Faculty of Engineering and the Built Environment Department of Electrical Engineering

EEE4036C Electrical Engineering Design Group Assignment

Prepared By:

Michael Rainey (RNYMIC001) Jesse Dicks (DCKJES003) Shana Peters (PTRSHA019)

1 September 2011

Table of Contents
Design Specifications .................................................................................................................................... 5 Functional Characteristics ......................................................................................................................... 5 Safety Characteristics................................................................................................................................ 5 Quality Assurance ..................................................................................................................................... 5 Timescale .................................................................................................................................................. 5 Economic Factors ...................................................................................................................................... 5 Ecological Factors...................................................................................................................................... 5 Aesthetic Factors....................................................................................................................................... 5 Life-Cycle ................................................................................................................................................... 6 Design Context .............................................................................................................................................. 6 Macroeconomic Factors ........................................................................................................................... 6 Social ..................................................................................................................................................... 6 Technical ............................................................................................................................................... 6 Environmental ....................................................................................................................................... 6 Economic ............................................................................................................................................... 7 Political .................................................................................................................................................. 7 Microeconomic Factors ............................................................................................................................ 7 The Market ............................................................................................................................................ 7 Resources .............................................................................................................................................. 7 The Customer ........................................................................................................................................ 8 Corporate Factors ..................................................................................................................................... 8 Corporate Enviroment .......................................................................................................................... 8 Corporate Structure .............................................................................................................................. 8 Corporate Systems ................................................................................................................................ 8 Corporate Strategy ................................................................................................................................ 8 Shared Values........................................................................................................................................ 8 Managment Style .................................................................................................................................. 8 Management skill .................................................................................................................................. 8 Management skill.................................................................................................................................. 8 Project proposal and task clarification ......................................................................................................... 9

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Interested parties...................................................................................................................................... 9 Client ..................................................................................................................................................... 9 User ....................................................................................................................................................... 9 Eskom .................................................................................................................................................... 9 Conflict Resolution .................................................................................................................................. 10 Competitors ............................................................................................................................................ 10 Design Task ............................................................................................................................................. 10 In the following section, we discuss all the aspects of our design in relation to this project. ............... 10 Magnitude ........................................................................................................................................... 10 Complexity .......................................................................................................................................... 10 Novelty ................................................................................................................................................ 10 Production Quantity and Quality ........................................................................................................ 10 Technical Risk ...................................................................................................................................... 10 Delivery Time Constraints ................................................................................................................... 10 Requirements of Stakeholders................................................................................................................ 11 Client ................................................................................................................................................... 11 User ..................................................................................................................................................... 11 Project Proposal (Scope of Work) ........................................................................................................... 12 Phases and Tasks:................................................................................................................................ 12 Timeline............................................................................................................................................... 14 Design review meetings ...................................................................................................................... 15 Decision points .................................................................................................................................... 16 Acceptance Test ...................................................................................................................................... 16 Systems Diagram of Design Tasks ........................................................................................................... 19 Design Concept ........................................................................................................................................... 20 Concept Idea 1 ........................................................................................................................................ 20 Concept Idea 2(Sci-Fi) ............................................................................................................................. 21 Concept Idea 3 ........................................................................................................................................ 22 Cost Estimate .......................................................................................................................................... 23 Embodiment design .................................................................................................................................... 24 Description of Solar hot water Systems .................................................................................................. 24 Description of the electrical back up system .......................................................................................... 24 3|Page

Heating Element & Thermostat .......................................................................................................... 25 Temperature Sensors .......................................................................................................................... 25 Digital Controller ................................................................................................................................. 26 Micro controlled Relay circuit ............................................................................................................. 28 Power Supply ...................................................................................................................................... 28 Failure Modes ......................................................................................................................................... 29 Design and Safe life time estimates ........................................................................................................ 29 Worst Case Design .................................................................................................................................. 30 Standards and Codes .............................................................................................................................. 31 Detailed Design - Digital Controller Subsection .......................................................................................... 33 Schematic Circuit Diagram ...................................................................................................................... 33 Description of the equipment and principals involved ....................................................................... 33 The implementation............................................................................................................................ 33 PCB board layout..................................................................................................................................... 37 Description of the equipment and principals involved ....................................................................... 37 The implementation............................................................................................................................ 37 Pseudo code ............................................................................................................................................ 38 Program flow chart ................................................................................................................................. 38 Detail Design worksheet Digital controller .......................................................................................... 39 Design quality assessment worksheet .................................................................................................... 40 Manufacturing of Digital controllers....................................................................................................... 41 Testing procedure for digital Controllers ................................................................................................ 41 User manual ............................................................................................................................................ 42 Detailed Cost Estimate ............................................................................................................................ 42 Appendix A .................................................................................................................................................. 44 References .................................................................................................................................................. 45

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Design Specifications
The Department of Electrical Engineering requires the design of an electrically powered backup for a solar water heater, which will be installed into an existing 200 litre capacity solar water heater system. The electrically powered backup system may be incorporated in the main storage cylinder or it may be provided in one or more separate components between the solar water heater and the points of use of hot water. The completed product needs to adhere to the following design specifications.

Functional Characteristics
Small in size No moving parts Heating element to integrate directly into solar water heating tank Temperature and pressure sensor Controller is multi-functional with temperature and pressure inputs Controller can be set for fixed water temperature output Auto-circulate, freeze protection and clock function

Safety Characteristics
Proper electrical insulation Auto-leak detection and over-heat detection with corresponding shut-off function No environmental hazards or safety concerns

Quality Assurance
Must conform to SABS, ISO and IEC standards Must undergo and pass an extensive testing period Must perform reliably

Timescale
Design period 1 month Development period 6 months Production period 6 months Delivery period 1 month

Economic Factors
Market analysis potential to save huge amount of money by user on electrical bills Design cost R10000 Development, manufacturing, distribution cost per unit R2000

Ecological Factors
No ecologically hazardous or damaging materials or liquids to be used

Aesthetic Factors
Low profile unobtrusive in appearance

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Life-Cycle
Have an approximate life time of 20 years Requires minimum maintenance when used within normal operating parameters Can be disposed of as normal electronic waste

Design Context
Macroeconomic Factors
Social
Effect on the community in which the product will be: Designed;Manufactured;Recycled Job creation The design will be simple enough to install so that it creates jobs for skilled and unskilled workers. It shall ensure work for at least 1 electrician, 1 plumber and 1 unskilled aid per installation Occupational safety The insulation and earthing will be according to industry standards to ensure maximum safety against electrocution. The design shall come equip with visual aid warning such as: danger of electrocution; correct use of personal protection equipment when installing, warning against storage of flammable material near the vicinity of the system. The design will be encased in such a way as to prevent injury to people (especially children) and vandalism. Community attitudes to the project The community will have a positive attitude towards the project as it will save them money. It will also revive a much needed culture of electricity saving that has been deteriorating since load shedding ceased.

