Solar Boler, Pictures of PV panel install on the Boler Options

[kevin61]

Here is a link to some photos of the progress of a Solar Panel install on the Boler.

Will complete a video once the project is complete.

http://flickr.com/photos/76boler/326376209...57613488933155/

[Frederick L. Sim...]

They look pretty slick. How many watts? Do they stay flat all of the time?

[kevin61]

They look pretty slick. How many watts? Do they stay flat all of the time?

Two 80 watt panels,approximately 42"X42" (together), wired in series. Should give me a Vmp of 33.4 volts, current of 4.8 amps.


The panels can stay flat, tilt towards door side, tilt towards drivers' side or be remotely mounted up to 35 feet away with the addition of a 12 AWG extension cord. I am thinking of adding a set of mounts to the cap of my truck. The trailer can then be parked in the shade and the panels can be secured to the truck which can be parked in the sun.

Also looking into a method to secure (lock) the panels to their mounts to help deter theft.

I'm pretty new to solar so it is taking me a while to get my head around the terminology and different wiring techniques.

A Morningstar MPPT charge controller should arrive for an install next weekend. Once I hook it up and run it through its' paces I will report back with the results.

This post has been edited by kevin61: Feb 8 2009, 05:57 PM

[Gerry]

I have a much smaller panel I used last summer while full timeing as camp host and it kept my battery charged for what I needed.
A few questions about your set up because I just moved mine around on its 15 foot lead to capture the max sun. Although it would work in ambiant sun I felt better when I saw ths sun right on it.
Do you plan to keep this panel on top of camper at all times even traveling down the road?
If so, did you build a cover to protect it? Does it need protection?
If not do you bring along a step-ladder so you can set it up?( do not think I would like this idea)
Even to get a cover off you would need to get up there.
Gerry

[kevin61]

I have a much smaller panel I used last summer while full timeing as camp host and it kept my battery charged for what I needed.
A few questions about your set up because I just moved mine around on its 15 foot lead to capture the max sun. Although it would work in ambiant sun I felt better when I saw ths sun right on it.
Do you plan to keep this panel on top of camper at all times even traveling down the road?
If so, did you build a cover to protect it? Does it need protection?
If not do you bring along a step-ladder so you can set it up?( do not think I would like this idea)
Even to get a cover off you would need to get up there.
Gerry

I will have mounts on my truck cap and have made a 50 ft extension from #10 AWG wire. (The length of the extension can vary for your installation depending how you have your panel or panels wired (series or parallel) and your particular charge controller.)

I will have the option of leaving the panels on the trailer or transferring them to the tow vehicle. It has been suggested by PeterH that the fibreglass roof may not be able to withstand the forces of the wind on the panels. I will not be doing a road test until April so won't be able to report back until I take it for a few runs. Chances are I will get better gas mileage with the panels mounted on the cap of my truck so the wind can travel over/under and around the panels. You will notice that the aluminum support brackets are broadside to the oncoming wind when the panels are on top of the trailer. The brackets on my truck cap will be turned 90 degrees to allow for better air flow.

Either way the panels will be plugged into the charging circuit so that the batteries are being charged while I am travelling.

The panels weight is only 35 lbs so it is just a matter of stepping up on a small stool to slide them on or off the trailer or truck. An easy one man operation.

There is no need to cover the panels. They are designed to withstand some punishment from the elements such as hail. As well if covered they will not be charging your batteries.

Once the project is complete and warmer weather comes back to Calgary then I will complete a video showing the setup in actual use.

[Chester Taje]

Very good job.You should be proud.

[Ed Harris]

One thing I have found to be helpful is to put a parallel connector from the panel and connect a Voltmeter there.

I have been able to use this to aim the panel for maximum output at any time.

I am always surprised that the angle I think is so different from the angle the meter will peak at.

I just have a cheap dedicated meter just for doing this.

On mine I use Anderson Power pole connectors to make it quick and simple to connect it all.

Ed

[kevin61]

I am placing all the links to the videos of the solar installation here in my original posting to make it easier for those doing a search. (thank you peterh)

Mounting two solar panels together and wiring in series
http://www.youtube.com/watch?v=Kh5b0yYVuvU...feature=channel

NEW TODAY
Solar panel mounting system on top of a 1976 Boler trailer
http://www.youtube.com/watch?v=akufm_DarLY

Installing wiring through roof of Boler trailer
http://www.youtube.com/watch?v=E5PyUbXvXRw

Installation of a Morningstar MPPT charge controller in a 1976 Boler trailer
http://www.youtube.com/watch?v=bP6pDkpe1-o


Initial testing of the solar installation
http://www.youtube.com/watch?v=QrjW8gnKSkY...re=channel_page

Still images

http://flickr.com/photos/76boler/326445047...57613488933155/

[Joseph Domingos]

Kevin,
Your videos have been very educational, thanks for all your work in sharing them with all of us. You are one careful and meticulous guy! If/when I'm working on projects of my own down the road, you're one that I might bounce a few ideas off of, K? hehe

Happy Modding and keep up the good sharing!

