Upgrading to a lithium battery and fitting a rigid solar panel on a pop top.

[The Flying Scotsman]

I’ve started to install my power upgrade and thought I would post a thread on it which might be useful for others thinking of upgrading to lithium.
I would like to point out that I am far from an expert on this and as much as I am capable of doing the installation I am totally reliant on the expertise of the very knowledgeable and helpful members on here.
Thanks guys
They have advised me on what I needed to buy and how it all goes together.
I spend a lot of time in my camper off grid so this upgrade is to allow me to stay off grid for as long as possible. I plan to keep my T6 for a long time so this investment is worth it to me. But not cheap.
My system at the moment is a standard camper set up of a lead acid leisure battery on a split charge relay with a small flexi solar panel and a Sargent EC155 to control the 12v system.
To change to lithium is not as easy as just swapping the batteries.
I’ve had to upgrade a lot of other components as they are not lithium compatible.
The split charge system needs replaced with a DC-DC charger
The solar controller needs replaced with an MPPT
I need to pull the fuse in the Sargent for the charger to disable it. And I’ve opted to fit a lithium charger to charge the leisure battery on EHU but realistically with this system I shouldn’t need EHU. I’m going to keep the Sargent for the fuses for my whole 12v system lights/pump etc.
In stead of fitting an inverter for off grid 240 power for normal plugs I’ve decided to keep the power in the LB that it would use and bought a separate EcoFlow Delta 2 portable power pack and am installing the EcoFlow 800w alternator charger to fast charge this on the move.
I’ve been advised to fit an Ablemail AMT. it’s a small box that will trickle charge my starter battery from the lithium battery so my van will always start.
I’m fitting both a shunt and the Cerbo GX with screen to monitor the whole system but the Cerbo is not required for this upgrade I’m just a sucker for shiny things and panels that light up.
I’m about to install a
Roamer SMART4 230a lithium battery
Victron Orion XS 50a DC-DC charger
Victron 360w rigid solar panel.
Victron MPPT 100/30 solar controller
Victron IP65 mains charger
Victron Cerbo GX and screen
Victron shunt
EcoFlow 800w charger
New wiring, fuses, bus bars, isolation switches.
I will update this thread as I progress and add pics.
Today I’m running the new power wire from the SB to the LB as well as running the wires from the EcoFlow charger to the LB

 

[T6ChrisO]

The last thread you created Gordon cost me a few hundred quid!!

 

[Drive Wayne]

The last thread you created Gordon cost me a few hundred quid!!

At least I got away with 6 bottles of Rioja at 30% off...

 

[The Flying Scotsman]

That’s the EcoFlow 800w charger in and wires ran. I’ve still to cut the wires and attach them.
I’ve also whipped out the existing LB and fitted the Roamer.
I’m in the process of installing the panel with the Orion and fuses. I’m managing to fit a bolt behind the Orion that fits into the original seat belt mount. So the panel will be solid.
I’ve ran the 16mm power wire from the SB to the LB. I can’t find my grommets so will need to pick up some more before feeding it through the metal panel below the wipers to the midi fuse holder.
I’m trying to upload pics but since I got a new phone it’s says file is too big? It’s an iPhone 16pro. Pics are set to standard.
Any ideas ?

 

[T6ChrisO]

That’s the EcoFlow 800w charger in and wires ran. I’ve still to cut the wires and attach them.
I’ve also whipped out the existing LB and fitted the Roamer.
I’m in the process of installing the panel with the Orion and fuses. I’m managing to fit a bolt behind the Orion that fits into the original seat belt mount. So the panel will be solid.
I’ve ran the 16mm power wire from the SB to the LB. I can’t find my grommets so will need to pick up some more before feeding it through the metal panel below the wipers to the midi fuse holder.
I’m trying to upload pics but since I got a new phone it’s says file is too big? It’s an iPhone 16pro. Pics are set to standard.
Any ideas ?

I have the same issue. I screenshot my pics and then they are an ok file size. There will be a better way no doubt but it works

 

[The Flying Scotsman]

That’s my main panel just about ready to fit.
I’ve got the additional power wires in for my sub/amp and hooked up the EcoFlow charger.
I’m making a timber block that I’m bolting to van through the original back seat belt mounts and will be able to screw my panel to that.
I’m still waiting on the VE cables for the Cerbo and the Roamer/Cerbo cable.
I’m about to disable the existing solar panel and controller and fit the MPPT.
I will pick up more rubber grommets and finish the power wire under the bonnet today also.

