Solar Generator (DIY Goal Zero Yeti)

javelinadave

Administrator
Staff member
Here is a portable solar generating system I built last year. It was built to power an ARB 12v refrigerator and as a power station for base camping trips. In a nut shell it's a Goal Zero Yeti 1250 for less than a third of the cost.

Here is the breakdown. I purchased these three dustproof containers at Home Depot ($98 OTD special) I only used the bottom wheeled box which by itself was $60.

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Next up was selecting the battery. I wanted something sealed so I went with a 70ah AMG battery from Auto Zone. I considered Optima but from my research the new ones lack quality and were WAY more expensive. The charge controller is a Morningstar 10amp model from Amazon ($56).

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I went with Blue Sea for the fuse panel, master switch, 12v outlets and the USB outlet. Amazon had them but they were about 10% cheaper from a marine shop on EBay.
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Here is the almost completed interior. I still need to cut some stiff foam to hold the battery in place.

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The RENOGY 100 Watt 12v solar panel was purchased from Amazon for $150. I also bought with it a 25 foot cord and cut it in half so I could have a positive and negative 12" section with the correct connectors for the panel. On the box side I went with an easier to connect/disconnect plug type.

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All the wiring is 10 gauge except for the wiring to the USB. Goal Zero wanted about $1600 for their unit plus a few hundred for the solar panel. I'm in it for less than $500 and am very happy with the final results. The rolling box weighs about 50 pounds and the panel weighs just a few pounds. I still need to make some folding legs for the panel and sew up a neoprene sleeve to store it in.

The experiment starts this morning and this should be a good test. Today's forecasted high...... 113F (45C) with an evening low of 85F (29C)



This turns out to be a great week to test things out. Record heat (114F) yesterday and hotter (115F) today. Here is the data thus far.
Battery started the test at 13.0v at 10:00a yesterday and the fridge set and pre-cooled to 32F.
07:00a this morning the battery was at 12.4v and the evening low was 82F
08:30a I lower the t-stat to 30F.

115F on the patio, the fridge is 27F degrees and the battery is 100% topped off. I'm calling this a successful project.
 

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Tbaumer

Technical Excellence Contributor
Thanks for the details. Nice clean work.
Great for my Doomsday prepping to get off the grid!
I am definitly doing this.
 
Where did you find the 25 foot cord with the correct connectors? Sorry you motivated me and I can't figure that part out, as well as I really like simple disconnect plugs you used exiting the box, did those come on that extension? Cheers and thanks again for writing the description
 
Nice, well done.
Those Ridgid brand boxes are so useful.
I have a first aid kit business and use the smaller top box as the container for my Industrial/Job Site Aid Kit.
 
Dave, in the VW Van community many people are converting to using two 6v Golf Cart batteries (like the trojan's) wired in series. I dont know much about this stuff but wanted to keep the conversation going on how you chose the battery, etc. I think this is an AWESOME project.
 

javelinadave

Administrator
Staff member
If weight wasn't an issue two 6v might have been an option. For this application I needed portability. Top priority was a sealed battery. I went with a sealed AGM battery. I am building a very similar system in my 110 and will go again with one 12v battery dye to the available space.
I believe people are using 6v golf cart batteries due to their ability to put out decent volts and amps for a very long period of time. They are also able to recover well after a total draining.
Disclaimer: I'm not an electrical engineer nor do I play one on TV.
 
ahh right. Those trojans are NOT sealed. I guess it depends on application. Sailboat has 8 sealed batteries. if it wasnt for heeling and waves, I could probably get away with 3 or 4 non sealed....
 
here is a few I saved
 

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javelinadave

Administrator
Staff member
I HATE PHOTO BUCKET!
All fixed!
Aqui tienes Pedro. Me alegro de que tu familia este a salvo.
 
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I totally forgot about this thread/project. I do not camp but I can see how this could be really useful and would like to try it out. The power in my neighborhood loves to go out.


My dad's boat lift has a solar panel and battery set up and he says it is acting up so this might be a good project for that. His present battery is in one of those boat battery boxes so aside from blocking sunlight it does get exposed to the elements a little bit.



Probably overkill but probably a cool way to install remote camera's around a property where wifi is available but power is not.



Questions
1. Instead of the wires exiting the box through a hole couldn't a plug and adapter be attached at the box so the box is sealed?


2. Does the box need to be vented or can the box be 100% sealed?
 

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javelinadave

Administrator
Staff member
Plugs could be used instead of pigtails for sure.
A sealed battery could probably be used in a sealed box but I’m not an expert on this subject. I’m sure others will chime in on this.
 
It is a bit risky as sealed battery can still vent in an emergency. You need to also be careful with heat generation from the electrical items. Probably not an issue with a fridge and solar panel as they are all low draw/supply.

For cameras and wifi, this is much bigger than needed. It matches well with the fridge use.

For the power outage scenario, at a house, a small generator, with an emergency sub panel and switchover is what you want to do. A lot cheaper than a suitably sized solar backup system which still needs the panel and switchover.
 
If you want to add a vent, something like an eave vent will probably work well and keep rain and critters out. I'd forgotten about this project. Its great!
 
It is a bit risky as sealed battery can still vent in an emergency. You need to also be careful with heat generation from the electrical items. Probably not an issue with a fridge and solar panel as they are all low draw/supply.

For cameras and wifi, this is much bigger than needed. It matches well with the fridge use.

For the power outage scenario, at a house, a small generator, with an emergency sub panel and switchover is what you want to do. A lot cheaper than a suitably sized solar backup system which still needs the panel and switchover.


A NG generator with switch over is still on my list of things to do. Building one of these would just be for emergency where I would plug in whatever I needed, fridge, fireplaces, etc. Much cheaper than a generator at this point.
 
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