Posted: 7/27/2014 8:35:47 AM EDT
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Hi Guys,
I know there are some smart solar types on here. I have a specific question regarding a DIY solar array w/ Bank I'm building. I have (8) 250W Sharp panels, Solar charge controller (Morningstar?), 12) 6V Golfcart Batts, 3500 KW Xantrex inverter. Pretty sure I got the setup covered as It charges and outputs. My question is how do I tie in a Generator backup to charge the bank? Either manual override, or preferably automatic (my Genset has a starter - Rigid/Generac 6000/8500) - Does someone make a controller for this application or do I need PLC type hardware for this. Thanks in advance for the help! Also does anyone have any GOOD references for other DIY solar projects (thinking tracker) - There is a LOT of crap on the 'net to dig thru... |
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Good questions...
Good choice for panels...  How long have you had them, the 250's haven't been out too long...
Here's what I'll be using [have used once] to charge 8 L16 batteries during solar insufficient/'heavy' juice-use periods... Little Kubota battery charger system There are lots of charge controllers with 110/220 inputs that automatically charge batteries when there is insufficient sun. Homeslice has one on his system IIRC. I have wanted to learn abt programming PLC's for a long time and have never done it. If you have that skill it should be easy to rig something up. Ebay has lots of them for great prices and maybe this winter, it's something to look into. I spent many hours trying to learn to program microprocessors/controllers and the only one I built so far related to solar was to automatically restart a Xantrex 1800 Sinewave inverter when the Outback charge controllers spike with an overvoltage near end of charge, when the charge output setting is set too close to 16 vdc. |
Here's the uproc mtd'd to the right of the Xantrex on a black plate from a bad inverter.
It could be programmed to measure battery voltage, and send a signal to an automatic generator starter like one of these... Generator controller |
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Thanks Expy,
Cool Project! - I've got a couple of the little MEP-002 3KW diesel surplus sets. I think I gave about $250 for them each about a year ago. Charged the batts and they fired right up :-) As far as the gen switch I would really prefer to buy something COTS if I can. With all the off-grid out there I would think there's something available but I'll be dammed if I can find anything. Spent about 2 hours on Google last nice looking (digging thru a lot of crap websites) too.. The closest thing I can find is an auto transfer switch for $$ but it senses AC voltage loss not a DC discharge set point. PLC isn't bad, but I'm VERY rusty (18+years since I've messed with them), But If you want to learn it Automation Direct has them for very reasonable prices and you can get the software and manual free via download form their website. |
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Look at the link above for controllers. They are pretty nice. and cheap...
I have a Dynagen, an older version of the ES52, that I picked up somewheres... Dynagen I've studied it but haven't hooked up. The hookup is similar between the mfgr's and you can use the Dynagen's web site for a User's manual... Fascinating to read the circuit hookup... The little Kubota, loafing, puts out abt 80 amps at ~12 vdc or 15vdc so that's abt 1000 watts. Your milsurp MEP genny sounds like a good [perfect?] choice. ETA- Your Xantrex may already have a 110/220 charger built into it. |
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Yeah, that's one of 'em!
Haven't run it any extended period to see what actual fuel consumption is. I've heard about 1.5 GPH at medium load, but haven't run it enough to confirm. Bought 'em cause of the price...! I'll check out the controller you have mentioned, and you may be right about the Xantrex, I'll have to look at the book. Any good links for a DIY tracker? Edit - Looks like the Dynagen would do the trick! - Thanks for the link. I'll post some pics of the project once I'm done! |
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Which Xantrex inverter? Some of the older ones have generator charge inputs built in, and/or generator autostart
(and yet others have it, but most of the new ones need an interface module that works as a standalone controller anyway.) Xantrex generator controller The two setups I've done, the inverters have generator inputs and we just do manual start. You need to pay attention to wiring and phasing in your setup -- both of the ones I did were the same phase on both panel bus bars (ie tied together, since they're off grid) and IIRC we needed to tweak some settings on the inverters to let a single phase generator drive it. |
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There should be something off the shelf that should be able to do a Low Voltage Detection of the battery bank and be able to send a signal to disconnect the solar charger and start the gen set. Might want to add some monitoring to the gen set in case it has a fault such as low oil or fuel. Also it might need to monitor gen output.
Now that you have created your AC how do you plan use it to charge your battery bank? Recently retired/disabled after 35 years of doing industrial automation and CNC. If you have any question I will be glad to help. Mostly Texas Instrument, GE, Omron, Allen Bradley, and for the last 15 years Siemens. |
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Is the inverter and inverter/CHARGER?
My (now) old skewl Trace 4024 from the 90's controls a genset. I'm sure if you bought an inverter that will also act as a charger that any of the new ones ought to be able to do it also. Output from the 12KW diesel genset goes into AC1 input. The inverter controls the charge let in via the genset. |
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Quoted:
Hi Guys, I know there are some smart solar types on here. I have a specific question regarding a DIY solar array w/ Bank I'm building. I have (8) 250W Sharp panels, Solar charge controller (Morningstar?), 12) 6V Golfcart Batts, 3500 KW Xantrex inverter. Pretty sure I got the setup covered as It charges and outputs. My question is how do I tie in a Generator backup to charge the bank? Either manual override, or preferably automatic (my Genset has a starter - Rigid/Generac 6000/8500) - Does someone make a controller for this application or do I need PLC type hardware for this. Thanks in advance for the help! Also does anyone have any GOOD references for other DIY solar projects (thinking tracker) - There is a LOT of crap on the 'net to dig thru... Solar controllers and AC-DC converters can play nice with each other for charging without a manual override if their voltage set points are identical when both are active. If not, then the one with the higher set points gets the priority while the other goes to float thinking the batts are charged. If using the genset for other AC items then there needs to be a transfer switch to keep the inverter out of the loop. Xantrex makes an inverter/converter but it is spendy. The converter is only 30 amps (I think) and you already have an inverter: http://www.bestconverter.com/81-2022-12-Freedom-458-InverterCharger-2000-Watt_p_386.html The better option is going with just a high amp 3-4 stage converter: http://www.bestconverter.com/PowerMax-PM4B-100-100-Amp-4-Stage-ConverterCharger_p_472.html Auto switches: http://www.bestconverter.com/Transfer-Switches_c_53.html DYI- Many believe true tracking is not worth the expense especially if you have MPPT: http://www.youtube.com/watch?v=vHaHHOJaWbY&list=UUpDl4WPpgvvOeZFpw4ewycA |