Author: BenjaminNelson via YouTube
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Getting ready for a sustainability fair, I try to quick finish off the wiring, take care of the grounding, clean up the planks, mount the battery, and paint the trailer! Please click SHOW MORE!
On the second set of three panels, I needed to wire them up. This is essentially the exact same thing as what I did on the first side. I used stainless steel clips and wire ties to hold the panels cables to the frames, and zip-tied a long red PV wire across the pipe to the front of the trailer. The PV wires go into the enclosure through cable glands and into the Combiner/Disconnect box where the red wire connects to the second DC breaker. The black wire gets connected to the negative bus connection.
-I also worked on grounding everything. Specifically, this is the EQUIPMENT GROUND. All metal frames, enclosures, and anything else which normally does NOT carry current, but COULD if an energized wire accidentally touched it needs to be bonded together. Should a metal part accidentally become energized, this will blow a fuse/breaker instead of allowing for a potential shock. This copper wire is known as the Equipment Grounding Conductor.
-After removing the planks from the trailer, I experimented with pressure-washing them. In the end, it turned out that sanding them was quicker, and I liked the overall look better as well.
-Lastly, I mounted down the back end of the pickup truck tool box and the battery. I cut a piece of 3/4" plywood to go under the battery, then drilled through that, the toolbox, the planks, all the way down through a metal cross-member of the trailer. I ran a pair of 3/8" galvanized carriage bolts through and bolted them down. The battery pack was then mounted by some large wood screws going through existing holes in the Nissan Leaf bottom plate.
-This project is a bit of an experiment in building a portable, off-grid solar system using mostly what I already have. The Charge Controller is one that I’ve already had for years. The battery is made from 7 Nissan Leaf Cell modules. See the video on building the battery at: https://www.youtube.com/watch?v=juk39…
The inverter is a repurposed Uninterruptable Power Supply (UPS) which ran on 48V and would have originally been used in a computer server room. I’m just using the inverter portion of this unit, but it could also be used as a battery charger if I connected it to wall AC power. I used this same unit to power my house during a blackout from my motorcycle. Learn more about that at: https://www.youtube.com/watch?v=-ydKi…
Tools and Materials used in this project:
Cup Wire Wheel for angle-grinder: https://amzn.to/3uYH2hk
Ryobi 18V Pressure Washer: https://www.homedepot.com/p/RYOBI-ONE-18V-EZClean-320-PSI-0-8-GPM-Cordless-Cold-Water-Power-Cleaner-Tool-Only-RY120350/312453233
Replacement Right Trailer Light: https://amzn.to/3mF5SiF
Milwaukee Sawzall blade set: https://amzn.to/3AzZI8i
Dymo Label Maker: https://amzn.to/2YMUYPI
2" Iron Pipe Coupling, 3/4" bolt
3/4" Pillow Block Bearings: https://amzn.to/3kOxan0
DC Circuit Breakers: https://amzn.to/3oeUkVL
Circuit Breaker DIN Box: https://amzn.to/2ZHjx0N
MC4 Tool: https://amzn.to/3BrCz9h
Xantrex C40 Solar Charge Controller: https://amzn.to/3F0pJ41
(I later upgraded the charge controller to an Outback Flexmax80. Find out why in a future video: https://amzn.to/3EYDoJ7 )
14S Lithium Battery (Leaf Cell Modules)
2200 Watt UPS (Recycled, Repurposed)
Solar Cable: https://amzn.to/3umPiHC
Replacement tool box gas lifts: https://amzn.to/3zMSVb7
DC Current/Power/Energy Multimeter Display: https://amzn.to/3ikkRwZ
Stainless Steel Cable Clips: https://amzn.to/3ATglwN
Anderson Disconnects: https://amzn.to/3oen7K1
Plug-In Electric Usage Monitor: https://amzn.to/3oeVZKZ
Weather-proof cord grip Cable Glands: https://amzn.to/3iinBej
DIN Rail Terminal Block Kit: https://amzn.to/3CZNBmr
Stainless Steel Zip Ties: https://amzn.to/3EYENiR
Outdoor Rated Metal 2-gang electric box: https://amzn.to/3oeqikV
Two-Gang Weather-proof outlet cover: https://amzn.to/3ojzWTu
Ryobi 18V Drill: https://amzn.to/3A3msxf
Step Drill Bits: https://amzn.to/3abVAAR
2.25" Exhaust clamps with u-bolts: https://amzn.to/3FviykT
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