Huge Low Cost Solar System Expansion!! Part One

This video is about starting two large expansions to my solar system on a low budget by using used parts and solar panels and welding and erecting my own ground based structure for mounting them. This will be broken into a few parts over the next couple of months so subscribe to get notifications of future videos. Thanks for watching.

[@bsod5608]

Another advantage of solar in different directions is that you can utilize existing inverters more, without exceeding the limitations. It would be really nice to see a follow up on this video, and also show how its connected to the inverters / batteries.

[@BajanAlan]

Even Andy is upgrading.

[@duanehulse2037]

To have time to do all of this you must have a very understanding wife!

[@kennethalmond8922]

Thanks for sharing - clearly you're coming at this from long, practical experience. In my case, offgrid in the city, I'm maxed out on the reasonable number of panels (48) I can deploy from a 'good neighborhood' standpoint. However, in the winter couple of months I only make 25% of what I do in summer which is certainly better than nothing but not enough. So.... I bought 40 used (8yr old, very cheap, tested >=95% of original specs) panels and store them under the house in the dark along with Unistrut + wire + misc so that in a dire emergency in the winter I could temporarily prop them up in the back yard, feed them into the existing solar system, and significantly increase the available winter power. Sort of a used panel backup generator concept that's $ competitive with a comparable fuel generator kw wise. Pro = no maint, no fuel. Con = storage space, much harder to setup.

[@cakeinfo6510]

thanks man, i am a first timer and your sincereity is trust.. i really love you man, i will love to learn how to build battery pack

[@chuxxsss]

Morning Ray, love this content. The more solar the better. I work out I need 20 KW. My new battery is on it's way. Server 2.ooooo dear on its way.

[@MichealG]

Wow. Welcome back. Hope you are ok. Was missing your videos. Wish you the best.

[@davidsoulsby1102]

Your short cable issue. Strip back the original cable, crimp or solder a straight through connection and heat shrink a sleeve on. a solid connect is better than a plugin.

[@awesomedee5421]

You can recreate your video with the bad mic by using the video and dubbing new audio onto it. Just mention what happened, and people will understand the audio won't be lip-synced exactly, but you'll get the info across.

[@RayBuildsCoolStuff]

Editing….. eeeeeek!

[@davidwright1752]

@@RayBuildsCoolStuff turn on captions in the channel settings it should be able to help . I’m with you trying to edit sucks for me. Not that cleaver myself

[@FutureSystem738]

Thanks Ray. Also be careful with all that rotating machinery (power take off and auger) with ANYTHING hanging loose- clothing, belts, and yes, hair. I’ve seen horrific injuries from that. Cya & Cheers from Oz. 🇦🇺

[@RayBuildsCoolStuff]

will do

[@royamberg9177]

You can solder the wire in the terminal box on the panel

[@VeryWarmBear1]

Hi Ray a bank of amorphous solar panels will make power in cloudy, overcast, rainy days from sunup to Sun down production, they have lower output but have a bigger solar time window.

[@duanehulse2037]

That stick welder would have been for heavy metal those rails that you're using that would best be done with a wire feed I was an auto mechanic in my day and when I was a drag Racer I was a bit of a fabrif you're gonna Weld 2 pieces steel I be to support Atlas floor in a basement or something you'd use that stick welder because that would be beyond the capabilities of the wire feed Unless of course you had access to commercial equipment there are wire feeds big enough to do that you're gonna be an industrial factory when you find that thoughAnd the ones that we had at Walker manufacturing they were 3 phase

[@ernestolaureanopineiro1123]

Happy new year. Hope you are well. May God Prevail in your life and family for all eternity. Que Dios Prevalezca en tu vida y familia por toda la eternidad.

[@pelecho]

Just Be careful with damaged panels. I know it’s really cheap but it’s for a reason. Look at last video of off grid garage

[@mwolrich]

Yes, Andy (From Sunny Hot Australia), found a hot spot on one of his ancient panels, said it could become a possible fire issue, it’s why he’s replacing his original Canadian Solar panels (and he’s getting the new panels for about 1/2 price with the government incentives)

[@lukefarmer5391]

Flux core is one of the most robust and forgiving of all welding. It will blow through rust, paint and dirt. I have watched professionals test flux core vs solid and, yes the solid is cleaner but it was almost never as strong. Stick with a good flux core and stick with it.

