Author Topic: New 160W solar system  (Read 5086 times)

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Speo

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New 160W solar system
« on: June 08, 2008, 04:09:01 AM »
Recently I put together (with Ghurd's help) a solar system for my parent's cottage.

Ghurd helped me a lot with the design - thank you G!


The solar system consists of:

 - 2 x 80W solar panels - Sharp 80W NE-80EJEA

 - C12 Xantrex charge controller

 - 110V, 150W Tripp lite inverter

 - 220V, 375W Tripp lite inverter

 - two power distribution blocks (one AGU fused for positive and an unfused one for negative)

 - Xantrex Battery Monitor, located in the house - to monitor the battery state of charge

 - one 12V, 115Ah Dyno deep cycle battery

 - AWG5 wires between the panel's junction box and the charge controller

 - AWG9 wires to parallel the panels

 - the charge controller, the inverters, the battery and the fuses  are installed in a metal cabin, few meters away of the house

 - the house was previously wired for two voltages, 110V and 220V



Here is a diagram of the system






The solar panels were well packed, to survive the trip from Canada to Romania.






The panels were installed on the South side of the roof, on a frame made of angle iron.







The frame is sitting on 4 legs which are going through the ceramic tiles and sitting on two heavy wood beams.















We cut the ceramic tiles with the angle grinder - later will be insulated with some expandable foam.







The AWG5 wires from the panels are entering in the attic in the same spot with one of the frame's legs.












The wires from the panels are going down in the space between the shigles and the idoor cover of the roof.

This space will be insulated in the near future.








The panels were wired parallel, for 12V 160W - the white wires between the panels are AWG9








Here are the three flexible tubes carying the cables between the house and the shed:

- one black tube is carying the AWG5 wires from the panels to the charge controller

- one black tube is carying the 110V and 220V wires from the inverters to the house

- one gray tube is carying the wires from the cabin to the house for the Xantrex Battery Monitor







The 110V cable is installed, the 220V cable is hanging, and the XBM cables are also installed








The circuit breakers box and the Xantrex Battery Monitor.

The wires coming out of the XBM box are used for an external alarm (window magnetic
alarm, hooked to the XBM NO relay) that was set up to be triggerd by the XBM whenever
the voltage drops below 11V, goes above 16V, or the battery state of charge drops below 75%)








Inside the cabin, the C12 charge controller, the inverters, the power distribution blocks,
the switches, the fuses and the XBM shunt. The fuses are 15A for the solar panel fuse and 10A for the inverters.
The fuses for the remote controls are 1A.

















The back of the panel. Here are 3 switches, the one on the right is cutting the solar panels out, the one in the middle
is providing positive 12V for the 110V inverter and it's remote control, and the one on the left is providing positive
12V to the 220V inverter and to it's remote control











The battery, 115Ah, deep cycle





Here is another fuse, close to the battery positive post - 30A











I used double sockets to hold two bulbs with high and low wattages and just unscrew one of them (the small one if
the battery is full, or the large one if the battery is getting close to 80% state of charge).







At the first level both 110V and 220V bulbs are on, at the second level only the 110V bulb is on





Thanks for taking the time to read my posting.
Speo
« Last Edit: June 08, 2008, 04:09:01 AM by (unknown) »

DamonHD

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Re: New 160W solar system
« Reply #1 on: June 08, 2008, 01:45:20 AM »
Excellent!


Rgds


Damon


PS. I'd be terrified to do the roof stuff!

« Last Edit: June 08, 2008, 01:45:20 AM by DamonHD »
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oztules

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Re: New 160W solar system
« Reply #2 on: June 08, 2008, 01:58:44 AM »
Thanks for posting it Speo


Very nice it is too.


I hope it provides much pleasure for your parents as well.


..........oztules

« Last Edit: June 08, 2008, 01:58:44 AM by oztules »
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wooferhound

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Re: New 160W solar system
« Reply #3 on: June 08, 2008, 05:45:36 AM »
wow ,   you have been putting in a lot of work and time and it's looking good at this point. But the battery wiring and switches to your inverters look WAY too small.

an inverter putting out 1 amp at 120 volts will pull 10 amps from a 12 volt battery

putting out 1 amp at 240 volts will pull 20 amps.
« Last Edit: June 08, 2008, 05:45:36 AM by wooferhound »

ghurd

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Re: New 160W solar system
« Reply #4 on: June 08, 2008, 06:38:45 AM »
Very nice.  Beats kerosene lamps!


