Solar Panel Warning.

I have a common make of solar panel controller on my 4WD.
This type of controller needs its battery connected first, to initialise the internal control program, prior to connecting the solar panels.
Today, whilst the system was in use, I disconnected and reconnected the battery, without disconnecting the panels.
This scrambled the controller’s brains; it lost its internal program and started to feed the panel volts (in excess of 18volts) unregulated to the battery. This was not a problem for the battery in the short term but had the 4WD’s motor been turned on, and I not had an isolating relay in the solar panel circuit, the excessive voltage could have caused major damage to the diesel’s electronics.
On disconnecting the panels and reinitialising the controller, all operated to specification.
Give it a bit of thought, when hooking up your expensive motor to a solar panel or other external voltage source.
Regards Dennis
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Reply By: gbc - Tuesday, Aug 24, 2010 at 05:51

Tuesday, Aug 24, 2010 at 05:51
Mine's getting a bit long in the tooth, but my solarex controller has always required connection to the load prior to the array. Doesn't take long to let the smoke out of them otherwise.
AnswerID: 428224

Reply By: hl - Tuesday, Aug 24, 2010 at 07:20

Tuesday, Aug 24, 2010 at 07:20
Not a good situation, but not as dangerous as you might think. The output of the panel is unlikely to get anywhere near 18V while it is connected to a battery.
AnswerID: 428230

Follow Up By: Dennis Ellery - Tuesday, Aug 24, 2010 at 10:33

Tuesday, Aug 24, 2010 at 10:33
Don’t you believe it mate.
The 18 volts was measured at the battery. This was on a cloudy day too.
Volt drop is low on a full battery, and in bright sunshine, they would have reached over 20volts.
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Follow Up By: oldtrack123 - Tuesday, Aug 24, 2010 at 11:11

Tuesday, Aug 24, 2010 at 11:11
Hi Dennis
A little question .
Were did you actually measure the voltage?
Directly off the battery posts or the connectinion leads?
A poor connection between batttery & leads could give that result with some regs
But yes NEVER connect or disconnect a solar panel to a load especially electronic without a battery in circuit
Same as never disconnect a battery from engine while running
PETER
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Follow Up By: Dennis Ellery - Tuesday, Aug 24, 2010 at 11:26

Tuesday, Aug 24, 2010 at 11:26
Hi Peter
I have 2 digital voltmeters connected permanently - each directly connected to a battery under the bonnet. There was no possibility of a loose connection as the voltmeters weren't disconnected and the controller was connected back in circuit before I noticed the high voltage. I have the knowledge, and I should have known better but " but hey - chit happens",
Regards Dennis
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Follow Up By: hl - Tuesday, Aug 24, 2010 at 16:10

Tuesday, Aug 24, 2010 at 16:10
What size panel is that?

The open circuit voltage on 12V panels is normally well less than 20V and if it is a 100W or smaller panel, I fail to see how it can pump enough into the battery to raise the voltage to 18V (unless the battery is stuffed).
Having said that, a controller that is fussy about the connection sequence is not very well designed in my opinion.

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Follow Up By: Dennis Ellery - Tuesday, Aug 24, 2010 at 19:57

Tuesday, Aug 24, 2010 at 19:57
Hi hl,
They are Sharp 130 watt panels which have an open circuit voltage of 22 volts.
They produce close to this voltage in bright sunshine under low load conditions such as fully charged batteries. Try measuring it some time. My batteries are in top condition. You need to do a little research on controllers to find out thier characteristics also.
Regards Dennis
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Follow Up By: hl - Wednesday, Aug 25, 2010 at 10:32

Wednesday, Aug 25, 2010 at 10:32
Ok,
You win......

That is very high for 12V panels.
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Follow Up By: Maîneÿ . . .- Wednesday, Aug 25, 2010 at 11:09

Wednesday, Aug 25, 2010 at 11:09
hl,
tis not a matter of winning or even loosing, but more of sharing relevant information :-)

The idea of a solar panel being called a "12v solar panel" is a bit of a misnomer, because they will deliver >17 Volts @ the panel.

It's just like the terminology '12v battery' that everyone uses and understands.
Because when they are 12v they are actually 1/2 flat, being 12.66v when charged (2.11v per cell - wetcell)

I can also remember when it was claimed you could not fully charge the aux battery from an alternator or even a solar panel will only deliver about 80% of the panel's rated wattage to the battery, both long since shown to be incorrect with efficient power systems.

Maîneÿ . . .
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FollowupID: 699098

Follow Up By: oldtrack123 - Wednesday, Aug 25, 2010 at 12:19

Wednesday, Aug 25, 2010 at 12:19
Hi All
I believe the real point Dennis was making was that his reg WAS NOT REGULATING
Under those conditions with a fully charged battery it is quite possible to overcharge the battery to that voltage with a higher voltage power source such as solar
In fact @ that point the solar panels would be operating @ their MAX OUTPUT
[volts by amps =watts]
A very rare occassion & not good for the battery

Peter
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Follow Up By: hl - Wednesday, Aug 25, 2010 at 13:07

Wednesday, Aug 25, 2010 at 13:07
I agree...
I guess the main point is that poorly designed regulators allow this to happen.
I still think that most panels that are car mounted would not be able to push a battery of reasonable capacity much into overcharge, especially if there is a fridge and other loads on that battery. To get a good 12V battery up to 18V would take a while and well and truly cook it.
I used 2 80W panels on the ground and 90 Watts car roof mounted on our last holiday and still ran out after a week of running the fridge, charging a few laptops, talking on the radio........no chance of overcharging.

