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AA Solar
4 Blue Gum Avenue
SILVERDALE, AUCKLAND 0932
Phone: 09 427 4040 or 09 427 4143
Fax: 09 427 4040
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Frequently Asked Questions

What kind of battery should I purchase for my motorhome?

How do I know if my SEALED batteries are charged?

How do I know if my WET batteries are charged?

Why do I need a Solar Controller/Regulator?

How many Solar Panels do I need for my motorhome?

How much power does a Solar Panel actually produce?

What affect does shading have on a Solar Panels output?

Schematic of 24 / 24 VDC System



WHAT KIND OF BATTERY SHOULD I PURCHASE FOR MY MOTORHOME?

If you are thinking of purchasing conventional,  wet type batteries, most motorhomes will require two :-

One for starting, and one for powering the motorhome’s domestic lighting, refrigeration, pumps and accessories!   For the best performance and life, the starting battery needs to be  the type that allows high cranking amps with reserve for starting.   If you are purchasing “wet type batteries” or “flooded acid type” as they are sometimes called, this type of battery for starting has more plates per size (thinner), for higher cranking ability.  They are not suitable for powering the domestic requirements, as they are not designed to be deep cycled and recharged.  They will fall apart internally in a short time if used for this service, and are not a good investment in the long term.
 For the domestic requirements in a wet type, a true deep cycle battery is required for good life and reliability.  These types of wet batteries have fewer but thicker plates, and heavier duty separators for cyclic use,  deep discharging and charging.  They will give good service if charged and maintained properly.  If charged properly they will require water regularly. 

There are some newer type battery technologies available, which have definite advantages for motor caravaners over the wet types for both applications, starting and deep cycling.  For one, they do not require any maintenance at all, other than charging correctly i.e. you never have to add water.  They do not discharge themselves like wet batteries if left standing, for instance they can be left for 6 months or more when fully charged and still be able to start your engine or power your motorhome requirements. Conventional wet batteries will discharge themselves as much as 5% or more per week, whereas the newer technology types discharge themselves less than 1% per month! The wet deep cycle type will require an “equalization charge” regularly to get good cyclic life. The newer technology types do not require any equalization to achieve long life and good cyclic ability.  These new technology batteries are generally referred to as VRLA (valve regulated lead acid),  “Sealed Type” or “Recombination Batteries”.  There are two main types, Gel and AGM.

Gel Batteries are exactly as they are called.  Their electrolyte or acid is combined with silica and other chemicals to “immobilize” the acid in a gel form.  They have the advantage of not stratifying the normally liquid acid, and generally do not require any equalizing.  They are quite efficient compared to wet batteries but require a very careful charging regimen, and  will give good long life if charged and discharged within their prescribed regimen.  They do not have, for their size, as high a cranking capability for starting, and cannot be charged as quickly, or accept charge as well as wet type or AGM.  Gel types tend to be more expensive than either wet or AGM batteries. 

AGM stands for “Absorbed Glass Mat” and are sometimes referred to as “Starved Electrolyte Batteries”.  They have specially constructed plates, which have been wrapped with a strong, micro-porous glass mat, and the electrolyte is held tightly to the plates. These plates are also compacted within the battery, which makes them very strong and rugged.  There are a number of different varieties of this type of battery, but the better ones have the ability to operate in both a deep cycle mode with very high cranking ability for starting, and also have the ability to accept charging quickly and efficiently.

In other words they are a true, dual purpose battery, and you do not have to buy two different types of batteries which require different charging regimens to properly keep them charged. Another plus is that they are a very safe battery as they are allowed to be carried on aircraft and they are not classified as “dangerous goods”.  Both GELs and AGM do not give off gas when charged normally within their specs, so are not dangerous like wet batteries when charging and discharging.  They can safely be mounted anywhere inside, and do not have to be upright.

All being equal,  AGMs will give better service, longer life and cost less to operate in the long run.  Additionally, if you are considering putting solar charging on your motor caravan, the additional charging efficiency gained and  the  low self discharge of AGMs,  ensures they will more than pay for themselves in the long run.  
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HOW DO I KNOW IF MY SEALED (SLA) BATTERIES ARE CHARGED?

SLA batteries come in a number of types, i.e. AGM, GEL and,  ‘so called’ Maintenance Free types. Because these batteries are sealed you cannot use an hydrometer to measure their STATE OF CHARGE or SOE.  They either need a very accurate DC volt meter (digital preferred), or a true “ampere hour meter”,  which is by far the most accurate and easily understood way.  If you are going to use a voltmeter, you will need one that has a resolution and accuracy of one tenth of a volt or better.  Your battery will also need to be in a steady state, that is, not to have been either charged or discharged for at least 6 hours previous, for reasonable accuracy.  This “steady state” for all practical purposes is hard to achieve in the real world.  Most installations require a battery input most of the time, like powering gas alarms, monitoring systems, or the memory back-up for a car type stereo.  Also, all forms of charging must be disconnected,  during this period.  Disconnecting the battery in most cases is really not practical for measuring of its SOC.

