Fitting solar panels
mention a few pitfalls that I
encountered or avoided.
■ Get daylight panels, not direct
sunlight ones that are still available
and deceptively discounted.
I used ‘PV Logic’ supplied by
BBL’s Plymouth branch, who
were really helpful.
■ Source real cable, not the spare
from the house lampshade rewire.
Western Electrical set me straight
with a whopping current capacity
within 2.5mm^2 section twin-core,
tinned and insulated cable for
marine use (Oceanflex 2.5x2). This
maxed on reduced resistance,
longevity in marine environment
and, more important for me, had
a small cross-section for feeding
into the boat and generally
squeezing through funny cavities.
In fact, it had the same overall
diameter as the 1mm^2 cable
supplied with the panels!
■ I didn’t have to remove the
headliner as I passed the cables
through between fittings: I used the
air vent deck contour area for entry.
Cable length to controller and
battery bank was less than 3m.
I am a marine sealant rebel, so
all sealing was done with my
favourite, theWORKS from
Geocel, which has not failed any
application I have ever used it on.
I decided not to use deck glands.
■ When drilling the PV solar panel
frame, I was delighted to see that
it was so rigid due to a twin-wall
construction, but this meant you
had to be very careful when siting
holes for hinges and the pivot
bolts, otherwise you are too close
to the glass or the sealing silicone
on the underside.
■ Considering the panel
instructions to allow an air gap,
I was still able to keep the pivot
brackets to 70mm high, although
I now think they would not have
looked out of place at 80mm. I did
isolate the stainless steel hinges
from the aluminium frames, but am
wondering why I bothered. I may
add drainage holes in the ‘lower’
edges of the frames if water
collects there, but it hasn’t done so
yet. It takes rather a big sea to wash
over the aft cabin on this boat!
■ The controller is a cheap 10A
PWM type from EP, which allows
for an extra panel, but a 20A
version was easily available.
I uprated the fuse between
controller and battery to 7.5A.
■ I was able to mount theSeparate hinges seemed more
aesthetic than the ‘piano’ typeCables are passed through the
air vent deck contour areaWingbolt on panel edge slides into
groove in pillar, locking it in placeSealant is applied to the
‘axis’ pillar baseThe hinges are screwed
tightly into positionDoor hinge from a glass cabinet
is mounted on the opposite pillarProper marine cable: the junction
box was later filled with siliconeThe cables are ‘mouse-lined’ between headliner fittings▼ ATTACHING THE HINGED PANELS
The controller is a cheap 10A PWM type from EP... ...which is hidden behind the aft cabin door
controller within 50cm of the
domestic battery bank. When
the aft cabin door is open, it hides
the controller, which suits me!
■ Lastly, and oddly the hardest bit,
was designing a locating/locking
bracket to prevent the panels
moving in their chosen position.
I’m still working on a neat and
simple version: I wouldn’t wantanyone to think that I have actually
finished a project that I’ve started...
The trial bracket features a glass
cabinet door hinge, mounted on
an aluminium L-shaped pillar so
that when the doubled solar panel
swings down, its radius doesn’t
hit the bracket when open. Then
it is click-locked with a firm press,
sufficient to stop the panels lifting
by motion, sea or wind. I have
added rubber pads to certain
parts for protection and cosmetics.
When the hinged pair of panels
is in the ‘apex’ configuration, the
edge of the inboard panel nestles
on a foam pad, having engaged a
slot in the side of the pillar, and is
locked into place with a wing bolt
fitted to the panel itself. The same
wing bolts on the port and
starboard assemblies could be
used to link the panels in what
I call the Star Wars Fury-class
configuration! As time goes on, I
may have all the support brackets
refabricated in stainless steel. In
the unfolded position, I still think
the panels are an eyesore, but
folded down, I find their aspect and
‘potential’ quite a pleasing view. By
the way, they work really well.