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The S-Team
East Penn Sponsored Project
Penn State Berks
Edesign 100




By:
Tyler Simches
Robert Swahl
Bradley Schwenk
Evan Steigerwalt


Table of Contents

Introduction.......................................................................................................................
...........3
Problem
Definition......................................................................................................................3
Methods.............................................................................................................................
............4
Research............................................................................................................................
2
.....5-10
Generated Concepts
.....................................................................................................12-15
Concept
Evaluation..................................................................................................................17
Concept
Selection....................................................................................................................18
Applications......................................................................................................................
...19-22
Conclusion........................................................................................................................
.........22
Worldwide
Assessment..........................................................................................................22
Societal Impacts
...................................................................................................................22
References
............................................................................................................................23

Fig 1 House power flow
diagram........................................................................................... 8
Fig 2 Factory power flow
diagram......................................................................................... 8
Fig 3 Apartment power flow
diagram.....................................................................................8
Fig 4 Cruise Ship power flow
diagram..................................................................................9
Fig 5 Electric Load Profile for Average House
Consumption.........................................9
Fig 6 Electric Flow Diagram for all
Concepts....................................................................10
Fig 7 Concept
1.........................................................................................................................10
Fig 8 Concept #1 Assembly of
Module...............................................................................11
Fig 9 Concept
2.........................................................................................................................12
Fig 10 Concept #2 Assembly of
Modules...........................................................................13
Fig 11 Concept
3.......................................................................................................................14
Fig 12 Concept
3
4.......................................................................................................................15
Fig 13 Baseline Application (House)
..............................................................................18
Fig 14 Factory Power flow
chart...........................................................................................19
Fig 15 Appartment Power Flow
Chart.................................................................................20
Fig 16 Cruise Ship Power Flow
Chart.................................................................................21

Table 1 Concept specifications for each generated
design..........................................16
Table 2 Decision
Matrix...........................................................................................................18







Introduction
East Penn Manufacturing is releasing a new product called the UltraBattery. This
revolution in the industry is a hybrid device that contains lead acid battery chemistry and
Ultra capacitor technology. It exhibits extraordinary endurance when in a partial state of
charge, between 30-70%. The concept is applied to MW scale systems that support
solar, wind, and grid scenarios. The main importance of having energy available to
individual homes or businesses is being able to access the power when and where it is
needed. The majority of people rely on the grid however it is possible to set up
individual systems using renewable energy. The objective of this project is to design a
standardized energy storage module that can be used for a distributed energy storage
solution using the UltraBattery in the East Penn 24HR3000 package or AVR 95-7
package.

Problem Definition
Energy is needed in every home in order for humans to live their lives to the highest
standard of living. However, there is no efficient renewable energy systems set up that
can meet the needs of individual homes, communities, or any other application. Design
a power grid that can be used for many applications, that successfully exhibits all of the
criteria for success. In order to solve this issue, a power grid will be designed that can
generate a large amount of power which can also be stored for later use upon need.
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The limitations that affected the thought process and results of this project include: only
use the batteries provided, meet required power, easily accessible and maintainable,
and proper placement of modules.






Methods
The first decision that needed to be made for each module was the selection of
the battery type
There were only two choices of battery types, the 2V or the 12V
Concepts one through three all used the 2V battery mainly for the reasons
that it is more adaptable and takes up less space.
Concept four used the 12V for the reason that it contains more volts and
amps per individual battery
All four concepts each used the sunny island inverter in the module
This inverter was selected due to its high efficiency and large range of
access in terms of connecting with other inverters, such as the sunny boy
and windy boy
The sunny boy and windy boy are inverters that take in solar power and
wind power respectively, and convert them to direct current power
All the concepts are adaptable to powering other applications because more
modules can be placed together in order to generate more power
The 2V modules are more adaptable since they have a larger range of
output they can reach
The next decision to comes across the creative process was determining if the
modules were going to be connected to the grid or completely separate
The decision was made that all of the concepts are completely off the grid
using all of the power generated for their own needs
This shows that the modules are very productive and can be used in
isolated places resulting in wide adaptability to other applications
The main way to determine if the modules are a good decision for purchase is to
calculate the return of investment
The return of investment is equal to ((annual savings - (first cost / life))/first
cost)100
The return of investment is a percentage that shows the amount of money
that is either gained or lost over the life of the module
All of the concepts are eco-friendly since all of them use renewable energy for
power
5
All of the modules use steel as the base material and the terminal posts are
connected with copper wiring
These materials were selected since steel in a very strong material which
is also cheap
And copper wiring is very conductive and cheap, as well
After all of these factors were taken into place, the four concepts were made and
evaluated based upon the decision matrix
The decision matrix consisted of voltage, current, size, adaptability,
accessibility, safety, weight, cost, and cooling as the tools of evaluation
Each module received a score from one to ten, with ten being the highest
rating, for each factor based on the effectiveness of the module for that
factor
A total score was tallied up to determine the best overall rated module,
with concept one having the highest rating
Therefore, concept one was the recommendation for this project and a
physical model was built to represent it


