Commandant United States Coast Guard
2100 Second Street, S.W. Washington, DC 20593-0001 Staff Symbol: G-SEC-2A Phone: (202) 267-1892
COMDTINST M16500.24 Dec. 11, 1997 COMMANDANT INSTRUCTION M16500.24 Subj: 1. 2. SOLAR DESIGN MANUAL
PURPOSE. This Manual is a guide for U.S. Coast Guard personnel who design powered aids to navigation power systems. ACTION. Area and district commanders, commanders of maintenance and logistics commands and unit commanding officers shall ensure that the provisions of this Instruction are followed. DIRECTIVES AFFECTED. The solar sizing tables in chapter 10 of COMDTINST M16500.3A Aids to Navigation Manual - Technical are no longer valid and will be removed. New tables are published in this Instruction. DISCUSSION. This Instruction provides District offices, Civil Engineering Units and field units the necessary information to design solar power systems for aids to navigation. This Manual is companion to the solar design program, an Excel spreadsheet intended to run on SWIII terminals. Additionally, solar sizing tables are updated and included in this Instruction to provide field units with quick-reference tables for sizing minor aids. CHANGES. Recommendations for the improvement of this Instruction shall be submitted to Commandant (G-SEC) at jgrasson@comdt.uscg.mil. FORMS/REPORTS. No reports or forms are generated by this Instruction.
Table of Contents Chapter 1 - Introduction A. B. C. D. E. Purpose Program Special Loading Getting Availability Features the Program Started 1-1 1-1 1-1 1-1 1-1
Chapter 2 - Solar Design A. B. C. D. E. F. G. Introduction Types Equipment Loads Wire Sizing Solar Sizing tables Assistance 2-1 2-1 2-1 2-1 2-1 2-1 2-1
Chapter 3 - Program Operation A. B. C. Data Entry Program Output Printing 3-1 3-4 3-4
Chapter 4 - Equipment A. B. C. D. E. F. Minor Aids Major Aids Day/Night Ranges Solar Panels Batteries Charge Controllers 4-1 4-2 4-3 4-4 4-5 4-6
Chapter 5 - Loads A. B. C. D. E. F. Lamps VRB-25 Rotating Beacon API Flashtube MAC, SDB & SACII Charge Controller Range Power Box 5-1 5-1 5-2 5-2 5-2 5-3

G. H. I. J. K.

Range Switch Box Racon Sound Signals Fog Detectors Low Energy ACMS

5-3 5-3 5-3 5-4 5-4

Chapter 6 - Wiring Sizing A. B. C. D. E. F. G. H. I. General Acceptable Voltage Drops Wire Sizes and Typical Voltage Drops Operating Current Example - Day/Night Range Example - Lighthouse Wire Terminations Grounding 6-1 6-1 6-1 6-1 6-2 6-3 6-6 6-6 6-6
Chapter 7 - Data Sites A. B. Data Sites (List) Data Sites (Map) 7-1 7-2 8-1
Chapter 8 - Solar Sizing Tables Appendix I - Sample Calculations Appendix II - Addendum for Solar Vertical Program Appendix III - Battery Acquisition and Application Data Appendix IV - Manufacturer's Instruction Sheet
CHAPTER 1 - INTRODUCTION A. Purpose. The purpose of this publication is to enable a person with little or no familiarity with the fundamentals of solar design to make use of the updated solar design computer program. Additional information is included to assist in the design of solar power systems, including: component selection, wire sizing, suggested sources of supply and solar sizing tables for quick reference power system selection for minor aids. Program Availability. The computer program is available from U.S. Coast Guard Headquarters (Commandant (G-SEC-2)) on an IBM formatted 3-1/2 inch floppy disk. The program is intended to run on the SWIII terminal in Microsoft Excel version 4.0 or later. Special Features. The new computer program differs from the old Solarcalc program in the following ways: 1. 2. 3. 4. 5. 6. D. The new format of the program in Excel is much more user-friendly, allowing the variables to be entered in any order; The output of the program is immediately displayed. Changes to any of the variables has an immediate affect on the output; The program gives recommended array and battery sizings; Seasonal aids can be easily evaluated by entering the operational interval; Additional data sites are entered to allow more accurate system sizings; Solar sizing tables are included for each data site to provide more accurate sizings for minor aids.

