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Farkles, Gear & Accessories => Construction and Major Projects => Topic started by: alans1100 on November 11, 2016, 11:57:44 AM

Title: Solar Power Install.
Post by: alans1100 on November 11, 2016, 11:57:44 AM
I've bitten the proverbial bullet and ordered an 80watt solar panel/10amp regulator kit (includes wiring) and a 20AH 12 volt deep cycle battery last night which will be installed in/on the trailer.

http://www.ecoonline.com.au/online-store/solar-battery-charging/solar-combo-kits/regkit-80w-10amp (http://www.ecoonline.com.au/online-store/solar-battery-charging/solar-combo-kits/regkit-80w-10amp)

http://www.ebay.com.au/itm/272151917935? (http://www.ebay.com.au/itm/272151917935?)

The only requirement is to be able to recharge the laptop battery while away from home and maybe phone camera etc. and maybe a LED light or two.

The panel dimensions (830 x 670mm) are similar in size to the rack (825 x 675mm) on the back of my trailer and should be fairly easy to mount though with what will be needed will have to wait until the panel is in place. The panel weighs 8kg and the battery is 6.5kg which should off set the weight from the Cooler and contents when that's on the front of the trailer.

(https://farm5.staticflickr.com/4265/35401902010_b49f7dd40d_h.jpg) (https://flic.kr/p/VWm15S)

(https://farm5.staticflickr.com/4289/35401899910_ed47deed90_h.jpg) (https://flic.kr/p/VWkZsE)

Title: Re: Solar Power Install.
Post by: StinkyPete on November 11, 2016, 12:47:11 PM
 :popcorn :popcorn
Title: Re: Solar Power Install.
Post by: Shiney on November 11, 2016, 04:21:47 PM
Sounds like a great idea, I'm looking forward to seeing how it all goes :thumbsup
 :popcorn     :popcorn     :popcorn
Title: Re: Solar Power Install.
Post by: johnnyYTED on November 11, 2016, 04:26:30 PM
 :dred11

 :popcorn :popcorn
Title: Re: Solar Power Install.
Post by: Biggles on November 11, 2016, 07:57:57 PM
Spending your new earnings already!    ;-*
Title: Re: Solar Power Install.
Post by: alans1100 on November 11, 2016, 09:22:18 PM
Sounds like a great idea, I'm looking forward to seeing how it all goes :thumbsup
 :popcorn     :popcorn     :popcorn
Same here
Title: Re: Solar Power Install.
Post by: BigTed on November 11, 2016, 11:43:56 PM
That's also my next project... when the trailer project is done ;-)
Title: Re: Solar Power Install.
Post by: Scarlett Thunderbolt on November 12, 2016, 03:52:46 AM
ditto to what Shiney said...  :thumbs  :popcorn :popcorn
Title: Re: Solar Power Install.
Post by: ST2UP on November 12, 2016, 06:57:23 AM
With that combo you will have loads of power, in fact you will be producing more amps from a 80watt panel than you will every use for the requirements mentioned. You could sell back to the grid  :nahnah

Are you using a pure sine wave inverter for the laptop & battery ??

When we first started playing with Solar 20 years ago we ran a 220amp/hr battery array with a 120watt panel (not fixed, so chased sun) in our camper trailer.


Cheers
Title: Re: Solar Power Install.
Post by: Lionel on November 12, 2016, 07:22:30 AM
You probably had to mortgage your first born child to pay for a 120 watt solar panel 20 years ago.   >:()
Title: Re: Solar Power Install.
Post by: Gadget on November 12, 2016, 08:01:07 AM
As panels are most efficient when pointing directly at the sun,  I would be inclined to hinge mount it on the front rail and have an adjustable bracket on the back rail. This is so you can leave the panel attached to the trailer and tilt the panel so that it gets sunlight hitting it at as close to 90° as you can.
Then as the day passes, you rotate the trailer drawbar to point to the sun.

The reason I would home on the front rail, it's in case the the other side comes loose, the wind form forward motion isn't going to get under it and flip it into the road.