[@worskaas]

High Frequency inverters are quiet, have a fan when heat builds up. But very low surge capacity. They are easy to pick up and move around. The problem is, they are advertised in KVA, and people don't take the power factor into account and run it for extended period on its maximum KVA rating which is usually only meant to run maybe not longer than a second. Low frequency 30kW inverter will weigh 250kG, not easy to pick up. They are noisy, less efficient, but more than likely to last longer due to them able to handle 3x the surge load in some cases. Ideally for anything with an electric motor. For example the 30kW low frequency can surge 90kW for 10 seconds. That could be handy, knowing you have a lot of room for motors to start up at the same time when there is a power interruption.

[@OffGridGarageAustralia]

My experience with used panels is, that they are very inefficient in cloudy weather. Sure, you can compensate a bit by increasing the area, but eventually the effort is so large that just buying new panels would be a lot better... and more efficient. I know it is about reusing and recycling and I'm all for it but especially the Renesolar have problems with snail trails, discolouration and performance and eventually burn out (literally). I have 25 of them... all not great. It will be interesting to see how you go with them.

[@RayBuildsCoolStuff]

Hi Andy, thanks for the comment. I will be watching these and I'll also be doing another addition with new panels. These are ending up costing the time to install them. If in the future I decide to replace them, the infrastructure will still be there for different panels of similar size. I'm looking forward to getting these on line and seeing the results. Keep up the good work on your channel. You are in beast mode lately.

[@USA-GreedyMenOfNoIntegrity]

Great to see you again! You are catching up to my present 20.6kW. I’m also adding another 13.3kW of pv. I am truly off-grid, all electric, 16-33SEER 6.25 Tons of Air Source Heat Pumps. Summer is easy. Winter’s cloudy days produce 5-10%, so I need a lot of PV, especially on a sunny day when you really want to get that 143kWh battery filled up.

[@RayBuildsCoolStuff]

Sounds like a great system.

[@MichealG]

You need to check your audio before going with the video or better to have a backup audio, just in case. You can use another phone with a recording app as a backup.

[@carlh2007]

Hey Ray I am in north qld autralia and I get panels for free. There is a solar install place around the corner from me, when they do upgrades they just leave piles of panels out the front of their store for people to collect. I have heard if you contact solar companies and ask some are more then happy to give you these panels, alot of them pay to put them into land fill!

[@peterdobrovansky8305]

Hi Ray, love your videos and what you do. Like you, I also bought second hand solar panels to add extra power for those cloudy days. The problem is you technically need to buy another Solar Charge Controller for those second-hand panels which costs many times more than what those panels cost. To save on costs, I have used an Arduino to monitors the current the existing panels are producing. When the output current drops to below to what the second-hand panels can produce, the Arduino (using a relay) connects the second-hand panels so that the existing panes and the second-hand panels are in parallel with the existing panels. The Arduino constantly monitors the current going into the Solar Charge Controller. If the current of the paralleled panels should approach the Controller current limit, then the Arduino disconnects the second-hand panels. Saved me not having to buy another Controller and the system works well. Keep up the good work.

[@RayBuildsCoolStuff]

That’s a good point for some of the viewers. In my case I’m using three all in one inverters which have plenty of solar charge controller capacity so adding these panels into some of the photovoltaic circuits available is easy.

[@bimmers323ci]

Cool

[@keithcress1335]

Hi Ray. I'd suggest you don't try to weld to the existing racking. Most racking has some sort of inserts made to extend racking on to more racking. This would be less risky then welding, which besides possibly weakening the existing racking, can also "shock' the panels or any equipment the panels are hooked to.

[@RayBuildsCoolStuff]

My plan wasn't to weld the racking but just the steel frame. I agree that there is a serious risk to electronics if I weld to anything that is in the electrical path. I think I will consider a bolted connection for the final connection. Thanks

[@patrickmckowen2999]

Good stuff 👍

[@bsalightning69]

You will like using the mig gas over the flux core wire since it has such less splatter. Glad I transitioned to mig gas years ago. Looking forward to more videos!

