Back around Christmas, I installed a solar setup in Hulk (my mom's high-top van). For reference, the topic was covered in <a href="/post/Revisiting-Theos-solar-install-5580917?trail=50" rel="nofollow" target="_blank">Revisiting-Theos-solar-install</a>. <br>The install was one of the 18 foot flexible solar panels, a 30 amp SunForce PWM controller, and cigarette-lighter type extension cords to connect the two parts together.<br><br>Unfortunately, there were a few issues with this install:<br><ol><li>The 18 foot flexible solar panels have a no-load voltage output which can exceed 35 volts. The solar controller has some components (filtering electrolytic capacitors) inside that are rated for 32 volts maximum. As a result, when the house battery is fully charged, the capacitor exploded with a distinctive 'Pop', and spewed capacitor guts into the interior of the controller. The fix for this was to have mom monitor the charge current during use, and cover the solar cell to maintain a lower solar output voltage. Not a good solution, but it was cheap. Oh, and I replaced the filter cap.</li><li>The cigarette lighter extension cords were convenient, but they were small-gauge wire. The connectors are not very good for high current, and they work themselves loose, and heat up. Several connectors melted. Bad news. These connectors were chosen based on their ease of connection/disconnection, because mom's hands just aren't strong enough for the heavy trailer hitch type connectors.</li><li>Various connections were made using spade-type connectors, which tend to come loose over time. The wiring was undersized in places. I knew this at the time, and commented that I'd like to fix the wiring issues if she had problems.</li></ol>When the plug on Mom's solar panel melted, she packed it all up and came to my house for some electrical rework. I decided to do it up right, and hopefully the second time is a charm. It's definitely a robust system now.<br><br><ul><li>I replaced the SunForce 30 Amp solar controller with a <a href="http://www.amazon.com/gp/product/B008KWPGAE/ref=oh_details_o00_s02_i00?ie=UTF8&psc=1" rel="nofollow" target="_blank">SainSonic MPPT 3215RN</a>. This controller is rated for a solar input voltage of up to 150 volts, so mom's solar cells won't be blowing up the filter caps this time. Also, being an MPPT controller, it's more efficient than the Sunforce PWM controller. If mom decides to upgrade her solar panels, this controller will handle a significant upgrade without breaking a sweat. The drawback is that the new controller is about twice as expensive as the old one.</li><li>I added a <a href="http://www.amazon.com/Remote-Meter-Display-Regulator-Meters/dp/B008KWPGLI/ref=pd_bxgy_hi_text_y" rel="nofollow" target="_blank">remote meter display</a></li><li>I upgraded all of the wiring to <a href="http://www.powerwerx.com/wire-cable/red-black-zip-cord.html" rel="nofollow" target="_blank">10 gauge</a> wire minimum. The only remaining smaller wire is the power going to the <a href="http://www.amazon.com/gp/product/B0009JB7GI/ref=oh_details_o01_s00_i01?ie=UTF8&psc=1" rel="nofollow" target="_blank">stout</a> 12V outlets, which is about 14 gauge.</li><li>The biggest upgrade was changing all of the connectors to use A<a href="http://www.powerwerx.com/anderson-powerpoles/" rel="nofollow" target="_blank">nderson Powerpoles.</a> These are awesome connectors, and the ones I used are rated for 45 amps (!). They are easy to connect and disconnect, can be snapped together like Lego bricks, and are just the nicest connectors I've used. <a href="" rel="nofollow" target="_blank">Here's</a> a video showing the connectors, and searching Youtube for "anderson Powerpoles" will give lots of other videos. One recommendation is to use the right <a href="http://www.powerwerx.com/crimping-tools/tricrimp-crimping-powerpole-contacts.html" rel="nofollow" target="_blank">Crimping Tool</a> to crimp the connector onto the wire.</li></ul><br>Unfortunately, I didn't get any pictures while I was doing the install. I'll try to get some to add, if the weather cools down enough before mom heads out of here. I was sorta ok with the previous install, but I'm confident in the current configuration. <br><br> I have a feeling the weak link is the flexible solar panel, because it's flexible. If/when if it fails, I have a pigtail staged in the system which can be connected to a replacement solar panel (probably one of the cool 'suitcase' sets that Bob is selling. I played with the one in Katie Two-Knives system, and it's a nice solar set.<br><br>I don't know if Mom is going to make it to RTR, it depends on when the weather cools down. If you see her, ask her to show you her solar. You might get some good ideas from it. If you have any questions about her system, just post them here.<br><br>Hmm, previewing my posting, the links aren't showing in blue... If you don't see blue links, just hover over anyplace I mention the name of something I've added. I put in links for most of the stuff.