Embedded Files
By N. Ngo for Compass/Gemini RV Only
First design: Feb 22, 2022
Updated May, 2025
March 1st, 2022: First version of design Schematic
Correct the connection from Alternator to the chasis battery and Li-BIM225
March 4th, 2022: Finished wiring batteries, turn-on both battery switches
Initial checked devices:
a. Existing system.
b. both batteries connected with Switches ON
c. Engine running with both batteries connected.
March 5th,2022: Installed 301A 12VDC LiFePO4 Battery System
March 5th,2022: Installed Dual Type Battery System.
March 6th,2022: Install Victron 100/50 MPPT.
Addendum:
EC1: DONE - Remove Solar Controller for Deep-Cycle battery due to in-effected and avoiding current path between 2 batteries and replace with the new MPPT
EC2: DONE - Add more Solar panels (400W 2x200w panels Dimension: ~42x11") Figure 19
EC3: N/A - Do not changed - Solar Open circuit output 48V
EC4: DONE - Dis-connected 'sig' from existing BIM to new BIM and run 'momentary' switch for new Li-BIM to avoid the unwanted 'clicking'
Mar 20 Option : Inverter Add-On - Figure 22
EC5: DONE : Upgrade WFCO 55Amp DC Converter - WFCO WF-9855-LIS Deck Mount Converter/Charger with Lithium-Ion Switch - 55A
Update Apr/12/22: Figure 2: Update Schematic with the wire size info.
Figure 26 Add 2x200w solar energy with the design details.
Figure 27 Analyze State-Of-Charge for Batteries
Apr/20/2022 : Release Version 2 Design in Figure 28
EC6: DONE - June 10th,2022 Figure 29 & 30 - Add 300W Inverter for 65W Monitor and Portable Air Compressor charging system.
Update Sept 6th 2022: Report the result after 6 months
Upgrade: How to setup to control your BMPro anywhere from your phone or home computer
Electronics Add-On:
1. 300W Inverter and connection
2. Rashberry PIE server with 110V monitor
From 2022 to 2023, Learning about the RV and RV Electrical System. In 2024 to-date, Redesigned the Electrical and Mechanical System with Soundproof and Mouseproof.
Version 1: Co-exist of Lead Acid and Lithium Batteries
Fig. 1 : Space limitation in the battery housing under the step.
Note: Before connect BMS control Signals to the BMS - Using balancer to check the BMS wiring.
Figure 2: Version 1 - Add the wire size in the schematic and correct the existing wiring - 310Ah LiFePO4
Fig 3: Version 1 Upgrade the Solar Panel System with 175W Flex Solar panel and the status of Battery from DALY phone Apps.
Fig 4: Video capture of Go-Power in normal charging state
House Battery Replacing with Lithium type
This upgrade is the most economic and easiest way
Fig 5: Schematic of the Low Cost Upgrade 310Ah Lithium Battery.
Fig 5: Schematic of the Low Cost Upgrade 310Ah Lithium Battery.
Fig 6: Part Cost (in $US 2021) break-down by Item of the system
Battery Compartment With Add-on Lithium Battery
Fig 7: Deep Cycle and 310Ah Battery with BMS on top in Lithium Battery in the Compartment
Fig 8: Had RV in less than 3 months, the BIM terminal are corroded
Fig 8: Had RV in less than 3 months, the BIM terminal are corroded
Question: Is the connector of Batt-A and Batt-B interchangeable?
Answer: Yes; When the engine runs, BIM connects Terminal A to Terminal B (Bidirectional) the energy flows to the couch Battery from the Alternator.
Figure 9: Version 1 used the VSR device to Cut in: LED On -charging both batteries
Figure 9: Version 1 used the VSR device to Cut in: LED On -charging both batteries
Figure 10: Version 1 - Both batteries connected - Engine ON
Figure 10: Version 1 - Both batteries connected - Engine ON
(No Smoking...)
