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Build one you canreally count on

By

Steve

Maxwell

When I was growing up in the suburbs in the 1960s and 70s, power failures hardly ever happened. If there was a particularly bad storm, we might lose electricity for

a few hours. That was about it. Electricity was reliable, and no one that I knew wished for their own source of backup power. We trusted the system and it served us well. Fast-forward 40+ years, BOE� UIJOHT�IBWF�EFUFSJPSBUFE� TJHOJmDBOUMZ�� *�N�OPU� TVSF�XIZ �CVU�JU�T� USVF�� "OE� JU�T� OPU� KVTU�NZ� PQJOJPO � FJUIFS�� 1FPQMF� FWFSZXIFSF�are feeling the same kind of creeping fears about energy security that I am. Even utility workers these days tell me that the electrical

TZTUFN�JTO�U�XIBU�JU�VTFE�UP�CF��"U�MFBTU�UIBU�T�XIBU�UIFZ�TBZ�XIFO�UIFZ�SF� CFJOH� IPOFTU� BOE� UIFJS� CPTTFT� BSFO�U� MJTUFOJOH�� 4XJUDI-ing gear is old, isolation switches have been bypassed because UIFSF�T� OP� UJNF�PS�NPOFZ� UP� SFQMBDF� UIFN��6UJMJUZ�QPMFT� SPVUJOFMZ�go years beyond their stated service life. Hey, even the massive electrical utility company that serves more than 13 million people XIFSF� *� MJWF� IBTO�U� CFFO�BCMF� UP�HFU� UIFJS� CJMMJOH� TZTUFN�TUSBJHIU�for years. The experience of declining electrical reliability is why UIFSF�T� NPSF� BOE� NPSF� UBML� UIFTF� EBZT� BCPVU� TPMBS� HFOFSBUPST�� Talk and hype mixed with actual promise.

GENERATORSOLAR


The term solar generator refers to small, portable, solar-pow-ered systems that create electricity from sunlight, store this electricity in a battery, then convert the electric power from di-rect current to the kind of alternating current used by plug-in chargers, lights, electronics and other small devices. Typically NBEF�UP�EFMJWFS��8�PG�QPXFS�PS�MFTT �TPMBS�HFOFSBUPST�BSFO�U�meant for big loads involving cooking, heat or large pumps. 5IFZ�EFmOJUFMZ�XPO�U�QPXFS�ZPVS�IPVTF��:PV�OFFE�TPNFUIJOH�bigger for that. But where solar generators really perform is XIFO�FMFDUSJDBM� TZTUFNT�BSF�EPXO�BOE� ZPV�EPO�U� IBWF� MPOH�term access to fuel, motor oil, repair parts for a typical gener-BUPS �OPS�UIF�PQQPSUVOJUZ�PS�JODMJOBUJPO�UP�PQFSBUF�POF��"T�MPOH�as the sun shines part of the time, your solar generator will re-charge itself enough to provide the most basic of basic power OFFET��4P�PCWJPVTMZ �UIF�JEFB�PG�B�TPMBS�HFOFSBUPS�JT�FYDFMMFOU�– at least in theory. Trouble is, the reality of ready-made solar generators on the market often falls far short of the potential. 5IBU�T�XIFSF�UIJT�1SFQQFS�1SPKFDU�DBO�NBLF�BMM�UIF�EJGGFSFODF�

'FBS�QSFTFOUT�QSPmUBCMF�NBSLFUJOH�PQQPSUVOJUJFT� GPS� UIPTF�more interested in making a buck than providing real value, BOE�UIF�nPPE�PG�VOEFS�FOHJOFFSFE�TPMBS�HFOFSBUPST�PO�UIF�NBS-LFU�UPEBZ�JT�B�DBTF�JO�QPJOU��:PV�DBO�QBZ�CJH�CVDLT�GPS�TPMBS�HFOFSBUPST�UIBU�EPO�U�QFSGPSN�OFBSMZ�BT�FGGFDUJWFMZ�BT�UIFJS�BE-vertising claims would lead you to believe. That said, you really DBO�U�CMBNF�UIF�nZ�CZ�OJHIU�TPMBS�HFOFSBUPS�QFEEMFST�FOUJSFMZ��5IFZ�SF� KVTU�NFFUJOH� UIF�EFNBOE� GPS�QFPQMF�XIP�IBWF�NPSF�trust and less practical sense than they should. Over-priced, under-engineered and unrepairable, many ready-made solar HFOFSBUPST�TJNQMZ�XPO�U�DPNF�UISPVHI�GPS�ZPV�XIFO�ZPV�OFFE�UIFN�NPTU��"OE�JO�NBOZ�XBZT �UIBU�T�XPSTF�UIBO�IBWJOH�OPUI-ing at all ready for times of trouble. The good news is that for UIF�TBNF�NPOFZ�ZPV�E�QBZ�GPS�POF�PG�UIPTF�PWFS�IZQFE�TPMBS�generators, you can build your own using high quality compo-OFOUT� UIBU�ZPV�DBO�USVTU �VQHSBEF�BOE�SFQMBDF� JG�OFFEFE��4P�MFU�T�HFU�TUBSUFE�PO�B�TPMBS�HFOFSBUPS�ZPV�DBO�CFU�ZPVS�MJGF�PO�

Hoping for the best is a lousy survival strategy. If there are warning signs in front of you, prepare the best

you can and leave hope to others.”“

<RX�FDQ·W�H[SHFW�WR�survive better than others if \RX�ZRQ·W�SUHSDUH�EHWWHU�

than others. ”“

Any solar generator battery will deliver more total energy with a slow discharge rate compared with a fast rate. Always use the

slowest rate of energy use possible from your solar generator. ”

“

/HDG�DFLG�EDWWHULHV�GRQ·W�develop a “memory” and even

GHHS�F\FOH�EDWWHULHV�VKRXOGQ·W�EH�fully discharged between uses. <RX·OO�JHW�PD[LPXP�EDWWHU\�OLIH�LI�\RX�GRQ·W�OHW�EDWWHULHV�GLS�EHORZ�

50% of their capacity. ”

“

Key Electrical Terms

Volts: a measurement of electrical pressure. Voltage is to electricity what pounds per square inch is to water pressure at a given moment.

Amps:�D�PHDVXUHPHQW�RI�WKH�ÁRZ�UDWH�RI�HOHFWULFLW\��$PSV�DUH�WR�HOHFWULFLW\�ZKDW�JDOORQV�SHU�PLQXWH�DUH�WR�OLTXLG�ÁRZ�

Amp-Hours: a measurement of the total quantity of elec-WULFDO�HQHUJ\��2QH�DPS�ÁRZLQJ� IRU�RQH�KRXU� LV�RQH�DPS�KRXU��$PS�KRXUV�LV�WR�HOHFWULFLW\�ZKDW�FDORULHV�DUH�WR�IRRG�

Watts:� D�PHDVXUHPHQW� RI� WKH� WRWDO� SRZHU��$Q�HOHFWULFDO�V\VWHP�ZLWK�RQH�DPS�RI�HOHFWULFDO�ÁRZ�DQG�D�SUHVVXUH�RI�one volt is putting out one watt. Watts are to electricity what horsepower is to a gas or diesel engine.


