portable solar, weather protecting the charge controller

[CO_Hunter]

I think I may have read all the solar threads here, well maybe not but it sure feels like it. A lot of great info and cool setups.

Maybe some of you can help. I have a 100 watt rigid panel and flooded deep cycle battery that I want to be able to use with a popup tent trailer, or use with my Land cruiser w/o popup and top off crank battery. Bottom line, I want to be able to move the set up around. I have seen some pretty cool portable box set ups but what I wonder about is adequate venting, for charge controller heat, plus being rain protected when unattended.

So any ideas on the best way to weather protect the charge controller while allowing for adequate venting at the same time in a portable scenario?

Thanks in advance and pics are always awesome.

 

[Joe917]

The charge controller needs to be mounted with the shortest cable run to the battery. Keep the charge controller in the pop up or LC depending on which battery you are charging (you should only be charging the truck in an emergency).
Move the panel around on longer cables and place it where you want. Check voltage drop tables for wire size.

 

[1Louder]

Here's what I did. Simple solution in a box that can be open or closed. Never had an issue with it getting hot.

http://www.expeditionportal.com/for...olar-Controller-Box-Setup?highlight=DIY+Solar

 

[4x4junkie]

The charge controller needs to be mounted with the shortest cable run to the battery. Keep the charge controller in the pop up or LC depending on which battery you are charging (you should only be charging the truck in an emergency).
Move the panel around on longer cables and place it where you want. Check voltage drop tables for wire size.

×2, the charge controller should be right near the battery with heavy-gauge wire going to it (I like to see 1% or less voltage drop between it and the battery). They also generate very little heat so as long as it's not sealed in a very tiny space it should be fine as far as ventilation goes (make sure the sun can't hit it though, as this can throw off the temperature compensation and result in your battery not charging properly).

For my setup I have 3½' of #10 awg to go from the controller (a SunSaver MPPT) to the battery, and 50' of #12 AWG to the panels that fold up briefcase-style (I built a "reel" of sorts on the back of one side to wind up the wire for storage). The controller typically sits under the hood or inside the fenderwell, depending which side of the vehicle I'm bringing the solar wire in from (both are out of the elements). The panels are wired series to take full advantage of the controller's MPPT functionality.
View attachment 153772
View attachment 153773
Oh and for the fuse police, yes the controller has a fuse (ATC 20A) at the battery clamp, that was an early pic barely after I had assembled it.

 

[CO_Hunter]

Understood on keeping runs from CC to battery short. Charging/maintaining the LC crank battery would be on more extreme trails w/o popup but still having the fridge along.

That box idea is close to what I was envisioning.

Good advice on keeping out of the sun for the accurate temperature compensation, I had been thinking of doing so just for general heat control of the CC itself.

I recall the caution in multiple other solar threads about making sure there is adequate airflow around CC heat sink and those have been the source of my concern. Especially summer time. However, I am hearing that may not be an issue.