“Ampere Hour Meters” or “True Battery Monitors” as they are sometimes referred to, are really the only practical way of telling accurately whether an SLA battery has really been charged enough.  Most of these “True Battery Monitors” can also give you a lot of information about what is really happening in your electrical system.  Because they count the real “Amp Hours” that your electrics have used out of your battery you will know how much you will need to replace.  Most give you “Amp Hours” removed and % left in your battery. Then when your battery is being charged it will count up to “0” and will let you know that all the power you have removed has been replaced.  If they are programmed correctly (which is very easy in most of the newer units), they will automatically calculate for the efficiency of your battery type and give you a very accurate answer as to SOC.   In our experience, the advent of “Battery Monitors” will make living with a DC system powered by batteries a pleasure and are a real necessity if you want your system to be reliable and your investment in batteries long lasting.

Recommended makes of battery monitors that we have tested and used are:   Trimetric 2020 by Bogart Engineering, Trace TM-500A by Xantrex  and  XBM Battery Monitor by Xantrex. 


HOW DO I KNOW IF MY WET/FLOODED ACID BATTERIES ARE CHARGED?

The best way to determine if a wet type battery is charged is to use an hydrometer.  This however is not always convenient, for I have noticed that most batteries are located in  locations difficult to
access in order to do this properly. Using a hydrometer is messy, and can be dangerous, although it is  a very accurate way of determining the state of charge of a wet type battery.  There are some
precautions :-  the reading will not be accurate if you have just topped up the water, or if the batteries have been stationary or not charged for some time, as the acid will stratify and become weaker at the top than at the bottom.  All wet batteries need an equalization charge regularly for this reason, besides bringing up the weak or lazy cells.

Below is an accurate table of % of charge in relationship to voltage and specific gravity in 12 & 24 VDC wet battery  systems,  as measured by an hydrometer.  To make determining charge state easier, 
expanded scale voltmeters and ampere hour  meters, or battery monitors, are the most convenient,
especially the ampere hour meter. Expanded scale volt meters are only accurate if the batteries have been static for some time,   meaning no charging or discharging taking place for 6 hours or more.  This is not always convenient or easy to achieve.  A much more convenient and very accurate way , is to use an Amp Hour Meter ,or Battery Monitor as they are usually referred to.  These not only give you very accurate voltage and instantaneous amps,  but will show most importantly,  the percentage of battery charge
remaining, how many amp hours have been used up, and when the battery is  fully charged.  Some also tell you how many days since the battery was fully charged.   Lowest and highest battery voltage , are also included  in some units for keeping a check on how the battery is being charged and discharged.  Some have total amp hours used, like an odometer in an automobile to measure total battery life.

Specific gravity values can vary + or – 0.015 points of the specified values. This table is for a flooded battery in a static condition, no charging or discharging occurring, at 25 degrees C.     Discharging or charging will vary these voltages substantially.


Percentage of Charge
12 volt Battery Voltage
24 Volt Battery Voltage
Specific Gravity
100
12.70
25.40
1.265
95
12.64
25.25
1.257
90
12.58
25.16
1.249
85
12.52
25.04
1.241
80
12.46
24.92
1.233
75
12.40
24.80
1.225
70
12.36
24.72
1.218
65
12.32
24.64
1.211
60
12.28
24.56
1.204
55
12.24
24.48
1.197
50
12.20
24.40
1.190
45
12.16
24.32
1.183
40
12.12
24.24
1.176
35
12.08
24.16
1.169
30
12.04
24.08
1.162
25
12.00
24.00
1.155
20
11.98
23.96
1.148
15
11.96
23.92
1.141
10
11.94
23.88
1.134
5
11.92
23.84
1.127
Discharged
11.90
23.80
1.12



WHY DO I NEED A SOLAR CONTROLLER/REGULATOR ?

The main function of a controller or regulator is to fully charge a battery without permitting overcharge. If a solar array is connected to lead acid batteries with no overcharge protection, battery life will be compromised. Simple controllers contain a relay that opens the charging circuit, terminating the charge at a pre-set high voltage and, once a pre-set low voltage is reached, closes the circuit, allowing charging to continue. The more sophisticated controllers have several stages and charging sequences to assure the battery is being fully charged. The first 70% to 80% of battery capacity is easily replaced. It is the last 20% to 30% that requires more attention and therefore more complexity.

