Make My Own Solar Generator For Intermittent Boondocking

[SJ Communicator]

Hello All,
So I am trying to conceptualize a way to power my rig with battery power for overnight stays and intermittent boondocking on longer treks that we plan on taking in the near future when my better 1/2 & I give a go at retirement. We have a 2019 (almost paid off!) Jayco 24RL. We love our rig and have mainly camped at semi/full hook up camp sites. We did take our longest trip from Tampa FL to just west of Austin TX last year for the eclipse. We're members of Harvest Host and we used several spots on our outbound & inbound travels. I did bring a 3200 watt generator with us which easily powers everthing in our rig. However found if the host didn't frown on our running the generator the other guests certianly did. We of course didn't run it all night long but even under 60db is loud on a quiet country night. Our rig is "prewired" for solar but from my research to use the provided wiring only still would take a bunch of additional equipment and loss of storage space for additional batteries and components. Not to mention I have yet to find the inside end of the wiring coming from the roof lol. I digress So I was looking into a solar "generator" to plug into the shorepower plug and power up all the (AC/DC) systems. After researching I have learned that solar generators are just basically a battery with a built in inverter with fancy electronics. Most are expensive and limited as far as extended run time. I know by self educating myself that if I was to have 1200 watts of power for 8hrs I need (9600 what hours) 800 amp hours of battery. That is way more than I think. I would use but I would rather over estimate than under estimate. But realistically could get away with 600 amp hours to do what I want it to. It seems much less expensive to buy batteries, solar controller and inverter (which I already have a nice 3000 watt one) and panels. Then buying a fancy battery pack with nifty electronics. The way I am thinking is basically providing a 3rd complete independent electrical circuit that would utilize the 30amp shorepower plug when in use and be able to be unplugged and charged by its own solar panels mounted on the roof when not in use. I have already reinforced my rear bumper so I'm thinking of mounting lifepo4 batteries in a box on a rack to the back, making a weather proof enclosure for the solar controller and inverter. Having a charging wire from the panels in the roof to recharge while underway or supplement if we had to rely on the 3rd system for an extended time. The system could also be charged/topped off with a battery charger when we are at a spot with at least power hook up. I am still learning about the solar panel aspect of what kind of wattage vs how many panels I want to put on my roof. I was just wondering if anyone had done or heard of anything similar to what I am envisioning. Also just to be known I am not looking to run my rigs AC. We'll if I can I will but was thinking of just plugging in a small 5k btu room ac unit that barely uses 700 watts. Any input would be greatly appreciated.

 

[FloHauler]

Are you sure you would need a full 1,200 watts for 8 hours straight? That’s a lot of watts - and amps. 100 amps continuous at 12 volts of I did the math correctly.

Don’t forget that you’ll have efficiency losses and that batteries will not deliver 100% of their rated storage, as well as degrading over time.

As you start looking at system components, you’ll want to consider not just your usage, but the potential current draw of the components. A 3,000 watt inverter can draw 250+ amps, which would require some pretty stout cabling.

Renogy and Victron have some good planning resources on their websites. More of everything (solar panels, batteries, etc) is always better. You’ll also likely want monitoring tools for the batteries and systems so you can see how everything is performing.

 

[SJ Communicator]

Thank you for your reply and good advice. As I mentioned the calculations I was starting with was what if I needed to run everything or at least the AC and microwave at the same time etc. As I crunch numbers I realize of course the most things I would need to run all through the night would be a TV ( my better 1/2 can't sleep without, I have learned to adapt lol) and a small AC unit. The AC unit probably not so much as we migrate out of the southeast and I could put it on a timer. However being from Florida AC is an essential aspect of out lives so we always account for it lol. I'm actually considering getting the Bluetti AC200L. It provides 2048 watt hours with the base unit and can be expanded to over 8000 watt hours with add on battery packs. The base model already has a 30 amp RV plug and can be charged with 5 different sources even when in operation as it has pass through capabilities. It has excellent reviews but is expensive and of course everything is proprietary as far as add ons and accessories go. But everything I need is self contained in an attractive relatively light package. Not a hodge podge of assorted components. I can already hear my better 1/2 saying thing llike "Are you sure it's supposed to look that way?" lol... I have the AC209L on several watch lists and if there's a good enough discount I may pull the trigger. The only thing I am not thrilled with is the fact the unit has no tolerance to whether. It would be a sad day to spend so much on a backup power supply and not be able use it because of inclement whether. Or worse if the unit is set out side and a rouge storm passes through in the .middle of the night. That scenario is also a more Florida/Southeast concern.

 

[FloHauler]

LOL. Pretty lights are Important!

Bluetti makes some good units. But as you noted, the household style battery and inverter units are not designed to be out in the weather. The capacity will also not support your design needs.

From their FAQ

BLUETTI AC200L: Revolutionizing Portable Power Solutions

Experience unmatched power with BLUETTI AC200L – 2.4X charging speed, reduced noise, 1.6X output power, UPS in 20ms, and an array of applications. Your power solution, redefined.

www.bluettipower.com

To be clear, I’m not dissing Bluetti. I like their products in the appropriate setting. Based on what you desire a unit to do though, you might be dollars ahead to work with someone to design a system that integrates all the components seamlessly and provides the capacity to meet your needs.

