Directions

Solar Station
Step-by-step construction plans
By Ben Peterson
Solar power made:
- Plug-in ready
- Multi-use
- Simple
- Easy
- DIY
600 watt off grid
Bonus:
2000 watt
Grid Tie Panel
Configuration
2000 watt grid tie
SolarStation.com
Why Solar Station?
We humans have a rapidly growing global population reaching for electrical devices
to power and inform our lives. It’s an almost unquenchable thirst as the world marches
toward full industrialization.
Renewables are slowly gaining market share, but unfortunately it’s not enough to meet
new demands in 99% of the world. So we make up the difference in fracked gas, coal
fired power, tar sands and all sorts of ugly energy from ugly places, creating a trail of
ugly politics all over the globe.
Solar power is one of the leading solutions as we shift our power sources to the 21st
century. It’s clean, quiet, renewable and it’s from free sunshine! But virtually every solar
power installation is custom, greatly slowing down the process. Did you know that?
To get solar to scale faster, it needs a Model T, a simple mass manufacturable power station that comes complete with battery and inverters so it’s plug in ready. Off an assembly line like a car or simple enough for the weekend warrior to build.
With that vision in mind we developed Solar Station. Several designs for a simple solar
power station were built during the summer of 2015 and these plans are the result of that
endeavor.
Now you can build a high quality power generating station for your home or recreational
activities fueled with cheap sunshine. Point it at the sun and plug into fun.
Copyright 2015 Ben Peterson, Reinvent The World, LLC
Dedications
This book and the mission of Solar Station would not be possible without the generous
support of our family, friends & funders. Thank you!
David & Karen Peterson
Emily & Steve Rayson
Issac Swearengin
Phillip Hollocher
Leon Crowe
John M Newhart
Angel
Paul Pittman
Frank Terhaar-Yonkers
D Chandler
Ryan A Brush
Dana Waletzki
And the dozens of other contributors to this campaign
Power
Storage
Camping bunk
Playhouse
Shed
Small office
Preparedness
Internet node
Bus stop
Bike charging
Let’s begin construction of your
v. 2 Solar Station Lander!
Tools:
Safety glasses
Ear plugs
Dust mask
Leather gloves
Skill saw
Pencil
T-square
Tape measure
Saw horses
Hand saw
Speed square
Drill
#2 phillips screw tip
Chuck key
Sliding clamps
Hammer
Ratchet wrench
3/8” & 7/16” sockets
Angle finder
4-1/8” hole saw
2” hole saw
1-3/8” hole saw
3/8” drill bit
3/16” drill bit
1” drill bit
Compass
Tall ladder
Step stool
Heavy duty stapler
T-50 staples 1/4” tall
Razor knife
4.5” grinder
Metal cut off discs
Caulking gun
Tin snips
Volt meter
Battery charger- “Speedy
charge” or similar
Wire strippers
Wire crimpers
Vise grips
Budget:
We spent approximately $3500 in materials for the
Solar Station with batteries making 600 watts.
The grid tied 2000 watt version cost about $4800
with inverters and panels, but no batteries. Electrician setup not included in price.
30% solar rebate off of these prices is available
through 2016.
Skid platform:
Directions
1) Cut 8’ long timber in half to make
two 4’ long boards.
1
2) Cut plywood sheet to length.
3) Screw attach the 4’ boards flush
with each end of the plywood sheet.
6” spacing.
2
3
Cut list
48”
4”x 6” timbers
48”
Materials
77.25”
Quantity 1) 4” x 6” timber, 8’ long.
Pressure treated or cedar.
Cut in half.
Quantity 1) 8’ x 4’ plywood sheet.
25/32” thickness. Cut to length.
Quantity 1 box) Exterior screws. 2.5”
long.
48”
Directions
1) Cut four 8’ long timbers down to length.
2) Attach them to the skid and screw them in flush with the edge of the plywood.
1
Materials
Quantity 4) 4” x 4” timber,
8’ long. Fir or cedar.
2
Cut list
70.25”
70.25”
70.25”
70.25”
It’s easiest to build this on
sawhorses so you can get
underneath to screw it
together.
3
77.25”
Diagram- skid
11” gap
At this stage, your skid frame
should look like the drawing and
photo.
