Test Project Solar Panel using broken solar cells

[matrixone]

Hello guys,

Before making the real DIY solar panel project, I decided to make the test first (in real life). Making DIY solar panels, we actually missed a lot of stuff to make a good one and for me experience is the key factor here. I live in the Dominican Republic and sun here is always welcome.

Also I being lucky making this projects because most of the materials I got if for free, because my uncle just moved his office and some glass, wood, etc. I reuse it to make the solar panel.

Thanks of the internet and this forum, later on I will make A1 Solar Panel using very good frame, glass and encapsulants. Also going to use good quality solar charger (purchased Morningstar brand). USE THE LINK IN MY SIGNATURE TO SEE THE PICTURES.

First let me give you the list of the materials and prices:

1-100% light pass-trough glass (free)
2-High caliber outdoor wood (free)
3-Heavy duty aluminum frame (free)
4-Silicone Tube 100% Marine Lanco Brand (4 USD)
5-Compressed wood with wholes, or peg-board (free)
6-140+ pieces of solar cells 3x6 (possible to make 4 panels). Pieces where from 60% to 90 % of the cell, almost all are pre-tabbed. (80 USD)
7-Roxin Flux pen (10USD with shipping)
8-Jota Solar charger 12/24v 12A (15 USD shipped)
9-Wood sealer and water repellent Lanco Brand(10 USD 1 galon)
10-Four Skottky diodes 3 amps (10 USD)
11-Some expenses, like cutting the wood, glass. (20 USD)

The first thing to make the panel is to tab all solar cells, because as you know, they are not 3x6 solar cells because they are broken, so in conclusion I need to cut the wood and glass 32"x22", this includes the borders (shades from the frames). I use aluminum frame with 1"x3" to have less frame on front and lot of back, to cover solar cells with glass on front and wood on the back.

Also to give space and better ventilation, I didn't put the solar cells in the glass, I just use the silicone to stick the cells in the peg-board and put in the border of the panel a half inch of peg-board too. Also I put silicone in the aluminum frame to glue the glass and later on, I ad silicone in the border of the backing wood too. I followed this guy so you can have the idea: http://www.ehow.com/how_4699372_home...ar-panels.html

Assembled everything and use a junction box that was laying around there, and in the positive side of the panel put the Skottky Diode (3amps), I use Skottky because they are more efficient and have less loss, means less heat too. They are a little expensive, but maybe on Ebay you can buy a bunch more for like 12 USD.

Finishing the solar panel (a little hard first), realize that the effort give results. Measuring the solar panel gives to me 19.11V and almost 2 amps! In 45mins gives me like 17.90 to 18.10 volts, because of the heat, so is not bad!
(Open circuit of course)

I made a test using the solar charger, a 12v battery and some loads and I can tell you that it works well (5 hours of test).

NOW I DID NOTICE SOMETHING, I saw some condensation inside of the panel, but only in the lower part of the solar panel, means that there some air going inside or something, need to check that.

Hope to finish the other 3 panels, so I can start using this solar cells and from 5 month to now, see the results and see what is good or wrong. Later to make the real solar panels, purchasing A1 solar cells.

Thanks

[Jason]

Hey, thanks for posting your album and putting it in your sig!

Great job and good luck on your project. I'm happy the forum helped you along the way. Hearing these types of stories are always music to the ears.

I look forward to reading more from you.

[Mike90250]

[QUOTE=matrixone;739

NOW I DID NOTICE SOMETHING, I saw some condensation inside of the panel, but only in the lower part of the solar panel, means that there some air going inside or something, need to check that.[/QUOTE]

That's going to eventually kill the panel. Any visible condensation, means water, and water and electricity = Bad News. You may have to put vents top and bottom of the panel to remove the water.
Wood will ALWAYS allow water vapor to get inside, and any humidity, is bad for the cells and wires.

[matrixone]

The water is only visible in the glass, not in the cells, also is only visible in the lower part of the panel. I will ad more wood sealer and see the results. Maybe next month, I will upgrade the post.

[Mike90250]

Any visible condensation, means water, and water and electricity = Bad News
Wood will ALWAYS allow water vapor to get inside, and any humidity, is bad for the cells and wires.

You cannot seal wood. Even if soaked in epoxy, most epoxy, silicone sealers and such, are permable to water vapor. You can try to seal it out, but you are more likely to succeed if you allow convection to carry most of it away.

[Moby Dick]

mobydick

Gee Thanks for saying you cannot seal wood. The DYI instructions I have say to use plywood backing and wood edging. Why am I told this if wood cannot be sealed?

[matrixone]

Wood solar panel have big issues:

1- Condentationm no matter how many coats of paint or whatever, there's allways condentation.

2- It will not last long

I did a test (check my pictures), with broken solar cells. I have running 3 solar panels (19v and 1.5 amps each). I had lucky that 2 of them, no condentation, but I have 1 that have some condentation, but this is for test so I am crossing fingers. I have 2 month, no issue's.

[Minnesota]

This should drive the message home:

http://www.youtube.com/watch?v=LpuDKKEd9O0

[Mike90250]

Gee Thanks for saying you cannot seal wood. The DYI instructions I have say to use plywood backing and wood edging. Why am I told this if wood cannot be sealed?

Because that was a salesman that said that. And the sports car at the corner of the lot, low mileage, only driven tuesdays to the corner store by a old lady, never abused the engine. And this bridge, only $35 today. I have the title right here, at the bank deposit box. Trust me

[bigsmile]

This is a little hard to believe. I have 8 year old motherboard from computer that's not nearly as corroded, and also various other metal objects subjected to room condition.

Holes on panel from corrosion within a couple of years? How and why?

This should drive the message home:
http://www.youtube.com/watch?v=LpuDKKEd9O0

[Sunking]

This is a little hard to believe. I have 8 year old motherboard from computer that's not nearly as corroded, and also various other metal objects subjected to room condition.

Holes on panel from corrosion within a couple of years? How and why?

Because your motherboard and electronics have ventilation and allowed to breath.

[bigsmile]

Did you watch the video? I think his cells are not even enclosed. He said he just put it in the air.

My guess is that he put the cell where condensation occurs. Without condensation, I simply don't see air do this damage to the cell.

I also don't believe his judgment about holes on the cell within a year. That's simply absurd.

Because your motherboard and electronics have ventilation and allowed to breath.

[Mike90250]

I also think a lot of that "corrosion" was flux residue wicking across the backside metal. And who knows if he used rosin or acid flux.

I do know that dis-similar metals, with electricity and water (condensation from water vapor) WILL corrode and ruin the cells. Flux residue or not.