BoonHauler Solar Project

[BoonHauler]

I told a few of you that I would post my Solar build here as well so here we go.

I had originally planed for an 800 watt array but since then I decided to double the size and I'm now at 1650 watts.

As some of you are aware I purchased six (6) SolarWorld ‘Sunmodule Protect’ series 275 Watt panels for my project. After much research I personally believe the SolarWorld ‘Protect’ panels are the most rugged and robust solar panels on the market today.

Here’s a pic of them coming in off the truck.



The panels are a 24 volt 60 cell configuration that’s roughly 66” x 38” in size, here’s a look at the panel.



The panels come pre-drilled for a two rail mounting system but being this was not going to be a standard static mount I decided to set them up as a three rail mount system. Here I’m drilling the panel side rails third (center) mounting hole.




I wanted the panel mount system to be fully tiltable in one axis. Here in this pic you can see the mounting system on one panel completed and ready for roof top installation.

[westend]

Nice, centralized monitoring and control panel. I'd bet once you get it all dialed in with MSView, your batteries will be as healthy as possible.

If you get a chance, post up the real time numbers from your array.

Real professional installation, BTW.

[BoonHauler]

In regards to the question about monitoring the system, when I get around to it (and it’s not very high on the priority list), is to network the two controllers with my on-board computer.

This will allow me to install Morningstar’s ‘MS View’ software. With their software I’ll be able to monitor power output as well as customize the charge profiles of each controller (the same profile for each controller). For now I’ve just set the controllers to one of Morningstar’s preloaded charge profiles for FLA batteries (Absorb stage 14.7 – Float stage 13.5 – Equalize stage 15.4).

All in all I think the solar system is just going to be operating in the background with the TriMetric battery monitor doing the bulk of the overall system monitoring. The nice thing about the parallel wiring is that it gives me a great deal of load control if I see the need for it in the future.

All network components are being roughed in right now and then down the road I’ll complete the installation and get the software up and running. You can see in the pictures with the front of the controllers open a yellow & blue LAN cable, one plugged into each controller. From the controllers the LAN cables go to a hub, in my case an old Linksys Router that I had laying around to act as the hub and from there up to the computer/entertainment center location.

Here’s a pic of the router installed. The light brown cable behind the router is the CAT5e cable that goes up to the entertainment center and still needs to be terminated.



I thought I’d throw this pic in as well; it’s the completed installation of the monitors and various switching.

[pianotuna]

Hi,

Yup. Ty.

BoonHauler wrote:

pianotuna wrote:
Could you share with us why you chose to do the tilting in the manner in which you have?

Hey Don, the panels tilt in both directions along the long axis of the panel. This allows for tilt to either side of the trailer.

Does this help with the tilt thing?

[mlts22]

For the TriStar CCs, are you going to have individual LCD panels on them, or will they go to a networked panel? I personally like having individual monitors on them, assuming the CCs are in an accessible area, just to see the good/bad/ugly at a glance.

[NinerBikes]

Very professionally done there. Well thought out and well executed. I feel there are some that would pay you top dollar for your level of engineering and workmanship down at Quartzsite.

[BoonHauler]

2oldman wrote:

BoonHauler wrote:
As it turns out the power conversion is a little better going from 24 to 12 rather than the high.

Yah, like you have to worry about efficiency! 🙂

I don't know what you're running with this.. a machine shop or what, but I can't wait to see your battery bank.

2 Old:

Well I don't know about a 'Machine Shop' but I do have an A/C I'd like to run..... 🙂

I have power tools (compressor, etc) that I'll be running off the system as well.

[BoonHauler]

pianotuna wrote:
Could you share with us why you chose to do the tilting in the manner in which you have?

Hey Don, the panels tilt in both directions along the long axis of the panel. This allows for tilt to either side of the trailer.

Does this help with the tilt thing?

[pianotuna]

Could you share with us why you chose to do the tilting in the manner in which you have?

[BoonHauler]

Here I’ve reinstalled the #2 GA cabling between the SCC’s and the main battery bank buss bars. The exposed buss bar between the controllers is the Negative Buss. The Positive cable between the two circuit breakers is #4 GA as well as the rest of the cabling between the breakers and buss bars on both Line and Load sides.



And here all the above mentioned cabling has been installed.



Here you can see the cabling from the SCC’s going down the right side. That’s all #2 GA as I mentioned above. I twisted it to hopefully cancel any EMI that maybe coming from the Charge Controllers.



and here the main buss bar wiring has been completed




and here the controllers are closed up. The controllers are Morningstar, TriStar - MPPT - 60 Amp

here’s a link TriStar MPPT

There’s a little loose wiring on the right side. That will be completed once the garage lighting is installed and beavertail control wiring is completed.

[BoonHauler]

2oldman wrote:

Salvo wrote:
You got it covered for the rising, and setting sun. .

The tilts are really going to be in opposite directions? (Yes, I saw the picture)

The panels are tilted that way to facilitate construction only. I'll most likely leave them flat but it's nice having the option to tilt if I want.

[2oldman]

BoonHauler wrote:
As it turns out the power conversion is a little better going from 24 to 12 rather than the high.

Yah, like you have to worry about efficiency! 🙂

I don't know what you're running with this.. a machine shop or what, but I can't wait to see your battery bank.

[BoonHauler]

pianotuna wrote:
I would have chosen 48 volts input to the controllers, as they are going to need to be MPPT. Nice work with great attention to detail.

Don:

I actually went round and round on this subject. As it turns out the power conversion is a little better going from 24 to 12 rather than the high.

It would have been easier to wire though........

[2oldman]

Salvo wrote:
You got it covered for the rising, and setting sun. .

The tilts are really going to be in opposite directions? (Yes, I saw the picture)

[Salvo]

I like it!

You got it covered for the rising, and setting sun. You probably added more tilt braces.