The Prepper Project Four-Part Solar Generator

100 wattphotovoltaic panel

20 amp - 125 volttwist-lock plug

charge controller

telescopinghandle

panel anglebased on latitude

formula

80 to 100 amp-hourdeep-cycle AGM battery rubber

tie-down strap

*case side not shown to increase visibility

1500 to 3000 wattinverter

weatherproof switch

weatherproofplug outlet

connect inverter to ground plateif it has a ground cable terminal

adjustable PV panel stand

ready-madeweatherproof rolling case


The main fact about building anything yourself is that you automati-DBMMZ�CFDPNF�UIF�XPSME�T�GPSFNPTU�BVUIPSJUZ�PO�mYJOH�JU��5IJT�NFBOT�SFMJBCJMJUZ � BOE� JU�T� POF� SFBTPO� *� BMXBZT�CVJME�BT�NVDI�BT� *� DBO� GPS�myself on my rural, island homestead. Two other reasons to build a TPMBS�HFOFSBUPS�ZPVSTFMG�BSF�RVBMJUZ�BOE�GFBUVSFT��:PV�DBO�NJY�BOE�NBUDI� EJGGFSFOU� DPNQPOFOUT� PG� UIF� TPMBS� HFOFSBUPS� DPODFQU� ZPV�MM�mOE�IFSF�UP�EFMJWFS�FYBDUMZ�UIF�SJHIU�LJOE�PG�TZTUFN�GPS�ZPVS�OFFET��4QFOE�NPOFZ�POMZ�XIFSF�JU�NBUUFST�UP�ZPV�BOE�ZPV�MM�HFU�UIF�CJHHFTU�bang for your buck.

The four parts of our solar generator design include:

Photovoltaic Panel

This is the part that creates electricity from sunlight, and the size of UIF�QBOFM�HPWFSOT�IPX�RVJDLMZ�UIF�CBUUFSZ�SFDIBSHFT��8F�SF�SFDPN-NFOEJOH�B��XBUU�QBOFM�GPS�PVS�EFTJHO�CFDBVTF�JU�T�TNBMM�FOPVHI�to be manageable and affordable, yet large enough to provide rea-TPOBCMF�SFDIBSHF�SBUFT��"��XBUU�QBOFM�XJMM� UZQJDBMMZ�QVU�PVU�CF-tween 60 and 95 watts of actual power in full sunlight depending on your latitude. The farther north you are, the lower the amount of power on the sunniest days. There are different types of photovoltaic QBOFMT�PO�UIF�NBSLFU �BOE�ZPV�MM�mOE�JOGPSNBUJPO�PO�DIPPTJOH�UIFN�wisely later on.

The Battery

8F�SFDPNNFOE�B��WPMU ��UP��BNQ�IPVS�EFFQ�DZDMF�"(.�CBU-tery for our solar generator and there are three reasons why. First, "(.� CBUUFSJFT� BSF� UPVHI � UIFZ� HJWF� PGG� OP� FYQMPTJWF� HBTFT� XIJMF�DIBSHJOH �BOE� UIFZ�DBO�U�TQJMM��-FBE�BDJE�CBUUFSJFT�BSF�BOPUIFS�PQ-UJPO�BOE�UIFZ�EFMJWFS�NPSF�DBQBDJUZ�GPS�B�HJWFO�DPTU�UIBO�"(.T��+VTU�use them in solar generators with lots of ventilation and where spills DBO�U�IBQQFO��&JUIFS�XBZ �EPO�U�JHOPSF�UIF�EFUBJM�BCPVU�iEFFQ�DZDMFw��Ordinary batteries are damaged when their state of charge regularly drops below 80% or 90% of a full charge, and this happens all the time when a battery is part of a solar generator. Deep cycle bat-teries, on the other hand, are made to keep on working even when UIFZ�SF�VTFE�NPTU�PG�UIF�XBZ�EPXO�UP�UIF�ESFHT��%FFQ�DZDMF�DPTUT�NPSF �CVU�JU�T�UIF�POMZ�PQUJPO�GPS�B�EFDFOU�TPMBS�HFOFSBUPS��%PO�U�VTF�anything else.

5IF� �� UP� �� BNQ�IPVS� CBUUFSZ� TJ[F� TQFDJmFE� JO� PVS� EFTJHO� JT� B�good compromise between relatively light weight coupled with a VTFGVM�BNPVOU�PG�QPXFS�TUPSBHF��:PV�DBO�HP�MBSHFS�PS�TNBMMFS�"(.�deep cycles come in many different sizes), but with its 12 volt out-put, the 80 to 100 amp-hour battery holds about 1000 watt-hours or 1 kilowatt-hour of electrical energy. What does this mean in real MJGF �8JUI�UIJT�CBUUFSZ�ZPV�DBO�SVO�B��XBUU�-&%�CVMC�UIBU�EFMJWFST�UIF�same light output as a 60 watt incandescent bulb for more than 100 IPVST��:PV�DPVME�BMTP�SVO�ZPVS�MBQUPQ�GPS�IPVST�PO�B�TJOHMF�DIBSHF�PS� FOKPZ�NPSF� UIBO� �� IPVST� PG� DIBSHJOH� UJNF� GPS� ZPVS� QIPOF��"�CBUUFSZ�MJLF�UIJT�XFJHIT�BCPVU��MCT �XIJDI�JT�KVTU�SJHIU�GPS�UIF�SPMMJOH�DBTF�XF�SFDPNNFOE� MBUFS�PO��:PV�SF�XFMDPNF�UP�VTF�B�TNBMMFS��



formula


rubbertie-down strap

1/4” eye bolt

1/4” eye bolt


volt battery to save money and weight, but you will have shorter run UJNFT��8IBUFWFS�ZPV�EP �NBLF�B�mSN�EFDJTJPO�PO�CBUUFSZ�TJ[F�OPX �rather than thinking you can add a second battery in parallel lat-FS��*U�T�UIFPSFUJDBMMZ�QPTTJCMF�UP�JODSFBTF�CBUUFSZ�DBQBDJUZ�XJUIPVU�JO-DSFBTJOH�WPMUBHF�CZ�BEEJOH�B�TFDPOE�CBUUFSZ �CVU�JO�QSBDUJDF�UIFSF�T�a problem. If one battery declines in capacity or ability to charge BOE� UIJT� BMXBZT� IBQQFOT� PWFS� UJNF� JU� DBO� DBVTF� BO� VOCBMBODFE�DIBSHJOH�TJUVBUJPO�UIBU�NBLFT�GPS�USPVCMF�MBUFS��5IBU�T�XIZ�ZPV�SF�CFU-ter off deciding on a single active battery as part of the system, then stick with it. Easily swappable batteries are an option for increasing system capacity.

The Charge Controller:PVS� QIPUPWPMUB-JD� 17� TPMBS� QBOFM�delivers power to charge the battery, CVU� 17� QBOFMT� BSF�pretty stupid. They EPO�U� LOPX� FOPVHI�on their own to slow down the rate of charge delivered to the battery, or to shut off the charge

altogether when the battery is full and the sun is still shining. Over-charging can ruin even a deep cycle battery, and this is where a charge controller comes in. This device senses the state of charge of the battery by measuring small changes in voltage delivered across the + and - terminals. The charge controller is the brains of any so-lar generator, and most models have a digital screen that tells you XIBU�T�HPJOH�PO��.PSF�PO�TFMFDUJOH�B�DIBSHF�DPOUSPMMFS�MBUFS��*U�T�FBTZ�UP�NFTT�VQ �TP�EPO�U�CVZ�BOZUIJOH�ZFU��8BJU�GPS�NPSF�JOGP�UIBU�DPNFT�later.