The gap under the side of the
skid is for forklift forks or hand
grabs.
48”
12” gap
11” gap
In the next step we will add corner braces to make it more rigid.
Top view
6.75”
Side view
Front view
1
7
2
8
3
9
4
10
5
11
6
12
Directions
Attach angle brackets to the inside corners of the skid as pictured using lag
bolts.
This will make the skid rigid enough to
be moved later.
Materials
Quantity 12) Angle
brackets. 1.5” x 1.5” x 3.5”
Buy premade or cut from
angle stock and drill
holes.
Quantity 24) 1/4” x 2” lag
bolts or gnarly screws.
Orientation
Bring your skid onto the
ground and use a compass to
create the alignment pictured.
North
East
West
South
Leveling
Place the skid on level concrete or a
pressure treated wood riser to keep it
from sinking in the mud. (maybe these
are just Seattle problems:)
West wall:
Directions
1) Cut plywood sheet to shape.
2) Cut 4x4’s, 2x4’s and 2x3’s to
length.
3) Clamp and screw on the perimeter boards working your way in.
6” screw spacing.
Materials
Quantity 1) 23/32” plywood
sheet 4’x 8’.
Cut list
Quantity 2) 4” x 4” timber, 8’
long. Fir or cedar.
Quantity 1) 2” x 4”, 8’ long.
Quantity 3.5) 2”x 3” , 8’ long.
48 deg.
95-13/16”
54-1/2”
Quantity 1 box) Exterior
screws. 2.5” long.
84-5/8”
Interior Boards
53-11/16”
53-3/16”
38-1/4”
48”
Perimeter Boards
#1
#2
#3
4x4
4x4
89-3/4”
51-3/8”
48 deg.
48 deg.
2x4
48 deg.
#4
64-13/16”
48 deg.
2x3
#5
2x3
#6
2x3
#7
2x3
1
2
3
Diagram
West wall assembly
#3
#6
Once all the boards are assembled,
the wall is ready to tip up and attach
to the skid. The timbers sit on top of
the skid surface while the plywood
hangs over the side.
48 degrees was chosen as an angle
to accomodate northern climates
and winter time solar orientation.
#1
#5
#4
#2
The angle of the solar panels can
be changed (if needed) by hinging
the top attachment rail to lessen the
angle for optimal solar gain.
#7
Screw locations
4”
East wall:
Directions
1) Cut plywood sheet to shape.
2) Cut 4x4’s, 2x4’s and 2x3’s to
length.
3) Clamp and screw on the perimeter boards working your way in.
6” screw spacing.
4) Use 4 1/8” hole saw to drill a
hole for our battery vent. (installed
in a later step)
Materials
Quantity 1) 23/32” plywood
sheet 4’x 8’.
Cut list
Quantity 2) 4” x 4” timber, 8’
long. Fir or cedar.
Quantity 1) 2” x 4”, 8’ long.
48 deg.
Quantity 3.5) 2”x 3” , 8’ long.
Quantity 1) Box exterior
screws. 2” long.
95-13/16”
54-1/2”
58-1/2”
4-1/8”
Interior Boards
53-11/16”
53-3/16”
14-3/4”
48”
7-1/2”
28-7/16”
22-1/8”
Perimeter Boards
#1
#2
#3
4x4
4x4
89-3/4”
51-3/8”
12-1/4”
48 deg.
48 deg.
2x4
48 deg.
64-13/16”
48 deg.
2x3
2x3
2x3
2x3
2x3
2x3
#4
#5
#6
#7
#8
#9
Diagram
#4
#3
East wall assembly
#6
Once all the boards are assembled,
the wall is ready to tip up and attach
to the skid. The timbers sit on top of
the skid surface while the plywood
hangs over the side.
#1
#5
#2
#9
#8
#7
4”
Screw locations
East/ West wall raising:
2
1
Directions
1) Lay each wall on the ground
ready to tilt into place.
2) Tilt the East wall into place and
screw into the skid. Get help if you
need it.
3) Tilt the West wall into place and
screw into the skid. Get help if you
need it.
3
Materials
Quantity 1) Box exterior
screws. 2.5” long.