Joe

[kevin61]

I am placing all the links to the videos of the solar installation here in my original posting to make it easier for those doing a search. (thank you peterh)

Mounting two solar panels together and wiring in series
http://www.youtube.com/watch?v=Kh5b0yYVuvU...feature=channel

NEW TODAY
Solar panel mounting system on top of a 1976 Boler trailer
http://www.youtube.com/watch?v=akufm_DarLY

Installing wiring through roof of Boler trailer
http://www.youtube.com/watch?v=E5PyUbXvXRw

Installation of a Morningstar MPPT charge controller in a 1976 Boler trailer
http://www.youtube.com/watch?v=bP6pDkpe1-o


Initial testing of the solar installation
http://www.youtube.com/watch?v=QrjW8gnKSkY...re=channel_page

Still images

http://flickr.com/photos/76boler/326445047...57613488933155/

Todays' project was to design a prototype for a rotating solar panel mount for the cap of my truck.

This short video clip demonstrates the time and effort involved to transfer the panels from truck to trailer.

http://www.youtube.com/watch?v=k7Cjrh-AydA

[kevin61]

This is just an update of the solar installation with all the links located in one location.
The newest video is at the bottom.

Mounting two solar panels together
http://www.youtube.com/watch?v=Kh5b0yYVuvU...feature=channel
Solar panel mounting system
http://www.youtube.com/watch?v=akufm_DarLY
Installing wiring through the roof
http://www.youtube.com/watch?v=E5PyUbXvXRw
Installing solar charge controller
http://www.youtube.com/watch?v=E5PyUbXvXRw
Initial testing of the solar installation
http://www.youtube.com/watch?v=QrjW8gnKSkY...re=channel_page
Transferring panels from tow vehicle to trailer
http://www.youtube.com/watch?v=k7Cjrh-AydA
Still Photos
http://flickr.com/photos/76boler/326445047...57613488933155/

NEW TODAY
Tilting and locking system for solar panels
http://www.youtube.com/watch?v=7TDKyE6L1D4...re=channel_page

[kevin61]

VERY IMPORTANT CHANGE TO SOLAR INSTALLATION

In my videos I show a MALE plug coming from my solar panels. This is incorrect and poses a serious SHOCK/SHORT HAZARD. With the panels in full sun the red and black prongs are HOT.
 connector_warning.jpg ( 116.16K ) Number of downloads: 15



Mounting two solar panels together
http://www.youtube.com/watch?v=Kh5b0yYVuvU...feature=channel
Solar panel mounting system
http://www.youtube.com/watch?v=akufm_DarLY
Installing wiring through the roof
http://www.youtube.com/watch?v=E5PyUbXvXRw
Installing solar charge controller
http://www.youtube.com/watch?v=E5PyUbXvXRw
Initial testing of the solar installation
http://www.youtube.com/watch?v=QrjW8gnKSkY...re=channel_page
Transferring panels from tow vehicle to trailer
http://www.youtube.com/watch?v=k7Cjrh-AydA
Still Photos
http://flickr.com/photos/76boler/326445047...57613488933155/
Tilting and locking system for solar panels
http://www.youtube.com/watch?v=7TDKyE6L1D4...re=channel_page[attachment=22159:connector_warning.jpg]

This post has been edited by kevin61: Mar 8 2009, 02:16 PM

[kevin61]

I am heading to Langley on Thursday and this will be the "shake down" trip for the solar panel installation on the roof of the Boler.

I decided to follow through on a suggestion by Peterh and have installed a wind deflector in front of my panels to help direct air over the panels. The mounting brackets are broadside to the wind
and the concern was raised that this may cause excessive stress on the panel/roof connection.

I haven't done a wind tunnel test (although my neighbour did suggest a large fan and a 50 lb. bag of flour)I just guessed and "eyeballed" an angle. Hopefully it won't create a vortex and rip the panels off from the back!

Not sure if it will get painted in time for the journey but the trip should also expose any cracks that may occur in the fibreglass/bondo that may occur from the flexing of the roof.

 wind_deflector.jpg ( 161.37K ) Number of downloads: 107


This post has been edited by kevin61: May 5 2009, 06:34 AM

[Jim Bennett]

Kevin, looking forward to seeing your setup on Friday.

[kevin61]

Hi Jim,

If you happen to find a couple of solar panels between Calgary and Langley just give me a call.
See you this weekend.