New Build - 6*12 Offroad Toy Hauler

[hankaye]

flboy, Howdy;

Question;

What is the device that you have installed on the shelf support
just above where the inverter is? Looks like it would get smooched
when ya close the door... jusr bein' curious. chuckle.

hank

[flboy]

Hi Hank. That is a DC breaker for the Solar Controller. It is the angle of the picture I am sure. The door hits the frame stops about and inch before the breaker. It was just a convenient place for it. I will be doing something similar when I connect the DV to DC charger.

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[hankaye]

flboy, Howdy;

Thanks, didn't think you'd install something where it might get
damaged. Was just an odd looking place for hangin' something.

hank

[flboy]

Got the batteries re-installed and all the DC bus bars, breakers, and etc. in the final configuration. I used 1/2 inch copper pipe I had and beat it flat and doubled it up to make some connections (busses) between bus bar, DC breakers, and cutoff switch as well as the chassis ground connection. I used 1/0 AWG copper to connect batteries and the connection to bus bars.

I doubled up 4 AWG to the inverter since I already had the wires made.

Tested at full 1500W of inverter and nothing even gets warm..I took out those ANL fuses. They are just not right for this application. They drop too much voltage and get warm. The entire path this time only dropped about 1/2 a volt. Also, I wasn't comfortable with the 4AWG wires, so I went with the 1/0 AWG and copper pipe busses. Overkill, but minimal losses. Much happier with the DC breakers as well.

Initially, I had unequal discharge from the two LiFePo4 batteries. It was about 1/3 to 2/3. I asked around on the electrical thread and got no good answers that I thought were actionable. I suspected it was an internal resistance issue as that would explain it the way I understand these things. With the 1/0 AWG connections and tightening all the cell connections in the 230aH battery, I am now getting an equal draw within a few amps at full Inverter Load. I can live with that. Learned something today!

I did add a ratchet strap to tie down the batteries as well. The trailer will get bounced around.

In any case, I am going to start on the AC wiring now. Got a manual transfer switch to install , the breaker panel, and and outlet for the A/C and Conveter.










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[featherliteCT1]

I have been wondering about your problem with unequal draw from the two batteries. I am glad to know you found the fix.

Do you use a hammer crimp tool to crimp the lugs on your large gauge wires?

In the past, I tried the soldering method and also tried using a cheap $80 hydraulic crimp tool, but was not happy with either of the results. Not wanting to pay for a $300 crimping tool to achieve OEM hex style crimps, where the wire gets cold welded inside the lug as a result of the compression, I bought and have been using a cheap hammer type crimp tool. Time will tell.

[flboy]

I have been using the hammer crimp for years. Have not had issues with any of the crimps yet. It seems to work well... cheap and effective. I don't know if it actually cold welds, but I think it makes a decent connection. I always use the heat shrink with the epoxy to make sure it seals well from moisture also, albeit most of the connections are not out in the weather.

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[flboy]

Got a few hours in today. I have the manual transfer switch in (above Fox's head) and the AC Breaker panel. I just need to wire a few outlets, get the stereo connected, the AC Power meter connected, and install the cabinet door I made, and then I should have the electrical cabinet done. Will start the shower probably on Tuesday. Lex has surgery tomorrow, so I will not get alot done after noon.

After the shower and gray water tank installation is done, the only other big fabrication project is the overhead cabinets. The rest will be paneling, finish work and some roof vents. Targeting getting done in 2 weeks. My plan it to take this CTC to my son's house in Nebraska at the end of July and work on a few projects for him over a few week period before I camp my way home for a few more weeks. Will be a good shakedown before all the Fall/Winter overland boondocking around Florida. At my son's, I will be living in it out behind his garage... so I will have a lot of time to ponder what I should modify, add, or just wish I did differently.

Oh yes... forgot to mention I got the solar all hooked up and programmed the Epever MPPT Charge Controller for LiFePo4 parameters and all is working well. It seems to be working as intended. Decided to put the remote MT50 display on the face of the electrical panel also.





For the Transfer Switch, I went with a Baomain Universal Rotary Changeover Switch ( SZW26-63 660V 63A 3 Position 3 Phase) I found on Amazon. I used only two of the phases (transfer hot and neutral only.. never switch safety ground) ) and just had to figure out what contacts to jumper to make a common output for the two active switch positions. The middle position is all contacts open. Makes a good service disconnect also in that case. I like it better than the blade switch I used in the 7*18 V-nose CTC.








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[bdosborn]

For the Transfer Switch, I went with a Baomain Universal Rotary Changeover Switch ( SZW26-63 660V 63A 3 Position 3 Phase) I found on Amazon.

Put a sticky note up at the switch to "Leave switch in 0 position for one mississippi when switching between live sources". It allows back emf from any motors that are running (like your A/C) to dissipate before switching to another source that will be out of phase. Back emf from motors causes a faulted condition in your electrical system that can blow fuses and is hard on your equipment.

Bruce

P.S. I wired LEDS to each source at the switch so I could tell if they were live.

[flboy]

Thanks for the tip Bruce! How do they handle that with these automatic transfer switches that Changeover in milliseconds? Or maybe they have a built in delay?

I have the AC Power meter on the switched AC Hot so I can monitor. Will be able to tell if it is live that way after I switch.

I do have a 110VAC LED indicator coming today so I can tell if my Inverter is on when remote switched, prior to turning the transfer switch from Shore/Gen to Inverter. So I suppose that will take care of that case.

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[flboy]

Well, there we are.

Fire in the hole!



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[hankaye]

flboy, Howdy;

No smoke??? Must be good ta go.



hank

[bdosborn]

Thanks for the tip Bruce! How do they handle that with these automatic transfer switches that Changeover in milliseconds? Or maybe they have a built in delay?

I had a 30A ATS and it had no phase control logic at all; it transferred when the preferred source wasn't available and then transferred back when it was. There was a fine print note in the warnings not to connect the generator while utility power was present or something like that. I tore my ATS out 10 years or so ago so maybe they're better now but hunch is they aren't. RV versions are just contactors so they transfer from one side to the other, and don't pause in a middle off position. Commercial versions have a time delay while transferring or they will phase match the two sources before transferring. However, the reality is that the A/C motor back EMF likely isn't an huge issue and it decays in 20 cycles but a one mississippi is so easy to do.
Bruce

[flboy]

flboy, Howdy;

No smoke??? Must be good ta go.



hank

No smoke so far
. Lol..I did get a spark when tightening a battery terminal and the wrench slipped. I need to get an insulated wrench!

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[flboy]

Ran the Air Conditioner from the battery bank and inverter today for 2 hours. Just took the bank down less than 10%. Nothing even gets warm. I think this is going to work well. Also got the stereo and all the electrical outlets and monitors wired up. Starting on the shower tomorrow.









I still have to tidy up wires and connect the Converter and DC/DC charger, but that is it. Just need to pick up some wire, else it would have been done today.







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[flboy]

Here's a pic of the Cell Phone Booster antenna and Radio Antenna which I installed at the same time. The radio antenna is the little stubby in front of Cell Phone antenna.



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