Ultimate RV Solar System Build Details - Turning an electrical Schematic into Reality (PART 2 )

This is part 2 of our Ultimate RV Solar System Build series. In this video we get into the details of the actual solar system components and show how we took our schematic we put together and turned it into reality and what the solar electrical components look like. Check out Part 1 of the series for a basic overview of components, where as this video goes over the schematic. We cover Lithium Batteries, Wiring and Busbars, Inverter, MPPT charge controllers, Transfer Switch, RV solar panel installation and wiring, RV Solar Panel Junction Box and Remote monitoring installation.
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[@solosailorsv8065]

SUBBED !!; when 'toob splits into 'regular' and 'intelligent', you'll be in the new 'toob !

[@Jim.Hummel]

You two did all the hard work and here I am breathless!! Dream system indeed!

[@KissesFromCanada]

It’s very impressive and desirable...but still intimidating! Your excellent and clear video is useful to me in determining what I can (or can’t) do!

[@BladeRunner-td8be]

After watching the complete video in one sitting, all I can say is I hope I learned something. Actually, I'm certain I did, but I'm miles from being able to competently duplicate this. At 64, I know there is a learning curve when attempting something new, and as long as I stay focused, all will be understood in due time. Cheers!

[@davidcolinstillman5585]

THIS IS AWESOME ! CAN'T WAIT TO SEE HOW THEY DIFFER FROM THE FIRST ONES . HOW THE HOLD UP WITH THE DIFFERENT WEATHER , HAIL ETC & MAYBE THE FLEX OF THE RV IF IT DOES AT ALL . I WAS THINKING ABOUT THE BACKING YOU PUT THE PANELS TO THEN TO THE RV IF RAIN , SNOW , HUMIDITY GOTTEN IN THE CHANNELS & THEN WEATHER GOTTEN COLD THE MOISTURE WOULD / WOULDN'T FREEZE & BUCKLE UP & SEPARATE FROM THE PANELS & RV ? JUST THINKING OUT LOUD & FLY OFF WHILE DRIVING DOWN THE ROAD / HIGHWAY ? THANK YOU FOR LETTING ME / US TAG ALONG WITH YOU ALWAYS ON YOUR JOURNEYS ! BE SAFE ! HAVE FUN ! HOPE YOU HAVE A GREAT YEAR ! GOD BLESS YOU BOTH ALWAYS ON YOUR JOURNEYS ! ENJOYED !

[@lrobie123]

If you look at the MPP Solar inverter product, they have a Hybrid series Grid tie with battery backup solution. They have 10Kwh product. At first, I started thinking to consider the Victron inverter 5000w but then later found the MPP solar 10kWh Hybrid product to build my Grid-tie battery backup system with the Kohler 14kwH house generator that I already own. This will be a 48 volt system which supports 220 volt appliances.

[@SuperSushidog]

Have you installed and are using this system yet? I am thinking of buying the MPP 3kw inverter/charger charge controller, PIP 3048LV-MK with 3,240 watts of solar and a custom built 14.5kwh 48v battery bank installed on my motorhome. I was wondering how you liked your MPP unit and how it was holding up? Thanks!

[@ABQdoubleG]

awesome, I look forward to the future videos!

[@michaelmcclellan916]

I really like your setup but would suggest that the shunt be installed before the disconnect so you don't lose any info when you switch it off.

[@janicewood5561]

Do you guys do solar lectures as seminars at RV rally’s? Those solar panels are amazing and I think would work better on Airstreams ... I have the stick down panels on mine but not from BB and I don’t think mine will last long; BB has great quality. As always...you guys Rock!

[@markmezo]

Nice setup, the only downside is the longevity of the flexi panels over the glass ones, but the weight saving is good.

