2015 IEEE Conference on Technologies for Sustainability (SusTech)

Solar Energy for Electric Vehicles

Fred Chiou, Ph.D., Member, IEEE
Electronics Engineering Technology, Weber State University

Abstract — Several energy efficiency projects have been Based on the available components, the target of this pilot
performed on Weber State University campus in the past years. project is to build two solar charging stations with different
The achievement is remarkable. This paper will address the capacities. One station is for charging electric motorcycles and
design of a pilot project, Solar Charging Station, through the other is for charging an electric bikes. The capacity for
student’s senior project for education and research. Students will
electric motorcycles is larger than that of electric bikes. The
learn the theory of solar Photovoltaic (PV) systems and to build
an experimental solar stations to charge the electric bikes and design consideration will be discussed in the following
electric motorcycle. The system will be demonstrated for two new sections. If the pilot project is successful, more solar charging
courses, Renewable Energy and Solar PV Systems. The project is stations will be installed on campus.
supported by the Office of Energy and Sustainability at the
University. If the pilot project is successful, more solar charging II. PROJECT MOTIVATION
stations will be installed on campus. The goals of this project are
to educate the students of the University with the concept of Weber State University encourages all faculty, staff and
sustainability, the theory and hands-on experience of solar students to utilize the public transportation and bikes for their
energy applications and to promote the sustainability on campus transportation between the train transit station and the
by utilizing renewable energy. University campus to reduce the use of automobiles. However,
the long uphill (about 4 miles) from the train transit station to
Index Terms— photovoltaic; solar panel; solar module; solar PV the campus will be a challenge to the bikers. Riding electric
system; electric bike; electric motorcycle; solar charging. bikes will be helpful to mitigate the burden and encourage the
utilization of the public transportation and improve the
I. INTRODUCTION environment. But if the electric bike is charged from the

A Lot of studies revealed the supply of fossil fuels such as

coal, natural gas and oil are limited. Researches have also
identified the impacts of using fossil fuel energy on global
electric outlet on the wall, it will not be sustainable because
the power from the electric outlet is generated by burning the
fossil fuel such as coal at the power company that generates
climate change. The demand for energy is increasing as the carbon dioxide (CO2) during the process of power generation.
world population grows and the economic growth in many
developing countries as well as the developed countries. The The idea of this project is to build "Solar Charging Stations"
energy crisis can be anticipated in the near futures. Alternative that will provide free electricity that is generated from the
energy or renewable energy opposed to fossil fuels ought to be solar Photovoltaic (PV) system for charging the electric bikes
actively explored earlier rather than late. Renewable energy and electric motorcycles on campus instead of charging them
such as solar energy can provide a long term solution and from the electric outlet on the wall. If the electric vehicle is
minimize climate change. charged with the electricity generated from solar energy, the
operation will be sustainable because the renewable energy
Using solar energy to build solar charging stations for (green energy) is used as the power source. For education,
charging electric bikes and electric motorcycles is a practical students benefit from this project by learning the theory and
application of sustainability. The idea is the solar charging hands-on experience of the system design. It also provides a
stations utilize solar PV modules to convert solar energy to platform for research in solar energy and its applications.
DC electricity. The DC energy can be stored in a battery bank
using a charge controller. An inverter is employed to convert III. SYSTEM DESIGN AND COMPONENTS
the DC voltage from the battery bank to 110 volt AC at 60 Hz The basic theory of the Solar Charging Station is to harvest
frequency that is identical to the power from the electric outlet the solar energy and convert it to AC electricity that can be
on the wall. This project will enable students to acquire an used to charge electric bikes and electric motorcycles. The
essential foundation towards how to design and build the solar Solar Charging Stations utilize solar PV modules to convert
PV systems for various applications. The students will also solar energy to DC voltage. The DC energy can be stored to a
learn the code compliances required by National Electric Code battery bank by charge controller. An inverter is employed to
(NEC) during the system design process. convert the DC voltage from the battery bank to 110 volt AC
at 60 Hz frequency for charging the electric vehicles. Two
Fred Chiou is with the Department of Engineering Technology, Weber State separate charging stations are built in order to efficiently
University, Ogden UT U.S.A. (email: [email protected]) monitor the system performance separately.

