Solar PV — Battery Storage & Charge Controller (CREATE Lesson 508)

This lab introduces students to the principles of energy storage and regulation within a solar photovoltaic system. Working with a bench-top trainer, students explore the interaction between a PV module, a deep-cycle battery, and a charge controller. Participants measure electrical potential and current across various system states to understand how a charge controller protects batteries from overcharging and deep discharge. Students also gain hands-on experience using a pyranometer to measure solar irradiance and apply Ohm's Law to calculate system power. The curriculum covers different battery technologies, including Lead-Acid, AGM, and Lithium-ion, and teaches students how to calculate battery runtime based on load requirements and discharge limits.

solar PV photovoltaics renewable energy battery storage charge controller deep cycle battery AGM lead-acid lithium-ion Ohm's Law PIE formula power equation electric potential voltage current amperage solar irradiance pyranometer DC electricity energy management

Uploaded by demo on 2026-07-19 · ready · Electronics · Original source ↗

Files: 508_Solar_PV_Battery_Charge_Controller.zip · NSF_ATE_provenance.txt

Readiness checks

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Latest report — 2026-07-19 15:27

Readiness: Solar PV — Battery Storage & Charge Controller (CREATE Lesson 508)

Verdict: Ready with caveats · 2026-07-19 · est. parts cost $600–$700

This is a cold check establishing the first baseline for this lab. The lab is implementable, but success depends on precision sourcing for two specific areas: the pyranometer (the original model is obsolete and requires a functional substitute) and the incandescent bulbs (instructors must ensure bulbs are rated for 12V DC, as standard hardware store E26 bulbs are 120V AC and will not function).

Action required

Part Problem Recommended action
Pyranometer (DS-05A) Discontinued/Obsolete by manufacturer. Purchase the General Tools or Tenmars substitute listed below.
12V 25W Lamp Easily confused with 120V standard bulbs. Use the Bulbrite specialized source to ensure DC operation for math exercises.

Parts

Core Power Components

Part Spec/Package Status Stock Price Source
PV Module 12V, 30W, rigid Ready (sub) Yes $44.90 Home Depot
Deep Cycle Battery 12V, 8Ah, AGM Ready Yes $23.80 NAZ Solar
Charge Controller SunLight-10 (12V) Ready Yes $99.00 NAZ Solar

Distribution and Load Hardware

Part Spec/Package Status Stock Price Source
Load Center Enclosure MNCBB (DIN Rail) Ready Yes $50.61 NAZ Solar
DC Circuit Breakers 10A, 150V DC Ready Yes $22.30 Missouri Wind
Lamp 25W, 12V, E26 Base Ready Yes $2.78 Bulbs.com
Lamp Holder E26 Keyless Ready Yes $3.95 Home Depot

Instrumentation

Part Spec/Package Status Stock Price Source
Pyranometer Handheld W/m² Obsolete 0 — —
Clamp Multimeter DC Amp Clamp Ready (sub) Yes $109.99 Tractor Supply
Standard Multimeter Digital VDC Ready (sub) Yes $34.98 Home Depot

Construction Materials

Part Spec/Package Status Stock Price Source
Plywood Base 3/8 in x 18 x 24 Ready Yes — Local Hardware
Electrical Box 4 in Octagon Ready Yes — Local Hardware
Wiring 14 AWG THHN/Romex Ready Yes — Local Hardware
Connectors 1/4 in Female Spade Ready Yes — Local Hardware

Substitutes

For part Substitute Differences Judgment
PV Module ACOPower 30W Mono Rigid Monocrystalline; replaces Peimar/Dasol. Acceptable. Matches 12V/30W spec.
Pyranometer General Tools Meter Digital handheld; replaces Daystar DS-05A. Acceptable. Measures in W/m² as required.
Clamp Multimeter Klein CL390 Successor to CL380. Acceptable. Retains DC Amp clamp.

Verify any substitute against its datasheet before ordering.

Other dependencies

  • Firmware: Not applicable.
  • Downloads: Teacher answer keys and guides were not checked for current link vitality.
  • Fabrication: Plywood base assembly requires a saw and drill (not included in BOM).

Watch list

  • 12V Incandescent Bulbs: These are becoming increasingly rare as specialty lighting. If they become unavailable, the lab's math exercises (designed for a 2.1 Amp load) must be updated for LED equivalents.
  • Battery Shelf Life: AGM batteries must be charged at least every 6 months during storage to prevent permanent capacity loss from sulfation.
Snapshot What the lab depended on when it was uploaded — the baseline the readiness checks research against.

This lab, "Solar PV — Battery Storage & Charge Controller (CREATE Lesson 508)," involves building a bench-top solar training system. It consists of a 12V DC power system including a photovoltaic (PV) module, a deep-cycle battery, a charge controller, and a lamp load, all mounted on a plywood base with industrial-style circuit protection. The lab depends on specific 12V DC components and specialized solar measurement tools.