You could even get clever and make a "sun sight". A + slit in a top plate with a white + painted on a back plane. Then when the panel is pointed directly at the sun, the sunlight passing through the slug slit will shining on the white +.
Alternate method is a thick plate with the slit and when light shines through it must be pointed at the sun.

Also carry a compass for finding north on an overcast day. You never know when it might clear. If the panels already facing north when it does, you start producing the most energy straight away. 



Cheers,
Gary

sent using another of Gadget's gadgets.
Title: Re: Solar Power Install.
Post by: Brock on November 12, 2016, 08:25:59 AM
You dont need an inverter to charge the laptop, just a power supply that can be found at JB HiFi or Jaycar. They are a multi Laptop device (different adapters) that run off 12V
Title: Re: Solar Power Install.
Post by: alans1100 on November 12, 2016, 08:37:57 AM
You dont need an inverter to charge the laptop, just a power supply that can be found at JB HiFi or Jaycar. They are a multi Laptop device (different adapters) that run off 12V
We bought an inverter ages ago. One that we could just put in the cig lighter. Came in handy to charge up Heather's video cam back then as to buy the car charger accessory was as much as the camera.

Now I can buy a car charger for the laptop for about $20.
Title: Re: Solar Power Install.
Post by: alans1100 on November 12, 2016, 08:44:32 AM
As panels are most efficient when pointing directly at the sun,  I would be inclined to hinge mount it on the front rail and have an adjustable bracket on the back rail. This is so you can leave the panel attached to the trailer and tilt the panel so that it gets sunlight hitting it at as close to 90° as you can.
Then as the day passes, you rotate the trailer drawbar to point to the sun.

Or you can just lift the lid on the trailer for a similar result.
Title: Re: Solar Power Install.
Post by: Gadget on November 12, 2016, 08:47:21 AM
As panels are most efficient when pointing directly at the sun,  I would be inclined to hinge mount it on the front rail and have an adjustable bracket on the back rail. This is so you can leave the panel attached to the trailer and tilt the panel so that it gets sunlight hitting it at as close to 90° as you can.
Then as the day passes, you rotate the trailer drawbar to point to the sun.

Or you can just lift the lid on the trailer for a similar result.
My concern with that is the contents are then exposed to the weather.

With the lid closed and panel up, at night you can point the trailer east to catch the morning sun. It won't matter if it rains overnight.

Cheers,
Gary

sent using another of Gadget's gadgets.

Title: Re: Solar Power Install.
Post by: ST2UP on November 12, 2016, 08:49:53 AM
As panels are most efficient when pointing directly at the sun,  I would be inclined to hinge mount it on the front rail and have an adjustable bracket on the back rail. This is so you can leave the panel attached to the trailer and tilt the panel so that it gets sunlight hitting it at as close to 90° as you can.
Then as the day passes, you rotate the trailer drawbar to point to the sun.

Or you can just lift the lid on the trailer for a similar result.

And the cooler the Panel in direct sunlight the more efficient it is  :wink1
Title: Re: Solar Power Install.
Post by: ST2UP on November 12, 2016, 08:55:00 AM
You probably had to mortgage your first born child to pay for a 120 watt solar panel 20 years ago.   >:()

I found the receipt in my "Boys stuff" shed filing system only a few days ago.....

1998 from Apollo Batteries in Armidale...Had a mate running it  :wink1

BP Solar Panel 120W $1250.   RR was closer to $1700 from memory.


 :beer
Title: Re: Solar Power Install.
Post by: alans1100 on November 12, 2016, 09:38:24 AM
Unless I play a DVD or two every night the laptop battery only needs charging every 4 or five days so catching every ray of sunshine from sunrise to sunset everyday isn't essential.

It'll be a little bit of trial and error stuff anyway.

Title: Re: Solar Power Install.
Post by: Gadget on November 12, 2016, 06:59:16 PM
I was also thinking future sale value.