Technical
Life cycle of technology The research and development stage should be kept as short as possible in order to see returns on the clients investment as well as other interested parties. Whole life-of-project technology issues The product can be deemed useless if newer technologies arrive. The design should thus be flexible enough to incorporate newer technologies. Appropriateness to other steep factors ..

Environmental
Resource usage and manufacturing cost to environment The design should ensure minimal to no water wastage by using sealing. During the manufacturing phase care should be taken to ensure environmentally safe resources are used to minimise the cost to the environment. End of project life issues The design should, as far as reasonably practicable, use recyclable material. Disposal information should be given to the customer indicating the safest method of disposal of non-recyclable materials.

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Economic
Financial background The design should not use unnecessarily expensive technologies and materials. This will ensure our final product is cost effective and financially viable. Sensitivity analysis,Tax/legislation ...... Globalization issues The design should use, as far as reasonable practicable, South African products in order to stimulate economic growth in our country. Capacity building Community issues The cost of the product should be reasonable enough so that is pays itself back in at least one year

Political
Interest Considering the recent electricity crisis in South Africa, citizens would respond positively to a government that supports projects aimed at improving electricity utilization. The government would thus have a vested interest in this project as it would stimulate more efficient use of electricity. Impending political change

Microeconomic Factors
The Market
Demand for product Solar water heaters are in high demand for financial reasons as electricity tariffs are becoming increasingly expensive. Solar water heaters are also becoming more popular as the green approach is being adopted both locally as well as globally. In South Africa, especially Cape Town, weather varies rapidly and one cannot rely on the sun alone for water heating. This makes the demand for a back up systems for our heaters very high. Competitors Our competitors are existing manufacturers of backup systems as well as other designers who look to improve on existing designs. It can be assumed that the competition is high. Some competitors include amongst others: Haining Fadi Solar Energy Co; Foshan Shunde Jnod Electrical Appliance Co; Jiangsu Audary New Energy Co etc. Financial Risk and market stage There is a certain level of concern with the financial return on the product as not many people have yet embraced the idea of greener products or more effective electricity usage. The market is however in its early adopters stage and growing bigger as the country is constantly encouraging energy saving.

Resources
Human Resources The designers are 3 electrical engineering graduates qualified to produce the most optimum design. If the tender is awarded technical staff will be employed to manufacture and distribute the design. We will also ensure that an employee is constantly liaising with the client to ensure no miscommunication. Documentation Financial Resources The University of Cape Town will finance the project if the tender is awarded. No finances are necessary during the design phase.

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Design information, technology and materials availability Information regarding components and existing designs is readily available on the internet. Appropriate technology and materials exist for an optimum design Energy Requirement The energy requirement for the design is reasonable as it would use mains electricity to operate

The Customer
The Department of Electrical Engineering at UCT are the primary customers. Based on the request for proposal it is evident that the customer does understand the need for this product. The customer expects st a full design proposal by the 1 of September. It is vital that this due date be met so that manufacturing can commence if approved.

Corporate Factors
Corporate Enviroment Corporate Structure Corporate Systems Corporate Strategy Shared Values Managment Style Management skill Management skill

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Project proposal and task clarification

Interested parties
Client
The Electrical engineering department at the University of Cape Town is the client. Requirements The client has put in a request for proposal for a design of an electrical back up for a solar water heater with the following specifications: o Functionality: It must work in such a way as to conserve as much electricity as possible while still being functional. It must be able to heat a tank of size no less than 200 litres. It must be easy to use by the householder o Safety: It must be safe to use for both the installer as well as the user o Quality: It must be in accordance with all the appropriate standards o Manufacturing: st o Timing: It must be complete by the 1 of September 20 o Economic: It must be cost effective o Ergonomic: o Ecological: It must be environmentally friendly o Aesthetic: o Life-cycle: o Other:

User
The users of our product will be homeowners that wish to have hot water. Requirements We have assumed requirements that the user might have for the product: o Functionality: It must be easy to use o Safety: It must be safe o Quality: o Manufacturing: o Timing: o Economic: It must save the user a considerable amount of money on electricity o Ergonomic: o Ecological: It must be environmentally friendly o Aesthetic: If it is not hidden (in the roof, basement etc.) it must be aesthetically pleasing o Life-cycle: o Other:

Eskom
Eskom will also be a stakeholder in this project as it is an electrical appliance that aims at to saving electricity. Requirements o Functionality: It must work in such a way as to conserve as much electricity as possible. It must run at the standard 60 Hz frequency. It must not dissipate too much power (maximum..) o Safety: It must be safe to use for both the installer as well as the user o Quality: It must be in accordance with all the appropriate standards o Manufacturing: o Timing: o Economic: o Ergonomic: o Ecological: It must be environmentally safe

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o o o

Aesthetic: Life-cycle: Other:

Conflict Resolution
Conflicting needs will be resolved by assuring open communication between us and the stakeholders. Weekly meetings will be held with the clients to ensure no issues are left unresolved. Users will be able to contact us via internet, email, or telephonically to discuss any discrepancies that they might have with the product. Eskom...

Competitors
Our competitors might put forward a better proposal if there design concept is more original than ours or designed with a better price. .....

Design Task
In the following section, we discuss all the aspects of our design in relation to this project.

Magnitude
Our project can be classified as medium, in terms of size and scope, for our three person team of engineers. We should be able to handle all areas involved with the design with little to no difficulty.

Complexity
As our team consists of three final year electrical engineering students, we are more than able to understand all aspects involved with this project, and hence to create the required proposal and final design.

Novelty
The general technology involved with electrically powered backup is not new or novel. However, we will be examining different possible design concepts and finally recommend one of these as the optimal choice. Some of these designs may incorporate some novel ideas which could add time and complexity to the design, if it turns out to be the concept of choice.

Production Quantity and Quality

As we are a small team, we will start our venture on a small scale. Once our design is completed, we plan to build only a few systems of high quality, and then to gradually increase our production rate as the venture expands.

Technical Risk
As already mentioned, we are experts in regards to electrical systems, and the general technology is well understood and developed. We will also be choosing our recommended design based on using the best, safest and most reliable technology. Hence, we foresee no serious technical risks.

Delivery Time Constraints

As we are consistently working on our design, we are assured it will be completed in time. Once production starts, as only a few systems will be built initially, we believe we will be able to conform to all the necessary time constraints.

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Requirements of Stakeholders
We now investigate whether our initial design specifications, meets the requirements of all the stakeholders involved.