Loading the Program. Copy the file SOLARDESIGN(version number).XLS from the floppy onto your hard disk. Remove the floppy and consider it your "Master" copy which should be safeguarded in case the working copy is corrupted or lost. Getting Started. Open a copy of the program. Ideally, the cells B2:M40 should be in view (this may not be possible on laptops; the battery SOC are repeated near the input data). If not, expand the screen by any combination of the following: 1. 2. 3. Under pulldown menu View, select Full Screen; Under pulldown menu View, unselect Status Bar and Formula Bar; Under pulldown menu View, select Toolbars then unselect any checked Toolbars;
Under pulldown menu View, select Zoom and adjust the level until the cells are within the limits of the screen. To simplify data entry, under the pulldown menu Tools, choose Options, Edit, then unselect "Move Selection After Entry". To prevent users from accidentally deleting or changing cells that perform calculations, all cells are locked with the exception of cells used to enter data. Data cells are shaded yellow or gray, depending on which version of Excel you are using.
CHAPTER 2 - SOLAR DESIGN A. Introduction. Solar power systems are used on over 90 percent of all lighted aids to navigation. An understanding of the types of power systems and the components used are necessary to design a reliable system. Types. Solar power systems are divided into two categories: self-regulated and regulated. Self-regulated power systems use a solar panel and battery matched to prevent overcharge. Virtually all minor aid power systems are self-regulating. Larger systems (lighthouses, day/night ranges) generally use a charge controller to allow the use of smaller batteries. Equipment. An understanding of the equipment used in a solar power system is necessary to successfully design one. Knowing what components are to be used allows the designer to construct a load profile, system layout and wire sizing for the power system. Chapter 4 details the components used in a typical minor aid, major aid and day/night range. Standard solar lighthouse and range configurations per COMDTINST 16500.8A Automation Technical Guidelines, COMDTINST M16500.3A Aids to Navigation Manual - Technical, and standard aids to navigation drawings provide more detail on categories, hardware and wiring. Loads. Electric power loads of aids to navigation apparatus are often an overlooked variable when designing or troubleshooting a solar power system. Parasitic, daily and nightly loads, if not calculated correctly, can lead to premature failure of the power system. Parasitic loads, however minor, add to the daily load. Each component in the power system and signal equipment must be evaluated as a possible drain on the battery. Chapter 5 details the various loads used on aids to navigation and their power consumption. Wire Sizing. Improperly sized wires in low voltage power systems can have a drastic effect on system performance. The physical separation of the solar array, battery and loads requires ample conductors to limit voltage drop to acceptable levels. Chapter 6 details the calculations necessary to properly size wiring at these installations. Solar Sizing Tables. Chapter 8 contains solar sizing tables for approximately 80 percent of the minor aid power systems. These tables eliminate repetitive calculations and provide field units with quick reference tables for power systems. Assistance. Sample calculations are provided in Appendix I. Design assistance is available from Commandant (G-SEC-2A). The worksheet can be attached or pasted into a Microsoft Exchange e-mail and sent to Commandant (SEC-2A) for evaluation.

CHAPTER 3 - PROGRAM OPERATION A. Data Entry. The spreadsheet is arranged with data entry from top to bottom. This order should be followed allowing the program to provide accurate system sizing recommendations. Any variable may be changed after all data is entered. 1. Aid Name. Enter the name of the aid in the box provided. The date and time is automatically inserted next to the aid name in order to keep track of the most recent design run. Latitude of Aid. Enter the latitude of the aid in decimal format. Minutes must be converted to decimals by dividing by 60 min/degree; i.e., 4248' = 42.80. Minor aids may use the latitude of the reference site. Panel Tilt. The panel tilt is the angle of the solar panel(s) with respect to horizontal. Generally, panel tilt for minor aids with nighttime loads is: Alaska Continental U.S. GANTSEC & Hawaii Buoys (Horizontal Mount) Tripod Buoy Mount Dual Panel Mount 75 degrees 60 degrees 30 degrees 0 degrees 60 degrees 15 degrees
Panel tilt for some Northern Continental U.S. sites can benefit from a steeper angle to capture more power in the winter. Day/night ranges generally benefit from a shallower tilt angle (45 degrees) as the maximum load occurs during the summer. Exposed location buoys and buoys with large signal packages should use the solar vertical design program available from Commandant (G-SEC-2A). 4. Ref Site #. Enter the data site number closest to the aid being evaluated. If the aid is between two sites, perform two design runs using each site and pick the solar sizing with the largest power system. Chapter 7 contains 92 data sites for the U.S., GANTSEC and Guam. Use Average Rad? Solar power systems must be designed using Design Radiation. Design radiation represents low radiation values that can be expected to occur once every 10-15 years. These are not the lowest radiation values possible, but values that we feel comfortable designing around. Leave this box blank to use design radiation. Use average radiation to see how a system will perform during an "average" year, and to determine how long it will take a system to recover from a low state of charge caused by personnel error or component failure.
Battery Type. Enter the battery type used by your ANTs/Tenders, or selected for a specific project. Delco-2000, Exide HC-31, Yuasa-Exide EI, EJ and FHGS batteries are wet batteries. The Sunlyte 12-5000 is an absorbed battery and the Deka 8GH30, Dynasty GC12V100B and Sonnenschein Dryfit A600 are gelled batteries. Autonomy. Autonomy is the amount of with little or no sun and is used to size. The default is 10 days; 10-14 local weather conditions (fog, rain, time the aid will perform determine the minimum battery days are typical, depending on overcast periods).

