project Goals
The project is dened and driven by the following three goals:
I. Integrate sustainable technologies into the Jacobs Ladder site.
II. Improve transportation systems for staff.
III. Design a simple and appropriate charging station for site vehicles.
2.2.3 Project Planning
Penn State engineers have been working with site operators and planners at MSC to
determine the course of action for the University involvement with Jacobs Ladder. This is a pilot
project, and will be the rst Penn State design-build project to be integrated with the Jacobs
Ladder site.
To ensure that the needs of the customer are met, design specications are developed
according to their needs, and that an objective design and implementation are chosen, a project
planning diagram has been developed.
Figure 7: Project Planning Diagram Showing Steps of Design Process

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When beginning a design-build project, it is important to assess the possible risks
encountered throughout the duration of the work, from preliminary planning to nal
development. International projects working with limited time and budget constraints face
many challenges and risks. These are listed below in the Risk Assessment Figure 8.
Figure 8: Risk Assessment Table

3. Project Needs and Specications
3.1 Customer Input
The project will meet the needs of two primary customers, both long-range MSC
planners, and MSC site operators. Although these two groups both have the same end goal of
providing care for handicapped youth and young adults, they envision different operational
paths. Complete customer needs information can be found in Appendix E.
Long-Range MSC Planners
The Long-Range MSC Planners are geographically separated from the day to day
operations at the Jacobs Ladder site, although an individual in this role does not immediately see
the impact of his or her decisions on the site, with proper communication, these individuals are
able to develop successful goals for site development.
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MSC Site Operators

Matthew Moran
Students from Penn State University began working with Mustard
Seed Communities in the Fall of 2007. Matthew Moran is the United States project
relations director for Mustard Seed, based in New York. He contacted the University
beginning a partnership to develop sustainable initiatives into the site, with hopes
that Jacobs Ladder would become a community showcase of sustainable and
renewable technologies.

Brother Anthony
Brother Anthony is the site operator for the MSC Jacobs Ladder.
Through two visits, Brother Anthony communicated the need for improved
transportation for staff workers to and from the site.
7

Clyde Ramkissoon
Clyde coordinates supplies, and manages many of the day to day
needs for all of the Mustard Seed Jamaica sites. When questioned about Brother
Anthonys golf cart request During a March 13, 2008 meeting, Clyde informed the
Penn State engineers that Jacobs Ladder would be receiving a shipment of two
electric powered golf carts to be used for transportation on and to the site.
4
-7-
3.2 Determination of Design Specications
The customer needs have been compiled into a Quality Function Deployment (QFD)
Matrix. This tool is used to translate the customer needs into engineering specications, which
can then be used to develop the design concepts. The QFD matrix can be found in Appendix F.
4. Preliminary Research
4.1 Solar Photovoltaic System Sizing Research
To meet the sustainability design objectives expressed by the Mustard Seed planning
staff, alternative sources will be used to provide the energy required to charge the electric golf
carts used on site.
4.1.1 Science of Solar Photovoltaic Cells
Solar cells generate power by absorbing the energy of photons from the Sun. When a
photon strikes the surface of a solar cell, electrons are transferred through the cell, and a
measurable current is formed. This process is known as the photoelectric effect, and it is the basis
for solar power. The total power produced by a solar module is limited by the total amount of
solar energy, in the form of photons, striking the surface of the panels.
8
4.1.2 Types of Solar Modules
Three types of solar modules are commonly used to generate electricity. A
polycrystalline cell is created by chemically treating thinly sliced silicon sheets. Monocrystalline
cells are cut in the same manner, but are uniquely sliced from a single crystal of silicon. Though
thin lm panels lack the efciency of the crystalline cells, the thin lm technique is becoming
more common because the coating can be deposited cost effectively using similar techniques to
an ink jet printer.
8

-8-
Figure 9: From Left to Right: Monocrystalline, Polycrystalline, and Thin Film Cells
D
4.1.3 Solar Insolation
Solar insolation can be thought of as the solar potential of a region, and is typically
expressed as the ideal number of kilowatt hours per square meter per day. For example, if a
region has a solar insolation of 4.5, a solar panel (with 100% efciency) could produce 4.5 kWh in
one day of operation.
8
It is important to remember that solar panels seldom operate at
efciencies better than 20%.
9
4.1.4 Array Orientation
The orientation of a solar array is important
to maximize the total power output of the system. In
the course of the year, the altitude of the Sun may
vary greatly depending on the latitude of the
installation site. In order to maximize the power
generation capabilities of a solar array, some
mounting structures are constructed to adjust angle
throughout the year. As a general rule, the optimum annual altitude angle for a solar panel is the
degrees latitude of the installation site.
8
For example, a solar array installed in State College, PA
(40 48' N 77 52' W) would be installed at approximately 41 degrees from horizontal.
10
Figure 10: Operable Solar Window
E
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4.1.5 On-Grid and Off-Grid Systems
Alternative energy systems fall into one of two categories: grid-connected, and off-grid
power systems. Grid-connected systems are used to replace a portion of the power provided by
the energy companies. Users installing grid-connected systems are typically attempting to cut
their energy costs by reducing the quantity of power purchased from the power companies. Off-
grid systems are able to deliver electricity to users far from power lines.
8
In many remote areas,
the cost of running an electric cable from the electric service can be insurmountable. Here, off-
grid systems can be used to provide the required power. Off-grid systems are relatively simple.
They only require a charge generation source, and typically utilize some form of charge storage.
4.1.6 System Components
A charge generation and storage system has several required components: a charge
source, a charge storage, and a charge monitoring device.
Charge Sources
Solar panels and wind turbines are commonly used charge sources for alternative energy
systems. These devices are relatively inexpensive, require no input fuel, and little maintenance.
Charge Storage
Although the energy produced by a charge source can be used immediately by a load,
few systems are sized exactly to match the load. A charge storage is often utilized to build a
reserve of power which can be used as needed. An example of a system not requiring a charge
storage would be a solar powered attic fan. The fan would only operate during the brightest sun
lit hours of the day. This is an ideal schedule for an item such as fan, where the only necessary
run time is during the heat of the day. Systems must be carefully evaluated to determine if a
charge storage device is necessary.
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Charge Monitoring
If a charge storage device is utilized, a control system is usually required to monitor the
charge state of the storage. These devices, called charge controllers, often contain
microprocessors that can determine what to do with the incoming charge: store it or dissipate the
excess. More sophisticated charge controllers offer monitoring options to determine total power
production.
4.1.7 System Sizing
The ideal off-grid solar power system is designed to store at least all of the charge
produced on a sunny day, and preferably enough to carry the loads through a few days of poor
electric generation potential. All system sizing begins with a thorough analysis of the load.
Whenever possible, the load should be reduced. Load reductions can dramatically decrease the
cost of alternative energy systems. Different charge storage scenarios also require additional
considerations to determine the total amount of charge storage demanded by the system. For
example, electrochemical batteries will last longer if not discharged completely. A common
recommendation for the regular, or cycling, depth of discharge of a battery is 50%. This means
that the total charge storage potential of the battery is only half of the listed to avoid over
discharge of the battery.
8
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4.2 Charge Storage Research
Several methods exist for storing the large amounts of charge needed to power a golf
cart. Of these, the most feasible have been chosen and are described below.

