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Performance of Our 120 Watt Solar Panel with Pole Mount

8/25/2016

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Picture120 Watt Solar Panel on a Pole Mounting System with Water Heater and Crane Options
This year we tested our new 120 Watt SunPower cell solar panel with our integrated water heating system on a 5 week cruise in Northern Lake Huron at a latitude of about 46 degrees.  We used an EP 20 amp MPPT Controller.  A 10 amp controller would have been sufficient but we wanted extra capacity so we could plug in an auxiliary 100 watt semi-flexible panel as a backup if we needed additional power because of a series of cloudy days. Plugging in an extra panel is simple using the MC4 connectors and an MC4 T-branch connector. We had mostly sunny days so we didn't need additional power beyond what the 120 watt panel provided.  The weather was awesome!  The 120 watt panel was mounted using our CMP pole mounting system so I could tilt and rotate the panel to achieve optimum sun angle.  I set the sun angle once and rotated the panel three times a day (morning, midday, evening) and figure I got about 30% more performance over a fixed horizontally mounted panel.

Operating statistics:

Our power usage averaged approximately 70 amp hours or 850 watt hours in a 24 hour period.  Our current draw was from a refrigerator/freezer running 24/7, our LED lights in the evening, cell phone chargers, laptop computer several hours a day and our radios and instruments during the day.  Our windlass is only run when the engine is running so we don't include it in our power consumption calculation as the alternator quickly makes up for its power usage.  We have a 75 amp Balmar alternator with a smart regulator.  Our house bank consists of 3 flooded cell batteries giving us a total capacity of 330 amp hours.  We started the engine to move anchorages about every three days.

Results and findings:

1. Our battery bank was fully charged by 2 PM most sunny or mostly sunny days when at anchor.  This is in contrast to 12-1 PM in past years using our 150 or 160 watt panels on poles.
2. The EP Tracer BN MPPT controller with the remote display proved to be an outstanding piece of equipment.  It was simple to program, easy to read, collected the appropriate data and was very efficient.  It was exciting (I get excited about these things) to see 8+ amps being poured into the battery bank in the morning.  It would be frustrating to see it only outputting and amp or two in the afternoon in full sun but then you realize it is doing its job.  It fully charged the batteries in the morning and was in float mode topping off the battery bank in the afternoon.
3. Rotating the panel during the day, especially in the morning, significantly increased the power generation of the panel.
4. Our weather was so sunny and the panel performed so well we had no reason to plug in the auxiliary 100 watt flexible panel using an MC4 T-branch for extra charging power.  I plugged it in one morning just to confirm the configuration would work and was easy to do.  It worked well and brought the charging amps to well over 12 amps.
5. The data gathered confirmed that this panel configuration supplied all the power we needed and has excess capacity to catch up on battery charge from a string of cloudy days.
6. The panel was affected by shading as would be expected.  Occasionally the panel was shaded by the back stay or the mast.  While the shading was minimal, it degraded the performance by up to 40%.

Data:
                                                  At anchor   Motor         Sunny to         Cloudy to
                                                                                 Mostly Sunny  Mostly Cloudy

Average watt hrs per day                  740        540             650                 290
Average amp hours per day                 57          45               50                   22
​Maximum watt output in 24 hours    960        630             960                 540
Minimum watt output in 24 hours        200         200             420                 170

Observations:
1. The minimum watt hour output doesn't mean much because it is dependent on both the cloud cover and the state of charge of the bank as a result of alternator charging,
2. The maximum watt hours per day of 960 is not the maximum output capacity of the system in a 24 hour period because the batteries were charged by 2 PM so the controller shut down the charge from the panel.  A higher drain on the house battery bank would have resulted in this number being higher.
3. Average amp hours per day is computed by dividing the watt hours by 13 volts.  This is a ballpark calculation.
4. This configuration proved to have plenty of capacity for our cruising needs even without using the auxiliary solar panel.  We have not used shore power to charge our battery bank for the entire summer.

Solar Water Heater:

We installed our new solar water heating system.  It consists of a heat collector or heat exchanger mounted on the back of the solar panel, and a circulating pump.  See our earlier blog for design considerations.  The pump circulates water from the water heater through the heat exchanger on the panel.  We used the same configuration on our 150 watt panel last year.