[@lorriebauer3225]

Great video ... Thank you! Did you seal all four sides of the panels? Your process using corregated panels under the solar panels to help with possible heat issues wouldn't work if all sealed, would it? (A solar wannabe here, lol)

[@1134Bigguy]

I'm not able to go full-time RVing yet, but wanted to get ready and install solar on our 34' 5th wheel. Your idea of using your excess solar to charge your car and bike gave me the idea of using the excess solar, while the RV is stored at our house, to power our house. Can you provide any insight into how that would work? How would we match the grid power frequency to use the RV solar to power our house and use the batteries to power at night. Any help/guidance is appreciated. Thanks for the great videos!

[@MortonsontheMove]

That would be a bit tricky as you would need a grid tie inverter and the utility to give you the grid code to use it. The inverter we installed can do it but I doubt the utility would allow it. You could island the house but your available power would be pretty low for a whole home. I will have to think on this one a little more 🙂

[@dwanehudson6904]

Hey Tom using the one 5000 watt inverters in your system was good i think and help me out with this? So rather then using two 3000 watt inverters it makes it easier to tie into your Breaker panel with just one line in and not having issues with separating your large load draws like two air conditioners to run together and washer and dryer etc. With using just one 5000 watt inverters you can run large loads with no problem right? what’s your thought if you can help me on this issue. i want to install 3000 plus of solar panels on my new 42.5 ft Grand Design and am not sure which way to go with inverter issue. need your opinion please?

[@scottleggejr]

Isn't it funny when you get done installing and wiring solar panels, there's always clouds. I live in freaking Phoenix, Arizona and had the same issue when I did mine. This is a monster system! Congrats! The only constructive feedback I have is the through-hole in the conduit on the roof isn't sized properly. Needs to be bigger per code, but it's probably fine :)

[@TheKandyGuy]

wow good work guys.. !!

[@CC-fx4nn]

Great system! You should be proud of it. I have been curious about these flexible solar panels for awhile now. My fear is that they would become so hot that they would degrade/damage the RV roof material. The insulating material you put under your panels is a good idea. I guess time will tell. Also, did you incorporate any form of external ventilation into the underbelly of your coach where the inverter and solar chargers are located. I could see the inverter putting out a lot of heat when under load and it wouldn't be such a good idea to having it recirculate the same air repeatedly. I hope you do several follow up reports over a period of time for all of us newbies out there!!!

[@kblakee8602]

What does a system like this cost?

[@robertphillips9017]

I once had a RP06 drive installed with a loose screw on the B+ terminal. Local techs struggled for nearly 5 months to fix the intermittent gremlin. To get it fixed DEC sent a tech from the Memorix factory to disassemble the entire drive to kill the gremlin. The loose screw was right under the spot where I could thump the drive to stop/start the fault. Loose screws happen.

[@ronmcdaniel1583]

Tom thanks for a beautiful video on a fabulous solar system. I can't imagine trying to Install a system like yours. How can a person find a professional installer to install on a class A coach? THANKS SAFE TRAVELS

[@KeithStarr]

Check out “AM Solar.” Their quality and attention to detail is second to none. They can design and install a custom system for you.

[@downeyd2803]

Nice job guys really 👍

[@stevest.martin3940]

Tom wish you would have made it to the pizza place crazy All's at Quartzsite last season with the RV Geeks would have loved to talk about solar with you.

[@badgerpa9]

You sure can contort into tight places. Very nice design and layout. Why did you use a small plumbing pvc pipe to go through the plenum area? That pipe has to be a heat and magnetic choke on the wires and that is not very safe in a plenum area even in a camper. Apologize if I am wrong on the pipe. The young Lady needs to be doing professional recordings for businesses and radio, she has a wonderful voice.

[@tingler0]

Any update on which application worked better?

[@HyPex808-2]

so you originally installed a tesla battery for your off grid power needs and made sure you installed a bms on the tesla batteries to make sure everything would balance out and be safe. now you are installing battle born batteries and now are worried about the safety of the tesla batteries? did u happen to pay for the battle born batteries? or were those free of charge?