Batteries
Batteries utilize electro chemical reactions to store energy. Lead-acid batteries are
the most common batteries used for storage in small-scale alternative energy systems. Lead
dioxide (PbO2) is used for the cathode, metallic sponge lead (Pb) is used for the anode, and the
electrolyte is a mixture of sulfuric acid (H2SO4) and water. A single cell exhibits a nominal
voltage of 2.1 V. These cells are then combined in series to sum voltages to the desired battery
voltage. Commonly six cells are used to form a 12 VDC battery.
8

Capacitors
Ultracapacitors differ from batteries as they store charge between solid state
materials, instead of through electrochemical reactions. This allows ultracapacitors to discharge
quickly and deeply without damage to the capacitor. Though ultracapacitors have many ideal
operating characteristics, their cost and must be lowered, and reliability improved before their
wide-spread usage in alternative energy systems.
12 F
5. Concept Development
5.1 Existing Product Search
Many electric vehicles are designed to meet some portion of their electrical demand with
alternative power sources. Many of these systems utilize solar panels to generate the charge
needed for powering the vehicles. These various designs can be used as benchmarks to rate the
success of the golf cart charging system for Jacobs Ladder. Following are some of the best
competing products:
-12-

Sunray Solar Roof Kit
The Sunray Solar Roof Kit is sold through the Cruise Car golf cart company of
Sarasota, Florida. The kit utilizes a 180 watt panel to supply a current of three amperes at 60
volts. A charge controller regulates the charging of the onboard cart batteries. The panel is
integrated into a roof replacement kit which can be purchased for $1895.00.
12
The company
claims that the cart can travel 30% farther because power is constantly being supplied to the
batteries.
13
Santa Monica 2.1 kW Solar Electric Vehicle Charging Station
Electric vehicles were rst marketed in Arizona and California in the 1997 model
year.
4
To prepare for these new vehicles, several cities began incorporating solar charging stations
for electric vehicles into the plans for new development areas. Some of these, such as the 2.1 kW
charging station in Santa Monica, California utilized solar photovoltaic cells to provide the
necessary power for the charging of seven electric vehicles.
5
The station is located near, and grid
connected to, the Santa Monica City Hall building. The photovoltaic panels provide a shaded
parking stall for the electric vehicles they charge, and incorporate educational displays to
demonstrate the power generated.
4

Solar-Shell Electric Bike Charging Station
The Solar-Shell is an enclosure that provides shelter and power for two electric
bicycles. The Shell uses solar panels to charge a 12 VDC battery bank. Charge is converted from
the DC battery storage back to AC with an inverter, allowing for any 110 VAC bike charger to be
used inside the station. The unit retails for $2,700.
6
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5.2 Problem Decomposition
A black box model is a simple tool used to determine the input and output parameters.
Regardless of the specic design used for the charging station, these components must be present
for the charging station to function. An important result of the black box model is determining
the desired outputs, and required inputs. The system outlined below will produce a charged
vehicle, and allow for a means to monitor the charge state of the vehicle given an input of charge,
here from solar energy.
Figure 11: Black Box Model
5.3 Preliminary Design Concepts and Ideation
Ideation is the process of collecting rough
ideas and gathering them into design concepts. In
the weeks after the community assessment site visit,
ideas were generated, and developmental concepts
were produced to match the functions described in
the black box model. The charging system shown
in gure 12 was one of the rst complete concepts
for a stand-alone charging station. Figure 12: Preliminary Charger Concept
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5.4 Charge Storage Design Concepts
5.4.1 Description of Concepts
Several charging options and current congurations could be used to deliver charge to
the golf carts at Jacob's Ladder. The following three concepts were developed through the
ideation and external research processes. Some of the advantages and disadvantages of the
concepts are also discussed to highlight the most important features of each design.
5.4.2 Option 1: DC to AC
The direct current (DC) produced by the solar array would be stored in a battery bank to
allow charging to take place at night, when the vehicle would not be in use. The batteries would
be protected from overcharge or overdraw by a charge controller. The current would be
transformed from direct to alternating current (AC) with an inverter. After the inverter, the
current will be the same as nominal household current at 110 V, 60 Hz, and can be used to power
a receptacle. This design allows for the most versatile end use because any AC appliance or
device could be plugged into the AC receptacle. If the charging station is located in a remote part
of the site, work lights, tools, and other equipment could be powered by the charging station.
Although the design is not complex, adding an inverter adds complexity, opportunity for
equipment failure, and added difculty in servicing a broken system.
Figure 13: DC - AC Charge Storage Concept
-15-
5.4.3 Option 2: DC With Storage
The DC to DC storage design allows charge to be delivered to the golf cart without the
incurring the losses of inverting the charge current twice, once to operate the AC charger, then
back to DC within the commercial charger unit itself. This design also avoids the complexity and
cost of the inverter. The charge controller monitors the state of the batteries, as the bank is
charged by the DC power generated by the solar array. In the evenings, the electric vehicle is
plugged directly into the charge controller load circuit, and is charged by the stored energy in the
batteries. This arrangement cannot be used to power anything except golf carts with a similar
voltage. No tools or other AC devices can utilize power generated by the charging station. This
is benecial because it focuses the use of the charging station, and guarantees that the station will
be able to charge the vehicles it was designed for. No other devices can steal power intended for
the vehicle charge.
Figure 14: DC - DC Storage Concept
5.4.4 Option 3: Onboard Storage
Instead of using a xed-location charging station, a solar array could be placed directly
on the roof of the electric vehicles. This system would not likely provide enough power to
completely recharge the vehicle, however, it would be able to extend the traveling range of the
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cart, or lessen the required amount of charge time in the overnight hours. A mobile power source
would also help if the vehicle ran out of charge while far away from the charging station. The DC
solar array would be connected to the batteries of the cart through a charge controller. The
system is simple and inexpensive, however, it can not meet the entire power demand of the
electric vehicle. The vehicle must also always be in direct sunlight for charging to take place.
Figure 15: DC With Onboard Storage Concept
5.5 Charge Storage Concept Selection
Several choices in the design process require an objective, detailed analysis of the factors
inuencing the nal decisions. For these, the decisions were made with the help of concept
selection matrices. The Analytical Hierarchy Process (AHP) matrix is used to weight the
importance of each design criterion. This weight is then used with the concept selection matrices
to determine which design concept is chosen. The AHP and concept selection matrices can be
found in Appendix G.
After establishing the weight of each design criterion, it was found that the
demonstration value and versatility of the charging station were the most important criterion for
designing the method of charge storage. The heavy weight of these, led to the selection of the DC
to AC charge storage system. This charger model will function similarly to the Solar Shell Electric
Bike Charging Station. An inverter will be used to convert the DC power back to AC. The
versatility of this design will allow for any AC device to operate from the output of the inverter.
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The matrices revealed that the charger must be able to perform a wide variety of tasks, though
specically designed for powering the golf carts.
6. System Level Design
6.1 System Sizing
6.1.1 Vehicle Usage
The primary use for the golf carts at Jacobs Ladder is to shuttle workers to and from the
main road. The road is known to be dangerous, and when the weather is stormy, workers will
not walk into the site. At a care facility like Jacobs Ladder where the majority of the residents
require constant care, it is essential that as many staff as possible arrive for work.
The path that workers must traverse is one mile long dirt road, constructed for bauxite
mining operations. The location of the road is shown in gure 16. Anticipated use of the golf cart
is to make two shuttle trips to the road and back in the mornings, and two shuttle trips in the
evenings, as well as some light random travel about the site throughout the day. The estimated
daily total for vehicle use is approximately ten miles.
Figure 16: Location and length of road to Jacobs Ladder
B
The site workers are currently used to having the electric vehicle available at any point
throughout the day, and are not accustomed to charging the vehicle at any point through the
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working hours of the day. Although they may be willing to change habits, the charging station
should be designed to meet their needs, not to change their customs. This requires the station to
have the charge storage capabilities to hold the energy needed to charge the golf carts through
the night.
6.1.2 Estimated Vehicle Efciency
At the time of design, the golf cart make and models used on site were unknown. To size
the system without this information, estimations were conducted to determine the cart efciency
based on hypothetically similar electric vehicles. The carts were acquired by donation, therefore
each cart will likely be of unique. The following gure is a comparison of several electric vehicle
efciencies compiled by the Colorado University Solar Decathlon Team. Included is a wide range
of electric vehicle types. Though many are much heavier than a golf cart, the assumed
inefciencies in the golf carts on site may make up for the weight difference.
Figure 17: Comparison of several electric vehicle efciencies
14

It will be assumed that the golf carts operate at an efciency of 5 miles/kWh for
calculations to develop the necessary power requirements. Using the estimated trip distance, trip
frequency, and vehicle efciency as calculation factors, the cart will require approximately 2 kWh
each day.
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6.1.3 Available Energy: Local Solar Insolation
Solar energy is more practical in some areas of the world than others. The solar
insolation value is a way to compare the equivalent power radiated on each portion of the earths
surface. Jamaica receives an equivalent average of ve hours of full power sunlight each day.
Figure 18: Solar insolation for the Caribbean
15
6.1.4 Anticipated System Efciencies
The design of this storage system requires
monitored charging and discharging of a battery
bank as well as conversion of the current from DC
to AC with the use of an inverter. The addition of
each step in this process also results in additional inefciencies of the system. The table in gure
19 shows the anticipated losses for each component. These efciencies can be multiplied together
to get the total system efciency. The system will deliver an estimated 50% of the energy
generated by the solar panels. Although this charge shufing results in a great loss, the
versatility of the design makes this an essential and unavoidable cost.
Figure 19: Estimated Efciencies
-20-
6.1.5 System Load Sizing Calculations
Solar power systems are sized by
required loads. Compiling the information of
the total distance the vehicles travel in a day, the
efciencies of the vehicle and of the charging
process, and the power available in Jamaica, the
required watt produced in the day can be
determined. The approximate power demand is
660 W. These calculations are shown in gure 20.
6.2 Available Charge Sources
6.2.1 Meeting the Power Needs with Photovoltaics
The original intentions of the project were to power the entire charger with photovoltaic
panels, however, these are expensive. The required panels would cost approximately $4,000.
Due to the budget limitations of the project, the cost of purchasing new panels to meet the power
requirements would be much greater than the funds available. When the Center for
Sustainability at Penn State was informed of the need of solar panels for the Jacobs Ladder
project, they responded by donating six
Solarex MST43-MV panels. These
panels had previously provided power
for the solar pump house at the
Renewable Energy Homestead. The
Homestead has fallen into disrepair, and
is slated for demolition before the Spring
of 2009.

