Solar Suitcase & Lithium Upgrades

[rideandfly]

When we purchased our 2015 LE2 used during 2016 it had two group 27 12V lead acid batteries without factory solar.  The following information & installation has happened over a few years.

Initially we purchased a Renogy 100W suitcase solar panel and used it charging the batteries through the trailer's 7 pin connector. Wanted to have a more efficient way to charge batteries.  Installed a Furrion Solar port and mounted Renogy Waterproof solar charger in the battery compartment.  Use about 36' of 10/2 cable with 12' sections from solar panel to Ollie's Furrion Port.

Had to drill holes in Ollie's pretty finish for the Furrion Solar port next to battery compartment. 

Furrion inlet under port bed:

Renogy Solar 20A Waterproof Charge Controller mounted on plastic kitchen cutting board in battery compartment:

When Ollie is in the shade it's nice to be able to reach out up to 36' placing panel in the sun, panel in lower LH corner of photo. Highest charge amperage seen using 36' of panel cable is 6 amps and highest charge amperage seen is 7.1 amps using one 12' section of solar cable.

We purchased a Honda EU2000i to charge batteries on poor solar days. Installed a EZ start on the 13.5K Dometic AC so the Honda gen-set can also run the AC unit, or microwave, or hot water heater.

Been actively reducing Ollie's weight when possible, currently Ollie's ready to camp weight is around 4950 pounds with full 6 gallon hot water tank and all other water tanks empty as per CAT scales.  

Replaced two group 27 12V (125 pounds) batteries with one BattleBorn 100AH Lithium (35 pounds) battery for loss of weight and Lithium battery performance benefits. Also installed the Progressive Dynamics Lithium charging section in our Progressive Dynamics convertor that BattleBorn said would work fine with their battery. Using the Honda gen-set connected to Ollie's 30 amp connection, the Progressive charger slowly drops charge amperage then cycles charge rate between .25 amps to .4 amps at full charge. 

BattleBorn told me not to worry about TV alternator damage when connected to TV with 7 pin plug with our particular system. They said because of charge cable's small diameter and distance from TV to battery,  would not see very high amperage charge with TV connected. So far with BattleBorn battery at 75% charge while connected to TV with engine idling have not seen more than 3.5 amps of charge. Our current TV has 180 amp alternator and with ignition turned off, the 12V power supply to Ollie is also switched off.

Initially installed a Victron BlueTooth shunt to monitor the battery, but my Android 5 was not supported by the Victron system. Believe Victron unit is the way to go, but at the time my Android was not compatible so purchased an inexpensive shunt & monitor from Amazon to monitor the battery. Found a automotive 2" instrument mount on Ebay to mount the monitor:

https://www.amazon.com/dp/B07FGFFHC6?psc=1&ref=ppx_yo2_dt_b_product_details

The battery monitor is not waterproof, use a 1 1/8" hole saw to cut out 1" OD plastic cutting board plugs to fill the existing ventilation holes in the battery compartment door. Did not want to mount these plugs permanently, sealed with clear RTV silicone for easy removal:

The benefits of the Lithium battery is much faster charging with gen-set or solar panel with plenty of battery capacity for our style of camping. Will be doing more camping without electricity and water connections with this system, too. 

[SeaDawg]

You've done a great job to customize your Ollie,  your way!

Congratulations. 

[SeaDawg]

Btw, your weight on an Elite II approaches that of a bloated Elite. You put a lot of thought, obviously,  in what you "need" vs what you might "want".

 

[rideandfly]

3 hours ago, SeaDawg said:

Btw, your weight on an Elite II approaches that of a bloated Elite. You put a lot of thought, obviously,  in what you "need" vs what you might "want".

 

For us we were taking lots of stuff we did not need on trips. Now we pack according to each trip. This rig handles nicely and stops easily, too.

Thanks,

[fairmontrvpark]

Great Post! Thank You for sharing. 

[rideandfly]

Purchased an iPhone and  replaced the existing battery indicator and shunt with a 500A Victron Bluetooth Smart Shunt on Ollie yesterday.  This system works great for our needs:

https://www.victronenergy.com/battery-monitors/smart-battery-shunt#pd-nav-video

Extra wire/cable needed to  roll out battery tray.

 

 

Edited July 4, 2022 by rideandfly
Udated Photo

[rideandfly]

Added an additional 100W Renogy solar suitcase making two total 100W solar suitcases. Currently using a Renogy PWM charge controller. Decided to increase solar port capacity from 10 Amps to 20 Amps.

Original Furrion 10 Amp solar port:

Installing Zamp 20 Amp solar port in existing Furrion unit:

 

Next modification will probably be installation of a Victron or Renogy MPPT charge controller.

 

[rideandfly]

Plan to replace the existing PMW charge controller in the battery compartment with this Renogy 20A MPPT charge controller and temperature sensor next week. 
 

 

[MAX Burner]

Eager to see the install...!  😎

[rideandfly]

7 hours ago, MAX Burner said:

Eager to see the install...!  😎

Will install the controller this week and post photos.

