Put the finishing touches on my Power Control Panel I've been working on for the past few months.
Backstory: I have two DIY solar generators I use for both back-up power here at home as well as when I'm out camping. When out in the sticks for 2 weeks back in August, I found out the system
works, but it's not very user-friendly. All sorts of patch cables, having to plug and unplug devices and chargers and cords and power supplies.... it was a mess. Besides, putting the two battery banks on the table put a lot of weight on it and hogged a lot of real estate on the table, which is only 2' x 4'.
So even before I got back home, I was scheming a solution to all these problems. And the solution was to make a control panel that will sit on the table. Smaller and lighter, and will use switches & fuses to control the various inputs and outputs. Power would travel both ways on cables between the controller on the table and the batteries on the floor.
This morning, I got out my crayons and colored the project 'done'... I printed out the labels and put them in their respective places. Then, it was time to set the solar panel up to my patio door (while sunny, it's danged cold and windy out right now), plug everything in and put it all to the charge test.
The control panel is built around a (Harbor Freight) Apache 2800 case. They're supposed to be watertight, but this one no longer is because it's full of holes now. Once I had the case, I started ordering all the bits and bobs I'd need to complete the project. Mostly, a charge controller, meters and panel-mount inputs and outputs.
When I sourced all the parts and was waiting for them to arrive (mostly via Amazon), I drew up a CAD layout of how I wanted it to look.
Once all the components were on-hand, I started to make sure everything would have the clearances needed to put everything where I had anticipated. I did have to make a few adjustments due to the dimensions of the various items, but I came close to what I had envisioned. I also added a few more small items.
This morning, I finished the last step in the build.... install the labels. And the result is:
(The pouch in the lid is a test lead kit). This is the first time it's been hooked up to both gennies as well as the solar panel. I'm doing this as a test to see how it charges the batteries.
The batteries and solar panel plug into the left side:
The two battery banks are plugged in on the left, the solar panel on the right (using Anderson PowerPole connections which are hidden by the floppy cover).
Detail of the main panel:
The top left is the solar charger portion. A switch and fuse for the input so I can toggle the input on & off instead of unplugging the cord from the panel. The large display is a remote for the charger itself, which is mounted inside the case. This charger display will let me keep track of the charging of the batteries, giving me volts, amps and other information.
On the lower left are the switches for the two battery banks. I separated them so I can control which ones I want to charge/discharge. To the right of the switches & fuses is the output metering. It will give me the voltage of the batteries as well as the current draw of any loads I have (chargers, laptop lights etc).
The entire right side is all outputs, each with their own switches and fuses. This way I can turn on only the loads that need power at the moment without resorting to unplugging those. So if I need to run my laptop, I turn on the top switch. Charge my phone or tablet? Turn on the middle switch.
As for BBIntExt switch and fuse.... that is for the lower right. The display is a buck-boost module. It accepts 5-30vDC input and can be set for 5-30vDC output. The output is wired to the banana jacks and DC coax port at the bottom right (Vout). The jacks and ports to their left (Vin) is connected to the SPDT-CO switch marked BB to allow a power supply other than my battery banks to be connected. This allows me to input any DC source from 5 to 30 volts and run it through the module to convert it to any output of 5 to30 volts. So if I can find a usable 24v truck or 6v lantern battery, I can patch it into this panel and convert it to voltages I can utilize... either by using the test leads or back-feed the 12v ciggy lighters and USB ports if necessary.
The hole below the switch serves two functions. One is a peephole so I can see the display on the charger itself. The hole is directly over a pushbutton on the charger to program it. So all I need is a short stick and I can push that button if I need to.
And a final note: If you look at the photo of the side of the case, you'll see another DC coax output nestled between the battery inputs. I installed that for the cabin tent lighting. It is connected directly to the fuse of one of the battery bank circuits. This allows me to run my cabin tent lighting without turning the bank on and running all the meters just to have lights in the tent. The power draw of the lighting (along with the RF controller I use) is so low I will easily be able to leave them plugged in all night without fear of draining the battery.