r/solar•
webbitor

Looking for feedback on my project, a solar power supply for camping.

My goal was to have a power supply I could use while camping, primarily to run two CPAP machines ~8 hours/night, as well as some 3V LED lighting, a small 12V fan, usb phone charger, etc. The CPAPs use 24V and possibly up to 4A (I found it to be ~1.5A in actual use). The other loads are much smaller. So the total draw is ~3A, which will use 24Ah, or ~37% of the battery's capacity in one night.

The plan is to use a solar panel to recharge the next day. Guesstimating a charging efficiency of 80%, and solar panel output exaggeration of 20%, it will take about 6 peak-sun-hours of full sun to recharge each day. In summer in the PNW, this is just about how much sun we get. :)

Main components:

I'm using a battery box typically used on trailers and boats, and mounted the charge controller etc. in the lid. Here is a diagram

I've just finished assembling it, but before I connect the battery and PV panel, I want to make sure it's as safe as I can make it. I'd also prefer to keep all the components' magic smoke inside. ;)

Here is what I have thought of so far:

  • What if there is a low-ohm short in SCC or battery-SCC wires? This seems like the biggest danger. The battery can easily melt wires and start a fire. My answer: 10AWG wire with 20A fuse close to + battery terminal to protect them. Silicone boots covering the battery terminals.
  • What if there is a short across the SCC output/"load"? My answer: The SCC has protection for current over 20A. (can it fail dangerously?)
  • Short across solar panel output? My answer: 8 and 10AWG wires can carry 52-75A. Solar panel's short circuit current is only 6.88A. I think this will just degrade the cells.
  • Short across the boost converter output? My answer: 14AWG leads can carry 20A. Module's current limit will be set to 6A (goes up to 10A). (can it fail dangerously?)
  • Short across the buck converter output? My answer: 22AWG leads can carry 3.5A. Module's max output is 3A. (can it fail dangerously?)
  • Battery will vent explosive mix of H2 and O2 while charging. My answer: The battery box has vent holes, and will not be charged in an enclosed space.
  • Battery will spill acid if tipped. My answer: Don't tip it. (Seriously though... is there some acid-absorbing material I could put around the vents just in case?)

What else have I missed? Thanks!

Posted Jun 16, 2017, 7:12 PM UTC · edited

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