200Ah, 2000W, LifePo4 Leisure Battery Box -- How I Done It --

[Dellmassive]

200Ah, 2000W, LifePo4 Leisure Battery Box -- How I Done It --​

Its Spring 2022 and time to look ahead at the summer camping season.

having a look over the new products that have come to market over the last 12mnths, especially the Lithium based battery boxes i was liking what i was seeing.


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I already have the ECOFLOW River pro (600w 720wh), which is awesome. - SOLAR GENERATORS -- How I done It --





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i also have the ALLPOWERS (372wh) - Awesome 3-in-1 Battery Bank - How I done It -







and i have the Enginstar (296wh) - SOLAR GENERATORS -- How I done It --







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i also made my own 100Ah lifepo4 battery box -

12v Lithium Leisure Battery Box 138Ah 1766Wh -- How I Done It --

12v Lithium Leisure Battery Box 138Ah 1766Wh -- How I Done It -- It's about time that I got this long-overdue project sorted out. The missing parts are on order and completion is in sight . . . . . . . . ready for the Post Pandemic 2020 Camping Trips (Hopefully) This is where it started. p1...

www.t6forum.com

well two in fact . . . .





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these are all great . . . . . but there was one problem!

non of the above would run Mrs Dellmassives 2000W hairdryer . . . (mobile, off grid, in the middle of a grass feild)

(plus an added benifit would be i could run the coffee & beer machine)





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so with this im mind and looking forwards to the 2022 off grid camping season . . . . i thought i wouls look at whats availible to power said hairpryer - ie 2000W.



i alraday had a copy of mobile 400w solar setups that can be deployed for summer recharge during the day, so that wasnt an issue.

what i needed was the battery capacity and inverter power to run a 2000w load for a while (say 5-15mins) - plus run the regular camp kit.

two compressor fridges,
tons of camp lighting,
USB packs galore,
chargers and fans and this and that and etc etc etc . . . . .

you get the idea.





looking at the new releases we can see a few options . . .

Ecoflow Delta (1800w/3300w / 1260wh) may be able to do the job. . . . . . https://amzn.to/3tBzReE

at £1300 its not cheap, but what they dont advertise freely is that they use Lithium-ion cell tech which has a very limited life - 800 charge cycles. =[ ( not good if you plan to keep it for 10 years)



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They also do the MAX version (more power) . . . - https://amzn.to/3sJAxzj





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ALLPOWERS 2000w unit is now available - https://amzn.to/3Ci4lq4

but also has a low charge cycle - (800-1000 cycles times.)




...

Ecoflow are to release the Delta PRO - EcoFlow DELTA Pro Portable Power Station

but at £3400 its not cheap . .

but does come with Lifepo4 batterys 6500+ charge cycles - which is good.




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i even considered the Bluetti AC200max - https://amzn.to/3Kk0ThA

but your still looking at £1600 - (yes its lifepo4 so 8000+ charge cycles plus)





so what to do . . . . . . ??


well after having all of these in the basket having been ready to hit the buy button . .

i resisted.

and decided to build my own . . . . . . . . . .



How and with what coming up next.


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[Dellmassive]

pt2

looking at all the above i realised that i already had most of the kit around me to make my own 2000w battery box.

so no need to shell out an additional £1500.

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from the previous battery box i had a Renogy 100ah Lifepo4 - https://amzn.to/3ISfjVJ

Low temperature lithium battery

mid test results added to post above . . current test results. 49 hours in . . . drawing 0.8A from the battery. 88ah @ 5v battery BMS shows battery still at 100% SOC. with no draw and standby status. +++ Vic SS shows battery at 63% SOC with the 0.8A load draw. thats 41ah @ 12v...

www.t6forum.com

ok, thats a start . . .

looking at the Renogy spec, they state you need 100ah worth of batterys per 1000w worth of inverter . . - 12V 100Ah Smart Lithium Iron Phosphate Battery





ok . . . so i need two batterys.

no problem there either as i just got a second one off ebay . . - For Sale - Renogy 12V 100Ah SMART LiFePO4 Lithium Iron Battery RBT100LFP12S



thats the two lifepo4 batterys sorted.

That gives me 200Ah worth of power thats about 1200wh per battery, so 2400wh for the two.



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up next is the Inverter.

i need a 2000w continouso, plus some surge on top.


i have a wide collection of invertes about me. . .

im running a 1000w Renogy in the van right now. which is great, - it just works - no issues. - https://amzn.to/35VrUJi





in fact i loved it so much i went out and got the 2000w version as well . . .

https://amzn.to/3HKxw6o

i also a have a few COTK inverters . . . COTEK - Professional Power Solutions Design and Manufacturing



and a range of Victron Inverters . .

https://amzn.to/3IO05B8

but the largest one i has is the 1200va model, so underpowered for 2000w. . . . plus the Victron inverters use a triordial transformer which makes them very heavy.

fine for a van install, but not good for a mobile box install.
so thats settles it . . . . the Renogy 2000w inverter it is . . .


looking like team Renogy so far . . .