 

[SJ Communicator]

LOL. Pretty lights are Important!

Bluetti makes some good units. But as you noted, the household style battery and inverter units are not designed to be out in the weather. The capacity will also not support your design needs.

From their FAQ

BLUETTI AC200L: Revolutionizing Portable Power Solutions

Experience unmatched power with BLUETTI AC200L – 2.4X charging speed, reduced noise, 1.6X output power, UPS in 20ms, and an array of applications. Your power solution, redefined.

www.bluettipower.com

View attachment 1314331

To be clear, I’m not dissing Bluetti. I like their products in the appropriate setting. Based on what you desire a unit to do though, you might be dollars ahead to work with someone to design a system that integrates all the components seamlessly and provides the capacity to meet your needs.

 

[SJ Communicator]

Thank you again for your reply & info! I wouldn't have to worry about running a refrigerator on 120 as I can use gas & 12v as we do while traveling. Also I wouldn't be running the (800w) microwave more than 2 1/2-3 minutes max (popcorn lol) at any one given time so 1.6hrs run time would be more than sufficient. As mentioned I realize my initial power need calculations were way on the heavy side. In reality for an overnight stay at a Harvest Host 2048 watt hours (appx. 20amps) would be (I believe now) more than sufficient. Other than if we were at a hot & humid location and would have to run a little stand alone room AC unit. I have one that we use when we're on genny power during a lovely hurricane event. We're used to that type of thing as we live in an older part of Tampa & if the wind blows 2 different directions within five minutes we will lose power. The city is in the process of relocating all the service to underground so hopefully we won't have to deal with loss of power too much anymore during tropical weather events. I digress, so we have a little 5000 btu stand alone AC unit we use. The power draw is barely 6-5 amps (600-720) watts. I have to be cautious in those events not to overload my generators sensible capacity. I also believe it has a soft start built in to it. I have also read that my 13000 btu unit would run with the AC200L but a soft start would be needed and the run tme would be ridiculously short. So I am not even going down that road. Even if the little room AC ends up problematic we will just deal with fans. We also once we get out of the southeast soup evenings are much cooler and wouldn't even need AC. I was thinking for the weather issue I could sacrifice my outside refrigerator and use the compartment it resides for either my home made unit or the AC200L & at least one additional battery. I have been pricing components and if I can score the Bluetti on sale within a couple hundred $$ of buying components, I may just get one just to run it through it's paces in simulated stay. If it didn't work I could just return it. Luckily I park my rig on my home property so a mock up test wouldn't be difficult to do. The one thing I have been thinking about in more depth would be the parasitic draw of the converter trying to charge my house batteries while under battery supply via the 30amp shore power plug. I have read I can just shut the breaker off that supplies power to the converter. However, I have also read that if the house batteries are fully charged the converter will not even be an issue.

 

[FloHauler]

Good luck with it. It’s all about wants, needs, and $$.

 

[SJ Communicator]

Good luck with it. It’s all about wants, needs, and $$.

Yes that much is certian!

 

[FloHauler]

Check this out. Bluetti has a new unit coming out. Supposed to be August availability.

Pre order pricing looks very nice.

 

[SJ Communicator]

Check this out. Bluetti has a new unit coming out. Supposed to be August availability.

Pre order pricing looks very nice.

Thank you!
Funny thing is I just pulled the trigger on getting the Bluetti AC200L & a B300k expansion battery. The main unit gives me a full 20amps (2400watts) of continuous output. The on board battery has 2048 watt hours (170 amp hours). The expansion battery offers another 2764.8Wh (220.4 amp hours) which is a total of 4812.8 watt hours (401.7 amp hours). After crunching the numbers with my wish list vs reality I am more than certian I'm right in the sweet spot! As for the price I did the "cart trick" and got the AC200L for $899 and bought the expansion battery refurb with full factory warranty for $650. So for a little over $1500 I got what the combo unit on sale for $500 less than the best sale & $1500 less than suggested retail. Yes a few hundred more than buying all the components and wire to build my own. But I think the fact I have something actually "engineered " by professionals and is basically plug & play was well worth the difference. Not to mention my better 1/2 was more in favor of the esthetic aspect too! The Bluetti line seems to offer the best of solutions & features for a portable power station. I still plan on building my own portable solar power/inverter charging station. This was some of the components I started to assemble for my original plan such as my panels & inverter will not go to waste. They have all passed their "return window" so I'm kinda stuck with them I'll provide updates when I actually get the unit(s) and run them through their paces.

 

[FloHauler]

Looks like that will provide a solid power source for your travels.

 

[Jaykol]

I picked up a AC200L as well, still trying to figure out where to put it though. As others said, it needs to be indoors, and for me, the simplest way to use it is the RV plug. 200W folding panels fit behind the fold out couch though.

 

[SJ Communicator]

I picked up a AC200L as well, still trying to figure out where to put it though. As others said, it needs to be indoors, and for me, the simplest way to use it is the RV plug. 200W folding panels fit behind the fold out couch though.

