How to build a Solar Power Station

This Instructable is on how to build a battery power pack that charges from the sun. I built it this past summer to have a portable device that I could run and charge my  gadgets on.

Step 1 Wiring Diagram

The first thing I did was draw a wiring diagram.

Comments

[GreenD]

Yeah, good work! 
I plan to make my own - but with a bit modification:
I won't have your bridge rectifier - just a diode (still don't know how I choose which type)
Is your SPST switch for the solar panel charging the battery? Why?
I was going to have the solar panel always connected to the battery - with a trickle charge indicator that will shut off current into the battery.
Then, for outputs I'm going to also add a USB port along with standard wall plug.

Have fun with your project, it's the best damn idea people don't have yet!

[DIY Dave]

Yes, the SPST is for the solar panel charging the battery. The reason why is because I didn't install a charge controller that prevents overcharging and so I put a switch to control charging manually. Also mine does have a 2 standard wall plugs and a USB port; that is what the inverter is for.

[K!LL!4N]

Where did you buy your inverter?

[DIY Dave]

I bought it at meijer for $21.99.There are also many other places you can get them from. If you don't have a meijer near your house, you could get one from a hardware store or from Northerntools.com

[K!LL!4N]

ok, thank you. I am planing on building 1 for myself

[DIY Dave]

Cool; post pictures when you are done.

[K!LL!4N]

ok

[CorProTechno]

Dave, great project. Can you provide more information on the bridge rectifier? Brand / Nomenclature? Where did you install it in your toolbox? Thanks.

[john17831]

I think it would be a good idea to also add some ventilation to this just to help with efficiency in a situation where you would want the lid down. it looks like you have the lid closed with the Solar panel on top for support. If there are no vent ports, the inverter will heat up. Without a charge controller this could be even more important for your battery. Your solar array probably isn't large enough to cause a major problem, but on a small scale, heat reduces your efficiency.

[kwxj61b]

If I have 2 40watt 20volt solar panels that is connected to two CSB gp12650 12V 65Ah batteries, how much watt of inverter do I need? If I fully charged the batteries (includes the solar is still running) and connect to a window unit air condition that sucks up 900 watt, how long will the A/C last?

[DIY Dave]

2 X 40 Watts = 80 Watts
12 hrs. of sunlight everyday X 80 Watts = 960 Watts

Every day you could use the air conditioning for only 1 hour. If you are running the air conditioner on the inverter you would need an inverter that was at least 900 Watts. In my opinion if you want some kind of air conditioning I would suggest making one of these-http://www.instructables.com/id/Portable-12V-Air-Conditioner---Cheap-and-easy!/ -This one even runs on 12 volt so you wouldn't even need an inverter.

[Electronics Man]

What is the Wattage on your solar panel?

[DIY Dave]

The one shown is a 5 Watt panel, but since then I have bought a 15 Watt panel which is what I now use.

[devilmaycry]

Instead of using a big inventer! can you use a small in-car inventer.

[DIY Dave]

Yes, actually that is what I originally planned to use but I found the 400 Watt inverter on sale so I decided to use it instead.

[devilmaycry]

can i use a 1000 watt inventer instead of 400 watt one?

[DIY Dave]

Yes

[theone57]

where did you get the solar panel and what voltage and amperage is it?

[DIY Dave]

I bought mine at Tractor Supply Co.( http://www.tractorsupply.com) But since then I have found them for cheaper at menards and Northern Tools (http://www.northerntool.com) The one shown is ~15 Volt and only 1/3 Amp, but I now usually use a 15volt 1 Amp panel.

[BuildHomeSolarPanel]

This generator is a big help to some home owners. This is a plus factor that can
save energy as well as money. Solar energy is an advantage to those who wants
to save energy and won't spend much money.

Great post. Keep sharing.

[mtman11]

were did u buy the tool box for 22.50 at. what store

[DIY Dave]

I bought it at walmart

[mtman11]

thanks alot for info

[rpvanpatt]

 So this 12v plug is just running straight of the solar panel and not the battery correct?

[DIY Dave]

This is the power output plug to plug in things such as a cell phone car charger. The plug in step 5 is the input plug for the solar panel. Both the output and input plugs are connected to the battery.

[rpvanpatt]

 oo ok, doesn't your diagram show an output car 12v plug?  I thought that was what this was

[DIY Dave]

Yes, this one is the output plug.