Interval Installed. Refers to when the program starts calculating the results of the design run. For example, if a temporary aid is installed in the beginning of June and will operate for 2 months, enter interval 11 and note the results during intervals 11 through 14. Otherwise, enter interval 18 as almost all systems are fully charged during this period. Be sure the maximum state of charge returns to 100 percent at interval 17 or the aid may fail. SofC at Install. Refers to the state of charge of the battery at installation. Generally, the battery is fully charged when installed (100(%)). This entry allows the user evaluate an aid with a failed battery to determine how long the array will take to charge it back to 100 percent. Load. Optional field used to describe the load entered, i.e., RL14, 35w, Iso6. Amps? The load current in amps. Refer to chapter 5 for current consumption figures. NOTE: when lamps are flashed, the average current (accounts for cold current surge) must be entered; i.e., 0.916 for a 0.77a lamp with a Quick flash rhythm. Duty Cycle. Enter the duty cycle of the load as found in chapter 5. The default duty cycle is 100 percent. D, N or DN. Enter when the load is on. Daylight controlled loads operate only at night so enter a N. Daytime loads, typically daytime range lights, Range Power Boxes and Range Switch Boxes operate only during the Day. Loads on 24 hours a day like rotation motors, sound signals and control equipment are entered as DN. # Hours Day/Night Loads Operate. If the loads are on a fixed amount of time (using a timer) or as an estimate for a fog detector controlled sound signal (8-12 hours/day), enter the number of hours the load operates. Otherwise leave this box blank. Note: DN must be entered in the adjacent block if a value is entered.

10. 11.

12. 13.
Seasonal Aids ON/OFF. If the load is seasonal, i.e., a sound signal that is turned off during the winter season, enter the interval that the device operates. This is useful in northern latitudes when unnecessary winter loads can be secured thereby saving power and reducing the power system size. Number of flashers. Enter the maximum number of CG-181 or CG-481 flashers that are operating at the same time, i.e., day/night ranges typically have one optic powered during the day and one on at night which count as one flasher. When overwriting or clearing an entry, use the backspace key to delete numbers and characters. Do not use the spacebar to clear entries, as the program will not interrupt them correctly.
Array Size. If evaluating an existing aid, enter the size of the array in watts, or if designing a new system, enter the suggested array size. For minor aids, enter the advertised solar panel wattage, i.e., 10, 20 or 35 watts. Aids using multiple panels should use the actual wattage produced by the solar panels. 10 and 20 watt panels are entered as 10 and 20 watts. 35 watt panels manufactured by Siemens Solar Industries are entered as multiples of 40 watts as it is impractical for them to trim solar cells to specific power levels. Additionally, aids using more than 100 watts should use multiples of 35 (40) watt solar panels; don't try to fine tune the array with 10 and 20 watt panels. Commandant (G-SEC-2) will publish the current power production of 35 watt solar panels when major changes occur. Aids using the molded acrylic pyramid require a 35% reduction in power output (multiply panel wattage by 0.65) Do not use this program to evaluate other than CG standard panels and Siemens M65 panels. Battery Size. If evaluating an existing aid, enter the battery size in amp-hours, or if designing a new system, enter the suggested battery size. Note that there are two choices. Minor aid systems are usually self-regulated meaning that there is no charge regulator. Instead, the battery is large enough to absorb any overcharge that the CG standard solar panel produces. Wet batteries are more tolerant of overcharge, therefore the suggested battery size using wet battery types is smaller than gelled or absorbed cells. The battery type chosen is dependent on Unit or Designer preference. Systems using a charge controller or Range Power Box (RPB) can use the suggested battery size for regulated systems. Regulated power systems should be used when the load is uncertain (fog detector) or to reduce the size, weight and cost of the battery system. Minor aid systems use multiples of 100 amp-hours; 300 amp-hours is the limit on shore aids, 500 amp-hours on buoys. Shore aids exceeding 300 amp-hours should use the Yuasa-Exide EJ/FHGS, the Absolyte II or Sonnenschein A600 Dryfit cells. Battery sizes in northern latitudes may be increased beyond the suggested size in lieu of increasing the array size to meet the minimum SOC requirements. 3-3

Figure 1.

Major Aids. A generic solar powered lighthouse (figure 2) will have a main array and battery system, an emergency battery with a small trickle charge solar panel, a main light, main sound, and emergency light and sound. Inputs from solar panels are gathered into Local Terminal Boxes (LTBs) and a PV Combiner, and a charge controller prevents overcharge of the battery. A Solar Distribution Box (SDB) provides a centralized location to combine solar power inputs and distribute power to the loads. COMDTINST M16500.8A and standard AtoN drawings 140400 series provides detailed information on these systems.

Figure 2.

Day/Night Ranges. Day/night ranges typically require large solar arrays due to the continuous loads associated with these aids. Many sites can benefit from shallower (45 degrees versus 60 degrees) tilt angle as the greatest loads occur during the summer months. Solar panels are gathered into a Local Terminal Box (LTB) and fed into a Range Power Box (RPB). The RPB is a commercially available photovoltiac charge controller manufactured by Specialty Concepts, Inc., and provides overcharge protection, low voltage disconnect (to protect against deep discharge) and a load center. The power is then routed to the Range Switch Box-DC (RSB-DC) which controls the day/night range lights. COMDTINST M16500.8A and standard AtoN drawings 140500 series provides detailed information on these systems.