South wall:
Directions
1) Cut plywood to shape.
2) Cut timbers to length.
3) Drill holes to accomodate wires.
(future step)
Materials
Quantity 2) 4” x 4” timbers.
Quantity 2) 2” x 4” boards.
Quantity 1) Box 3” long exterior screws.
Quantity 1) 23/32” plywood
sheet.
Quantity 8) Angle brackets
Cut list
33-7/16”
#1 2x4
33-7/16”
48 deg. bevel
48”
#2 2x4
30-3/4”
6-1/2”
70-3/16”
2” holes
#3 2x4
15” 12” 8”
21-1/2”
46”
1-3/8” hole
59”
40”
12” 10”
8”
70-3/16”
#4 4x4
48”
42-7/16”
1” holes
#5 4x4
Plywood
5-1/2”
78-3/4”
8”
Directions
1
1) Screw 2x4’s #1 & #2 into the skid,
leaving a gap in the center.
2) Place the #5 4x4 center post with
holes toward the top facing east/west.
Use angle brackets to secure.
2
3) Attach the #4 4x4 horizontally with
holes facing vertically, toward the east.
Use angle brackets to secure.
3
1
2
Directions
1) Place board #3 as pictured with the
holes positioned toward the east.
2) Secure with angle brackets.
1
2
Directions
1) Mount the large plywood sheet as
shown. 6” screw spacing.
2) Mount the beveled plywood strips
next. Sand to match (if needed)
Diagram
Angle
brackets
Angle
brackets
North wall:
Directions
1) Cut plywood to shape.
2) Cut timbers to length.
3) Drill holes.
Materials
Quantity 1) 4” x 4” timbers.
Quantity 3) 2” x 4” boards.
Quantity 1) Box 3” long exterior screws.
Quantity 2) 23/32” plywood
sheet.
38-7/16”
4-3/16”
Quantity 6) Angle brackets
8-1/8”
96”
Cut list
3”
1-1/2”
6-1/2”
90”
2x4
48 deg. bevel
QTY 2
70-1/2”
2x4
48 deg.
bevel
36”
4”
4x4
36”
Plywood
36”
4”
12-1/4”
Plywood
4-1/8”
96”
1
2
Directions
1) Use two 90” 2x4’s screwed together to make
the center post. Raise the center post leaving
36” to the right for the door.
2) Mount angle brackets on the 4x4 timber at
the ends.
3) Place the 4x4 horizontally leaving 80” below
for the door to fit into.
3
1
2
3
Directions
1) Mount angle brackets on each
side as shown in step 1.
2) Place the beveled 2x4 peak. Attach to brackets. Screw into center
post.
3) Clamp on the plywood skin.
1
2
3
Directions
1) Screw the plywood skin
into place.
2) Attach plywood trim below the door, flush with the
floor.
3) Attach plywood skin
above and to the right of the
door opening.
Diagram
Angle
brackets
36”
80”
Roof:
Directions
1) Cut plywood to shape.
2) Cut timbers to length.
3) Drill holes.
Materials
Quantity 1) 2” x 4” board.
Quantity 2) 23/32” plywood
sheet.
Quantity 1) Flat brackets
Quantity 1) Box 1-1/2” screws
Cut list
41-3/4”
56-3/4”
Plywood
37”
26-3/4”
26-3/4”
7-1/8”
16-1/8”
20”
65-3/8”
65-3/8”
West
2x4
48 deg. bevel
East
48 deg. bevel
1
Directions
1) Mount the center support post
at the peak. Use 3” long screws.
2) Attach the bottom end of the
board using a flat bracket and
1-1/2” screws.
2
Directions
3) Get your plywood sheets layed
out and ready. You are going to
want some help for the next steps.
4) Clamp and screw the East sheet
into place.
5) Clamp and screw the West sheet
into place.
4
3
5
Tar paper:
Directions
1) Apply tar paper working from
the bottom up using a stapler.
Overlap the top layer by a few
inches to prevent water from leaking through a seam.
Materials
Quantity 1) 4 sq. roll of 15
pound felt. 36” wide. 400
square feet total.
Siding South wall:
Directions
1) Cut sheet metal to length.
