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Polar Services - Remote Station Engineering - Power Systems
This webpage is maintained with specifications for power components which represent the current best-practices employed
by UNAVCO in the Polar Permanent GPS Station design. Specifications are subject to change as the design evolves, however the
most current design will always reside here.
TECHNICAL NOTES
Through 2007, the bulk of design work has focused on the Antarctic Margin (Coastal) Station design, which will
operate in high wind environments but without the extreme cold found on the Antarctic Plateau. Components and
suppliers have been selected, and an initial set of drawings has been released. This system has been fielded in
quantity as part of the POLENET project in Greenland and Antarctica. In the coming year emphasis will also be
placed on the Plateau design, which will operate during longer winter darkness and extreme cold, but with much
milder winds.
Test Series: Forgen 500 wind turbine
Performance Test Report (Updated 4/30/08)
Test Series: SLA battery cold performance
Gel vs. AGM
POWER SYSTEM HARDWARE USED BY UNAVCO IN POLAR APPLICATIONS
POWER COMPONENTS
| Component |
Photo |
Manufacturer |
Part Number (click for PDF drawing) |
Description |
Weight (lb) |
Cube (ft^3) |
Why? |
| Solar Panel |
 |
Sharp |
NE-80EJEA |
12VDC, 80W. See Structural Systems page for
mounting braces and backing plates for solar panels. |
Panel only: 21 |
Panel only: 1
(47.25"x21.1"x1.8") |
Robust structural frame and panel face. Sealed junction box with good terminals and knockouts for 1/2" cable
gland fittings. Standard panel from large manufacturer; unlikely to be discontinued soon. |
| Solar Regulator |
 |
Flexcharge |
NC30L12 |
Temperature compensated battery charge regulator. Order with integral wires (no screw terminals).
Regulator OFF (LVD) at 11.0V, ON at 12.85V. Regulator power draw is < 0.1 Watt. |
Incl. in electronics assembly |
Incl. in electronics assembly |
Standard regulator for UNAVCO permanent stations worldwide, including many polar locations. Low parasitic power draw,
available without screw terminals which can loosen over time. |
| Power Board |
 |
Cablenet |
PPS-DC-001 revC |
Distributes power from solar, batteries, and wind to electronics. DC breakers, DIN rail, spring-loaded terminal
blocks, solar regulator. |
Incl. in electronics assembly |
Incl. in electronics assembly |
Clean, modular, compact design, based on well-proven UNAVCO PBO board. Spring-loaded terminals eliminate screws
which can loosen over time. |
| Electronics Assembly |
 |
UNAVCO |
|
System electronics are mounted to 26" x 16" x 1/2" wood board. |
13 |
1
(26"x16"x4") |
All components are immediately accessible when enclosure lid is opened. Cables are routed cleanly. |
| Electronics Foam Housing |
 |
R&B Sales
2291 Waynoka Road, Suite B
Colorado Springs CO 80915
719-596-3211 |
PPS-EN-006 revB |
Foam housing insulates critical electronics: GPS receiver, solar charger, timer switch, and modem. |
1 |
1
(16"x16"x5") |
Effectively conserves heat around temperature-sensitive electronics. |
| Wind Turbine |
 |
Goodridge Engineering |
Forgen 500-LT |
Use modified version with low temperature bearings, cold-flexible cable, and high-gloss black polyester coating.
See Structural Systems page for custom mount to
attach turbine to corner of structural frame. |
Including mount: 12 |
1.5
(18"x8"x8") |
Relatively robust turbine for high wind environments, recommended by British Antarctic Survey. Only suitable small,
vertical axis turbine commercially available. Very low power trickle-charger (<1W average) with cut-in wind
speed approx 5 m/s at 12V. Wind turbine power flows to electronics first, then excess power charges batteries.
Turbines are wired directly to battery bank via one 10A breaker; two unregulated turbines will not overcharge
a 1000 amp-hour battery bank. Easy setup. Used by UNAVCO at dozens of polar locations. |
| Lead-Acid Battery |
 |
East Penn Deka
Identical battery also remarked and supplied by MK Battery |
8G31ST |
12V, 98 amp-hour, deep cycle, sealed lead acid gel cell for solar applications. ST model with two threaded stud terminals.
Deka 8G31DT Brochure
(same as ST) [PDF]
Deka 8G31DT MSDS
(same as ST) [PDF]
Deka Solar Battery Info [PDF] |
70 |
1
(13"x11"x7") |
Gel-cell technology used by UNAVCO and numerous others at multi-year polar installations with good success.
