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Old 09-11-2007, 06:18 AM   #1
3 Rivet Member

 
hshovic's Avatar
Profile:  2007 25' Safari FB SE
Bozeman , Montana
Posts: 140
Images: 15

Thumbs up AM Solar installation on a Safari

I just installed an AM HPV30 solar panel 100 w system on my 2007 25'Safari Special edition.


However, it is not as simple as just connecting up some wires, even though the Airstream is "solar prewired". I appreciate the forum's members' help in their posts, so here is some additional info.

AM provided almost all the fittings, fuses, and wiring I needed in their kit. Their less expensive model has an integrated controller/monitor. However, this would never have fitted in the available space on a wall in the unit, so I went for the more elaborate model with separate controller and monitor.

Here are some comments on it.

* Getting on the roof was via a tall ladder leaning on an attached carpeted bar. I stayed on the rivet lines, but the roof seemed plenty strong.

* I had to unrivet the refer vent cover, as well as the screen (grind flat spot on rivet, then drill out). There was no way the feed wire would snake through there without removing it, note the baffle in the way (picture below). I riveted it back with a snap riveter and caulked with aluminum-specific caulking. I used aluminum rivets.

* I glued on the panel using AM's special tape. (below) I buffed off the white paint
with a wire brush on a drill, used alcohol to clean and did it when temps in the 80's. Don't grind through the roof! You only get one chance at positioning, so I buffed a bigger than necessary area, and chose a windless day to settle all four feet standing above the panel.

* I ran wires underneath the body to access the battery. These wires are for both measuring battery temperature and voltage. This consumed most of my time for what may only be a small benefit. I ran the wires through the refer compartment floor, under the couch, and out the wheel well, then tied to a convenient gas pipe and through a frame member to the front where I screwed them to the underbody, then caulked (below).

Note! The provided wiring was just long enough to reach the battery. I would have liked to have another two feet.

* The solar power unit fit nicely in the refer compartment, after I moved the 110V receptacle used for the refer (below). Note the unit is screwed down solidly. The refer compartment floor is plenty strong. I didn't want it vibrating off and tilting against the refer. There was plenty of room for access and venting.

* The factory-installed yellow/green wiring led to the brass under-bed busses. I hooked it up with a fuse, and to charge even if the store/use switch is off. I

* Airstream wires one cat5 cable to a location under the status monitor. I would have liked to use that, but the AM solar needs TWO cat5 wires. Sounds like old technology. Hence I mounted it in the only place it could go; that is under the TV. This location was carefully selected and measured, as there is little room for error (below).

* I have strain relief and cable covers on all stress points and on exposed wires.


* Seems to work fine! I may get another panel at some time. There is room on the roof and the AM solar buss will make wiring the next panel very easy with no more un-riveting... The glued-on panel appears stable, but time will tell. Space shuttle tiles are also glued on.



I did kill the batteries one time (left a light in the storage compartment on for a week), and the solar panel monitor was blank. I guess it needs some juice to work.



Here are some cell phone pictures of the process.


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Hank

WBCCI 1489 AIR 20708
2007 Chvy 3/4 ton 4 x 4 gas

"Its better to light just one candle than to curse the darkness,

Unless you're blinded by the light..."
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Old 09-11-2007, 06:27 AM   #2
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Profile:  1977 Argosy Minuet 6.0 Metre
Colorado Springs , Colorado
Posts: 486
Images: 7
Airstream Registry

Hank,

Welcome to the forums. And thanks for the great description of the process and the photos. Karma on the way.
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Old 09-11-2007, 08:28 PM   #3
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Profile:  1986 25' Sovereign
Southern Middle , Tennessee
Posts: 3,038
Images: 23

I also used the AM Solar products for my installation several months ago. Where did you install your panel? I placed two 100 watt AM panels side by side between the AC and rear Fantastic Vent fan. I later found an AM65 watt panel and put it on the front curb side. The HPV22B controller worked for me and will handle up to 400 watts.
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'01 2500hd ext. cab, 8.1 litre gas, 5 sp. Allison auto
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Amsoil Dual by-pass oil filtration system
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Old 09-11-2007, 08:54 PM   #4
3 Rivet Member
Profile:  2001 19' Bambi
Greensburg , Pennsylvania
Posts: 121
Images: 9

It looks like a nice setup you've put in.

One thing concerned me about your pictures-
I think you may want to reconsider the placement of your HPV-30DR solar controller. Is it acceptable to place it in a location that is exposed to moisture?

My experience with my 2001 Bambi is that the reefer compartment gets moisture from the road and wind, and that could be a problem for your controller.

From the picture you posted, I would be concerned that your screwdown terminals and RJ45 connectors could easily get corroded.

You may want to check with AM Solar to ask if you should take any precautions locating the controller here. At the very least, I'd consider placing it inside a moistureproof box and using anti-oxidant electrical paste on all terminals.

Good luck with your project and keep us posted.
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Old 09-11-2007, 09:26 PM   #5
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Profile:  2007 25' Safari FB SE
Bozeman , Montana
Posts: 140
Images: 15

Good point on the moisture potential. I had a torrential downpour last weekend on the road, and no water entered. Of course that doesn't mean it won't.

AM recommends a "relatively dust and moisture free" place, and "some amount of air flow". Sooo.. It appears that is what I have. I will consider a cover, possibly on the outside side, but need some cooling, especially if I hook more panels., however,and some sealer on the wiring!
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WBCCI 1489 AIR 20708
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"Its better to light just one candle than to curse the darkness,

Unless you're blinded by the light..."
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Old 09-11-2007, 09:29 PM   #6
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Profile:  2007 25' Safari FB SE
Bozeman , Montana
Posts: 140
Images: 15

Location of solar panel

I put my panel between the air con and the rear fantastic fan (just enough room), centered on the roof. I would add the next one on the sloping roof portion on the left front quarter.
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WBCCI 1489 AIR 20708
2007 Chvy 3/4 ton 4 x 4 gas

"Its better to light just one candle than to curse the darkness,

Unless you're blinded by the light..."
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Old 09-12-2007, 09:08 PM   #7
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Profile:  1986 25' Sovereign
Southern Middle , Tennessee
Posts: 3,038
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Quote:
Originally Posted by hshovic
I put my panel between the air con and the rear fantastic fan (just enough room), centered on the roof. I would add the next one on the sloping roof portion on the left front quarter.
Right behind my A/C is my antenna and halfway toward the rear Fantastic Fan vent is a support approximately 6" wide for the antenna arm. I would have mounted both AM100 panels just 2" apart from each other but the support would not allow it. I elected to mount each panel out a couple of inches from the antenna support and it looks OK. I also purchased two sets of tilt bars in case I want to tilt the panels for winter sun or cleaning. I have also considered buying three additional sets and having them cut in half in order to bring each panel to horizontal but have not decided if this will even be necessary.

Your system looks good and I am sure that the HPV30 will be a great controller.
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Mag-Hytec rear diff cover
Amsoil Dual by-pass oil filtration system
Amsoil synthetics all around
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Old 09-12-2007, 10:17 PM   #8
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Profile:  2005 25' International CCD
Everywhere , North America
Posts: 278
Images: 42

Guys,
Motoman did a really fantastic install description for two 130 watt solar panels and a controller for his 2005 25' CCD International in the past year. Take a look at it on these forums -- search motoman then solar and you'll find another really solid installation.

We are anticipating installing similar to Motoman's before end of 2007 to take advantage of Federal Income Tax credit for solar on our rolling home. Great project for October or November, I think.
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