We have an outside refrigerator on our 24RL. I am thinking about losing the refrigerator and using that space for the Bluetti. The compartment (of course) already has a 120v outlet so I could recharge when hooked to shore power. The compartment is on the curb side of our rig so I would have to make a medium length jumper to reach the shorepower outlet on the other side. I'm still on the fence though as we like to have the extra fridge as an overflow if we end up with too many groceries (My better 1/2 & I have have yet to learn how to shop or cook just for two lol)and of course to be able to grab a cold one without having to go inside lol. I am still exploring options. I will know exactly what type if space whe my B300k expansion battery arrives. But more than likely I will lose the fridge and maybe get a 12v cooler. I think actually bluetti makes one what can be used as a powered cooler/ freezer or both. On a side note I am impressed with the charging speed of the AC200L. It charged from the 50% it was shipped with to 100% in less than 1 hour. But man does it pull some juice 1200w/10amp. I will be running it through it's paces this weekend weather permitting

Edit:
I guess I was mistaken by stating Bluetti makes a 12v cooler. In my research so far Dometic and Bouge RV are the front runners with Bouge RV being the more economical choice...

 

[Jaykol]

Running the cord from your regular shore cable to the hatch would mean creating a pass thru into the space or leaving the hatch open I think? That is the part I can't figure out. Adding a second plug inside seems like a potential disaster the day I brainfart and plug both in unless there was a transfer switch or something.

Side note 1) - you can set the Bluetti to a lower amp slower charge rate. I think it is better for the batteries too.
2) - we use a portable ice maker and regular cooler. Also have fresh ice all the time this way.

 

[FloHauler]

Running the cord from your regular shore cable to the hatch would mean creating a pass thru into the space or leaving the hatch open I think? That is the part I can't figure out. Adding a second plug inside seems like a potential disaster the day I brainfart and plug both in unless there was a transfer switch or something.

Side note 1) - you can set the Bluetti to a lower amp slower charge rate. I think it is better for the batteries too.
2) - we use a portable ice maker and regular cooler. Also have fresh ice all the time this way.

You could add a transfer switch so you could only run one or the other. You could also add a properly sized cable and plug and an outlet that would allow you to either connect the shore power or the bluetti. Just depends where you were locating the pieces and available space.

 

[SJ Communicator]

Running the cord from your regular shore cable to the hatch would mean creating a pass thru into the space or leaving the hatch open I think? That is the part I can't figure out. Adding a second plug inside seems like a potential disaster the day I brainfart and plug both in unless there was a transfer switch or something.

Side note 1) - you can set the Bluetti to a lower amp slower charge rate. I think it is better for the batteries too.
2) - we use a portable ice maker and regular cooler. Also have fresh ice all the time this way.

Thank you for the advice! Well I could make a cord port on the compartment door and just run the cord through it when in use. Our 1st camper had a little round door where the power cable pulled out. It even had a little slot to close over the wire portion. If I could find something like that would help keep 99.9% of any wheather out less driving wid & torrential rain. The other plug in end on our current rig is already weather proofed. Considering I will not be using the Bluetti for 100% of the time mainly for overnight stays but there maybe the need to boondock for a couple of daze. I really don't want to ( even though the thought has crossed my mind) tamper with the factory wiring circuit. Even for just being able to resell without having to lose what I have installed. So basically just run an extension (probably 8AWG) cord from one side of the camper to the other would all I need to do. As for charging, yes there are different settings I just plugged it in for the 1st initial charge. We also invested in a counter top ice maker! We use it all the time. The quality end of DC coolers ain't cheap. But the Bouge RV 48qt is not too ridiculously priced and received excellent reviews. That thought process is still "embryonic " . What I am still trying to conceptualize is the recharging of the Bluetti while traveling. But I will figure something out. I usually always do

 

[SJ Communicator]

You could add a transfer switch so you could only run one or the other. You could also add a properly sized cable and plug and an outlet that would allow you to either connect the shore power or the bluetti. Just depends where you were locating the pieces and available space.

Thank you for the reply.
Yes there are several different options. Right now I am aiming to have the least tampering with the factory wiring system as possible.

 

[DaveT-JAY]

BougeRV tried to pass off to me a trashed powered cooler in a trashed ripped up box as new. Just a data point while you are shopping.

 

[bow-man]

Thank you for the reply.
Yes there are several different options. Right now I am aiming to have the least tampering with the factory wiring system as possible.

If your Bluetti has a 30A plug, you can use the factory cord. Put the Bluetti in a watertight container under the camper? Not very secure, I'm aware, but an option...

 

[Jaykol]

For charging, I know Bluetti has an alternator charger option, but it might be possible to trickle in 12V to the solar port as an alternative. I like the idea of the RV plug cover as a pass thru, my rig has that now for the regular 30amp plug. The only thing is, it is a 95% seal even with the little door, I use a few pieces of electrical tape around the cord after hook up to fully seal it off.

The outside box option is also interesting, could add a cable lock to the whole thing and keep all the space available. Hooking up portable solar would be simpler this way too, everything is outside.