Part 11: Koffer Electrics
1 August 2013 - Dec 2018

So finally got round to sorting out the electric cables that hung for so long over the Day Bed waiting to be connected into a Fuse Box. It took one day to sort out as some of my labelling had fallen off over the 3 years that it all had hung here.

How it has been for the last 3 years with labelled cables just hanging down the wall


Tools and components laid out ready to hand as I use them


My main power feed is a 35mm2 cable from the battery bank to a main distribution busbar that then has wires leading down to the individual fuses. All the black wiring is from 2.5mm2 cable.
The Ammeter shows the current coming from the Solar Panels


I have put the power supply to the Stereo thru a 40A fuse and 25mm2 cable


The Fuses are in and the Earth busbar mounted. 2 earth cables are soldered together as they join the stereo with the battery and the earth busbar. The surrounding box frame is now also in place.


Finished with a Voltmeter, switchable between the two battreies and Water Tank level meter.
IVT Solar Regulator above.


My battery box with an old 120Ah Banner starter battery from the truck thats still working, and my new Winner AGM VRLA Solar Free WF 230Ah battery
I always mark my batteries with the battery details: Ah & buying date as well as clearly mark + & -
I mark all my earth (-) cables with Yellow/Green electrical tape


New Solar Panel
September 2014

I had already a 100W  Polycrystalline Solar Panel ( efficiency of 11.3% and Max Current (Imp) of 5.46A and now Ive  just added a 150W Monocrystalline Panel with an efficiency of 18% and Max Current (Imp) of 8.43A
With the 100W Panel I was able to get through sommer solely from its out put, but winter left me deficient. So Im hoping by adding another Panel I am able  to get through the winter using only Solar energy for all my electrical needs. I may need to add another panel yet!

I have mounted the panels with a system so that I can angle them towards the sun with an angle of 33° as during winter in Berlin we receive less amounts of direct radiation with approximately half arriving as diffuse radiation, due to frequent heavy cloud cover.
By using hinges with removable centre pins, (locked with a split pin) Im able to put in lifting spacers to set the angle.



The two Solar Panels on my roof.
Also can be seen is my Powerlink Outdoor Plus WLAN Long Distance Antenna, just in front of the roof hatch.


        This is the Panel in tilt mode

Detail of my hinge setup


            This is how Ive connected the system

I was using an IVT 20A, PWM Solar regulator.

But now Ive updated to a more efficient Votronic MPPT MPP 430 Duo Digital regulator.
430W Solar input with a 31A output.
Also when the battery is fully charged it will send 1A to the Starter battery to keep it charged.



Votronic B2B Charger 1212-25 IUoU
April 2015

In 2015 I fitted a Votronic B2B Charging Converter VCC 1212-25 IUoU. This allows me to charge the battery while driving. It keeps the batteries separate and only charges the House battery once the Truck battery is full and charged. I mounted it just above the water tank in the compartment right beside the battery compartment, to keep the cable length to a minimum.

Mine is 12 Volt to 12 Volt at 25 Amps.










New Solar Panels
February 2018

In February 2018 I put two more Solar Panels on my roof as during a winter in Danmark I am just not getting enough light.
 I am going to need to add some more before next winter as I know this is still not enough.
I have room for three more on the roof but will probably need to make something on the  ground to hold some of them.




I had to remove my ladder to make room on the roof. So I built a lockable holding rack on the side of the Truck.




I have now run the Solar Panels through 40A switchable fuses (about to by replaced with 20A) so I am able to isolate each panel as I need.
Also I bought a Solar Computer for the Charge Controller so I can monitor how much Solar I receive each day. It is at the moment temporarily mounted until I get the time to set it into the wood.
Also can be seen is the Battery Monitor for keeping track of the battery capacity.



New Solar Panels & MPPT Charger
                                November 2018

So in November 2018 I added another 150W Monocrystalline Solar Panel to the roof and rewired my complete electrical fuse box, then put in a new Victron Smart Solar Charge Controller 150/85 TR.

I used to have the wires running up behind the wall to the fuse box, so these I pulled out and they now run up the corner of the house behind a board so I can get to them and add more if needed.
I also insulated the battery box with another layer of 50mm Styrodur to both outside facing walls.

Here can be seen the two new 50mm Styrodur pieces before I faced them with plywood and the newly run cables hanging down the wall.

Now one board is on and Ive got the tidy cables laying along the top out of the way

Starting to put in the new "Plus" & "Minus" Busbars and the fuse holders

Glued and screwed mounting rails for the new board and have most of the wiring finished and cable tied in order.
The tip down front will give access to the fuses as well as hold the Victron Smart Battery Monitor 712, Victron MPPT Control and my Water Gauge. The Water Gauge later gets moved and the monitor from the Votronic Mppt goes in the middle.
Attached to the battery is a Victron Smart Battery Sense, providing through a Bluetooth connection to the MPPT, the actual Temperature and Voltage.


On the left are two 120A Latching Relays for the High Voltage Cutoff and Low Voltage Cutoff as well as new Main fuses.
I will later be putting in a LiFePO₄ Battery system, so Im setting every thing up for that now.


The backing board is about to be mounted

Ive got the Circuit Breakers set in place and about to wire them in.
The black Circuit Breaker is from the Solar Panels, which are set up as 2 in series then 2 in Parallel.
The white Circuit Breakers will be used to disconnect the Solar input to the MPPT and instead the input will then be connected to a Power Supply for charging when they is no sun.


Everything is now in place

At the top is the old Votronic MPPT that now has only the old Polycrystalline Panel connected to it.
My Circuit Breakers.
New Victon MPPT connected to my 4 Monocrystalline Panels
The old Amp Meter is connected to the Polycrystalline Panel and goes thru a 20A Circuit Breaker.
And the Monitors and Gauges

Truck with 5 Solar Panels on the roof giving total capacity of 700Watt

My wiring diagram for the Project!

Battery box with Latching Relays in place but not set to cut off. Plastic cover screwed over the contacts to prevent short circuit.

Latching Relays will be wired into the LiFePO₄ cells BMS once I finally get around to putting it in.

Now just waiting for me to install in the future the LiFePO₄ cells to make the Battery as my AGM is on its last legs!


                                                                                                      Return to "Trucks New House"
                                                                                                     Go to "Part 12: Water filter"
 

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