978-1-4799-1802-7/15/$31.00 ©2015 IEEE 234

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A. Solar Charging Station # 1 – For electric motorcycles The following sections describe the functions, specifications
Solar charging system #1 is built for charging electric of each component and the design considerations.
motorcycles. We have one electric motorcycle for this project.
The loads of the electric motorcycle is 2500 Wh (Watt-hours). 1. PV modules
Fig. 1 shows the block diagram of the system for charging the
electric motorcycle. For simplicity, the combiner box, Three 265 watts modules are used. The total maximum
Ground-Fault Protection Device (GFPD), overcurrent power output is 795 watts. It is known that the output voltage
protection devices and system grounding wires are not shown of a PV module is influenced by the ambient temperature. The
in the figure. range of the voltage output due to the extreme temperature
should be within the specification of the charge controller. The
temperature data from ASHRAE handbook is normally used
along with open-circuit voltage (Voc) and the temperature
coefficient of Voc (TCVoc) to calculate the range of the output
voltage from the PV module [1].

(a) The range of DC output voltage from PV modules

From the electrical specifications of SolarWorld Sunmodule

Plus SW 265 mono at STC (Standard Test Conditions):
Fig. 1 System block diagram solar charging station # 1
Open-circuit voltage Voc = 39.0 V
Table 1 lists the component used for station #1. Fig. 2 shows Temperature coefficient of Voc = – 0.30% / ºC
the wiring diagram and components detail of the system.
The low temperature history at Hill AFB, Ogden [2]:
TABLE 1 ASHRAE Extreme Annual Mean Minimum Design Dry Bulb
COMPONENTS USED FOR CHARGING STATION #1 Temperature = – 16 ºC
Component Qty Specifications
PV modules 3 SolarWorld Sunmodule Plus SW 265
Tmin = – 16 ºC – 25 ºC = – 41 ºC
GFPD 1 MidNite Solar MNDC-GFP63 V1 = Voc x { 1 + [ (– 41 ºC) x (– 0.30% / ºC)]}
DC Disconnect 1 Square D HU361RB, 3P, 600V, 30A = 39 x 1.1312 = 43.8 V
DC circuit breaker 2 MidNite Solar MNEPV 150V DC, 30A
MidNite Solar The KID, Input voltage < There are three PV modules in series per string, therefore the
Charge controller 1 150V DC, Output voltage 12V~48V DC,
Load current 30A, MPPT
maximum output voltage from PV modules after temperature
Battery bank 4 Deka 8A27, 12V, 92Ah correction will be 131.4 V that is within the input voltage
Xscorpion CB200A, 12V DC, 200A (for specification of MidNite Solar’s The KID charge controller.
DC circuit breaker 1
battery output)
Xantrex PROWatt SW 2000, 1800W, Input 3 modules in series Æ Vmax = 43.8 x 3 = 131.4 V
Inverter 1 12V DC, Output 104V~127V AC @ 60Hz
True Sine Wave
AC circuit breaker 1
Square D QO 20 Amp Single-Pole Circuit (b) The maximum output current from PV modules
Breaker
Short-circuit current Isc = 9.31A
Temperature coefficient of Isc = 0.04 % / ºC
ASHRAE 2% High Temperature = 34 ºC

Tmax = 34 ºC – 25 ºC = 9 ºC
Imax = I1 = Isc x { 1 + [ 9 ºC) x (0.04% / ºC)]}
= 9.31 A x 1.0036 = 9.34 A

2. Ground-Fault Protection Device (GFPD)

For the electrical industry, ground fault is the undesirable

condition of current flowing through the grounding conductor.
The cause of this undesirable current flow is an unintentional
electrical connection between a current-carrying conductor in
the PV system and the equipment grounding conductor (EGC)
Fig. 2 Wiring diagram of solar charging station # 1
[3]. NEC Article 690.5 specifies the ground-fault protection