A Power Inverter17�BSSBZT�BOE�CBUUFSJFT�deliver direct current %$ � CVU� NPTU� TNBMM�appliances, chargers and light bulbs are designed to use alter-OBUJOH� DVSSFOU� "$��"O� JOWFSUFS�NBLFT� UIJT�conversion, and the technology behind inverters has come a

very long way over the last 10 years. Inverters are now cheaper, more SFMJBCMF �BOE�NPSF�FGmDJFOU� UIBO�FWFS��"MUIPVHI�ZPV�SF�TUJMM�CFUUFS�PGG�GSPN�BO�FGmDJFODZ�QPJOU� PG� WJFX� UP�VTF� KVTU� TUSBJHIU�%$� GSPN�B�CBU-UFSZ �ZPV�EPO�U�MPTF�NVDI�QPXFS�XIFO�VTJOH�BO�JOWFSUFS�UIFTF�EBZT��8IFO� ZPV� CVZ� BO� JOWFSUFS� GPS� ZPVS� TPMBS� HFOFSBUPS � ZPV�WF� HPU� UXP�NBJO� UIJOHT� UP�EFDJEF�PO��IPX� MBSHF�PG�BO� JOWFSUFS�ZPV�MM�OFFE �BOE�IPX�QVSF�UIF�QPXFS�JU�OFFET�UP�QSPEVDF��:PV�MM�HFU�UJQT�GPS�TIPQQJOH�wisely later on.

A System Case

Depending on the battery, charge controller and power inverter you choose, your solar generator case will need to house and support 60 lbs to 90 lbs of stuff, and there are two options you can follow to NBLF�JU�IBQQFO��*G�ZPV�SF�IBOEZ�XJUI�XPPE �ZPV�DBO�CVJME�B�DVTUPN-J[FE�QMZXPPE�CPY�UP�IPVTF�UIF�HFBS��w�PS��w�UIJDL�FYUFSJPS�HSBEF�QMZXPPE�JT�B�QFSGFDU�NBUFSJBM�GPS�UIF�KPC��"OPUIFS�PQUJPO�JT�UP�DPOWFSU�a rolling toolbox to function as a case. Details coming up.

Cables, Connectors and Cool HardwareDo you want a system that allows easy battery swapping? Or maybe ZPV�E�MJLF�UP�CF�BCMF�UP�LFFQ�UIF�TZTUFN�CPY�JOEPPST �XJUI�UIF�TPMBS�BSSBZ�PVUTJEF�JO�B�SFBMMZ�HPPE�TQPU�UP�DBUDI�UIF�TVO �)PX�NBOZ�"$�PVUMFUT�XPVME�ZPV�MJLF�PO�ZPVS�TZTUFN �"MM�UIFTF�GFBUVSFT�BOE�NPSF�ultimately come down to the kind of connection cables and hardware you choose. Tips, tricks and recommendations coming up later.

%DWWHULHV�GRQ·W�VWRUH�ZHOO��Keep them active or trickle charged at

a rate of 1/1000 of amp-hour capacity for good battery health.

Inactivity causes sulphur build up on plates and deterioration. ”

“


Building Your Solar Generator$SFBUJOH�ZPVS�PXO�TPMBS�HFOFSBUPS�NJHIU�CF� UIF�NPTU�DPNQMJDBUFE�UIJOH�ZPV�WF�UBDLMFE �CVU�EPO�U�CF�EJTDPVSBHFE��*U�T�TJNQMZ�B�NBUUFS�of doing the right steps in the right order, beginning with some vital planning.

Step#1: Determine Your Power Needs and Charge TimesThis bit of planning is the most important part of building your so-MBS�HFOFSBUPS��5IBU�T�CFDBVTF�UIF�EFTJHO�PG�ZPVS�TZTUFN�EFUFSNJOFT�XIFUIFS�PS�OPU�JU�XJMM�NFFU�ZPVS�FOFSHZ�OFFET��"OE�EPO�U�GPSHFU �UIJT�JTO�U� TPNF� IPCCZ� QSPKFDU� XF�SF� UBMLJOH� BCPVU� IFSF�� %VSJOH� BO� FY-tended grid-down situation, your solar generator will probably be the only thing allowing you to reach out with a short wave radio or a cell phone. It may be the only source of night time light you and your GBNJMZ�XJMM�TFF�GPS�NPOUIT�o�FWFO�ZFBST��"OE�ZPV�MM�BMTP�OFFE�ZPVS�TP-MBS�HFOFSBUPS�UP�DIBSHF�UIF�CBUUFSJFT�PG�WJUBM�DPSEMFTT�UPPMT��"MM�UIFTF�BSF�DSVDJBM�GVODUJPOT �BOE�UIBU�T�XIZ�ZPV�OFFE�UP�QMBO�BOE�CVJME�ZPVS�solar generator with all the precision and foresight of a well-executed tactical operation. Have you ever noticed how tough and high-qual-JUZ�NJMJUBSZ�HFBS�JT �5IBU�T�CFDBVTF�DFOUVSJFT�PG�DPNCBU�FYQFSJFODF�

IBT�UBVHIU�UIBU�KVOL�IBT�OP�QMBDF�XIFO�UIF�HPJOH�HFUT�UPVHI��"OE�ZPVS�TPMBS�HFOFSBUPS�NBZ�KVTU�CF�QBSU�PG�UIF�UPVHIFTU�TJUVBUJPO�ZPV�BOE�ZPVS�GBNJMZ�XJMM�FWFS�GBDF��*G�ZPV�SF�TNBSU�FOPVHI�UP�TFF�UIF�OFFE�GPS�B�TPMBS�HFOFSBUPS �NBLF�TVSF�ZPV�SF�BMTP�TNBSU�FOPVHI�UP�CVJME�it right.

5IF�mSTU�RVFTUJPO�UP�BTL�ZPVSTFMG�JT�IPX�MBSHF�PG�B�CBUUFSZ�ZPV�OFFE��"OE�UP�BOTXFS�UIJT�ZPV�OFFE�UP�XSJUF�EPXO�BMM�UIF�JUFNT�ZPV�MM�CF�FY-QFDUJOH�UP�QPXFS�XJUI�ZPVS�TPMBS�HFOFSBUPS�XIFO�JU�T�OFFEFE��.BLF�B�MJTU �BEE��GPS�FGmDJFODZ�MPTTFT�PG�UIF�JOWFSUFS �UIFO�EFUFSNJOF�how long you want to run these essential items between charges. :PV�EPO�U�OFDFTTBSJMZ�XBOU�BMM� UIFTF�JUFNT�UP�SVO�BU�UIF�TBNF�UJNF �but a list will give you a sense of what you can operate together and what will need to be staggered over time. Here are typical energy DPOTVNQUJPO�mHVSFT�GPS�FNFSHFODZ�JUFNT�JO�XBUUT�

100 watt photovoltaic panel

12-2 flex cable

12 volts frompanel to charge controller

12 volts from batteryto inverter

120 voltsat inverter outlet

12 volts fromcharge controller

to battery

#1 to 4/0 cabledepending oninverter rating

FUSE

FUSE

80 to 100 amp-hour (AH)deep-cycle AGM battery

connection to electrical groundif inverter has a terminal for it

ChargeController

Inverter

Design is 90% of success. Get the design right and the rest is

just following instructions.

