solar + led work bench lighting

butcher_block

Newly Enlightened
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Oct 2, 2006
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ok so im getting ready to make a new set of work benches. while i was walking lowes i see solar pannels and say to self

why cant i run LED lighting in my shop least most the time and not hav eot pay for it (yes i know i pay first :) ) i have a few moded flash lights and love them

for the shop tho i need 2 say 4' long strips of ok light and 2 pin point (beam for inspection type) movable spot lights

there is other lighting in the shop and also a radio and it would be great to run extrta if i could tho i know i will not be runing mmy shop tools on solar yet

i was lookign at the 50 watt or 2 20watt setup with a few 12v batt.s

with this will i be ok at least most the time
OOO o in south PA and if needed i coudl put the pannels on a swing arm so after lunch i could "flip " the into more light


thanks all
 
ok so im getting ready to make a new set of work benches. while i was walking lowes i see solar pannels and say to self

why cant i run LED lighting in my shop least most the time and not hav eot pay for it (yes i know i pay first :) ) i have a few moded flash lights and love them

for the shop tho i need 2 say 4' long strips of ok light and 2 pin point (beam for inspection type) movable spot lights

there is other lighting in the shop and also a radio and it would be great to run extrta if i could tho i know i will not be runing mmy shop tools on solar yet

i was lookign at the 50 watt or 2 20watt setup with a few 12v batt.s

with this will i be ok at least most the time
OOO o in south PA and if needed i coudl put the pannels on a swing arm so after lunch i could "flip " the into more light


thanks all

To tell you honestly you should go with a thin film technology panel.

As most would say do with a thick film such as a Monocrystalline(High Efficiency) or a poly crystalline(Lower) or if you have the bucks a Gallium Nitride(Highest). These three are going to give the most power when the sun is out and clear but they are going to cost the most in $/Watt. Also the three thick films/crystalline will only work well when the sun is is within a 45+/- degree angle of perpendicular(directly over) and also will hurt performance and life when they aren't exposed or if they are shaded a little(trees and debris). Beware of these as you are going to have to pay a premium in order to get these panels with protection diodes and anti reflective film on them as the cheaper one come without and that why you are able to get these so cheap.

A quality thin film(Amorphous or CIGS/CiS) by sanyo, sunpower or sharp will give more power in a given day with all lighting conditions, rain or shine(even on low light, sun up til sun down). These are going to cost less in terms of $/watt and still are going to last the same with a 20-30 year lifetime with only a 30% reduction in power within these 20-30 years and still will put out ample power but the manufacturer calls it time to change within these specs/lifetime(30% or 10%/ decade(10years)). These are still going to have the same lifetime as a mono/poly/GaN too without the crazy costs and are also going to have the anti reflective film and protection diodes too.

They(amorphous or CiGs or CiS) will provide more current for charging and have a longer working time(8-10+ hours/day of collecting light Amorphous(Lower efficiency/Lowest cost and lowest heat degradation) or CiGs/CiS(higher cost/Higher efficiency and higher heat degradation) vs.(5-6hrs/day max of collecting light of mono/poly/GaN(higher efficiencies/ higher cost and highest heat degradation).

Heat degradation is a key problem next to mounting location as this is going to effect power output and seems to effect the thicker technologies as they are great insulators and keep heat a lot better, which is a bad thing for the chemistry of silicon as they perform poorly as they need to stay cool as possible. It effects the performance when they are converting the photons in to electrons and replacing the electrons holes efficiently and thus generates a voltage and then current.

This is why the thin films do much better in the current territory as they collect much more of the broad spectrum of light and this = more current vs the thick films as they have a very thin spectrum absorption and thus a higher voltage with lower current. Might seem weird but this is the characteristics of the grade of silicon and number of n-p junctions used.

It applies like a japanese motors as they call them junk when they reach 40k mi as it fails to meet their emission standards, but as we all know they will last 300k mi easy with little emissions and power degradation with proper maintainance of course.

Also with the batteries, you should go with an agm battery for a golf cart as these are the same as a premium optima but are going to cost a 1/3rd of the funds. They are also maintainance less(don't require water to be added periodically and safer) and when they go out in about five to ten years they wont break the bank.