Figure 20: System Sizing Calculations
Figure 21: MST43-MV panels at the PSU CFS site.
-21-
The panels are a thin-lm design manufactured in 1999. A weakness of the panels is a
high inefciency; each panel is rated at 43.0 W.
16
The six panels available from the Center for
Sustainability total 260 W. Using the solar insolation value for Jamaica, the panels would
produce approximately .65 kWh on a sunny day. This leaves 1.35 kWh to be produced by
alternative means. The remaining panels needed to produce this remaining power could be
purchased at approximately $1000 for a 200W panel.
6.2.2 Available Wind Energy Production Resources
In addition to the solar panels
available at the Penn State Renewable Energy
Homestead, a small wind turbine has also been
decommissioned. Another option to provide
power for the charging station would be to use
a hybrid system including both solar and wind
energy sources. Wind turbines are cost
effective. The Southwest Air X turbine is priced
at approximately $600, and can provide 400 W.
17

6.2.3 Advantages and Disadvantages of Hybrid Power Systems
A hybrid charging system is able to
take advantage of the benets of both the solar
and wind. Hybrid wind and solar energy
production methods work together to supply a
more constant power source than either system
would do in a stand alone format. In many
areas, wind speeds vary seasonally. In much of
Figure 22: Air X Turbine at CFS Site
Figure 23: Hybrid Power System
-22-
the United States, wind speeds are low in the summer when the sun shines brightest and longest.
The wind is strong in the winter when less sunlight is available.
18
This arrangement produces a
smooth power source, and can be installed with little extra equipment or effort. The
diversication of power sources is a key advantage of hybrid arrangement.
6.2.4 Mustard Seed Wind Development Plans
Mustard Seed Communities is hoping to expand their renewable energy portfolio to
include power generated from biofuels, waste methane, and wind energy. Small wind turbines
are simple, relatively efcient, require little maintenance, and provide an exciting visual
appearance of sustainable energy sources.
2
6.2.5 Wind Availability at Jacobs Ladder
Preliminary wind data provided by AWS Truewind for the site shows little promise at
successfully placing a wind turbine on the site. This data can be found in Appendix D. In a
statement accompanying the data, however, AWS states: the proprietary data is an estimate, and
an on-site Met station must be established to conrm the potential of the region.
19
Although no
anemometer has been placed on site, two site visits conrmed a steady breeze blowing out of the
mountains in the Northeast, and peaking in velocity near the crest of the main hill at the center of
the site. If any area of the site has the wind potential necessary to generate power, it would be the
location planned for the station. Regardless of the preliminary wind data, Mustard Seed is
planning to develop wind turbines on the site anyway to provide a visual of sustainability.
2
6.3 Station Location Concepts: Finding the Optimum Placement
6.3.1 Option 1: Site Entrance
Visitors and Staff entering Jacobs Ladder must rst pass through a gated front driveway.
Although some areas of the facility are fenced to keep residents from danger, the front gate is a
traditional feature of most Jamaican businesses, public areas, and complexes. The charger could
be positioned South of a grove of trees the left side of the path leading from the site entrance.
-23-
This position would provide optimum accessibility for staff, using the carts for transportation
into the site. As homes continue to be constructed stretching deeper into the site, this location
will not be central to the operations.
Figure 24: Proposed Site Entrance Location
6.3.2 Chapel
Faith is at the center of the mission of Mustard Seed Communities, and the chapel is
located near the proposed center of the site. This location would be an easily accessible location
for a charger. Visitors to the site, and investors interested in the development of sustainable
technologies at Jacobs Ladder will pass through this location. The chapel also serves as a
valuable central hub for transportation and the movement of people throughout the site, forming
a bridge to the rest of the currently undeveloped site.
-24-
Figure 25: Proposed Chapel Location
6.3.3 Demonstration Village
Penn State has begun concentrated design work on a 10-15 acre plot of the entire 100 acre
site. This land will serve as a demonstration village to showcase the sustainable and renewable
agriculture methods Penn State is working to develop on the site.
5
Locating the charging station
here would group all of the Penn State contributions in one area, and would become a more
centralized facility as the site continues development.
Figure 26: Proposed Demonstration Village Location
6.4 Station Location Selection
After completing the AHP matrix for the station location, the most important design
criteria were determined to be the educational value of the location, and the ability of the location
to benet future development of the site. The results of the concept selection matrix showed that
the chapel location provided the greatest benet for educational potential, locating the charger at
the center of the site, and at the gateway to the Penn State Demonstration Village. The AHP and
concept selection matrices can be found in Appendix H.
-25-
6.5 Station Conguration Concepts: A Functional Design
6.5.1 Mounted on Existing Building
The hill at the center of the site is
occupied by two structures: the chapel, and
the administration building. These buildings,
originally constructed for the Jamaican
wharves, were transported to Jacobs Ladder
after they were decommissioned from
service. The buildings have large galvanized
steel roofs, and are adequately oriented to optimize solar panel efciency. Panels mounted in this
location would be visible, but would not have an obvious link to the load driven by the charger.
6.5.2 Mounted on Proposed Library
The rst Penn State project to be
installed at Jacobs Ladder is a sustainable
library constructed from a recycled shipping
container. This library will serve as the
gateway to the demonstration village, and
contain resources for the Mustard Seed staff
to maintain and learn about the technologies on
site. This scenario groups the charger with other Penn State projects, and keeps the solar panels
from being shaded or damaged.
Figure 27: Existing Chapel
Figure 28: Container Library Mount
-26-
6.5.3 Ground Mount
Perhaps the most simple option for
solar panel mounting is a ground rack. The
ground mount provides a low prole, a
reduced wind load for hurricanes, and is a
stand-alone system. The ground mount also
has an associated risk: the panels could easily
be blocked by vehicles, growing vegetation or
even buildings constructed after the installation of the panels. The power output of shaded
panels is dramatically reduced. Panels on the ground also are at a higher risk of being damaged.
6.6 Station Conguration Selection
After evaluating the criteria for the station conguration, it was determined that
educational value, safety, and durability of the design were the most important factors
inuencing the design choice. The library mounting scenario was chosen. This design places the
panels at a facility that is meant to be the center for educational information regarding
sustainability, and gets the panels off of the ground where they could be blocked, or damaged.
The AHP and concept selection matrices can be found in Appendix I.
7. Detailed Design
The charging station is made up of three basic components: the charge source, processing
electronics, and the charger - user interface. This section is an exploration of each of these
systems, and the decisions and procedures used to arrive at the nal design.
Figure 29: Ground Mounted
-27-
7.1 Station Design: The Charge Sources
7.1.1 Solar Array
The Penn State University Center for Sustainability donated six
Solarex MST43-MV thin lm solar panels. The panels had previously
been utilized in a solar water pumping station at the Renewable Energy
Homestead. Although the panels are designed for use in moderate to
high voltage arrays, the panels were previously utilized with a 12 VDC
battery bank. As much of the system had already been salvaged, no other electronics could be
utilized from the Homestead.
An important tool to understand the operating characteristics of a solar panel is the
current voltage curve (I-V curve) as designated by the manufacturer. The curve is used to
determine the maximum current and voltage of the
panel.
8
Figure 30 shows the I-V curve for the MST43-MV.
The two curves shown in the gure represent different
light test illuminations: the upper curve is tested at 1
kW/m
2
and the lower is tested at 250 W/m
2
. Electrical
power is the product of current and voltage, therefore
the maximum power point of the panel is at the knee of
the curve. The I-V curve conrms the panel
specications that claim a maximum power point of 43
W when the voltage is 72 VDC, and the current is 0.6 A.
16
7.1.2 Solar Integrated Green Roof
The Jacobs Ladder Library design is a twenty foot long by eight foot wide shipping
container. Recycled shipping containers are widely used across Jamaica for houses and shops.
Jamaica receives the majority of their goods in a constant stream of container ships, creating an
Figure 30: MST43-MV I-V Curve
-28-
available supply of shipping containers. The metal box provides a weather-tight, sturdy shell for
a wide variety of needs.
One weakness of shipping containers is a lack of insulation. Especially in tropical
climates like Jamaica, containers are prone to overheating if placed in direct sunlight. One
advantage of the solar integrated green
roof design is provide a form of
insulation for the roof. Growing plants
on a roof requires approximately four
inches of soil, but builds thermal mass on
the roof, moderating the temperature of
the living space below. The solar array
will also shade the majority of the
container roof, and will be elevated
slightly to allow air ow to whisk excess
heat from the roof.
20