I would like to point out the logistics of the project.

The smallest details had to be considered well in advance.

A quick trip to Lowe's or Radio Shack was not an option.

G-

« Last Edit: June 08, 2008, 06:38:45 AM by ghurd »
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Speo

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Re: New 160W solar system
« Reply #5 on: June 08, 2008, 06:43:14 AM »
Damon, Oztulez, Woof, Ghurd, thanks for the input.

Speo
« Last Edit: June 08, 2008, 06:43:14 AM by Speo »

Speo

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Re: New 160W solar system
« Reply #6 on: June 08, 2008, 06:55:10 AM »
Woof, the consumption shoud never go higher than 5A at 12V for 2 or 3 bulbs @ 13W. Both inverters are fused with 10A.

The battery is wired with AWG5 - welding cable - and the inverters' original cables were AWG16 for the 110V inverter and AWG12 for the 220V inverter. I shortened those original wires to half of their original length and used AWG9 to hook the switches to the power blocks. I was thinking the wires I used are even better than the original ones, from the manufacturer.

The switches for the inverters are also rated 100amps at 12V: http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=92688

Are these too small for up to 10 Amps at 12V?

Thanks,
Speo


 
« Last Edit: June 08, 2008, 06:55:10 AM by Speo »

wooferhound

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Re: New 160W solar system
« Reply #7 on: June 08, 2008, 07:55:02 AM »
OK then, the picture doesn't show it clearly I guess.

Yeah, I've seen those switches, That is what I would use too.
« Last Edit: June 08, 2008, 07:55:02 AM by wooferhound »

RUFUS

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Re: New 160W solar system
« Reply #8 on: June 08, 2008, 09:45:27 AM »
It is refreshing to see a man who

loves, respects and cares for his folks

to do a project like this one long distance

is really inspiring.

Good show old man

                          RUFUS
« Last Edit: June 08, 2008, 09:45:27 AM by RUFUS »

dnix71

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Re: New 160W solar system
« Reply #9 on: June 08, 2008, 08:09:00 PM »
Nice work.
« Last Edit: June 08, 2008, 08:09:00 PM by dnix71 »

Norm

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Re: New 160W solar system
« Reply #10 on: June 09, 2008, 06:33:55 AM »
  What size...(amp/hr) is the battery?
« Last Edit: June 09, 2008, 06:33:55 AM by Norm »

Tritium

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Re: New 160W solar system
« Reply #11 on: June 09, 2008, 06:57:02 AM »
Looks like 115 amp hour from the label on the top of the battery in one picture.


Thurmond

« Last Edit: June 09, 2008, 06:57:02 AM by Tritium »

Speo

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Re: New 160W solar system
« Reply #12 on: June 09, 2008, 07:35:09 AM »
Rufus, dnix, Norm, Tritium, thanks for the input.


Norm, as Tritium said, the battery is 115Ah.


After discharging it to 80%, by using 23Ah over night, the panels brought it to float next day before 1:00 PM.


Speo

« Last Edit: June 09, 2008, 07:35:09 AM by Speo »

wooferhound

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Re: New 160W solar system
« Reply #13 on: June 09, 2008, 08:36:28 AM »
 Its Time for another Battery then
« Last Edit: June 09, 2008, 08:36:28 AM by wooferhound »

Speo

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Re: New 160W solar system
« Reply #14 on: June 09, 2008, 09:52:06 AM »
Woof, the battery is already oversized.


I forgot to mention that 23AH is double or maybe three times the intended average daily use. It will be used only for lighting, with no more than 3 bulbs simultaneously, for no more than 3 hrs per night. Bulbs are 13W, CFL.


I had to run many lights a long time to drain 23Ah and I did it only to see how fast it will be recharged next day, from the lowest state of charge admissible - 80%.


I know I could use less than 106W of panels, but I wanted to make sure the battery will not get abused.


Thanks,

Speo

« Last Edit: June 09, 2008, 09:52:06 AM by Speo »

elvin1949

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Re: New 160W solar system
« Reply #15 on: June 09, 2008, 11:41:28 PM »
 Speo

 I agree with Woof.Add one more battery just in case they get several days with no sun in the winter.