[@svp2587]

nice setup but i dont know if i would trust the aluminum angle holding the batteries up especially when traveling across rough roads.

[@rob1484]

WOW! That Tesla battery looked pretty sweet! I'm really interested in how you got that and how you hooked it up..

[@mgkleym]

They have a video series from a few years ago on setting it up. Its salvaged from a wrecked tesla. You can just buy them online.

[@lrobie123]

they ripped out the Tesla battery on this install to replace with the safer Battleborn batteries. He mentioned in the video that the Tesla battery is Lithium Carbon and can catch fire easier.

[@lrobie123]

If you watch the DIY Solar KZbin channel by Will Prowse he shows in detail specifically about building solar for use in home. Also, the top solar inverter manufacturers send him gear to test and review. He replaced his Tesla battery with Battleborn batteries too. He also explains wire crimping, building the inverter wiring and test performs the system. Definitely an excellent channel

[@raven7068]

Maybe I missed it in the video I was wondering how many watts of solar you put on your roof with all the panels. When you do an update on performance can you also give us the actual watts numbers that reaches the batteries. Heat loss from the solar panels and the wire loss genuinely will be less power output from the total wattage on the roof.

[@citizencane3492]

Looks like 10 panels on the roof and 2 on the front cap. Tom said they 230 Watts each so I estimate 2760 Watts under optimum conditions.

[@detroit19531]

WOW you system rocks 🎸

[@kenfetter8445]

how did you like the Tesla over all? I still just looking into getting an RV but I see most 5th wheels have a 3" frame work on the elevated area and it looks to me like I might be able to fill that area with the Tesla battery's.

[@johnnylightning1491]

Tom, one big disappointment for me was seeing you use vice grips on hex fasteners. One other question is whether or not you were doing yourself any favors sealing the tube in the corrugated plastic panels. It seem to me that even the slightest amount of wind would help to evacuate the hot air out of those tubes and keep the heat out of the rig. But all in all a really neat and tidy installation. Keep the good stuff coming.

[@liedebunker1253]

That's a lot of work!😲😬

[@adammeany7807]

The pipe that they ran the wires to the roof in is a plumbing pipe. PVC electrical conduit is grey, plumbing pipe is white.

[@robertgarbe6348]

Adam Meany So, no requirement for conduit in an RV roof. No harm, no foul.

[@JustPeaceLoveAndKindness]

Why did Battle Born pull their solar panels off their website? I went looking for them, and they were just not there. Please explain.

[@jeffcallahan8918]

? What materials do you need to remove the stick on panels if they break?

[@michael_silverback_henders8156]

Tom, You still didn't go into how you connect the AC the the fuse panel, so the RV has power on that side. I have watched these two videos several times and that is the part i am confused about... In fact, i have watched dozens of solar install videos and that is the part no one covers....... Please Help.

[@MortonsontheMove]

The fuse panel (DC) or the breaker panel (AC). If your referring to the DC fuse panel I just cut the main wires that originally ran to the main batteries and connected them to the 12v converter. If the battery bank we're 12v you just connect to the busbars.

[@Spyn2nr1012]

Hi Tom! I've enjoyed many of your informative videos but none more so than the ones on your ultimate solar system. I'm in the process of gathering information and funds for a solar panel system and changing over to lithium ion batteries. I was fascinated with your choice of the flexible solar panels that you used. After the last six months of usage do you have any new insights or thoughts about sticking down panels directly to the RV roof? Have you had any adhesion issues in changing temps? Is heat transference from the panels into the RV an issue on hot days because of the lack of an air gap? What are the names of companies making flexible panels? Any other bits of wisdom would be appreciated! Thanks!

