solar panels ebook

7/27/2019 Solar Panels eBook

1/24

How To Build A Solar Panel

www.DIYSolarPanelsWorld.com


2/24

Legal Disclaimer


The Author(s) And Publisher(s) Of This Book Disclaims Any Responsibility For The Accuracy Of The Content Of This Book. Readers Assume AllRisk Of Viewing Reading Using Or Relying Upon This Information. Unless You Have Otherwise Formed An Express Contract To The ContraryWith The Author(s) And Publisher(s) Of This Book You Have No Right To Rely On Any Information Contained Herein As Accurate. The Author(s)

And Publisher(s) Of This Book Makes No Such Warranty. All Contents From This Book Are Given In Good Faith. They Are Not A Substitute ForProfessional Advice. Accordingly, Readers Should Not Rely On These Contents Alone But Shall Also Seek Professional Advice AsNecessary. The Author(s) And Publisher(s) Of This Book Shall Have No Liability For Claims By, Or Damages Of Any Kind Whatsoever To, A UserOf This Book Or Any Other Person For A Decision Or Action Taken In Reliance (Directly Or Indirectly) On The Information Contained On ThisBook. Such Damages Include, Without Limitation, Direct, Indirect, Special, Incidental Or Consequential Damages. Your Use Of This BookConstitutes Your Agreement To The Provisions Of The Disclaimer.

Disclaimer For Harm Caused To Your Computer Or Software From Interacting With This Book Or Its Contents Readers Assumes All Risk OfViruses Worms Or Other Corrupting Factors:

The Author(s) And Publisher(s) Of This Book Assumes No Responsibility For Damage To Computers Or Software Of The Reader's Or AnyPerson The Reader Subsequently Communicates With From Corrupting Code Or Data That Is Inadvertently Passed To The Reader's Computer.

Limitation Of Liability:

By Viewing Using Or Interacting In Any Manner With This Book Including Banners Advertising Or PopUps Downloads And As A Condition OfThe Author(s) And Publisher(s) Of This Book To Allow His Lawful Viewing Reader Forever Waives All Right To Claims Of Damage Of Any And AllDescription Based On Any Causal Factor Resulting In Any Possible Harm No Matter How Heinous Or Extensive Whether Physical Or EmotionalForeseeable Or Unforeseeable Whether Personal Or Business In Nature.Copyright:No Part Of This Book Shall Be Reproduced In Any Form,Electronically, In Print Or In Any Other Form.



3/24

Objective Of This Book


My main objective for this book is to bring you the essence of building a DIY solar

panel without all the fluff and fillers.

This can certainly be a 400-page book like most others, but you'll be poking bicyclespokes into your eyes before you can even finish half of the boring contents in it.

If you need the history and development of photovoltaic cells (and different scientistswho researched about solar energy), then this book is not for you. There are betterresources out there.

By the end of this book, you'll have a practical introduction of how to build your ownsolar panel and what tools and resources you need.

If this is the kind of content you're looking for... then let's ride on.



4/24

Contents


1. Materials and Components You'll Need2. How To Build the Solar Panel Frame3. How To Prepare the Substrate4. Tips On Painting the Solar Panel Frame5. Connecting The Solar Cells

6. How To Mount the Solar Cells7. Testing the Solar Panel8. How To Mount the Plexiglass Protector9. Final Touch Ups



5/24

Materials and Components You'll Need


The material and components that you build your solar panel with is of utmost

importance. With respect to your budget, go for better quality materials so your solarpanel can perform at its best.

Here's a list of materials you need:

1. Solar Cells2. Plywood & Plexiglass3. Masonite board

4. Jones Plug5. Silicone Caulk6. Super glue and screws7. Diode and Wires8. Paint9. Battery



6/24



Solar Cells

Depending on your budget, you can either buy new cells or purchase blemished ones.However if youre not comfortable (or inexperienced) working with blemished cells,you can simply get new ones. Although they're more costly, they last longer thanblemished ones.

