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ouR escaPOD mods

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offgrid View Drop Down
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Post Options Post Options   Quote offgrid Quote  Post ReplyReply Direct Link To This Post Topic: ouR escaPOD mods
    Posted: 01 Mar 2020 at 8:09am
The vast majority of solar modules are used in large arrays and so are connected in series strings building the voltage up to near 600V or higher before parallel connections are made, and those parallel connections are done in a combiner box with fuses. So single conductor connectors are standard practice in the solar world. MC4 connectors became the standard about 10 years ago, and now almost all modules use them or more commonly "compatible" knock-offs from China, some of which are not all that "compatible", resulting in some serious field problems. 

For single module 12V battery charging the MC connector approach doesn't offer any advantages. By all means convert over to a two conductor cable (or 3 if you use a grounded extension cord).  You could just cut off the MC connectors, solder in butt splices, and heat shrink, but you would probably get an argument if you were ever to make a warranty claim on that module. 

Be sure to check the gauge of the extension cord if you go that route. A 15A cord is likely to only be 12 gauge or smaller, which is only going to be good for about 25 feet before you lose too much voltage. You'll want at least a 10 gauge cord.  Cut off both ends of the extension cord and either connect one end permanently (to the module or battery) or use dedicated connectors at both ends. Don't use the 120Vac connectors for 12Vdc so no one can get confused and connect the wrong stiff together. And don't try to use the MC's to make connections on a daily basis, they're not meant for that and also require a tool to disconnect which would be a PITA. Please do use a properly sized fuse at the battery end to protect that cord and the module. A 10AWG cord should be good for 30A but most modules are rated for 15A so a 15A fuse is a good choice. 

PWM controllers are fine for a 100 watt 12V module, if you go to one or more 250-350 watt residential/industrial modules those are high voltage so you need an MPPT controller to charge at 12V. Those module are so much cheaper per watt that its worth the extra expense for the MPPT at that point.  
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Post Options Post Options   Quote StephenH Quote  Post ReplyReply Direct Link To This Post Posted: 29 Feb 2020 at 5:20pm
It is a Renogy Traveler Series: Voyager 20A Waterproof PWM Controller w/ LCD Display and LED Bar. It supports Lead-acid (Gel, AGM, Flooded, and Calcium) Lithium-ion (LiCoO2, LiMn2O4, LiNiMnCoO2, and LiNiCoAlo2), LiFePO4, and LTO (Li4Ti5O12) batteries. An MPPT controller would have added significant cost to the kit. I figure I can always upgrade later.
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ouR escaPOD mods
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Post Options Post Options   Quote GlueGuy Quote  Post ReplyReply Direct Link To This Post Posted: 29 Feb 2020 at 1:49pm
Originally posted by StephenH

I'm not sure why two cables, positive and negative, are not run in one jacket for use whith solar panels like this. To me, it would make a lot of sense. As it is, I will be using a lot of zip-ties to fasten the + and - cables together for easier management. 
Solar systems are wired in a very wide variety of configurations. We have solar sites with anywhere from one panel to 18 panels, all with different series/parallel configurations. The MC4 connectors are "fairly" standard, and they seem to be the ones on most of the panels we get these days.

I know that kit comes with a controller that can be configured for lithium batteries. is it by any chance an MPPT controller (I assume not, since it would be a "feature")?
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Post Options Post Options   Quote StephenH Quote  Post ReplyReply Direct Link To This Post Posted: 29 Feb 2020 at 12:01pm
Originally posted by offgrid

Ho long an extension cable do you want to make? You will need some reasonably heavy gauge conductors to keep the voltage drop down if it’s very long. For a single 100 watt module I’d use 10 gauge up to 40 feet, 8 AWG above that. The Zamp conductors needs to be counted as part of that distance so it’s probably better just not to use them if you want to run very long.
I ordered a 20' extension cable. That seemed to be a good compromise between length, weight, and cost. I am testing it now with the Zamp connector. I did have to use a gender changer, mainly because the MC4 to SAE adapter would have been feeding power to the wrong port. I could probably get in there and change the connectors around so that it will be correct for the current setup. I also ordered a kit so that I will be able to work with the MC4 connectors. When it gets here, I will be able to reverse the ones that have the reversed polarity and thus have the cable able to plug in directly instead of having to use gender changer. Other connectors will go to make a connector at the front of the RPod which will feed in through the heavier battery cables.

