Solar panel connections info/help please

scotsy

Guest
Hi, i'm in the process of turning my sprinter van into a basic campervan and have just bought an 80watt solar panel for the roof.

It arrived from Germany a lot sooner than i anticipated (i'm trying to get on with insulating it and carpeting the walls and ceiling at the mo) so i now need to gather together the other equipment needed for the installation. I've got the alloy brackets today and have a suitable bonding agent but the electrical components are a bit of a mystery to me.

Would buying this controller from maplins be Ok? Dual 16A Solar Charge Regulator : Charge Regulators : Maplin

I'll be getting a humongeous battery (plant machinery) to run the 12v items off so what 'guage' of wire is required to connect the regulator to the battery and the panel to the regulator?

2011-10-10201041.jpg


I'm assuming these connections are 'waterproof' but if i install a grommet in the roof and seal it properly could i remove them (cut them off) and connect the ends to the wires from the 'leisure battery' inside the van/roof lining (thus being less susceptible to water ingress)

2011-10-10200958.jpg


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Thanks
Ian
 
I'm sure Techno100 will be along to advise - he's our forum expert in my opinion - but take a look at these two Ebay items

Regulator eBay - The UK's Online Marketplace - Techno has advised offering £69 to secure

Roof gland/grommet eBay - The UK's Online Marketplace

In particular the regulator is a much more sophisticated product than Maplin's offering ... Instructions can be found here http://www.taiwantrade.com.tw/resources/member/142894/productcatalog/97ae964e-c00d-402d-988d-d63cb820ac9c_SCC-MPPT_manual.pdf

Regards

Chris
 
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I'm using almost exactly the same panels as you and also the !6A regulator from Maplins. I may get a better regulator later on, but you can spend hundreds on these things. Maplins reg was only £20 and it got OK reviews, so I am trying that first to see how it performs.

I am wiring my panels in parallel, but not using those connectors with the panels. They are designed to connect many panels in series on a house roof I think

I just cut them off, and fed the wires into a plastic food saver box. Then I used crimped bullet connectors inside the box to connect to the wires which go to the regulator. The plastic food saver box is waterproof and acts as a junction box. The wires to the regulator go through a rubber grommet in the roof which was designed to be used when fitting a roof rack.

It says the max current from the panel is 5A but since my panels are not angled I bet most of the time it will be more like 2-3A even on a warm British summer day. With two panels that's say 4-6A. Anyway, rightly or wrongly I used 20A cables from the solar panels to the regulator, and 30 A cables from the regulator to the battery. Obviously the cables must be big enough to take the current, but the bigger you can make them within reason the less the losses in the charging circuit (losses = I^2 x R x t .... so double the cable size , halve the resistance, halve the losses).

If I make my video part II you'll be able to see all these things in the flesh.
 
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Firefox said:
I just cut them off, and fed the wires into a plastic food saver box. Then I used crimped bullet connectors inside the box to connect to the wires which go to the regulator. The plastic food saver box is waterproof and acts as a junction box. The wires to the regulator go through a rubber grommet in the roof which was designed to be used when fitting a roof rack.
Click to expand...

Beware!

I have used such plastic boxes outdoors in the past - for example on the roof of my narrow boat - and they very quickly go brittle and shatter when exposed to UV/sunlight ...

Regards

Chris
 
Good tip, Chris.

I'm aware of UV degredation and it comes up sometimes in my day job when specifying materials. I just stuck the box up there to complete the installation quickly without worrying about spending £30 on some weatherproof junction box to IP whatever.

I think I shall wrap the connections in denso tape or similar tough waterproof product. Then even if the box degrades before I get a chance to inspect it, the connections will still be intact.
 
Now I could use some advice ...

I plan to fit a regulator within the hanging cupboard in my van, above the housing for the van's control panel.

I intend to drill up through the roof from within the cupboard, but in the corner of the cupboard there are three sets of cables from the control panel each running up through concertina style trunking.

What I can't work out is in which direction the cabling then goes once it's through the roof lining/insulation.

I don't wish to risk damaging the cable when drilling.

The cupboard is mid van between the dinette area and the rear corner bathroom, and the control panel is on the front edge of that cupboard facing the dinette.

Any suggestions how to work out where the cables are routed? I would think they either run straight forward along the ceiling, or more likely across to the edge of the van and then forward.

Help please :)
 
scotsy said:
Could you borrow something like this? Rapitest Wpp123 Wire/Pipe and Power Detector: Amazon.co.uk: DIY & Tools

Ian


My 'roof gland' has arrived and i'm going for the Maplins 16a regulator in morning so should all be wired and fitted in next day or so, i'm also having a split charge relay fitted this week as well.

Where is it best to buy a couple of leisure batteries from?
Click to expand...

I used Car batteries direct Unit 1, Ambrose House, Ambrose St, Manchester , M12 5DD Tel: 0161 230 8085

My anti virus reports a trojan on their website but their batteries are ok.

110 AH for about £70 delivered or 10% off if you collect.

Or try Griffin Battery Centres
9/11 Bolton Road
Bury
BL8 2AB
0161 763 1840

Mr B.
 
mrbigglesworth said:
I used Car batteries direct Unit 1, Ambrose House, Ambrose St, Manchester , M12 5DD Tel: 0161 230 8085

My anti virus reports a trojan on their website but their batteries are ok.

110 AH for about £70 delivered or 10% off if you collect.

Or try Griffin Battery Centres
9/11 Bolton Road
Bury
BL8 2AB
0161 763 1840

Mr B.
Click to expand...

i have just bought one off them today, best value i could find.

edit here is the link http://www.ebay.co.uk/itm/180737747377?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649
 
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I also brought 2 -110 leisure batteries from car batteries direct delivered next day.

John.
 
Just wire them up positive to positive and negative to negative and fuse the positives as close to the batteries as possible, I think the auto spares I used supplied 30amp fuses.

John.
 
ordered 2 yesterday

I used the link and ordered 2 x 120ah seeing as my 'humungous plant battery' didn't materialise :idea:

Thanks for all the tips, i'll post some pics in the next day or two (if i remember to 'take' the pics as i go along:wacko:)

Ian
 
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