Materials
Quantity 3) 2’ x 8’ corrugated
metal siding.
Quantity 1) Box of exterior self
tapping sheet metal screws.
Quantity 3) 1” pipe floor flange
Quantity 2) 1” x 4” pipe nipple.
Quantity 1) Tube of exterior
sealant.
Cut list
26-1/2”
26-1/2”
54-1/2”
26-1/2”
54-1/2”
Corrugated sheet metal
1
Directions
1) Start the first sheet 1-3/4” in
from the east side of the south wall.
This way 3 sheets will cover the
wall with no filler pieces.
2) Attach the sheet with exterior
sheet metal screws.
2
3) Your South wall should look like
the photo below. Now go inside the
shed and drill through the sheet
metal with the same hole saw bit
that you used before.
3
Directions
1) Cut the pipe nipple in half.
2) Screw into flange as pictured.
3) Insert into south wall and secure with
screws.
4) Seal from the outside with caulking.
1
2
3
4
This port in the South wall
is where you are going to
run your solar panel wires
through.
Siding East wall:
Directions
1) Cut sheet metal to length.
2) Cut T&G boards to shape.
3) Drill battery vent hole.
Materials
Quantity 1) 2’ x 8’ corrugated
metal siding.
Quantity 5) 5” x 8’ T&G siding.
Quantity 1) 4” dryer vent.
Quantity 1) 2” x 3” galvanized
corner trim.
Cut list
Quantity 1) Quart exterior sealant.
Quantity 1) Box of 1.5” exterior
screws.
Quantity 1) Box of 1” exterior
screws.
96-3/4”
75-3/4”
75-3/4”
54-1/2”
4-1/8”
hole
Corrugated
sheet metal
8-11/16”
14-13/16”
24-3/4”
25-5/8”
1
2
Directions
1) Seal the boards with spar urathane.
2) Apply boards starting at the northeast corner.
3) Screw on the sheet metal siding.
3
1
2
Directions
3
1) Dab some caulking on the dryer vent flap.
2) Fold it open and tape until dry.
3) Apply caulking around the flat surface.
4) Screw the vent into place.
5) Add corner trim with the 3” sides on the North/
South.
4
5
Siding West wall:
Directions
1) Cut sheet metal to length.
2) Cut T&G boards to shape.
Materials
Quantity 1) 2’ x 8’ corrugated
metal siding.
Quantity 5) 5” x 8’ T&G siding.
Quantity 1) 2” x 3” galvanized
corner trim.
Optional- Solar Security light
Cut list
Corrugated
sheet metal
75-3/4”
96-3/4”
75-3/4”
54-1/2”
25-5/8”
24-3/4”
1
Directions
1 & 2) Apply siding and trim like
you did in on the East wall.
3) Optional solar light- Sunforce
82156 60 LED Solar Motion Light.
Available at Amazon.
2
3
North wall:
Directions
1) Cut wood siding to length.
Materials
Quantity 9) 5” x 10’ T&G boards.
Quantity 1) Box of 1” exterior
screws.
Quantity 1) 4” dryer vent.
Quantity 1) 36” x 80” storm
door.
Quantity 3) 2” x 3” galv. trim.
Optional- 12 volt led exterior
light.
Cut list
7-1/2”
5”
10”
12-3/4”
T&G
36-1/8”
96-7/8”
96-7/8”
36-1/8”
4”
Galv
Trim
39”
T&G
T&G
T&G
Galv
Trim
1
2
Directions
1) Begin applying wood from East to West.
Add trim and dryer vent like you did in
the previous steps.
2) Continue working to the right.
3) Trim around the doorway.
3
1
Directions
1) This is what the exterior siding
should look like at this step. Be sure to
seal the boards before proceeding.
2) Add galvanized trim along the
doors bottom edge.
3) Optional exterior LED light.
4) Get your 36” x 80” storm door
unpacked.
2
3
4
1
Directions
1) Install the door as pictured. Make
sure to keep it square.
2) Apply exterior caulking at the top
edge.
3) Recommended: Finish trimmimg the
doorway with T&G.
4) Attach the gas shock mechanism.
2
3
4
Roofing:
Directions
1) Cut sheet metal and trim to
length.