Results:

On sunny days at anchor we had warm water for showers and dish washing.  The water temperature in our 8 gallon hot water tank would warm from 60 degrees to about 105 degrees in 2-3 hours on a sunny calm day.  This was slower than the system we tested last year on our larger panel but it was perfectly adequate to meet our needs.  As expected, we confirmed that strong winds tend to cool the panel and reduce the heating efficiency as do clouds.  Overall, the water heating system cools the surface of the panel by at least 20 degrees.  This increases the efficiency of the panel since solar panel performance degrades as they are heated by the sun. Insulating the tubing running between the heat exchanger and the water heater significantly increased the efficiency of the system.  In conclusion, the radiant energy water heating system works well on sunny days with both our larger and our standard sized panels. See our product section or read our earlier blog for details.

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Finally, a Flexible Marine Solar Panel with High Efficiency

5/16/2014

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Picture100 Watt Flexible Solar Panel
When our supplier told me they had a new high output marine solar panel that was flexible I was skeptical.  The specifications seemed just to good to be true.  So I ordered some to test.  Well, I was pleasantly surprised.

These panels are very well constructed and they have a power generation comparable to our hard panels.  These panels can be flexed to 30 degrees so can conform to most boat curved surfaces.  The 100+ watt panels have an electrical box on the front (not shown in the picture) which contains two blocking diodes.  The 50 watt panel has one blocking diode.  The base material is very sturdy and strong.  Each panel has grommets for attaching the panel.  

I have tested the output of these panels under various weather conditions and their susceptibility to shading.  Below is a quick comparison of output of our three mid-range panels laying flat at mid day on a mostly sunny day measured with a meter:

                                                      Flexible 100 watt         Rigid 105 watt          Rigid 100 watt
                                                      Monocrystalline           Monocrystalline        Polycrystalline

Short Circuit Current (Isc)                      5.48 amps                   5.50 amps                5.26 amps
Open Circuit Voltage (Voc)                    19.2 volts                    19.7 volts                  20.5 volts
Computed Power (not rated power)         105 watts                    108 watts                 108 watts

Additional information is available on our solar panel page.


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Important Considerations When Purchasing a Marine Solar Panel

9/6/2011

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At other places on this blog and on our web site we talk about how to determine the size of solar panel (how many watts) you will need to meet you power consumption requirements.  Once you know your panel size requirement there are some things to consider in selecting a solar panel.

Panel Type - There are many articles written on the two types of solar panels; monocrystalline and polycrystalline.  Monocrystalline panels are made up of single crystal silicon wafers.  Polycrystalline panels are made up of silicon that has a multiple crystalline structure.  There are pros and cons to each type of panel.  Monocrystalline panels have a higher output per square inch in direct sun but are very sensitive to shading and output will degrade faster on cloudy days. Polycrystalline  panels are not as sensitive to being shaded and output will not degrade as much on cloudy days.  At CMP we offer both a polycrystalline and a monocrystalline panel.
Panel Crystal Quality - Because we have a confined space on our boats, we need to have the maximum output per square inch from our solar panels.  The quality of the silicon crystals used to make the panel is a key factor in determining the panel output.  Crystals are passed under a fixed light and graded as to their output (1-10).  Grades are grouped into classes.  Class A crystals are grades 8-10, Class B crystals are grades 4-7 and so on.  Crystal quality follows a bell curve; there are many more Class B crystals than Class A.  We at CMP specify only the best Class A crystals for use in our panels.  Less expensive Class B and C panels are often used on land based solar farms where space is not an issue.
Panel Shape - The largest market for solar panels is commercial applications where many many panels are mounted on a roof or in a field.  These panels are usually rectangular in shape often twice as long as wide.   This shape is often not ideal for marine application.  Often a more square shape is preferable, especially for pole mounting.

Choosing the right panel for your needs will require study and/or discussion with panel experts.
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Solar Panel Power Generation Log

8/23/2010

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The weather for our cruise in the North Channel of Lake Huron this year was excellent.  It was warmer and sunnier than last year.  Our Kyocera 85 watt solar panel performed very well.  The following are some statistics:

Days cruising:                                       22 days
Max power generation:                        40 amp-hours
Min power generation:                         13 amp-hours
Average power produced per day:  35 amp-hours

Average power consumed per day:      51 amp-hours

Our primary use of power was for the refrigerator/freezer.  We ran a power deficit each day of about 16 amp-hours at anchor but with our 360 amp-hour battery bank, this not a problem.  Moving on every 4 days or so gave the 75 amp alternator plenty of time to bring the batteries back up to charge.
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Solar Panel Power Generation Log

8/11/2009

2 Comments

 
We spent the month of July in the North Channel in Northern Lake Huron north of the 45th parallel.  We logged the output of our top-of-pole mounted 85 watt Kyocera solar panel and our daily power consumption.  It was an unusually cloudy July.  Here are some statistics.