Solar Generator Wiring Diagram


*shortwave radio: 1,000 to 5,000 watts (limited range)

*cell phone charger: 2 to 6 watts

*laptop computer: 50 to 100 watts

*emergency lighting system: ��ZDWW�/('�[��RI�EXOEV

ÁDVKOLJKW�EDWWHU\�FKDUJHU��about 10 watts while charging 4 AA batteries

*household water pump:

1200 watts (2000 watts at startup)

This list gives you an idea about the basics, but to be completely ac-curate, you should measure your own electrical loads directly, then UBMMZ�UIFN�VQ��"�EFWJDF�DBMMFE�B�,JMM�B�8BUU�NBLFT�JU�FBTZ�UP�TFF�IPX�NVDI�QPXFS�BOZ��WPMU�JUFN�BDUVBMMZ�VTFT��*U�T�XIBU�XF�VTF�UP�NPO-JUPS�BOE�NBOBHF�PVS�PXO�QPXFS�DPOTVNQUJPO�BOE�JU�XPSLT�XFMM��:PV�MM�mOE�B�EFWJDF�MJLF�UIJT�WFSZ�VTFGVM�JO�UBLJOH�DPOUSPM�PG�ZPVS�IPVTFIPME�FMFDUSJDBM�VTF�BOE�mOEJOH�UIF�QPXFS�XBTUFST�JO�ZPVS�MJGF�

There are two numbers you need to get from the exercise of tallying up electrical loads you want to cover with your solar generator: First is the maximum rate of power consumption at any given time FYQSFTTFE�JO�XBUUT��"O�FMFDUSJDBM�nPX�SBUF�PG��BNQ�PG�DVSSFOU�XJUI�B�WPMUBHF�PG��WPMU�JT��XBUU��:FT �B�XBUU�JT�B�WFSZ�TNBMM�BNPVOU�PG�QPXFS�"OE�TFDPOE� JT� UIF�UPUBM�BNPVOU�PG�QPXFS�DPOTVNFE �FYQSFTTFE� JO�XBUU�IPVST��"�XBUU�IPVS�JT�B�nPX�SBUF�PG��XBUU�PG�QPXFS�TVTUBJOFE�GPS�1 hour. The battery we recommend for this solar generator design holds about 1000 watt-hours of power.

Step#2: Buy Your Battery, Inverter and Charge ControllerThe best way to design a system case to build out of plywood or to JOUFMMJHFOUMZ�CVZ�B�SFBEZ�NBEF�DBTF�PG�TPNF�LJOE�JT�CZ�mSTU�IBWJOH�all your solar generator components in front of you on your work-bench. This way you can try different equipment arrangements until ZPV�DPNF�VQ�XJUI�B�MFOHUI �XJEUI�BOE�IFJHIU�mHVSF�OFFEFE�GPS�ZPVS�TZTUFN�DBTF��"T�ZPV�XPSL �NBLF�BMMPXBODFT�GPS�BU�MFBTU�B�MJUUMF�FYUSB�TQBDF�JO�UIF�DBTF��:PV�NJHIU�XBOU�UP�TUPSF�EJGGFSFOU�MFOHUIT�PG�DBCMF�GPS�DPOOFDUJOH�UIF�TZTUFN�DBTF�UP�UIF�17�BSSBZ��1FSIBQT�ZPV�E�MJLF�UP�

TUPSF�TQBSF�GVTFT�PS�FWFO�B�TQBSF�DIBSHF�DPOUSPMMFS�PS�JOWFSUFS��"MMPX�room for this kind of stuff as you plan case choice.

)FSF�BSF�UIF�TQFDJmD�JUFNT�UIBU�PVS�PXO�1SFQQFS�1SPKFDU�TPMBS�HFO-erator is based on, and some things to think about as you choose your items:

Battery: The Heart of the System

Deep cycle batteries are widely available from many different local TPVSDFT�BOE�UIJT�JT�XIBU�ZPV�OFFE�GPS�B�TPMBS�HFOFSBUPS��8IFO�ZPV�SF�choosing a deep cycle battery, one important thing is to understand IPX�CBUUFSZ�DBQBDJUZ�BOE�ZPVS�VTBHF�QBUUFSOT�BGGFDU�CBUUFSZ�MJGF��:PV�OFFE� UP�DIPPTF�B�CBUUFSZ� UIBU�T� MBSHF�FOPVHI� UP�NFFU� ZPVS�OFFET�XJUIPVU�CFDPNJOH�EJTDIBSHFE�UP�EBNBHJOH�MFWFMT��)FSF�T�XIBU�UIJT�means:

Deep cycle batteries are rated to discharge down to use up 80% of capacity without obvious damage, but reality is more complicated. In the battery business, discharge levels are described in terms of iEFQUI� PG� EJTDIBSHFw� PS�%0%�� 5IF� TIBMMPXFS� UIF�EJTDIBSHF� PG� UIF�battery, the longer it will last. For example, if you regularly use 80% PG�B�EFFQ�DZDMF�CBUUFSZ�T�DBQBDJUZ�CFGPSF�SFDIBSHJOH �ZPV�SF�DZDMJOH�EPXO� UP��%0%��"�CBUUFSZ� UIBU�T�VTFE�NPSF�HFOUMZ �TBZ� UP��%0% �XJMM� MBTU� UXJDF�BT� MPOH��"OE� UIPVHI� JU�T�OPU�QSBDUJDBM �B�EFFQ�cycle battery used only to 10% DOD will last 5 times longer than the same battery regularly used to 50% DOD. In practice, size your bat-tery so you can run your solar generator down no further than 50% PO�B�SFHVMBS�CBTJT�BOE��%0%��PO�PDDBTJPO��%P�UIJT�BOE�ZPV�MM�hit a practical sweet spot between battery life and real-world usage.

4P�IPX�EP�ZPV�EFUFSNJOF�TUBUF�PG�DIBSHF�EVSJOH�VTF �1SFDJTF�WPMU-BHF�NFBTVSFNFOUT �UIBU�T�IPX��&WFSZ�EFDFOU�DIBSHF�DPOUSPMMFS�IBT�B�TDSFFO�UIBU�TIPXT�QSFDJTF�WPMUBHF�NFBTVSFNFOUT�CFDBVTF�UIBU�T�


IPX�JU�EFUFSNJOFT�IPX�UP�DIBSHF�UIF�CBUUFSZ��"�GVMMZ�DIBSHFE ��WPMU�deep-cycle battery will have a no-load reading of 12.7 volts. This drops to 12.42 volts at 20% DOD, 12.06 volts at 50% DOD and 11.58 volts at 80% DOD. Want a simple rule of thumb for how low to run ZPVS�EFFQ�DZDMF�CBUUFSZ �%PO�U�MFU�B��WPMU�CBUUFSZ�ESPQ�NVDI�CFMPX��WPMUT�BOE�ZPV�MM�HFU�FYDFMMFOU�CBUUFSZ�MJGF�

Bottom line: $IPPTF�B�USVF�EFFQ�DZDMF �"(.�CBUUFSZ�GPS�ZPVS�TPMBS�HFOFSBUPS�UIBU�PGGFST�BOZXIFSF�GSPN��UP��BNQ�IPVST�PG�TUPSBHF�DBQBDJUZ��"T-TVNJOH�BO�JOWFSUFS�FGmDJFODZ�PG��TPNF�BSF�IJHIFS �CBUUFSJFT�PG�this size will supply 400 watts of power for 1 1/2 to 2 hours. Expect to QBZ��UP��GPS�B�EFDFOU�"(.�EFFQ�DZDMF�CBUUFSZ�PG�UIJT�TJ[F��The best kind have two terminals for each of the + and - poles: one post and another threaded stud with a wing nut.

Choosing an Inverter – DC to AC Conversion

"O�JOWFSUFS�DIBOHFT�UIF�%$�DVSSFOU� GSPN�B�CBUUFSZ� JOUP�"$�DVSSFOU�SFHVMBS� JUFNT� DBO� VTF � BOE� ZPV�WF� HPU� UP� BOTXFS� TPNF� RVFTUJPOT�before you can select an inverter intelligently.