[@RayBuildsCoolStuff]

Thanks. I’m sure that’s true except outside in a breeze on the solar frame. I do use anti spatter and that helps a lot. I do like gas bottles

[@RayBuildsCoolStuff]

@Simon Messer alibaba is set up as a wholesaler. They expect you to be buying product that you are selling to your customers.

[@typxxilps]

You might remember a song and tune that was released shortly before the end of the cold war i think in the last year. 'We didn't start the fire' was the title track back then by Billy Joel and that came to my mind when I checked your channel for video I might have missed even though all the subscriptions notification and what now are turned on and stumbled across this title PART ONE. So as you had started the fire with PART ONE I am asking about the release of PART TWO of that fire you had ignited. Just kidding, I simply ask about what has happened or when you are going to work on that or did I miss it in other videos ? And of cause it is a sign that your community members are there and still watching even though the release of videos have slowed down a bit compared to last year. Thanks for all the great input had given so far especially those excursions to non solar power and battery related topics like architecture and how to build things that will last long.

[@RayBuildsCoolStuff]

I’m still alive and thinking about you. I’ve been focused on lots of ranch work and other things. It won’t be long now. I’ll get back into this project.

[@sh839c]

That's plenty deep

[@Dutch_off_grid_homesteading]

Heya, if you have the space you can do that nore panels for lower cost. for me living in the city I can only use my roof so I'm limitted in space so I have to go with the highes power panels as possible ( found 600W panels for around 100 euro per piece ) have already installed 12 on the east/south roof and 12 on thd south roof total of 6KW and want to install 12@600W on the west/south roof. but have to safe some many to bay new panels inverters batteries etc etc

[@scotthorslin5482]

Thx for this Ray! 👍🏻

[@AndyFletcherX31]

I have about 100% solar over-provisioning on my 48V/100A charge controller. The only thing you have to watch with some systems is the maximum Isc for all the PV strings in parallel doesn't exceed the maximum input rating of the charge controller.

[@RayBuildsCoolStuff]

My inverters have plenty of capacity not their solar charge controller circuits. It is something to watch for though.

[@johnelliff8298]

Hi Ray, Hope you are taking an extended break because of too much fun and excitement happening. Take care, your presence is missed🙂

[@RayBuildsCoolStuff]

Thanks, I’ll be back!

[@forerunnert]

Same here, good stuff!

[@michaelcoghlan9124]

Thanks very interesting, hope your travels go well, take care. Michael

[@9111logic]

Nice one Ray, I wish I had more ground space in order to install more modules like you - Thanks for this one more video 🙏

[@RayBuildsCoolStuff]

More videos to come. Been busy with other things but I’m getting caught up.

[@BajanAlan]

The guy with the Swiss Accent did an interisting video on pannels

[@CoquiAudio]

oh man this video is so good and the mic wasn't working, 😔 anyway still a good video I like it 😊

[@jamesbsa6450]

Hey, Ray, thanks for putting this together. I see you are needing to build more battery boxes. Do you suppose when it comes to assembling your packs you could take us through all the things you NOW do (as result from all that you've learned) and show your polishing, resistance checks, wiring tips (length, etc.)? Hoping you had a great Thanksgiving and you get to enjoy another dive soon. All my best!

[@davepartlow6430]

Dubb the other video. I'm looking forward to seeing this project to the commisioning. Also the review on this new power pack. I also weld and use a 10kw welder gas generator which also runs my 250A wire welder. It would be nice to get off the gas. Have some questions, now that I'm all caught up. Do you still recommend Jenny Wu for the cells? Will the Seplos BMS boards you're using communicate with each other for discharging, charging, and balancing of the cells? And also be able to monitor the cells via computer? I'm getting ready to order cells and planning on two battery builds. Thank you very much for the videos that you've done and the information you've provided. Stay well. 🤙

[@houseofancients]

njoy your holliday ray, looking forward to your build. come next week , depending on delivery, might drop you a surprise email with some pictures :)

[@RayBuildsCoolStuff]

Something to look forward to.