[@MortonsontheMove]

Hi Burt! Great questions! We recommend checking out a few of the solar articles on our blog, starting with this one about flexible panels: mortonsonthemove.com/flexible-solar-panel-performance/

[@pauldem544]

In the list of parts, I see no mention of the CSL but that is a part I am most curious about since I am concerned about that for the system I plan to build, mostly since I plan to build my own LiFePo4 batteries (

[@ScottVenier]

Did you tape up the edges of the corrugated plastic or leave it open for airflow?

[@RollinHomies]

Was your roof sealed with any type of “Henry’s” like materials, or is your roof still working with just the original membrane cover? And if so, how confident are you about the peel and stick backing on the solar panels? Did you guys use flex tape to cover edges? I heard you “testing” the panels (not available yet through BB) and am apprehensive about installing any in worries of them blowing off, what type of heat could be transferred underneath the panels to roof and if there could be accumulated moisture buildup over time.

[@MortonsontheMove]

All good queetions,will be answering them all soon in a blog post. The roof is the original material but the edges and one repair area has henry's selant on it so some panels are mounted to it. We did use 3m extreme seal on the edges. BB has had trouble with stock of these panels but they should be available soon.

[@gardeneyes1]

Any update on how you like the flexible panels after 3 months of use?

[@MortonsontheMove]

The solar panels have been great!

[@coopercraige]

What lifespan are you expecting for the flex panels .

[@sambrown6178]

How many SuperDuty dually trucks do you have?

[@TwoDogsBiology]

We have a 2014 DRV and I would like to know what you did to get your roof so clean? What products did you use? Thanks for the great RV info.

[@RVingwithHenri]

Thank you very much for your video. We hope to do some long part -timing when we retire and a decent solar system is very much desired. I realize that this is your 'dream' system. However, for mere mortals, I wondered if you could comment on my sizing question. I figure that comfortably, my wife and I would not exceed 200Ah per day (probably more like 150 Ah). With my current system in Ontario, I find that I can have cloudy days where I get only 20 or 30Ah out of 400W of solar and a 40A MPPT charger with the batteries flat enough that they could have accepted 100 Ah or more. So, I figure that I should have enough battery to handle 3 full days => 6 x 100 Ah LiFePO4 batteries. OK. Now, how would you size the solar? The LiFePO4 batteries are going to charge a lot faster if the sun is out. If my entire bank is near flat I would need 540 Ah (ish). Should I size the solar so that I could charge up this in one day of full sun? Is that a decent rule or pick at least 2 days worth of energy (ie 400 Ah)? etc. I am thinking of 800W. What would you suggest? I was thinking of going with the 3000 VA hybrid inverter charger as my AC does not take more than 13A and we do not have that many high current appliances. You advice would be appreciated. Travel safe. henri

[@erichakanson9514]

Great stuff; I appreciate all that you do, and especially the perspective of an EE on the RV's electrical system. However, the battery wiring gauge is weird--how do you fuse it? As I understand it, the fuse would have to be chosen to protect 1 AWG (unless the batteries limit the current to 1 AWG level, but I don't think that's the case), but then what's the benefit of that larger gauge cable (other than lower resistance, which doesn't seem to be a benefit in this case)? If you could GUARANTEE equal current sharing among the batteries this could work, but you can't guarantee that (even though it is likely to happen if the batteries are balanced). Is there an NEC section that specifically allows this?

[@unique3phase]

The two links Camera Gear and Our RV Life Gear don't work. At least not on my system. Great video by the way.

[@michaelmcclellan916]

did your OCTO come with any VE.Direct cables?

[@gokuro91]

What exactly is that manual transfer switch you put in to bypass the inverter when needed?

[@gokuro91]

I looked on the blog and it was not listed that I could find

[@bigdanc.8429]

Where in Florida were you?

[@joshsuperduty1270]

Do you guys still have the Ford ?

[@gajeep94yj]

You want to sell the hardware you took out? Specifically the victron inverter?

[@CraigMullins1]

those battery supports don't look near strong enough. One good bump and....