Inverter Question#1: How much peak wattage of power do you need? "�UZQJDBM�TPMBS�HFOFSBUPS�XJMM�IBWF�B��8�JOWFSUFS �CVU�ZPV�DBO�HP�larger or smaller. 750W is probably as small as you should go, and ��8�JT�BT�CJH��8IZ�DIPPTF�B�CJH�JOWFSUFS�XIFO�ZPVS�CBUUFSZ�XPO�U�MBTU� UIBU� MPOH� VOEFS� B� CJH� MPBE � "� MBSHF� JOWFSUFS� XJMM� BMMPX� ZPV� UP�QPXFS�TPNFUIJOH�CJH�GPS�B�TIPSU�UJNF��"�IPVTFIPME�XBUFS�QVNQ �GPS�JOTUBODF �NJHIU�POMZ�PQFSBUF�GPS�B�GFX�NJOVUFT �CVU�UIBU�T�BMM�JU�UBLFT�to get a few gallons of water for drinking in a grid-down situation. This is key in areas with no municipal water supply or when munici-pal supplies go down.

Inverter Question#2: How pure does your AC power need to be?Broadly speaking there are two kinds of inverters in the world: less FYQFOTJWF�NPEFMT�UIBU�QSPEVDF�XIBU�T�DBMMFE�iNPEJmFE�TJOF�XBWFw�PVUQVU �BOE�NPSF�FYQFOTJWF�NPEFMT�UIBU�QSPEVDF�iUSVF�TJOF�XBWFw�PVUQVU��.PEJmFE�TJOF�XBWF�JT�MFTT�iQVSFw �CVU�mOF�GPS�DIBSHFST�BOE�laptops running from a charger, but true sine wave power is needed GPS�TFOTJUJWF�FMFDUSPOJDT�UIBU�SVO�EJSFDUMZ�PGG�"$��%FUFSNJOF�XIFUIFS�or not the equipment you want to run needs pure sine wave power and buy accordingly.

Inverter Question#3: Do you want to be able to charge batteries from grid pow-er as well as produce AC power from your battery?In any grid-down situation, you might not necessarily have no grid QPXFS� BMM� UIF� UJNF�� *U�T� FOUJSFMZ� QPTTJCMF� UIBU� UIF� HSJE� DPVME� HP� VQ�and down over time. In cases like these you might want something DBMMFE�BO� JOWFSUFS�DIBSHFS��6OMJLF�B�DPOWFOUJPOBM� JOWFSUFS� UIBU�POMZ�DPOWFSUT��WPMU�%$�CBUUFSZ�QPXFS�UP��WPMU�"$�QPXFS �UIF�JOWFSUFS�charger has the ability to charge your battery from grid power if and XIFO�JU�CFDPNFT�BWBJMBCMF��"T�B�TVQQMFNFOU�UP�UIF�DIBSHJOH�QPXFS�GSPN�ZPVS�17�QBOFM �PQUJPOBM�HSJE�QPXFS�DIBSHJOH�DPVME�NBLF�B�CJH�difference.

So here are some recommended inverter choices for your solar generator, each with different sizes and features:

AIMS Power 2000W Inverter/Charger PICOGLF20W12V120VStreet price: $5905IJT�VOJU� JTO�U�DIFBQ�CVU� JU�T�SFBMMZ� JNQSFTTJWF��"CMF�UP�EFMJWFS��

Battery Size Codes$V�\RX�VKRS�IRU�EDWWHULHV��\RX·OO�UXQ�LQWR�´VL]H�FRGHµ�designations. These refer to a range of amp-hour ratings as follows:U1 = 34 to 40 amp-hoursGroup 24 = 70 to 85 amp-hoursGroup 27 = 85 to 105 amp-hoursGroup 31 = 95 to 125 amp-hours


watts of continuous, pure sine wave power, it can also handle peak MPBET�PG��XBUUT�GPS��PS��TFDPOET��$IBSHFT�CBUUFSJFT�XIFO�HSJE�QPXFS�DPNFT�CBDL�VQ �UIF�POMZ�ESBXCBDL�IFSF�JT�XFJHIU��"U��MCT� �JU�T�B�TFSJPVT�QJFDF�PG�FRVJQNFOU��4J[F��w�Y��w�Y��w�

*R�3RZHU�*3��+'�PRGLÀHG�VLQH�ZDYH�LQYHUWHUStreet price: $360This is a reliable, heavy-duty unit that offers no grid charging abil-JUJFT� JU�T� BO� JOWFSUFS� POMZ � OPU� BO� JOWFSUFS�DIBSHFS��"OE� UIPVHI� JU�T�NPEJmFE�TJOF�XBWF�PVUQVU�JTO�U�JEFBM�GPS�BMM�EFWJDFT �JU�JT�MFTT�FYQFO-sive than pure sine wave models. Delivers 3000 watts of continuous "$�PVUQVU �XJUI� GPVS�CVJMU�JO�"$�PVUMFUT��"O� JEFBM�XPSLIPSTF�NPEFM�XJUI�B�HPPE�USBDL�SFDPSE��8FJHIT�BCPVU��MCT�BOE�NFBTVSFT��w�Y��w�Y��w�

MicroSolar 1000W INV-1000PSStreet price: $1705IJT�JT�BCPVU�BT�TNBMM�BO�JOWFSUFS�BT�ZPV�E�XBOU�UP�VTF�GPS�ZPVS�TPMBS�HFOFSBUPS �CVU� JU�EPFT�QVU�PVU�QVSF�TJOF�XBWF�QPXFS��"U� KVTU��MCT��BOE�NFBTVSJOH��w�Y��w�Y��w �JU�T�FBTZ�UP�mU�JOUP�BOZ�DPNQBDU�TZTUFN�DBTF��'BO�DPPMFE�BOE�SBUFE�BU��FGmDJFOU�

Choosing a Charge Controller

"T�ZPV�MFBSOFE�CFGPSF �B�DIBSHF�DPOUSPMMFS�SFHVMBUFT�UIF�nPX�PG�FMFD-USJDJUZ�GSPN�UIF�QIPUPWPMUBJD�QBOFM�CBDL�UP�UIF�CBUUFSZ��(PPE�DIBSHF�controllers also give you information about how the system is per-forming and offers different charging patterns depending on the TUBUF�PG�DIBSHF�PG�UIF�CBUUFSZ��1BSBNFUFST�TVDI�BT�CBUUFSZ�WPMUBHF �TUBUF�PG�DIBSHF �BNQFSBHF�nPX�JOUP�UIF�CBUUFSZ�BOE�CBUUFSZ�UFNQFSB-ture are common pieces of information you can read from the screen of a good charge controller.