Bill of Materials

Core Power Components

  • Photovoltaic (PV) Module
    • Identity: Peimar OS30P (or Dasol DS-A18-30).
    • Specs: 12V nominal, 30 Watt, polycrystalline or monocrystalline.
    • Quantity: 1.
    • Substitution Latitude: Any rigid 30W, 12V nominal PV module is compatible. Dimensions should be roughly 15-20 inches per side to fit the trainer board.
    • Sourcing Plan: retail shopping search: "30W 12V solar panel".
  • Deep Cycle Battery
    • Identity: Universal Battery UB1280 (or equivalent AGM deep cycle).
    • Specs: 12V nominal, 7.2 Ah to 8 Ah capacity, Sealed Lead Acid (SLA) / Absorbed Glass Mat (AGM).
    • Quantity: 1.
    • Footprint: Standard 12V 7Ah/8Ah battery (approx 5.9 x 2.5 x 3.7 inches) with F1 or F2 spade terminals.
    • Electrical Constraints: Must be deep-cycle rated; standard starter batteries or high-rate UPS batteries will degrade quickly under the lab's discharge cycles.
    • Sourcing Plan: retail shopping search: "12V 8Ah deep cycle AGM battery".
  • Solar Charge Controller
    • Identity: Morningstar SunLight 10 (SL-10L-12V) or Morningstar SunSaver 10L.
    • Specs: 12V, 10 Amp rating. Must include Low Voltage Disconnect (LVD) and support PWM charging.
    • Quantity: 1.
    • Electrical Constraints: Must be a 12V PWM controller. High-end MPPT controllers are not required, but the unit must have separate terminals for Solar, Battery, and Load to function with the lab's wiring logic.
    • Sourcing Plan: distributor lookup: Morningstar SunLight-10.

Distribution and Load Hardware

  • Load Center Enclosure
    • Identity: Midnite Solar Big Baby Box (MNCBB).
    • Specs: 4-slot DIN rail enclosure rated for DC.
    • Quantity: 1.
    • Substitution Latitude: Any small DIN rail enclosure or a 3-gang PVC electrical box (as noted in the BOM alternative) works.
    • Sourcing Plan: retail shopping search: "Midnite Solar Big Baby Box".
  • DC Circuit Breakers
    • Identity: Midnite Solar MNEPV10 (or similar DIN rail DC breaker).
    • Specs: 10 Amp, 150V DC rated (or minimum 48V DC rated), single pole.
    • Quantity: 3.
    • Electrical Constraints: Must be DC rated. Standard AC breakers will not quench a DC arc and are a fire hazard in this application.
    • Sourcing Plan: distributor lookup: "10A DC DIN rail breaker".
  • Lamp and Socket
    • Identity: 12V Incandescent Lamp (e.g., Philips 25W A19 12V bulb).
    • Specs: 25 Watt, 12 Volt DC, medium E26 base.
    • Quantity: 1.
    • Substitution Latitude: A 12V LED bulb (approx. 10-12W) can be used, but note that the lab's math exercises (Question 18) are specifically calculated for a 0.1 Amp (1.2W) or 2.1 Amp (25W) load.
    • Sourcing Plan: retail shopping search: "12V 25W incandescent E26 bulb".
  • Lamp Holder
    • Identity: Leviton Plastic Keyless Lamp Holder (or similar).
    • Specs: Standard E26 base, plastic or porcelain, surface mount.
    • Quantity: 1.
    • Sourcing Plan: retail shopping search: "keyless lamp holder E26".

Instrumentation

  • Pyranometer
    • Identity: Daystar DS-05A.
    • Specs: Handheld solar irradiance meter, measured in Watts per square meter (W/m²).
    • Quantity: 1 per lab group.
    • Substitution Latitude: Essential for measuring "sun strength" for efficiency calculations. Any handheld solar power meter is acceptable.
    • Sourcing Plan: general web research: "Daystar DS-05A pyranometer".
  • Clamp-on Multimeter
    • Identity: Klein Tools CL380 (or equivalent).
    • Specs: Must be capable of measuring DC Amps via the clamp (many budget clamps only do AC Amps).
    • Quantity: 1.
    • Sourcing Plan: retail shopping search: "DC clamp multimeter".
  • Standard Multimeter
    • Identity: Klein Tools MM400 (or equivalent).
    • Specs: Basic digital multimeter (DMM) for DC Volts.
    • Quantity: 1.
    • Sourcing Plan: retail shopping search: "digital multimeter".

Construction Materials

  • Plywood Base: 3/8 inch thickness, approx. 18 x 24 inches.
  • Electrical Box: Standard 4-inch metal octagon box (for the lamp holder).
  • Wiring: 8-10 feet of 14 AWG Romex (2-conductor + ground) or THHN stranded wire (black and red).
  • Connectors: 1/4 inch Female spade crimp connectors (for battery and controller terminals); Romex cable connectors/strain reliefs.
  • Sourcing Plan: Items are standard hardware store commodities.

Temporal Dependencies

  • URL Vitality: The BOM contains several "Altestore" and "Home Depot" links. These are highly likely to break over time as product catalogs are updated. Sourcing must rely on the specifications (e.g., "12V 30W PV module") rather than the specific URLs provided in the 2020 document.
  • Measurement Units: The lab requires measurement in W/m² for irradiance. If a substitute pyranometer uses different units (like BTU/ft²*hr), conversion will be necessary to match the lab's provided answer keys and Table 4.
  • Standard Test Conditions: Lab calculations assume 1000 W/m² (Full Sun). If performing this lab indoors under artificial lighting, the PV module will produce significantly less current, and the expected values in the teacher's key will not match measurements.
  • Battery Shelf Life: The BOM notes batteries must be fully charged before the lab. Lead-acid batteries stored for more than 6 months without charging may sulfate and fail, making the "discharged" state behavior (Question 1a-1g) difficult to demonstrate.