 

[The Flying Scotsman]

I’ve been trying to chase the existing cables for the solar panel and found them by removing the top panel at the back of my van.
Unfortunately I won’t manage to put my new cables in the same place they were obviously fitted before the carpeted panels were fitted then the kitchen.
I’m pretty confident i can still run the new cables so they are all hidden behind panels.
It’s the exact same for the cables from the Sargent to the battery. They disappear inside the metal frame. But I can easily run the new cables in behind the kitchen. So should manage to hide the new cables from the MPPT to my bus bar and Cerbo.
I’ve removed the split charge relay behind the Sargent and removed the charger fuse also.

 

[The Flying Scotsman]

I got the MPPT fitted in the back cupboard along with the isolation switches for the solar panel.
I’ve fitted them above the Sargent.
I’ve also fitted the touch screen for the cebro beside all the other controls and sockets.
It was dark by the time I finished so will take pics tomorrow.
I’m going to tackle fitting the huge solar panel on my pop top tomorrow.
I will have to seal the screw holes left by the old panel.
I’m going to use the kit below to mount the panel.

I’m going to draw around the feet once they are in position on the pop top.
Then I will key the gel coating where the feet sit by roughing it up with course sandpaper.
I’m going to do this with all 6 feet and stick them down with sikaflex.
The front 2 feet I will bolt through the pop top and make sure they are well sealed.
I will post pics of my progress tomorrow

 

[The Flying Scotsman]

I’ve started replacing my solar panel today.
I’ve got the old one off.
I planned on using the existing gland but the plastic nut that holds the front on has fallen inside it.
I’m going to use fishing braided line as a cheese cutter wire to remove it. It’s quite abrasive.
I’ve offered up my new panel and marked out the feet.
These will be the areas I rough up to key for the adhesive.
Once I’ve fitted all the feet I will let the adhesive cure over night then wash the roof and check for leaks before fitting the new panel.

 

[The Flying Scotsman]

I’ve had to bore another hole in the metal roof close to where the solar panel wires went through before.
The existing wires disappear into the metal framework and I can’t access them
I’ve ordered a new double gland for the cables to go through the fibreglass and this for the hole in the metal roof below.
I had to bore another fairly big hole for it. It has a plastic nut on the bottom to tighten it on and I will seal it before tightening the nut.
My 2 panel cables just fit through it.
Once the wires are fitted I will seal the top of it and put black conduit around the wires.


The cheese wire technique worked great.


New hole in metal roof. I’ve moved it onto a raised channel so there’s less chance of water sitting there.

Plastic grommet fitted.
I will seal it before final fitment.

MPPT and isolation switches fitted to rear cupboard panel.
The Sargent goes below it.

Cerbo screen in and fitted.
Tomorrow I’m going to clean the roof and fit the panel feet and panel.
There’s screw holes left by the old panel.
I’m going to fill these with epoxy resin and then cover them in touch up before the new panel goes on.
Using the feet to fit my panel makes replacing the panel if it ever fails easy.
Just unscrew the broken one and screw on a new one.

 

[The Flying Scotsman]

The solar panel is on and working.
I’m ready pleased with the finish.
Everything went to plan and I’ve put a stainless steel bolt in the 2 front feet and sikaflex’d them all. They are solid and I’ve no worries at sitting at 70mph.
I’m having trouble setting up the Cerbo unit but other than that everything seems to work fine.
I’ve still to check the 3 chargers (DC-DC, EcoFlow and EHU)
So will go for a drive and also plug an EHU cable in to test them.
Managed to get some sikaflex on the canvas so will need to clean that after I wash the whole van.

New gland finishes it off nicely

 

[TallPaul_S]

Nice! Welcome to the 'proper' solar club aka the 300w big boys club

Overcast and cloudy here in Polzeath at the moment but I'm still getting 50w

 

[The Flying Scotsman]

Nice! Welcome to the 'proper' solar club aka the 300w big boys club

Overcast and cloudy here in Polzeath at the moment but I'm still getting 50w
View attachment 280163

I seen 168w coming in earlier and my van is not pointing the best way.
I’ve no idea why I can’t connect my Cerbo to WiFi.
Most frustrating getting this far to be screwed by WiFi connection.

 

[Drive Wayne]

Nice! Welcome to the 'proper' solar club aka the 300w big boys club

Overcast and cloudy here in Polzeath at the moment but I'm still getting 50w
View attachment 280163

I'll stick with the 'poxy 180' club! Until the probable demise of my second flexi panel!
The topmost layer that was delaminated I managed to peel off today, it looks as good as new now!