Figure 3

Solar Panels. CG standard solar panels are procured from vendors listed on a Qualified Products List (QPL) by ELC Baltimore. Power ratings are 10, 20 and 35-watts. The current vendors are: Solarex Siemens Kyocera CG standard Corporation Solar Industries America, Inc. panel sizes and mounting details are shown in figure 4.
Figure 4. U.S. Coast Guard solar panels use between 29 and 33 crystalline or semi-crystalline silicone cells (32 cells typical) with a maximum power point (point in panel performance curve that yields maximum voltage and current) of 13.8 volts at 25 degrees C (cell temperature). This power point voltage charges lead-acid batteries at most solar installations without the use of a regulator. Commercially available panels, such as the Siemens M-55, a 12 volt, 50 watt panel, have a maximum power point of 17.0 volts, must use a regulator, and can not be evaluated with this design program. The program can be modified to allow sizings with non-standard panels; consult with Commandant (G-SEC-2A) for assistance. The Siemens M65 solar panel is similar in power output to the CG standard 35 watt module, but not as robust and is not suitable where wave action reaches the array. Power output is 43 watts as the frame is more densely packed than our standard module making it suitable for high density arrays. The Siemens Standard Ground Mount (SGM) may be used to mount these panels. Appendix IV contains data sheets on these components. This program may be used to design arrays using M65 panels. The transparent clear acrylic pyramids used as bird deterrents on buoys 4-4

Duty Rhythm Cycle 0.25a 0.55a 0.77a 1.0a 1.15a 1.9a 2.03a 3.0a 3.05a 50w 75w 100w 110w -------------------------------------------------------------------------------------------------------Fixed 100.250.550.770 1.00 1.15 1.90 2.03 3.00 3.05 4.17 6.25 8.33 9.17 Oc 4 75.252.559.785 1.02 1.18 1.97 2.10 3.12 3.17 4.35 6.54 8.75 9.63 Iso 6 50.252.559.785 1.02 1.18 1.97 2.10 3.12 3.17 4.35 6.54 8.75 9.63 Iso 2 50.258.578.816 1.08 1.24 2.11 2.23 3.37 3.42 4.73 7.20 9.75 10.73 Fl(2)6 33.258.578.816 1.08 1.24 2.11 2.23 3.37 3.42 4.73 7.20 9.75 10.73 Q 30.278.639.916 1.24 1.42 2.55 2.76 Mo(A) 30.262.592.844 1.29 2.38 3.70 IQ 18.278.639.916 1.42 2.76 Fl2(5) 16.271.621.894 1.38 2.62 4.15 Fl(2+1)6 15.278.639.916 1.42 2.76 Fl 2.5(.3) 12.278.639.916 1.42 2.76 FL2.5(1) 40.258.578.816 1.08 1.24 2.11 2.23 3.37 3.42 4.73 7.20 9.75 10.73 Fl 4(.4) 10.271.621.894 1.38 2.62 4.15 FL4(1) 25.258.578.816 1.08 1.24 2.11 2.23 3.37 3.42 4.73 7.20 9.75 10.73 Fl 6(.6) 10.266.596.859 1.31 2.45 3.81 B. VRB-25 Rotating Beacon. The VRB-25 is the standard 12 volt rotating beacon. It replaces the Amerace ESNA 190mm beacon and API FA-251-DC. The power consumption of the lamp is entered as a Nighttime only load at its rated current and 100% duty cycle as the flash rhythm is Fixed. The power consumption of the rotation motor must be entered into the program as a separate load. The motor typically operates 24 hours a 5-1
day in order to prevent the sun from focusing on the lampchanger. Power consumption is 0.10 amps, 100% duty cycle, Day/Night load. C. API Flashtube. The power consumed by the API 12-volt flashtube may be calculated as follows: The power XFB-001 = XFB-005 = XFB-010 = XFB-015 = consumption must be calculated 0.39 amp-secs, flash rate of 1 1.34 amp-secs, flash rate of 1 2.28 amp-secs, flash rate of 1 2.87 amp-secs, flash rate of 1 for each flick flash per 0.40 flash per 0.55 flash per 0.95 flash per 1.20 of the flashtube: seconds seconds seconds seconds
Where the flash rhythm must be equal to or longer than the flash rate listed above. Next, the power consumption for the specific rhythm must be calculated. For a 5 joule flashtube (XFB-005) with one flash every 2.5 seconds equals: Flash rate is within limitations (1 flash every 2.5 seconds; 2.5s 1.34 amp-secs / 2.5 secs = 0.536 amps The idle current of the flashtube must be added to this. milliamps for all models: It is 8 0.55s):
0.536 amps + 0.008 amps = 0.544 amps. Enter this as a Nightly load if daylight controlled with a 100% duty cycle. Note: this calculation is different from what was previously published and existing aids using this device should be re-evaluated. D. Multiarray Controller (MAC), Solar Distribution Box (SDB) & Solar Aid Controller SAC II). The MAC and SDB consume and average of 0.025 amps, continuous. The SAC II consumes an average of 0.0025 amps, continuous. These loads are day/night loads. A typical lighthouse with a SDB and 2 SACIIs will consume 0.030 amps, 100% duty cycle, Day/Night load. The SDB will accept up to 1/0 AWG for main battery input, 6 AWG for emergency panel and battery input, and lugs sized for a number 10 stud for all loads. Charge Controller. The charge controller used in lighthouse and large range solarizations manufactured by Specialty Concepts and Process Automation Company consumes 0.010 amps, 100% duty cycle, Day/Night load. The controller does draw considerably more power when the mercury relays are energized, however this occurs when excess power is generated by the array in the daytime and the load does not have to be accounted for. It will accept up to 1/0 AWG wire for all inputs/outputs.