Then for the charger controller this is going to be based on power requirements that you set as 100watt seems to be most you will use with a few batteries and about a handful of led bulbs.

The main thing is that you don't use incandescent and compact florescent as they state that they only use 20-30w but are going to be very dim and going to put out some heat as well.

I would advise you use these led bulbs as they are only 6 watts each and they use any standard e27 light bulb fixture, us standard as well.
http://cgi.ebay.com/700-Lumens-AC-L...621?pt=LH_DefaultDomain_0&hash=item19bf2454a5

Don't be discouraged of the ebay thing as this is a reputable dealer as I have and a dozen others have bought from this gut and they are the real deal and the specs are 100% on. You just have to choose from cool white or warm as this is also another choice of yours as the cool is going to give a little better efficiency than the warm. Also for other led fixtures its going to be hard to beat the 120-130 lumen/watt with a power led array as they put out a lot of heat and need to be fan cooled or have a pretty big heat sink, so they are in the compact fluorescent territory. The fixture i have posted will put out no heat and therefore doesn't require heat sinking and that why they put out the efficiency they do for the cost as well.

Make sure you choose a quality manufactured panel with descent agm(absorbed glass mat) batteries and the controller/charger will come from the store you choose as they couple these things and choose quality at the same time. Then for the led bulbs it your choice as the ones i listed are going to be lowest consumption of power and will run for weeks if not months on a single battery and still leave you with power for your radio or other small peripherals.

I can pm you links to great manufacturers and great prices but i don't want to get banned as they have been putting the smack down with links and pictures lately. I feel that I can steer you in the correct direction and then you can make choices on power and aesthetics if you do not mind.

Also I am glad to help as I am very knowledgeable in this field as its my profession/obsession and its also awesome that you chose such a great technology to be self sufficient or partially sufficient in this matter as its the small things that make a great impact for the better. I admire your choice to do such a responsible project and not to mention cool as S#$T. Also like to see that you already see that this will pay for itself within time and will work when the powers out as I hate the dark(i think that's why I love flashlight so much)


Disclaimer:The market will favor the mono/poly/GaN due to it providing more instantaneous power as it trying to meet current power demands with incandescent lighting and other ac fixtures. These require the DC power to be converted into AC(which results in a 30% reduction in transfer of power) and will fit the higher demand profile much easier.

If you use led lighting and stick to as much as DC power usage as you can(not a lot but majority) the thin films will meet and exceed your needs and not to mention put a lot more money in your pocket. As we all know that you can do just as much work without trying as much when you play it smart. Also it doesn't make sense to use 60watt or 100watt lighting any more as you would have to use a lot of batteries and have more panels but its not a bad thing its just going to cost you more up front.


Hope this helps as I can provide tons more of info, specs and chemistry but have given you a basic layout of the best options with what you have given me already. Don't be discouraged too as this is a very easy to understand technology once you get the basics and are able to determine what the differences are. They have their strong points but there are a few that are the best rounded.

Eric
 
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What is the budget? how big is the shop?
Do you plan on using 12v lights/radio or an a/c inverter(power waster) connected to your batteries?
What is the wattage of the a/c incan/fluorescent lights now so that we can calculate equivalent dc lights?
How long does everything run daily? power draw/time?

I'm using solar+battery and 12vdc outdoor lights. Pretty easy to set up once you sit down with the 'numbers'. I needed reserve power(12hrs of overnight lighting) so battery capacity is higher than needed. This also means battery life is increased since battery is never discharged to a damaging point. And, since my solar panels are not mounted perfectly, aesthetic and not for optimum solar gain, I tend to use larger panels than needed.

From my experience, if you need to use the lights daily, for 8hrs.... you'll need plenty of battery and solar panel. Daily usage, for every 1 watt of light(recommend LED/LVD/CFL/CCFL bulbs/strips/DIY), you'll need about 2-3 watts of solar panel. For batteries, a single marine walmart MAXX29 per 50-80watts of bulb will last a long time.

