by Joe Sanders

KM4JXS

Presentation Overview

• Solar Block Diagram

• Solar Panels

• Solar Controllers

• Batteries

• Safety Precautions

• HT Go Box Example

Solar Block Diagram

What is a Solar Panel?

A solar panel is a collection of solar cells that converts light into electricity. Diodes connected in series are used to prevent reverse current flow from the battery to the panel when the sun goes down. Each panel consists of individual solar cells wired together, routed to a junction box where the diodes are located, and then wired to external cables for distribution to the solar controller.

Solar Panel Examples

Solar panels are available in a variety of sizes and wattage ratings. In Ham Radio applications 25, 50, and 100 watt panels are typical, based on the radio load requirements and portability.

Why Solar Panel Output > 12 Volts?

Voltage Drop

Solar panels typically output 15 - 21 volts because some drop in voltage occurs between the solar panel and the solar controller via the connectors and the length of the connecting wiring.

Solar Panel Angle to the Sun

Optimum Solar panel efficiency angle to the sun varies with the season of the year.

No Shade on Any Solar Panel Cells

Do not allow any portion of your solar panel or panels to become shaded while charging. All cells must be in the sun.

Solar Panel Wiring & Interface

MC4 Connectors

(from panel)

MC4 connectors are most commonly used on the output wires of the panel. One cable is for the positive + polarity, and the second cable is the negative - polarity.

Solar Panel Wiring & Interface

Panel Back View

Solar panel with junction box where diodes are located, and output leads with MC4 connectors. All mounted on aluminum frame.

What is a Solar Controller?

A solar controller, charge controller, or charge regulator is a voltage and/or current regulator. It regulates the voltage and current coming from the solar panel(s) going to the battery to maintain the optimum battery charge without overcharging.

Solar Controller In – Out Voltage

A typical controller will regulate a Solar panel(s) with an output of 15 - 21 volts down to a 12 volt battery in a 12 volt system. The output voltage from the controller to the battery is typically 13.5 - 14.1 volts.

* Match your controller to your radio’s voltage tolerance requirements.

Solar Controller Interface Example

Why Use a Battery?

The solar system battery stores electricity from the solar panel(s) and powers the Ham Radio when it’s cloudy or the sunlight is dim.

Battery Types

8 Ampere Hour

35 Ampere Hour

Or Larger

Sealed Lead Acid/AGM

Marine Lead Acid

* Automotive Batteries not recommended *

Graphics not to scale

Marine Battery

Safety Precautions * Solar power can produce enough amperage

to generate heat that can melt wiring insulation, damage components, and cause flesh burns if not used correctly. Always observe correct polarity, and use correct wire gauge at all times. *

* Never allow anything metallic to fall across

the battery terminals short circuiting it. This can cause the battery to melt, create a fire, and possibly cause an explosion.*

Safety Precautions

* Battery Acid in contact with the skin can cause burns. Safety Glasses and gloves should be worn to avoid direct contact with acid. AGM Batteries are considered to be safer to use. *

- Continued -

Safety Precautions

* Fuse(es) should be used in circuits to avoid damaging components.*

- Continued -

* Power Off Switch should be used to provide a quick means of shutting down the system.*

Safety Precautions

* Short Circuit Fire Potential exists if system is wired incorrectly.*

- Continued -

* Hydrogen Gas Explosion possibilities exist when lead acid batteries are being charged. Avoid sparks and open flames near battery(ies) while charging.*

Disclaimer

Information provided in this introduction presentation is for education purposes only. The suitability of any items discussed here may or may not be the proper ones for your application. Consult with a knowledgeable professional before attempting to design and build your own solar powered system. No guarantee to suitability, amperage, wattage, voltage, or other technical specifications are stated or implied.

HT Go Box for Solar Power

HT Go Box for Solar Power

Use to Power: • Handy Talkies • USB Light • Cell Phones • Tablets • Emergency TV • MP3 Player • Etc.