[@jon.landry47]

Dumb question... if the shunt is connected to the negative side where the power comes in and goes out, why are fuses always on the positive side?

[@robertgarbe6348]

John Landry shunt is not a fuse.

[@jon.landry47]

Robert Garbe I know. But my understanding is that energy flows is from the negative side towards the positive side. Putting the fuse on the positive side seems to protect a circuit from overload after any damage could have been done. My understanding of flow may be wrong, I’m just starting to figure this stuff out. Thanks for responding.

[@robertgarbe6348]

Well the deal is this.. most RV’s have chassis grounds that many systems attach to, which is any bolt attached to the frame. SO anytime you work around you 12 or 24 volt system, you can possibly short the positive to negative. This is the same with a car where you always disconnect the negative so you don’t short your wrench to any metal when disconnecting the positive. Disconnect the negative and no stray connections can short out..

[@jessicam.4148]

It's too bad those battleborn solar panels aren't available to the public on their own.

[@howardkepple5623]

Price ?

[@Sir_Kevin_001]

Several hundred dollars, and that's just for the wire.

[@Hammer9000]

Its very important not to let the smoke out your electrical components. They will not work if you let the smoke out.

[@WorldOfPPG]

Why I have feeling that people avoid to state cost of system ? Is it just me ?

[@MortonsontheMove]

We discuss the cost in this article: mortonsonthemove.com/ultimate-off-grid-rv-solar-power-system-build/

[@noconz0727]

5000 volt inverter?

[@johnpalmer3848]

No

[@robertgarbe6348]

Man you gotta have a thick skin to take all the stupid and offensive comments on here. With COVID it seems that more people have nothing else to do but criticize and complain.

[@OldJohnT102347]

Fun video, lots of work huh??? To need that much solar you must require a lot of energy WOW !!! Those front vertical panels are a waste in this engineers opinion and major bug catchers, but its YOUR rig... What you referred to early in the video as a Hole Saw (on your cordless drill for making a hole in the roof) it's always called a Spade Bit or Paddle Bit everywhere I've been. John T BSEE,JD

[@DennisWintjes2]

Thanks! Like #69

[@detroit19531]

Would you like to sell me your old system?

[@michael4104]

Well now Tom. You get us all pumped up about using a Tesla battery for our solar system. We spend our hard money, buy the battery/batteries and the rest of the components that you and Will recommended. Now you suggesting that the Tesla system may be a bad idea. Why Tom? Maybe there’s a sponsorship involved? You guys are losing your credibility with me and maybe with other also.

[@gezzuzzful]

Is that pvc in the air plenum? That is very bad.

[@tigersharkzh]

Flexible panels are the worst and you've installed them in the worst maner. In 3 years they won't be delivering 50% of what they do today.

[@vppnbrent]

Was this a joke?

[@warrior9086]

Buying solar panels without a Spec sheet and info on warranty from the manufacturer ?¿? What kind of BS is that ? You gotta be kidding.

[@rvnaut]

..I believe they didn;t buy any of it... did they?

[@johnpalmer3848]

You assume a lot...

[@MrJJSimonds]

@@johnpalmer3848 I believe you will find that they did not...

[@warrior9086]

@@johnpalmer3848 Yes, You are right, I am assuming a lot and what´s required are Spec sheets and proper information so people understand what they are looking at and not just a nice video. After all there are links of the products to the "KIT PAGE" on their web site. That is promotion or would that also be assuming too much ?

[@davidmcconnell8690]

:-)))) :-))))

[@jekroes]

Nice cutting edge technology, then you program it with a Gateway laptop... hum

[@michaelmartin7375]

I wanna know why i wasted my time watching the first video when u went over almost everything in the second video i dont know why i am bothering at this point.

[@Mobutusese]

This was just too simple to follow, and too basic of a system, oh and too cheap too. Thumbs way...down.

[@BlondynCh]

expensive as hell lol I would still go with Tesla battery instead