Research
Grid Scale Energy Storage
Grid scale energy storage is another wording for large scale energy storage. This is
where when there is a surplus of energy being created compared to the demand for
energy and the excess is stored until it is needed. This energy is then tapped into when
the demand for energy is greater than the amount being produced. By doing this it
allows power plants to run on a more constant level of production rather than fluctuating
up and down to meet the needs of power consumption. This allows them to run more
efficiently and operated easier
Currently the largest form of grid scale energy storage is pumped-storage
hydroelectricity. This is where during periods of low energy consumption water is
pumped from an low area to a higher one so that when a large amount of energy is
needed the water can be released and passed through turbines thus creating electricity.

Lead Acid Battery Types and Applications
There are three main types of lead acid batteries. They are wet cell, gel cell and AGM.
The wet cell or flooded cell is a battery filled with an electrolyte solution and is prone to
hydrogen leaks and corrosion. The gel cell also has an electrolyte solution but it is
suspended near the plates and a silica additive is added to stiffen the solution so that
the possibility of leaks is much less than that of the flooded cells. The AGM or absorbed
glass mats is where the solution is suspended right next to the plates and this allows for
a much faster charge and discharge rate and a much more efficient one.
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Ultra Battery
The Ultra Battery is an AGM lead acid battery. The main difference between this battery
and other AGM batteries is that the ultra battery is a battery and a capacitor all rolled
into one. This means that it can give off high amounts of energy very fast and for a long
lasting period of time. Other impressive feats of the ultra battery include its ability to
power at a partial state of charge and its cycle life. This battery runs at optimal states of
charge between 30% and 70% charge. The cycle life of this battery is supreme reaching
about 194,000 to 200,100 cycles while remaining healthy.

East Penn 24HR3000 package
This is the 12V ultra batteries. These batteries are 259xmm167mmx209mm and the
battery weight is 56 lbs. These batteries have a capacity of 48.3 Ah for about one hour.

East Penn AVR 95-7 Package
This package can come in a multitude of possibilities. For the non-interlocking modules
you can get them in a three cell or a six cell configuration. The interlocking modules can
come in a two cell, three cell, four cell, or six cells per module. All of these modules
have a capacity of 285 amps over an eight hour period. Each cell is one of the 2V ultra
cell batteries.

PV-Hybrid Cycle Test
This test shows that the Ultra battery keeps its capacity at 100% over a 40 day period of
160 cycles. Comparatively this is amazing since the other batteries in the test dropped
to 80% in under 30 cycles or one of them lasted to 70% in 60 cycles before they all
died. This stated that the ultra battery had a far superior cycle life and is capable of
holding its full charge for a much longer period of time than other lead acid batteries.


Deficit Charge/Partial State of Charge
Deficit charge and partial state of charge are what makes the ultra battery so amazing.
These batteries do not need to be at a full charge to give off their full amount of
capacity. These batteries run optimally at a partial state of charge in between 70% and
30% state of charge.

PNM Network
The PNM network is the network of high voltage lines in New Mexico that connects the
power plants to the homes. This grid is connected to the larger grid serving the entire
western United States so that power can be moved about quickly so that power can be
moved in case of an emergency.

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Inverter Systems
SMA technologies offers a few inverters that would work very well with these concepts.
The have the sunny boy, sunny island, sunny towers and many others. The sunny
islands are capable of working on large scale systems and very efficiently converting
the energy with about an efficiency of 96%. The others are just as good but are for
smaller systems and work better with directly from solar panels to the grid.

