Merge PR #758
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Alexander Whitestone
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docs/lab-004-solar-deployment.md
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# LAB-004: 600W Solar Array Deployment Guide
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> Issue #529 | Cabin Compute Lab Power System
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> Budget: $200-500
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## System Overview
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4x 150W panels → MPPT controller → 12V battery bank → 1000W inverter → 120V AC
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```
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[PANELS 4x150W] ──series/parallel──► [MPPT 30A] ──► [BATTERY BANK 4x12V]
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│
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[1000W INVERTER]
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│
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[120V AC OUTLETS]
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```
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## Wiring Configuration
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**Panels:** 2S2P (two in series, two strings in parallel)
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- Series pair: 18V + 18V = 36V at 8.3A
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- Parallel strings: 36V at 16.6A total
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- Total: ~600W at 36V DC
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**Battery bank:** 4x 12V in parallel
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- Voltage: 12V (stays 12V)
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- Capacity: sum of all 4 batteries (e.g., 4x 100Ah = 400Ah)
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- Usable: ~200Ah (50% depth of discharge for longevity)
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## Parts List
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| Item | Spec | Est. Cost |
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|------|------|-----------|
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| MPPT Charge Controller | 30A minimum, 12V/24V, 100V input | $60-100 |
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| Pure Sine Wave Inverter | 1000W continuous, 12V input | $80-120 |
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| MC4 Connectors | 4 pairs (Y-connectors for parallel) | $15-20 |
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| 10AWG PV Wire | 50ft (panels to controller) | $25-35 |
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| 6AWG Battery Wire | 10ft (bank to inverter) | $15-20 |
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| Inline Fuse | 30A between controller and batteries | $10 |
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| Fuse/Breaker | 100A between batteries and inverter | $15-20 |
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| Battery Cables | 4/0 AWG, 1ft jumpers for parallel | $20-30 |
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| Extension Cord | 12-gauge, 50ft (inverter to desk) | $20-30 |
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| Kill-A-Watt Meter | Verify clean AC output | $25 |
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| **Total** | | **$285-405** |
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## Wiring Diagram
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```
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┌──────────────────────────────┐
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│ SOLAR PANELS │
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│ ┌──────┐ ┌──────┐ │
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│ │ 150W │──+──│ 150W │ │ String 1 (36V)
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│ └──────┘ │ └──────┘ │
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│ │ │
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│ ┌──────┐ │ ┌──────┐ │
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│ │ 150W │──+──│ 150W │ │ String 2 (36V)
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│ └──────┘ └──────┘ │
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└──────────┬───────────────────┘
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│ PV+ PV-
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│ 10AWG
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┌──────────▼───────────────────┐
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│ MPPT CONTROLLER │
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│ 30A, 12V/24V │
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│ PV INPUT ──── BATTERY OUTPUT │
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└──────────┬───────────────────┘
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│ BAT+ BAT-
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│ 6AWG + 30A fuse
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┌──────────▼───────────────────┐
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│ BATTERY BANK │
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│ ┌──────┐ ┌──────┐ │
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│ │ 12V │═│ 12V │ (parallel)│
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│ └──────┘ └──────┘ │
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│ ┌──────┐ ┌──────┐ │
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│ │ 12V │═│ 12V │ (parallel)│
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│ └──────┘ └──────┘ │
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└──────────┬───────────────────┘
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│ 4/0 AWG + 100A breaker
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┌──────────▼───────────────────┐
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│ 1000W INVERTER │
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│ 12V DC ──── 120V AC │
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└──────────┬───────────────────┘
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│ 12-gauge extension
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┌──────────▼───────────────────┐
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│ AC OUTLETS │
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│ Desk │ Coffee Table │ Spare │
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└──────────────────────────────┘
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```
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## Installation Checklist
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### Pre-Installation
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- [ ] Verify panel specs (Voc, Isc, Vmp, Imp) match wiring plan
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- [ ] Test each panel individually with multimeter (should read ~18V open circuit)
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- [ ] Verify battery bank voltage (12.4V+ for charged batteries)
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- [ ] Clear panel mounting area of snow/shade/debris
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### Wiring Order (safety: work from panels down)
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1. [ ] Mount panels or secure in optimal sun position (south-facing, 30-45° tilt)
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2. [ ] Connect panel strings in series (+ to -) with MC4 connectors
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3. [ ] Connect string outputs in parallel with Y-connectors (PV+ and PV-)
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4. [ ] Run 10AWG PV wire from panels to controller location
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5. [ ] Connect PV wires to MPPT controller PV input
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6. [ ] Connect battery bank to controller battery output (with 30A fuse)
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7. [ ] Connect inverter to battery bank (with 100A breaker)
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8. [ ] Run 12-gauge extension cord from inverter to desk zone
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### Battery Bank Wiring
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- [ ] Wire 4 batteries in parallel: all + together, all - together
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- [ ] Use 4/0 AWG cables for jumpers (short as possible)
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- [ ] Connect load/controller to diagonally opposite terminals (balances charge/discharge)
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- [ ] Torque all connections to spec
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### Testing
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- [ ] Verify controller shows PV input voltage (should be ~36V in sun)
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- [ ] Verify controller shows battery charging current
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- [ ] Verify inverter powers on without load
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- [ ] Test with single laptop first
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- [ ] Monitor for 1 hour: check for hot connections, smells, unusual sounds
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- [ ] Run Kill-A-Watt on inverter output to verify clean 120V AC
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- [ ] 48-hour stability test: leave system running under normal load
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### Documentation
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- [ ] Photo of wiring diagram on site
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- [ ] Photo of installed panels
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- [ ] Photo of battery bank and connections
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- [ ] Photo of controller display showing charge status
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- [ ] Upload all photos to issue #529
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## Safety Notes
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1. **Always disconnect panels before working on wiring** — panels produce voltage in any light
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2. **Fuse everything** — 30A between controller and batteries, 100A between batteries and inverter
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3. **Vent batteries** — if using lead-acid, ensure adequate ventilation for hydrogen gas
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4. **Check polarity twice** — reverse polarity WILL damage controller and inverter
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5. **Secure all connections** — loose connections cause arcing and fire
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6. **Keep batteries off concrete** — use plywood or plastic battery tray
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7. **No Bitcoin miners on base load** — explicitly out of scope
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## Estimated Runtime
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With 600W panels and 400Ah battery bank at 50% DoD:
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- 200Ah × 12V = 2,400Wh usable
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- Laptop + monitor + accessories: ~100W
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- **Runtime on batteries alone: ~24 hours**
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- With daytime solar charging: essentially unlimited during sun hours
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- Cloudy days: expect 4-6 hours of reduced charging
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---
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*Generated for issue #529 | LAB-004*
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