T6.1 Camper Wiring plan / layout

[T6Jay]

Hi

I've a T6.1 panel van arriving in March and I'll be managing the conversion and may do the wiring myself. Rather than just asking 'how do I wire it?' I've trawled though the goldmine of information on here and come up with a wiring plan. I would very much appreciate your view on this!

Wiring

• T6Jay
• 31 Jan 2020
• 1

Things I'v still to decide:
Do I need the EHU charger to charge the Starter battery? and how can i do this?
Should I Fit isolators anywhere? (i.e. between MPPT controller and leisure battery, Lights, Pump etc)
Is 30A EHU charger overkill?

All and any suggestions/criticism/praise is gratefully accepted!

Thanks

 

[Dellmassive]

HI @T6Jay

your taking all the loads from the "Load output" of the victron . . . with on the 75/15 is limited to 15A . . . so maybe look at upping that controller to the 100/20 ?

or run some of the heavier loads direct from the battery?

12v heater . . . ? what sort of heater.

Look at adding some sort of battery monitor to the system . . . . maybe a BM2 or BMV712? to keep any eye on your setup.

have a look at the kit list here > Kit List And Stuff -- How I Done It & What I Use --

and some sample schematics here > Diagrams, Schematics & Wires -- How I Done It --

Is 30A EHU charger overkill?

- not for Lithium. . . . maybe for SLA, but its good to future proof and a larger charger will run cooler etc. (depends on your AUX battery setup)

Do I need the EHU charger to charge the Starter battery? and how can i do this?

- yes if you are long stay camping . . . you can use a small EHU charger (like this https://amzn.to/2u1UN3Y) . . . . or a MPPT or DC-DC that has the reverse charge feature (Dc-dc Charger (for Leisure Battery) -- How I Done It --)(Solar Pwm & Mppt Controllers - How I Done It -)

Should I Fit isolators anywhere? (i.e. between MPPT controller and leisure battery, Lights, Pump etc)

- possibly on the PV side of the solar if you plan to switch off/or add additional mobile solar . . maybe on the main AUX battery as a OFF when not in use to stop any discharge.



other info:


Battery Monitoring -- How I Done It --
.
Battery Chargers - How I Did It -
.
Which Jump Starter?
.
Lithium Lifepo4 12v Batteries - - - Time For An Upgrade ? - - -
.
Battery Charging - Main Battery Earth Point -
.
Dc-dc Charger (for Leisure Battery) -- How I Done It --
.

 

[T6Jay]

Hi Dellmassive and thanks for the reply. I had read through a lot of your threads before I started, they were great info!

The 160W PV panel I've picked is max 8A so a 10A MPPT would have been enough, but I'd worked out my load was about 12A with EVERYTHING switched on, this will never happen so I thought 15A would be plenty. However I'll take on board what you said about futureproofing.

I had taken the load through the MPPT so I could use the MPPT to monitor the consumption, but If I'm to fit a battery monitor as you suggest, I may connect all the 12V load to the battery. Then I could fit the cheaper 10A MPPT.

The heater is a diesel night-heater, I think they use around 3A on the 12V.

I can't justify £500 on a lithium battery, I'll be buying GEL (or AGM) for now but may upgrade when lithium gets cheaper, so Ill keep the 30A charger.

On the subject of EHU charging of the STARTER battery, I thought some B2B chargers would do this when the LEISURE battery was full, but only when the solar was working? Is there a B2B out there that will divert some Amps from the EHU LEISURE battery charger back to the STARTER? (I had thought the CTEK would do this, but it cannot accept my PV panel with an OCV of 23.9V, I just cant find one with a lower OCV and a rear mounted round junction box )

I'd be happy to just use the MC4 connectors to isolate the PV panel, and yes I'll fit an isolator on the leisure battery.

Awesome help! thanks again.

 

[Deaky]

Just be aware a diesel heater will pull around 10-12 amps as it’s starting up. Your fridge will also spike as it start up. Make sure you have plenty of headroom.

