300w Solar installation.

[RichardThe3rd]

I have been travelling in my recently purchased James Cook (2004). I am intending to travel a great deal, including wild camping. I want enough solar to be able to stay off-grid in one place for a few weeks at a time. I had a 100w solar panel fitted to the roof when i bought it and went travelling in it for a couple of months. I soon realised that after wild camping for a few days in the same spot it would not be anywhere near enough wattage for my needs. With my fridge on and charging laptops etc, my batteries went down every day, and after 3 days or so, I had to drive off to re-charge them. So, on my return, I did some roof space calculations. I have worked out I can actually fit 3 x 100w semi-flexi panels on my roof. I also purchased an mppt controller to replace my pwm one.. I had a terribe job getting off the old panel. They used so much sikaflex that the panel was ruined removing it. ( maybe i did it wrong). I ended up using 'sticky stuff' solvent and an old sharpened credit card together with a similar sized but thicker 'ice scraper'. It took a long time ! I opted for semi-flexible panels again, but found clamps on ebay which I can highly recommend. Much less glue overall, and now the panels are boltable for any future eventualities. The first pic below shows the sikaflex left behind by the old panel, and the second, two of my new panels fixed using these new clamps...My third panel will go in front of the large Heki roof window. I have found there is no need to drill any holes in the roof for cables. I just route them through a little slot cut in the side of the air vent. No leaks, and it looks very neat.

Here is a link to the panel clamps i used.

http://www.ebay.co.uk/itm/NEW-6-x-Corne ... rmvSB=true

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[KlassikJames]

Great work!
You can cut Sikaflex under solarpanels very easy with a wire saw or a 'Fein Multimaster'.

[RichardThe3rd]

Thanks for the tips on removing panels. I'll remember that for next time.

[RichardThe3rd]

Here are 3 more pictures of my solar installation. The first shows the flexible panel clamps for 3 x 100w panels including the ones at the front of the van roof. These are sikaflexed in place, but i am now looking into tape options to provide a little extra strength holding the panels down (edit: I used VHB tape in the end )......The main thing for me is that the panels are removable, quickly and easily if ever a panel needs replacing, as well as being firmly attached enough that they don't move in transit. The second picture shows the 3 x 100w panels installed.
The third picture shows my location for the MPPT controller. My criteria for the mppt was:

1. No holes or any damage to the van when fitting it, so it can be removed with no signs it was ever there.
2. Near to the batteries
3. Enough space for cooling according to the Mppt manufacturer recommendations.
4. I can hide the connecting wires easily

So, as you can see, to the right of the kitchen sink was the best location that achieves this for me. It also allows me to hide the wires, and to check the controller easily. I built a mounting support that takes it's weight. It will be secured with very strong double sided tape. It won't move in an accident, but can be taken out and will have left no clue it was ever there if i want to.
I also purchased a 'bluetooth' attachment for the controller that allows me to view the readout of solar charge etc and control the Mppt all from my iphone or ipad. This means no other display for readout need be fitted.

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[RichardThe3rd]

Here is the finished unit with front guard and perspex roof, just in case any drips of water ever fall on top. I dont think it will ever happen, but if it did, no problem.

I wired 2 x 30a circuit breakers into the + wiring. One between solar panels and mppt, and one between mppt and battery. These are important, as they allow you to disconnect the panels without needing to remove any wires etc, and protect you if there is any fault.

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[jens735]

Hallo zusammen, die Durchführung und Montage des Ladereglers kann man auch so lösen. Gruss Jens

[RichardThe3rd]

Hello Jens,

thankyou for the pictures. That is a tidy solution.

Greetings, Ivor