Client
We have been approached by the Department of Electrical Engineering of the University of Cape Town, who requested us to design an electrically powered backup for a solar water heater. Their initial request was for us to submit a design specification. In terms of the Client, our design specification meets the following requirements: Consists of the requested general functional form, such as a heating element integrated directly into the solar heating tank. Contains safety and backup systems, as well as being environmentally friendly. Conforms to all the necessary industrial and engineering standards Its stipulated that there is a period of one month for completion of the design, in order to meet the hand in date.

User
The users of our product will consist of any people, institutions, or organizations in the general public who buys and uses our electrical backup system for solar water heaters. In terms of the User, our design specification meets the following requirements: Consists of a multi-functional controller, to satisfy most needs and desires of people using the device, in terms of configurable settings and switches, such as temperature etc. Small in size, hence does not require much space. Automatic safety and protection systems, that will engage when needed without any input from the user. Will perform reliably. Base unit will not be very expensive, and user will start to save money on electricity bills while always having hot water, as soon as unit is installed. Unit will be aesthetically pleasing and unobtrusive. Unit will have a long life time and require a minimum amount of maintenance and care during its life cycle.

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Project Proposal (Scope of Work)

In this design project the specific requirements are to prepare a design report of an electrically powered backup for a solar water heater. The backup heating and controller design is only required for the scope of the design project. The scope of work required is only design report, and not testing, manufacturing and production of the detailed design. The design report includes the project identification, the design context, the project proposal and task clarification, design concepts, embodiment design, and finally the detailed design. The specific detailed scope of work carried out by our design team will be described in detail below, including the phases and tasks, timescales, design review meetings, and the decision points discussed throughout the project. The scope of work will only entail everything required to produce the design report and nothing more.

Phases and Tasks:

All the tasks below were compiled in this report Phases: Project identification and the design context Tasks: Determining the client and the key performance details of the product/system. Prepare a specification list (client requirement) for the design task for this new product/system. Determine the macroeconomic, microeconomic, corporate factors/issues that might be considered in choosing the best solution. Show how these factors/issues are relevant and important to your design. Identify the interested parties and their requirements for the project. (Client, users, and other stakeholders) Determine how the conflicting needs of the interested parties can be resolved. Determine how competitors can produce a better proposal. Assess the design specification based on the interested parties needs, and how well it defines the design task needed. Produce a statement of the scope of work. Including the phases and tasks, timescale, design review meetings, and decision points. Prepare an acceptance test for the design stage. Produce a systems diagram of the main components of the design task and its context. Develop four concept designs for the project. Including all the main components of the system and diagrams. Discuss the benefits of each concept design. A complete evaluation of the concepts, including

Project proposal and task clarification

Design concepts

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Embodiment design

Detailed design

the weak points. Selection of the concept recommended for the design with reasons. A cost estimation of the selected concept. Description of selected concept design (including diagrams, circuits, etc.) List of the possible failure modes, with probabilities, consequences and the required actions to alleviate the problem. Description of the design life limit with the safe life limit, and what factors will limit it. A detailed worst-case calculation on one or more components or sub-systems of the design. A description of at least one standard or code that applies to our design. Preparation of the detailed design for one subsystem, including the following: A description with details of the design (diagrams, drawings, circuit diagrams, calculations, etc.) Produce a detailed design checklist Complete the design quality assessment worksheet. Description of the manufacture process to be taken for the product or sub-system. Description of the testing process to be taken for the product or sub-system, during or after the manufacture/installation. Create a table of contents for the user/installation manual or help files. Create a detailed cost estimate for the supply of the product/system, including all costs. (Design, manufacture, delivery, salaries, etc.) Design review: Compare the design with the requirements of the initial design specification. Produce the acceptance test for the design activity.

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Timeline

Start
Mon 8/1/11

Design Group Formation

Mon 8/1/11 - Sun 8/7/11

Mon Aug 1

Thu Aug 4

Sun Aug 7 Project identification and the design context

Mon 8/8/11 - Fri 8/12/11

Wed Aug 10

Project proposal and task clarification

Sat 8/13/11 - Mon 8/15/11

Sat Aug 13

Design concepts
Tue 8/16/11 - Thu 8/18/11

Embodiment design
Fri 8/19/11 - Mon 8/22/11

Fri Aug 19

Mon Aug 22 Detailed design

Tue 8/23/11 - Mon 8/29/11

Thu Aug 25

Sun Aug 28 Design review and hand in

Tue 8/30/11 - Thu 9/1/11

Wed Aug 31 Finish

Thu 9/1/11

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Design review meetings

At end of every project phase we met for a design phase review meeting. During which we discussed the tasks and the problems encountered by each project member. Further we discussed the next step to take, the decisions and choices we had to make, and allocated the work evenly and accordingly to match the strengths of each member. The table below shows the meetings scheduled. Meetings: Group formation Phase 1 Date & Time: 8/1/2011 13h00 8/8/2011 13h00 8/12/2011 13h00 Purpose: To form a dynamic project team, and to assess our strengths and weaknesses. To discuss the design task presented to us (i.e. the scope of work, structure, initial tasks for phase 1 and allocation of work). Review of phase 1 by assessing the issues that came to light, and compiling phase 1 in the report document. Further to discuss the tasks for phase 2, along with allocating the work. Review of phase 2 by assessing the tasks and making decisions on rectifying the problems encountered, and compiling phase 2 in the report document. Further to discuss the next phase tasks, and allocating the work. Review of phase 3 by assessing the problems that arose and rectifying them, and compiling phase 3 in the report document. Decisions were made on proposed concept for phase 4. Further to discuss the next phase tasks, and allocating the work. Review of phase 4 by assessing the tasks and making decisions on rectifying the problems encountered, and compiling phase 4 in the report document. Further to discuss the next phase tasks, and allocating the work. Review of phase 5 by assessing the tasks and making decisions on rectifying the problems encountered, and compiling phase 5 in the report document. Further to discuss the next phase tasks, and allocating the work. Review of the design project as a whole, assessing how well it fits the initial design specification. Proof reading the final draft document and submission.

Phase 1 review

Phase 2 review

8/15/2011 13h00

Phase 3 review

8/18/2011 13h00

Phase 4 review

8/22/2011 13h00

Phase 5 review

8/29/2011 13h00

Complete Design review and hand in

8/31/2011 13h00

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Decision points
The decision points discussed were the concept design to be chosen, the functionally of the detailed design, how well the detailed design meets the clients specifications, how well the design meets the design context, design life time and the safe life time of the system to be chosen, whether found codes or standards is applicable to our design, and finally the software coding to be implemented.

Decision No. Decision 1:

Description of the decision to be made: Design concept to be chosen.

Chosen decision: Design concept 4, as it is the most likely concept to work and is most cost and power efficient design.

Decision 2:

Functionally of the detailed design.

Decision 3:

How well does the detailed design meet the clients specifications? How well the design meets the design context. Design life time and the safe life time of the system to be chosen. Whether found codes or standards are applicable to our design. The software coding to be implemented.

