Project Choose Your Own Adventure

[ScottyB]

first test of the battery system worked!  the solar panel isn't wired in yet (just 2 wires) and no formal wiring runs to the interior lights, but i was able to confirm that:
• the main fuse panel is getting power
• the kill switch works
• the solar charge controller is seeing power and sending it to the fuse panel
• and the battery charger is doing its job.

here's the contigo bin turned into a tongue box.  i fitted 1x1 aluminum square tubing to the bottom front/back to support the bin across the frame.  it'll need it - the battery alone is 75lbs.  the tubing is attached at each corner with grade8 bolts and nylock nuts.


i wanted the charger and a 3-way extension cord splitter to live onboard in the bin at all times, so i needed a way to get AC power through the side in a weatherproof way.  this Marinco 15A charger inlet did the trick and will keep water out as its intended as a hookup for boats and has nice rubber gasketing.  on the other side of the inlet, i chopped the plug off the splitter and the wires plug easily into ports on the back side of the inlet.


the guts.  from right to left - power comes through the inlet to the yellow outdoor rated GFCI 3-way splitter.  from there i have the CTEK charger/tender plugged in to charge the battery whenever we have AC power to hook up to.  the 6-circuit fuse panel, solar controller, and kill switch live on a piece of scrap 1x4 bolted to the back of the bin because i'm SEW FAHNSEH.  the kill switch leads to a 10A fuse and finally the battery itself.  the battery is then grounded to the frame.  10AWG wire throughout which should be very capable of handling my power needs as its good up to 30 amps, waaaay more than i should ever be pulling from my gaggle of LED lights, a fan, and maybe a 2 speaker stereo at most.  i'm in the process of adding some 1.5" round mini vents along the back at the top, and more will go at the bottom to allow air circulation for the electronics, and being on the back they'll be protected from rain spray during transit.  ignore the crappy weather stripping around the edge, i'm working on it.


kill switch to "ON", solar controller status light is green ("PV" is photovoltaic, aka solar panel wires)!  let the power flow, huzzah!  the controller's job is to not only meter out the solar power to the battery, but in turn also send power from the battery to the fuse panel, so it was critical to see that it was getting power and happy.  it has its own internal replaceable 20A fuse just in case something short circuits or the controller bricks.  lots of redundant fusing and extra headroom here just in case. 


lastly, the party piece - had to see if the fuse panel was live and ready to send power.  grabbed one of the "porch lights" aka outdoor light that will live above each door so we don't trip onto our faces and piss our pants trying to get to the bathroom in the middle of the night, and tossed a red wire on the positive side and a black wire on the negative buss.  BAM SON.  illuminati, i mean illumination, confirmed.  now i know if i send my wires through the camper structure right, i should see working lights on the other end.


oh yeah, here's a wiring diagram.  i forgot to add that the charger has its own 10A fuse on the positive line as well.  FUSE ALL THE THINGS

"overhead lights" is basically the galley lighting, "porch lights" are the outdoor lights over the doors, and "stereo" will basically just consist of a cheap headunit and 2 6-in speakers mounted in the galley hatch.