On exercise we had generators, and after a few years ypu looked back on what you first took on exercise, and what you took every exercise now, and realise that it was because of the generator.

Over time, I expect the list of appliances will also grow. :grin

Cheers,
Gary

sent using another of Gadget's gadgets.

Title: Re: Solar Power Install.
Post by: alans1100 on November 12, 2016, 07:08:46 PM

Over time, I expect the list of appliances will also grow. :grin
I can relate to that as in we managed around the coast from Adelaide to Sydney with just the bike and basics. Now we have the trailer to carry more stuff.
Title: Re: Solar Power Install.
Post by: alans1100 on November 15, 2016, 11:48:36 AM
The Battery arrived this morning and quite heavy (6.5 kg) for its size. Good thing is I can use it in any position as it's fully sealed.

(https://farm5.staticflickr.com/4240/35658775161_565474208b_h.jpg) (https://flic.kr/p/Wk3xwi)

As I was typing this the panel arrived and I placed it on trailer to see how it would look.

(https://farm5.staticflickr.com/4282/35402164770_c84b9bc263_h.jpg) (https://flic.kr/p/VWnmcd)

(https://farm5.staticflickr.com/4229/35790686995_b6af0de31d_h.jpg) (https://flic.kr/p/WwGCjg)

And the charge controller

(https://farm5.staticflickr.com/4116/35621193942_5a3a024e05_h.jpg) (https://flic.kr/p/WgHVWf)
Title: Re: Solar Power Install.
Post by: Shiney on November 15, 2016, 12:50:27 PM
Looking great mate :thumbs

Sent from my SM-N9005 using Tapatalk

Title: Re: Solar Power Install.
Post by: twisted 1 on November 15, 2016, 06:31:59 PM
If the panel is going to live on the trailer lid it might pay to run a bead of silicone around the edge where the solar panel meets the surrounding aluminium frame just to make sure its got a good seal, we always recommend this at work to people who we sell panels to that are to be used in this sort of fitment.
Title: Re: Solar Power Install.
Post by: Brock on November 15, 2016, 06:42:20 PM
Use the heaviest cable thats practical, not for current carrying, but to minimise voltage drop.
Title: Re: Solar Power Install.
Post by: alans1100 on November 15, 2016, 08:03:37 PM
Use the heaviest cable thats practical, not for current carrying, but to minimise voltage drop.
About 15M of cable supplied to suit the panel and 10amp regulator as a kit (includes 15amp fuse).
Title: Re: Solar Power Install.
Post by: spanner on November 16, 2016, 09:21:18 AM
 :popcorn :popcorn :popcorn :popcorn
Title: Re: Solar Power Install.
Post by: alans1100 on November 21, 2016, 03:30:48 PM
I came up with mounting two off cuts from some fence railing on the rear of the panel which is as far as I could get until I ran out of time. Next step is to mount on the trailer after working out which way to route the wiring as a hole or two need drilling in the trailer lid.


With the days off work I got from the doc I should get most of it done.

(https://farm5.staticflickr.com/4290/35621293382_c053ba2856_h.jpg) (https://flic.kr/p/WgJruJ)

(https://farm5.staticflickr.com/4236/34950407654_ec3160993c_h.jpg) (https://flic.kr/p/VfrYxq)
Title: Re: Solar Power Install.
Post by: alans1100 on April 18, 2017, 12:46:05 AM
This project is not dead - just on hold.

Waiting on a part to arrive which had to be re-sent as the first one didn't arrive. The joys of international postage and just as well it was bought through e-Bay and no charge for the newly sent item. Could be a couple of more weeks before they arrive.

I've also had to get some water proof caps for the leads that go into the trailer from the panel connections plugs. The panel can then be removed when not needed.





Title: Re: Solar Power Install.
Post by: alans1100 on June 03, 2017, 03:53:10 PM
With cold nights and warmish days I decided it was about time to get on with this though I can only mount the panel to the trailer at this time. The electrical connection are getting done by a friend who lives in the southern suburbs of Adelaide; a road trip in the near future as soon as we get dates that suit us both as it'll be an overnighter.

