Build Your Own Solar Panel.pdf

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copyright ©2000, 2006 Phillip Hurley
all rights reserved
illustrations and e-book design
copyright ©2000, 2006 Good Idea Creative Services
all rights reserved
ISBN-10: 0-9710125-2-0
ISBN-13: 978-0-9710125-2-3
Build Your Own Solar Panel
Wheelock Mountain Publications
i
is an imprint of
Good Idea Creative Services
Wheelock VT
USA
How to Use this E-Book
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Table of Contents
Notice of Rights ..............................
ii
How to Use this E-Book ..................
iii
Solar panel ratings ........................
18
Designer watts ..............................
19
Finding and choosing cells
for solar panels .......................
20
Tab and bus ribbon ........................
21
Panel frames .................................
23
Thermal resistance ........................
24
Moisture resistance .......................
25
UV resistance ...............................
26
Glass in solar panels .....................
26
Plexiglas in solar panels ................
27
Solar panel backing and sides .......
28
The benefits of long screws ...........
28
Planning the panel wiring – series
and parallel connections ..........
29
Voltage and distance to the battery ..
31
Panel arrays and connections ........
32
Panel size and shape ....................
32
Introduction
Solar cells
Solar cell basics ..............................
3
Amorphous cells ..............................
4
Flexible solar cells ...........................
6
Crystalline solar cells ......................
7
Monocrystalline and
polycrystalline cells ....................
8
New cells vs. old-style cells .............
9
Solar cell output ...........................
10
Watt rating of solar cells ................
11
Testing solar cells .........................
12
Match solar cell output ..................
12
Tools for testing solar cells ............
13
Using a calibrated cell ..................
15
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Solar Panels
Click on the chapter head or subheading page number
to go to the section or chapter
iv
Solar panel output for
different applications ................
17
Table of Contents continued
on the
next page
Table of Contents
Connecting solar cells
Choose and inspect the
cells carefully ..........................
33
Preparing the tab ribbon ................
34
Flux ..............................................
35
Soldering ......................................
36
Soldering tips ................................
37
Soldering technique .....................
37
Types of solder ..............................
39
Attach the tab ribbon to the cells ..
48
Pre-tabbed cells ............................
50
Make a layout template .................
50
Solder the cells together ..............
51
Prepare the panel structure ...........
54
Attach the screen .........................
55
Place the cells on the panel .........
55
Attach the tab ribbons
to the bus ribbons ...................
56
Insulate the bus connectors ..........
57
Junction box ..................................
57
Test the panel ..............................
58
Seal the panel ..............................
58
Materials and tools ........................
41
Figuring panel output ...................
42
Calculate the number of cells
you will need .........................
42
Plan the panel layout ....................
42
Over-all panel length .....................
44
Over-all panel width .....................
45
Bar stock length ...........................
46
Cut the tab ribbon ........................
46
Prepare the tab ribbon .................
47
Tinning ........................................
47
v
Crimp the tab ribbon ......................
48
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Building a solar panel
Click on the chapter head or subheading page number
to go to the section or chapter
A small solar panel array project
Solar II project specifications .........
60
Panel layout and dimensions .........
61
Panel construction
Panel backing ...............................
64
Cutting the Plexiglas .....................
68
Drilling the Plexiglas ......................
69
Table of Contents continued
on the
next page

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