We don’t have an inverter, so can’t use 125V appliances when using only solar. Normally use about 25% of the single BattleBorn 100AH lithium battery daily when dry camping. We can easily camp three days without charging the single lithium battery. We have a three way Dometic refrigerator using LP gas to operate when dry camping.

Going  to monitor heat in the battery compartment with a Renogy temperature sensor, if needed,  plan to add vents that open & close easily on the battery compartment door leaving the original vents plugged since they are fixed vents. Will see how testing goes! 🙂

Thanks,

Bill

[rideandfly]

Installed the Renogy 20A MPPT solar controller on the existing plastic mounting board with the temperature sensor and 9’ of cable on top of the battery this afternoon. Plan to install a “taller” plastic mounting board relocating the controller higher than it’s current position.

Decided to leave the original battery compartment door vents plugged since rain can get in the compartment if left unplugged, but plan to install additional louver style screen vents on the battery compartment door for air circulation. These vents will be the same style that Oliver installs on new Ollies, unless I come up with a better vent system, will see.
 

Additional photos:

 Furrion solar port with Zamp 20A modification mounted on Ollie. The new 100W Renogy Suitcase panel is smaller than the older panel:

 

[rideandfly]

Contacted Oliver to see if current battery compartment door with louvered vents will fit on our #75 LE2 Ollie, but Oliver said the latest door is a different size and will not work on our Ollie.

Decided to remove plastic plugs I installed in original battery compartment door vents and use 1/16" thick soft silicone plugs that can be installed & removed easily in original vents.

Purchased a silicone lid and cut out 8 plugs installing in existing vents.

Plan to monitor battery compartment temps or remove vent plugs while away from campsite when solar charging with an indoor/outdoor Acurite temperature monitor this season, will see:

[topgun2]

1 hour ago, rideandfly said:

Purchased a silicone lid and cut out 8 plugs installing in existing vents.

And - 

now you can use that lid as a strainer!😇

[Patriot]

@rideandfly Nice work Bill - thinking outside the battery box!  Looking good!

Patriot 🇺🇸

[rideandfly]

5 hours ago, Patriot said:

@rideandfly Nice work Bill - thinking outside the battery box!  Looking good!

Patriot 🇺🇸

David, Thanks! Going to test the system very soon, too!

[rideandfly]

On 5/31/2023 at 11:42 AM, topgun2 said:

And - 

now you can use that lid as a strainer!😇

Now that you mention it, I did have enough lid left to make a sink stopper, all for a $1.96! 🙂

[topgun2]

Strainer - stopper   What ever!

You da man!

waste not, want not.

[Geronimo John]

12 hours ago, rideandfly said:

Decided to remove plastic plugs I installed in original battery compartment door vents and use 1/16" thick soft silicone plugs that can be installed & removed easily in original vents.

Would some gorilla tape over the line of vent holes stick?  Would be a lot faster!  Cost beats $1.98!  But alas likely less life span.

GJ

[rideandfly]

3 hours ago, Geronimo John said:

Would some gorilla tape over the line of vent holes stick?  Would be a lot faster!  Cost beats $1.98!  But alas likely less life span.

GJ

John,

Tried tape & neoprene plugs, the tape did not stick well on the door interior surface or seal well. Neoprene plugs did not install easily. Silicone plugs seal nicely and easy to install & remove.

Are you working on your suitcase solar panel installation?

[Geronimo John]

3 hours ago, rideandfly said:

Are you working on your suitcase solar panel installation?

Have a 200 watt solar suitcase.  Used it last year but just ran the cables thru the battery compartment gasket.  WIll be installing the z-amp 20 amp plug in the door this summer.  After last summer's use, if I were to do it again, I would have gotten two of the 100's.  Easier to pack and would fit in more spaces on the move.

Looks like I'll be getting a Mainstays silcon lid.  Where did you find it?

GJ

[topgun2]

8 hours ago, Geronimo John said:

Looks like I'll be getting a Mainstays silcon lid.  Where did you find it?

Wal Mart for certain and possibly Amazon.

 

[rideandfly]

5 hours ago, topgun2 said:

Wal Mart for certain and possibly Amazon.

 

Yep, Walmart is where the white plastic board the solar charger & Victron Shunt were mounted on (Cutting Board) and silicon lid were both purchased.

[Geronimo John]

22 hours ago, rideandfly said:

And - 

About 60 years ago, my grandfather and I built a buss bar knife switch very simular to yours.  I had totally forgotten about it until I saw yours.  Well done! 

GJ

 

[rideandfly]

13 hours ago, Geronimo John said:

Have a 200 watt solar suitcase.  After last summer's use, if I were to do it again, I would have gotten two of the 100's. 

GJ

Yep, I'm the same way, easier to pack. The older I get the more I don't like picking up heavy stuff if I can avoid it.

[rideandfly]

3 hours ago, Geronimo John said:

About 60 years ago, my grandfather and I built a buss bar knife switch very simular to yours.  I had totally forgotten about it until I saw yours.  Well done! 

GJ

 

Like my old 2003 Toyota pickup, it's simple and durable.

Thanks!