 Nice setup

later

Elvin
« Last Edit: June 09, 2008, 11:41:28 PM by elvin1949 »

ghurd

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Re: New 160W solar system
« Reply #16 on: June 10, 2008, 05:51:53 AM »
Add another Battery, or another Panel?  Another panel would make more power on the low sun days...

And that battery is US$600 in Romania, IIRC.


That puts a kink in the normal way things are calculated!

G-

« Last Edit: June 10, 2008, 05:51:53 AM by ghurd »
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independent

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Re: New 160W solar system
« Reply #17 on: June 10, 2008, 03:16:38 PM »
An interesting point. I read this article from homepower magazine and it really changed how I think about the purpose of batteries; that is, power in vs power out. You can't use what you don't make in other words.

So I now think of the sun (or the wind) as the battery, the battery as a capacitor and your panels/wind generator/hydro as the way to get that energy into your system..
« Last Edit: June 10, 2008, 03:16:38 PM by independent »

DigitalMind

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Re: New 160W solar system
« Reply #18 on: June 11, 2008, 10:46:59 AM »
Very well done.  Good job !!

That's crazy though that that battery cost $600 ..


I installed a ridiculously small solar power system for my sister and her hubby who have been using candles for the last year.  It cost a total of $600.  Same idea, just for lights. ( www.techienation.com/?p=21 ) I only put in 30 Watts worth of panels, but it's been working for almost a year now!  (They have been instructed to ONLY use it for lights, up to 4 hours per day) They have 2 6 volt 225amp batteries in series.


If you get another battery, i'm sure though could use this setup for a lot more than just lights though ! (You can do a lot with 160 Watts of panels compared to my 30!)

« Last Edit: June 11, 2008, 10:46:59 AM by DigitalMind »

Jeff

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Re: New 160W solar system
« Reply #19 on: June 11, 2008, 01:22:41 PM »
I run practically EVERYTHING with 45watt Harbor Freight panels, and a 2amp charger at night that draws 400milliamps of 110. I have 4 of those 115 amp/hour batteries, and another questionable car battery that is tied into those. The seperate battery is limited by the size of wire tieing it into the larger bank, with a large diode to prevent drawing from it to the larger bank. It's used for a small fan and light in a back room. All the rest of my lights, computer, fans for heating & A/C, and my fridge run from the "big bank".

The pump for the well, and a washing machine are run from a small generator. It takes about a gallon a month for gas for the generator.
« Last Edit: June 11, 2008, 01:22:41 PM by Jeff »

elvin1949

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Re: New 160W solar system
« Reply #20 on: June 12, 2008, 12:39:49 PM »
 WOW $600 for a battery,i agree another panel

would be cheaper.

 G I forgot about it being in Romania.

Sorry about that.

later

Elvin
« Last Edit: June 12, 2008, 12:39:49 PM by elvin1949 »

ghurd

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Re: New 160W solar system
« Reply #21 on: June 12, 2008, 12:58:42 PM »
My mistake.  It was Only ~$350.

G-
« Last Edit: June 12, 2008, 12:58:42 PM by ghurd »
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Speo

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Re: New 160W solar system
« Reply #22 on: June 12, 2008, 08:01:05 PM »
Thank you all for your inputs, suggestions and for your nice words.

After using the system for one week, my parents just told me they never reached 3Ah per night. They were using a 13W bulb in the living room and a 5W bulb in the bedroom. I think it's about time to convince them to use bigger bulbs (after I thought them to save as much energy as possible).

Speo

« Last Edit: June 12, 2008, 08:01:05 PM by Speo »

elvin1949

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Re: New 160W solar system
« Reply #23 on: June 12, 2008, 10:18:43 PM »
 Still high.

later

Elvin
« Last Edit: June 12, 2008, 10:18:43 PM by elvin1949 »

elvin1949

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Re: New 160W solar system
« Reply #24 on: June 12, 2008, 10:21:24 PM »
  Speo

 Don't do that.You want a little left over for when you visit.

later

Elvin
« Last Edit: June 12, 2008, 10:21:24 PM by elvin1949 »

Speo

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Re: New 160W solar system
« Reply #25 on: June 13, 2008, 09:06:38 PM »
:)
« Last Edit: June 13, 2008, 09:06:38 PM by Speo »