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requirements for grounded DC photovoltaic arrays. Ground 5. Charge controller

fault protection is also required for ungrounded PV systems;
these requirements are detailed in 690.35(C). The specified The charge controller receives and regulates the input
purpose of a ground-fault protection device (GFPD) as part of voltage from PV power source and stores the energy by
a PV power system is to reduce the risk of fire associated with charging the battery bank. MidNite Solar’s The KID charge
a ground fault. The ground fault is a kind of shorted circuit, controller is used for this function. The charge controller
the fault current can be very high that could create a charges the battery bank with a 3-stage charging process as
significant fire hazard as bare metal is heated by the current demonstrated in Figure 3 [5]. The charging control settings for
flow. In addition, the ground fault causes a safety hazard [3]. Bulk and Float stages for lead acid battery are shown below,
as specified in the user’s manual of MidNite Solar The KID
The ground fault protection device (GFPD) is connected
charge controller [5].
between grounded conductor and system ground. If the current
flows through GFPD is larger than the rated current (for
Absorb: 14.3 V DC
example, 1 amp), the protection device will trip and
Float: 13.9 V DC
disconnect the DC ungrounded conductor, i.e. the wire
between PV positive and charge controller that is connected
through the GFPD. As shown in Figure 2, the GFPD is
protecting the ungrounded conductor between DC disconnect
and charge controller.

3. DC disconnect and AC disconnect

DC disconnect is used as PV power source disconnect to

comply disconnecting means required by NEC 2011, Sections
690.13, 690.14(c), and 690.15 [4]. DC electricity has
continuous energy than the cyclic AC electricity and is
Figure 3. 3-Stage battery charging Process
therefore harder to cut of the running current in the conductor.
A specialized DC rated disconnect is required for the DC side MidNite Solar’s The KID charge controller is featured with
of PV system. I our system, Square D HU361RB, 3P, Maximum Power Point Tracking. It monitors the voltage and
600VDC, 30A disconnect is used as the DC disconnect. current outputs from PV modules to maximize the power
output.
NEC 2011, Sections 690.13 indicates: PV power source
disconnect, specifically referring to DC power portion of the
6. Battery bank
system. In our system, the DC disconnect works as the PV
power source disconnect.
Four 12-volt Deka 8A27 valve-regulated AGM deep cycle
solar battery are connected in parallel as the battery bank.
NEC 2011, Sections 690.14(c) requires PV system disconnect
Each battery has the capacity of 92 Ah (Amp-hour). This
so that the system can be safely and easily shutdown and
battery bank provides 4,416 watt-hour of energy storage.
disconnected from building wiring. The AC disconnect in
Figure 2 is utilized as the PV system disconnect.
7. Inverter
NEC 2011, Sections 690.15 also requires PV equipment
The Xantrex PROWatt SW2000 inverter is rated 2,000 W
disconnect so that all sources of power can be disconnected to
output power. It takes 12 V DC electricity from the battery
service or remove individual components in the system. For
bank and converts it to true sinusoidal 120 VAC, 60 Hz
inverter, the DC disconnect and the AC disconnect in our
electricity.
system work as the PV equipment disconnect.
8. Equipment Ground
4. DC overcurrent protection
Non-current-carrying conductive materials such as the
DC circuit breakers are used to protect the wires from metal enclosure or case of all the components of the PV
overcurrent. On the PV power source side, the circuit breaker system need to be properly grounded (connected to earth) to
with rating of 30A @ 150V DC is used. For the circuit reduce the risk of electric shock.
between battery bank and inverter, a 200A @ 12V DC circuit
breaker is installed. 9. Electric Outlet

