Added 235w Solar Panel to H33

[sea_casper]

Deciding to go Solar, I observed that the best buys in Solar Panels per watt are those in the 200-250w range, since they are the produced in the highest volume mainly for the housing market. Unfortunately they have high shipping cost due to their size. (68"x38") especially if you buy only one.

I decided that I did not want to mount the panel over the dinghy davits but wanted to mount it over the bimini, aft of the bimini window used for viewing the mainsail tell-tales, the Hunter 33 arch provides two convenient places to mount a deck hinge. Using 5 foot lengths of 1' SS tube and standard tubing fittings I was able to construct a mounting frame and only having to cut two pieces of tubing. Using 5 ft lengths saved money over the 6 ft lengths commonly sold.

I could have mounted the U-Bolts directly to the Solar Panel Frame, but it would have been awkward tightening the bolts from underneath the panel. Instead I decided to bolt two aluminum angle bars to the sides of the Panel Frame and flush with the bottom, This allowed for easy acess for tightning the U-Bolts from above. The Solar Panel can be easily removed, by removing the 4 U-Bolts, and disconnecting the wires. Likewise removing 4 screws allows for removal of the support frame.

I used 10/2 AWG Marine Duplex wire to connect from the TYCO Connector pigtails (extended 2 feet, Oops!) I ran the wire into the arch and down to an aft cabin starboard access panel and then forward to the MPPT controller mounted just above the AC & DC Panels. From the MPPT I used 6/2 AWG Marine Duplex to the DC Ground Buss and the battery selector switch. The Positive out, first goes to a 25a fuse in a Marine Grade Electrical Inline Fuse Holder (ATC, 12-Gauge).

I finished the project just in time for a one week cruise, where it performed up to expectations, bringing the batteries up to 100% everyday. The biggest
continuous draw on my boat is the fridge at 3.9a, and due to the unusual hot weather seemed to be always on. The next biggest draw on the cruise was our thermo-electric "beverage" cooler at 5a, that we only ran during the day. Since we got back I have not run the battery charger and have relied on the solar to keep the battery up, the fridge is of course still on. I have not done a total check on power output but did see 160watts to the batteries at 2PM one day. The controller will limit output power to 200w, but with a non-tilting panel I doubt I will ever be controller limited. I also plan on running Morningstar's datalogging software "MSView" on my laptop, as soon as I get an adapter.

As you can see from the side view photo there is a slight tilt forward to the panel, I plan to put blocks under the deck hinges on the arch to elevate the front of the support frame enough to get a slight tilt aft.


Cost of SS Support Frame was $279
Cost of 235w Solar Panel & Shipping $268
Cost of MPPT Controller $199
Cost of Wire $37

Total Cost $783 or $3.33/watt

Solar Panel
1 x MX Solar 235W 24V Solar Panel MX60-235 = $165.00
Federal Express (40lbs) (Home Delivery (5 days)): $103.38
Total: $268.38

Morningstar Sunsaver MPPT 12/24V 15A Charge Controller ( 140803890002 )
Total $199.99

Solar Panel to MPPT Controller Wire
Genuinedealz.com Item #13345644
10/2 AWG Marine Duplex - Flat Blk/Red 25 FT (Oops needed 27 ft!)
Price: $26.45

MPPT Controller to Battery Switch Wire
Genuinedealz.com Item #13353494
6/2 AWG Marine Duplex - Flat Red/Yel PER FT
Price: $2.80
Quantity: 5.00
Total: $10.40

Stainless Fittings
QTY.ITEM NO. PRODUCT PRICE EXT. $
2 88287 Stainless Rail Fitting - 90 Universal T | 1" - each $7.15 $14.30
2 88320 Straight deck hinge | With a Panhead Bolt - each $3.35 $ 6.70
2 88366 Split Rail Fittings | 1" rail - each $9.25 $18.50
4 88397 Stainless Outside Eye End | 1" - each $4.45 $17.80
Subtotal: $57.30
Handling & Insurance: $2.00
Shipping: $12.77
TOTAL: $72.07

2 Stainless 1" 90 Elbow $12.25 each Total $24.50

Stainless Tubing
5 pieces @ $23.52/piece=$117.60
Stainless T-316/316L
Welded Tube
1" x 0.035" x 0.93"
Cut to: 60"
Shipping Cost: $20.34
Cut Fee: $0.00
Total: $137.94

4 SS U-bolts @$5 ea =$20

2 Aluminum 1"x1/8"x72"angle stock@$12 ea = $24

 

[Bob 04 H260]

sea casper, very nice job ! the arch makes it so much easier, we are looking at doing the same thing on our boat so I really appreciate all the details and in particular the great photographs, it all looks very well thought out and a nice install........