+------------------------------------------------------+ | | VM-100 HEATER LOAD | |____ |________________________________________________| |Data | | Suggested | Suggested | |_____|______________________|____________|____________| |Site#| Data Site Name | Duty Cycle | Internal | |_____|______________________|____________|____________| | 1 | Portland, ME | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 2 | Boston, MA | 75% | 23 - 4 | |-----|----------------------|------------|------------| | 3 | Providence, RI | 75% | 23 - 6 | |-----|----------------------|------------|------------| | 4 | Bridgeport, CT | 75% | 23 - 4 | |-----|----------------------|------------|------------| | 5 | New York, NY | 50% | 23 - 4 | |-----|----------------------|------------|------------| | 8 | Newark, NJ | 50% | 23 - 4 | |-----|----------------------|------------|------------| | 12 | Baltimore, MD | 50% | 23 - 4 | |-----|----------------------|------------|------------| | 49 | Rochester, NY | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 50 | Buffalo, NY | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 51 | Erie, PA | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 52 | Cleveland, OH | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 53 | Toledo, OH | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 54 | Detroit, MI | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 55 | Alpena, MI | 100% | 21 - 6 | |-----|----------------------|------------|------------| | 56 | Traverse City, MI | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 57 | Muskegon, MI | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 58 | Chicago, IL | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 59 | Milwaukee, WI | 100% | 23 - 6 | |-----|----------------------|------------|------------| | 60 | Green Bay, WI | 100% | 21 - 6 | |-----|----------------------|------------|------------| | 61 | Sault Ste. Marie, MI | 100% | 21 - 6 | |-----|----------------------|------------|------------| | 62 | Houghton, MI | 100% | 21 - 6 | |-----|----------------------|------------|------------| | 63 | Duluth, MN | 100% | 21 - 6 | |-----|----------------------|------------|------------| | 76 | Portland, OR | 0% | N/A | |-----|----------------------|------------|------------| | 78 | Quillayute, WA | 0% | N/A |
|-----|----------------------|------------|------------| | 79 | Seattle, WA | 0% | N/A | +------------------------------------------------------+

Low Energy Aid Control Monitor System (LEACMS). The LEACMS is a low power version of the ACMS and can be used at solar powered lighthouses to monitor the status of the aid, including low battery alarm and main battery transfer. The LEACMS may be outfitted with an EF Johnson radio or cellular phone link to the master control unit. The power consumption of the LEACMS with the EF Johnson radio is 0.50 amps continuous, 100% duty cycle, Day/Night load, and with the cellular link is 0.75 amps continuous, 100% duty cycle, Day/Night load. 5-4
CHAPTER 6 - WIRING SIZING A. General. In conventional electrical systems (120-240 VAC), wire is sized according to its safe amperage carrying capacity know as "ampacity". A voltage drop of 2-3 volts in these systems is acceptable. Since voltage drop is based on wire size and current, not voltage, if these practices are carried over to low voltage systems, the resultant voltage drop would cause inadequate charging of the battery and low voltage to the aids to navigation. Acceptable Voltage Drops. The acceptable voltage drop for 12 volt solar power aids to navigation is 0.75 volts in the charging system and 0.35 volts for the load(s). The "charging system" is considered the wire run from the solar panels to the battery, and the "load(s)" is considered the wire run from the battery to the device (CG-181, FA-232, etc.). These voltage drops are maximums and efforts to reduce these values is encouraged. The voltage drop for minor aids remains at 0.10 volts for the load. Wire Sizes and Typical Voltage Drops. The following are common wire sizes and their calculated voltage drop for a 1 amp current at 1000 feet: Wire Size K* --------------------------12 AWG 3.960 volts 10 AWG 2.480 volts 8 AWG 1.556 volts 6 AWG 0.982 volts 4 AWG 0.616 volts 2 AWG 0.388 volts 1/0 AWG 0.244 volts 2/0 AWG 0.193 volts 3/0 AWG 0.153 volts 4/0 AWG 0.122 volts *These K values are based on National Electric Code (NEC) recommendations for uncoated, stranded copper conductors. These values are conservative. Resistance values from the cable supplier may be used to calculate new K values. To calculate K: K = Wire Resistance (ohms) per 1000 feet x 2 Therefore, the voltage drop for a given wire run is: Voltage Drop (V1324 Drop & TA &) = K x A x D --------1000 Where: A is the current in amperes D is the one way distance in feet
Operating Current. The operating current must be found before the wire size can be calculated. For solar arrays, the current is equal to the rated wattage divided by the peak power point voltage. For USCG standard panels, the power point voltage is 13.8 volts. For loads, the current consumed by each operating device must be summed for each segment of wire. Example - Day/Night Range. Figure 5 is a typical day/night range installation. This aid has six 40 watt solar panels (battery size is unimportant), a daytime range light with 12 volt, 35 watt lamps and a nighttime light with 0.55 amp lamps. The array is 25 feet from the RPB and the range lights are 100 feet from the RPB. The RPB is 6 feet from the battery.