Simple system:
120-130watt polycrystalline solar panel. <$450 on ebay.
2 Maxx29 parallel batteries or equivalent- ~$200
charge controller $40
12vdc light bulbs, led, fluorescent(RV/marine/automotive).... depending on what you need $50-$200

Upgrade: would be a couple series 6v golf cart batteries from Sams club, bigger panels if you decide to power more, larger charge controller, and a/c inverter to occasionally power a/c circuits.

Downgrade: smaller panels/single battery if overnight usage isn't and if extended run times aren't planned. Also, less works fine if not used daily.

There is no need to go with exotic or overpriced solar panels for a garage/shed rooftop solar mounted system. Even the lesser panels will provide plenty of power for 20-30years.

A good 'test system' for your shed: a group 24 marine battery $60, couple 12vdc automotive fog lights $30, $20 charge controller, $150 generic 50w solar panel
 
looking at this or the 160watt set up
http://www.mrsolar.com/page/MSOS/PROD/remote/RPS-80/SESSION_ID/114d12f623d12fd31051b32bb2d17a03

i will go look at the lighting i have running now and add watts up

i work till about 9PM most nights so no over night use needed but i do use a few lights all day

and the work bench lights would not be on all the time (wish i could run my whole shop on solar but thats way out of budget as i have a 220v grinder and kiln (2300 watt) for heat treating knives
 
Mrsolar seems to be a little pricey for what they are giving.

Definitely list the total number of light bulbs that could be on and the wattage of each, whether they are incan or CFL, and their locations.....

You'll need enough surplus solar power to power all of them along with providing enough charging capability to give you the battery reserve to run them to 9pm.
 
imm running CFL right now in clamp on shop light reflectors. 26 watt each with 2 being ful time and 2 beign part timme use

the 2 that are part time will be part of the new set of work bench lighting so they can be thought of as replaced

so really i have liek 50 watts of use + radio and when i use the work bench (it will have 2 sides) i will use one side or the other
with the hopes of 6 foot of light + one strong spot light (thats per side )

so as you see imm not a strong draw cause i know wht kind of juice it woudl take to power my mill, kiln or one of my grinders
 
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The way the market is going you are going to spend at the least 3$/watt up front and this is just for the solar panels.

Then you are going to need an adequate charge controller that will meet your power demand as these are around 100 bucks for less than a 1kw system.

Then for batteries as you are going to need a few agm golf cart batteries which can be had at 60-80/battery and these are going to have 800Ah which is great as they meet and exceed optima batteries, which have been failing alot lately poor quality control i guess?

Just an estimate for 200W system:

$500 for 2 x 100watt monocrystalline panels

$100 for 40A charge controller

$250 for 4 x agm 12v@800Ah batteries(golf cart ones are the cheapest and best)

$100 for mounting hardware and cabling diy

$120 for (4 led bulbs using standard e27 fixtures) 2500lumens of light which is equal to 4 good car headlights and would only consume a total of 24 watts...

If you get small things like led bulb/fixtures you are going to save money on a smaller system. Then again you are better off getting a larger than needed as rx7 said as you can always run more stuff in the future as it sucks to be limited.

Also wind power is about half as cheap but wind is come and go but if you go half in half it will save you about half as much.

Solar is going to be $3/watt

Wind is going to be $1/watt.

So if you ratio these right you can save alot of money and have a very versatile system.
 
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Since your shop has electricity, I think your best bet is to just 'utility grid inter-tie' a couple solar panels to reduce your electric bill.

The feasibility/cost/gain from trying to make it solar only lighting isn't too beneficial.

Replace the CFL with lower wattage LED when the CFLs burn out.

The benefit from going with solar-only lighting is that you're immune to outages. Do you regularly have power outages? If power outages are NOT an issue, than solar dependent lighting isn't the way to go. And, if you lose power, your power tools/kiln.... are out of commission so you don't need the battery powered light anymore, right???

If your electric bill is excessive(and who's isn't), than grid-tie inverter is your best bet. Start with what you can afford and expand it accordingly.