Only thing I need do now is consider where the battery and charger regulator will be placed. The front centre seems logical for the battery as it would counter the weight of the panel.


The clamps I need to hold the panel in place while I drilled at least the first two holes arrived a week ago and it was just a matter of waiting for a few hours of fine weather.

I had this clamp but need a couple more so a couple of cheapies from eBay did the trick.

(https://farm5.staticflickr.com/4238/34980546763_ee2020d757_h.jpg) (https://flic.kr/p/Vi7rRe)

First hole drilled

(https://farm5.staticflickr.com/4256/35402150540_65e03ee97b_h.jpg) (https://flic.kr/p/VWngXS)

and bolted. Same process for the four holes; drill a small pilot hole and follow up with the right size drill.

(https://farm5.staticflickr.com/4217/35658766641_9b3656c5f9_h.jpg) (https://flic.kr/p/Wk3uZp)

Panel completely bolted to the trailer rack.

From the left

(https://farm5.staticflickr.com/4231/35621175062_5fbc32f7f3_h.jpg) (https://flic.kr/p/WgHQjJ)

From the front

(https://farm5.staticflickr.com/4232/35790663845_ee5bca68bb_h.jpg) (https://flic.kr/p/WwGvr8)

From the rear

(https://farm5.staticflickr.com/4238/35621169082_9f177bc788_h.jpg) (https://flic.kr/p/WgHNxC)

With the trailer lid open

(https://farm5.staticflickr.com/4266/34980530433_df7ac464ba_h.jpg) (https://flic.kr/p/Vi7mZF)
Title: Re: Solar Power Install.
Post by: Gadget on June 03, 2017, 05:25:03 PM
Looks good.

The only comment I would make is either
1. Get Stinkypete to weld caps on the ends of the RHS tube to increase the strength to prevent the bolted sections walls collapsing or,
2. Use wider washers to distribute the force towards the vertical walls.


Sent from my SM-G930F using Tapatalk

Title: Re: Solar Power Install.
Post by: Gadget on June 03, 2017, 05:29:35 PM
This is where it needs a wider washer.

Experience tells me the steel will bend under the bolt force and everything will slowly loosen.(https://uploads.tapatalk-cdn.com/20170603/df42ebedb4d79af9c6d6583284470646.jpg)
Title: Re: Solar Power Install.
Post by: Shiney on June 03, 2017, 05:50:04 PM
Awesome work Alan, and great advice Gadget :thumbsup
Title: Re: Solar Power Install.
Post by: alans1100 on June 03, 2017, 06:04:08 PM
Looks good.

The only comment I would make is either
1. Get Stinkypete to weld caps on the ends of the RHS tube to increase the strength to prevent the bolted sections walls collapsing or,
2. Use wider washers to distribute the force towards the vertical walls.


Sent from my SM-G930F using Tapatalk
Thanks. At the moment it's only secured for transport and I was thinking of end caps to cover the hole or putting a sleeve around the bolt after the panel is remounted after the wiring through the lid is completed.
Title: Re: Solar Power Install.
Post by: Brock on June 03, 2017, 06:13:45 PM
Drill the bar out a little, to take a piece of tube that the bolts fit through, and weld them in. all pressure will then be directed and distributed by the ubes/sleeves. welded end caps are good, keeps moisture and air turbulence out.
Title: Re: Solar Power Install.
Post by: alans1100 on August 15, 2017, 01:41:40 PM
I needed some expert soldering done on the wiring that connects the panel to the charge controller so last Thursday (11th August) I had a ride to a friend who lives in the city who did the work for me.

I was supplied the connectors and a coil of wire (more than I need) so I just had the connectors soldered at each end and I could cut the length needed to complete the circuit.

While I was in the city I bought some terminals to connect the wiring to the battery. Same type of connection as our bike batteries but a lot smaller and the nuts and bolts came with the battery.