How Controllers Work and Available Options

The circuitry in a controller reads the voltage of the batteries to determine the state of charge.  Designs and circuits vary, but most controllers read voltage to reduce the amount of power flowing into the battery as the battery nears full charge. Features that can be included with controllers are:-

Reverse current leakage protection:- by disconnecting the array or using a blocking diode to prevent current loss into the solar modules at night.

Low-Voltage Load Disconnect (LVD):- to reduce damage to batteries by avoiding deep discharge

System Monitoring:- analogue or digital meters, indicator lights and/or warning alarms

Overcurrent Protection:- with fuses and/or circuit breakers

Mounting Options:-  flush mounting, wall mounting, indoor or outdoor enclosures

Systems Control:-  control of other components in the system: standby generator or auxiliary charging system, diverting array power once batteries are charged, transfer to secondary batteries

Load Control:-  automatic control of secondary loads, or control of lights, water pumps or other loads with timers or switches

Temperature Compensation:-  utilized whenever batteries are placed in a non-climate controlled space. The charging voltage is adjusted to the temperature. Recommended on most systems.

Central Wiring:-  providing terminals to interconnect system wiring

Some systems require all of these funcions, others require only one or a certain combination.  We can help you select a unit to meet your specific needs.

Sizing a Controller

Charge controllers are rated and sized to the systems they protect by the array current and voltage. Most common are 12, 24 and 48 volt controllers.  Amperage ratings run from 4.5 amp to 60amp:

For example, if one module in your 12 volt system produces 3.5 amps and four modules are utilized, you produce 14 amps of current at 12 volts. Because of light reflection and the edge of cloud effect, sporadically increased current levels are not uncommon. For this reason  increase the controller amperage by a minimum of 25% bringing the minimum controller amperage to 18.7amps.  Looking through our products  find a 30 amp controller, as close a match as possible. There is no problem with going to a  larger controller, besides possible additional cost.  If you think the system may increase in size, additional amperage capacity at this time should be considered.

Link to Morningstar Solar Controllers

                                                                                                               


                                                                                                         

How many Solar Panels do I need for my Motorhome?


Solar modules and RV's with batteries are a natural match

Since batteries are charged when traveling, RV's nor­mally depend mostly on the vehicle's alternator for the primary power source. Power to charge the battery bank is also provided through a battery charger when plugged into mains power. However, for those who like to spend days, weeks (or longer) not traveling and not plugged in, solar panels can mean freedom. And, because a solar array can put as much power into your batteries during an hour of bright sun as a small gasoline generator, it can also mean reclaiming peace and quiet. As well, the RV's existing battery bank and fuse box make the transition to solar a smooth and economical one. While most RV systems utilize 1 to 2 modules, it is important to analyze your power needs.  Just as with all solar systems, you need to consider the wattage of the appliances and lights you are powering as well as the average hours used each day. Unlike most other systems, however, RV's travel through different regions of climate, park at varying angles to the sun, sometimes in shade and sometimes not. People with similar vehicles can have very dissimilar power usage and patterns of travel. These factors should be considered.  If you have any questions about how to go about this, please give us a call.


Buy now and save later

Your Solar Charging System will pay for itself several times over by increasing battery life and reducing the amount of money you spend on camping-ground hook-ups and generator maintenance. Batteries that are "deep cycled" too many times or sit idle for several months can be permanently damaged. Solar  modules provide a daily maintenance charge to your batteries and eliminate this problem. By recharging every day, the depth of discharge is reduced, and battery life and performance are greatly improved.


Keeps batteries charged, Summer or Winter

Solar panel output is dependent on light intensity and exposure time in the sun. You'll be amazed at how much power your system provides on a bright day. And even in cloudy weather, your panels will produce power although at a lower output.

So, How many Solar Panels do you need?

The more solar panels you can fit onto your roof, the better your system will be.  This does not need to be done all at once, but can be spread over time.   If you have no heating or cooling loads (eg. refrigeration is running on gas when freedom camping) then you could start with a single 80 watt or 130 watt solar panel.    See how you go.  Are you running out of battery power on a daily basis and having to start the engine to boost your batteries?   Then you need more solar panels.  As long as you initially install a solar regulator  large enough to take additional panels, and leave sufficient extra cable length up top on the roof, you can add more solar panels when needed.

Link to Suntech Solar Panels



How much power does a Solar Panel actually produce?

While on the subject of using solar panels for power, it might be a good idea to explain how much power can really be produced by a solar panel to charge batteries and how that equates to usable power to power your loads.    