I have used the s/s tubes and fittings myself in the past and when the set screw gets tightened down too much the tube starts to collapse, so the force is limited. I once put a piece of 7/8" tubing inside a 1" tube to allow more force to used with the set screws. I am wondering if there is any concern in this application if the tube could be pulled out the fitting by a gust of wind ?

I was also thinking about drilling a hole for the set screw to go right through the sidewall of the tubing to lock the fittings and tubing all together.

Bob

 

[sea_casper]

sea casper, very nice job ! the arch makes it so much easier, we are looking at doing the same thing on our boat so I really appreciate all the details and in particular the great photographs, it all looks very well thought out and a nice install........

I have used the s/s tubes and fittings myself in the past and when the set screw gets tightened down too much the tube starts to collapse, so the force is limited. I once put a piece of 7/8" tubing inside a 1" tube to allow more force to used with the set screws. I am wondering if there is any concern in this application if the tube could be pulled out the fitting by a gust of wind ?

I was also thinking about drilling a hole for the set screw to go right through the sidewall of the tubing to lock the fittings and tubing all together.
Bob

Thanks for the kind words, my biminies and dodger both use setscrews and I have never had a fitting pull out. drilling seems ok but complicates any reassembly.
I never really tighten down on setscrews, I suppose one could use thicker wall tubing to prevent collapse, or wood plugs. Interesting question, I wonder if anyone has any data on pull force necessary?

 

[Bob 04 H260]

Yes I see your point. I think with a bimini or dodger the Sunbrella and straps usually push the tube and the fitting together. My concern for me is this may not be the case with my solar panel frame.

I think in your case with the two vertical posts you have at the stern the horizontal tubes can not pull back out of the fitting on the arch.

If the wind gets under the panel could it lift it straight up off the two stern supports ? I guess with your panel close to the bimini it would be difficult to get much lift under the panel in a gust ?

I was also glad to hear the panel size you used was able to keep the batteries charged. We seem to be using about 90 to 110 Ahrs per day in Florida in winter. We have a AB air cooled fridge/freezer, LED lights, laptop. We don't usually run the TV etc. off the inverter. Our anchor light is not LED, that might be upgraded at some point.

Bob

 

[seadaddler]

Same

I did lthe same install using the arch with stainless tubing but my bimini goes maybe about a foot further back and my bimini has vertical support arms and so just used them to support the rear of the panels with a frame like you did,I used 2-190 panels that go length wise from the arch to rear stern and so used aluminum angle to support the panels from the tubing.
If you live in Florida I and many in Punta Gorda got panels in Miami driving to pickup saved shipping.
I am up in NY and have many photo's on a extra hard drive but maybe look here in search that I had posted.
But very nice job for sure.
Nick

 

[Mike B1026]

Nice job. The only minor thing I might have done differently, would have ordered some anodized aluminum angle stock. We buy ours from a company in NY. You are right, that freight is a killer. Too bad you didn't know someone else locally that you could have split a larger shipment with.

 

[sea_casper]

Nice job. The only minor thing I might have done differently, would have ordered some anodized aluminum angle stock. We buy ours from a company in NY. You are right, that freight is a killer. Too bad you didn't know someone else locally that you could have split a larger shipment with.

I wish I did get anodized, but it was a last minute thing, I will probably repace the raw aluminum if it shows signs of deterioration, but since I probably will remove it during winter storage it probably will be OK for a while.

 

[NotCook]

I'd like to learn more about the wiring. I saw that you went to the battery selector switch. So, you're getting to the batter through the battery selector switch instead of directly to the battery? I'm still planning the installation of my panel, so this is definitely a subject of interest. What happens if you turn off your batteries? Does the controller manage the load/shut down the panel?

Nice installation!

 

[sea_casper]

I'd like to learn more about the wiring. I saw that you went to the battery selector switch. So, you're getting to the batter through the battery selector switch instead of directly to the battery? I'm still planning the installation of my panel, so this is definitely a subject of interest. What happens if you turn off your batteries? Does the controller manage the load/shut down the panel?

Nice installation!

Yes the panel goes to an Open voltage mode, however although I wired to the battery selector switch, the controller is always connected to a battery, unless I pull the fuse at the MPPT Controller output. I wired to the selector switch because it is closer than the batteries.

 

[sea_casper]

I received my Morningstar Serial Communication Adapter today and downloaded the log file from the MPPT controller. The first 5 days reflect a cruise in which we ran extra electrical loads, GPS, Instruments, Tablet, MIFI, Thermo-electric cooler, LED lights, etc. During the days we did some motoring due to lack of wind. Since the cruise the only constant load is our built in Fridge.
Because the last 2 weeks we have had constant visitors, the boat has seen light use and has been on the dock. I have not plugged in the Dockside power, and have relied entirely on the solar panel to recharge the batteries each day. The fridge has been the only night time load.
According to the battery monitor, the batteries have been getting to 100% almost every day, and we have had some cloudy days.

Here is a .jpg of relative info from the.csv log file.