The functionally meets the specifications requirements and also allows for future development of the product. Very well, it fits the specification almost perfectly.

Decision 4:

Decision 5:

Very well, it fits the design context in all microeconomic, macroeconomic and corporate factors. It was chosen accordingly; refer to the relevant section in the embodiment design. They are very applicable; refer to the relevant section in the embodiment design. This was chosen based on the three principle modes of operation, deluxe, energy efficient, and user defined mode. Refer to embodiment design on specific details of these modes.

Decision 6:

Decision 7:

Acceptance Test
Once the design is complete the client will overlook the following check list to assure that the design has met the specifications. If a specification is not met the design will be revisited until it satisfies all conditions. An example of what to do when a specification is unmet is marked in red.

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Specification Functional: General Is the size 20x400? Are there any moving parts? Is the heating element integrated inside the water tank? Sensors Are the temperature sensors situated on the appropriate places Are the pressure sensors situated on the appropriate places? Controller Is the controller is multi-functional with temperature and pressure inputs? Can the controller be set for fixed temperature outputs? Does the controller have Auto-circulate, freeze protection and clock function? Safety Special features Does the design include auto-leak and overheat detection with corresponding shut-off function? Does a battery backup exist? Standard compliance Is the electrical insulation according to standard.....? Is the electrical supply according to standard.....? Is the battery back up according to standard....? Environmental Safety Are there no environmental concerns? Quality Assurance Is the design in accordance with SABS standard.....? Is the design in accordance with ISO standard....? Is the design accordance with IEC standard...? Time Was the design submitted by the 01-092011? Economic Is the design cost less than/ equal to R10000 Is the unit price estimate less than/equal to R2000? Ecological Are there no ecologically hazardous/damaging materials /liquids used?

Complete (Y/N) N

If No, Give details and specify remedial action to be taken The design is 30x40. Re-design to meet specification

Re-evaluation Date: 03-09-2011

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Aesthetic Is the design unobtrusive in appearance? Life-Cycle Is it designed to have an approximate life time of 20 years? Does it require minimum maintenance when used within normal operating parameters? Can it be disposed of as normal electronic waste?

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Systems Diagram of Design Tasks

Initial Client Request

Design Specification

Design 1

Design 2

Design 3

Design 4

Best ? y y

Best ?

Best ? y

Best ? y

Final Design Concept

Test and Refine Final Design

Procure, Assemble, Prepare Components Assemble, Manufacture, Prototype n Test Prototype

Assemble, Manufacture, Product y

Satisfactory?

Deliver Product

Working Product

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Design Concept
The following section contains four developed ideas as possible design concepts of the electrically powered backup system for a solar water heater, to be installed into an existing 200 litre capacity solar water heater system.

Concept Idea 1
This concept of the electrically powered backup system consists of an electronic controller incorporated into the main storage cylinder of an existing solar water heater. The controller turns on an electric heating element, if the water temperature in the main cylinder drops below the desired level. The controller will be multi-functional consisting of an input pad with which one can set the threshold temperature, a timer, etc. It will contain temperature and pressure sensors to monitor the state of the water at all times, as well as an alarm and auto shut off. Components: 230 V AC Supply Cables Electric heating element Sensors Electronic controller o Multi-functional programmable core o Digital display o Keypad o RS232 port for installing upgrades

Advantageous: Meets all requirements, plus extra features Non-intrusive installation Ease of use Most efficient use of energy Most efficient in terms of monetary savings Onboard safety systems such as auto shut off

Disadvantageous: More complex circuitry More expensive components More programming

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Concept Idea 2(Sci-Fi)

This concept of the electrically powered backup system, consists of a highly advanced electronic controller, incorporated into the main storage cylinder of an existing solar water heater (same general setup as for Idea 1), with a sensitive EM-field generator and sensor. The solar system has a confined water flow system that heats up the useable water of the main storage cylinder. The confined water of the solar heating system contains 0.5% specially constructed nanites, and 25% of a specially designed Carbon-Argon-Indium compound, by mass. These nanites have been created using the biological microorganism Escherichia coli. If the water temperature in the main cylinder drops below the desired level, the nanites can be controlled with a special EM-field, to cause the slow gradual breakdown of the compound, which releases enormous amounts of heat in the water, as well as safe and inert molecular by-products. Thus by varying the EM-field, the rate of molecular breakdown can be controlled, and hence the change in temperature of the water. Components: 230 V AC Supply Cables EM-field generator EM-field sensor 1kg of JX027-ECOLI Nanites 40L of (Cx-Ary-Inz) liquid compound Controller Battery Backup Electronic controller o Multi-functional programmable Quad-Core processor o Digital display o Keypad o USB3 port for installing upgrades

Advantageous: Meets all requirements Least-intrusive installation Most savings on electricity (only used to control nanites) Can heat water even when there is a power outage (battery controls EM-field)

Disadvantageous: New technology that hasnt been tested extensively Most complex circuitry Most expensive components Most complex programming required Nanites needs to be replaced every 5 years (Cx-Ary-Inz) liquid compound needs to be replaced every year

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Concept Idea 3
The electrical back up system for a solar water heater designed here consists of two heating element units, two temperature sensors, a digital controller key pad, and the wiring to these components. The heating element unit is tubular steel unit with built in heating and sensing components. The unit screws directly into the copper piping, allowing water to flow through it while getting heated. These units are located on both sides of the storage tank, as illustrated in the diagram below. The heating element components consists of two built in temperature sensors located on the ends of the unit, one flow rate meter, one a heating element coil located within the centre of the tube covering a large surface area of the waters flow path, and finally a thermostat for control of the heating element. The temperature sensors are also located on the solar collectors input and output pipes. The sensors units consist of small housings that are bolted around the copper piping and the temperature sensor embedded within the housing. The final component is the digital controller. This consists of 8 ADC inputs, 3 DAC outputs, 16 button keypad, LCD display, Pic32 and Pic18 microcontrollers, USB connectors, wireless communication sender/receiver, and an internet/telephone jack. The benefits of this system are that the installation of the system fairly easy, any qualified plumber can do the job. It requires minimal alterations to the existing solar water heating system, and has no interference with the storage tank at all. It can have additional digital control algorithms programmed into the system; it can be updated, monitored and controlled by remote access from the utility company. The down side to this system is that it required two heating elements and relays, a more complicated microcontroller with more sensing equipment required, thus twice the power and cost requirements.