If you have to work with blemished solar cells (due to budget constraints), eBay is agood place to buy them. You'll often see these going for dirt-cheap price. Or you can

contact solar panel contractors who will often (gladly) give you these "trash" for nomore than a can of soft drink.

In case those used solar cells are chipped, you can even cut them to size and they'llstill work... but they'll generate less power. For your first DIY solar panel project, avoidcutting solar cells.



7/24



Plywood & Plexiglass

The plywood we need is 3/8 inch thick. For the plexiglass, its thickness is not crucial.Both of these are easily available at your local hardware store. As you get moreexperienced, you can also use aluminum for the solar panel box and glass for thecover -- they tend to last longer than wood and plexiglass.



8/24



Jones Plug

A set of jones plug, both male and female, is required to connect between the solarpanel and the charge controller. This allows the solar panel to be detached from thecharge controller easily. Jones plugs are available at Newark Electronics.



9/24



Silicone Caulk

This is a strong, waterproof seal that is used to install many bathroom furnishings likebathtubs and kitchen sink. Most hardware shops carry this.



10/24



Super Glue & Screws

When joining wood, you'll need some super glue to attach the pieces of woodtogether before turning in the screws to hold them tight. This will help the woodenpieces stay in alignment as you work on the screws. This technique helps improveyour workmanship.



11/24



Diodes & Wires

A diode is needed so electricity can flow only in one direction -- from the solar panel tothe battery -- not the other way round. Otherwise the battery can discharge into thesolar panel during the night. Wires, obviously, connect components together.



12/24



Paint

A solar panel is exposed daily to solar radiation. Thus high quality paint with UVprotection is necessary to protect the wood from damage. Paint also preventswarping and damage due to moisture and precipitation.

When you buy the paint, choose a light color (like white),so that the solar panel will not absorb more heat thannecessary.

Excessive heat reduces the power output of yoursolar panel.



13/24



Battery

The battery bank forms one of the most important parts of the solar energy system. Itensures electricity is available to the electrical system when there isnt enough powerfrom the solar panel (probably due to a cloudy day or during the night).

Many hobbyists prefer maintenance-freebatteries and these, too, are easily available.



14/24

How To Build Solar Panel Frame


After you have gathered the materials together, you'll have to create a shallow box (as

the solar panel frame) for the solar cells to sit in.

The area inside the box should be designed to hold all the necessary solar cells. Anexample: For a 12 volt, low-powered solar panel, an area of 46 inches by 23 incheswould be sufficient for all the 36 solar cells. (Each solar cell, in this case, is about 3inches by 6 inches) Remember to have a little spacing in-between solar cells.

The border around the box should be about 3/4 inch high by 3/4 inch wide. If it's too

high, it will cast a shadow on the cells as the sun comes in from the side. If it's toolow, it doesnt allow sifficient (height) clearance for the solar cells.

Although the borders can be a little wider -- such as 1 inch -- it really shouldn't gobeyond that because the excess plywood will add to the overall weight of the solarpanel.



15/24

How To Build Solar Panel Frame


The design of the solar panel frame will be similar to the drawing below. There should

also be a center divider across the center of the frame to provide added structuralsupport.



16/24

How To Prepare The Substrate


The substrate is a firm backing that's used to mount the array of solar cells. It can

either be a Masonite board or a piece of perspex. (Perspex is usually moreexpensive)

To prepare it, cut the Masonite board (or perspex) so that it fits snugly inside the solarpanel frame. If you're using a Masonite board, give it a few layers of protective paint,and let each coat dry thoroughly before applying the next.

If you do not paint the Masonite board, moisture may

creep into the material, causing it to warp. Thisalone can cause you much trouble later on.

Take care to cover every inch of the board -- bothsurfaces, the sides and corners -- so that it can serveyou for as long as the solar cells can last.



17/24

Tips on Painting The Solar Panel Frame


As you're painting the substrate, you can also work on the solar panel frame.

Apply at least 3 layers of paint to the inside and outside surfaces -- in fact, even thesides and corners...everywhere -- of the solar panel frame. Similar to the substrate,allow each layer of paint to dry completely before applying the next.