[patlaceusa]

 What size of a panel and an inverter would you need to run a hot plate and an small electric room size heater? Does anyone know and would be able to help me? Can I do that? Thanks, Patricia

[DIY Dave]

Patricia,

As Spanbox and isacco have said this setup is too small for running heaters and hotplates.

What I would suggest for a heater (if you're wanting something portable) is that you should get a small propane heater such as this one.
http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200362083_200362083

[spanbox]

A solar system would be very expensive to do what you want. Generating heat from electricity requires a lot of electricity. Solar systems, batteries and inverters are never 100% efficient either, so, to use a 1000W heater or hotplate for 1 hour you would  need about 1200W/h of stored energy.
At 12V, 1200W will draw 100amps. So, if you have a fully charged 100A/h battery it would be dead after 1 hour, but draining any battery is bad for the battery.
Better would be to have 5 x 100A/h so that each one only uses 20% after 1 hour, and stays 80% charged. A 100A/h deep cyle leisure/solar battery does not come cheap, let alone 5 of them. Then you need an expensive inverter capable of the high load, and then enough solar panels to charge the batteries again.

I would think about trying to use a different method for generating heat e.g. a gas fire or a gas hotplate. Wood is also carbon neutral and a good source of renewable energy.

Hope this helps.

[isacco]

Usually, a hot plate or an electric heater has between 500 and 1000 watts of power consumption. A Silicium mono-chrystal panel delivers a nominal (maximum) power of about 100W per square meter. The battery and inverter should be sized on this power. It would not be a portable system.

Isacco

[patlaceusa]

 I could purchase enough panels and an inverter I saw from Coleman was rated at 100o W. But, I don't know what I would need in batteries. Can you help? Thanks

[isacco]

I know some basic info because I am exploring the market for a photovoltaic systems for my house.
From my market investigation (I am in Italy) the cost of 1 Kw nominal power (panels + inverter) is between 4000 and 5000 Euros.
I cannot give you more technical details because I am not an expert. May be you can post your questions in forums devoted to photovoltaic energy.
Isacco

[shinjikun34]

 Great idea for camping or emergencies (or when you want to be cool and tote it around with you for max battery life)

but a lot of the build pictures didn't give a relative view of where you put everything inside. I know the battery was in the bottom and braced with wood - but besides that I have no idea of where anything else was at.

Would you go back and take some zoomed out shots of everything to help me understand placement so I can build one myself (maybe even a better one)

also some more info on why you did what you did - what was the reasoning for using the 12v plug instead of a standard wall plug for power from the solar panel to the battery. just touch up and such like that would be appreciated.

Awesome build!

[DIY Dave]

I just posted a new picture of the inside of the toolbox. I hope that makes it clear where everything is inside.

The reason I used a 12 volt plug for the solar panel input is because the solar panel came with a 12 volt plug on it (because its made to be plugged into a car cigarette lighter plug).

If you have any more questions feel free to ask.

[GreenD]

I'm just learning electrical systems and engineering - If I wanted to bypass the rectifier (I don't have any plans with wind turbines!) what type of diode would I use & rating, and how would that change this layout?

I've been planning on making this for a long time and I thank you for your effort on this DIY!

[DIY Dave]

If you use the solar panel I use, you won't actually need to install a diode because the solar panel has one built in.

[glasscutr]

Step two says the total cost is $197 for a solar project that uses a 5 watt panel.  That's $39.40 / watt; which is about five times more than systems commercially available on the market.    I would hardly say this is an economical project and you're better off looking for other alternatives.  Even though it's a GREEN project and gives you a warm feeling of doing something good for the planet, you'll run yourself bankrupt doing something on a larger scale.  Suggest waiting until the solar technologies can be better developed by manufactures and their associated costs come down to a more realistic price range.

[CybergothiChe]

 it IS economical, as you only can use the one Watt that you get from the electricity company once, however the cost of the solar panel and such dissipates the cost over the amount of Watts used. So the more you use your solar power station, the cheaper and cheaper the Watts become, until you reach a point upon whence you find yourself following in the footsteps of Xeno (Zeno), and asking yourself how small you can divide the cost of a Watt, until the Watt is worth nothing...

[mhkabir]

I do not understand  why the bridge rectifier is needed. The solar panel produces DC, not AC

Kabir