7.1.3 Solar Array Mounting Conguration
A green roof is an effective insulator, but also adds a large amount of weight to the roof.
To support the combined weight of the green roof and solar array, a frame has been designed to
transmit the weight to the four corner support posts of the container. Loaded containers are
normally stacked on ships up to eight containers high. The added roof weight is insignicant if
carried by these supports. To accomplish this, a frame has been designed from 2 x 6 boards to
sit on the side rails of the container. The frame serves to contain the support the green roof, and
to provide a mounting location for the solar array. The solar array will be mounted on a wooden
Figure 31: Solar Array and Green Roof
-29-
frame constructed from 2 x 4 boards. The frame is angled at eighteen degrees from horizontal,
equal to the latitude for the site.
20
Figure 31: Solar Array Roof Mount Assembly
The six Solarex MST-43MV panels are afxed to the mount with two angle iron rail pieces
on the top and bottom of the panel. Neighboring panels are bolted together, and the entire
assembly is secured to the roof rack with lag bolts. The mount for solar panels must be safe and
secure, especially in Caribbean, hurricane-prone locations. To ensure that the solar roof rack
would survive the high winds of the hurricane, the structure was was designed with similar or
stronger materials and techniques than the buildings already on site. All connections on the roof
rack are also to be made with screws instead of nails. Screws hold stronger in the wood, and rip
out less frequently in a hurricane.
21
Figure 32: Solar Panel Attachment Design
-30-
7.1.4 Wind Turbine
The Air X wind turbine is rated for 12 VDC output. The rotor
diameter is small, only 46 inches, yet the turbine is capable of
generating 400 W with a 28 mph wind. A unique feature of the turbine
is the speed control
function. The turbine is controlled by a
microprocessor, allowing the turbine to be
connected directly to a battery bank. The turbine
will reduce rotation speed if the wind speed is to
high, or if the battery is charged.
17
7.1.5 Wind Turbine Placement
The chapel location is ideal for
the placement of the wind turbine. The
area is the highest location on the site, and
a steady wind blows from the North. The
wind speed and direction data for the
Mustard Seed site are located in Appendix
D. The turbine must be located near the
charging station to reduce the losses of the
generated DC power.
17
Regardless of
engineering requirements for power loss,
the turbine should be located close to the
container library to promote the vision of
a unied power system for the building.
Figure 33: Monthly Output of Air X Turbine
H
Chapel
Admin
Figure 34: Red Dot Shows Proposed
Location of Wind Turbine on North Side of
Wind Direction
-31-
The wind turbine may face power losses due to the proximity of the turbine to the
chapel. Although the structure is currently open-air, Mustard Seed plans to enclose the sides as
the development of the site continues. The primary wind direction is not impeded by the
structure, but turbulence from the building may reduce the power generated. Another option for
the mount of the turbine was to attach the support poles to the main beams of the chapel. This
mounting scenario was discarded due to concerns of vibration, noise, and the difculty to repair
and access the turbine in the case of a hurricane. A ground mounted turbine can quickly be
disassembled, and will not face as the same strength winds as a turbine mounted high on an
existing building.
To provide rigidity yet ease of disassembly, the
turbine will be mounted on a twenty foot long piece of
metal schedule 40 pipe, and afxed to the ground with
three guy wires. The guy wires are attached to the
cement piers surrounding the pole. All areas of cement
will need to be reinforced with rebar.
7.1.5 Electrical Connectivity
To protect the wires from the elements, all cabling will be
strung through electrical conduit. The plastic enclosure on conduit
keeps the wire from deteriorating in the sunlight, and also helps to keep
the wiring organized.
Figure 35: Sketch of Guy Wires
-32-
7.2 Station Design: Processing Electronics
7.2.1 DC Breaker Box
The original breaker box from the Renewable Energy
Homestead at Penn State was salvaged to be reused for the solar array.
The box is manufactured by Outback, and was originally intended to
pair with the PS1 power system and Outback charge controller. The
breaker box is the location for all electrical connection in the system. The
front panel contains circuit breakers which enable the batteries, and panels to be disconnected.
The wiring for the solar array and the wind turbine will be combined in the breaker box. Every
device in the charging station is routed through the breaker box.
7.2.2 Wire Sizing Calculations
The sizing of electrical wire in any power system is important because the gauge of the
wire determines the total current that can safely ow through wire. Decreasing the wire diameter
increases the resistance of the current
through the wire. As resistance increases,
the wire is in danger of overheating, with the
potential of starting electrical res. To avoid
possible hazards, wire gauge has been
standardized by the American Wire Gauge
(AWG).
8
Figure 36 shows the relative wire
cross sections of several different wire gauges.
Figure 36: AWG Sizing Scale
8
-33-
7.2.3 Charge Controller
The charge controller used for the charging station is the
Outback MX-60. A solar array typically operates at 12 - 24 VDC, and
therefore most charge controllers operate at this range. The Solarex
MST43-MV panels operate at a moderate voltage range of 72 VDC
nominal. Few commercially available charge controllers can actually accept a voltage this high.
The MX-60 was primarily chosen for the wide voltage range of input and outputs; accepting any
PV array voltage up to 72 VDC, and 12, 24, 36,48,
and 60 VDC battery banks. The voltage step down
from the 72 VDC array to a 12 VDC battery bank is
made possible by the digital Maximum Power
Point Tracking (MPPT) circuitry. This function
searches the array to determine the maximum
power point voltage, and proceeds to charge the
batteries at this point.
22
The MST43-MV I-V curve
in Figure 37 has been annotated to describe the
effect of MPPT on the power output of the
system. Without the step-down abilities of the MX-60, the charge controller could only charge the
batteries at the voltage of the battery bank, here 12 V. The location of 12 V is designated on the I-
V curve by the letter A. The maximum power point is marked by the letter B. The power output
at A can be calculated by multiplying 12 V by approximately 0.78 A current, resulting in an
output of 9.36 W compared to the rated output of the panels at 43 W, an 80 percent power loss in
the output of the panels.
8

A
B
Figure 37: Effects of MPPT
I
-34-
In other areas, the Outback MX-60 is more of a powerful and sophisticated device than
the charging station would require. It can handle up to 60 A of input current, where the solar
array will likely output no more than 3.6 A. The unit also has many features that are benecial
for educational demonstration. The MX-60 logs and saves 64 days of operational data that can be
reviewed. These data can be used to compare the output of the power generation sources with
weather conditions, and be used to log the energy production of the entire system.
22
7.2.4 Battery Bank
The battery bank was donated to the project by the Penn State
Solar Decathlon team. The four UB12900 batteries had been purchased
as a replacement batteries for a set used in the 2007 Solar Decathlon
competition. The batteries operate at 12 VDC nominal, are each 90 Amp
hours, totaling 360 Amp hours of storage. The four batteries will be wired in parallel. In this
conguration, the current will add and the voltage will remain constant.
8
To maximize the life of the battery, the bank should be designed to operate in the
required range without discharging below 50% of the total storage capacity. This battery bank
then has 180 Amp hours of storage. A simple conversion can be used to convert the total Amp
hours to the number of kilowatt hours stored in the batteries. Since power is the product of
current and voltage, a kilowatt hour is equal to the Amp hour storage of the battery bank
multiplied by the voltage of the battery bank, and divided by 1000. Here, the total kilowatt hours
stored by the four UB12900 batteries is 2.16 kWh. The approximate required demand for the golf
carts is 2 kWh. As anticipated, the storage in the battery bank is larger than a single day of
operation. Ideally, the battery bank would be large enough to allow for more than one day of
storage. The relatively high cost of batteries, and the tight budget demands on this project did
not allow additional batteries to be purchased to expand the bank, although the bank can be
-35-
expanded at any point. Also, because the batteries are wired in parallel, additional batteries can
be added at any time.
7.2.5 Inverter
Inverters are separated into two primary categories: those that
produce a modied sine wave, and those that generate a pure sine
wave. The difference is in the quality of the power, and the price of the
inverter. The voltage provided by a modied sine wave inverter does
not follow the same smooth oscillation as a pure sine wave generator as shown in Figure 38.
Figure 38: Comparison of Modied Sine Wave and Pure Sine Power
J
The consequence of using a modied sine wave instead of a pure sine wave is
diminished performance from electrical equipment using the output power of the inverter. The
efciency of motors and transformers will be reduced, and more sensitive electronics will
experience uncharacteristic performance problems. Problems such as crackling in audio
equipment or rolling lines on digital display screens are common results of diminished power
quality.
24