[@douglasrobbie9998]

Since you are a DIY type have you considered setting up panels to track the sun? Not the very expensive 2 axis on a single pole but something else. I looked into this and thought something like the following might work. The array of, for example, 12 (400w+) panels mounted vertically (a row of 12) on a base frame that rotates around a single pole in center rear, The frame pivots around pole being driven by small motor/wheel that rides on a curved track. Other wheels support frame but are not driven. This provides 1 axis movement E/W. For the N/S tracking, 6 or the panels would be on one upper frame that hinges on the S side (for northern hemisphere)of the base frame. There would 2 of these upper frames, one on each side of the pivot pole. each of these upper frames is raised or lowered to face the sun's height in sky via 24v slow rpm motors used to roll up plastic sheeting on greenhouses. These motors attached to 18' long est round bar (or sq bar with round bar ends welded on) that have cogs at beginning and end. These cogs fit into track that is attached to curved supports (4 of them) that are securely attached to the base frame. Using the inexpensive 2 axis solar trackers that would control the motor wheel for E/w movement and the greenhouse sheet motors to control the N/S movement. In addition, a wind speed instrument that can be purchased with solar tracker, would be attached to top of frame and connected to solar tracker and would make panels lie flat if wind was over a user set limit. Just something I've thought about to get 30-40% more solar power. Might require newer high wattage panels to make worthwhile. Given the 2 axis tracking, might provide the AM and PM power you are looking for and adjust for seasons and height for sun during day.

[@RayBuildsCoolStuff]

I have looked at it and decided it was chasing rainbows. More panels are a better use of capital in my opinion. You have to be pretty far off axis for it to matter and by then you are already down on angle and intensity.

[@silverbackag9790]

Getcha a downforce kit for that post hole digger. Or better yet, a hydraulic one for the front end loader if you can justify it.

[@RayBuildsCoolStuff]

If I had a heavy duty auger with carbide points for digging rock then the downforce of a skidsteer attachment would be important. With an auger designed for soil, it is less important and can even lead to abusing and damaging the auger. This auger was 200$ from tractor supply. It isn't very heavy duty and I am surprised at how well it is holding up but I am being gentle with it. These augers get abused routinely and the one that was on this digger was literally destroyed from misuse. The teeth couldn't be replaced because the auger itself had been worn down from misuse. It was a heavy duty auger in the hands of someone that tried to brute force holes in bad conditions and then tried to weld carbide points to it without understanding the required geometry. It wouldn't even dig in soft dirt. It will go to the scrap pile now.

[@chuxxsss]

My father in law said to me Lacker the broken panels. Check my vlog on fixing old panels mate. Oh I have not put it up?

[@Bob.W.]

Hi Ray, noticed you haven't posted for awhile and hope to see your progress. When your expansion is complete will you keep your shore power connected if needed? If so, I would like to know how it will interface with solar? I am building a small system and have wired some inverter only receptacles in key locations, keeping the systems separate. Thank you.

[@RayBuildsCoolStuff]

Sorry I haven't posted. Building a big garden, mending fences, cleaning up ice storm damage, welding gates recovering from illness and other fun stuff that isn't moving my channel projects forward but all stuff that needs to be done sooner than later and can't be put off. I'll be back at it soon. Tomorrow I'll be welding and painting garden gates and then I have a cattle guard to repair. It's all fun but eats up the calendar.

[@Ontariolabz]

Hi Ray! Love your channel. I see the compressed gas cylinders and I think I've heard you mention scuba diving in your videos - do you have any content showing your set up? I dive and recently procured an older Bauer compressor that needs attention. I also scored a gas booster. Love me some gases! Would love to see your content on that front ;-) Be well and Thanks!

[@RayBuildsCoolStuff]

I only have a video about diving sidemount. Mixing gases and continuous blending through the compressor has inherent risks that can be deadly. I don’t want to lead people down a path where a misunderstanding or incomplete knowledge can cause the death of them or their family.

[@marktheunitedstatescitezen185]

Good morning Ray , I have a Question if you could help me , I have 3.2v lithium batteries I bought from AliExpress different sellers but my issue is they will not charge over 3.31v I have 20 PCS 3.2v 280AH batteries all in parallel like 1 big circle , a buss bar at each end connecting the positives and the negatives battery charging cables connecting them 1 big circle! “ What am I doing Wrong ! “ please HELP you’re Wisdom goes far beyond you age like Tessler !