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Cost Estimate
Category Product Component Cost Main Components Hot water cylinder components Sub - Components Heating element (3KW) Element gasket Thermostat with fuse Thermo sensor screw in (for hot water cylinder) Variable fit pipe mounted temp sensor Digital Controller Unit Wiring for temp sensors (10m) 2 core Wiring for pump motor (10m) 3 core Wiring for heating element (10m) 3 core Relay for heating element control Wiring for digital controller power supply (5m) + plug Wiring for heating element (5m) 3 core Manufacturing of digital controller Acquiring all other components Packaging of final product Component Cost R218 - 59 R8 - 95 R165 - 00 R60 - 00 No. of Components 1 1 1 1 Total Cost R218 - 59 R8 - 95 R165 - 00 R60 - 00

Digital Controller + sensing + wiring components

R60 - 00

R120 - 00

R300 - 00 R4 00/m

1 3

R500 - 00 R120 - 00

R6 00/m

R60 - 00

R8 00/m

R80 - 00

R65 - 00 R6 00/m + R5 (for plug) R8 00/m

1 1

R65 - 00 R35 - 00

R40 00

Manufacturing and packaging costs

R200 - 00 R30 - 00 R50 - 00 R247 - 46

1 1 1 1

R200 - 00 R30 - 00 R50 - 00 R247 - 46 R2000 - 00

Design and administration costs Total Product Cost

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Embodiment design
Description of Solar hot water Systems
The electrical backup system for the solar water heater is designed to operate on the two most common solar water heating systems available. These systems will be described below so that sufficient knowledge is understood in order to design the electrical back up system for these topologies. The first system is the passive open loop system. This system is commonly called the thermo siphon. It operates by solar collectors being either placed on the roof or on the ground where sufficient sunlight can be absorbed. The storage tank is placed directly above the solar collector this so that the hot water produced from solar will rise directly into the storage tank, while pushing the cold water at the bottom of the tank through the bottom of the solar collectors. [1] The second system is the active solar water system. This system has two variations, the first is the active open loop system, and second is the active closed loop system. The active open loop system consists of the solar collectors been placed on the roof of a house while the storage tank placed inside the house. The cold water at the bottom of the storage tank is pumped up into the bottom of the solar collectors, and the hot water leaving the top of the collectors is circulated back into the top of the storage tank. [2] The active closed loop system works similarly to the open loop. The major different is that the fluid circulating through the solar collectors run through a different system compared to before when the water in the storage tank circulated through the solar collectors. This hot fluid from the top of the solar collector passes through a heat exchanger inside the storage tank, and is then circulated back into the bottom of the solar collector via an electric pump. This is to prevent freezing/boiling of water in the solar collectors during extreme conditions. Thus in the isolated system, antifreeze mixture can be added to the fluid preventing it from freezing/boiling. This prevents damage to the solar collectors. [2]

Description of the electrical back up system

The electrical back up system that has been chosen consists of the following components: A heating element & thermostat, three temperature sensors, digital controller, power supply, a micro controlled relay, and various wiring connecting the heating element, pump, and temperature sensors to the digital controller.

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Heating Element & Thermostat

The heating element is mounted horizontally into storage tank. The dimensions of the element are 56mm by 127mm deep, where 56mm is the screw in thread size. A pre allocated location for a heating element half way up on the wall of the storage tank is designed into all of the common solar water heating systems. This was designed for the option to install a heating element for back up. The elements were not pre-installed as it would increase the overall cost of their product. However the option for additional installation is simple. The heating element screws into the location with gasket that will be provided. A typical thermostat used in all geysers will be provided as a secondary fail-safe backup to prevent overheating of the tank. The primary fail-safe backup for overheating will be the control of the relay using the digital controller. The heating element is connected to a relay controlled by the digital controller. It is further connected via DAC outputs on the controller. This controller controls when the heating element will switch on and off depending to the conditions of the system to maintain an efficient use of electrical energy.

Temperature Sensors
An immersion temperature sensor is installed into the side of the storage tank via one of the heating element ports. (See appendix A for details on the storage tank [3]). The heating element port is a 56mm female thread, so for the temperature sensor to be installed a bushing is needed to reduce the size from 56mm to 27mm (refer to figure 4). Once the thread is reduced to 27mm the pocket housing can be screwed in (see figure 3), and followed by the immersion sensor (see figure 2). The temperature is measured accurately and its value is read to the digital controller via the ADC inputs.

Two further temperature sensors are installed on to the inlet and outlet of the solar collectors and are linked to the digital controller via the ADC inputs. The sensors are exterior pipe mounted temperature sensors obtained from certain suppliers. These sensors are able to accurately measure the temperature of the fluid flowing inside the pipe. These sensors provide valuable information of the current state of the system to the controller. The use of the information these sensors provide will

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be discussed in the detail functionally of the digital controller, as it directly relates to the efficient use of the heating element and pump.

Digital Controller
The digital controller is designed to control the heating element and the variable speed drive pump efficiently to maximize the output of hot water from the solar water system. The controller consists of two microcontrollers, an LCD display, a 16 button keypad, three ADC inputs, two DAC outputs, a wired communication RJ-45 jack, and a USB port. The microcontrollers that are going to be used are the PIC32MX360F512L and PIC18F4550QFN. The reason for two microcontrollers being used is that the Pic32 chip (that has superior processing power, memory and functionality) does not have a USB interface for programming. The Pic18 chip has this functionally so these two chips are linked together via the JTAG ports, so the Pic32 chip can be programmed through the USB interface on the Pic18 chip. The ADC inputs are set up with adjustable gains so the voltage can be adjusted between (3V 18V) on the input of the ADC. This allows for compatibility with the temperature sensors that will be connected to the ADC inputs. The DAC outputs have the exact same setup, as 12V is required for the micro controlled relay for the heating element and even less (between 3V 12V) for the chopper circuit on the variable speed drive DC pump. The variable speed drive DC motor commonly used in solar water heaters is controlled by the microcontroller by connecting the PWM output to the gate of the IGBT in a DC chopper circuit. It will be a class A chopper only which will only operate in one quadrant (forward motoring). The wired communication interface is setup so that the software on the microcontrollers can be automatically updated providing the latest and best control methods to obtain the most energy efficient system through the internet site created for this purpose. Its also created for the possibility to be connected to the utility company through the internet, so that the solar water systems can be controlled remotely. This is to provide even greater savings to the users by using energy when the tariffs are low, and also to help reduce the peak load on the national grid by using energy at alternative times of the day when the load is low. There are two pre-defined modes programmed into the controller, and a manually setup control mode to meet the users exacts needs from the solar water system. The Pre-defined modes are the deluxe mode and the energy efficient mode. For the control scenarios the following variables have been defined: Temp1 Outlet solar collector temperature sensor Temp2 Inlet solar collector temperature sensor Temp3 Storage tank temperature sensor Pump Variable speed drive DC motor Element heating element

The deluxe mode is for users who want hot water at any time of the day while still saving some money when the solar collectors are transferring heat to the tank. The system is to maintain a temperature of 60 degrees in the storage tank at all times. The control system will continuously be reading the three temperature sensors. The following scenarios can occur and the control system must be programmed accordingly.