Materials
Quantity 3) 2’ x 8’ corrugated
metal siding.
Quantity 1) 1” x 3” galvanized
flashing.
Quantity 2) 2” x 3” galvanized
corner trim.
Quantity 1) 4” x 4” galvanized
crown trim. Installed in a later
step.
80”
Quantity 1) 2” x 2” alum. angle.
2x2
83”
Cut list
4x4
Corrugated
sheet metal
Corrugated
sheet metal
Corrugated
sheet metal
67-3/4”
66”
26-1/2”
67-3/4”
66”
26-1/2”
2x3
26-1/2”
1x3
79-3/4”
2x3
1
Directions
1) Install lower flashing.
2) Install side flashing. Trim as
needed.
3) Install roof sheeting.
2
Note: Start roofing 2-3/8” from the
right edge of the East wall if you
want to only use 3 roofing sheets.
3
1
Directions
1) Drill hole through the roofing for wires and install pipe and
flange like you did for the South
wall. Seal with caulking.
2) Add 4x4 galvanized crown cap
and 2x2 aluminum angle drip rail.
2
Use tin snips to notch the ends and
fold the extra metal tabs over for a
clean look.
3
Optional- Add gutter for rain
water collection.
This is what the Solar Station looks like now
that we are ready for some solar panels!
Solar panels- bottom set:
Directions
1) Cut angle stock and flat bar to
length.
Materials
Quantity 3) Grape Solar GSSTAR-100W 12 volt panels.
(Browse internet for best current price)
Quantity 4) Heavy duty galvanized hinges. 1 is extra for hole
templates.
Quantity 17) 1/4” x 2” lag bolts.
Quantity 2) 1-1/2” x 1-1/2” x
1/8” aluminum angle stock.
Quantity 1) 1-1/2” aluminum
flat bar 1/4” thick.
Quantity 12) 1/4” x 1” bolt, nut,
lock washer. Stainless preferred.
Quantity 1) Box of heavy duty
self tapping screws.
79-1/8”
Angle
1-1/2”
79-1/8”
Angle
1-1/2”
24-3/4”
Cut list
Flat Bar
1-1/2”
24-3/4”
1-1/2”
Flat Bar
1
Directions
1) Place the 3 panels side by side
and screw angle to the tops and
bottoms with the angle leg toward
the bottom side of the panel as
pictured.
2) Place the hinges at the ends and
the center. Mark and drill holes,
then attach with bolts and nuts.
2
3
Directions
3) Center the solar panels on the
South wall and mark the hinge
location. Set the panels off to the
side and drill a 3/16” pilot hole for
the lag bolts to attach the hinges.
Get help to hold the panels in position while you tighten lags or set
the panels on a table as shown and
use wood to get the proper height,
then attach.
1
Directions
2
1) Lift the panels and prop them
up with wood to gain access to the
wires
2) Run wires through the holes. It
is optional if you want to put caulking in the holes to make it bug and
weather proof. (Suggested)
3
Directions
3) Fold out the panels and use
the flat bar to brace each end
to hold the desired angle. Lag
to the station and screw to the
panel perimeter.
Solar panels- upper set:
Directions
1) Cut angle to length.
2) Drill holes.
Materials
Quantity 3) Grape Solar GSSTAR-100W 12 volt panels.
Quantity 6) 1/4” x 2” lag bolts
and washers.
Quantity 2) 1-1/2” x 1-1/2” x
1/8” aluminum angle stock.
Cut list
79-1/8”
Angle
1-1/2”
38-1/2” hole spacing.
5/16” hole size
Angle
1-1/2”
79-1/8”
1
2
Directions
1) Assemble the panels together like you did in the previous
step. Install the lower edge on
the roof with lag bolts.
2) Prop up the top edge and
run the wires through the holes.
Seal with caulking from the
inside.
This is how your Solar
Station should look as we
switch to the inside for wiring, battery, inverter and
finishing.
Battery bank:
Directions
1) Cut angle and boards to length.
2) Screw angles to lid as shown in
cut list.
Materials
Quantity 6) UB 12750 AGM
Maintenance free batteries.
Quantity 5) Angle braces.
Cut list
Quantity 1) Slotted steel angle.