Solar Vertical Program Sample Calculation
Oct 97 Appendix III - Battery Acquisition and Application Data The following is a list of batteries recommended by Commandant (G-SEC-2) for use in solar powered aids to navigation. Batteries listed here have shown, through manufacturer's literature, testing or field experience, to perform well in our unique environment. Batteries are categorized as either "qualified" or "conditionally qualified". "Qualified" refers to batteries that have been tested and perform well in the field. "Conditionally qualified" are batteries that are new technology being evaluated, or batteries that have limitations placed on them. New batteries that are conditionally qualified should not be placed in critical aids or in aids at the outskirts of your area of responsibility. All batteries are 12 volts, 100 ampere-hours (nominal) and intended for use in all solar powered minor aids, unless otherwise specified. Please call the vendors for a current price quote and shipping costs (if applicable). Delco 2000, Delco S2000 Features: 12 volt, liquid electrolyte, lead calcium grid, maintenance-free, not sealed. Available from the factory in quantities of 54 (Delco 2000) or lesser quantities from local wholesalers (Delco S2000). Price $63.50 to $68.00. Price quoted from factory is delivered to destination by truck freight. Price quoted from wholesaler is delivered to destination by Mobile Battery Truck (MBT). Status: Qualified
Ordering Addresses: Factory: Delco Remy P.O. Box 2439 Anderson, IN 46018 (317) 579-3591 Wholesalers: Batteries, Inc. 4788 Lake Mirror Place Forest Park, GA 30050 (404) 361-6260 Attn: Randy Dunn Delcoline, Inc., Automotive Parts and Warehouser and Exporter 4631 Tanglewood Drive 1
Oct 97 Hyattsville, MD 20781 (301) 864-4455 Attn: Kambiz Majidi
Diesel Service Unit P.O. Box 3486 Portland, OR 97208 (800) 556-4998 [(800) 452-9179 in OR] Attn: GNB Sunlyte 12-5000

Larry Clay

Features: 12 volt, absorbed electrolyte, lead calcium grid, maintenance free, handle, sealed. Price: Status: $96.00 plus shipping (must be prepaid). Conditionally qualified (not recommended in hot climates) See below.
Ordering address: GNB Absolyte IIP
Features: 2-volt, absorbed electrolyte, lead calcium grid, sealed, maintenance free, used in large lighthouse and range power systems. Capacities from 340 AH to 5700 AH. Price: Status: $144.00 - $1585.00 per cell plus shipping (must be prepaid). Conditionally qualified (not recommended in hot climates)

