MOOS SOLAR PANEL CONSTRUCTION NOTES 4/16/04From: Scholfield, Jim
Sent: Friday, November 04, 2005 11:05 AM
To: Heller, Ken; Pickerill, Mark "Zorba"
Subject: MOOS SOLAR PANEL CONSTRUCTION NOTES 4.doc

                     MOOS  SOLAR   PANEL   CONSTRUCTION   NOTES                                    11/04/05

 

see  pictures for documentation

 

USE   CABLEMAX 9-49C       100/22 RATIO           HAVE ½ Gal. Available for each ass’y

 

USE 600 LBS DISTRIBUTED WEIGHT,  BATTERIES IN CARTONS WORK GREAT

 

FLAT,  LEVEL  AND  STURDY WORK TABLE IS REQUIRED.   

 

SUGGESTED GLUE  PATTERN ON SOLAR PANEL BACKSIDE:  Attached

 

TEKLAM PREPARATION

-if Teklam was cut by waterjet-NOTE: always cut into edge of  teklam panel, DO NOT PIERCE.

-      Let dry and remove any loose garnet left over from cutting process. 

-          Use smoothest side towards cell array. 

-          Bend down the outside bottom edge of connector rect. hole to reduce chafing on wires.

-          Cover exposed hex center with RTV so is adequately sealed.  

 

Sequence

1.        jig

2.        wax paper-to prevent glue from adhering to jig. The teklam is delivered with a suitable waxy paper.

3.        cardboard/plastic sheet-to slide out once frame is removed

4.        lay solar panel FLAT down-do not twist- USE EYE PROTECTION

5.        remove frame, moderate heating of frame helps- this can be difficult, PANEL CAN SUDDENLY FRACTURE

6.        Carefully peel mounting tape off edge of  panel-be sure none adheres to front face of panel which could compromise flatness of fit into jig.

 

ONCE the frame is removed, carefully slide cardboard out so as to not leave anything between the panel front side and the jig except the wax paper. 

 

GLUING PROCEDURE:

-get area and ~600 lbs of weights ready,( batteries good, handles)

-clean backside of solar panel

-clean glue side of teklam honeycomb

-weigh out 9-49C, 275+60 grms=335,    X2= 670 gms total

-mix well, degas.  Pull ~ 29inHg-expands ALOT then collapses, use a 5 gal. bucket

-repeat for 2nd batch, no hurry, you have a 3-4 hr. working time.

-pour out in dogbone pattern as above, also wet out glue side of teklam

-set teklam down on solar panel aligning edges to jig and/or ref. lines  

-use small weights around edge to hold in this position

-carefully set big weights down- starting in center and working towards  ends and sides

-glue should spread and show up in connector area in about 30 min.  and  overflow out corners in 2-4  hrs

-working time is about 3-4 hours and let set overnight ~70 deg. F.

                                                                                                                              

-when set carefully remove weights and clean overflow glue from jig,       panel, etc.

-check corners  and edges for voids, fill using  a syringe if necessary.

 

 

 

 

 

 

 

 

                                                                                                                                                   PAGE 2

 

 

 ATTACHING HINGE SUPPORT FRAME TO SOLAR PANEL:

 

REQUIRED:

-good quality 35yr type siliconized acrylic (white pref.)  caulk to seal aluminum trim to panel and teklam, 2 tubes

 

- DC 832 to attach extruded edge seal to teklam edges-grey preferred - 2 tubes

 

-Scotch easy release masking tape

 

- flat table and supports which keep frame flat and parallel to work surface

 

 

PROCEDURE:

-place supported frame on work table, 

 

-locate  and identify top left of frame 

 

-place teklam/panel ass’y appropriately on frame

 

-align solar panel by eye to frame

 

-clamp to hold position, drill a few holes in corners guided by frame to    hold ass’y together. 

 

-alum. TRIM PIECES will probably take a lot of trimming to fit properly, do this before drilling the rest of the holes.

-lay down a bead of siliconized acrylic  caulk under trim pieces

 

-attach ,using ¼ - 20 x 1 ¾ for most of frame  and 2 ¼  for handles,  nyloks-just snug-teklam bends easily

 

-fill inner edge of Z-trim to seal to solar panel

 

-carefully cut pieces of extruded silicon edging to fit edges of Teklam

 

-leave ¼” gap in bottom corners of extruded silicon edging to  allow drainage

 

-use the DC 832 to attach the edging and the blue masking tape to hold in position

 

-NOTE:  The Sunpower panels are slightly shorter and narrower.  We will eventually redesign the Z-trim. The lower edge will not fit to the frame so we are using 3M VHB 5952 stuctural tape to fix the lower piece to the Teklam.

 

Final- after completing the wiring, trim  all connectors so they can be covered with at least a ¼ inch of 9-49C.  Fill the connector box and the cut-out in the Teklam  such that the cover can still go on properly.