[@zaprodk]

Ray, what decides if you use the audio on the camera or the wireless lapel mic.? The lapel mic has a terrible flat sound compared to the mic on your camera.

[@RayBuildsCoolStuff]

The camera is just my iPhone. If it is windy it does not mute the wind very well at all. The real problem is when the camera zooms in or out it changes the volume dramatically and if we zoom in the sound drops so low that it’s hard to understand. What decides whether or not I use the lapel mic I s whether or not I remember to bring it. 😂😂😂

[@Jaimen403]

The problem is that for having the same power on a cloudy day you need to install 10 times more panels.

[@RayBuildsCoolStuff]

It’s not as bad as that. I’ve been monitoring my production and consumption for about seven years now. Even on cloudy days unless it is really dreary or raining will still make 15 kWh. If you double that you really aren’t going to drop behind much on your battery state of charge. On days when the sun comes out for two or three hours having double the capacity can really recover a lot of state of charge. I think I will be using my generator almost not at all once I double the capacity.

[@Jaimen403]

@@RayBuildsCoolStuff Thank you for sharing your experience. I have simply studied fo rdesigning installations. I only have 5Kw on my roof as a major experience and I know that with clouds I get 10%.

[@USA-GreedyMenOfNoIntegrity]

I can produce 125kWh max on good sunny summer days. Typical is 50-80kWh. Presently, on warm, cloudy, early Nov days, I can barely maintain with 10-20kWh of production per day. If it was very dark days, forget it. The Generac would be cranked up.

[@Jaimen403]

@@USA-GreedyMenOfNoIntegrity same experience with my 5kW installation. Thanks God I’m still connected. My weather in Spain is similar to Ireland. Now I’m trying to find some domestic eolic generator. Difficult task…

[@houseofancients]

heya Ray, howś your expansion comming along ?

[@etusuku8848]

Hi Ray, you have nice videos. I'm not native English, but they are really nice and easy to follow. Have you had any experience with Topband batteries, I can't find any information of them, besides the factory promotional videos. My best regards from Finland, Eeli

[@RayBuildsCoolStuff]

Thank you very much! I have never heard of topband batteries.

[@etusuku8848]

@@RayBuildsCoolStuff Yeah, maybe they sell them mainly here in the Scandinavia. I hope you didn't get any harm from the battery kit company that was threathing you. That wasn't a nice story.

[@upnorthandpersonal]

I never had the chance to build using used rails/panels since solar isn't popular here up north. I guess you might have seen my low cost ground mount solution for my 500W panels.

[@peterking1134]

Where are you at?? Miss ya!

[@RayBuildsCoolStuff]

I’m a busy beaver. I’ll be back.

[@duanehulse2037]

OK I'm on a shoe string budget so thin that it would be fair to say I don't have a budget she's wanting me to build a chicken coup out there I wonder if I can use that and some steaks in the ground to anchor panels and why I couldn't just use 2 x6's instead of these pieces of metal which are so expensive even if I find them used iron is $400 a ton i did find some used panels they wanted 125 and 150 each for them We are out in the country so I do have room I could put up a bunch of 250 W panels On the video where you showed you were adding on to yours and you were talking about being just West of straight South and you were gonna put some up just East of South I would probably have room to split it up into 3 which would probably be extra work to have one straight South 1 East and 1 West I have clear place where it would be easy to get morning sun and afternoon mid high noon sun afternoon sun would have to be positioned correctly I do have some trees to the Southwest Many of the things that you do are what my friends when I do similar things would call overkill would 3 arays be overkill or would 2 be sufficient in your mind?

[@RayBuildsCoolStuff]

I would have to say in this instance, more is always better if it doesn’t compromise other needs.

[@yasasjayasuriya1258]

Ray, do you think storing solar panels top of the each on it, is a good idea? There is a good chance to make more additional damage to panels in the bottom. It's better to store them in vertical position

[@RayBuildsCoolStuff]

All the weight is on the frames. This is how they are shipped.