-36-
In this case, the modied sine wave inverter may cause decreased performance for the
charger. When designing a system for the lowest possible cost, it can be difcult to determine
where to sacrice quality for price. In this instance, where the donated solar panels and wind
turbine prevent the quantity of available charge from being the most serious concern, a modied
sine wave inverter was chosen.
The Go-Power GP-1750HD inverter is capable of continuously producing 1500 W of
output power. The side view of the inverter in gure 39 shows the output and status indicators
on the GP-1750HD inverter.
25
The bar graph meters, over temp and overload indicators are
valuable status indicators to help diagnose possible problems with the inverter. The most
signicant feature of the inverter for a small scale charging station with few loads is the pair of
AC outlets. These outlets allow the charger to simply plug into the inverter.
Figure 39 : Side Panel View of Inverter Showing Indicators and Connections
K
-37-
7.3 Station Design: The Charger - User Interface
7.3.1 Benets of an AC Receptacle
The charger has been designed and sized specically for a single golf cart charging unit.
Although this is the intended use of the power, the needs of the site will likely change, and the
charging station should be designed to be exible. The output of the charging station is an AC
receptacle, allowing the users to plug any 110 VAC device. A light, radio, or fan could be plugged
into this receptacle with little consequence to the total available power.
7.3.2 Golf Cart Charger
The golf cart is charged with a mobile charging unit. Currently,
the Jacobs Ladder site operators keep the charger on the golf cart at all
times in a small compartment beneath the rear seat. The charger is
plugged into the golf cart, and has a standard US three-prong plug to
connect to a 110 VAC source. When the golf carts pull up to the library container, the plug can be
inserted into the 110 VAC receptacle for the duration of the charge. After an unfortunate string of
days with little wind or sun, when the station is depleted of charge, the cart can dock instead at
another receptacle.
7.4 Station Overall System Design
7.4.1 Charging Unit Placement
All charger components must be grouped in the container library to maximize their
functionality, accessibility, and educational potential. The design for the charger must also
complement the intended purpose of the library. To accomplish this, an overall design for the
container was created. The design species a corner of the container to hold all of the solar
components in a centralized and concentrated location.
-38-
Figure 40: Container Floor Plan
C
In this arrangement, visitors will be able to view the solar electrical components
immediately upon entering the door of the container. This location has been chosen to reduce the
risk of water damage to the electrical components. All equipment is wall mounted above the
level of the air vents. This placement of the electrical components will unify the entire North half
of the container as an informational area for sustainable development of the site.
7.4.2 Electrical Component Arrangement
The electrical components are all to be mounted on a sheet of 1/2 thick plywood. The
components are arranged to provide a logical ow of electrical current through the equipment.
Figure 41 shows the mounting location of the system components.
A
B
D
C
E
Figure 41: Component Arrangement
-39-
Wires from the solar array will rst enter the disconnect box (A), then enter the Outback
breaker box. The breaker box forms the central network for the remaining components; both the
charge controller and inverter are wired onto respective terminals of the breaker box. The nal
disconnect box is used to separate the batteries from the breaker box. The full circuit diagram of
the breaker box, is found in Appendix O.
7.4.3 Solar Charging Station Rack Mount
The charging station rack mount has been
designed to hold and protect the solar components, place
the components in an educational arrangement, and
interface smoothly with the library bookshelves.
In this arrangement, all components are
protected, yet visible for viewing. The batteries will be
placed off the ground on an extended bookshelf, and will
be covered by plexiglass. Although batteries are not
particularly dangerous, they should be kept out of reach.
The rear 2x4 support posts will be bolted to the
Western wall of the container. Upon completion of the
container library, bookshelves will interface with the
edges of the charging station rack mount to form a
unied transition between library and electrical
container spaces.
Figure 42: Component Mounting Scenario
-40-
7.5 Project Budget and Cost Analysis
The project was sponsored by In total, the charging station components could all be
acquired for approximately $1100. Detailed budget information can be found in Appendix P. An
additional $750 was spent to ship the components to Jamaica.
8. Implementation: Jamaica Design-Build
8.1 Overview of Design Build Week
Over the Thanksgiving week of 2008, the Penn State Jacobs Ladder Design-Build team
traveled to Jamaica to construct the shipping container library and the solar wind hybrid
charging station. A total of ve University students were led by Dr. Neil Brown. The team had
planned a four day intensive build to complete the projects. The team had coordinated the
delivery of the container and the shipping of the solar components to arrive on site before the
team arrived on November 22, 2008.
8.2 Murphys Law
8.2.1 Weather
November is rainy season in Jamaica. Daily periods of rain wash over the Blue
Mountains. The MSC staff working in Jamaica intended to build a concrete foundation for the
container before the team arrived, however, due to the periodic rain, this foundation could not be
poured. Instead, a temporary foundation was
constructed from cement blocks.
Concerns over the strength of the blocks led
to caution during the build week. Similar concrete
blocks on site crumbled when used as a stepping
stool, or even when moved. As a result, massive
building components were not assembled such as the green roof and solar mounting rack
Figure 43: Temporary Block Foundation
-41-
8.2.2 Where are the Solar Components?
To reduce the budget, every attempt was made to acquire donated project materials in
the United States. Costs were reduced dramatically by utilizing the solar panels and the wind
turbine donated by the Penn State Center for Sustainability. In this way, the high cost of new
materials led to the hybrid power system, a better design for the site.
Though not particularly sustainable, or benecial for the local economy of Jamaica, plans
were made to ship many of the donated materials to the site. These plans were formulated after
learning that MSC has free international shipping with Food For the Poor, a faith-based non prot
organization. MSC representatives reported to the Penn State Jacobs Ladder development team
that a shipment could be sent to Jamaica in the period of two weeks, and arrive on site.
2
Little
more than a month before the implementation week, the team was informed by MSC staff that
the two week quote had been a mistake; rather, a two week notication was needed to get the
materials picked up. Shipping required another two months. Another shipping option was
necessary.
Next, the Jacobs Ladder team contracted with an independent shipping company,
promising arrival of the solar components over a week before the team was schedule to arrive in
Jamaica. The components were packed, and the shipment was made. The day before departure
for Jamaica, the team learned that the shipment of the components had been delayed, and the
new estimated arrival date was after the implementation week.
8.3 Revised Plans
8.3.1 Theory of Appropriate Technology
The absence of solar components brought a new set of questions. Should the installation
be pushed off until the next trip to Jamaica? Will future Penn State design teams know how to
install the solar power system? Could the charging station be constructed and maintained by
local Jamaicans without help of Penn State?
-42-
The nal question set a new standard for the continuation of the project that shouldve
been with the project from the beginning. Appropriate technology utilizes environmentally,
economically, and socially sustainable solutions for communities to reduce poverty and protect
natural resources.
26
When implementing a new technology, can a build-and-run installation ever
be successful? Although the charging station encompassed many aspects of sustainability, it
lacked the self-sustaining component that frequently makes similar projects fail. A technology is
not a solution if individuals on the ground cannot understand enough to keep it working.
8.3.2 Installation and Instruction Manual
The charger is not particularly complicated, but if the designer hundreds of miles away is
the only person who understands the functionality of the entire system, even the smallest glitch
could derail successful operation. In an attempt to make the design comprehendible and within
technological reach of the local staff workers, an installation manual will be developed to
describe the system components, how they are assembled, and cared for. The installation manual
will begin as a specic instructional document for installing this specic solar charger design, but
over time will develop into a more general installation manual to train and prepare electrical
installers for solar work.
8.3.3 Developing Local Connections
To test the appropriateness of the solar installation manual, and the appropriateness of
the design, Jamaican University students will assemble the charging station with the installation
manual. Local technical connections are needed to guarantee the successful future operation of
the charging station, and to build sustainable international relationships for future developmental
work at Jacobs Ladder. In past projects, The Engineering Design School at Penn State has
partnered with the University of Technology (UTech) in Kingston, Jamaica. UTech is again
interested to partner with the installation of the solar components. A masters student with an
interest in solar power for water pumping applications will be starting at UTech in the Spring of
-43-
2009. This student will work with the Penn State Jacobs Ladder design team to install the power
system.
8.3.4 Future Alternative Energy Conference
The design team is hoping to expand on the partnership formed from the solar
installation into an international forum on alternative energy. One of the goals of MSC is to give
back to the neighboring communities struggling to solve daily problems. Upon installation of the
solar charger, The Penn State University will plan a weekend long alternative energy conference
at the MSC Jacobs Ladder site. The numerous alternative energy technology companies in
Jamaica will be invited to share products and expertise. Jamaican University professors, students
and interested community members will be invited to learn about alternative energy and
sustainability. The conference will close by re-assembling portions of the hybrid charger to give
conference attendees hands on experience with solar and wind systems.
8.4 Results of Design-Build Week
8.4.1 Placement and Finishing of Container Library
Despite the unfortunate weather conditions, and lack of solar components, a large
amount of work still was completed on the
container library. Holes were cut in the
container wall to form spaces for air vents,
windows and doors. After completion of the
chapel, the container library and sensory garden
will be a welcoming place for residents to pause
and relax.
Figure 44: South Container Elevation
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Figure 45: View of Container looking Westward toward Chapel
8.4.2 Completed Library Interior
The interior of the library was converted from a empty shipping container into library
with bookshelves surrounding the perimeter of the building. Figure 46 is a view from the open
doors of the container. The photo on the left is an actual image of the container taken at the end
of the build week. The photo on the right is an image of the container with digitally
superimposed solar components, books, and display posters.
Figure 46: Developed Container Library
-45-
8.4.3 Identication of Electrical Vehicle Specications
Sizing calculations for the charger specications were completed before the electric
vehicles arrived at the Jacobs Ladder site. Two golf carts were acquired by MSC, however, only
one is currently operational. The cart is an EZ-GO TXT Shuttle. On this trip, the cart usage could
be observed for the rst time. The primary user of the cart was the site operator, Brother
Anthony on many quick trips about the site; although he was suffering from an injured foot and
had difculty walking.
9. Conclusions
9.1 Experiences and Lessons Learned
The difculty planning for and organizing the build week in Jamaica revealed many
realities of international work. It is difcult. Proper preparation and planning does not
guarantee a successful implementation. When weather, language, and cultural differences clash,
plans change, and project goals are redened. The shipping problems changed the scope of the
project, and as a result, the entire design became more sustainable. International relationships are
being developed that would not have otherwise. The project revealed that problems can be an
opportunity to improve a design.
9.2 Improvements: A Marketable Design
