DIY Solar Generator

The Bear78

150 000 miles and just broken in!
VIP Member
T6 Legend
Evening all,
For a while now, I've been comparing the offerings from the likes of Bluetti/Ecoflow etc. While it's difficult to argue against the lower capacity offerings, as soon as you go over the 1000 watt/hr threshold, the prices seem to ramp up quite considerably to the point where (in my opinion) the DIY option starts to look more attractive. Certainly if just looking at higher capacity batteries to use.

A few years ago, I added a small lighting upgrade (reading lights in the back and a halo roof LED strip) which are starter battery powered but relay isolated when the engine was off.
My plan was to eventually add a leisure battery and connect all of this to it. Life and work got in the way so 5 years later I am finally looking at leisure battery options.

Rather than going all in, I thought I would create my own solar generator set up with the option of permanent installation once proven, or potentially keeping the generator seperated if it proves useful as a mobile power supply.

As always, @Dellmassive has been there and done it, so his build thread proved very useful, thank you Dellmassive.

My initial usage plans were just powering a decent sized fridge freezer and couple of USB outlets to keep phones and laptops topped up as required. Within that plan is the option to upgrade as required and potentially include an inverter. This could be useful for our portable induction hob and other camping extravagance but it's not a priority at the moment.

Various examples online suggest that 100 AH will power a mid sized fridge for two or three days but I didn't want the worry, especially with unknown USB usage. In the end I went with;

- Renogy 200AH Mini LiFePo4 (2560 W/Hr)
- Renogy 220 watt solar suitcase
- Victron 75/15 MPPT
- Victron 300Amp smart shunt
- Assorted cables and connectors

The plan is to contain everything in the Stanley wheeled tool box. It's a good fit for the longer battery on it's side with about 5 inches free at one end for the MPPT etc.

Not having a fridge, I spent a while reading various reviews and initially ordered an Alpicool unit. As per other threads regarding the company, their stock numbers didn't seem to reflect availability in the UK. "7 in stock" with no mention of a location proved to mean a 6 week delivery time. No good for me so I cancelled. Annoyingly, after receiving no updates I had to speak to several people to eventually get this information...

Anyway, I settled on a Totalcool unit. Suspiciously similar in design, at least they appear to have a UK base with UK stock.
The 50l was tempting ( go big or go home?..) but the power consumption seemed a big jump from the 40.

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Rough circuit diagram here, fuse and cable size TBC. I have also added an isolator switch on the battery positive feed.
I'll set the MPPT load output to cut off the USB earlier than the fridge which I can hopefully maintain until a lower voltage using it's own low voltage cut out setting.

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Any comments and observations welcome, it's my first time ;)
 
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Hi @The Bear78 …..

Welcome to the battery in a box club…did something similar a while back ..got a lot of my inspiration from @Dellmassive .
But my needs and demands for more power grew ….one tip I can pass on its too get the biggest battery you can afford and the best fit box to match….i did small box..them BandQ toolbox and finally the extra strong really usefull box….happy crimping

IMG_0858.jpegIMG_1783.jpegIMG_2582.jpegIMG_2584.jpegIMG_3888.jpeg

Just ensure you future proof your system…..
 
Hi @The Bear78 …..

Welcome to the battery in a box club…did something similar a while back ..got a lot of my inspiration from @Dellmassive .
But my needs and demands for more power grew ….one tip I can pass on its too get the biggest battery you can afford and the best fit box to match….i did small box..them BandQ toolbox and finally the extra strong really usefull box….happy crimping

View attachment 296935View attachment 296936View attachment 296937View attachment 296938View attachment 296939

Just ensure you future proof your system…..
Then put your really big boxes, in a really really big impressive box on wheels towed behind your impressive van! Job done, possibly!
 
Had he got that second battery yet?
 
Hi @The Bear78 …..

Welcome to the battery in a box club…did something similar a while back ..got a lot of my inspiration from @Dellmassive .
But my needs and demands for more power grew ….one tip I can pass on its too get the biggest battery you can afford and the best fit box to match….i did small box..them BandQ toolbox and finally the extra strong really usefull box….happy crimping

View attachment 296935View attachment 296936View attachment 296937View attachment 296938View attachment 296939

Just ensure you future proof your system…..
Cheers,
Yep. I had a good read of the battery in a box threads and spent a while trying to find the smallest box to fit the biggest battery, if that makes sense!!
You can see it in the picture, it's a Stanley STST1-80150. With wheels and a handle it's a very good fit for the 200 AH, hopefully leaving just enough room for the MPPT, shunt and a few wires. Possibly even a little cooling fan too...
 
She's finished, now for testing!!

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Positive disconnected.

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2 x 12v, 2 x USB, kill switch (except shunt)

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XT60 Solar input.
 
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The battery parameters were set from the Renogy manual with additional information from a couple of Victron YouTube videos.
The load output 13.0v cut off should equate to 50% SOC.

I'm happy to take advice from anyone who knows differently? The charger settings aren't particularly clear when using different brands.

Cheers.

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I had some fun trying to upload the pictures, it took 5% out of it!!

Plugged in to the 220w panel today to top the battery up and set the 100% SOC.

0nly 75w at the moment with the odd cloud. With no loads I'm hoping it will fill the battery by the end of the day.
 
We camped at Litton Lakes in Dorset last weekend and I managed to give the battery in a box a bit of a test run.

Initial impressions are positive as power usage was quite low and the battery could have easily lasted the 4 days without solar.
The first night I only had the fridge connected and my phone charging. It started at 97% after a bit of Solar in the afternoon but had only dropped to 93% in the morning.
With higher demands from future upgrades such as additional outlets and maybe an inverter, this will not be the case. However, 200AH (2560 watt/hr) goes a long way!

I thought that the Victron smart shunt and MPPT were brilliant. I like the App and it really does everything you'd want it too (this is my first solar set up so I'm new to all of this technology).

The 220w solar suitcase worked well. I saw over 200 watts a few times but it is a faff to set up. Realignment during the day isn't too bad but the flimsy legs don't stay out unless there's weight on them. Supporting the four semi flexible panels while trying to hold out the three (?) legs takes a bit of technique!

The fridge/freezer appears to be good but it's only had limited use so far. On an initial cool down test it drew about 58 watts.
I plugged it in at home the night before so it was stabilised and switched it to Eco mode before we left. Typical draw was around 40-42 watts. This was with both zones set to 3 degrees C.
The power demand intermittent of course and during the night, the Victorn App showed it cycling on for 15 minutes and off for around 90. I don't recall what the power usage was during the off periods but it was very low. My maths makes that comfortably under 10 watt hours during the night when the ambient temperature was lower and of course, the lid stayed shut!
I need to look into changing the settings on the fridge though as the temperature ranges seem too wide. Set at 3 degrees it would often cycle between 0 and 6.
Also, as useful as the App is, it seemed to get stuck occasionally. When opening the page on my phone it seemed to take a long time to refresh the data. Compared to the instantaneous Victron data it's notably lacking.

Over the weekend, the only downside was that our pitch, chosen by our friends who had arrived a few days earlier, was against a hedge. This put us in shadow after about 3 pm. With a longer cable it wouldn’t have been such an issue but I had to drag everything out to keep the panel out of the shade.

I bought an MC4 to XT60 cable to connect the solar panel to the box. I thought 3m would be enough but I'll probably buy the 5m version for next time.

The real test will be this weekend when my wife takes the whole lot to a horse event. She still hasn't asked how much it all cost...
 
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