(https://farm5.staticflickr.com/4388/35768934113_6ce3550a85_b.jpg) (https://flic.kr/p/WuM8Wz)

What I needed and forgot was another 15 amp inline fuse (one was supplied for the battery connection) for the load (power sockets) and some 15 amp wire for the battery to charge controller. Once I get these I can start connecting it all up.

I'm wiring as suggested in the left diagram.

(https://farm5.staticflickr.com/4371/36440448651_611e835c72_b.jpg) (https://flic.kr/p/Xw7PPr)
Title: Re: Solar Power Install.
Post by: alans1100 on September 24, 2017, 05:10:21 PM
I got adventurous this afternoon and sorted the wiring out for the final connect up.

Panel and battery wiring have been secured into the regulator with the other ends left free to be connected in sequence. I was going to mount the regulator in place but I need to locate the bolts to suit the nylock nuts I have; may have to buy some more.

The fuse has been added to the double power socket and ready to be connected to the regulator.

Need to remove the panel so I can drill two holes in the lid for the wiring to go inside. Near as possible to the hinge point and under the panel. Hoping the drill is the same size as the wiring to reduce the chance of water getting inside after some water proof sealant is applied.
Title: Re: Solar Power Install.
Post by: alans1100 on October 07, 2017, 01:44:01 PM
Removed the panel off the trailer lid and drilled the two holes for the cables to pass through. Wiring had to be under the panel and as close as possible to the hinge point.

(https://farm5.staticflickr.com/4451/37511157312_39984505ff_b.jpg) (https://flic.kr/p/Z9JucA)

While I had everything handy I did a temporary connect up with just the panel and battery connected to the charge controller (fancy term for regulator) and so far it works. If work starts before I can get this finished I can still use it and tidy it all up later.

The battery (deep cycle) has been sitting around for over a year and was still in an almost full state of charge. It took about 5 mins in an ad hoc set up to fully charge the battery indicated by its respective (flashing at the time) green light. The type of battery indicator stays on all the time and the load indicator goes off unless you're using power. There is an on/off switch for the load because you can't disconnect the panel wiring unless you turn the load off.

Since I hadn't connected any power sockets and not using that circuit the load light eventual went off - looks like a self test via the on/off switch.

(https://farm5.staticflickr.com/4491/37511156962_7867283e1d_b.jpg) (https://flic.kr/p/Z9Ju6y)

The panel (though turned around) was just leaning against the bike as in the following photo..

(https://farm5.staticflickr.com/4500/37284062210_b5932b1837_b.jpg) (https://flic.kr/p/YNEyJN)

I need to put more sealant on and tidy it all up before I put the panel back on. Also need to get some more zip ties for the cables.

(https://farm5.staticflickr.com/4514/37511157282_df99b5dd23_b.jpg) (https://flic.kr/p/Z9Juc5)

(https://farm5.staticflickr.com/4514/37511157112_cb654b417f_b.jpg) (https://flic.kr/p/Z9Ju99)
Title: Re: Solar Power Install.
Post by: richo on October 07, 2017, 01:53:30 PM
 ++. Looking good.  Looks like it will keep you going off grip for a while
Title: Re: Solar Power Install.
Post by: alans1100 on October 15, 2017, 03:24:39 PM
Finally finished this off today.

The other day I made sure the panel charged the battery and before going to far I today I made sure the battery was powering the twin power socket.

With that little test out the way I could mount the regulator and I chose the rear trailer panel. I only needed to drill three holes as I took advantage of one of the bolts used for the added reflector I installed.

All the wiring connected and the regulator as mounted on the rear of the trailer. The battery can be used in any position so I chose to lay it flat. Just need to secure it in place for the rare time the trailer is actually empty.

I'm considering getting some carpet off cuts to place along the rear to hide all the wiring and bolts.

(https://farm5.staticflickr.com/4505/36993610294_102a72ceec_b.jpg) (https://flic.kr/p/YmZVv9)DSC_1124 (https://flic.kr/p/YmZVv9) by Alan Williams (https://www.flickr.com/photos/152195423@N05/), on Flickr

Power socket located behind the rear wheel and low enough to keep the most of the wiring under the carpet.