9.2.1 A Justication for Alternatives: The Cost of Power
Though alternative power systems may seem complex and expensive, It is important to
remember that power is not free, especially in areas of developing nations far removed from an
electrical provider. During the rst community assessment trip to the Mustard Seed site in
January of 2008, the Jamaican Public Service (JPS) was working to erect 13 concrete power
transmission poles to carry electricity to the Jacobs Ladder site. Although Mustard Seed as a
-46-
non-prot organization did not pay for
the transmission lines, they are quite
costly. When long power-line runs are
brought into consideration, off-grid
power systems may become the only
option.
Electricity in many developing
countries is largely a temporary notion.
Variable rates and intermittent service keep the grid from being a reliable power source, even if a
community is lucky enough to have a power transmission line stretching to their homes.
9.2.2 An Analysis of the Project Costs
The implementation of any solar power system is a signicant investment, in this case,
signicantly more than the available grants. Fortunately for the success of the project, the Center
for Sustainability at Penn State was able to provide a large amount of the equipment. Without
these donations, the cost of the charge sources (solar panels and wind turbine) would have been
beyond the available project budget. Despite the nancial advantage, the solar panels carried a
set of disadvantages. The panels operated at a low efciency, a high voltage, required a large
mounting space, and a sophisticated charge controller to make the charge usable. Had all of the
components been purchased, a unied design would have greatly streamlined the charger, and
decreased the cost and sophistication of components.
Figure 47: Power Lines Stretching to MSC Site
-47-
9.2.3 The Redesign
In an attempt to determine the actual cost of the charger without donations and
unusually group parts, the charger has been redesigned with new, commercially available parts.
This charger has an identical power output with the Library Charger.
Southwest Wind Power Air X 12 V Turbine
The Southwest wind turbine is the same design as the turbine used in the
charging station. The turbine is microprocessor controlled, and does not require a charge
controller.
17
Kyocera KC130TM 130 W
The Kyocera polycrystalline panel operates at 12 VDC, and outputs a current of
7.39 A, producing a total power rating of 130 W. Two of these panels produce the same power as
the six Solarex thin-lm panels used in the charging station.
27
Morningstar Prostar 15A, 12V Charge Controller
The charge controller is the most signicant change from the original design.
The Morningstar Sunsaver is simple, but complete in operational functionality. The primary
disadvantage of the Sunsaver compared to more expensive charge controllers is the lack of
Maximum Power Point Tracking capabilities, therefore the system will loose efciency as the
solar intensity changes throughout the day.
28
Go Power GP-1750HD Inverter
The Go Power inverter is the same model as implemented in the charing station
-48-
design. The inverter is low cost and delivers dual 110 VAC outlet for plug loads, making
transitions quick and easy.
25
UB12900 Sealed 12 V AGM Battery 90 Ah
The redesign utilizes the same battery bank, providing 360 Ah of storage. The
batteries are connected in parallel. The bank could be expanded by adding an additional battery
if additional storage is desired.
23
Midnite Solar MNPV6 Combiner Box
The combiner box is the central linking unit for all electrical components. The
combiner box contains the busbars and fuses for electrical interconnections.
29
Square D Disconnects
Electrical disconnects are needed to cut electrical power to components during
system maintenance. The Square D disconnect utilizes 100 A fuses to protect electrical inputs.
30
Figure 48: Charging Station Redesign - Component Cost Estimation
-49-
As expected, the cost of the components is far greater than the project budget, however,
when shipping costs are added, the gures become much closer. The system cost is certainly
reasonable for a small scale power system.
9.3 Feasibility of Implementing Design in Developing Nations
The design is feasible for developing countries, especially if the solar energy systems are
sold as kits, manufacturers use interchangeable parts, and knowledgeable technicians exist to
answer questions and repair broken systems. A benet of solar power is that there are no moving
parts, creating systems requiring very low maintenance. The cost of solar power systems is
signicant, however, in many cases this cost may be the only option for power.
9.4 Personal Impact of Development Work
After completing a full degree of credits at Penn State, the most meaningful learning
experiences have happened outside of the classroom. I believe that an international education is
one of the most important prerequisites for life after college. Whether working internationally or
at home, past experiences abroad are valuable in shaping a global worldview. My work with
Mustard Seed Communities and their Jacobs Ladder community has been my longest extended
international experience, with three trips and counting. Each time I leave Jamaica, I have the
knowledge that I will be back before long. This project has helped me to understand the
importance of sustainability. I am now beginning to grasp the importance of all aspects of a
sustainable design: how does it benet the people, their nancial well-being, and the health of
their environment.
-50-
10. Acknowledgments
This project never would have been completed without the patience, sacrice, and
assistance of many professors, friends, and family. To Dr. Colledge, thank you for opening the
door to international development and appropriate technology. Thank you Dr. Lau for teaching
me about sustainability. To Dr. Riley and the Penn State Center for Sustainability, thank you for
donating a wealth of system components. To the Carter Academic Service Entrepreneur (CASE)
Grant Selection Committee, the Alliance for Earth Sciences, Engineering, and Development in
Africa (AESEDA), and the Schreyer Honors College, thank you for providing the funding to
make this project possible. To Vaughn, Mclean, and Grim, thank you for sacricing your
Thanksgiving break to work from dawn to dusk in Jamaica. To Dr. Neil Brown for the mentoring
and friendship. Thank you for placing trust, hope, and condence in idealistic undergraduates.
To my family, thank you for sending me to Penn State, and encouraging my educational
development. To Spud, I think were still on track to save the world. Finally, to Ruth, thank you
for your endless love and encouragement. I love you, and cannot wait till I can call you my wife.
-51-
Appendix
Appendix A: References 2
Appendix B: Image Credits 5
Appendix C : Community Assessment: Site Maps 6
Appendix D: Wind Data 7
Appendix E: Needs Assessment Evaluation 8
Appendix F: Quality Function Deployment (QFD) Matrix 11
Appendix G: Charge Storage Selection Matrices 12
G.1 Analytical Hierarchy Process Matrix 12
G.2 Concept Selection Matrix 12
Appendix H: Site Location Selection Matrices 13
H.1 Analytical Hierarchy Process Matrix 13
H.2 Concept Selection Matrix 13
Appendix I: Station Design Selection Matrices 14
I.1 Analytical Hierarchy Process Matrix 14
I.2 Concept Selection Matrix 14
Appendix J: Dimensioned Library Drawings 15
Appendix K: Dimensioned Solar Mounting Rack 16
Appendix L: Wind Turbine Mounting Design 17
Appendix M: Dimensioned Solar Charger Drawings 18
Appendix N: Wind Turbine Hybrid Wiring Scheme 19
Appendix O: Breaker Box Wiring Schematic 20
Appendix P: Detailed Budget and Cost Analysis 21
-1-
Appendix A: References
1. "Mission Statement." 2007. Mustard Seed Communities. Nov. 2007 <http://
www.mustardseed.com/about/mission_statement.html>.
2. Moran, Matthew. "Jacob's Ladder Planning Sessions." Telephone interview with Steven F.
Marshall and Eric M. Sauder. Dec. 2008.
3. Ramkissoon, Gregory. Interview with Eric M. Sauder, Steven F. Marshall and Neil E. Brown.
Mar. 2008.
4. Ramkissoon, Clyde. Interview with Eric M. Sauder and Neil E. Borwn. Mar. 2008.
5.Brown, Neil E., Steven F. Marshall, and Eric M. Sauder. "The Plan for Jacobs Ladder." Jacob's
Ladder: A Sustainable Community for Disabled Individuals of Jamaica. Vol. 1. Oct. 2008.
2-3.
6. "Mining." The Gleaner. 4 Dec. 2008 <http://www.discoverjamaica.com/gleaner/discover/
geography/mining.htm>
7. Brother Anthony. Interview with Eric M. Sauder, Steven F. Marshall and Neil E Brown. Mar.
2008.
8. Dunlop, Jim. Photovoltaic Systems. Ed. Todd W. Stafford. Homewood, Illinois: American
Technical, Inc., 2007.
9. "Nanosolar to build world's largest solar cell factory." 21 June 2006. Nanosolar. 4 Dec. 2008
<http://nanotechweb.org/cws/article/tech/25180>.
10. "Latitude and Longitude: USA." BCCA. 22 Nov. 2008 <http://www.bcca.org/misc/qiblih/
latlong_us.html#pennsylvania>.
11. Baxter, Richard. Energy Storage : A Nontechnical Guide. New York: PennWell Corporation,
2005.
-2-
12. Sunray Solar Roof Kit. Electric Transportation of Arkansas. 2007. 18 August 2008. <http://
shop.etarkansas.com/product.sc;jsessionid=DC1A02EA6D520EA191880B9
4D762044F.qscstrfrnt02?categoryId=1&productId=1>
13. Solar Roof Kit. Cruise Car. 2007. 18 August 2008. <http://www.cruisecarinc.com/
product-solar-roof-kit.htm>
14. Transportation Analysis for the Solar Decathalon Competition. Tech.No. Solar Decathalon
Team, Colorado University. 2-4.
15. Mexico and Central America Solar Insolation Map. Alternative Energy Store. 7 Sept. 2008
<http://howto.altenergystore.com/reference-materials/solar-insolation-map--
caribbean,-mexico--central-america/a67/>.
16. Photovoltaic Modules: MST-43MV. Solarex, 1999.
17. Air X Owners Manual. Southwest Windpower, Inc. 9 October 2002.
18. Small "Hybrid" Solar and Wind Electric Systems. 12 Sept. 2005. Energy Efciency and
Renewable Energy. 5 Oct. 2008 <http://apps1.eere.energy.gov/consumer/your_home/
electricity/index.cfm/mytopic=11130>.
19. "AWS Truewind Wind Resources." Email to Matthew Moran.
20. Marshall, Steven F. "Sustainable Design and Construction of a Library for Disabled Children
of Jamaica." Thesis.
21. The Denitive Guide to Hurricane Protection." 4 Oct. 2007. Hurricane Protection Guidance. 2
Dec. 2008 <http://www.hurricaneprotectionguidance.com/hurricane-protection/
protecting-yourself-from-hurricanes/home-hurricane-protection.html>.
22. MX60 PV MPPT Charge Controller: Installation, Programming and Users Manual. Outback
Power Systems. 29 January 2007.
23. UB12900 Specications Sheet. Universal Battery, 2008.
-3-
24. DC - AC Converter Sizing Considerations. 2007. BD Batteries. 2 Dec. 2008 <http://
www.bdbatteries.com/inverterconsiderations.php>.
25. GO Power! Modied Sine Wave Inverter Owners Manual. Go Power! Electric Inc.
26. The National Center for Appropriate Technology. 2008. NCAT. 6 Dec. 2008 <http://
www.ncat.org/>.
27. Kyocera KC130TM Specications Sheet. Kyocera, 2008.
28. Morningstar Prostar Specications Sheet. Morningstar Corporation, 2008.
29. Midnite Solar MNPV6 Installation Instructions. Midnite Solar, 2007.
30. Enclosed Safety Switches. Square D, 1999.
-4-
Appendix B: Image Credits
A. MSC Logo. Digital Image. 2007. Mustard Seed Communities. 7 Dec. 2008 <http://
www.mustardseed.com>.
B. Jamaica Satellite. Digital Image. 2008. Google. 5 Dec. 2008 < http://www.maps.google.com>.
C. Penn State Jacobs Ladder Development Team. 2008.
D. "Solar Electric." 2008. Real Goods. 2 Dec. 2008 <http://www.realgoods.com/category/solar
+power/solar+electric.do>.
E. Solar Window. Digital Image. Lighting. OK Solar. 5 Dec. 2008 <http://www.oksolar.com/
lighting/>.
F. Ultra Capacitors. Digital Image. 2008. Tree Hugger. 15 Nov. 2008 < http://i.treehugger.com/
les/DDE-eichenberg-f2.jpg>.
G. Small "Hybrid" Solar and Wind Electric Systems. Digital Image. 12 Sept. 2005. Energy
Efciency and Renewable Energy. 5 Oct. 2008 <http://apps1.eere.energy.gov/
consumer/your_home/electricity/index.cfm/mytopic=11130>.
H. Air X Turbine. Digital Image. 2007. Southwest Windpower.
I. Photovoltaic Modules: MST-43MV. Digital Image. Solarex, 1999.
J. DC - AC Converter Sizing Considerations. 2007. Digital image. BD Batteries. 2 Dec. 2008
<http://www.bdbatteries.com/inverterconsiderations.php>.
K. GO Power! Modied Sine Wave Inverter Owners Manual. Digital image. Go Power! Electric
Inc.
L. Haddon Hall, Saint Ann. Digital Survey Image. 2003. J.R. Mais & Associates Ltd.
M. Mustard Seed - Jacobs Ladder Development Mean Annual Wind Speed at 30 Meters AWS
Truewind.
N. Wind Rose Chart. Digital Image. AWS Truewind.
-5-
Appendix C : Community Assessment: Site Maps
Figure 49: Jacobs Ladder Political Map
B
To Ocho Rios
To Moneague
Figure 50: Jacobs Ladder Topographic Map
L
-6-
Appendix D: Wind Data
Figure 51: Preliminary Wind data for MSC Jacobs Ladder Compiled by AWS Truewind
M
Figure 52: Wind Rosette Showing Primary Wind Directions At Jacobs Ladder
N
-7-
Appendix E: Needs Assessment Evaluation
Before the start of the project, several individuals were questioned to help dene
customer needs, develop design criteria, and determine weightings. The following diagram can
be used to clarify the ow of information into the design process. Both MSC planners, and staff
operators feed customer input into the concept development stage of the design process. Penn
State engineers and site planners will also contribute expertise to create a design-build project
that can be used by the Jacobs Ladder community.
Figure 53: Information Flow Process Diagram