A good quality 80 watt solar panel mounted flat on the roof of a motorhome will produce an average of 240 watts per summers day charging into batteries.  This would be the usable power available from the batteries to run appliances, after all losses including regulators and the efficiency  of batteries.  In winter it would be a little more than half that figure.  Now, how does that equate to the amp/hour storage in the batteries or what your loads are.   If we take the figure of 240 watts per day and divide that by the nominal charging voltage of 14 VDC for a 12 VDC system, we would have replaced approximately 20 usable amp/hours into our batteries.  That would be enough for a very basic electrical system as in example number 1.   If for instance though, you have an average 80 to 110 litre DC fridge which requires about 40 amp/hours per day (24 hours running) you would need at least 2 x 80 watt solar panels to sustain the fridge only.  In other words, a good installation for instance would normally require 2 x 130 watt panels to power both a DC fridge and other essential electrics, if there was no other charging source to keep the batteries well charged.  In winter the above system would run at a deficit, and  another 130 watt panel would be needed in order to be completely independent.  It might also require a bit of extra electrical conservation!  You can increase the average output of solar panels per day especially in winter, by aiming them more at the sun.  That is not as difficult as it sounds.  A number  of motorhomes and caravans do this, and get almost twice the power in summer, and 3 times the amount of power out of their solar panels in winter, especially in the South Island.  See pictures.  Most motorhomes and some caravans also have provision to charge their house batteries while driving, and if you drive for a few hours every few days, that will help put some amp/hours back into the house batteries, especially if the system has been set up correctly.  Most motorhomes and caravans also have a  240 VAC charging system  and if this is a good deep cycle battery charger,  it will fully charge the batteries over night.  This would require of course going to a motorcamp and plugging in.  It could be that the washing needs to be done too, as a good excuse.   Some motorhomes also carry generators to supplement their power usage and also for emergency.  With the new type “Inverter Generators” and a larger charger this can be a reasonably efficient and quiet way to charge the house batteries when you do not have enough solar panels or you have lots of rainy days. 


The size of a battery for an alternative power system is an important decision too.  Too little storage will cause the battery to be deeply discharged often and will drastically shorten its life.  A rule of thumb here is to take your average consumption per day in amp/hours and multiply that by at least 4 or even better 6 times, to get good  battery life.  In practice this means if your average daily consumption is about 50-60 amp/hours per day then you would need a 200 to 360 amp/ hour battery system for a reliable system and reasonable battery life. 

Totally alternative power is possible and practical (no LPG or generators) if one is willing to spend enough money on solar panels, batteries and a large sinewave inverter.  One such installation is our own converted 9 meter Hino bus.  It is all alternative power, meaning everything is electrically operated including all of our cooking except for barbequing, which is wood powered of course for flavour.  Even the solar panels are raised electrically by a push of a button.  The only other charging source is a very large heavy duty 24 VDC alternator with a very smart 3 stage regulator which will produce 70 amps with the Hino engine idling, and up to 200 amps if needed when running.  We have had this system operating for 6 years now and would do it all the same again if we did another bus, but would probably include a built in inverter generator in case we stay somewhere for more than a week and it rains every day!



What affect does shading have on a Solar Panels output?

PV modules are very sensitive to shading. Unlike a solar thermal panel which can tolerate some shading, many brands of PV modules cannot even be shaded by the branch of a leafless tree.

Shading obstructions can be defined as soft or hard sources. If a tree branch or roof rack is shading from a distance, the shadow is diffuse or dispersed. These soft sources significantly reduce the amount of light reaching the cell(s) of a solar module. Hard sources are defined as those that stop light from reaching the cell(s), such as a tree branch, bird dropping, or the like, sitting directly on top of the glass. If even one full cell is hard shaded the voltage of that module will drop to half of its unshaded value in order to protect itself.

Partial-shading even one cell of a 36-cell module, such as the AAS130M, will reduce its power
output. Because all cells are connected in a series string, the weakest cell will bring the others down to its reduced power level. Therefore, whether ½ of one cell is shaded, or ½ a row of cells is shaded, the power decrease will be the same and proportional to the percentage of area shaded, in this case 50%.

When a full cell is shaded, it can act as a consumer of energy produced by the remainder of the cells, and trigger the module to protect itself .The module will route the power around that series string. If even one full cell in a series string is shaded, it will most likely cause the module to
reduce its power level to ½ of its full available value. If a row of cells at the bottom of a module is fully shaded the power output may drop to zero.

The best way to avoid a drop in output power is to avoid shading whenever possible.

Shading diagram




Schematic of 24 / 24 VDC Motorhome System












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updated September 2009