Very little difference observed in polar performance between AGM and Gel batteries, qualified with cold-chamber
test. |
| Battery Wiring Harness |
 |
Optimum Systems |
PPS-DC-005 revB |
2-way Weatherpack connectors with 13" red/black leads and 3/8" heavy-duty crimp ring
terminals. See below for Battery Wiring Harness Assembly. |
Incl. in battery |
Incl. in battery |
Robust connectors. Reduces field wiring time and accidental mis-wiring. Batteries are pre-wired with male/female
harness elements prior to deployment. |
| Battery Wiring Harness Assembly |
|
UNAVCO |
PPS-DC-004 revC
sheet 1
sheet 2 |
Shows wiring for banks of 10 and 6 batteries in parallel. |
|
|
Connect batteries in a ring circuit so that any one broken connection will not cause loss of power. |
POWER CABLES AND ACCESSORIES
Power connections use commercial versions of MIL-DTL-5015 bayonet circular connectors. Connectors are a well-proven design
and are environmentally sealed. Large form factor and 1/4 turn bayonet engagement allow easy connection with gloved
hands. Unique pin arrangements for solar (2-pin), battery (4-pin with two blanks), and wind (4-pin with two blanks, rotated
120 degrees) prevent mis-engagement. Connectors use large-size crimp contacts. Cable assemblies use 2-conductor 14 gauge
cable proven flexible to -50C.
| Component |
Photo |
Manufacturer |
Part Number (click for PDF drawing) |
Description |
Why? |
| Power Cable |
 |
Polar Wire Products |
AUF-TC142 |
14 gauge, 2 conductor power cable (red and black). Connectors and cable assemblies
also accept 12 gauge, 2 conductor cable (P/N AUF-TC122). |
Extremely rugged cable, tested flexible to -50C. |
Cable Assembly:
Internal Wind |
 |
PEI Genesis
Contact for all UNAVCO parts: PEI Genesis Arizona Office |
HA-070051-01 revD |
Connects Power Board wind terminals to pass-thru connector on enclosure wall. |
Internal cables are potted for sealing and strain relief, ends are stripped and tinned for insertion to terminal blocks |
Cable Assembly:
Internal Solar |
 |
PEI Genesis |
HA-070051-02 revD |
Connects Power Board wind terminals to pass-thru connector on enclosure wall. |
Internal cables are potted for sealing and strain relief, ends are stripped and tinned for insertion to terminal blocks |
Cable Assembly:
Internal Battery |
 |
PEI Genesis |
HA-070051-03 revD |
Connects Power Board battery terminals to pass-thru connector on primary enclosure wall. Also connects auxilliary
battery bank to auxilliary enclosure wall if more than one battery enclosure used. |
Internal cables are potted for sealing and strain relief, ends are stripped and tinned for insertion to terminal blocks |
Cable Assembly:
External Solar |
 |
PEI Genesis |
HA-070051-04 revD |
Connects pass-thru connector on enclosure wall to solar panel. |
External cables are potted and overmolded for sealing, strain relief, and ease of handling. |
Cable Assembly:
External Battery |
 |
PEI Genesis |
HA-070051-05 revD |
Connects pass-thru connector on primary enclosure wall to pass-thru connector on auxilliary battery enclosure wall
if used. |
External cables are potted and overmolded for sealing, strain relief, and ease of handling. |
Connector:
Wind Turbine Cable |
 |
PEI Genesis |
ITT Cannon CB6U18-10SXC |
Straight cable plug to connectorize wind generator cable, with crimp contacts. |
Connectors potted for sealing and strain relief. Cables terminated at UNAVCO with professional hand tools and epoxy system. |
Connector:
Wind Pass-thru |
 |
PEI Genesis |
ITT Cannon TBF18-10PSXB |
Bulkhead pass-thru connector mounted to wall of primary enclosure. |
Bulkhead connector eliminates cables hard-mounted to enclosure. Connector uses O-ring seal. |
Connector:
Solar Pass-thru |
 |
PEI Genesis |
ITT Cannon TBF18-3PSB |
Bulkhead pass-thru connector mounted to wall of primary enclosure. |
Bulkhead connector eliminates cables hard-mounted to enclosure. Connector uses O-ring seal. |
Connector:
Battery Pass-thru |
 |
PEI Genesis |
ITT Cannon TBF18-10PSB |
Bulkhead pass-thru connector mounted to wall of primary enclosure. |
Bulkhead connector eliminates cables hard-mounted to enclosure. Connector uses O-ring seal. |
| Nut Plate |
 |
PEI Genesis |
M85528/2-18A |
For mounting bulkhead pass-thru connectors with 4-40 x 1/2" socket head cap screws. |
Makes life much easier when assembling. |
| Connector Drill Template |
 |
UNAVCO |
PPS-EN-004 revB |
Fits inside hole in foam insert to allow accurate thru-hole drilling for power connectors, RF connectors,
and vent plug on recessed rib of Hardigg MM36 or MM24 enclosure. See below for drilling layout and instructions. |
Makes life much easier when assembling. |
| Layout Drawing for Enclosure Connectors |
|
UNAVCO |
Large (MM24): PPS-EN-009 revA
sheet1
sheet2 |
Layout for placement of power bulkhead connectors, RF bulkhead connectors, and vent plug on large (MM24) enclosure.
Includes drilling instructions. |
Optimizes placement of various connectors to allow maximum space for connection with gloved hands. |
Last modified
Thursday, 01-May-2008 15:27:14 MDT
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