Always let the paint dry in a well-ventilated area, away from direct sunlight.

If there are gaps in-between the wooden joints, you can fill and seal it with some wood

putty and let it dry thoroughly before painting over it.Although painting may take some time, it's pretty easy to do it well as long as you takenote of the few points above.



18/24

Connecting The Solar Cells


As you're waiting for the paint to dry, you can take some time to wire up your solar

cells.

Each solar cell produces about 0.5 volts. If you want your solar panel to produce 18volts to charge a 12-volt battery, you'll need about 36 of these photovoltaic cellsconnected in series for you to be able to get 18 volts.Note: You can't charge a 12 volt battery with a12 volt supply. The supply needs to be at least

5 volts higher than the battery voltage.

If you need more current from your solar panel,you can connect more solar panels in parallel.Treat this as you would batteries and you'll dojust fine.



19/24

How To Mount The Solar Cells


After you have connected the solar cells in series, you're now ready to mount them

onto the substrate.The best way to do this is to squeeze a small blob of silicone caulk to the back(center) of the solar cells and paste them onto the substrate. Do not apply siliconecaulk to the entire surface because this will restrict the expansion and contraction ofthe solar cells.Since solar cells expand (and contract) at a different rate as compared to the

substrate, they'll crack when stressed because they are brittle.

After you're done pasting all the solar cells onto the substrate,allow the silicone caulk to dry completely before putting it intothe solar panel frame. This means letting it sit for at least24 hours (or longer) in a well-ventilated place.



20/24

Testing The Solar Panel


Before you cover the solar panel with the protective plexiglass cover, test the solar

cells again. Make sure that they indeed generate the correct voltage and power outputunder the sun. If possible, connect it to the actual load that it's supposed to drive andsee that everything works before covering the solar panel with the plexiglass.

Not forgetting the diode, you should connect it in series withthe solar cells. Then place the diode inside the solar panelby sticking it to the side with a little silicone caulk.

After that, hold down the loose wires and cables within thesolar panel using tiny blobs of silicone caulk.



21/24

How To Mount The Plexiglass Protector


After all the silicon caulk is completely dried inside the solar panel, we can begin to

cover it up with plexiglass.

To prepare the plexiglass for mounting, we'll need to drill the holes for the mountingscrews and countersink it. These holes are at the edge of the plexiglass. The screwsgoes through them into the border of the solar panel frame.

Note: Take care to apply moderate, consistentpressure while drilling and screwing so that

the plexiglass wont crack. Pasting some tapeat the spot you're drilling also helps preventcracks.



22/24

Final Touch Up


After the solar panel is covered with the plexiglass, you can connect it to the rest of

the electrical system.

At the end of the wire that dangles out of the solar panel, attach the (male) Jones plugby soldering them to the terminals. Also solder the (female) Jones plug to the input ofthe charge controller. Then connect the output of the charge controller to the battery.

Note: Take care to get the polarities right.

After hooking up these parts in the correctmanner, youve made for yourself a completesolar power generator that can power up yourelectrical gadgets!



23/24

Conclusion


There are many applications for the solar panel you've built. If you're following thedesign described in this book, you can use it to power any appliance that runs on 12

volts DC. Examples of some interesting home applications are:

Automatic gate openerGarden sprinklerGarage lightsPatio lightsWater fountain pumpsVacuum cleaner charger

etc..

Finally, the most important thing is to let your imagination run wild. Think of how youwant your solar panel to serve you, then whip out a piece of paper and startdesigning!



24/24

Any Questions?


As mentioned at the beginning, this book is meant to be a practical introduction onhow to build your own solar panel.

If you have any questions in your mind or are interested in a relevant topic that youcannot find on www.DIYSolarPanelsWorld.com, please feel free to contact us via thecontact form and we'll get your questions answered or prepare some materialsspecially for you.

Hopefully you've got at least one thing out of this book.

That's all for now... talk soon!

www DIYSolarPanelsWorld com

solar panels ebook

Documents