Solar system 2.0 build

I've had some questions and interest about my first solar setup so figured i'd document the 2.0 build in case anyone is interested. Nothing groundbreaking or earth shattering here but it might help someone

For the past few months i've run a GoalZero Yeti 400 Lithium as a 2nd battery of sorts mostly to power the fridge and to provide some "off grid" power for USB devices and such. Since that model has a small battery I figured i'd rebuild the system as a true dual battery with solar. I'd also like the option of removing that from the truck to power stuff, such as in the tent, without bringing the fridge with it. So thus the 2.0 build was born.

First I built a board for the main components and this is mounted in the front of the bed using the factory bed rail. This houses the 30A MPPT controller, main breakers for PV input (one for PV+ and one for PV-), main breaker for 12v loads, fuse panel for 12v loads, inverter and AC to DC charger. Also here is a crappy old battery out of my former 2007 BMW M5 that I had kicking around that still seems to work just fine so using that for now. This whole part of the system is also chassis grounded to the frame under the bed. Gotta clean up that wiring a bit but that might wait until I put in a better battery.


Next I built a 2nd board that is in the rear of the bed that has the remote head for the MPPT controller, remote on/off for the inverter, a 2nd 12v load panel that is connected to the first at the front and some 12v sockets (1 usb and 1 socket). Like the other board it's mounted to the bed rail system. Plenty of room here to add more stuff as needed. Eventually will add the Dometic 2pin socket here once they are back in stock. Also added a little LED battery monitor since I had it already ... just need to drill a hole and run the wire through the board so it looks better.


For solar I have a Lensun 100W flexible mono panel that is mounted to the tonneau cover. Perfect size and the tri-fold cover still works normally without touching the panel. This panel connects with MC4 to a 2-way MC4 splitter. Main feed on the splitter goes to the MPPT controller and the other side goes to a MC4 to Anderson adapter. This allows me to connect additional panels as needed.


Quick wiring diagram that I think is still correct:


So there ya have it. Just added a Renogy 20A DC-DC charger as well as a Genius 2A battery charger for the primary/starter battery. Now I can plug an extension cord into the rear bumper and both the primary and aux battery chargers will start doing their thing.

Pretty much all of this was sourced from Amazon except for the Lensun panel. Links are below.

AC to DC Charger:

NOCO Genius GEN1, 1-Bank, 10-Amp (10-Amp Per Bank) Fully-Automatic Smart Marine Charger, 12V Onboard Battery Charger and Battery Maintainer

https://www.amazon.com/gp/product/B003JSHQW0/ref=ppx_yo_dt_b_asin_title_o00_s00?ie=UTF8&psc=1

MC4 to Anderson Cables:

$13 iGreely Connector Solar Panel Cable Kits for Solar Panel RV Marine Boat Portable Solar Generator Power Station 10AWG 60cm/2ft

https://www.amazon.com/gp/product/B07T3K9TND/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1

12v Fuse block:

FXC 6-Way Fuse Block, Blade Fuse Box with Waterproof Cover W/Negative Bus 5A 10A 15A 20A Free Fuses LED Indicator for Automotive Car Marine Boat

https://www.amazon.com/gp/product/B08975FHKN/ref=ppx_yo_dt_b_asin_title_o03_s00?ie=UTF8&psc=1

Inverter:

$90 Krieger 1100 Watt 12V Power Inverter Dual 110V AC Outlets, Installation Kit Included, Automotive Back Up Power Supply For Blenders, Vacuums, Power Tools - ETL Approved Under UL STD 458

https://www.amazon.com/gp/product/B00T564EIY/ref=ppx_yo_dt_b_asin_title_o03_s00?ie=UTF8&psc=1

30A DC Breaker:

$20 WOHHOM 30 Amp Circuit Breaker DC 12V -48V Waterproof 30A-300A Manual Reset Fuse Inverter for Trolling Motor Auto Car RV Marine Boat Current Overload Protection (30A)

https://www.amazon.com/gp/product/B08DXW3TNQ/ref=ppx_yo_dt_b_asin_title_o08_s00?ie=UTF8&psc=1

MC4 to bare wire cable:

