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diy solar

RV Build--2.55 kw Panels 560 ah 24 v Lithium Battery

chrisski

Solar Boondocker
Joined
Aug 14, 2020
Messages
5,087
This is an upgrade to 2.2 kw and 24 volt lithiums from my 1.3 kw V build with 4 GC2H FLA Batteries discussed here:


Batteries
I have two Batteries, 24 volts with 8 Eve 280 cells. The BMS is Overkill 100 amps. I fused each battery with Class T fuses. This is the sketch of what it should look like when sittign in a 2' X 2' Battery tray:

1642302795092.png

And this is the side view and also a View of the Busbars and Class T fuses. Those busbars and fuses are bigger than I thought.
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BMS: Overkill 100 amp 8S 24 V
Completed sitting on top as pictured above. I had some worries about cold cutoff and based off another thread, I got decided on these numbers, and tracked temps for a night:
1642303182635.png1642303197932.png
These January temps show me I ought to install some sort of heating, or not use it, but I have some time to think about this.

AC to DC COnverter
Off Will's recommendation, I got a, AIMS 120 VAC to 12/24 VDC converter. I liked the Gel profile better than the lithium and have that set. I finished installing it today and powered it up to test it, and it charged the battery slightly over its rated 35 amps at 36.9 amps:
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24 Volt to 12 Volt DC to DC converter
I did away with the 12 volt battery altogether and because I needed 50 amps for trailer jacks, I put in an Orion 24 volt to 12 volt 70 amp DC to DC converter and fused the 24 volt input at 50 amps and the 12 volt output at 80 amps with ANL fuses:
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Inverter
I installed a SAMLEX 3000-watt inverter and used a 30-ohm 25-watt resistor to go in line to prevent sparking when I first hooked it up:
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I still need to hardwire the output to get the full 25 amps. Right now what I have is an extension cord from the GFCI outlet to shore power which limits me to 16 amps continuous. All parts for hardwiring will be in by next week.

Solar Panels:
I started the upgrade with 2.2 kw panel total, with 900 watts of that portable set up on the ground, and 1300 watts on the roof:
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I show data for about four days. 11 Jan I did not use much power and did not put out the portable panels. From the 9-11 Jan the RV was parked in a non-ideal orientation North South, and on the 12 Jan, was parked in an ideal East West so the roof panels faced south. Unfortunately, there was a thin, light scud layer of clouds you don't even notice unless you have solar, and I lost about 25% production:
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Needed More Panels
I upgrade with 2.55 kw panel total, with 900 watts of that portable set up on the ground, and 1650 watts on the roof so I could get my goal of 6 hours of AC which draws a constant 1700 watt load:


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Main Battery Fuse
I left off replacing the 200 amp ANL fuse for the old FLA batteries with a 225 amp class T fuse:
Before with a ANL to Class T size comparison:
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After
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Finished Hard Wiring the inverter. An extension cord through the 20 amp GFCI receptacle is limited to 16 amps, but hard wiring allows the inverter to push 25 amps.

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Also gathered some data on the AC to DC charger. Ran well off a 2300 watt continuous inverter generator and charged at a little more than 35 amps and took 40 minutes to go to return the 22.7 ah used the night before. The "knee" was hit at 35 minutes when charging amps tapered down and amps were replenished 5 minutes later.
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Last thing to install is an Easy Start from micro air hoping to power the AC when it warms up in a few weeks. Took the case off today to figure the wiring out. After the confusion was over, won't be a hard install:
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Nice, do you know how long you will be able to go off grid without a generator? How long could you go with the old setup? Just finished up my travel trailer system, it's a nice feeling congrats.
 
Nice, do you know how long you will be able to go off grid without a generator? How long could you go with the old setup? Just finished up my travel trailer system, it's a nice feeling congrats.
It’s enough power I worry more about tank limitations. Mostly the 35 gallon water tank and the 25 gallons extra I take. Alone I can use as little as 2 gallons a day. With the other three it’s about 30 gallons a day.

With my family power wise, I can go for three or Four normal power usage cloudy days with no generator. By myself, indefinitely.

In the summer, goal is for the AC to run from 12 pm to 6 pm on a sunny day. Have not had a chance to try it yet. I could probably not last a single cloudy day.

Prior to this upgrade I had 4 golf cart batteries. With the family, I could almost make it through one cloudy day, but usually had to turn the generator on.
 
This is the part list and links for what I ordered on line. There was a bit of hardware from home depot that was not included. Also not included was 1200 watts of panels. Prices are not just for the batteries, but for the inverter, AC to DC charger, and a 24 volt to 12 volt DC to DC converter to run the Landing Jacks.

