An Epic Journey Toward Cleaner and More Efficient Transportation
You know how a small project can turn into a big one very easily? This is what happened when I moved to a different house, and at about the same time, decided to buy a Tesla. It turned into a project of epic proportions – although, I have to admit- I brought it on myself, and honestly have enjoyed every minute of it.
First, here is what happened with the house. About 15 years ago, friend of mine built a house up on top of a hill overlooking the northern end of Lake Tuscaloosa. I told him, “If you ever go to sell this place, talk to me first.” And, he did! I was fortunate to be in a position to buy it. Now, I had to have some electrical work done to support the hot tub we were adding, and also electric car charging, and a large amateur radio station. The electrician contacted Alabama Power to see if the existing service could handle the additional loads (we knew that the main panel was already close to capacity – on cold winter nights, our 5-ton heat pump runs almost constantly). They said the service would need to be upgraded (along with the main panel)… and that they would do this at their own expense. What a project that turned out to be, just by itself. While our electrician upgraded the main panel from 200 amp to 400 amp, Alabama Power brought in an array of equipment and personnel to bore in a new 5-inch conduit for 300 feet between the power pole and the road, and the main panel:
The guys boring the hole for the conduit were experts – after 300 feet, they were able to control the drill so that it came in between the sewer line below and water line above (separated by about 18 inches), and also miss the AT&T line. The project was supervised by a couple of tiny, goose-stepping chihuahuas.
Once the hole was bored, they set about pulling in the 5” conduit:
All went well until the conduit was pulled in about ¾ of the way back, where it became stuck. At that point, they had to dig down about 10 feet to it and splice it there; then they pulled in 500 MCM electrical cable for the residential service.
I believe this means each conductor has a cross section of 500 square millimeters – each of the 4 cables (a pair of 240 lines, neutral, and ground) are about an inch in diameter.
Now we had 400 amp service, capable of providing a sustained load of 320 amps.
Alabama Power’s crew was here for 4 days at $1500 per day – I figure the labor plus materials for this upgrade cost them about $7000. I didn’t tell them at the time that I was planning to add a grid-tied solar photovoltaic system which should actually drive my electric bill down. More on that later.
Now why an electric car?
I have always tried to pick the most energy-efficient vehicles. Sure, there are more efficient modes of transportation than cars, but since moving away from New York in 1969, I have never been fortunate enough to live and work in a place that had any kind of public transportation. First there were the diesels (I had two of the ill-fated attempts by GM to do diesels on the cheap in the 1989s - both of mine ran very well, but as an engineer I knew how to fuel and care for them; not everyone was so lucky with them). Then a VW Jetta diesel which got a delightful 52 mpg (probably emitting lots of oxides of nitrogen, but hey, you can't have everything, regardless of demands by the CEO). Then once in the lower management ranks at Mercedes Benz US International, I bought a used E300 diesel through ebay. That car had 125,000 miles on it when I bought it (just getting broken in). It wad still running fine when I sold it with 335,000 miles on the odometer.
Then I thought, can I find something even more efficient? I leased a Nissan LEAF. This let me enjoy the zero gas plus takes-off-like-a-scared-rabbit experience for 3 years while letting Nissan carry the battery risk. The LEAF was perfect for my 40 mile round trip commute- now at the University of Alabama I somehow persuaded the University to let Chargepoint put a couple of charging stations in the parking decks. At the end of 3 years and 35,000 miles, the batteries still had almost their original capacity. Now I was confident enough to go for the Tesla. I waited with bated breath to see how the Model X's release would go. I much preferred the styling of the Model S; and, as a former car assembly plant guy, I foresaw some of the problems now being experienced with building the falcon doors (what a terribly hard thing to build and adjust... and I expect the warranty costs to be very high on these. So I ordered a Model S. I saw on my MyTesla page a delivery window the car would be delivered April 20 to May 4. By strange coincidence, this corresponded exactly with a long planned cruise around Italy for our 25th wedding anniversary. I asked the Marietta sales center to hold the car for May 4, and we flew back to Atlanta (where we had put our other vehicle at the airport Doubletree with park-n-fly). We went for delivery. Oh-ho, delivery day! This is a 90D.
Being familiar with the MS after having obsessed about it for over a year, I asked for the delivery briefing to be brief. I did wonder if we would need to go via the Auburn supercharger, but since the 90D was charged to 285 mile range this was unnecessary. We drove both vehicles the 220 miles home without a hitch. The Monroni sticker gave the car's fuel economy as an equivalent 100 mpg.
Now, what could I do to make my transportation even more efficient? Solar panels!
I decided on a grid-tied system. SolarTechnology of Eva, AL, designed a 10kw system using SolarEdge optimizers and inverter (this was necessary since, although my south roof is perfectly sited for panels, we have some large trees that would shade part of the array in the mornings).
The system has 38 260-watt panels (you can’t see them all in the photo):
These are connected with 2 strings of 19 optimizers each to a 10 kw inverter. I did something out of the ordinary here – I specified common-mode chokes between the optimizers (and also between the optimizers and the panel). This is to minimize radio frequency noise created by the system (the optimzers are like switching power supplies, so can be RF-noisy).
We are still working the kinks out of the solar system. String 1 works great. We think the chokes may have been wound incorrectly on string 2, because some of the optimizers don’t sync with the inverter (OK, maybe they communicate occasionally, but not enough to produce power). So usually I get 3.5 kW to 6 kW during the day. (I should be able to get 6 kW to 8 kW). We will be taking some panels off to check the wiring later in the week.
Will I be able to charge my Tesla using this system? Well, sort of; the system is grid-tied and hooked up in parallel with all other loads in my house (including the 5-ton HVAC, hot tub, and electric dryer). If we work hard to ensure that we only use one of these heavy loads at once, then I guess I could charge the car. Other than that, I have received Alabama Power’s PEV Rate Rider, which gives a 15% discount on power used between 9 PM and 5 AM, and schedule charging during that time. The solar PV system will have the effect of replacing the power I use at night. (Not as cool as directly charging the car using the system, but I will experiment with this a bit once the system is fully operational).
The large box between the (white) inverter and the main panel is part of the RFI filter. The whole solar system is extensively filtered to hold down radio noise, so that my other hobby (amateur radio) should not be affected (there will be some sensitive antennas near the solar array).
We are still working the kinks out of this complex system, but I anticipate that we should be able to get about 1,400 kwh out of it per year (using most of it locally, so that it is a direct cost savings). Alabama Power will pay for energy pushed out to the grid, but only at wholesale rates (I don’t complain about this – look what they spent on my upgrade, all on the grid side). There is also an additional rate available from Alabama Power for owners of EVs: the PEV Rate rider, which gives you a 15% discount on power you use between 9 PM and 5 AM.
And all this just to run this 14-50 outlet in the garage for the Tesla!