$23 Renogy 10Ft 10AWG Solar Wire Extension Cables with Female and Male Connector, 1 Pair, Adaptor Kit, Black

https://www.amazon.com/gp/product/B00JH1PABW/ref=ppx_yo_dt_b_asin_title_o09_s00?ie=UTF8&psc=1

30A MPPT Controller:

$120 EPEVER MPPT Solar Charge Controller 30A 12V 24V Auto, Solar Charge Controller Max 100V Input Negative Grounded Solar Regulator, for Lead-Acid and Lithium Batteries

https://www.amazon.com/gp/product/B071XP39BK/ref=ppx_yo_dt_b_asin_title_o01_s00?ie=UTF8&psc=1

MC4 connectors:

$21 PowMr 48PCS Solar connectors - IP67 Male/Female Solar Connectors(24 Pairs Solar connectors)

https://www.amazon.com/gp/product/B07R8BXH6B/ref=ppx_yo_dt_b_asin_title_o01_s01?ie=UTF8&psc=1

MC4 extension cable - 5'

$12 PHITUODA 5FT Black + Red 12AWG(4mm²) Solar Panel Extension Cable Wire, Solar Adaptor Cable with Female and Male Connector - Set of 2

https://www.amazon.com/gp/product/B087QXMVBT/ref=ppx_yo_dt_b_asin_title_o02_s01?ie=UTF8&psc=1

MC4 branch connectors:

$10 BougeRV Solar Branch Connectors Y Connector for Parallel Connection Between Solar Panels FMM+MFF (1 Pair)

https://www.amazon.com/gp/product/B07DJ5PHSB/ref=ppx_yo_dt_b_asin_title_o08_s00?ie=UTF8&psc=1

10 gauge cable:

$43 GS Power 10 Gauge Stranded Flexible Copper Clad Aluminum CCA Primary Automotive Wire for Car Audio Video Amplifier 12 Volt Trailer Harness Hookup Drone Model Train Wiring. 100ft Red & 100 ft Black

https://www.amazon.com/gp/product/B0776BQYY8/ref=ppx_yo_dt_b_asin_title_o05_s00?ie=UTF8&psc=1

Lensun 100W black flexible panel:
https://www.lensunsolar.com/Flexible-solar-panel/Black-flexible-solar-panel?product_id=371

 

What led you to those solar panels? I've seen a lot of long term issues with flexible panels and was looking into the sunpower brand. The one you went with looks promising too. How long has e you had them?

I'm looking to replace my rigid panels eventually.

 

While doing some looking around for larger panels (had a 50W Renogy flexible on there before) I found the Lensun panels. 100W and was the perfect size for the spot I needed ... bonus was it was black so it's a little more stealthy than the white Renogy panel. A rigid panel wasn't an option due to the thickness.

From what I found a lot of the issues with flexible panels is due to de-lamination and the PET plastic used. For my Renogy panel there are a bunch of complaints about this on Amazon but so far it's been fine and I still use it as an extra panel when needed. The Lensun claims to be ETFE instead of PET so maybe that will end up better long term but I haven't owned either panel long enough (about 6 months for the Renogy and 2 for the Lensun).

I guess in the end i'm not too worried about it if I get 3-5 years from the panel. For $200 it's a great deal and in a few years i'm sure I can find something comparable in price with a higher wattage.

 

How did you attach panel to tonneau cover?

 

Velcro actually. I used some 3m outdoor heavy duty velcro and it's been working great.

$15 VELCRO Brand Extreme Outdoor Heavy Duty Tape | 10Ft x 1 In | Holds 15 lbs | Black with Stick on Adhesive | Strong Weather Resistant Holding Power - 91843

https://www.amazon.com/gp/product/B00JJPPYF8/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

 

Nice setup @abomb60. You’re like the original terravis
Wonder if anyone on here will spring for one once it comes out. They have photos of their setup on the back of a 3rd gen so I’m assuming they’ll come out with one.

 

I had looked around for tonneau covers with built in solar but doesn't look like any are on the market yet. My setup will be a bit different once my topper shows up. Gonna ditch the 100W flex panel and use a 100W rigid panel mounted to the topper crossbars. Flex panel will be used to toss up on the awning if I need the extra juice.