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diy solar

diy solar

Golf cart conversion with a bit of solar

wrybread

New Member
Joined
Nov 26, 2019
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55
This cute little 48v electric golfcart just fell into my lap for free:

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It's a Club Car Precident, I dont' know the year, it's 48v, currently with 4 impressively large 12v lead acid batteries which are of course inert. I'm looking at this 48v 100ah LFP battery from Lossigy:


$760 for the battery, 18 amp charger and battery monitor, and the BMS has bluetooth so can be monitored from a phone. They claim their BMS can do 200 amps continuous with a 3 to 5 second peak up to 1000 amps. Sounds optimistic but if it's anywhere close it should be plenty. I'm planning to use it to putter around the flat neighborhood, maybe a little mini golf at best.

I'd like to put a 300 to 400ish watt solar panel on the roof for trickle charging, and I need to use it so infrequently that I'm hoping I'll hardly need to plug it in to charge. I have grid power to plug in if I need it, but it would be fun to figure out how to power this entirely from inexpensive solar. I found this solar charger by Genasun that's marketed for golf carts:


The main advantage is that it boosts the voltage so even a 60 cell panel (30 to 40 volts) can charge a 48v battery via MPPT. And they're waterproof, which isn't super crucial for me since I plan to put the charger under the seat which should be dry. It's a slick charger though, says it can handle a 350 watt solar panel. I'm guessing it can be overpaneled a little to 400 watts, especially since I'm flat mounting the panel (20% loss?) at lattitude 38? Let me know if anyone disagrees.

The golfcart's roof dimensions are 48" wide by 54" long. I'm thinking it's fine for a solar panel to overhang a bit, especially in the rear. I'll soften the edges and corners so they're not dangerous. Anyone know of a compact 400-ish watt solar panel? I know energy densities have been improving, I wonder if there's a small one, especially smaller in the length that I should consider? Most of the panels I'm seeing like this one are in the 78" x 42" range, which would overhang about 2 feet length-wise, or about 1 foot on both the front and back.

Also planning to get a 48v inverter to make the thing a mobile power station. I don't think I need anything particularly fancy, just something in the 3000 watt range, probably pure sine. Any recommendations there by chance?

And anything you'd do differently?
 
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Anyone know of a compact 400-ish watt solar panel?
Compact is subjective and 400 is probs not going to fit as well as a mono 300-350W panel.

Monocrystaline panels are a few percent smaller than polycrystalline panels are for the same wattage.

You will still need that charge controller like what you mentioned.
 
A 240w panel is 63"x39" or 10 square inches per watt, and that's roughly the size of a golf cart roof. A 400w panel is 78"x40", or 7.8 square inches per watt. You also have to take into account the weight of the panel, they're not light. 240w is 40lb where 400w is 53lb.
 
A 240w panel is 63"x39" or 10 square inches per watt, and that's roughly the size of a golf cart roof. A 400w panel is 78"x40", or 7.8 square inches per watt. You also have to take into account the weight of the panel, they're not light. 240w is 40lb where 400w is 53lb.

Thanks for that, and good point on the weight. I wonder how much I can over-panel the charge controller. 240 watts would be plenty if I could connect a 2nd 240 watt (or bigger) panel in parallel when it's parked. Could make an easy disconnect with XT60's.
 
Thanks for that, and good point on the weight. I wonder how much I can over-panel the charge controller. 240 watts would be plenty if I could connect a 2nd 240 watt (or bigger) panel in parallel when it's parked. Could make an easy disconnect with XT60's.
I have found that xt60's are not made for repeated plugging and unplugging and fail after a few dozen times, so I wouldn't count on that.
 
Hello, just found this topic.
It happens that in a glider club, we decided to mount a solar panel on a golf cart which is used to tow the gliders on the airfield.
Far from wanting to recharge totally the battery, our goal is only to avoid recharging at midday, because the cart can be needed at any time, and because without recharging it may run out of juice in the middle of the landing field while towing a glider out of the runway.
There is plenty of sun to recharge, because the days we need the cart the weather is usually sunny, even more at the 5500ft airfield altitude.

The battery is 48V=6 x 8Volts Trojan , a club member gave the 2nd hand panels (180Wp, 24V@max power, frameless!).

charge_1.4Ax51V_soleil.jpg0.46402200_1500320796.jpg


We bought from aliexpress some cheap chinese 300W mppt boost controller: they are able to boost the voltage up to the max battery voltage (~ 58V). Good thing is they are supplied directly from the panel, so they dont sip the battery during the long period without flying activity.
mppt_solar_boost_controller.jpg
The big work has been to tie the frameless panel on the roof, with some damping foam, and protecting the edges from injuring someone. This is the result:

golfette_verte_AR_G.jpg
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The charge controller has been mounted in front of the steering wheel and is quite well protected.

fixation_gauche_mppt.jpgfixation_droite_mppt.jpg

As we finished to mount the system at the very end of the flying season, we dont have any return from using it yet. But I am confident, and we sure will also modify the second (white) cart next summer.
 

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That is a very similar charge controller that I used on mine, but mine was an eco-worthy from Amazon. Probably the same thing.
So for my other cart I bought a 36 volt lithium iron phosphate battery and my solar panel output 40ish volts maximum so I think I'm just going to go straight from the panel to the battery and let the BMS deal with being the charge controller.
 

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