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Scenario 1: Scenario 2:

Scenario 3: Scenario 4:

If temp3 < 60 and temp1 = temp2. Control systems response: pump off; element on till temp3 = 60. If temp3 < 60 and temp1 > temp2. Control systems response: pump on (flow rate will depend on the difference between temp1&2, large difference in temp1&2 will have a larger pump flow rate); element off. If temp3 < 60 and temp1 < temp2. Control systems response: pump off; element on till temp3 = 60. If temp3 > 60 and (temp1 < temp2, temp1 > temp2, temp1 = temp2). Control systems response: pump off; element off.

Energy efficient mode is for users whose main interest is saving energy and money. This control mode will only provide guaranteed hot water at 55 degrees during certain times of the day (5:30am 8:00am and 5:00pm 9:00pm). These times are based on times when most people are awake and at home, thus majority of the users who only use hot water at these times will not notice any difference to their hot water supply. The following scenarios can occur and the control system must be programmed accordingly. Scenario 1: Scenario 2: If temp3 < 55 and temp1 = temp2 and time within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump off; element on till temp3 = 60. If temp3 < 55 and temp1 > temp2 and time within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump on (flow rate will depend on the difference between temp1&2, large difference in temp1&2 will have a larger pump flow rate); element off. If temp3 < 55 and temp1 < temp2 and time within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump off; element on till temp3 = 60. If temp3 > 55 and (temp1 < temp2, temp1 > temp2, temp1 = temp2) and time within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump off; element off. If temp3 < 55 and temp1 = temp2 and time not within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump off; element off. If temp3 < 55 and temp1 > temp2 and time not within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump on (flow rate will depend on the difference between temp1&2, large difference in temp1&2 will have a larger pump flow rate); element off. If temp3 < 55 and temp1 < temp2 and time within not intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump off; element off. If temp3 > 55 and (temp1 < temp2, temp1 > temp2, temp1 = temp2) and time not within intervals (5:30am 8:00am and 5:00pm 9:00pm). Control systems response: pump off; element off.

Scenario 3: Scenario 4: Scenario 5: Scenario 6:

Scenario 7: Scenario 8:

Manual mode is for users who want hot water at certain times of the day, and at a certain temperature. The users will push the button for manual mode, and will then be asked to enter the start time of interval (in 24h00 mode) followed by the enter button. It will then ask user to enter the end time of interval followed by enter. It then asks for the temperature of the hot water they would like. Then the controller will ask if the user would like to enter other interval, and the user will be faced with an option (Yes press 1, No - press 2), and if no is pushed the setting will be saved and implemented, otherwise it will begin to setup the next interval by asking the user to enter the time of the next interval start, etc. The display on the digital controller will display the time in the top right hand corner, the storage tanks temperature in the top left, the mode that is running (deluxe, energy efficient, or user defined mode) in the top middle. If the system detects a fault it will display the fault type in the center of the display, faults types will be explained in user manual.

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Micro controlled Relay circuit

The heating element is controlled by the digital controller and therefore to control it the system will require a relay to open and close the heating element circuit which is connected to the mains (230VAC). The low voltage side of the relay operates at 12V. This voltage is adjusted down to 3.3V by the variable gain op amp circuit connected to the DAC pins. See figure 6 below for the relay circuit.

Power Supply
The power required for the digital controller is 15V DC. This voltage will then get regulated to -15V, 5V and 3.3V on the main circuit board. This is the entire power requirement for the digital controller. The 15V DC will be rectified from the mains supply, using an instrument transformer with voltage ratio 230VAC: 16.4VAC and a full bridge rectifier with a smoothing capacitor.

Figure 7: Power supply, taken from [7].

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Failure Modes
Failure Mode Sensors Failure to detect/ give in correct readings Power supply Short circuiting Overload Controller False outputs to the heating element Display might indicate incorrect measurements Keypad could fail to work Low power supply to the controller High power supply to the controller Heating element Corrosion of the heating element Battery Short circuiting Battery acid leakage Seals Leakage through the seals Probability medium Consequence The system would turn on/off incorrectly or not at all. Over heating Equipment could break. Possible electrocution if the user is touching the power supply Equipment could break. Possible electrocution if the user is touching the power supply The system would turn on/off incorrectly or not at all. Over heating User might switch the device on/off unnecessarily .... The controller will switch on thus the system will not work The controller will over heat and break

medium medium

low low low medium low

high medium low high

Water contamination. Equipment could break. Possible electrocution if the user is touching the power supply Equipment can break. Loss of water and possible flooding of the surrounding area.

I NEED TO SEE FULL DESIGN IN ORDER TO SEE WHAT OTHER COMPONENTS EXIST

Design and Safe life time estimates

The design life as well as Safe life of the system is estimated at 20 years. The safe life would decrease if any of the above failure modes occur and is not attended to.

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Worst Case Design

Our electrically powered backup system requires electricity to work. This electricity will be supplied via 230 V AC. The controller itself however requires an input of 15V DC. This input is then further voltage regulated to supply 5V DC and 3V DC. An important component then to consider when doing worst case calculations is the subsystem that changes the AC voltage to the desired DC voltage. To convert the AC voltage to DC voltage, you firstly need a transformer (to step down the 230V AC), then a fullwave rectifier (consisting of 4 diodes for uncontrolled or 4 thyristors for controlled rectification), and finally a low pass filter (consisting of a resistor and a capacitor).

Figure 1 Rectifier

One can now use the general rectifier equation to find the value of , which will be the midpoint voltage on the secondary side of a single tap transformer, for , which is the desired output. Thus,

So the primary side voltage is 230 V and the secondary side is approximately 16.6 V. The turns ratio of the transformer is then,

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Now for a worst case calculation, suppose the AC voltage delivered is not exactly 230 V. Assume a maximum of 240 V and a minimum of 220 V. What will be the corresponding voltage delivered to the controller ( )? The previous calculations are now performed in reverse order and the results are summarized in the next table.

220 V 230 V 240 V

15.7 V 16.6 V 17.1 V

7.85 V 8.3 V 8.57 V

14.1 V 15 V 15.4 V

Hence, from this its clear that the incoming DC voltage which the controller receives may be as low as 14 V and as high as 15.5 V. Our system therefore needs to be designed to handle these possible fluctuations. One approach is through the careful selection of the capacitor for the low pass filter that is in parallel with the voltage source. If the voltage source is higher than the capacitor voltage, the capacitor will pull the voltage down, and if it is lower, the capacitor will pull the voltage up, essentially smoothing out the voltage to some average. There is also a resistor between the voltage source and capacitor to prevent too much current from flowing into the capacitor.

