How to Build a Homemade Solar Panel from Scratch in 25min Video

How to make a homemade solar panel this
is the first in three videos of a solar DIY project everything you should know
to build a 100 watt solar panel at home in order to charge a 12-volt battery
with solar energy a solar panel with 18 volts is required so to build a solar
panel capable of charging a 12-volt battery you will need 2 millimeters of
tabbing wire and another of 5 millimeters solder wire is a must have a
flux pen strapping tape also known as short tape regular tape a solder iron
between 60 and 80 watts an multimeter one that conveyor of both voltage and
current silicon pastes preferably crystalline with UV protection epoxy
resin the best and easie way to do it yourself to encapsulate the back of a
solar panel this epoxy resins have excellent adhesion to glass and acrylic
plastic and ethoxy hardener here the measure is two to one ratio and of
course last but not least the solar cells here is up to you
you can purchase preet absolu cells they have tabbing wire already attached it
will cost a bit more but will saves you a lot of time and work in video
description below you find links to everything you need to start building
your solar panel let's get started the first set we have to take is to measure
the length of the tabbing wire between two cells grab two cells and join them
close to each other like this two or three millimeters between them is enough
with one cell face up is the negative side and face down is the positive side
measure the length of the tab wire along both cells the job here now is to
measure and cut the tabbing wire for all 36 cells for your solar panel
to make this task less tedious cut the tabbing wire to one row of nine cells at
a time and after that you can start cell during the tabbing wire on the negative
side of each cell to do this first pass along each conduct line the
flux pen this will prevent beating of the solder
Arum and also helps the cell to flow cleanly position the tab wire on the
cell and start soldiering from top to bottom in a continuous movement
soldiering is not so hard you get it right very fast but get prepared for a
couple hours of work so this type of 6×6 polycrystalline cells usually has three
connecting bus lines we have to weld 36 cells on the negative side first where
next it must be welded on the positive side that is the back of each cell
creating a string of 18 volts the needed current to charge a 12 volt battery one of the best and strongest materials
to use in a solar panel is tempered glass three millimeters are more than
enough for strength and durability being also the ideal surface to start cell
during your solar cells start by giving a good cleaning now with a clean surface we can start
put things together but first let's again see how a solar panel works the
first cell in this row is the negative side of the solar panel that will be
welded to the negative bass wire becaming this way the negative pole of
the solar panel and continuing with the next three strings of cells all welded
together from front to back of each other making this way a total of 36
cells of 18 volts another thing to note is that solar
cells are very fragile for this reason and almost guarantee you will break one
or more cells even if it is a very small crack you can use regular tape and
repair it easily now that you know how a solar panel works it's time to connect
all cells together to make this task much easier here are some tips you can
use to do this correctly it is convenient to use a type off
tweezers or even a way to hold the wire in the correct place to weld Here I am
using a scissor which works very well another useful tip is to use normal tape
to hold the cells in place in this way they remain aligned helping you to weld
more easily and quickly and if the tabing wire is a bit long simply cut off
the loose ends when you finish the job now with all cells tab together it's
time to clean again the glass surface now with the glass clean it's time to
position and secure the cells in place by measuring the string of cells closest
to the edge of the glass we find the margin on all sides of the panel then
with all cells in place we need to keep each string off cells tightly attached
to the glass first with normal tape and next with short tape now pass the short eight from top to
bottom between each string of cells and at the same time it is convenient to
double check for any broken cells even if there is a slight crack the cause
affair is the encapsulation will pass through it and the epoxy resin will
eventually yellow over time now with all cells secure in place let's
proceed by cell during the string of cells into the bus wire start by cutting
a five millimeter wide tabbing wire to the width size of the two middle cell
strings and secure the bus wire with regular tape cut the loose ends of the cell tabbing
wire and you're ready to solder the two middle rows together here I will weld
the tab wire from the positive side of the cell to the bass wire which will
then weld to the negative side of next string of cells easy as you will see
right away now is to do the same for the other two row of cells on the top of the
panel and then it ends with this two bus wires which show the positive and the
negative poles and after this with a string of 36 cells
connected to the positive and negative bass wire we have to test if we have a
promising solar panel with the panel facing the Sun measure the voltage with
a multimeter and make sure that it produces at least more than 18 volts
here I tested on a spring morning keep in mind that solar panels always lose
tension in the hottest hours depending your region you should get about 18
point six volts during the peak Sun hours now back to the office we going to
proceed by soldering two copper wires to the poles of the panel here you can
choose to use the 5 millimeter bass quieted also to be connected to the
junction box in the bottom middle of the panel if I choose a pair of copper wires
does the same job and I am not using a bypass diode this because I will use a
PWM charge controller to protect the solar panel and the battery from
overcharging and reverse current respectively now let's continue by preparing the
solar panel for the encapsulation the first step we need to do is by placing
the silicon on the edges of the glass this will prevents the resin from
spreading out of the panel epoxy resin is one of the best ways to
keep solar cells from a home made solar panel away from moisture for a panel of
this size you will need about 40 ounces about three pounds or one kilogram is
enough it's not cheap but it is the best choice over the eva film to encapsulate
a solar panel made at home to know where to get this type of clear epoxy resin
follow the links in video description below and of course epoxy hardener here
the blend should be two times the epoxy resin for one hardener and mix these two compounds in a plastic
container and mix it slowly mainly to avoid getting air into the mixture after about two minutes mixing the resin
with the hardener mix it again in another container to obtain a faster and
stronger curing finish this second mixture must be made to obtain a perfect
and well cured resin now what we have to do is to pour the
mixture on the back of the panel to do this simply pour the EPOC see resin from
top to bottom in a constant movement and after 12 hours you will have an
encapsulated solar panel now is time to make the panel frame get
three l-shaped aluminum profiles two meters long and at least three
millimeters thick you can also go with wood it all depends on your budget and
how much you want to spend with your panel this part can be done at the
beginning knowing the size of the glass the panel frame can be made and then
with the glass attached on the panel frame with silicone proceed with the
welding of the cells and the bass wires until finally the encapsulation is made
but always put the silicone in the edges of the glass before doing the
encapsulation now I'll leave you with the images on how to make the frame for
your panel measuring the length of each side of the glass mark each profile with
a marker leave at least two millimeters of cutting edge next to cut the profiles you can use a
cutter holder with a 90 degrees angle but it is best to use a miter saw an angular ruler can also be used to
check the cutting angle it is also useful to keep the profiles in place
during assembly and the best thing to attach the glass
and frame together as to use stainless steel brackets and screws for this panel
I use twelve brackets eight to support the glass and four to join the profiles
position the brackets in place mark and drill the holes and now join each frame
together as I mentioned earlier we can make the
frame before starting putting things together we can make the frame and
attach the glass with silicone then start soldiering the solar cells the bus
wire and in the end with the encapsulation so add the silicon to the
inner base of each profile then attach the glass to the frame next put the
brackets in place add the junction box and then the 100 watt solar panel it's
finally concluded so now we assemble the frame and the encapsulated panel
together and now we put the brackets in place but
if you decided to add a back sheet like this one on the back of your panel do it
before making the holes of the frame and then proceed by putting the brackets in
place Here I am NOT using the back sheet and the reason is for you to see how the
back of a solar panel looks like and now glue the junction box with the
same silicon paste make a hole to pass the pole wires and you have a solar
panel in your hands now watch this next part where we test the voltage and
amperage thanks for watching and subscribe if you haven't already see you
in next videos

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