 

[Dellmassive]

On the subject of EHU charging of the STARTER battery, I thought some B2B chargers would do this when the LEISURE battery was full, but only when the solar was working? Is there a B2B out there that will divert some Amps from the EHU LEISURE battery charger back to the STARTER? (I had thought the CTEK would do this, but it cannot accept my PV panel with an OCV of 23.9V, I just cant find one with a lower OCV and a rear mounted round junction box )

- nearly all the B2B / DC-DC chargers rely on the Solar being connected to reverse charge the starter battery. . . . this is due to the fact that they are only charging when the engine is running and alternator producing power and charging the starter too..

so you can choose a MPPT that has a duel output . . ie . . Voltronic, but will loose the awesomeness of the Victron MPPT.

so most people would choose a duel output EHU charger . . . like the Victron.

or

the possibly cheaper/easier option of a small standalone maintenance / smart charger. (like say 2-5A ish range)

if your camping OFF GRID/NO EHU then your only source of power is Engine or Solar (possibly Genny) (So MPPT & DC-DC)

or ON GRID/WITH EHU - then its free 240v so EHU chargers is a no-brainier.

or . . .

If your not Lithium you can use one of the Votonic Standby by trickle chargers . . . (to reverse charge the starter from the Aux battery regardless of charging method)

https://amzn.to/2RQZIxN




.

 

[Salty Spuds]

Another thing to consider when looking at EHU/MppT chargers is whether they have fans or not. I deliberately went “fanless” to keep the night time noise down.

 

[T6Jay]

Just be aware a diesel heater will pull around 10-12 amps as it’s starting up. Your fridge will also spike as it start up. Make sure you have plenty of headroom.

Yes! thanks Deaky

I tried to find if the Victron MPPT can tolerate a momentary overload, but there's no mention of it. I also looked for the Vitrifrigo C50i surge current, but can't find that either.

I may just ditch the MPPT load terminals and put a shunt at the battery.

 

[T6Jay]

- nearly all the B2B / DC-DC chargers rely on the Solar being connected to reverse charge the starter battery. . . . this is due to the fact that they are only charging when the engine is running and alternator producing power and charging the starter too..

so you can choose a MPPT that has a duel output . . ie . . Voltronic, but will loose the awesomeness of the Victron MPPT.

so most people would choose a duel output EHU charger . . . like the Victron.

or

the possibly cheaper/easier option of a small standalone maintenance / smart charger. (like say 2-5A ish range)

if your camping OFF GRID/NO EHU then your only source of power is Engine or Solar (possibly Genny) (So MPPT & DC-DC)

or ON GRID/WITH EHU - then its free 240v so EHU chargers is a no-brainier.

or . . .

If your not Lithium you can use one of the Votonic Standby by trickle chargers . . . (to reverse charge the starter from the Aux battery regardless of charging method)

https://amzn.to/2RQZIxN


View attachment 59714

.

I'll probably go for the Votonic at least for now, as the Van battery is lead acid. Thats 4 charger's i'm up to now! (B2B, MPPT, 30A EHU, 2A trickle).

I'd contemplated one of these VOTRONIC - VBCS 30/20/250 that will do all of the above, but I quite like the idea that with separate chargers, a failed unit leaves 3 others still working.

 

[T6Jay]

Another thing to consider when looking at EHU/MppT chargers is whether they have fans or not. I deliberately went “fanless” to keep the night time noise down.

Good one Salty, consider it considered

 

[Deaky]

You’ll probably find the heater and fridge will have their own low voltage cut off built in. You’d be best off connecting these directly to the battery and just run the lights etc, that can run the battery totally flat, through the load switch

 

[T6Jay]

Right here's my (final?) wiring plan. Thanks for the guidance!

I've ordered the Renogy DCC50S as it's got MPPT and will trickle charge the starter battery with any spare solar power, and it's a great price with 10% off the list for new customers.

I think the Victron 65A battery protector is big enough even with the fridge and heater start up surges.

I like the look of the Votronic battery monitor and may use this to remotely control the Victron BP65, or I may just let the Victron do it's own thing.

For the EHU battery charger I like the Victron IP22 12/30 looks like travelvolts on here has them at a good price.

Things still to decide;
Lithium or AGM or GEL?
When/where to run a 0V cable and when to just use a van body ground

Wiring Renogy

• T6Jay
• 28 Feb 2020

 

[Salty Spuds]

The Victron 12/30 has a fan FYI. Do you need 30A on EHU? If you go Lead Acid, you wouldn’t be able to use all of the 30A anyway.

 

[Dellmassive]

Looks good......

I'd recomend the Victron BMv712 battery monitor.

And the BM2 battery monitor..

(I run both the above.......


And 2/1x AGM for now or if you can afford go straight for Lifepo4.

.
Kit List And Stuff -- How I Done It & What I Use --

.

 

[T6Jay]

The Victron 12/30 has a fan FYI. Do you need 30A on EHU? If you go Lead Acid, you wouldn’t be able to use all of the 30A anyway.