A couple solar panels, whatever is in your budget, + a 1200w 120vac grid tie inverter, plugged directly into your outlet(gorilla method), or tied into your circuit breaker by an electrician, are your best bets.

1. solar panel-- gridtie inverter--power outlet = smaller electric bill

2. solar panel--charge controller--battery--12vdc lighting = smaller electric bill

Grid-tie is great when there is reliable power.
Battery is great for those garages/sheds/poles/workshops that do NOT have any power.

I had no choice but to use #2 since NO a/c power was available where I needed it.

The ebay China-made inverters are usually good for up to ~1/2 their power rating. So, if you get a 1200w grid tie 120vac inverter, it'll be good for about 6 100w panels. Any more and it will overheat.

For example: $270 1200w inverter(good for 600w)
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=360296543894

With up to 6 $280 100w panels:
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=280559187178
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=310248859102
Or up to 5 of these 125w panels:
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=310245458343

If you don't want more than a couple panels, than a 600w inverter might be a little more efficient for up to ~1-3 of the above mentioned solar panels.
http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=260638186913
 
I recommend checking your electric bill for cost/kwh and your local electric about backfeeding power into the grid. I recently was thinking about solar power and read a few sites online most of which equated it would take up to 50 years to break even if you didn't live in certain areas with certain electric company policies and prices and/or state/local subsidies on taxes for them.
You may find out that if you don't have power blackout issues just having adequate battery backup to run for a day or two that is recharged off the grid would work fine.
 
Payback shouldn't even be considered. Its a lifestyle, hobby, or convenience decision. And, its no different than the money wasted to depreciation when buying a car, boat, motorcycle, gun, rifle, shotgun, fishing pole, atv, jetski, flashlight, clothing....or other lifestyle choice.

Most of the tax breaks are for 'sized' systems. If its available in your area, then milk the taxpayer and utilize it. But, be prepared to pay thousands for a contractor installed and 'stamped' system for your rebate.

Payback for money wasted on my car, boat, motorcycle, beer, clothing, movies..... is, ummmm, NEVER, eh?

There's really no grid back-feeding until you can produce more than what you're using. Trust me, unless his utility bill is <$10 a month, several hundred watts won't be back feeding at all. It'll just be used by all his normal household/shop loads.

My solar panels 'immediately' served a purpose, to provide power where there wasn't any, which in turn reduces my need to run 100's of feet of underground conduit. I actually saved money investing in a few solar panels/batteries. And, I plan on buying a couple more soon using my discretionary income, as it should be.

I believe the thread starter understands the up front cost, his choice, and the pros/cons of solar assisted lighting.

BTW, my LED lights, flashlights, floodlights, solar panels.... are some of my hobbies. As such, I could care less what the solar panel payback was. I find that my solar panels have made some of my other hobbies more enjoyable. Solar powered trickle charger keeping the boat and motorcycle batteries topped off and I prefer never needing a jump start. Solar powered lawn lights to prevent 'nighttime' mistakes by passerby's. Solar powered yard/driveway lighting because I didn't want to cut into the paved areas or chew up the sod to run conduit. I also swipe/swap AA and AAA batteries from the lawn lights to the flashlights/radios/electronics since these are usually fully charged before sun sets. Who needs a battery charger or alkalines anyway?
 
i woulod love to run totaly off grid my shop but the cost so far is in the way

so this is more like baby steps and yes i know it will not save much

really i would almost have ot do both wind and solar to get the juice needed and a few K$

im also not the type that thinks i want to pipe watts back into the grid and get paided for it
 
i woulod love to run totaly off grid my shop but the cost so far is in the way

so this is more like baby steps and yes i know it will not save much

really i would almost have ot do both wind and solar to get the juice needed and a few K$

im also not the type that thinks i want to pipe watts back into the grid and get paided for it

Just figure the kwh cost, and do the math, plus adding in cost of replacing batteries when they go out perhaps every 5-10 years
 
Doesn't need to figure the kwh. Its pretty straightforward when working with solar panels. No matter how many you buy or get, its not enough.