Standards and Codes

Since we are designing an electrically powered backup for a solar water heater, which will be installed into an existing 200 litre capacity solar water heater system of a household, the following seems to be the most relevant standards: SANS 60730-2-8 and 60335-2-21 The following table are copied in its entirety (to give a detailed outlook of the standard) from the following website: https://www.sabs.co.za/webstore/standards/product.php?id=14012228 SANS 60730-2-8 Title

Date Approved Edition Amendments Abstract

International Relatedness Date Reaffirmed Issued By Price (ZAR, excl. VAT) Shipping Costs (Hardcopy) Stage Code Stage Date

Automatic electrical controls for household and similar use Part 2-8: Particular requirements for electrically operated water valves, including mechanical requirements 10-10-2003 1.01 1A: International:03/10/2003 Applies to electrically operated water valves for use in, on or in association with equipment for household and similar use that may use electricity, gas, oil, solid fuel, solar thermal energy, etc. or a combination thereof, including heating, air-conditioning and similar applications. IEC 60730-2-8 12-12-2008 STANDARDS 194.00 See Terms & Conditions for more details. 91.60: Standard Reaffirmed 2009-02-16

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Committee ICS Number ISBN Collection Cross-reference Standards Alert Service

72 97.120 0-626-14898-7 This standard is not part of a collection Register now, to receive notifications about this standard.

The following table are copied in its entirety (to give a detailed outlook of the standard) from the following website: https://www.sabs.co.za/webstore/standards/product.php?id=14009025 SANS 60335-2-21 Title Date Approved Edition Abstract

International Relatedness Replaces Use In Conjunction With Issued By Price (ZAR, excl. VAT) Shipping Costs (Hardcopy) Stage Code Stage Date Committee ICS Number ISBN Collection Cross-reference

Standards Alert Service

Safety of household and similar electrical appliances Part 2-21: Particular requirements for storage water heaters 08-08-2000 1.00 Deals with the safety of electric storage water heaters for household and similar purposes and intended for heating water below boiling temperature, their rated voltage being not more than 250 V for singlephase appliances and 480 V for other appliances. Covers appliances intended to be used by laymen in shops, in light industry and on farms. Deals with the common hazards presented by appliances which are encountered by all persons in and around the home. IEC 60335-2-21 SANS 60335-2-21( SABS IEC 60335-2-21 edition 1.000 of 1998) SABS IEC 60335-1 STANDARDS 159.00 See Terms & Conditions for more details. 60.60: Standard Published, in use 2000-08-04 72 91.140.65 0-626-12585-5 This standard is not part of a collection Shoppers buying this also bought: SANS 151 SANS 1307 SABS IEC 60335-1 Register now, to receive notifications about this standard.

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Detailed Design - Digital Controller Subsection

Schematic Circuit Diagram
Description of the equipment and principals involved
Eagle Cad v5.10 PIC32MX360F512L-80I/PT - Microchip PIC32 32bit microcontroller PIC18LF4550-I/ML - Microchip PIC18 USB microcontroller RJ45 Jack SN74HCT541 - Octal line driver 2* LM317 - 1.5A adjustable voltage regulator LCD - 16 character 2 line LCD PIC32MX3XX-4XX+Family+datasheet Various other datasheets for required components Various resistors, capacitors, leds, and crystals.

The implementation
It began by reviewing the datasheet for the pic32 microcontroller, and connecting up all the basic connection requirements for the microchip on eagle cads schematic layout. This involved choosing/connecting the two crystals (8 MHz and 32 KHz) for the pic32 microchip, setting up the decoupling capacitors, setting up the capacitor on the internal voltage regulator, and setting up the master clear pin with a reset button. (See figure 10) Connection for the pic18 and pic32 microchips were implemented next via the JTAG ports; this was to enable USB communications to the pic32 chip which did not have the functionally. Next connecting up the LCD display was done via the octal line driver chip to the pic32 microchip this also included a potentiometer for adjusting the display brightness. Connection of the 16 button key pad which was connected directly to the ports on pic32 chip was done next. (Refer to figure 8, 9 and 10 for implementation.) Next setting up the ADCs and DACs was implemented, using two inverting opamps for each I/O so the voltage gain could be varied between 3V - 18V. (One with unity gain and the other with variable gain using a potentiometer). The push buttons were then connected next via the ports. The USB port was connected to the pic18 microcontroller. (Refer to figure 8 and 9 for implementation.) Finally the power supply for the microcontrollers, octal line driver is set up using the 15V rail rectified to a 5V rail and further rectified to a 3.3V rail. I did this done by using an adjustable regulator. The various connections were made for the components power needs (5V and 3.3V). (Refer to figure 8 to see how the power supply was set up.)

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PCB board layout

Description of the equipment and principals involved
Eagle cad v5.10 PIC32MX3XX-4XX+Family+datasheet PIC18F2455-2550-4455-4550+data+sheet

The implementation
Components were placed in various locations across the board in Eagle CAD, keeping in mind that the RJ- 45 and USB connectors need to be at the edge of the board. The microcontrollers (pic18 and pic32) have restrictions on how far the decoupling capacitors can be located from the chips, thus review of the datasheets was needed to find out the maximum distance. Once the capacitors were placed within the maximum distance to the microchips, the placement of the rest of the components was done using both sides of the board. The design settings were chosen specifically to meet the requirements of the machine that cuts the tracks and drills the holes in the board in the department. Drill sizes, minimum clearance between tracks and the track width, etc. was all chosen. (See figure 11)

Figure 11: PCB layout of digital controller ready for printing.

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Pseudo code
1. Initialize all start conditions (variable name indicated in parenthesis) Set heating element off ( Heat_el) Set the desired temperature to 60C (Set_temp) Set the delay to 5 seconds (delay) Initialize a variable for the actual temperature, reading taken from the temperature sensor, and initially set it to 60C (Act_temp) 2. Delay for 5 seconds before taking the first reading 3. Take the reading from the temperature sensor 4. Is the temperature sensor reading smaller than the set temperature? 5. Is the heating element off? If 4 and 5 are both true switch on the heating element and repeat from step 2 If 4 and 5 are both false switch off the element and repeat from step 2 If 4 is true and 5 is false repeat from step 2 If 4 is false and 5 is true repeat from 2

Program flow chart

Initialization: Heat_el=0 Set_ temp=60C delay=5 seconds Act_temp=60C

delay

Switch off heating element Get Act_temp from sensor

Switch on heating element

Heat_ el off?

Heat_ el off?

