I helped my son install a solar system for his 5er. It’s was originally intended as small solar system to maintain the batteries while in storage. Due to the availability of 2 used panels it grew and will help with dry dock camping. Here are the details.
Two Kyocera KC80 used panels are mounted on the front of the fiver (160W total). The wires run from the right panel to the left panel and then down to the controller.
Click For Full-Size Image.
Click For Full-Size Image.
The angle brackets were chosen so that the panels could be easily removed. 2 3” pieces are secured with stainless bolts. The foot is secured with 3M VHB tape and 3 stainless #10 1” screws. Perhaps overkill but we wanted to make sure they didn’t move with their location on the front downward slope of the front of the 5er. Panels could be raised but there is no plan to raise them.
Click For Full-Size Image.
The wiring from the panels runs down inside a closet to a storage area in the front and then forward to the controller. The wire is 10ga-2 UV resistant wire. 10’ of wire between the two panels (3’ extra on each panel to allow for cleaning under the panels). From the controller to the battery is an additional section of the wire. 30’ total wire length (60’ total two way) and 2.5% voltage drop from the panels to the battery. The controller is mounted near the battery and contains a temperature sensor so that a battery mounted temperature sensor is not needed. The controller does not have a battery voltage sense capability and one isn't needed do to the short wire length to the batteries.
Click For Full-Size Image.
There is a single fuse on the positive side of the battery terminal. The battery wiring by the mfg is deplorable with the 2 12V batteries located 7’ apart – a project for another day. We installed lightweight wire from the battery to the entertainment center where it’s connected to a $3 digital voltmeter from HF and provides a very convenient way to view the battery voltage.
Panel specs: 80W, Voc 21.5, Vmp 16.9, Imp 4.73 Isc 4.97, 40”x26”, 4x9 cells with bypass diodes consisting of 2 sets of 3 parallel diodes – ie each set bypasses 1/2 of the panel cells.
Performance: 9am, good sun, 8.4A charging.
Update on mounting: Using VHB tape besides adding to the bonding made the installation very easy. Drill the hole connecting the two pieces slightly larger, do not snug the bolts, place the tape on each foot with the bottom side covered and position the panel on the roof. When in place lift one foot at a time and remove the bottom tape cover. The screws then help to secure the feet. With the panel now in place tighten the bolts and calk. We used SS bolt and self locking SS nuts with the plastic insert. Purchased from HD.
Costs:
2 Kyocera KC 80 panels (160W) used $180
Morningstar SS 10L 12V PMW controller, 10A $57
30’ 10ga-2 solar cable $51
S&H for the above 2 items $12
Angle brackets, stainless hardware and Misc $55
Remote digital voltage monitor $3
Total $358
Note: The above is a repeat of the original post 2012 which is now closed and now has non viewable photobucket photos. There was a concern raised about the aerodynamics of the front mounted panels and how the panels were mounted. No issues after 5 years. Here is the original thread. Click
Two Kyocera KC80 used panels are mounted on the front of the fiver (160W total). The wires run from the right panel to the left panel and then down to the controller.
The angle brackets were chosen so that the panels could be easily removed. 2 3” pieces are secured with stainless bolts. The foot is secured with 3M VHB tape and 3 stainless #10 1” screws. Perhaps overkill but we wanted to make sure they didn’t move with their location on the front downward slope of the front of the 5er. Panels could be raised but there is no plan to raise them.
The wiring from the panels runs down inside a closet to a storage area in the front and then forward to the controller. The wire is 10ga-2 UV resistant wire. 10’ of wire between the two panels (3’ extra on each panel to allow for cleaning under the panels). From the controller to the battery is an additional section of the wire. 30’ total wire length (60’ total two way) and 2.5% voltage drop from the panels to the battery. The controller is mounted near the battery and contains a temperature sensor so that a battery mounted temperature sensor is not needed. The controller does not have a battery voltage sense capability and one isn't needed do to the short wire length to the batteries.
There is a single fuse on the positive side of the battery terminal. The battery wiring by the mfg is deplorable with the 2 12V batteries located 7’ apart – a project for another day. We installed lightweight wire from the battery to the entertainment center where it’s connected to a $3 digital voltmeter from HF and provides a very convenient way to view the battery voltage.
Panel specs: 80W, Voc 21.5, Vmp 16.9, Imp 4.73 Isc 4.97, 40”x26”, 4x9 cells with bypass diodes consisting of 2 sets of 3 parallel diodes – ie each set bypasses 1/2 of the panel cells.
Performance: 9am, good sun, 8.4A charging.
Update on mounting: Using VHB tape besides adding to the bonding made the installation very easy. Drill the hole connecting the two pieces slightly larger, do not snug the bolts, place the tape on each foot with the bottom side covered and position the panel on the roof. When in place lift one foot at a time and remove the bottom tape cover. The screws then help to secure the feet. With the panel now in place tighten the bolts and calk. We used SS bolt and self locking SS nuts with the plastic insert. Purchased from HD.
Costs:
2 Kyocera KC 80 panels (160W) used $180
Morningstar SS 10L 12V PMW controller, 10A $57
30’ 10ga-2 solar cable $51
S&H for the above 2 items $12
Angle brackets, stainless hardware and Misc $55
Remote digital voltage monitor $3
Total $358
Note: The above is a repeat of the original post 2012 which is now closed and now has non viewable photobucket photos. There was a concern raised about the aerodynamics of the front mounted panels and how the panels were mounted. No issues after 5 years. Here is the original thread. Click
