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Topic ClosedConnecting a 100 watt solar panel to Zamp port

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Don Halas View Drop Down
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Direct Link To This Post Topic: Connecting a 100 watt solar panel to Zamp port
    Posted: 07 Jun 2016 at 1:01pm
I'd hope they expect long term sun exposure with sun panels.   Description suggests they're more tolerant of the environment.

I won't do this if I need to suitcase or carry panels. I don't want anything else to pack, set-up or secure (theft or weather).

The total investment will be less than $400. $600 if I add a second panel.

Thanks for the thought.

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JandL View Drop Down
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Direct Link To This Post Posted: 07 Jun 2016 at 12:09pm
You might want to do a Google search on long term sun exposure to the bendable panels.
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Don Halas View Drop Down
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Direct Link To This Post Posted: 07 Jun 2016 at 11:41am
I'm close to pulling the trigger on this. First I've got to see if my current battery box has enough extra space to accommodate the charge controller mounted inside.

I'm planning on mounting one HQST 100 Watt 12 Volt Monocrystalline Flexible Solar Panel to the roof on the toe side of the Pod. If my approach works I may add a second panel on the rear side at a later date. (http://www.amazon.com/dp/B017OMTAV6/ref=wl_it_dp_o_pC_nS_ttl?_encoding=UTF8&colid=1OFFIBLM4EPOJ&coliid=I180JN9A4WMLPF&psc=1). I'm going to run the wire down the front of the pod directly into the battery box and not use the zamp port on the back. I plan on attaching the panel using 1/2" VHB tape and then using Dicor sealant around the entire panel. Wires will be secured using wire cable clips that I hope will be adequately mounted using command strips. If the command strips fail it shouldn't be a big deal to find a suitable alternative.

I hope to mount a Morningstar SS 20L 12V SunSaver 20 amp 12 volt Solar Charge Controller with LVD controller inside the battery box. It's a little over sized for the one panel, but I believe allows me the option of adding the second panel in series with the first panel. It's supposed to be good for exterior applications. (http://www.amazon.com/dp/B017OA5DH8/ref=wl_it_dp_o_pC_nS_ttl?_encoding=UTF8&colid=1OFFIBLM4EPOJ&coliid=I18UBPLNOQR164)

I'm guessing a 20 amp fuse between the charger and battery should suffice.   

Any thoughts or guidance will, as always be appreciated.




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Don Halas View Drop Down
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Direct Link To This Post Posted: 06 Jun 2016 at 7:39am
Thanks again all.

Gotta do some homework, but the MorningStar chargers look like they'll work nicely with what I'd like to do. It looks like I might be able to mount them to my existing battery box and not worry about trading up on that yet.

I appreciate the input. I'll post some information of the projects progress if I get going on it.

Thanks again.

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Rustler View Drop Down
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Direct Link To This Post Posted: 06 Jun 2016 at 3:39am
Originally posted by Don Halas

Moving forward with this.

I am considering doing this and running the solar output to a charge controller and directly to the battery forgoing the zamp connector. To do this I'll need to mount the charge controller inside the battery box or at least in a weatherproof enclosure close to the battery.

Because I'm always looking forward and hate re-doing things or wasting money I think I might want to replace the battery box (not the battery) with one large enough for a battery upgrade (the two in series 6volt golf cart type) and to mount the controller say in the lid.

Again, I intend to keep my current 12 volt battery, but would rather upsize the box now in anticipation of a battery upgrade in the future.

Does anyone have any opinion on the size of box I'd need to accommodate the battery upgrade and mounting a charge controller (in as of yet undetermined size) in the box?

As always thanks for feedback.

Something to keep in mind is that some charge controllers require a certain amount of clearance around the unit for cooling. For instance my Morningstar SSMPPT-15L controller requires a vertical mounting with 6 inches above and below the unit for air circulation. It also cautions against exposure to direct sun, high temperatures and water. 

You might make your decision based on what charge controller you want as well as its requirements for clearance and air circulation.
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WillThrill View Drop Down
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Direct Link To This Post Posted: 05 Jun 2016 at 4:38pm
Originally posted by Rustler

Originally posted by WillThrill

Originally posted by Don Halas

Just curious, but I'm guessing that using an SAE plug you could use the Zamp plug as a DC source.

Yes, you could easily use the Zamp port as a 12 volt power source.  Keep in mind that the wire running the 20' or so is just 16 gauge, so I wouldn't recommend pulling more than 10 amps or 120 watts through it.  All you need to plug into it is a universal 2-way connector.  You could then wire this into a 12 volt socket adapter that you could then plug almost anything you wanted in to (i.e. USB charger, small fan, lights, etc.).

Willthrill if that wire connection is just 16 gauge, I really would be very reluctant use more than 2-3 amps. To run 10 amps at 12.5 volts through 16 gauge wire for 20 feet would give a voltage drop of 1.6 volts (less than 11 volts at the load). 10 amps would work, but not very efficiently. And there is the risk of overheating the wiring.

The following link gives a nice, convenient voltage drop calculator:


Running 2 amps for 20 feet on 16 gauge wire gives a more reasonable voltage drop of just 0.3 volts (less than 3%).

Does anyone know for sure what the wire gauge on that run? 16 gauge seems awfully light, especially for a solar charge connection with up to a 200 watt Zamp solar panel. Also is there any fuse on that run of wire? If not I would definitely add a fuse for electrical and fire safety.


I have verified that the wiring to the Zamp port is indeed 10 gauge.  According to the Zamp manual, they say that you can run up to 15 amps of current through this line, depending on which solar panel you have.

15 amps would be about the equivalent power from 200 watts of solar panels.  Yes, the at maximum output, you could theoretically be sending 16.6 amps through the line, but given that solar panels almost never provide their rated output in normal circumstances and the loss of power in the lines going to the charge controller, you would be fine.
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JandL View Drop Down
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Direct Link To This Post Posted: 03 Jun 2016 at 3:53pm
Here is the link to the manufactures web site. It's a sealed unit and I have had no problem. The other advantage with mounting next to the battery I don't have to install any Temperature Compensation.

http://www.morningstarcorp.com/products/sunkeeper/
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Don Halas View Drop Down
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Direct Link To This Post Posted: 03 Jun 2016 at 3:11pm
Thanks JandL. Not a great picture, but more importantly is the charge controller supposed to be rain or weather proof? How's it handling the elements?
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JandL View Drop Down
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Direct Link To This Post Posted: 03 Jun 2016 at 3:06pm
"I've looked for weather proof charge controllers and not seen anything specifically promoted as such"

I bolted my charge controller, Morningstar “SK-12 SunKeeper” 12 Amp PWM Charge Controller on the side of my battery box. You can see my mod here on page 39 of "List Your mods". The battery box is the biggest I could find, it's an Attwood Corporation 9084-1 Large Battery Box

http://www.rpod-owners.com/forum_posts.asp?TID=842&PN=39&title=list-your-mods
JandL
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Don Halas View Drop Down
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Direct Link To This Post Posted: 03 Jun 2016 at 2:50pm
I'm hoping not to drill any holes in the Pod itself and since the first panel will be at the front of the pod, going directly to the battery makes sense.

The alternate is going through the zamp connector (or the hole they've already drilled for it) and mounting the charge controller in the storage area behind it. That's the less favored approach.

I've looked for weather proof charge controllers and not seen anything specifically promoted as such. Also, doesn't seem worthwhile to spend a lot on that when an enclosure will not be that expensive.


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