0OF�SFBTPO�JU�T�B�HSFBU�UJNF�JO�IJTUPSZ�UP�CVJME�ZPVS�PXO�TPMBS�HFO-erator is because the specialized hardware you need is so readily available and the selection is so large. In our case, because the XBUUBHF�GSPN�UIF�QIPUPWPMUBJD�QBOFMT� JT�SFMBUJWFMZ� MPX��8�JO�PVS�design), most any charge controller will be large enough to handle UIF�DIBSHJOH�MPBE��5IF�LFZ�JT�mOEJOH�B�NPEFM�XJUI�B�USBDL�SFDPSE�PG�reliability, a sophisticated charging pattern for maximum battery life, and useful information feedback. With this in mind, in no particular PSEFS �IFSF�BSF�UISFF�SFDPNNFOEFE�DIBSHF�DPOUSPMMFST�GPS�UIJT�1SFQ-QFS�1SPKFDU�TPMBS�HFOFSBUPS�

Windy Nation P30L Street price: $55Despite the name, this unit is meant for controlling photovoltaic sys-UFNT �OPU� KVTU�XJOE�TZTUFNT��5IF��XBUU�NBYJNVN� MPBE� JT�NPSF�UIBO�FOPVHI�GPS�PVS��XBUU�17�QBOFM�BOE�JODMVEFT�BO�-&%�SFBEPVU�that delivers all the system information you need. The only legitimate DSJUJDJTN�PG� UIF�1��-�JT�UIBU� JU�EFMJWFST�POMZ�UXP�TUBHF�DIBSHJOH � JO-stead of the more sophisticated three- or four-stage charging. This may result in slightly shorter battery life under some circumstances. 5IF�1��-�DPNFT�XJUI�B�CBUUFSZ�UFNQFSBUVSF�QSPCF�

MorningStar Pro Star PS-30MStreet price:$150Expensive but very good quality and reliable. This is one of the best DIBSHF� DPOUSPMMFST� PO� UIF�NBSLFU� SJHIU� OPX�� 5IF� 14��.� JODMVEFT�full, three-stage charging, temperature-compensated charging, and a feature that automatically shuts down the system when battery voltage drops to damaging levels. Handles charging loads of up to ��BNQT �XIJDI�JT�NPSF�UIBO�FOPVHI�GPS�PVS��XBUU�17�QBOFMT��5IF�14��.�BMTP�PGGFST�TPNFUIJOH�DBMMFE�QVMTF�XJEUI�NPEVMBUJPO�18.��5IJT� JT� B� QBUUFSO� PG� FMFDUSJDBM� nPX� UIBU� QSPWJEFT� B� UBQFSFE� SBUF� PG�DIBSHF� UP� UIF�CBUUFSZ�EFQFOEJOH�PO� UIF�CBUUFSZ�T� TUBUF� PG� DIBSHF��*U�T�XJEFMZ�SFDPHOJ[FE�UIBU�18.�MFOHUIFOT�CBUUFSZ�MJGF�BOE�DBO�FWFO�improve the capacity of batteries that are starting to fail from plate sulphur build up.

Renogy Tracer 4210 MPPT Street price: $2105IJT� JT�BOPUIFS�QSFNJVN�NPEFM �BOE� JU�T� UIF�DPOUSPMMFS� UP�DIPPTF� JG�ZPV�UIJOL�ZPV�NJHIU�MJLF�UP�BEE�FYUSB�17�QBOFMT�MBUFS�UP�TIPSUFO�CBU-UFSZ�DIBSHJOH�UJNFT��.115�TUBOET�GPS�NBYJNVN�QPXFS�QPJOU� USBDL-JOH � BOE� JU�T� B� TZTUFN� UIBU� HFUT� UIF�NPTU� GSPN�NVMUJQMF� 17� QBOFMT�connected together. The 4210 handles up to 400 watts of charging power and offers four-stage charging with pulse width modulation 18.��5FNQFSBUVSF�DPNQFOTBUFE�DIBSHJOH�BOE�PQFSBUFT�TBGFMZ�BU�IJHI�BNCJFOU�UFNQFSBUVSFT��5IJT�JT�B�$BEJMMBD�NPEFM�


Step#3: Buy or Build a System Case#VJMEJOH�ZPVS�PXO�TZTUFN�DBTF�GSPN��w�PS��w�FYUFSJPS�HSBEF�QMZ-XPPE�JT�UIF�CFTU�XBZ�UP�NBLF�B�DBTF�UIBU�T�FYBDUMZ�UIF�TJ[F�ZPV�XBOU �for the smallest overall size of solar generator unit, with no wasted TQBDF�CFZPOE�ZPVS�OFFET��"MUFSOBUJWFMZ �ZPV�DBO�BMTP�CVZ�B�XFBUI-erproof toolbox and modify it to store a battery, inverter and charge DPOUSPMMFS�� 5IFSF� BSF� NBOZ� PQUJPOT� PO� UIF� NBSLFU�� 5IF� %&8"-5�%4��5PVHI�4ZTUFN�9-� TUPSBHF� VOJU� �� JT� BO� FYDFMMFOU� PQUJPO�GPS�TNBMMFS�TZTUFNT��5IF�%&8"-5�%845��JT�B�MBSHFS�SPMM-JOH�DIFTU�UIBU�T�TVJUBCMF�GPS�TPMBS�HFOFSBUPST�XJUI�MBSHFS�BOE�IFBWJFS�batteries. There are many other ready-made cases that work well as the foundation of a solar generator. Different people have different JEFBT�PG�XIBU�NBLFT�B�HPPE�DBTF��4FF�UIF�PQUJPOT�JO�QFSTPO�CFGPSF�you make a choice.

Step#4: $VVHPEOH�<RXU�6\VWHP�LQ�,W·V�&DVHHow you place the battery, inverter and charge controller in the sys-UFN�DBTF�XJMM�WBSZ�EFQFOEJOH�PO�UIF�EFUBJMT�PG�XIBU�ZPV�WF�DIPTFO��That said, keep these principles in mind for best results:

For the Battery5IF� UPQ�PG� UIF�CBUUFSZ�NVTU�CF�PQFO�BO�BDDFTTJCMF��:PV�MM�OFFE� UP�DIFDL�BOE�NBJOUBJO�XBUFS�MFWFM�JO�UIF�CBUUFSZ�JG�ZPV�VTF�B�MFBE�BD-JE�CBUUFSZ �ZPV�MM�OFFE�BDDFTT�UP�UIF�UFSNJOBM�QPTUT�GPS�DPOOFDUJPO�BOE�DMFBOJOH �BOE�ZPV�MM�OFFE�FOPVHI�SPPN�BSPVOE�UIF�TJEF�PG�UIF�CBUUFSZ�TP�ZPV�DBO�HSBC�JU�XJUI�ZPVS�mOHFST�UP�MJGU�JU�PVU��(JWF�ZPVSTFMG�space for all this.

:PV�MM�OFFE�UP�TFDVSF�UIF�CBUUFSZ�TP�JU�EPFTO�U�NPWF�BSPVOE�BOE�DBO�U� GBMM� PWFS�� 5IJT� DPVME�NFBO� JOTUBMMJOH�BO� JOUFSOBM�XBMM� JOTJEF�B�ready-made case, or installing a removable rubber strap hooking to eye bolts.

For the InverterInverters can draw hundreds of amps of current at full output, so the TIPSUFS�UIF�TVQQMZ�DBCMFT�UIF�CFUUFS��1MBDF�UIF�JOWFSUFS�BT�DMPTF�BT�QPT-TJCMF�UP�UIF�CBUUFSZ �ZFU�XJUI�TVGmDJFOU�BJS�BSPVOE�UIF�JOWFSUFS�GPS�DPPMJOH�

"MM�JOWFSUFST�IBWF�CVJMU�JO�"$�QMVH�PVU-MFUT �CVU�UIFTF�XPO�U�OFDFTTBSJMZ�CF�IBOEZ�to plug things in to if the inverter is in the system case. For maximum convenience, install a weatherproof outlet box on the outside of your system case. Install wiring so this outlet box can be plugged into the outlet of the inverter in the system case. The plans show details.

Inverters usually take some power even when no power is being demanded of UIFN��5IBU�T�XIZ�ZPV�MM�XBOU� UP� JOTUBMM� BO�easily accessible switch to shut the invert-FS�PGG�XIFO�ZPV�SF�OPU�VTJOH�UIF�TPMBS�HFO-erator. The plans show how this should be a weatherproof switch.