Matthew Moran
Students from Penn State University began working with Mustard Seed Communities in
the Fall of 2007. Matthew Moran is the United States project relations director for Mustard Seed,
based in New York. He contacted the University beginning a partnership to develop sustainable
initiatives into the site, with hopes that Jacobs Ladder would become a community showcase of
sustainable and renewable technologies.
Moran and Penn State engineers have been working on a plan to phase sustainable
technologies into the Jacobs Ladder project. Moran plans to use sustainability as a marketing
point of attraction. Moran feels that bringing sustainability to the site will not only benet
-8-
Mustard Seed by controlling the cost of utilities and supplies, but garner grants and international
interest.
Since the beginning of the project, Moran supported the idea of using solar power as a
simple, versatile and reliable alternative energy source for any possible device installed in the
community.
2

Brother Anthony
The tangible need for this design project was originally expressed by Brother Anthony,
Jacobs Ladder site operator, in a January 2008 visit to Jamaica. During a January 5th, 2008
meeting, Brother Anthony explained that few staff persons from the surrounding towns own
vehicles for personal transportation. He mentioned that they were hoping to get golf carts to
shuttle staff into the site.
During a meeting with Brother Anthony on March 13, 2008, the need for
improvements in staff transportation was again mentioned by Brother Anthony. This time, the
problem was explained more fully. The most common method for transportation to the site is the
local taxi service. Although taxi fares are reasonable on well traveled routes, travel the last mile
back into the site incurs signicant rate increases. Brother Anthony explained that this cost for
this nal mile could exceed $14,000 Ja ($200 US). Anthony explained that in a country where a
large percentage of the population is living in poverty, this cost could be more than a quarter of
their monthly income. This cost forces most of the workers to walk the nal distance into the site.
On days with inclement weather, the staff wont come. This results in a highly variable staff
attendance for a medical facility which requires all of its personnel to be in attendance.
-9-
Brother Anthony stated that MSC staff was working to nd electric golf carts to carry
staff to and from the main road, back into the site. Anthony felt that irregularities and
deciencies in transportation were some of the greatest problems for preserving the operation of
the site.
7
Clyde Ramkissoon
Clyde is in charge of coordinating supplies, and managing many of the day to day needs
for all of the Mustard Seed Jamaica sites. Clyde was questioned about Brother Anthonys golf
cart request During a March 13, 2008 meeting. Clyde informed the Penn State engineers that
Jacobs Ladder would be receiving a shipment of two electric powered golf carts to be used for
transportation on and to the site.
4