Quantity 1) 2” x 12”
Quantity 1) 25’ black 8 gauge
stranded copper wire.
2-1/2”
Lid
bottom 2”
view
2x12
11”
6” angle
Quantity 1) 25’ red 8 gauge
stranded copper wire.
32-3/4”
33”
Quantity 1) 10’ roll of 12 gauge
green wire.
Quantity 1) Box of 5/16” eyelets
for 8 gauge wire.
Alum angles
Quantity 1) Box of 5/16” eyelets
for 12 gauge wire.
Quantity 1) 1-1/4” x 1-1/4” x 8’
aluminum angle.
Quantity 1) 5/16” x 2” bolt, nut,
washers.
Quantity 1) 2x4 remnants. 36”
total.
12-1/8”
2”
Slotted
angle
12-1/8”
23”
Alum angle
13-1/2”
23”
QTY 2 ea.
Alum angle
34-1/4”
2 x 12 boards
QTY 2 ea.
Top view
(Actual size 1-1/2” x 11”)
Quantity 1) Battery anti-corrosion gel.
Optional clear coat for wood.
12-1/8”
2x4
11-3/4”
11-3/4”
2x4
2x4
https://www.batterystuff.com/batteries/upc-telecom/UB12750-45821.html
Specs:
https://www.batterystuff.com/files/45821.pdf
Schumacher SSC-1000A SpeedCharge 2/6/10 Amp Battery
Charger and Maintainer with
50-Amp Battery Clips
(Amazon)
1
Directions
1) Charge up each of your batteries using
a smart charger with automatic shut off and
staged charging for maximum efficiency.
2) Screw the aluminum
angles onto the the wall and
the long 2 x12 as pictured.
Then assemble the lower
level of the box with angle
brackets in the corners.
Drill a 3/8” hole through the
floor for your green ground
wire. Crimp on an eyelet,
then run a bolt through the
eyelet and the floor. Bolt
from below. Attach a ground
spike as needed.
3) Build the upper level of
the battery box.
2
3
1
Directions
1) Install the fully charged batteries on the
lower level, placing 2x4’s between for spacing and air flow.
2) Install aluminum angles with the legs
facing up to cradle the batteries on the top
level. Space about 7” or as needed for the
batteries.
2
Note: This configuration is compact for
space saving inside the station and it forms
a convection chimney to allow any gases or
heat to escape safely.
However it is not ideal for servicing wet
cell batteries. That is why we used maintenance free AGM batteries.
3
3) Cut red wire lengths to3 @ 48”
3 @ 37”
Cut black wire lengths to3 @ 48”
3 @ 37”
Crimp eyelets to the 8 gauge wires and attach
the red wires to positive, black wires to negative. Longest wires on the bottom.
Use anti-corrosion gel at each battery terminal. Place tape over any bare metal ends to
prevent arcing!!!!
1
Directions
1) Install the top rack of batteries.
2) Connect the wires. Attach the slotted angle to hold up the back side of
the lid.
2
3
3) Set the lid in place.
Leave 5/8” gap between
the East wall and the lid
for paneling.
The angles keep the lid
in position. There will be
a small amount of play.
Wiring:
Directions
1) Cut wires to length.
2) Cut wood panels to length.
Materials
Quantity 6) 20’ UL Solar Panel
Extension Cable Wire with MC4
PV - 12 AWG - 600VDC [Cut in
half]
(Amazon)
Quantity 6) Sunforce 7 amp
charge controller.
(Amazon)
Quantity 1) 50’ roll of 14 ga.
black stranded copper wire.
Quantity 1) 50’ roll of 14 ga. red
stranded copper wire.
Quantity 2) Plastic junction
boxes and covers.
Quantity 2) 5/16” x 2” bolts and
3 nuts.
Quantity1) Bag small zip ties.
Quantity 1) Bag coaxial cable
holders.
Quantity 2) MicroSolar - 2000W
pure sinewave inverter.
(Amazon)
Materials
Quantity 1) SMAKN® 2 Wire
Green Dc 4.0-30v LED Panel
Digital Display Voltage Meter
Voltmeter.