Lead Acid Battery Packaging
When shipping or storing batteries it is very important to keep a few things in mind. The
biggest thing to worry about is leaking battery acid. To avoid any problems with this
there are a few things that need to be done first is to set down some sort of absorbent
layer under the batteries. This can be anything from cat litter to paper towels. Another
thing to do is make sure that the batteries are placed face up so as to keep the chances
of leaking down. Another thing to keep in mind is to place something in between the
batteries to keep them from jostling around and bumping into each other such as a
small piece of cardboard. The final thing to do is keep them cool. Batteries at extreme
temperatures are prone to losing their ability to keep a charge and thus keeping them
stored at a temperature around 60 degrees is optimal.

Current Ultra Battery Applications
Currently the Ultra Battery is being used in two big projects. The first is out in New
Mexico as they are being used in the PNM network. This is a megawatt system that is
used to lighten the load on the grid by shifting in solar power. The other project that is
going on is at Deka Batteries itself. Their System that is used to either hold excess
power from the grid when needed or can give off power to the plant when more is
needed. It can also give power back to the grid when power consumption is high and
production is low.

Existing Solutions
Currently homes get their off grid energy one of two ways. They either take the
generated energy directly and use it or pump the excess into the grid or they store the
excess for later. As of now there is no storage system that works anywhere near as well
as the Ultra Battery will. Nothing has the cycle life or the ability to last as long at a partial
state of charge.

Currently this is how certain places deal with their off grid energy.

8

Fig 1: House power flow diagram


Fig 2: Factory power flow diagram

Fig 3: Apartment power flow diagram
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Fig 4: Cruise Ship Power Flow Diagram



Fig 5: Electric Load Profile for Average House Consumption






10

Fig 6: Electric Flow Diagram for all Concepts



Generated Concepts
Similar Concepts in all generations
Each Design will be using the same terminal connectors and terminal posts
The terminal posts will be screw in plugs into each module
The terminal connectors will be the same ones currently used in East
Penns unigy II models

Fig 7: Concept 1
Uses the 2V batteries
It uses the Sunny Island Inverter
6v
1
142.5 Ah per hour for 8 hours
in mm 180x840x635
11
The batteries will be connected with copper plates
The modules will be connected using high capacity copper wire
In each module there are 12 batteries 4 sets of 3 batteries in series and those 4
sets are paralleled together
There are 8 modules and they are in series they have 48V and 142.5 Ah
This module is made of steel and for racking has slots in the top for extruded
parts on the bottom of others to fit into so as to avoid sliding around
The ideal placement would be underground outside of the house or town and
kept cool using geothermal means


Fig 8: Concept #1 Assembly of Module



12

Fig 9: Concept 2
Uses the 2V batteries
It uses the Sunny Island Inverter
Each module is 60V
Each has 35.625 Ah per hour for 8 hours
In mm 250x840x760
The batteries are all connected by copper plating
The modules are connected using high capacity copper wiring
In each module there are 15 batteries all in series
There are 2 sets of 2 modules each set has 120 V and 35.625 Ah with each set
using a sunny Island inverter
The module is built of steel and each one has feet on the bottom that fit into
holes in the top to keep the module from moving around
Placement for this module is varied such as underground or in a shed or other
enclosure outside of the house yet protected from the elements, while using
geothermal means to keep it cooled.

13

Fig 10: Concept #2 Assembly of Modules
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Fig 11: Concept 3
Uses the 2V batteries
It uses the sunny island inverter
Each module is 8V
Each has 105Ah per hour for 8 hours
In mm 235x675x635
The batteries will be connected using copper plates
The modules are going to be connected using high capacity copper wires
In each module there are 12 batteries with 3 sets of four batteries in series and
those three sets are in parallel
The module is made of steel and the modules would be welded together to keep
them from moving about.
Placement for this one is also varied and can be placed underground or outside
sheltered from the elements

15

Fig 12: Concept 4
Uses the 12v batteries
Uses the sunny island inverter
Each module has 48V
Each has 108 Ah per hour for 1 hour
In mm 518x565x209
The batteries will be connected using copper plating
The modules are connected using high capacity copper wiring
In each module there are 8 batteries with 2 sets of 4 in series and the 2 sets are
in parallel
The module is made of steel and the modules simply rest on or next to each
other




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Concept Chart for individual model

