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Old 10-20-2018, 09:10 PM   #1
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1979 31' Sovereign
Spring , Texas
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New Electrical with Battle Born Batteries

This will be a multi section post of the new electrical system. The first part will be the build, the second is testing and the third will be performance.

The planning of this project started a few years ago with a huge goal in mind—being able to run any device in the trailer using lithium batteries and solar with minimal shore/generator power. Of course, any good project starts by doing a lot of research. Mine consisted of internet searches of the various companies and watching numerous hours of YouTube videos. Seeing what others have done—what they liked, didn’t like and what I liked or didn’t like, and seeing what might be improved upon. I also private messaged several on the Airforum, emailed the authors of the YouTube videos, and called different companies. So, when the first post about Battle Born Batteries showed up on the Airforum, I was intrigued with the possibility of a lithium “drop-in” replacement for our AGM.

I sent an inquiry to Battle Born via their web site and within a couple of hours was contacted by Sean Nichols. One of the first things I explained to Mr. Nichols was how I would have to piecemeal the components over time as money became available. After several email and phone call exchanges with Mr. Nichols and Dr. Denis Phares, we came up with a plan. A complete re-do of all the electrical. And after several more email and phone calls with them about the build, it was time to place the first order.

Ordering items for this build took about 2 years.

The following was ordered from Battle Born

1) 4 X 100-amp hour Battle Born Batteries
2) Victron 150/60 MPPT
3) Victron Multiplus 3000
4) Victron Color Control GX
5) Victron BMV 700 battery monitor
6) VE direct cables X 2
7) VE direct dongle
8) MK3 interface

This is the list of other items ordered

1) 4/0 cable and lugs
2) 2/0 cable and lugs
3) #2 cable and lugs
4) #4 cable and lugs
5) Heat Shrink Tube
6) Cable Lug Crimper
7) Different size In-Line Breakers
8) 100-watt solar panel X 4 (so far)
9) 3 X Bus Bar
10) Shorter RJ-45 cables
11) Class T Block and Fuse
12) Battery Master Switch
13) Battery Bolt Set
14) Victron Monitor Box
15) 50amp WFPO Power Center
16) 30amp Smart Plug kit
17) Various wire crimps
18) Radiant Barrier roll
19) Cooling Fans with controller and thermometer
20) Micro-Air EasyStart
21) Plus, a bunch of miscellaneous stuff that I didn’t foresee—cable ties, flexible tubing to hold wires, 3m VHB tape, hinges, screws, nuts, bolts, washers, scrap wood etc.…

The different orders from Battle Born went smoothly and all items were received as expected. In particular the batteries were extremely well protected and packaged. I will note that the second set of batteries ordered did come with the nuts, bolts and washers, which is standard now.

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This is the rough sketch of the build

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When we purchased the ’79, the 12-volt fuse system was located in the front and the 120 breakers were in the wardrobe closet. The main power cord was wired through and stored in the back bumper trunk. The previous owner removed the gaucho and closed off the battery compartments. They relocated the original Univolt to an outside enclosed box on the tongue behind the propane tanks and strapped a single plastic battery box on top of the Univolt.

The front at time of our purchase.

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The 12-volt wiring after removing the front panels.

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The front with temp wiring. We traveled with temp wiring for 2 years while we gathered enough items to start the build.

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Old 10-20-2018, 09:20 PM   #2
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1979 31' Sovereign
Spring , Texas
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The start of the new electrical front. Installed Smart Plug shore power and reflective insulation and batt insulation. Next a vapor barrier with taped seams. Finally, the assembly board where the majority of the components were mounted and the rack with a shelf for the rest of the components.

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One master switch with both positive and negative cables. One in-line circuit breaker that cuts off the power from the 7-way. One master in-line circuit breaker from the MPPT solar controller.

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Some of the in-line circuit breakers are slightly modified with a breaker box lug connector to accommodate the larger cable size.

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With the new face frame and intake cooling fan on the bottom. The cooling fan isS mounted to 1/4-inch plywood and can be slid either to the right or left, allowing full access to the batteries. Also added 1/8-inch neoprene under the batteries to help cushion and keep them in place.

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Old 10-20-2018, 09:33 PM   #3
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With the new power center and Victron Color Control. Shore power went first to the 30-amp breaker located in the center of the distribution panel, and a second 30-amp breaker completes the circuit to the Victron Multiplus. From the Victron Multiplus, power returns to the Main 30-amp section on the left and distributed to all 120-volt components. The open area on the right side of the power center is for the 12-volt blade fuses.

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Master cut off switch for the 12-volt blade fuse.

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The MPPT solar controller. 2 solar arrays, each array is first connected to an in-line circuit breaker then combined to another in-line circuit breaker before being connected to the MPPT. This way one array can be taken off line at a time if work or maintenance is needed.

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The Multiplus wired up. The extra RJ45 cable is for the Victron MK3 Interface.

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All wired up.

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Old 10-20-2018, 09:35 PM   #4
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The front before adding the final touches. On the top in the center are ventilation grates, on each side are exhaust fans and just left of center is the thermal control for the fans. The left/right front face panels can be lifted out for easy access to all of the components.

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The completed front with the original curtains dyed blue and the multi-color poured resin top.

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Old 10-20-2018, 11:20 PM   #5
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Nice job! Very well documented.
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Old 10-21-2018, 10:24 AM   #6
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When I copied this from my word document I missed these paragraphs.....

I want to point out some things very unique about Battle Born as a company.

They are a USA company, which is very important to me. I am a 100% disabled veteran living on the VA fixed income. They understood my limitations both physically and financially. If I found any of the components they sell for a less expensive price, they price matched without any hesitation. They also provided me with a generous veteran's discount. This level of service is becoming more and more rare these days.
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Old 10-21-2018, 10:25 AM   #7
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Quote:
Originally Posted by rowiebowie View Post
Nice job! Very well documented.
Thank you
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Old 10-21-2018, 10:38 AM   #8
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Nicely done. Thanks for sharing.
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Old 10-21-2018, 04:23 PM   #9
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Great job, appreciated reading and seeing this project. Kudos to you, thanks for posting.
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Old 10-21-2018, 05:55 PM   #10
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Crazy nice upgrade!
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Old 10-21-2018, 10:12 PM   #11
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Battleborn is the greatest!

We LOVE our Battleborn batteries! And while their products are worthy of praise, their company ethics are really what we'd like to praise. It's difficult to find a corporate business deserving of praise in today's money-grabbing corporate world. Wish everyone were as honest and concerned about their customers as Battleborn is!
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Old 10-22-2018, 09:05 PM   #12
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Quote:
Originally Posted by iaqstuff View Post
We LOVE our Battleborn batteries! And while their products are worthy of praise, their company ethics are really what we'd like to praise. It's difficult to find a corporate business deserving of praise in today's money-grabbing corporate world. Wish everyone were as honest and concerned about their customers as Battleborn is!
I fully agree. After hours customer service is excellent as well. They have gone above and beyond all my expectations.
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Old 10-22-2018, 09:08 PM   #13
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Originally Posted by gklott View Post
Nicely done. Thanks for sharing.
Thank you
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Old 10-22-2018, 09:09 PM   #14
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Quote:
Originally Posted by Backfortyjoe View Post
Great job, appreciated reading and seeing this project. Kudos to you, thanks for posting.
Thank you
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