2300w kiln, 100w lighting, and bench grinder(wattage not stated so assume 600w under load) = 3kw! That's a pretty big array costing about $20k to setup! Not quite a solar hobby anymore.

This is the best $50 anyone could spend if they want to go solar:
http://homepower.com/store/index.cfm?page=item&pid=15

If you're lucky, your local libraries might have some in the periodical section. http://homepower.com/store/?page=item&pid=2

I myself prefer the 'one panel' at a time approach. 12vdc lighting with battery, panel, charge controller...is easily doable. Or keep the lighting you have(until it fails) and use a panel to inverter grid-tie to any outlet to slow down your electric meter.

Each 100w panel saves me $1.50 a month on my electric bill. Pretty scary realistic number. Theres no payback and your not going to save tons of money. But, there is that good feeling you get, even if you forgot that energy was wasted and resources used up to make that solar panel.
 
yep to go off grid i would need a bio diesel generator to power the big tools (or have a hell of a strong wind set up :) )

but there is the cool factor of solar and every little bit helps (no im not a tree hugger ) and like said its really pennys on the $
 
Yes, cool factor. I keep forgetting that. Everyone that sees the 'pole light' on at night is surprised because its solar powered.
And during the day, they always ask "whats that" near the pole? 'That' is a solar panel that charges a battery during the day that powers the yard lights ALL night long, every day....

Cool factor is probably the 2nd main reason why I use solar panels.

Funny, I'm pretty conservative and am not a tree hugger. But, my life is full of 'common sense'. That sense is why all my incans were replaced with CFLs when they burned out. And, when the CFLs burn out, they will get replaced with LEDs. Recycling is too easy not to do. And, organic eating means taking the gun and slaughtering tasty wild animals during hunting season or going fishing. :) I do **** off my pot smoking rarely showered dread-locked neighbors plenty enough. But, I have more solar panels and LEDs than they do :laughing: And, my Cali-emissioned Kia gets better MPG and has cleaner tailpipe emissions than their VW bus. Go figure!

BTW, I admire your knife work. Good to see tradesmen still cranking out quality work.
http://www.harnerknives.com/?page_id=40
 
thanks for the thumbs up on my work (i love my job )

and im with you about jsut doing good things and not being wasteful
 
Pretty much ignore the post on thin film. It is highly inaccurate. Add in that the thin film companies like to promote this viewpoint but it is never proven out in actual tests. The "good" companies listed as thin film in that post are actually market leader in crystalline. The one place where thin film can be better is where shading occurs and even then that is specifically amorphous silicon and other deposited on glass panels. Most CIGS panels are done with cells and hence have the same shading issues crystalline panels do. CdTe panels, and some CIS panels are done the same as amorphous. With the exception of CIGS, most of these panels are high voltage, low current which is not the best thing to work with for off grid in most cases.

Seeing as you are in PA, keep in mind the amount of solar you are going to collect in the winter is pretty low at times and could be highly variable. If you plan to use the shop every day, then you need to count on about 7 days of storage or so for guaranteed light and 5 days for a reliable source. 3 days and you can count on outages most years.

The other thing mentioned in many of these posts was charge controllers for $50 or $100. Again given you location, you should get an MPPT controller (Maximum power point tracking). In northern locations that is going to give you about 35% more output from your panels.

I would suggest starting with a single 200 watt panel ($400-450 at sunelec.com). Add in $200 for a mppt charger. Most 200 watt panels are higher voltage so you need MPPT chargers to match the battery. Buy a good quality AGM battery designed for multiple deep discharge operation. Don't buy a marine battery or similar. That AGM battery for deep discharge may cost you 25-35% more, but it will last 2-4 times longer easily paying for itself.

If you can, run DC LED lighting.

Long term the KILN is likely not going to run on solar. The issue is not how much power it draws instantaneously, but the fact is draws a lot and is on for a long time. The grinder on the other hand would be quite reasonable to run on solar as you likely do not have it on for very long. It becomes more an exercise in battery selection and planning with a good sized inverter.

I do this for a living so yes I somewhat know what I am doing... :) ... feel free to PM me for more information.

Semiman
 
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