HOW TO MAKE A SOLAR PANEL:
If you are here to learn how to make a solar panel, then you are in the right place. I will help you make a 63 watt panel. The procedure is quite simple and is outlined below.
STEPS TO MAKE A SOLAR PANEL:
1. Make a template for your solar cells. You will need a regular cardboard, plywood, a staple gun and tile spacers for this process. The tile spacers serve the purpose of keeping even the solar cells. Use a ruler for alignment and jigsaw to cut your plywood.
Put your frame together once the template is ready. Cutting a 1x2x8 piece of wood for the outer frame will do. Make sure the outer frame is not too high to create a hindrance to the sunlight. This can be achieved by screwing those pieces onto the 2×4 pressure treated framework.
Apply the siding paint as well as the deck on the frame.
2. Assemble the solar cells keeping in mind that the bottom part of the cells is the positive side. Connect the cells in series using tabbing wire and soldering iron. Thirty six cells will give you 63 watts.
Use a bus wire to connect three solar cell strings. The bus wire will curl up to create one long string.
3. The frame and pegboard should have two coats of paint. Put carefully the cells inside the frame so you can get a rough idea of where to insert the screws then remove them. Screw the pegboard down.
4. The positive and negative connections need to run out. Drill two holes for this at the end of the frame.
5. To glue down the solar cell strings to the pegboard, you will need silicon.
Solder your bus wire to bond the solar cell strings on one end. Confirm the voltage once you solder two strings instead of waiting till all solar cell strings are connected.
6. Once the solar strings are set up in your choice, the gauge wires are ready to be soldered. You can ease the soldering process by connecting connectors on the lead ends of the gauge wires.
7. You can make the inside of the panel look better with the use of wire mold strips running along.
8. At this point, test the voltage of the panel by taking it outside in daytime.
9. You will need to hook up a deep cycle battery to an inverter and charge controller. The process is simple. Connect charge controller (solar side) to the panel connection. Connect the other side of the charge controller to the deep cycle battery. Hook the battery and the inverter and you are good to go.
10. There should be even pressure for the security of your Plexiglas on the edges of the solar panel. For this to be, the same outer plywood frame you have at the bottom covering the plexi wood should be spread at the top. The screws you are using should be made from pressure treated lumber, and should be carefully drilled to avoid cracking the glass.
11. At this point, the solar panel should have a junction box installed. When the solar panel is hooked to the battery, there is backflow of current so if the charge controller does not control this, it is advisable to bring a blocking diode along with the junction box. Put the diode outside the panel so that if it needs replacing you will not have to open the whole package. Check the voltage again before mounting the panel on your roof.
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