As for using the 30A power cord, I would prefer to leave that heavy thing stowed. I thought of taking a heavy duty 15A extension cord and modifying it. That way, I would only have one cable running between the panels and the RPod. To me, that would make more sense. I'm not sure why two cables, positive and negative, are not run in one jacket for use whith solar panels like this. To me, it would make a lot of sense. As it is, I will be using a lot of zip-ties to fasten the + and - cables together for easier management.

I like the Anderson Powerpole connectors and wish I had seen them and the boots earlier. I may order a few for the one  set of connectors I would like to make for the A frame connections.
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Post Options Post Options   Quote geewizard Quote  Post ReplyReply Direct Link To This Post Posted: 29 Feb 2020 at 8:27am
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Post Options Post Options   Quote Pod People Quote  Post ReplyReply Direct Link To This Post Posted: 29 Feb 2020 at 8:24am
INo, I did not use the zamp connector or the alligator clips.  I installed a standard 30 amp RV receptacle on the pod's exterior so that I use the 25' standard power cord that came with the pod.
Here is a post I made about 4 years ago detailing that installation.  There were several comments about the exposed terminals which I have changed. Otherwise, the installation  is basically the same as the article.
http://www.rpod-owners.com/forum_posts.asp?TID=8194&title=installing-a-renogy-100-watt-suitcase-solar-panel
hope this will help you
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Post Options Post Options   Quote offgrid Quote  Post ReplyReply Direct Link To This Post Posted: 29 Feb 2020 at 7:32am
Ho long an extension cable do you want to make? You will need some reasonably heavy gauge conductors to keep the voltage drop down if it’s very long. For a single 100 watt module I’d use 10 gauge up to 40 feet, 8 AWG above that. The Zamp conductors needs to be counted as part of that distance so it’s probably better just not to use them if you want to run very long.
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Post Options Post Options   Quote StephenH Quote  Post ReplyReply Direct Link To This Post Posted: 28 Feb 2020 at 8:21pm
Thanks for the advice. Do you use the Zamp connector? If so, did you have to use a gender reverser? I got a cable to convert from MC4 to the SAE connectors if I decide to use the Zamp connector. It also came with a gender reverser. It looks like I will need to get an extension cable also. I don't plan on using the alligator clips so I might change them out for something I can connect into the wiring harness at the front of the RPod since the battery cables are heavier gauge than the Zamp wiring.
StephenH
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ouR escaPOD mods
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Post Options Post Options   Quote Pod People Quote  Post ReplyReply Direct Link To This Post Posted: 28 Feb 2020 at 4:51pm
you will love this system and wonder why you didn't do it sooner! We have used a Renogy system for 3 years and it keeps our 2 6v Gc batteries charged. It is simple and effective.
We set up the angle  at night before we go to bed. It will start getting direct sun before you even get up in the morning. then adjust the angle before you leave for the days activity and readjust when you get back.  Occasionally, We had to add  blocks under the arms to get the angle we wanted.
good luck
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Post Options Post Options   Quote StephenH Quote  Post ReplyReply Direct Link To This Post Posted: 28 Feb 2020 at 10:14am
Latest mod: I've gone solar. I purchased a Renogy Eclipse 100W 12V Folding Solar Panel Suitcase RV Off Grid Battery Charger. It arrived today. It has a case for protection while traveling. It did not have much padding so I added some of the thin foam sheets that protected my LiFePO4 battery while it was in shipment. I haven't tried it yet, so I will post more once I have the opportunity to test it.

Edit: I realized that the alligator clips with fuse that was supposed to be included in the order are missing. I have sent a message to Renogy so that this oversight can be remedied. In the meantime, this puts a kink in my plans to test this panel.
Edit: I contacted Renogy and the missing cable with fuse and alligator clips will be sent and should be here in about a week.
Edit: I feel stupid! The black bag containing the alligator clips fell behind another black bag so I could not see it when I looked for it. I had to move the one bag, and there is was! The ones Renogy sent are on the way back.
StephenH
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ouR escaPOD mods
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