Neil Brown
Neil is a Post-Doctoral student in animal science at Penn State, and a native Jamaican.
Neil has worked on the Mustard Seed project with Penn State since the beginning, developing
long range solutions for Penn States future involvement. This long range plan includes a
detailed integration of solar power with the developing Jacobs Ladder site.
Neil provided valuable insight to culturally shape designs to work in the country he is
most familiar with. Early on in the project, Neil expressed the need to keep any designs simple,
and as free as possible of maintenance concerns. Neil also emphasized the importance of
securing and maintaining the safety of any equipment placed on site from theft.
5
-10-
Appendix F: Quality Function Deployment (QFD) Matrix
Figure 54: Quality Function Deployment Matrix
-11-
Appendix G: Charge Storage Selection Matrices
G.1 Analytical Hierarchy Process Matrix
Figure 55: Charge Storage AHP Matrix
G.2 Concept Selection Matrix
Figure 56: Charge Storage Concept Selection Matrix
-12-
Appendix H: Site Location Selection Matrices
H.1 Analytical Hierarchy Process Matrix
Figure 57: Station Location AHP Matrix
H.2 Concept Selection Matrix
Figure 58: Station Location Concept Selection Matrix
-13-
Appendix I: Station Design Selection Matrices
I.1 Analytical Hierarchy Process Matrix
Figure 59: Station Design AHP Matrix
I.2 Concept Selection Matrix
Figure 60: Station Design Concept Selection Matrix
-14-
Appendix J: Dimensioned Library Drawings
Figure 61: Front View of Library
Figure 62: Side View of Library
-15-
Appendix K: Dimensioned Solar Mounting Rack
Figure 63: Top View of Solar Mounting Rack
Figure 64: Side View of Solar Mounting Rack
-16-
Appendix L: Wind Turbine Mounting Design
Figure 65: Wind Turbine Guy Wire Arrangement
Design and Installation Notes:
The pole will be greased, wrapped in plastic, then cement will be poured around it.
After the cement hardens, the pole can be pulled out, plastic removed, and a shaft will be formed
in the cement. This eliminates the need for nested metal pipe to support the turbine. The guy
wires will be attached to the cement piers surrounding the pole. All areas of cement will need to
be reinforced with rebar. The turbine post is approximately 25 schedule 40 metal pipe, and the
guy wire posts are mounted on a circle with a radius of 10.
-17-
Appendix M: Dimensioned Solar Charger Drawings
Figure 66: Front and Side View of Charger Unit
-18-
Appendix N: Wind Turbine Hybrid Wiring Scheme
Figure 67: Hybrid Array Wiring
17

-19-
Appendix O: Breaker Box Wiring Schematic
Figure 68: Breaker Box Wiring Diagram
22

-20-
Appendix P: Detailed Budget and Cost Analysis
Figure 69: Detailed Budget Showing Components Acquired on Build Trip, And Components Purchase on
Subsequent Trips.
-21-
ACADEMIC VITA
ERIC MICHAEL SAUDER
1412 Landisville Road, Manheim PA 17545
717.519.9190 sauder@psu.edu
www.personal.psu.edu/ems5054
______________________________________________________________________________

EDUCATION
The Pennsylvania State University
Graduation: December 2008 University Park, PA 16801
Bachelor of Sciences in Mechanical Engineering
Certicate of Community Service and Engineering
Current GPA: 3.52/4.0
Schreyer Honors College Scholar
Honors in Engineering Design.
Thesis: Development of an Appropriate Solar and Wind Hybrid Charging
Station for Electric Vehicles in Developing Countries.

SUSTAINABLE DESIGN EXPERIENCE
Jacobs Ladder Penn State Development Team Leader
September 2007 Present Haddon, Jamaica
Presented Penn State development plan to Prime Minister of Jamaica
and MSC Founder
Traveled to MSC Jamaica three times to perform community
assessments and thesis research
Public relations with Mustard Seed Communities (MSC) Penn State,
Jamaican Bauxite Institute, and University of Technology Jamaica
Prepared water storage and solar pumping proposal for the Jamaican
Bauxite Institute and the Prime Minister of Jamaica
Honors Thesis Research Project
September 2007 Present Penn State University Park
Designed 1kW off-grid solar power system for charging electric
vehicles in Jamaica
Charger constructed at Jacobs Ladder in November 2008
American Indian Housing Initiative
June 2007 Lame Deer, MT
Participated in Design Build of Morningstar Montana Home
-22-
ADDITIONAL WORK EXPERIENCE
TeamAg Inc.
May 2007 - August 2007 Lancaster, PA
Site survey experience using Trimble Total Station 5700
Worked with PA DEP and EPA to develop water certication
documents
Met with farmers and performed site inspections
United Campus Ministries
August 2005 December 2007 Penn State University Park
Ran leadership meetings and organized weekly group activities and
projects
Planned two Gulf States Service Trips: 100+ students traveled to
hurricane damaged coastal areas for week of service
Lancaster County Bible Church - Audio and Lighting
June 2006 Lancaster, PA
Trained in basic operation of audio and lighting control boards
Set up weekly live stage audio components

Eugene Forrey Woodworking - Cabinet Maker
May 2006 - August 2006 Lancaster, PA
Operated wood shop machinery
Led project teams to ll shop orders
ADDITIONAL SKILLS
Mac OS, Matlab, AutoCAD, Solidworks, MS Ofce, Sketchup, Adobe
CS3, Windows
AWARDS
Humanitarian Engineering Community Engagement Award
(April 2008)
College of Engineering Deans List (3/7 semesters)
George Settlemyer Fund for International Agriculture Experiences
(April 2008)
Nominated for Lamarr Kopp International Achievement Award
(December 2008)
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