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48 Volt System Toy Hauler Build

HRTKD

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Since I was remiss in documenting my 12 volt RV build, I'll begin documenting the new 48 volt build from the day that I received the cells.

The RV will be a 2025 Northwoods Desert Fox 27FS. This is a four season bumper pull toy hauler with a GVWR of 12,800 Lbs with a theoretical cargo capacity of 3,858 Lbs. My current toy hauler has a GVWR of 11,000 Lbs so this isn't a huge step up. The Desert Fox is on order, with an expected delivery of late August 2024. I chose this trailer because of Northwood's quality. The chassis is certified for off-road. No crappy Lippert frame on this beast. I requested a couple of deletions from the factory to make sure there is plenty of open space on the roof. It should come with 400 watts of PV on the roof installed at the front. I'll leave that in place for now and use the power from it to charge the OEM 12 volt battery on the tongue.

Designing a system for a trailer that I don't have is a little stressful. I found a 2024 model that they allowed me to crawl on/in/under and that gave me enough of a warm fuzzy on dimensions and obstructions that I think I'll be OK. (Famous last words
crampe.gif
)

Why 48 volts? If you've read any of my past posts where the question of system voltage for an RV comes up you'll see that I almost always recommend sticking with 12 volts. For an RV, a 12 volt system is less complex, easier to understand and less expensive.

The main reason for going 48 volts is that I'm planning to put at least 1720 watts of PV on the roof. 2s2p of 430watt panels. A 48 volt system (instead of 12 volt) allows me to use a less expensive solar charge controller or depending how it's wired, just one solar charge controller.

The secondary reason is that I can put 16 cells in series (16s) and have explicit monitoring of all of them (as opposed to 2s8p) and have inverter communication with the BMS. No daisy chaining of communication or power cables.

Saving money by being able to use smaller cabling is not a factor in my decision to go 48 volts. Any savings from smaller cabling is easily eaten up by having to install step up and step down devices. I'm planning to wire the system as if it was a 12 volt system, mainly because I have plenty of that size cable leftover from my prior build.
 
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This post details the components and supplies that were purchased.

I'll update this post as things change.

The Victron part numbers came from this Victron page. It's a European Price List but if you ignore the prices, it's a great list.

DescriptionPart NumberQtyVendor PriceTotal
Victron SmartSolar MPPT 150/35 (2s2p PV)SCC115035210
1​
162.75​
162.75​
MPPT WireBox for MPPT 150/35SCC950200000?
1​
26.25​
26.25​
Victron Lynx Shunt VE.CanLYN040102100
1​
313.5​
313.5​
Victron Lynx Distributor M8LYN060102000
1​
177.75​
177.75​
Victron GX Touch 50 (not flush mount)BPP900455050
1​
194.25​
194.25​
Victron Cerbo GX MK2BPP900450110 or
BPP900451100
1​
243​
243​
Victron Orion Tr 48/12-30ORI481240110
1​
177.75​
177.75​
Victron Orion XS 12/12-50ORI121217040
1​
289.5​
289.5​
Victron Quattro 48/3000/35-50/50 120VQUA483021100
1​
1226.25​
1226.25​
Victron Battery Switch 275aVBS127010010
1​
30.75​
30.75​
Victron Smart Battery Protect 48v - 100 ampBPR110048000
1​
121.5​
121.5​
Victron MK3-USBASS030140000
1​
0​
VE.Direct cable 1.8m Right Angle (MPPT & Orion XS)ASS030531218
2​
12​
24​
VE.Bus cable 1.8m (Quattro to Cerbo GX)ASS030064950?
1​
9.75​
9.75​
Victron MC4 Y ConnectorsSCA520500000
1​
22.5​
22.5​
Temperature Sensor (Lynx Shunt and Cerbo GX)ASS000001000
2​
18​
36​
0​
RuuviTag 4-in-1 Bluetooth SensorRuuviTag
3​
28.5​
85.5​
RuuviTag Silicone CaseRuuviTag Silicone Case
3​
3​
9​
LiFePO4 cells 3.2v 280 AhLF280K
18​
$ 76.00
1368​
JK Inverter BMS 150 amp, 2a balJK-PB2A16S15P
1​
$ 84.00
84​
JK 4.3" LCD Display Screen
1​
$ 22.00
22​
Luyuan 16s Battery Box
1​
$ 220.00
220​
Mission Solar MSE430SX9Z
4​
Low Profile Aluminum Strut
Lynx Shunt Fuse CNN 175ampLittlefuse 0CNN175E.H
3​
$ 26.05
78.15​
Class T Fuse 175ampLittelfuse JLLN175.XXP
3​
$ 58.06
174.18​
Lynx Distributor Fuses Mega 80 ampLittelfuse 0998080.UX-2M8
5​
$ 12.00
60​
Lynx Distributor Fuses Mega 60 ampLittelfuse 0998060.UX-2M8
8​
$ 12.00
96​
UltraHead-Dual Set of Heat Panels 52VDC, 0.8 amp, 8"x22"AM-BAT822-52V-Set
2​
$ 149.60
299.2​
Mopeka Check SensorMopeka Pro
2​
$ 46.00
92​
600VDC Din Rail Mount Two Pole Breaker - 30ampMNEPV30-600-2PP
1​
$ 55.76
55.76​
150VDC Din Rail Mount Single Pole Breaker - 40 ampMNEPV40-150-1PNP
3​
$ 23.01
69.03​
150VDC Din Rail Mount Single Pole Breaker - 5 ampMNEPV5-150-1PNP
1​
$ 23.01
23.01​
Distribution Box DIN Rail ABS Clear CoverMTHT-8WAY
1​
$ 17.50
17.5​
Red: Temco 12 AWG, 100'
0​
Black: Temco 12 AWG, 100'
0​
TEMCo 30 amp 6 pairs (m/f)
0​
6 AWG black/red 25' each
0​
120x120x25mm low speed fan (Cooler Guys)840556091929
2​
3Pin Splitter Wiring Harness 42/50 (Cooler Guys)840556104537
2​
120Mm Steel Mesh Filter Grill, Black (Cooker Guys)840556087601
2​
Kapton Tape
0​
5808.83​
 