Act_Temp<Set_temp?
b) Detail design checklist

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Detail Design worksheet Digital controller

Requirements Functional Contributing factors Geometery: Is the circuit board 20x40mm? Motion of parts: Are all the parts firmly connected to the circuit board? Energy needed: Is there a 3v supply/transformer Materials: Does the hardware include: 1. Apic32 chip 2. USB system for communications to PC, including programming 3. Keypad and/or pushbuttons 4. Display (LCD that displays either text or bits) 5. Analog inputs (12 bits with two or more channels) 6. Analog output (12 bits) Control system: Is the controller reset compatible? Informational flow: Is the program logical? Forces involved Operational: Human: Does the controller have overvoltage protection? Environmental: Are the materials used able to withstand harsh temperature conditions? Quality assurance: Quality control: Reliability: Production of components: Are the components that are produced in working order? Are the components that are produced according to standard? Purchase of components: Are the components that are purchased in working order? Are the components that are purchased according to standard? Assembly: Is the assembly according to the design? Has the design been completed on time? Has the design been completed within budget? Are there any materials used that are harmful to the environment? Is the circuit board neat? Is the casing compact and neat? Current status Required action

Safety

Quality

Manufacturing

Timing Economic Ergonomic Ecological Aesthetic Life-cycle

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Design quality assessment worksheet

very clueless

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Manufacturing of Digital controllers

All electronic hardware will be ordered from local manufactures (e.g ). The choice of which manufacturer will demand on price and quality of the components. We will then use EAGLECAD to construct our schematics of the circuit board. We will use FR-4 laminate for our printable circuit board. The laminate is flame retardant and constructed from glass fabric impregnated with epoxy resin and copper foil .We will use LPKF Protomat S42 system to create our printable circuit board. This machine will etch our schematic onto the laminate creating a working circuit board.

Figure:LPKF Protomat S42 The laminate will then be coated with a green solder mask. All the components (resistors, capacitors, IC mounts etc.) will be soldered onto the circuit board. After testing a conformal coating will be added in order to protect against environmental impact. The circuit board will then be fully enclosed in a Perspex housing.

Testing procedure for digital Controllers

The following testing procedure has been laid out for the digital controller. After manufacturing and assembly of the digital controller the electrical circuit will be tested. This will be done in the following manner. The digital controller will be powered up, and an oscilloscope will be used to test and measure the following below, these results will be checked to see whether they lie within their spec value range: The DC voltage on the power supply to see whether it is in the correct range (14.5 15.5 with the DC ripple less than 1V. The regulated voltages will be tested next, +/-15V, 5V, and 3.3V rails. Various power rail pins will then be tested on the microcontrollers and ICs across the board.

The digital controllers that pass the previous testing phase will then be factory programmed with the software code required for operation. Finally these digital controllers will be connected to the testing rig. (the complete system) They will then be check rigorously in the system for controller functionally, correct operation, and how the controller handles its self during fault conditions. Once the digital controller passes all these tests it will be quality control accepted and then be ready for packaging.

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User manual
1. Introduction 1.1. Operational procedure 1.2. Initializing Components 2.1. Hardware 2.1.1. Push button operation 2.1.2. Display 2.1.3. Printed circuit board 2.1.4. Casing 2.2. Software 2.2.1. Operational flow 2.2.2. Memory Map 2.2.3. Default settings 2.3. Power Supply Installation 3.1. Mounting 3.2. Wiring Safety 4.1. Safety warnings 4.2. Fault detection 4.3. Troubleshooting Regulatory Requirements 5.1. Standard compliance Contact Information Glossary

2.

3.

4.

5. 6. 7.

Detailed Cost Estimate

All of the materials were sourced for other companies, so delivery of the materials required is incorporated into the cost. The only parts manufactured are the power supply, digital controller and the DC chopper drive. All only parts were sourced from various companies. The pricing for delivery of materials is done on a per unit basis, and normally 200 500 units will be manufactured at a time. Category Product Component Cost Main Components Hot water cylinder components Sub Components Heating element (3KW) Element gasket Basic Components Heating element Supply delivery/ unit Element gasket Supply delivery/ unit Thermostat with fuse Supply delivery/ unit Thermo sensor Supply delivery/ unit Component Cost R217 - 59 R1 00 R8 00 R0 - 95 R164 - 00 R1 00 R55 - 00 R5 No. of Components 1 1 1 1 1 1 1 1 R60 - 00 Total Cost R218 - 59

R8 - 95

Thermostat with fuse

R165 - 00

Thermo sensor -screw in (for hot water cylinder)

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Wiring for temp sensors (10m) 2 core Wiring for heating element (10m) 3 core Relay for heating element control Digital Controller Unit

Wiring (10m) Supply delivery/ unit Wiring (10m) Supply delivery/ unit Material Costs Supply delivery/ unit Material Costs Wiring for digital controller power supply (5m) + plug Supply delivery for materials Material Costs Supply delivery for materials Wiring(10m) Supply delivery/ unit Temp sensor Supply delivery/ unit Material Costs Supply delivery/ unit Wiring (10m) Supply delivery/ unit -

R40 00 (R4 00/m) R1 - 00 R7 90/m R1 - 00 R64 - 00 R1 - 00 R350 - 00 R6 00/m + R5 (for plug) R10 00 R40 00 R2 - 00 R40 00 (R4 00/m) R1 - 00 R58 - 00 R2 - 00 R20 - 00 R2 - 00 R6 00/m R1 - 00 R100 - 00

1 1 1 1 1 1 1 1

R41 00

R80 - 00

R65 - 00

Digital Controller

R437 - 00

1 1 1 2 2 2 2 1 1 1 1 1 R100 - 00 R22 - 00 R120 - 00 R82 - 00

Power Supply Unit (230VAC to 15VDC) Solar Collector temperature Sensors Wiring for temp sensors (10m) 2 core Variable fit pipe mounted temp sensor DC Motor (Pump) Drive DC Chopper Drive Wiring for Pump (10m) 2 core Product manufacturing and packaging costs Manufacturing of digital controller Manufacturing of Power Supply and DC Chopper Packaging of final product

R61 00

R30 - 00

R30 - 00

R20 - 00 R388 - 46 R100 + (R1/product delivered)

1 1 1

R20 - 00 R388 - 46 R101 - 00

Design and administration costs Delivery of product to client

Total Product Cost

R2000 - 00

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Appendix A
Diagram for Solar storage tank to be used in conjunction with the design for the electrical backup system, taken from [3].

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References
[1] http://solarheatcool.sustainablesources.com/#PASSIVEDHW [2] http://solarheatcool.sustainablesources.com/#ACTIVEDHW [3] http://www.bradfordwhite.com/images/shared/pdfs/manuals/238-47073-00C.pdf [4] http://www.omniinstruments.co.uk//images/downloads/2523.pdf [5] http://www.samallen.com.au/sinks.pdf [6] http://www.iq3.cn/trend/UploadFile/SENSORS/ds_tpi.pdf [7] http://www.kpsec.freeuk.com/powersup.htm [8] http://csalarmsystems.com/faq.html

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