Next up is monitoring . . .

i already have a few Renogy BT-2 units that plug directly into the Renogy Smart batterys . . .

https://amzn.to/3KhskZe#

The renogy book shows that you can daisy-chain the batterys together . . . so only one BT-2 needed.



ill also decided i wanted to add a Victron Smart Shunt as they are awsome and can be connected to the internet for remote monitoring.

and again i have a couple of these about that i can re-purpose . . . - https://amzn.to/3CfRVPD




...

ill add some MIDI & Mega fuses. - https://amzn.to/35VhfOv






power wise, the inverter is expected to draw 200A from both batterys.

100A from each,

so i need cables and fuses that can handle 100A from each battery, then 200A combined to the inverter.

because all the cable runs are short as they will be in a box . . . we wont need masses of cable.

I've ordered some fat 25mm2(170A) and 50mm2(345A) for the job.




also a 200A master battery isolator switch as a master ON/OFF - Amazon.co.uk










im thinking of adding a couple of 50A anderson connectors for the 12v IN/OUT


for solar and other bits . . . so ill

get some of them . . . https://amzn.to/3sJesRI








and some 8awg silicone cable for them - i like the nice flexable stuff . . . . - https://amzn.to/3MpoleZ






i might add a USB & 12v panel to the front . . . . but not sure yet.




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TBC.

 

[Dellmassive]

pt3

so what about the box . . . . ?

well i have this Dewalt "dewalt tough system 2.0" -

Error 410 | Screwfix

Thousands of products at low trade prices | FREE next day delivery available | 30 day money back guarantee on all orders.

www.screwfix.com

which seems to fit the bill . .



its waterproof . . .



two batterys will fit in either standing up . . or lying down . .




plus the inverter fits in nicly with space for cables and fuseboxes etc.




at also has handles on the side to lift and carry . . .


plus its super durable . . .


BUT . . . . ITS HEAVY loaded up with two batterys and inverter.

so, looking back at this. . . . got me thinking.





what about a roller tool box >?


well i have a few of those two.

size wise they look similar . . .







.

a quick test with the battery looks good . .






and the inverter too . . .




both look good . . .


so i have two options . . . the roller box, or the tough box. . .



tbc.

 

[Dellmassive]

part4

now waiting for the rest of the parts so we can begin the build.



some bits have started to arrive . . .

switch,

beefy cable

MEGGA fuses and holders

Renogy Battery bolts in too as they odd size (M8 / 1.0mm pitch / 10-20mm)

 

[Dellmassive]

pt5

 

[flo.flowers]

Lee, what type of crimper will you use for those inline mega fuse holders?
.I can see that the crimps are open and not the cylindrical closed type.

 

[Dellmassive]

i used these . . . .





SEE HERE:

Battery cable crimping tool recommendation please

next up is this beauty . . . my first port of call and go to large crimper. it will crimp most large lugs and crimps . . . . if it fits on the gap . . . it will crimp it. I've have some tough crimps before . . . and even with 15stone leaning down on it its not broke. its big at 13 inches...

www.t6forum.com

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Amazon.co.uk : battery crimper tool

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[flo.flowers]

Me again Lee…
The inline mega fuse holders I got are the 25mm2 to 35mm2 type and the wings on the crimp terminal don’t fit into the jaw of the crimp tool, as per the foto.
Have I got the tool/crimp combo wrong?

 

[Dellmassive]

just double checked mine.

the MEGA fuse holder crimp just about fits.

its tight, but does fit.

 

[Dellmassive]

on really big cables or ends . . .

i use the Hammer crimp tool . . and a big mallet.

https://amzn.to/3uhjZzu

 

[BortVan]

Dellmassive, loving your battery box build (and everything else you’ve been posting about / videoing (is videoing an 80’s term? Showing my age!). It’s inspirational mate and you’ve got my OCD about wiring juices flowing. Whilst I decide which toolbox I’m gonna use as a stand-alone battery box for my T6.1 PV can you help me fill in a gap in my mind. Love the concept of the box. Take it out and put it away when I‘m doing day to day stuff or if I don’t want it getting nicked. Brilliant. I don’t have to start messing with my new van until I know what I’m doing. Even better! Is there an easy way to tap into a power source somewhere in the vehicle to charge as I drive? I’m about to pull the pin on ordering the OVANO switch XL and the power box will live in the tray. What / where would you put a hook up to charge from the vehicle battery when driving? There‘s a 12v outlet on the dash but I’d like to have something nearer the battery box in the OVANO to keep wiring tidy.