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FollowupID: 699107

Follow Up By: Maîneÿ . . .- Wednesday, Aug 25, 2010 at 15:16

Wednesday, Aug 25, 2010 at 15:16
hl,
Maybe, your solar system is not operating at it's maximum rated performance ?
Maybe, you were camped in inclement weather conditions ?
Maybe, the regulator you use is not efficient ?

Yes, just too many "maybe's" and not enough answers.

Reasoning is 250 Watts (>14 amps) should give you enough amps to more than replace the current used by all the items you have listed.

I only use a 203 Watts solar system and run a fridge drawing 10 amps, which will be much more than you use, also with lights, computer and battery charging all done with an inverter, I've never seen the 200ah agm battery system showing below 12v (50%) in all the years it has been in use.

The way solar panels are rated is by their 'maximum' watts, most times these maximum watts are never seen by the regulator at all, and many lesser expensive panels are next to hopeless when used in low light conditions, this is what causes most of the real life, but avoidable lack of solar power problems.

Maîneÿ . . .
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Follow Up By: hl - Wednesday, Aug 25, 2010 at 16:25

Wednesday, Aug 25, 2010 at 16:25
We had a few cloudy days.... that makes a lot of difference, other than that, the panels on the truck are obviously never at the optimum angle, but the 2 80W panels were moved around for maximum exposure.
Solar can be fickle....
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FollowupID: 699119

Follow Up By: Maîneÿ . . .- Wednesday, Aug 25, 2010 at 17:36

Wednesday, Aug 25, 2010 at 17:36
hl,
you have me confused now, because you say "the panels on the truck are obviously never at the optimum angle, but the 2 x 80W panels were moved around for maximum exposure"
Do you mean "the panels (plural) on the truck are..." being more than one (1) panel?

"but the 2 x 80w panels were moved around for maximum exposure" obviously moving them is not working for you at all is it?
My system sits horizontal on the roof rack, indicating 'maybe' you have not invested wisely in solar components ?
Can I ask what you are using ??

Cloudy days don't make such a huge difference, as solar works by converting solar radiation not just direct sunshine, that's why you get much more current produced when under areas of Columbus clouds
Image Could Not Be FoundMaîneÿ . . .
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FollowupID: 699130

Follow Up By: hl - Wednesday, Aug 25, 2010 at 22:39

Wednesday, Aug 25, 2010 at 22:39
Hi,
Well, there are 2 panels on the roof, a 30W and a 60W, the 2 extra ones are 80W Kyocera panels and they work very well when positioned correctly, the ones on the car get whatever, I make no particular effort to park for maximum exposure as they are mainly there to power the fridge and the car usually gets at least a short run every day, probably putting in as much from the alternator in 1/2 hour as the panels can do in a day. I have 2 100Ah batteries, one 80Ah and one 40 Ah (some in the truck, some in the trailer.
However, my usage is probably somewhat heavier than most people, with lots of gadgets and stuff (including an electric bike) that needs charging, hence the comments that we "ran out" after a week and all the batteries were pretty exhausted at the last day. I am an electronics person and do understand all the factors involved, believe me..... (I have built my own regulators, Ah meters based on PIC chips etc....

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Reply By: Member - Barry (NT) - Tuesday, Aug 24, 2010 at 12:21

Tuesday, Aug 24, 2010 at 12:21
Yep it happens.

An "expert" at Caboolture chabged an AGM battery for me and tested the others.

Saw him disconnection all 4 batteries and queried this. reply was with my controller you can open circuit no problems.

Lucky I checked later as the controller had defaulted to 1000aH battery capacity instead of the 400aH capacity of the 4 batteries and was going to put in up to 30amps till the cows come home.

On the day the batteries were fully charged (about 13.4V) but still had 18 amps being pumped in.

Lesson here - don't believe the "experts".

Went back and told the boss - couldn't care less,,,,, with comment oh we don't selll that brand of controller so why should we be expected to know.

WELL that's why I went there as they're supposed to be the experts.

Cheers Baz
AnswerID: 428264

Follow Up By: Gronk - Tuesday, Aug 24, 2010 at 13:53

Tuesday, Aug 24, 2010 at 13:53
OK, as most portable panels have a reg mounted on the panel with a lead and plug on the end......how do you connect the battery 1st when the panel is hard wired to the regulator ??
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FollowupID: 698979

Follow Up By: Maîneÿ . . .- Tuesday, Aug 24, 2010 at 14:17

Tuesday, Aug 24, 2010 at 14:17
gronk,
if it's connected this way as you say, I would think everyone with any solar knowledge will be telling you to disconnect it (regulator) and place it at the battery anyway

Maîneÿ . . .
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Follow Up By: Gronk - Tuesday, Aug 24, 2010 at 23:51

Tuesday, Aug 24, 2010 at 23:51
Yep...thats what I have done, but the reg is still hard wired to the panel (albeit with 10M of wire )..

Are you saying I should add another plug ( would be 2 of course ) into the cct ????
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Follow Up By: Maîneÿ . . .- Wednesday, Aug 25, 2010 at 11:58

Wednesday, Aug 25, 2010 at 11:58
No, just unscrew 'all' the cables and reinstall the system from scratch, only takes a few minutes and you know everything is done correctly and all is working as it is meant to be.
Even if it was just a 2 cable 'plug' you have to unplug and reinstall the other cables too.

Maîneÿ . . .
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FollowupID: 699100

Follow Up By: Gronk - Wednesday, Aug 25, 2010 at 23:42

Wednesday, Aug 25, 2010 at 23:42
Sorry mate, I don't get it ??

I have a free standing panel with 10M of cable on it going to a reg which has an anderson plug on it that plugs into the side of the camper....and I only use the panel a few times a year...rest of the time its packed away at home..
How I use it at the present time is to put out the panel then connect the plug from the reg to the camper......but others are saying to connect the reg to the battery 1st , then connect the panel to the reg ????
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