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The electric outlet provides the receptacles for the charger TABLE 2
of electric bikes. It is the only device installed outdoor. So it COMPONENTS USED FOR CHARGING STATION #2
needs to be an outdoor electric outlet.
Component Qty Specifications
10. Safety Practices PV modules 4 Grape Solar GS-Star-100W
GFPD 1 MidNite Solar MNDC-GFP63
The PV system can generate a high DC and AC voltage
Square D Disconnect HU361RB, 3P,
during the operation. Proper personal protection equipment DC Disconnect 1
600V, 30A
(PPE) such as helmet, safety goggles, electric gloves, and DC circuit breaker 2 MidNite Solar MNEPV 150V DC, 30A
footwear, etc. should be used when the system is energized. Xantrex C35, Input voltage < 55V DC,
Students will learn the importance of safety practices and Charge controller 1 Output voltage 12V/24V DC, Load
operate in a safe condition [6]. current 35A, PWM charging process
Battery bank 2 VMAX SLR155, 12V, 155Ah
Xscorpion CB200A, 12V DC, 200A
B. Solar Charging Station # 2 – For electric bikes DC circuit breaker 1
(for battery output)
Magnum MM-1512AE, 1500VA, Input
Solar charging system #2 is built for charging electric Inverter 1 12V DC, Output 120V AC @ 60Hz
Modified Sine Wave
bikes. We have two electric bikes for this project. The loads of Square D QO 20 Amp Single-Pole
each electric bike is 230 Wh (Watt-hours) and 360 Wh AC circuit breaker 1
Circuit Breaker
individually. Figure 4 shows the block diagram of the system
for charging the electric bikes. For simplicity, the combiner The wiring diagram of charging station #2 is demonstrated
box, Ground-Fault Protection Device (GFPD), the overcurrent in Fig 5. The components used for this system are listed in
protection devices (the circuit breakers) and system grounding Table 2.
wires are not shown in the figure.
Charging station #2 is mainly designed for charging
electric bicycles. The capacity of charging station #2 is
different from charging station #1 because the load demand
from electric bicycles is smaller. We could use the same
capacity as charging station #1 for more days of autonomy, i.e.
how many days that the battery bank can supply the required
energy. But subject to the budget and the available equipment
and the materials, some components such as PV modules,
charge controller

(a) The range of DC output voltage from PV modules

From the electrical specifications of Grape SolarGS-Star-

Figure 4. System block diagram solar charging station # 2
100W at STC (Standard Test Conditions):

Open-circuit voltage Voc = 21.9 V

Temperature coefficient of Voc = – 0.32% / ºC

The low temperature history at Hill AFB, Ogden [2]:

ASHRAE Extreme Annual Mean Minimum Design Dry Bulb
Temperature = – 16 ºC

Tmin = – 16 ºC – 25 ºC = – 41 ºC
V1 = Voc x { 1 + [ (– 41 ºC) x (– 0.32% / ºC)]}
= 21.9 x 1.1312 = 24.77 V

There are two PV modules in series per string, therefore the

maximum output voltage from PV modules after temperature
correction will be 49.55 V that is within the input voltage
specification of Xantrex C35 charge controller.

2 modules in series Æ Vmax = 24.77 x 2 = 49.55 V

Fig. 5 Wiring diagram of solar charging station # 2

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IV. OUTCOMES AND FUTURE DEVELOPMENTS

The Solar Charging Stations project is a multidisciplinary
project involving students from electrical, electronics, and
mechanical engineering technologies. Students benefit from
this project by learning the theory and hands-on experience of
a practical example of solar energy. Several students who are
taking the Solar PV Systems course are doing this project as a
senior capstone project. Students acquired an essential
foundation towards how to design and build the solar PV
systems for various applications. This project will promote the
concept of sustainability on campus and encourage school
members including students, faculty and staff to use public
transportation and electric vehicles that are charged from solar
energy. For future development, a plan promoting the use of
electric vehicles on campus might be proceeded if this pilot
project is successful.

REFERENCE

[1] Justine Sanchez, Determining PV Array Maximum System Voltage,

Home Power Magazine Issue #146, December / January 2012
[2] Paul Mync and John Berdner, SolarPro Magazine, Issue 2.5, Aug/Sep
2009
[3] National Electric Code 2011 (NFPA 70), National Fire Protection
Association, September 2010
[4] National Electric Code 2011 (NFPA 70), National Fire Protection
Association, September 2010
[5] Xantrex C35 Charge Controller Owner’s Manual, Xantrex Technology,
Inc.
[6] Personal Protective Equipment, OSHA Publication 3151-12R 2003

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