Weather
Mostly cloudy      7 days
Partly cloudy       8 days
Partly sunny        8 days
Mostly sunny       7 days

Power Generation
Maximum power produced in a day was 38 amp-hours
Minimum power produced in a day was 12 amp-hours
Average power produced per day for the 30 day period was 25 amp-hours

Power Consumption
Average power consumed for the 30 day period was 46 amp-hours

Our travel pattern was to stay at anchor for 2-3 days and then motor/sail to another anchorage.  We connected to shore power one night.  While we ran a power deficit of 21 amp-hours per day while at anchor, our high output 75 watt alternator quickly replenished our batteries on our travel days.

We ran our refrigeration/freezer every day as well as our computer (chart plotting) and autopilot when underway.  We found the combination of our 85 watt panel and our 75 watt alternator provided us with ample power for the trip.
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Sizing a Solar Panel to Your Needs

3/20/2009

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Solar panels provide an excellent solution for obtaining the electrical power needed  to support on-board electrical systems.  They are quiet, require little maintenance and are reliable.

While cruising, we take a very conservative approach to using electricity on board our 38 foot sailboat.  Even so, when considering the solar option, I concluded that  using solar panels to supply all our electrical needs would be expensive and would require considerable panel surface area.  With this in mind,  I set out to use solar power to augment the generation of power with the goal that we could be at anchor for three days without running the diesel to charge the batteries.

The 85 watt Kyocera KC85T is rated at 5 amps (17 volts) and measures about 26" by 40".  We can generate about 35 amp-hours on a sunny day on the Great Lakes by adjusting the angle 3-4 times a day for optimum efficiency.  Our energy usage is roughly 55amp-hrs a day at anchor.  Thus we run a deficite of about 20 amp-hours per day.

Here is how we calculated our energy usage per day at anchor.
Equipment            Amps            Amp-hours/day
Refrigeration          5                        20
Instruments            1                         4
Computer               4                         6
Lighting                  2 (avg)                10
Pumps                    5                         5
Other                     1                       10
 (propane monitor, etc.)
                                                ________
Total amp-hours                                55

When under sail we have an additional current draw of 20 amp-hours from our auto-pilot and instruments.

We have a 75 watt alternator on board and a 360 amp-hour battery bank.  Because we typically run the engine several hours on the days we are moving, the battery bank gets charged on those days.  This system works out well for us.

Each cruising boat has different patterns of energy usage and different requirements.  Calculate your usage, consider your sources of power generation and select the size of the solar array you will need.  Based on this, you can determine whether a single panel or multiple panels will be required to meet your needs.

Contact us if you would like assistance in determining the size of panel that will be required to meet your needs.



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Solar Panel Mount Design Considerations

3/20/2009

4 Comments

 

Top-of-Pole Mount

The top-of-pole mount offers excellent functionality for getting the maximum performance out of your solar panel.  The closer the surface of the panel is to being perpendicular to the rays of the sun the higher the performance (amps output).  Thus, the panel needs to be both tilted and rotated.  I have found that adjusting an 85 watt panel 3-4 times a day will achieve power generation of up to 40 amp-hours on a clear day on the Great Lakes.

A panel mount should be adjustable easily without the use of tools.  Our panel mount provides 13 tilt positions by simply pulling a pin, tilting the panel and replacing the pin.  The panel, which is atop our crane pole can be rotated 360 degrees.  We provide a pole locking mechanism to keep the pole from rotating on a windy day and have found that using the mechanism as a brake to limit free rotation of the pole works well.

As shown in the picture, our pole is mounted to the stern rail away from the boom so there is nothing to cast a shadow on the panel.  Shadows can significantly reduce the efficiency of a solar panel.  The pole is mounted high enough to clear the bimini yet easy enough to reach to adjust the angle to the sun.

My sense is that the 120 watt solar panel is about the maximum size
(31" X 48") to mount on the top of a pole such as ours.  The limiting factor is the strength of the stern rails that stabilize the pole.  A larger panel would require bracing struts from the pole to the deck.  Clearly this is possible but I would recommend mounting larger panels to a frame above the bimini, on dinghy davits or directly to the stern rail.

Pro and Cons:

Top of pole mount
Pros: Easily adjusted for best sun angle, clear of shadows, out of the way.
Cons: Limited size of panel that can be pole mounted.

Bimini frame panel mount
Pros: Can mount large panels, out of the way.
Cons: Cannot easily adjust for best sun angle, often have shadows cast by the boom, back stay or topping lift.


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    Author

    Thomas Trimmer has been cruising with his Ericson 38 sailboat on the Great Lakes for over 20 years.  He has pioneered the use of solar energy for wilderness cruising.  He is continually designing and building equipment to simplify and enhance the cruising experience.

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