Two Batteries 24 Volt 280 ah Lithium Battery 280 ah cells
ItemDescriptionNotes
16 X EVE 280 Cells16 X 280 AH Eve cells https://szluyuan.en.alibaba.com
BMS100 amp Overkill with 8 AWG wires. Qunatity of 2https://overkillsolar.com/product/bms-100a-8s-lifepo4/
110 VAC to 24 VoltDC Converter12V & 24V Smart Charger 75 Amps - Listed to UL 458/CSA
CON120AC1224VDC
https://www.aimscorp.net/ac-convert...art-charger-75-amps-listed-to-ul-458-csa.html
2 X BusBar
2 X Cover
2 X BusBar 2127 Blue Sea; 2 X BusBar Cover 2129 Blue Sea
10 X 2 AWG to M6 LugLugs For AC to DC Converter/Charger and Lithium Batterieshttps://www.amazon.com/gp/product/B073Y9KG28/
10 X 6 AWG to M6 LugLugs For Lithium Batterieshttps://www.amazon.com/gp/product/B093DS4KBG/
Heat ShrinkRed Black 3/4" Heat Shrink 3:1 ratio 4 feethttps://www.amazon.com/gp/product/B07VQ6W7RN
DC to DC Converter and SCC70 amp 24 Volt Dc to DC Converter and 75 Volt 15 Amp DC SCChttps://www.amazon.com/gp/product/B01BF5BQLA/15 amp SCC in small 25 AH battery
DC Power SupplyDC Power Supply 30 Volt 10 amphttps://www.amazon.com/gp/product/B082HXVRNF/
OxGaurdAluminum Antioxidanthttps://www.amazon.com/gp/product/B000BOCBCA/
Ring Terminals10 AWG to 1/4" For Power SupplyAutozone
M6 Nutts15 total M6 NutsLowes
Neoprene 1mmBlack Neoprene 8" X 48" to place between cells.https://www.ebay.com/itm/224389419928?var=523175325684
Protective tape for terminalsOrange transparent. Kapton Tapehttps://www.amazon.com/gp/product/B00HFN67OS/
Wire StripperWire Stripper for small 26 AWG wires on Overkillhttps://www.amazon.com/gp/product/B000XEUPMQ/Turns out manual incorrect and BMS wires 22 AWG
Ring TerminalOpen End Crimpable Ring Terminals for small sized wireshttps://www.amazon.com/gp/product/B08PK98SFP/
ring terminalsCrimpable heat shrink terminals 26 AWG to 1/4" Studhttps://crimpsupply.com/26-24-ga-heat-shrink-ring-terminals-1-4-stud.htmlDid Not Use
SAMLEX 24 PST 300024 Volt 3000 Watt Inverterhttps://www.amazon.com/gp/product/B01EX48IL6/
Resistor25 watt 30 ohm resistor t0 install inverterhttps://www.amazon.com/gp/product/B074Q5Y5YH
125 Amp Class T FuseFor After Batteries Combined Quantity of 2https://www.amazon.com/gp/product/B000XBCXVA/
Class T Fuse Holder 110 Amp to 200 ampQuantity of 2https://www.amazon.com/gp/product/B0753JPYQZ
Cancel
Class T Fuse Holder 110 Amp to 200 amp
Saved $40 by going to Del City 9/28/2021
Class T Fuse Holder 225 amp to 400 Amp

Class T Fuse 225 Amp


Class T Fuse Holder 110 Amp to 200 ampQuantity of 2https://www.delcity.net/catalogdetails?item=79735
Spare
- 125 Amp Class T fuse


-225 amp Class T Fuse
https://www.ebay.com/itm/393454700673?ViewItem=&item=393454700673

https://www.ebay.com/itm/255149131792?ViewItem=&item=255149131792
1/4" Threaded RodFor Battery Box. 1/4"-20 Threaded RodHome Depot
Locking Tooth Washers 1/4"Holds Bolts on for moile apphttps://www.amazon.com/gp/product/B07R59HPCF
1/4" X 3/4" X 12" C110 Copper FlatMade three Busbarshttps://www.ebay.com/itm/274867691930
1 mm Neoprene RubberBetween Cell Protectionhttps://www.ebay.com/itm/224389419928?var=523175325684
100 Watt Portable PanelTO Make 3S3Phttps://www.walmart.com/ip/Lion-Ene...anel-Foldable-Portable-with-Handles/422072307
1 mm Neoprene RubberBetween Cell Protectionhttps://www.ebay.com/itm/224389419928?var=523175325684
Plastic Cuttign Board FlexibleBetween Cell Protectionhttps://www.amazon.com/gp/product/B09DKJBNG4/
MC4 Connectorshttps://www.amazon.com/gp/product/B07P8NSH2N/
80 Amp ANL Fuse QTY 2For DC to DC Converterhttps://www.ebay.com/itm/313422645841
100' 3/8" White Wire LoomMake Roof Wires look Neathttps://www.ebay.com/itm/131571481083?var=432802129692
50 amp ANL Fuse and HolderFor DC to DC Converterhttps://www.amazon.com/gp/product/B000K2K7TW/

https://www.amazon.com/gp/product/B000THQSB4
Orion DC to DC converter 70 ampReplacement for bad converterhttps://www.amazon.com/gp/product/B01BF5BQLA/
30 Amp Female PlugFor Hard Wire Extensionhttps://www.amazon.com/gp/product/B00192MU2Y/
25' 8/3 WireHard Wire Extension Cordhttps://www.amazon.com/gp/product/B07BS37H31/
50 amp to 30 amp adapterAdapter to plug in extension cordhttps://www.amazon.com/gp/product/B07V39FMHM
8 AWG to #6 StudTo attach Ground Wireshttps://order.ebay.com/ord/show?orderId=10-08129-90638#/
Wire Ferrules and CrimpersFor Neutral and line leads for AC extension cord

ANL Fuse HolderANL Fuse for AC to DC Converter DC Sidehttps://www.amazon.com/gp/product/B000K2K7TW
50 Amp ANL FuseHold ANL Fuse for AC to DC Converter DC Sidehttps://www.amazon.com/gp/product/B000THQSB4
 
Air-Conditioner Ran for six hours off Solar today. There's some stats I put on this thread https://diysolarforum.com/threads/15k-btu-on-solar-stats.36767/

Here is a summary for the six hour day:

-The AC used 12.7 kwh of power for 6 hours of use
-The AC barely cycled off and mostly towards 6PM when I shut it off. I guess the duty cycle was 95%
-My solar panels made 16.1 kwh of power that day
-The AC takes different amounts to run it, and will draw between 1660 watts and 1900 watts

For the Easy Start install:
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