Ordering address: GNB Battery Technologies 829 Parkview Blvd. Lombard, IL 60148-3249 (708) 629-5200 Ask for Government sales Exide EJ and FHGS series Features: 2-volt, liquid electrolyte, tubular lead calcium low antimony grid, requires annual watering, not sealed, used in large lighthouse and range power systems. Capacities from 390 AH to 2915 AH. Price: $307.50 to $1468.50 per cell delivered in 48 states (6 cells must be ordered, and 1.300 specific gravity must be specified). General Services Administration schedule pending; call for availability. Status: Qualified (must be used on stable platform)
Oct 97 Ordering address: Yuasa-Exide, Inc. 9055 Guilford Road Columbia, MD 21046-1879 (410) 381-8500 Exide HC-31 Features: 12 volt, liquid electrolyte, lead calcium grid, maintenance free, handle, not sealed. Price: Status: $54.00 plus shipping (must be prepaid). Conditionally qualified (new vendor)
Ordering address: (note: this is a different division and should not be confused with Yuasa-Exide). Exide Corporation 817 Manufacturers Drive Westland, MI 48185 (800) 323-2914 Sonnenschein Dryfit A 600 Solar Features: 2-volt, gelled electrolyte, lead calcium grid, sealed, maintenance free, used in large lighthouse and range power systems. Capacities from 360 AH to 3500 AH. Price: Status: $144.00 - $893.00 per cell plus shipping (must be prepaid). Conditionally qualified (new vendor in US, established in Europe)
Ordering address: Exide Corporation - International Gel Product Sales 645 Penn Street Reading, PA 19601 (610) 378-0500 Peter Grimes Johnson Controls Dynasty GC12V100B Features: 12 volt, gelled electrolyte, lead calcium grid, handle, maintenace free, sealed, same as Solar Electric Specialties 12SC90B which is no longer available. Price: $112.00 to $150.00, depending on quantity, plus shipping (must be prepaid).
Oct 97 Status: Conditionally qualified (new vendor)
Ordering address: Contact Commandant (G-SEC-2) for nearest distributor Deka Solar 8G30H Features: 12 volt, gelled electrolyte, lead calcium grid, maintenance free, handle, sealed. Price: Status: $140.00 plus shipping (must be prepaid). Conditionally qualified (new vendor)
Ordering address: East Penn Manufacturing Co. Lyon Station, PA (215) 682-6361
DESCRIPTION OF COAST GUARD ELECTRONIC EQUIPMENT
DESCIPTION OF COAST GUARD ELECTRONIC EQUIPMENT
SIEMENS M65 Self regulating solar electric module
RATED POWER 43 WATTS. With 30 cells in series, the high efficiency Siemens M65 is a 43 watt, self regulating solar electric module. Self regulation eliminates the need for seperate charge control devices, resulting in a simple, reliable and economical power generating system. The M65 module regulates its electrical output to the needs of the battery. As the battery approaches full charge, it decreases its typical current charging rate of nearly 3 amps to less than 1/2 amp. Utilizing the highest standard of construction, the M65 module is able to withstand some of the harshest environments in the world and continue to perform efficiently. Siemens solar electric modules are tested to meet or exceed industry standards, and even more rigorous Siemens quality and performance requirements. 10 YEAR WARRANTY. The Siemens M65 solar electric module carries a 10-year limited warranty on power output and is listed by Underwriters Laboratories (UL), an independent, not for profit organization, testing for public safety. Siemens solar electric module features: Silent operation Sunlight as fuel High power density Easy installation Rugged, durable construction Simple, reliable operation East to expand systems Low maintenance No moving parts to wear out No environmental pollutants

AGV Photvoltaic Battery Delco 2000 Maintenance-Free Battery
12-5000X 6-Cell, 12 Volt Valve Regulated Lead Acid Battery
Tubular Stationary Batteries for Shallow Cycle Solar
Specifications Cell Dimensions - Weights
Ironclad-Tubular Type EJ General Purpose
Capacities - Dimensions - Weights

ABSOLYTE IIP Batteries

THE WORLD LEADER IN SEALED BATTERY POWER Proven field experience since 1983. The Absolyte IIP represents the third generation of the Absolyte product line. Without an increase in size, it offers 15% more capacity than its predecessor, the Absolyte II. Patented MFX positive grid alloy* provides long-life. This propriety alloy gives Absolyte IIP superior cycling performance and excellent float characteristics: 1200 cycles to 80% D.O.D. and a twenty year life in float service @ 25C (77 F). This alloy also has low gassing characteristics and is designed to allow for deep discharge recovery. Absorbed glass mat seperators for efficient operation. The positive and negative plates are seperated by a highly porous fiberglas mat which functions as the electrolyte retainer and provides the highest oxygen recombination efficiency. In addition, the low resistance of the glass mat improves high rate discharge performance. Reduced installation and maintenance time. The Absolyte IIP cells are housed in protective, modular steel trays designed for easy installation and balanced thermal management. Modules may be stacked horizontally (preferred) or installed vertically (50A, 90A only). When stacked horizontally, the standard Absolyte IIP is qualified for use in U.B.C. Seismic Zone IV installations. With the sealed design, maintenance is also kept to a minimum. No water additions or scheduled equalization charges are required. Periodic visual inspections, voltage readings and connection retorqing is all that is required. Highest reliability is assured by GNB's quality program. Cell covers are hermetically sealed using a special GNB double-sealing process. Post seals are formed by fusing the lead bushing to the post with a robotic welder. Cells are checked by an automated, ultra-sensitive helium leak detection unit prior to the controlled electrolyte "fill by weight" process. These steps virtually eliminate any potential for leaking cells. Finally, all cells are capacity tested prior to shipment to verify attainment of specified ratings. APPLICATIONS The Absolyte IIP batteries are ideal for numerous applications including: Telecommunications Uninterruptible Power Systems Switchgear and Control
Railroad Signal and Communication Photovoltaics Marine Alternative Energy Systems ADDED FEATURES & BENEFITS Does not require a seperate Battery room Transparent, flame retardant module cover Recombination efficiency greater than 99% Freezing tolerant Deep discharge recovery Accepts high rate charge Meets U.B.C. Seismic Zone IV requirements Simple cell replacement capability CELL SPECIFICATIONS Container and Cover - Polyproylene is standard. Flame retardant, UL94 V-0/28% L.O.I. is optional. Separators - Spun glass, microporous matrix. Safety Vent - 400mb (6psi) nominal, self-resealing (patented). Teriminals - Integral solid copper core. Positive Plate - Patented MFX grid alloy.* Negative Plate - Lead calcium grid alloy. Life - 20 years float @ 25 C (77F). Self Discharge - 0.5 to 1% per week maximum @ 25 C (77F). Float Voltage - 2.23 to 2.27 VPC (2.25 recommended) @ 25 C (77F). ASSEMBLY CONFIGURATIONS Horizontal Stack Assembly (Preferred). Depth is overall, including module cover assembly. Add 102mm (4") for bottom I-beam supports to determine total height (width) of assembled horizontal stack.