(Amazon)
Quantity 4) T&G wood 10’
Optional: GW21500 12 RV reading light. (Amazon)
Optional: 12 volt switch.
Wood panel cut list:
Approximate light location
64”
1-1/8” x 5/8”
1-7/8” x 1-1/8”
14”
1” x 5/8”
12”
34”
Wiring diagram:
(Holy Mole - That’s alot of wires!)
36” ext.
28” ext.
30” ext.
100” ext. 90” ext.
75” ext.
Charge controllers
Neg.
junction
Pos.
junction
120 volt
power out
Inverter
Batteries
Ground to
outside
1
Directions
1) Use a volt meter to test the output
of your panels. Voltage may vary depending on sunlight conditions, but
expect between 17-19 volts for a 12
volt panel on a typical day.
2
2) Drill 5/16” holes through the bottom of your junction boxes.
3) Trim your wires if needed and attach eyelets. Run your wires from the
battery box to one side of the junction box. Attach another wire to the
other side (of the junction box) that
will connect to your inverter.
3
1
2
Directions
1) Extend your solar panel wiring. Be
sure to keep your positive and negative wires properly labeled.
2) Mount the charge controllers on
the North interior wall. Connect to
the battery bank, then connect to the
panels.
1
Directions
1) Complete the wiring as shown in
the diagram. Make sure all connections are tight.
Add a voltage meter so you can
gauge the charge of the batteries.
2) Finish paneling the wall and then
mount the inverter and connect the
wires. Don’t forget the green ground
wire that goes from the inveter to the
floor bolt.
2
Interior wall- East:
Materials
Insulation
Quantity 8) T&G wood
paneling 8’
Quantity 1) 4’ x 8’
foam insulation, 1-1/2”
thick.
56-1/2”
49”
9-3/4”
22-3/8”
26-1/8”
Wall paneling
64-3/8”
52”
9-1/2”
22-1/2”
30-3/4”
1
Directions
2
1) Cut sheet to size.
2) Press snug into place.
3) Install T&G paneling.
3
Interior wall- West:
Materials
Insulation
Quantity 8) T&G wood
paneling 8’
Quantity 1) 4’ x 8’
foam insulation, 1-1/2”
thick.
78-3/4”
47-3/4”
36”
Wall paneling
86-1/2”
52”
40-1/4”
1
2
Directions
1) Cut sheet to size.
2) Press snug into place.
3) Install T&G paneling.
4) If you install a cot, then screw a
support stud into the wall on each
side.
3
Interior wall- South:
Materials
Quantity 8) T&G wood
paneling 10’
Quantity 1) 4’ x 8’
foam insulation, 1-1/2”
thick.
Quantity 1) roll of R-13
fiberglass insulation.
Directions
1) Cut the panels to size.
73-3/4”
51-1/2”
1
Directions
1) Cut the insulation and
layer in first.
Cut the panels to size and
press into the framing.
2) Cover with paneling.
2
Ceiling:
Materials
Quantity 1) T&G wood
paneling 8’
Quantity 2) 2’ x 8’ galvanized roofing.
Quantity 1) roll of R-13
fiberglass insulation.
Directions
1) Cut T&G to size
2) Cut roofing to size.
Roofing
26-3/4”
72-1/2”
Roofing
26-3/4”
72-1/2”
5”
T&G
72-1/2”
1
2
Directions
1) Install the T&G board
along the bottom edge.
2) Install the two sheets
on the ceiling.
Screw at the edges and
the middle.
Floor:
Materials
Quantity 1) Box bamboo flooring. 25 sq. ft.
Quantity 1) Aluminum
angle bullnose.
Optional: 6) Edge trim
moulding.
Directions
1) Cut flooring to fit.
2) Cut bullnose.
2
1
3
4
Directions
1-3) Install flooring with
staggered seams.
4-5) Attach aluminum
trim. Trim edges with
moulding strips as desired
5
Upgrading capacity
2000 watts grid connect
v. 3 pictured
Using the funds from our crowdfunding campaign we developed a larger Solar Station
called “Version 3.” It features 2000 watts of 24 volt power panels designed for residential
use.