@Dellmassive

 

[Dellmassive]

@BortVan im glad your inspired . . . and enjoy the threads .


im not sure on your vans spec.

but for me i have a lithium leisure battery under the drivers seat . . thats fed by a 50A DC-DC

and have made up a 50A Anderson fly lead that i can plug into.

. . . .

ultimately you want to use a DC-DC charger between the van and the battery box - so you can regulate the charge and don't fry the vans electrics.

. . . ..

12v sockets are ok . . . but you need to limit to 6-8A or they get too hot.

. . . . .

i also use solar when at camp. . .



++++


have you seen the other battery box builds?

12v Lithium Leisure Battery Box 138Ah 1766Wh -- How I Done It --

12v Lithium Leisure Battery Box 138Ah 1766Wh -- How I Done It -- It's about time that I got this long-overdue project sorted out. The missing parts are on order and completion is in sight . . . . . . . . ready for the Post Pandemic 2020 Camping Trips (Hopefully) This is where it started. p1...

www.t6forum.com

.

 

[BortVan]

Van is a 2022 T6.1 150 DSG SWB PV. I keep wanting to jump in but know from past experience that I need to hold back or I’ll regret it van will be in bits and not running. That’s why I like the concept of everything being stand alone while I get up to speed in knowing enough before messing with the van directly, stand alone projects allows me to tinker without risk. I’m now looking at Andersen plugs - all thanks to you. I need to pay my subs and join up. What I’ve learned so far is well worth £13 & I need to give back, I’ve bookmarked your additional posts and will read enough times so they’ll sink in. thanks @Dellmassive

 

[Dellmassive]

welcome to the VIP club @BortVan

here is the direct link to all the good stuff . . .

Dellmassive’s "How I Done It" blogs.

-- Dellmassive`s -- "How I Done It" -- thread -- ************************************************** Dellmassive`s -- "how I Done It" -- Thread ************************************************** Kit List And Stuff -- How I Done It & What I Use --...

www.t6forum.com

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[Colstroid]

@Dellmassive cool build! But what happened to build thread? Have you finished it?

 

[Dellmassive]

@Dellmassive cool build! But what happened to build thread? Have you finished it?

well . . . .

yes and no.

i had the 2kw box all built on the bench and tested . . .

it run the wife's hairdryer no probs - so a great success

i had it charging via EHU, Solar, DC-DC - so that was great.



it was all go and ready to get fitted in the roller-box.




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BUT , , , , ,


then (in the background) i bought the Bluetti AC200Max portable power station . . . .

Portable Power Packs - LifePo4 Battery Boxes -- How I done It --

We're heading out for a 5man, two tent, 1 gazebo, 5day camping trip. - off grid. With the full complement of twin compressor fridges, lights, chargers etc etc. .. We'll have all the small usb power packs for the normal phone charging with out and about.. . This will all be powered by...

www.t6forum.com

and the EcoFlow Delta 2

Portable Power Packs - LifePo4 Battery Boxes -- How I done It --

ECOFLOW DELTA 2 ITS coming. And now with Lifepo4 cells.

www.t6forum.com

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so it kinda made the DIY box redundant. . .


i ended up selling on the items separately, as in the Renogy battery's and Renogy inverter.


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I've also sold on the Bluettti AC200max ----

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having said that i still have a couple of Poweroad 100ah Lifepo4`s and a few inverters floating around. . .



so there no reason why i cant make up another 2kw box.




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[Dellmassive]

as it happens i know @BoroBoy is looking to make a similar box,

with a Renogy 2000W inverter.

he run his parts list past me and all looks good.


lets see what he comes up with as well.

 

[StevenH]

Do you think that the all in one box is a better system than built in battery and inverter? Looking at adding power to my van with a dc-dc charger and lipo battery.

 

[Colstroid]

Do you think that the all in one box is a better system than built in battery and inverter? Looking at adding power to my van with a dc-dc charger and lipo battery.

All depends what you need to power. If it's just a few lights, usb phone/tablet chargers, 12v fridge, water pump etc a built in, basic leisure battery system is good and cheap. If you need extra juice for bike batteries, coffee machines, hairdryers etc then the portable power station seems to be pretty cost effective (up to a point) and way more versatile.

 

[StevenH]

All depends what you need to power. If it's just a few lights, usb phone/tablet chargers, 12v fridge, water pump etc a built in, basic leisure battery system is good and cheap. If you need extra juice for bike batteries, coffee machines, hairdryers etc then the portable power station seems to be pretty cost effective (up to a point) and way more versatile.

Great point. I’m hoping to go induction hob so gas-free kitchen so looking at 1.5kw max.