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The installation of an off-grid solar system can be a complex task, but with careful planning and attention to detail, it can be completed successfully. In this project, we will demonstrate how to install a solar-powered lighting system in a garage.
First, we mounted the switch sockets and a junction box to the right wall of the garage using screws secured by pipe clips, ensuring that there was a distance of 10 cm from each electrical component. Additional pipe clips were added in between these components, with a maximum distance of 60 cm between them.
Next, we measured the length between the first and last clip for one pipe length, adding 8 cm to this measurement. This length was marked onto a pipe used the handsaw to cut it to size, and then clicked into place.
To ensure that AC and DC cables are laid separated from each other, not only through the pipes but also when it comes to wiring inside the junction boxes, we decided to use two installation conduits parallel to each other instead of just one.
After finishing the installation on the right wall of the garage, we added a junction box for the LEDs at the back of the garage and mounted most of the installation conduit WDS there as well. We then drilled holes for the LED strip clips and secured them in place with screws.
Before attaching the LEDs, though, we marked a point in the center of the first LED clip row and drilled a hole there all the way through up to the roof of the garage. After enlarging the hole from the other side, I hammered the pipe through it and applied a layer of bitumin to seal off the newly created hole.
To mount the solar panel, we created a fitting square shape out of the bitchman (a type of material used for insulation) directed the extension solar wires through the pipe hooked them up to the panel using MC4 connectors, and pressed the panel into the bitumin square to further protect the initially created hole from water. We added an additional layer of bitumin all around the edges of the solar panel inside the garage.
Next, we shortened the pipe and continued by creating fitting lengths of warm white and cold white 5630 LED strip to mount it to the ceiling. I utilized a piece of wire installation between the LED strip and clip to apply enough pressure to the LED strip so that it stays in place, but only used this additional piece of insulation for the first and last clip - not for the other Clips in between them.
To ensure that the wiring is secure, we sold 1.5 mm wire pieces to cover a total area of 4 square meters, making it easy to hook up to the beginning of each LED strip without ripping off the cover pads. We then mounted the remaining DC and AC junction boxes as well as the solar charge controller to the back of the garage.
Using instant glue, we attached the recharge switch to the garage door mounting and fitted magnets to the garage door. By hooking up two wires of the USD cable to the read switch and directing the cable into the D junction box, we started off with the actual wiring - pushing all the required cables through the pipes and partly into the junction boxes, cutting them to size, and wiring up the switch and both sockets.
We then connected all the LEDs in parallel using Wago terminals added a mounting for the inverter to the wall which was attached with zip ties. We continued by adding load wires to the charge controller which we then connected to the inverter and relay circuits inside the DC junction box, and of course it is always a good idea to solder along with PCB terminals to a piece of perfboard beforehand to make the wiring easier.
Finally, to perform the first test of the system, we connected 4 square mm wires to the battery terminals of the charge controller which directly connects to the battery terminals and attached the wires of the solar panel to the PV Terminals. By flicking the light switch, the LEDs turned on without a problem and by adding a Bluetooth module to the charge controller, we can even use an app to see whether the battery gets charged through the solar panel or discharged through the LEDs.
After finishing the AC wiring and closing all the junction boxes, the solar off-grid system was complete and works like a charm. I hope you like this project and learned a thing or two about electrical wiring as always, don't forget to like, share, and subscribe - stay creative, and I will see you next time!