Solar Panel Breaker Question

[ClydesdaleKevin]

Okay, so the instructions for the Morningstar Tristar MPPT 60 amp charge controller says I need to install breakers on both the solar side of the controller, and the battery side of the controller...which actually works out well, since I would then be able to turn off the power at both sides of the controller using the breakers as switches.

The instructions say I need at least 75amp breakers. 

So here are my questions:

Is there a difference between 12 volt DC breakers and AC breakers, or can I just use standard breakers from Home Depot?

Does each solar panel need its own breaker, or can I install just one breaker right before the controller, where the panels get tied together in parellel?

Lastly, what amp breakers would you recommend?  I know I need at least 75 amp according to the instructions.  Is there an upper limit?  I found 12 volt breakers on eBay made for high power stereo systems on cars for about 10 bucks each, ranging from 80 amps up to 300 amps.  I don't want to get too high an amperage, so what's the upper limit?

Thanks!

Kev

[gadgetman]

I would use 80 amp dc breakers for both the batt feed to the controller and the solar into the controller. Your panels from the top each one should be fused before they are in parallel, you should use fuses twice the amp rating of each panel. 8 amp panel 15 amp fuse. I would also use breakers that do not self reset.

[ClydesdaleKevin]

So what you are saying is that I should use a 15 amp fuse (which is also what is recommended in the Canadian Solar spec sheet for my panels) for each panel before tying them into parellel, and then use a manual reset 80 amp DC breaker after the parellel connection to the controller, and another manual reset 80 amp DC breaker between the batteries and the controller.  Did I get that right?

What kind of fuse setup did you use?  Inline or a fuse block with spade fuses or tube fuses?  Also, what breakers would you recommend?

Kev

[gadgetman]

Yes you have it right.

I used inline marine fuse holders from a old 3 bank marine charger because it had #10 wire. any inline will work spade or glass, just dont use the cheap spring holders for glass type. Inside the coach I used a napa glass fuse box #782-3208 its has 2 feeds to it so 3 fuses are isolated from the other hmmmm 5 fuses. I cut it and made 2 fuse boxes out of it. That fuse box was 20.00

There are nice breakers if you can get them in 80 amp
http://www.ebay.com/itm/CIRCUIT-BREAKER-200-AMP-INLINE-RESET-SELF-TEST-gold-plated-terminals-/250920493416?pt=LH_DefaultDomain_0&hash=item3a6c06e168

another choice would be the breakers boats use at the battery for trolling motors usually 40 amp but im sure you can get larger ones.

[ClydesdaleKevin]

Thanks Gadgetman!  I found similar ones on eBay as well, even in 80 amps, but wanted to make sure what I was looking at were the right ones.

So this morning I'll Google to see if there are any car stereo shops nearby, the kind that specialize in high output loud systems that stupid kids blow their eardrums out with...lol!  Turns out this style breaker is commonly used in those systems, so if I can find a shop like like within a reasonable driving distance I'll call them and see if they have a couple of 80 amp breakers in stock.  Otherwise I'll just order a couple on eBay, wire in the rest of the system, and wait for the breakers to arrive before finishing the project.

We busted our butt in the workshop yesterday so I could have today off to work on the solar, so I'm hoping I can find a local supplier to complete the project.

Kev

[ClydesdaleKevin]

West Marine had all the goodies needed, including the breakers!  They look a lot like the breakers that Gadgetman posted a link to, but are 80 amps and totally waterproof.  They are made by Blue Sea...about 55 bucks each...and they had them in a variety of amperages.  We went with the 80 amp models.  Surface mountable and manual reset, so they'll do the trick nicely!

Only got as far as wiring in the panels to the fuse block, also made by Blue Sea, so I'll finish the project on Monday now that I have everything needed!

Kev