(https://farm5.staticflickr.com/4471/37033357483_152d086b8e_b.jpg) (https://flic.kr/p/YqvCXv)DSC_1125 (https://flic.kr/p/YqvCXv) by Alan Williams (https://www.flickr.com/photos/152195423@N05/), on Flickr

A zip tie controls the new wiring when the lid closes. Loosely secured to the OEM internal trailer lid light wire.

(https://farm5.staticflickr.com/4478/37671843162_d7c21a44a9_b.jpg) (https://flic.kr/p/ZoW3vh)DSC_1126 (https://flic.kr/p/ZoW3vh) by Alan Williams (https://www.flickr.com/photos/152195423@N05/), on Flickr

Once the panel was reinstalled and all the connections made I tested the system by charging up our laptop. I have a 12 to 240 volt inverter so I plugged that in and then the laptop via it's 240 volt charger and it all works. Just need to get the laptop's car charger for permanent usage.

I found a couple of spacers and added a couple of washers/nuts  when securing the panel to the trailer lid. Hardware store up here didn't have anything I could use so I used what I could find.

(https://farm5.staticflickr.com/4450/37703896081_ee833bdb33_b.jpg) (https://flic.kr/p/ZrLjHP)DSC_1127 (https://flic.kr/p/ZrLjHP) by Alan Williams (https://www.flickr.com/photos/152195423@N05/), on Flickr

External wiring secured to trailer rack. Wiring connector in the centre to allow for trips when I don't need to have the panel.

(https://farm5.staticflickr.com/4453/36993609614_b3d8f39ed6_b.jpg) (https://flic.kr/p/YmZViq)DSC_1128 (https://flic.kr/p/YmZViq) by Alan Williams (https://www.flickr.com/photos/152195423@N05/), on Flickr
Title: Re: Solar Power Install.
Post by: richo on October 15, 2017, 03:46:02 PM
 :thumb. Looks good,  will keep you in touch with civilisation no matter where you are.
Title: Re: Solar Power Install.
Post by: Gadget on October 15, 2017, 09:53:45 PM
Alan,

Very impressive.

This really needs a larger washer.
It will only get worse. Voice of experience. (https://uploads.tapatalk-cdn.com/20171015/43b5146447770f3a85b268674706138e.jpg)
Title: Re: Solar Power Install.
Post by: alans1100 on October 15, 2017, 11:27:52 PM
Alan,

Very impressive.

This really needs a larger washer.

It's got some support inside around the bolt. I over did the tightening a little when I temporarily mounted the panel for transport. 
Title: Re: Solar Power Install.
Post by: alans1100 on December 13, 2017, 12:28:54 AM
The 100watt solar panel and the 12volt/20AH/20HR battery was more than ample for my needs while being used at Snowtown.

I could charge three items at the same time if I needed to.

12 volt phone charger for the phone
The car charger for the laptop also allowed charging via a USB cable so the tablet could have gone there.

This was the first time when camping with the bike that I didn't need to have the bike idle while inflating/deflating my air bed via the bikes 12 volt power sockets.

Usually I would use the laptop in the camp kitchen in the mornings and then charge while at work in the afternoons. Sometimes when not working due to rain I would take a half charged laptop back to the trailer at night and watch a DVD. By the time the movie had finished the battery alone would charge the laptop to full.

What was surprising was that at sunset (trailer lid up) the panel was still charging while I was accessing the trailer though for most of the day the trailer lid was closed.

 
Title: Re: Solar Power Install.
Post by: richo on December 13, 2017, 05:20:51 PM
Great to see your hard work as paid off.  A lap around Aus free camping.  There's a thought
Title: Re: Solar Power Install.
Post by: alans1100 on December 13, 2017, 06:58:50 PM
I rarely pay for accommodation while touring anyway so a lap of Aust. would be the same.