Solar Panel Assembly: This unit is comprised of two 290-watt solar panels, generating a total maximum output of 0.58 KW. The panels are mounted to a stationary assembly. The panels are wired to the solar charger control box which manages the charging system. A 300 watt DC to AC inverter and a duplex 5-20R receptacle allows operators to power equipment that required 120V AC.
Solar Charge Controller: In this 24 volt system solar control system, each panel is terminated with a fused combiner box with a single lever action cut-off switch. With the switch set to the ‘on’ position, the combiner box passes power to the 80-amp capacity Outback Extreme charge controller. This solar charge controller system uses the Outback Extreme series since it standard temperature threshold is more than 160 degrees Fahrenheit, due to its integrated heat sink and fan assembly. Oddly enough, most charge controllers aren’t rated past 104 degrees Fahrenheit despite the fact the will always be close to direct sunlight. In the summer time in Texas, our fabrication shop is normally warmer than that, so this solar light tower uses a charge controller that would support the southern heat. We improve on that capability by shading the charge controller and adding additional air flow from the exhaust of a 1400 CFM component cooling system.
Component Control Center In order to ensure that the 50% threshold on the batteries is controlled, this solar trailer includes a system of min/max voltage sensors and relays that monitor the voltage produced by the batteries and will automatically shut off power distribution when the battery capacity falls below 50%. This protects the batteries from failure. We also include ground fault protection and an Outback Mate 3 monitoring system to track and log all activities related to the charger controller and battery health. In the event there is an issue with the solar trailer, the SD card can be removed from the Mate 3 and sent to Larson Electronics for analysis.
All the electrical components, including the combiner panel, charge controller, over/under battery monitoring and ground fault isolation are encapsulated in a NEMA 3R job box that is bolted to the trailer. Since most of these components are not rated for high heat, our component cooling system circulates air within the job box at 1400 CFM when the ambient temperature exceeds 90 degrees Fahrenheit. The component control center also includes a terminal block so that customers can mount additional electronic gear without interfering with the charging systems. The job box that contains the component control system includes locks for security purposes.
Trailer Assembly: The entire assembly is mounted to a 10` by 6`, single axle trailer via six 1/2" anchor bolts. The two wheel trailer is equipped with 5,4000 lbs axle and leaf springs with 15" trailer tires. The trailer can support and haul an additional 3,500 lbs of equipment. A standard 2" ball coupling, two standard safety chains, and 7-pin flat trailer plug allow for easy hookup and towing. A rugged and waterproof job box is included, safely secured to the trailer.