Vertical Assembly, Side-by-side. Height is overall, including module cover assembly. Add 51mm (2") for bottom channel support to determine final height.
ABSOLYTE IIP Batteries Absolyte IIP Module Weights and Dimensions

dryfit A 600 solar

PPC/50 - Photovoltaic Charge Control SPECIALTY CONCEPTS,INC. PHOTOVOLTAIC CHARGE CONTROLLER
The PHOTOVOLTAIC POWER CONTROL (PPC/50) is a versatile, industrial quality controller for the efficient use of the photovoltaic energy and the protection of expensive batteries. It is available for 12, 24, 36 and 48 volt negative ground systems. Models are available for 50 amps of charge current. The PPC/50 consists of a series-relay battery charge regulator with low-voltage load dissconnect, battery, array and load circuit breakers, system status lights and digital metering. The lights indicate "CHARGING" and "LOW-VOLTAGE LOAD DISCONNECT" conditions and the digital meter monitors battery voltage, charging and load current. A provision is made for monitoring an external shunt. The PPC/50 is housed in a sealed indoor enclosure and has a terminal block for up to 6 guage wire. FEATURES CHARGE REGULATION 50 amp charge current, 12, 24, 36 or 48 volt Two-step, series charging, 12, 24 v Single step, series charging, 36, 48 v Adjustable charging set-points Plug-in temperature compensation LOW-VOLTAGE LOAD DISCONNECT (LVD) 30 amp LVD, 12 volt 20 amp LVD, 24 volt 15 amp LVD, 36 and 48 volt Adjustable charging set-points Plug-in temperature compensation DESIGN FEATURES Maximum array usage Over-current protection and manual disconnects - battery, array and load circuit breakers Reverse polarity protection Reverse leakage protection Lightning protection Input noise suppression Remote battery voltage sense MONITORING Digital volt/amp meter
External shunt metering Charging Light Load disconnect light MOUNTING Indoor wall mount enclosure Outdoor enclosure (optional) OPERATION (12,24 volt units) Note: The operation of the 36 or 48 volt unit is identical with the exception that no float unit is included. CHARGE REGULATION The PPC/50 features two charging steps to effectively charge the batteries and protect them from over-charge damage. The PPC/50 monitors the battery and array voltage, using a relay to control the charging. STEP 1 - FULL CHARGE: At sunrise, the rising array voltage will energize the charging relay and initiate a full charge mode, as indicated by the "CHARGE MODE" light. All available current from the array will pass through to the batteries and raise the battery voltage until the battery reaches the full charge termination threshold. STEP 2-FLOAT CHARGE: When the battery reaches the full charge termination threshold, the full-charge mode ends and the "CHARGE MODE" light goes out. The PPC/50 resumes charging at a reduced charging rate. As the battery approaches the float voltage, the current will taper off, eventually reaching the battery's maintenance current. LOW-VOLTAGE DISCONNECTThe low-voltage disconnect (LVD) of the PPC/50 prevents damage from deep-discharge of the batteries by automatically disconnecting the loads. The disconnect threshold is load current compensated, and has a time delay to prevent false disconnects. When disconnect occurs, the load relay is energized and opens, and the "LOAD DISCONNECT" light will indicate that the loads have been disconnected. Normal battery charging will continue. At the reconnect threshold the loads will automatically be reconnected and the light will go off. The LVD function has a reset/disable switch and user adjustable set-points. DESIGN FEATURESThe PPC/50 has many superior design features that contribute to the controller's efficiency and reliability. This controller provides maximum utilization of the array during hours of charging by reconnecting the array for direct charging as soon as the battery drops below a full charge set-point. Over-current protection is provided in the form of circuit breakers. A timing circuit will disconnect the array at night, to prevent reverse current leakage. The control circuit is protected from reverse polarity connection on all inputs, and has MOV lightning protection. Input noise suppression filters out most of the spikes and interference to reduce false switching. Remote battery sense terminals allow accurate monitoring of battery voltage. OPTIONAL ENCLOSURES 3R - Outdoor, moderate protection 4X - Outdoor, maximum protection