Table #1: Concept specifications for each generated design
Concept 1 Concept 2 Concept 3 Concept 4
Voltage 6 30 8 48
Current 142.5 35.625 106.675 96.6
Size (mm) 180x840x635 250x840x760 235x675x635 518x565x209
Inverter sunny island sunny island sunny island sunny island
Accessibility No back
access, screw
on front panel
No back
access, units
can be stacked
for various
power needs
has front
terminal posts
and front
removable lid
No back
access,
Stackable units
provide variable
stack heights,
widths and
output
no back, only
front terminal
posts
Safety ie electrocution Front plate over
the batteries,
no back
access, and
units stack into
each other
Only access
from the lid and
must be
opened for that
and the
terminal posts
signs explaining
risk warning not
to touch or
electrocute
only front
access, air
holes small
enough where
nothing fits in to
them
Weight (lb) 578 750 590 475
cost $8,465.50 $5,311.50 $6,357.00 $1,008.75
Cooling Vents an inch
and a half from
the sides and
every inch
down the
module. Two
holes on top of
module for
terminal posts
on top module.
And
Geothermally
placing of the
modules.
vents on sides
with
geothermal unit
on one side to
cool
Vents on sides,
tops, and
bottoms of each
single storage
container.
container legs
provide space
in between
units for air
flow.
vents on all
sides of the
module, space
between
modules for
natural odd
shape
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Explanation of Decision Matrix
To power a house volts need to be 240.
All designs reach required voltage
The higher the amps the better.
Design 1 has the highest amps
Size and Adaptability are similar.
Smaller the Module better it can adapt
Design 1 is the smallest therefore the most adaptable
Weight also ties into size and adaptability.
Design 3 weighs the least and has a good adaptability rating
Able to access but still safe.
Design 3 is the most accessible but 1 is the safest
Batteries optimally need to be at 77 degrees.
Designs 3 and 4 have the most airflow therefore have the best cooling
Finally cost, high cost is bad the lower the cost the better.
All pretty cheap designs 1 and 3 are the cheapest
Because they have the same number of batteries















Table #2: Decision Matrix
Weight Concept 1 Concept 2 Concept 3 Concept 4
Voltage 10% 10
100
10
100
10
100
10
100
Current 10% 10
100
5
50
8
80
2
20
18
Size 15% 9
135
6
90
8
120
6
90
Adaptability 10% 10
100
7
70
9
90
9
90
Accessibility 2% 7
14
7
14
8
16
5
10
Safety 8% 9
72
7
56
8
64
2
16
Weight 15% 9
135
7
105
9
135
10
150
Cost 20% 9
180
8
160
9
180
10
200
Cooling 10% 9
90
7
70
10
100
10
100
Total Score 100% 926 715 885 776

Application for Concept #1
Baseline Application (House)

Fig 13: Baseline Application (House)
The generation and load profile are about the same but over different periods of
time this Concept would generate about 30 Kwh per day and the house uses
around 27.5 Kwh per day
This Concept would use around 16 modules for a house
These would be set up in two groups of eight and each group would have one
inverter
Customers Without Solar Panels and Wind Turbines (in PA)
Only Solar would be a -5.6% Return on Investment (per year)
Half and half would be a -5.2% ROI (per year)
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Not Worth it
Customers With Solar Panels and/or Wind Turbines already installed
10.09% Return on Investment (per year)
Worth it
Investment turns positive when cost for solar panels and/or wind turbines is less
than $20,000.
Payback Period
7.83 years 8 years
To power a house with solar power it becomes much cheaper in areas with more
sunlight
The cost for solar panels with low sunlight is about $200,000
In areas with medium amounts of sunlight the cost is around $150,000
Areas with the highest amounts of sunlight will cost about $80,000

Alternate Applications
Factory

Fig 14: Factory Power flow chart
One system produces about 30 Kwh per day and this concept would need at
least 60 Kwh per day, therefore the systems would need to be doubled from the
baseline
Since the system is doubled in order to meet the requirements of this application,
32 modules would be needed and they would be split into groups of eight with
four inverters
Customers Without Solar Panels and WInd Turbines (in PA)
Only Solar would be a -8.4% Return on Investment (per year)
Half and Half would be -7.8 ROI (per year)
Not Worth It
Customers with Solar Panels and/or Wind Turbines already installed
15.1% Return on Investment (per year)
Worth It
Investment turns positive when cost for solar panels and/or wind turbines is less
than $20,000.
Payback Period
11.7 years 12 years
To power a house with solar power it becomes much cheaper in areas with more
20
sunlight
The cost for solar panels with low sunlight is about $200,000
In areas with medium amounts of sunlight the cost is around $150,000
Areas with the highest amounts of sunlight will cost about $80,000