HT Go Box - Meter/12V/5V

5 Volt Jacks 12 Volt Jack Battery Meter

Battery Meter 12 Volt Jack 5 Volt Jacks

HT Go Box for Solar Power

HT Go Box Inside

HT Go Box Inside

HT Go Box with Solar Power

Handy Talkie HT& 12 V Adapter

Baofeng BF-F9 V2+ 8 Watt

HT Go Box with Solar Power

Example Circuit

Version 1.1

Recommendations

Use two smaller solar panels rather than one larger panel for ease of portability and redundancy. Unexpected total loss of solar output is also minimized by using two panels.

Always double check each cable connection to insure continuity.

Recommendations

Use a solar controller rated for 30 amps if you think you might want to experiment or build a larger mobile Go Box or other application.

Run Time on Solar Power

There are many variables affecting solar radio run time. Talk versus receive time, radio output power settings, size of battery(ies), sun brightness, solar panel output wattage, number of panels, temperature, etc.

Midway through a bright sunny day solar panels will produce their maximum output for 4 to 5 hours in TN, and a lesser amount before and after that.

Conclusion

Questions?

This Presentation is Online at:

www.downlinktv.com/solar/solar.pdf

- References Follow -

Solar Panel References

Zebra 25 Watt Polycrystalline Panel

https://www.amazon.com/Zebra-Energy-25w-Solar-Panel/dp/B0137T7KNK/ref=sr_1_1?s=lawn-garden&ie=UTF8&qid=1510288723&sr=1-1&keywords=Zebra+25+watt&dpID=51chnBVxWaL&preST=_SY300_QL70_&dpSrc=srch

50 Watt Solar Panels

https://www.amazon.com/s/ref=nb_sb_ss_i_1_13?url=search-alias%3Dlawngarden&field-keywords=50+watt+solar+panel&sprefix=50+watt+solar%2Clawngarden%2C174&crid=2S6QC1KQC7RLB

Solar Controller References

ET Valley Model LMS 2430

PDF Manual https://manblan-a.akamaihd.net/iblock/50e/50e0fc46407da0ceda21f51ecd23aa0c/de5f6ab55f6109b758ba0e082b8030ca.pdf

Morningstar Prostar 30

PDF Specs

http://www.gosolarltd.com/morningstar.pdf

References - Continued

Harbor freight Ammo Cans https://www.harborfreight.com/ammo-box-61451.html

https://www.harborfreight.com/50-Cal-Metal-Ammo-Can-63181.html

Iztos 12-24 V Meter/12 V Jack/ 5V USB Jacks https://www.amazon.com/gp/product/B015W0XW2K/ref=oh_aui_detailpage_o01_s00?ie=UTF8&psc=1

HT Ham Radio Reference

Baofeng BF-F9V2+ Handy Talkie

https://www.amazon.com/Baofeng-Radio-US-400-489-99-Transceiver/dp/B00PTJ43FU/ref=sr_1_3?ie=UTF8&qid=1510289182&sr=8-3&keywords=baofeng+bf-f9+v2 Baofeng BF-F9V2+ PDF Manual https://baofengradio.us/fileuploader/download/download/?d=0&file=custom%2Fupload%2FFile-1423083989.pdf

Other Parts References

Amazon - Solar Panels/Meter/Jacks/Switches Amazon - 8AH Battery/Solar Controllers Morningstar – Solar Controllers Batteries Plus - 8AH/35AH Batteries WalMart – Marine Batteries Harbor Freight – Ammo Box

Video References

Solar Power for your Ham Station AD #52 https://youtu.be/g-hqt6pvGxo Portable Solar Power - a Primer for the Radio Amateur https://youtu.be/8SuvAKZt0Vs DIY How To Build A Solar Powered Radio Comm. Go Box - The Ham-O-Can https://youtu.be/vr_rGJ8Rq5c SOLN1 25 - Easy to Build DIY Portable Solar Energy Generator https://youtu.be/FUQOO0mQlRU