Some of our funders wanted to tie into the electrical grid to save money on batteries while
installing a larger system like this one so we decided to show you how easy it is to configure your Solar Station for a 2000 watt array with 220 volt micro inverters for direct grid
feeding.
Most of this you can do DIY, but you will need an electrician to hook up to the power grid,
plus permits, plus a net metering agreement with your power company. Professional installers can handle these details for you most times.
The version 3 models used custom welded supports to be able to collapse the panels for
traveling, but upon real world testing it makes more sense in time and cost to just install
the panels on site in the same manner we did in the previous steps, using aluminum angle
stock. Upgraded in size and thickness here to carry the added weight of these
larger panels.
Materials
Quantity 4) 2” x 2” aluminum angle 1/4” thick.
Quantity 3) Heavy duty galvanized hinges
Quantity 1) Box of rugged self
tapping screws.
Quantity 8) Amerisolar 250
watt panels 64-5/8” x 39-1/8”.
Quantity 8) Enphase M250 micro inverter.
Aluminum angle
Panel
Panel
Panel
156-1/2”
Aluminum angle
156-1/2”
Aluminum angle
Directions
1) Cut angle to length.
156-1/2”
Aluminum angle
Panel
Quantity 1) Bag of 5/16” x 1”
bolts, nuts, washers
Panel
Panel
156-1/2”
Panel
Panel
The Enphase micro inverters
can be mounted to the under
side of each panel and the output wires run to a junction box.
This type of inverter will maximize the output of your system
on cloudy days or when shade
is present.
Solar power in: 24 vDC
Grid power out: 240 vAC
Let your electrician take it from here
Directions
Side view
3
1) Slide panesl up the roof until
you can pull the wires down the
North wall.
1
2) Then affix the panel to the roof
along the bottom edge.
3) Use angle brackets to secure
the top edge to the structure.
4) Attach lower panels to the structure with hinges.
65”
2
4
5) Secure the lower edge of
the panel bank.
Output wire:
97”
55”
Output wire
5
Set lower edge on raised timbers to set angle.
(simplest)
Or run support bars from the structure to the
angle iron. As shown below. (best for windy
areas)
Care & Maintenance
Keep solar panels clean of dust and leaves.
Keep it pointed South... duh.
The recommended AGM batteries are maintenance free. Hooray!
Keep the batteries topped up for long life. Use
heavy loads in short bursts.
Use battery terminal gel to prevent corrosion of
terminals.
Place tape over bare electrical leads when
servicing to avoid arcing!!!
And have fun :)
Camping out
If you want to use your Solar Station as a camping hut, then you can
build a small cot from plywood and hang it on braces screwed to
each wall. It just sets in place and its easy to remove if needed. See
photo below (lower center)
Since some variation will occur in a hand built Station,
measure and build to fit. It’s just a hair over 6’ so it can work for most
people. Find a nice cushion and cozy up high and dry.
Moving the Solar Station
It’s no accident that the Solar Station is the size it is. I wanted a solar power system you could take
with you when you move.
Using just some straps and a
ratchet winch I was able to pull
the station up on a 5’ x 9’ utility
trailer I rented from U-haul.
Keep the battery side toward the
front so the load will be balanced.
I layed a sheet of plywood down
so it would slide easier.
I would highly recommend wrapping foam around it to keep from
scratching anything.
Other books by Ben Peterson
Available at: www.WoodGasifierPlans.com
“Harness the stored sunlight in wood
to make free generator fuel”
Make BIG POWER Day or Night. Summer or Winter
The sun doesn’t always shine, so many off grid solar owners have a backup
generator. The problem is that they use expensive petroleum fuels. Screwing
up the world’s politics and the environment.
Did you know that there is a 150 year old technology that can make free biogas from wood? It’s a simple, small scale form of refining that is clean for the
environment and cheap for your wallet. If you have wood, this is a must read
step-by-step construction guide.
Turn wood into free gas. You have to see it to believe it!
Convert engines to run on biogas automatically
The Electronic Carburetor Workshop is the campanion
book to the Wood Gasifier Builder’s Bible. Modify generators to run on biogas with computer precision.
A step-by-step construction guide to hands free operation.
Available at: www.WoodGasifierPlans.com
Thank you for
your support :-)
[email protected]
www.SolarStation.com