Apartment

Fig 15: Appartment Power Flow Chart
This application is very similar to a house where it uses about 27 Kwh per day
and one system would produce about 30 Kwh per day so that would be all that is
needed
A system consists of 16 modules which would be all that is needed
The 16 modules would be split into two groups of eight with two different
inverters
Customers Without Solar Panels and Wind Turbines (in PA)
Only Solar would be a -5.6% Return on Investment (per year)
Half and half would be a -5.2% ROI (per year)
Not Worth it
Customers With Solar Panels and/or Wind Turbines already installed
10.09% Return on Investment (per year)
Worth it
Investment turns positive when cost for solar panels and/or wind turbines is less
than $20,000.
Payback Period
7.83 years 8 years
To power a house with solar power it becomes much cheaper in areas with more
sunlight
The cost for solar panels with low sunlight is about $200,000
In areas with medium amounts of sunlight the cost is around $150,000
Areas with the highest amounts of sunlight will cost about $80,000

Cruise Ship

21
Fig 16: Cruise Ship Power Flow Chart
This application has a wide range of Kwh per day but this range seems to
centralize around 30 Kwh per day and one system produces 30 Kwh per day
On average one system would be enough to power a cruise ship, so 16 modules
would be needed however some can may need to added or taken away
depending on the size of the cruise ship
Recommendation for Cruise Ship
The 16 modules would be split into two groups of eight with two inverters, one for
each group
Customers Without Solar Panels and Wind Turbines (in PA)
Only Solar would be a -5.6% Return on Investment (per year)
Half and half would be a -5.2% ROI (per year)
Not Worth it
Customers With Solar Panels and/or Wind Turbines already installed
10.09% Return on Investment (per year)
Worth it
Investment turns positive when cost for solar panels and/or wind turbines is less
than $20,000.
Payback Period
7.83 years 8 years
To power a house with solar power it becomes much cheaper in areas with more
sunlight
The cost for solar panels with low sunlight is about $200,000
In areas with medium amounts of sunlight the cost is around $150,000
Areas with the highest amounts of sunlight will cost about $80,000

Conclusion
Concept #1 provides the ideal amount of batteries to properly power a house completely
off grid. To do this it uses 16 battery modules. These are split into 2 groups of 8 with
one inverter for each group. Each of the modules uses twelve 2V batteries. These
batteries are in the configuration of 4 sets of 3. The 4 sets are in parallel and then the 3
batteries in each set are in series.
The terminal connections can be error proofed for the DIY community by painting the
connectors certain colors. For example one could paint the outgoing connector brown
and the ingoing yellow. These colors would be good because people who are color blind
are most likely red-green color blind so the chances of not being able to see yellow and
brown is greatly reduced. On top of that one can write in and out on the connectors to
erase any confusion.
22
Worldwide Assessment
This recommended concept has the possibility to be used very well in other parts of the
world. If this concept is used in PA it will not be very profitable or worthwhile, yet if it is
placed in areas with greater amounts of sunlight it has the possibility to be fantastic.
Placing this in an area such as the Sahara Desert would be ideal. The amount of
insulation hours for solar panels there is much higher than in PA. The insulation hours
are about 6.9 hours of sunlight in the Sahara compared to the 2.9 in PA. With this
higher insulation rate the amount of solar panels needed to support the system drops
and the ROI and Payback period is much shorter as well.
Societal Impacts
The societal Impacts for the recommended battery module are not that great. For the
module itself and the connectors they are all made of steel and copper. Once that
module breaks or is out of date the steel would all be melted down and the copper
would be reused in other parts of the home because copper is a very expensive metal.
As of the batteries they will be recycled and used to create new batteries. There will be
no great impacts on the society.
References
http://arpa-e.energy.gov/LinkClick.aspx?fileticket=k-81ITzfv34%3D&tabid=259
http://www.batterystuff.com/kb/articles/battery-articles/battery-basics.html
http://www.pnm.com/systems/lines.htm
http://itep68.itep.nau.edu/itep_downloads/Anchorage_11SWM_Haz/Day2/Backhaul/TRI
%20Lead%20Acid%20Battery%20Instructions.pdf
http://www.sandia.gov/ess/docs/pr_conferences/2010/hund_snl.pdf
http://www.furukawadenchi.co.jp/english/research/new/ultra.htm

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