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The shipment from Shenzhen Luyuan Technology. From order time to delivery time it was 40 days. That's pretty good. Everything arrived in great shape. Amy and her crew do a fantastic job of packaging to ensure that there is no in-transit damage.

1721434112498.png

The terminals look good. There might be one outlier or it could be how the cell is sitting on the tailgate. Could just be the photo.
1721434220717.png

1721434250316.png

Before Top Charge
CellInternal ResistanceVoltageDifference From Avg
1​
0.24​
3.2949​
-0.0001​
2​
0.22​
3.2951​
0.0001​
3​
0.24​
3.2950​
0.0000​
4​
0.22​
3.2948​
-0.0002​
5​
0.21​
3.2948​
-0.0002​
6​
0.20​
3.2950​
0.0000​
7​
0.21​
3.2950​
0.0000​
8​
0.20​
3.2953​
0.0003​
9​
0.21​
3.2950​
0.0000​
10​
0.21​
3.2951​
0.0001​
11​
0.20​
3.2950​
0.0000​
12​
0.20​
3.2951​
0.0001​
13​
0.20​
3.2949​
-0.0001​
14​
0.21​
3.2950​
0.0000​
15​
0.21​
3.2947​
-0.0003​
16​
0.21​
3.2950​
0.0000​
17​
0.19​
3.2949​
-0.0001​
18​
0.19​
3.2948​
-0.0002​
Avg
0.21​
3.2950​
Min
0.19​
3.2947​
Max
0.24​
3.2953​

Busbars connected to nine cells, getting ready for top balancing. Don't use just one screw for each terminal. I did it that way, then checked the resistance along the entire line of busbars. Then added a second screw to each terminal and rechecked the resistance. I don't have the numbers but they were different enough to justify the second screw.
1721434450088.png

Power supply set to 3.4 volts without being connected to the cells.
1721434563676.png

Shut off the power, connected to the cells, then turned the power back on and let it rip. I'm not using the cables provided with the power supply. I made my own cables that do NOT have an alligator clip.
1721434621068.png

I then checked the voltage at every cell, touching the probes to the cell terminal surface not the busbars.
1721434749154.png

Just for giggles I shot a couple pictures with my Flir One Edge Pro.
1721434849135.png

Different picture, zoomed in on the bottom right of the above picture. This is the terminal where one of the power supply leads connects.
1721441041219.png
I haven't had my Flir camera very long, so I'm learning how to use and figuring out what it's telling me.
 
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The Victron Quattro is used instead of the Multiplus II because the Quattro is over 7" shorter. 14.3" versus 22.8". The two compartments that the inverter will go in probably aren't tall enough for the Multiplus II. The extra room for air movement is good too.

The Multiplus (not the Multiplus II) is similar in size to the Quattro, but does not come in a 48 volt model.

Since the trailer needs 12 volt power, the Orion-Tr 48/12 is used to step down from 48 volts to 12 volts. The 30 amp rating is good enough to run everything in the trailer, but not enough to start the generator. I'll retain one 12 volt battery on the tongue for starting the generator. It may also be used to run the tongue jack and the trailer breakaway system. From my experience with my current trailer, not all loads go through the trailer's main distribution panel. The Orion-Tr will power anything going trough the trailer's main distribution panel.

I would like to have the ability to turn off the Orion-Tr if the LiFePO4 house battery gets too low. The default (non-adjustable) low voltage cutoff is 28 volts, which is way too low. I'm looking into using the Orion's remote on/off switch and a relay on the Cerbo GX or one of the relays on the Lynx Shunt or Quattro to do that. If that doesn't pan out then I'll put the Smart Battery Protect between the Lynx Distributor and the Orion Tr.

Having a Smart version of the Orion Tr would have eliminated the need for interfacing it with a relay or the Smart Battery Protect.

The Orion XS is intended to keep the tongue battery charged when the generator is running. I'll throttle it back to 5 to 10 amps. There should be enough solar to keep the tongue battery charged otherwise.

I don't have any power coming from the tow vehicle to the LiFePO4 house battery at this time, mainly because there is no Victron component that supports that. The Orion-Tr 12/48-8 is not intended for battery charging.

I may have to add a Victron "Fuse holder 6-way for MEGA fuse" to handle 12 volt distribution that occurs near the battery/inverter. However, the MEGA fuses typically start at 40 amps and for the 12 volt loads I'm thinking of that's overkill. A non-Victron fuse holder may be needed.
 
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