Thanks for pointing that out. The charger's fan knocks off in NIGHT or LOW mode (<15A) and the manual says the fan is 'Low RPM (silent) fan'. Still, I'll have a dig around for another charger.

Has anyone got a VICTRON 12/30 bluesmart? just how noisy is it?

If have the heater/fridge and light on and running a laptop I'd like the charger to have enough to run all this and charge as well. So 30A doesn't seem massively overkill to me. Also I will most likely end up with a Lithium battery eventually, so I'll be ready for this. Also, I like the idea that 3 hours charging will fill a Lithium batttery from (almost) empty.

 

[T6Jay]

I'd recomend the Victron BMv712 battery monitor.

And the BM2 battery monitor..

.

I'm curious why you would pick those over the Votronic, am I missing something?

I'd picked the Votronic one based on looks really, and they all look to do the same thing really, except the bluetooth which I don't really need.

this is the one I mean;
12V solar panels charging kits for caravans, motorhomes, boats, yachts, marine

 

[Dellmassive]

I'm curious why you would pick those over the Votronic, am I missing something?

I'd picked the Votronic one based on looks really, and they all look to do the same thing really, except the bluetooth which I don't really need.

this is the one I mean;
12V solar panels charging kits for caravans, motorhomes, boats, yachts, marine

.

I use the bluetooth for data logging...and monitoring.

I use temp sensor data from it.

It has alarm outputs for various things.... I use low temp disconect...

And it all works together with the one app...

But its personal preference for the functions you require.

My choice was Victron.

I have the Victron charger.... the fan comes on when drawing a large load or it gets warm...
It's not noisy.

 

[Salty Spuds]

Thanks for pointing that out. The charger's fan knocks off in NIGHT or LOW mode (<15A) and the manual says the fan is 'Low RPM (silent) fan'. Still, I'll have a dig around for another charger.

Has anyone got a VICTRON 12/30 bluesmart? just how noisy is it?

If have the heater/fridge and light on and running a laptop I'd like the charger to have enough to run all this and charge as well. So 30A doesn't seem massively overkill to me. Also I will most likely end up with a Lithium battery eventually, so I'll be ready for this. Also, I like the idea that 3 hours charging will fill a Lithium batttery from (almost) empty.

I have the 12/15 ip22 bluesmart. Plenty of oomph for normal campervan needs & I’m also running Lithium. You don’t need a high output charger for when on EHU. Chances are you will be plugged in overnight or for an extended period of time. Also when you arrive at the campsite, the battery will be already charged as it will have had a run on the B2B en-route. I’d go large B2B (30A+) & smaller mains. You’re never going to be pulling anything like 10A constantly from the leisure battery.

 

[T6Jay]

I've got all the kit mounted under the seat now. The 16mm cable is through the existing grommet behind the battery. I'm having the EHU and consumer unit under the bonnet, so I've drilled two holes for the blue 240V cables though the plate high in the passenger footwell (there was no way to fit two flexes through existing grommets). The carpet had to come out to run the cables down the middle and into the passenger seat. While I was there I also ran the renogy ignition wire to the driver side fusebox (hope there's a ignition feed there!). More pics to follow....

 

[travelvolts]

Thanks for pointing that out. The charger's fan knocks off in NIGHT or LOW mode (<15A) and the manual says the fan is 'Low RPM (silent) fan'. Still, I'll have a dig around for another charger.

Has anyone got a VICTRON 12/30 bluesmart? just how noisy is it?

If have the heater/fridge and light on and running a laptop I'd like the charger to have enough to run all this and charge as well. So 30A doesn't seem massively overkill to me. Also I will most likely end up with a Lithium battery eventually, so I'll be ready for this. Also, I like the idea that 3 hours charging will fill a Lithium batttery from (almost) empty.

You have to get your ear right next to the charger to even discern if the fan is running or not.

 

[T6Jay]

I've got a load more done during my cancelled holiday. Here's where I'm up to;

EHU installed under the bonnet



Main 70A 12V fuse to feed the DC/DC charger under the bonnet



Under the passenger seat
Excide 95ah (c20) AGM battery (I noticed a lot of 110ah batteries are c100 rated, and therefore equivalent to a 95ah C20)
Renogy DCC50S 50A DC/DC charger with MPPT
Victron 240V 15A Bluesmart EHU charger
Victron BP65 battery protection
Victron BMS shunt
3x Midi fuseholders tucked down the front of the battery.
All the original VW wiring and connectors, re-positioned