[@USA-GreedyMenOfNoIntegrity]

I have 28 stacked. Like he said, the weight is on the frames. I run alum foil tape strips up each end to prevent sliding. Cut or remove tape as you go down.

[@johngermain5146]

Thanks for Sharing ... I dont' understand AC coupled panels since panels put out DC.

[@RayBuildsCoolStuff]

AC coupling is when you have an inverter that converts your panel voltage to AC and then you couple that into a hybrid inverter that can accept power from multiple and various sources.

[@BajanAlan]

Enphase!

[@RayBuildsCoolStuff]

@@BajanAlan Solar Edge with optimizers!

[@BajanAlan]

My Enphase system has a micro invertor on each panel. THhe AC output feeds strait into the main switchboard!

[@BajanAlan]

@@RayBuildsCoolStuff I am not sure about that!

[@bobcole3852]

nice system you've built! where did you find "such a deal" on the panels?

[@RayBuildsCoolStuff]

Local solar contractor that installed my original system.

[@bobcole3852]

@@RayBuildsCoolStuff thanks! BTW, aren't you tied to grid too? Have safe travels...

[@RayBuildsCoolStuff]

@@bobcole3852 currently tied to grid. Goal is to cut the cord.

[@keithbrookshire]

Ray, When patching the cables on the panels is it important for all cables in the array to be the same length? OR is it important for each cable on the same panel to match each other? I have one panel that has a cable cut off by about 18" and I don't know if I need to extend it to match the other cable or can I just put an end on it and use it. BTW: Since you already made the video about patching the cabeling maybe you could do a voice over and still use the footage. Thanks for all the great information.

[@RayBuildsCoolStuff]

The length is not important. I can build anything but editing video crushes my spirit.😂

[@user-sl4ms1oj9o]

@@RayBuildsCoolStuff ，Sorry to bother you, but are you interested in sharing test videos of 48V battery packs?

[@RayBuildsCoolStuff]

@@user-sl4ms1oj9o my email is [e-mail]

[@user-sl4ms1oj9o]

@@RayBuildsCoolStuff ，Thank you, I will contact you by mail tomorrow.

[@sforce05]

Hi ray is it okay to used thhn/thwn wire for solar panels? The wire that goes to inverter and connection to the panel only. I was worried if they are sun resistance.

[@RayBuildsCoolStuff]

Those wire types are not UV resistant

[@USA-GreedyMenOfNoIntegrity]

I use 10 ga THHN inside gray conduit to a pull box and pv disconnect. I mount my SPD by Midnite Solar on side of pull boxes. There I convert over to PV wire.

[@ericzimmerly1]

Are you in the Texas Hill Country? Live Oaks and Mountain Cedar.

[@RayBuildsCoolStuff]

Yup

[@ericzimmerly1]

@@RayBuildsCoolStuff I was skeptical for a minute when you said you were going to go 4 feet down. Then you said the soil was added. I'm lucky if I can get 6-12 inches down..everything is anchored into the rock on mine.

[@RayBuildsCoolStuff]

@@ericzimmerly1 😂😂

[@chuxxsss]

Can you link your video on the testing mate?

[@RayBuildsCoolStuff]

I wasn't able to post it because the microphone didn't work. Very disappointing.

[@chuxxsss]

@@RayBuildsCoolStuff You can do a voice over mate. You blank the original out.

[@dangoras9152]

Brother if u need more panels hit me up... I can get u new panels that are old stock the business went under and we got pallets different ones from 235 to 435 and im not far from u..... Keep it up brother

[@geoffleach8948]

I'm looking for about 40 panels if you can point me in the right direction

[@davidsoulsby1102]

How about using that video footage and do a voice over..... seems a shame to waste it.

[@RayBuildsCoolStuff]

I really don't do editing on my videos. So sorry sir.

[@repairman2be250]

Terrible sound.

[@pelecho]

Just Be careful with damaged panels. I know it’s really cheap but it’s for a reason. Look at last video of off grid garage

[@RayBuildsCoolStuff]

These panels have nothing like the manufacturing defects that Andy had from his Canadian Solar panels.