For the Charge ControllerThis is a low-amperage device that han-

dles less than 10 amps of current from the 100 watt photovoltaic panel to the battery. This is quite different than the inverter, so the XJSFT�EPO�U�OFFE� UP�CF�OFBSMZ�BT� MBSHF��DBCMF�XJMM�CF�mOF��"T�you plan things, position your charge controller in the system case TP�ZPV�DBO�TFF�UIF�TDSFFO��:PV�EPO�U�OFFE�UP�NBOVBMMZ�PQFSBUF�UIF�charge controller in any way, but you will want to check state of charge, battery voltage, battery temperature and such during use. *O� GBDU � JG�ZPV�SF� MJLF�NPTU�TPMBS�FOFSHZ�FOUIVTJBTUT �ZPV�MM�QSPCBCMZ�HFU�BU� MFBTU�B� MJUUMF�PCTFTTJWF�BCPVU� UIJOHT� MJLF� UIJT��:PV�MM�EFmOJUFMZ�want to be able to see the screen easily when you open the case.

5IF�DIBSHF�DPOUSPMMFS�JT�UIF�QBSU�PG�UIF�TPMBS�HFOFSBUPS�UIBU�T�DPO-nected directly to the photovoltaic panel, so you need to wire some LJOE�PG�RVJDL�EJTDPOOFDU�GFBUVSF��"�UXJTU�MPDL�QMVH�PO�UIF�FOET�PG�UIF�cables connected to the charge controller and photovoltaic panel offers easy disconnects, but positive connections when together.

Step#5: Buy, Install and Connect a Photovoltaic Panel

1IPUPWPMUBJDT�BSF�CFDPNJOH�NBJOTUSFBN �TP�ZPV�DBO�CVZ�17�QBOFMT�BOE�TUBOET�JO�NBOZ�QMBDFT�UIFTF�EBZT��"MM�ZPV�SFBMMZ�OFFE�UP�DIPPTF�is a panel that delivers 12 volts, one that comes in a decent frame



formula



PV Panel Angle

The closer your PV panel is to 900 to the rays of the sun, the more power that panel will produce. So, how much dif-ference does angle make depending on season, time of day and latitude? The short answer is about 25%. Although it’s not practical to equip your solar generator with an auto-matic tracker to keep the panel at an optimum angle to the sun, if you did use one you’d be getting 100% of the possi-ble electrical output from your location. With this in mind as a benchmark, the following formulas gets you as close as possible to the ideal electrical output, with no seasonal angle adjustment. Just set the angle and leave it there. All angles are measured from horizontal:

For latitudes less than 250, tilt your panel the latitude degree figure x 0.87

For latitudes between 250 and 500, use the latitude degree figure x 0.76, plus 3.10

Simply setting your panel to this one angle all year long delivers a little more than 70% of the ideal electrical output overall. If your location is further from the equator than 250, adjusting your panel angle twice a year seasonally delivers just over 75% of the potential maximum output. Here’s the twice-yearly formula:

For latitudes between 250 and 500 during summer, tilt your panel the latitude figure x 0.93 plus 210

For latitudes between 250 and 500 during winter, tilt your panel the latitude figure x 0.875 plus 19.20.

There’s no benefit to seasonally adjusting solar panel an-gle at locations closer to the equator than 250. All panels should be pointing directly south (or north if you’re in the southern hemisphere).

that protects the panels, and choose a model with a reliable track record. There are lots to choose from, but this panel is one of our favorites:

Renogy 100 watt, 12 volt mono-crystallineStreet Price: $1505IJT�JT�B�USJFE�BOE�USVF�QBOFM�UIBU�T�XBSSBOUFE�UP�EFMJWFS�OP�MFTT�UIBO��PG�SBUFE�PVUQVU�GPS��ZFBST��*ODMVEFT�EJPEFT�TP�CBUUFSJFT�EPO�U�back feed through the panels.

"MUIPVHI�JU�NJHIU�CF�UFNQUJOH�UP�NPVOU�ZPVS�17�QBOFM�PO�UIF�SPPG�PG�B�CVJMEJOH �ZPV�MM�CF�CFUUFS�PGG�XJUI� JU�TJUUJOH�PO� UIF�HSPVOE� JO�BO�BEKVTUBCMF�BOHMF� TUBOE��(SPVOE�NPVOUJOH� MFUT� ZPV�NPWF� UIF�TPMBS�HFOFSBUPS� UP�EJGGFSFOU� MPDBUJPOT�BT�OFFEFE �BOE� JU�T�FBTJFS� UP� LFFQ�UIF�17�QBOFM�DMFBO�BOE�TBGF�GSPN�XFBUIFS�FWFOUT��"�nFYJCMF �FYUFSJ-or-grade 12-2 cable is ideal for connecting a 100 watt panel to the DIBSHF�DPOUSPMMFS��,FFQ�UIJT�DBCMF�BT�TIPSU�BT�QPTTJCMF�

The optimal angle of your panel for maximum electrical produc-UJPO� EFQFOET� PO� ZPVS� MBUJUVEF � UIF� EBUF� BOE� UIF� UJNF� PG� EBZ�� "OE�XIJMF� JU�T� OPU� QSBDUJDBM� UP� PQUJNJ[F� QBOFM� BOHMF� BMM� UIF� UJNF� XJUI� B�TJNQMF�QBOFM�TUBOE �IBWJOH�B�NBOVBMMZ�BEKVTUBCMF�TUBOE�XJMM�HFU�ZPV�QSFUUZ�DMPTF�UP� JEFBM��:PV�DBO�NBLF�B�TUBOE�PVU�PG��Y�T �CPMUT�BOE�deck screws, fabricate your own from metal, or you can buy ready-NBEF�TUBOET�QSFUUZ�DIFBQ��)FSF�T�B�HPPE�POF�

WindyNation Adjustable Panel MountStreet price: $55"MVNJOVN�BOE�TUBJOMFTT�TUFFM�DPOTUSVDUJPO�BOE�NBEF�UP�mU�QBOFMT�up to 100 watts.

When the going gets tough a little bit of appropriate technology can go a long way. The ongoing power you get from your solar generator NBZ�TPNFEBZ�QSPWF�UP�CF�UIF�NPTU�WBMVBCMF�LJMPXBUU�IPVST�ZPV�WF�FWFS�IBE�BDDFTT�UP��"OE�ZPV�MM�FOKPZ�BDDFTT�UP�UIJT�QPXFS�JOEFQFO-EFOU�PG�BOZUIJOH�UIBU�T�IBQQFOJOH�BSPVOE�ZPV��"T�MPOH�BT�#JH�#SPUI-FS� EPFTO�U� mHVSF� PVU� IPX� UP� UBLF� UIF� TVO� BXBZ � TPMBS� SFNBJOT� UIF�ultimate freedom technology.

Sourcing Cables and ConnectorsThe most unusual wir-JOH�TVQQMJFT�ZPV�MM�OFFE�are the heavy cables and connectors need-FE� UP� KPJO� UIF� JOWFSUFS�to the battery. The auto industry deals with the

same high amperage, low voltage circuits we do when dealing with JOWFSUFST �TP�UIFZ�SF�B�HPPE�TPVSDF�PG�IBSEXBSF��"VUP�TVQQMZ�PVUMFUT�

carry the kind of heavy cable needed to connect inverters to a bat-tery, so you should be able to buy what you need locally. One ex-DFMMFOU�POMJOF�TPVSDF�PG�BVUP�XJSJOH�TVQQMJFT�JT�XXX�EFMDJUZ�OFU��*�WF�CPVHIU� GSPN� UIFN�BOE� UIFZ�SF�HSFBU��%PO�U�CPUIFS� MPPLJOH� JO�IBSE-ware stores for heavy cable. That said, they do carry what you need GPS�XJSJOH�UIF�17�QBOFM�UP�UIF�DIBSHF�DPOUSPMMFS �BOE�UIF�"$�TJEF�PG�the inverter to separate outlets.

Batteries will deliver only 90% to 95% of their rated storage capacity until

WKH\·YH�EHHQ�WKURXJK��WR��FKDUJH�GLVFKDUJH�F\FOHV�DIWHU�QHZ��7KDW·V�ZK\�QHZ�EDWWHULHV�need to be “broken in” before they deliver

full capacity. ”“


How to Paint Cool Camo

Steve Maxwell lives on a 90 acre rural island homestead and

studied alternative technology in college. He grazes cattle,

builds things in his workshop and teaches people how to

live self reliantly. Visit Steve online at SteveMaxwell.ca

AGM Batteries – Pros and ConsConventional lead-acid deep cycle batteries are great for so-lar generators that operate with lots of ventilation and with no chance of tipping over. But there’s a safer battery option you might consider instead for your solar generator. It’s called absorbed glass mat (AGM) batteries and though they cost roughly 1 1/2 or 2 times as much as lead-acid, it offers unique advantages. AGM batteries contain acid just as conventional lead-acid batteries do, but it’s held in an absorbent internal mat. With no liquid acid to slosh around, there’s no chance for spilling. Also, AGM batteries are completely sealed, which means they never emit hydrogen gas as they charge. The amount of gas given off by lead-acid batteries is very small and easily dealt with by ventilation holes in the system case, but in very small spaces or potentially explosive locations, AGM batteries are the way to go.

Four Small But Vital Tech DetailsHere are four vital things that make a big difference when it comes to building your solar generator right:

Vital Thing #1: Size the cable to the inverter, then the fuse to the cable. By far the largest current draw in your solar generator will hap-pen between the battery and the inverter. Determine the maxi-NVN�DVSSFOU�ESBX�PG�UIF�JOWFSUFS �HFU�B�DBCMF�UIBU�T�BQQSPQSJBUF�GPS� UIF� MPBE� OPU� UPP�DSB[Z�MBSHF � BOE�DFSUBJOMZ� OPU� UPP� TNBMM �UIFO�DIPPTF�B�GVTF�UP�QSPUFDU�UIBU�TJ[F�PG�DBCMF��)FSF�T�B�MJTU�PG�current draws and matching cable sizes and fuse ratings. These DBCMF� TJ[FT� POMZ� BQQMZ� GPS� TIPSU� SVOT� MFTT� UIBO� ��w�� 6Q�TJ[F�DBCMF�POF�TJ[F�KVTU�UP�CF�DFSUBJO�ZPV�EPO�U�TVGGFS�GSPN�FYDFTTJWF�voltage drop along the circuit feeding the inverter. Exact cable TJ[F�EFQFOET�PO�DBCMF�UZQF�BOE�MFOHUI��"MXBZT�DIFDL�XJUI�ZPVS�JOWFSUFS�NBOVGBDUVSFS�GPS�mOBM�BQQSPWBM�PG�DBCMF�BOE�GVTF�TJ[F�

Load and fuse size Cable Size ��$�� $�� $�� $�� $�� $�� $�� $�� $� � �� $�� $�� $��

Vital Thing #2: Never connect neutral and ground conductorsNeutral conductors offer a path back to the energy source to DPNQMFUF�B�DJSDVJU �BOE�BT�B�SFTVMU� UIFZ�SF�BMXBZT�BDUJWF�QBUIT�GPS� FMFDUSPOT�XIFO� B� DJSDVJU� JT� PQFSBUJOH��(SPVOE� DPOEVDUPST �by contrast, are emergency routes for electricity to travel to the earth instead of through people if and when a wiring fault PDDVST��,FFQ�OFVUSBM�BOE�HSPVOE�XJSFT�TFQBSBUF�GPS�NBYJNVN�safety.

Vital Thing #3: Keep Lead-Acid Batteries Away from Inverters*G�ZPV�EP�PQU�UP�VTF�B�MFBE�BDJE�CBUUFSZ�JOTUFBE�PG�BO�"(.�CBU-tery, build a sealed separation wall between the battery and the inverter. Inverters can produce heat and sources of ignition, and UIFSF�T�B�TNBMM�DIBODF�JU�DPVME�JHOJUF�IZESPHFO�HBT�HJWFO�PGG�CZ�a charging lead-acid battery.

9LWDO�7KLQJ��'RQ·W�SXW�ZDVKHUV�XQGHU�KLJK�FXUUHQW�WHUPLQDOV8BTIFST�BSFO�U�OFDFTTBSJMZ�NBEF�PG�IJHIMZ�DPOEVDUJWF�NBUFSJBM �BOE�UIPVHI�UIJT�EPFTO�U�NBUUFS�XJUI�MPXFS�BNQFSBHF�TJUVBUJPOT �it can matter a lot when amperages get up as high as those GFFEJOH�BO�JOWFSUFS��5IBU�T�XIZ�DPOOFDUPST�GSPN�IJHI�BNQFSBHF�cables should be in direct contact with underlying connection MVHT��:PV�DBO�QVU�XBTIFST�PO�UPQ�PG�UIF�CPMUT�IPMEJOH�UIFTF�DPO-OFDUJPOT�UPHFUIFS �CVU�OFWFS�VOEFSOFBUI��:PV�DPVME�DBVTF�IJHI�resistance, heating and connector damage if you do.

&WFO�JG�ZPVS�TPMBS�HFOFSBUPS�OFWFS�TFFT�DPNCBU�BDUJPO � JU�T�still pretty cool to paint the system case in real camo co-MPVST��*U�T�BMTP�FBTJFS�UIBO�JU�TFFNT��.Z�GBWPSJUF�DBNP�QBJOU�JT�NBEF�CZ�,SZMPO��5IJT�TUVGG�TUJDLT�MJLF�DSB[Z�FWFO�UP�QMBTUJD �UIFZ�NBLF�JU�JO�B�WBSJFUZ�PG�DBNP�DPMPST �BOE�JU�T�FBTZ�UP�VTF��$IPPTF�BU�MFBTU�UISFF�DPMPST�GPS�QBJOUJOH�ZPVS�PXO�SBOEPN�camo patterns.

Vehicle Battery Survival System:DQW� WR�EXLOG�D�VRODU�JHQHUDWRU�EXW�FDQ·W�DIIRUG� WR�EX\�DOO� WKH�parts at once? Start with an inverter wired into your vehicle. 7KRXJK�QRW�DV�JRRG�DV�D�VRODU�JHQHUDWRU�� LW�ZLOO� JLYH�\RX�$&�SRZHU�DV�ORQJ�DV�\RX�FDQ�UXQ�WKH�HQJLQH�WR�NHHS�\RXU�EDWWHU\�FKDUJHG��-XVW�EH�FDUHIXO��$��RU��ZDWW�LQYHUWHU�FDQ�GH-SOHWH�D�FDU�RU�WUXFN�EDWWHU\�LQ��RU��PLQXWHV�LI�GHOLYHULQJ�ORWV�RI�$&�SRZHU��0DNH�LW�D�SROLF\�WR�DOZD\V�UXQ�\RXU�YHKLFOH�HQJLQH�when operating the inverter.

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