Fig 11: POC (proof Of Concept) is working -Dual Battery Isolator Cut-In : LED ON means both batteries are charged or discharged when DC Voltages above 13.3VDC
Fig 11: POC (proof Of Concept) is working -Dual Battery Isolator Cut-In : LED ON means both batteries are charged or discharged when DC Voltages above 13.3VDC
Picture A
Picture B
Fig 12: State: Engine OFF - Generator OFF - No plug-in
All Light OFF: Picture A (Left): Batteries are charged 33W (2.43A) by Solar Panels.
All Light ON: Picture B(Right): Consumed 54W (-4.08A) Batteries are charged and discharged
Total consumed = 87 watts.
Step 2: Version 1 - Install Lithium BIM
Replace BIM with Li-BIM and relocated Li-BIM in the Passanger side storage compartment
Tapping the alternator wire and 3 signals wires into the new BIM
Q/A: What kind of alternator does a Ford Transit have?
Standard Alternator: 250 amp alternator on 3.5L PFDI V6 and 3.5L EcoBoost® V6 engines. Available Dual Alternator: 250 amps each - Includes Auxiliary Fuse Panel with High Spec Interface Connector.
Figure 13: Wiring Li-BIM parallel with the existing one
Figure 14: State of Charge for both batteries
Engine ON
Engine ON
Figure 14 SmartShunt current indicates the Alternator charged 57Amp for both batteries.
SmartShunt apps can check the SOC of Lithium Battery
Figure 15 SmartShunt current indicates the Alternator charged 57Amp for both batteries.
Figure 16: BMS of Lithium Batttery status during the engine ON and charging from the alternator for both batteries
Figure 17: Alternator is charging both Wet and Lithium batteries
Total charged 805W with alternator and Solar Panels.
Figure 18: Alternator is charging Wet battery only
EC2: There is enough space for 2 additional solar panel 42x11"
EC2: There is enough space for 2 additional solar panel 42x11"
Figure 19: Total ~600watts of Solar panels. - According to Solar Panels Manufacturing, I don 't think I can get 60% of 675 Watts.
How to setup to control your BMPro anywhere from your phone or home computer
Figure 20: Video DEMO in Youtube - During experiment with Lithium Battery, I need to monitor the status of the battery. My RV is in the RV storage and and it is about 2 miles from my house. I setup the system so that I can remotely to view the status and control the BMPro anytime from my home computer
Setup System:
1 - Subcribe Data plan from Phone provider: In my case, I am in T-Mobil voice and data plan, I subscribed an extra data plan with new SIM card or stand-a-lone device ( T10 Mobil hotspot or 5G MIFI from $3.75-$14.0/mo.)
2 - Hardware&Software:
a - Raspberry PI: Setup connection to your WIFI hotspot in (1) and download VNC Server/Viewer and create account with VNC. Then run VNC Server.
b - BMPro touch pad: Setup connection of BMPro with WIFI hotspot as in 2.1, down load and install 'droidVNC-NG' from Google store (when install droidVNC-NG will give the local address of VNC)
Operation:
Login in Rasberry PI and connect VNC to BMPro
1 - At Home Computer: Can use direct VNC to BMPro or from Raspberry PI -
NOTE: Raspberry PI as server:
1 - Consuming less than 6 watts and USB plug-in
2 - Build in WIFI - Bluetooth
3 - Easy add-on more devices such as Security Camera inside or outside
4 - Download from web the VNC/Server and VNC/Viewer - Available free for personal use only.
Figure 21: Status of RV at 5:45PM Mar/14/2022 can view from home computer through VNC
Figure 21: Status of RV at 5:45PM Mar/14/2022 can view from home computer through VNC
NOTE: During daytime, Solar Energy charged the battery.
Option : Adding Inverter
Installation Instruction:
Un-plug the shore-power wire.
Generator OFF
Open Transfer Switch located near the fresh water tank compartment
Suggest vertical mount Inverter in the storage underneath of bunk bed.
Disconnect wire of Generator input in the transfer switch and connects into Inverter AC-Input. (might be need to install extra AC junction box to connect this wire to reach the AC-input in Inverter)
Running AC Line-Out 1 of Inverter to the gen-input to the transfer switch.
Running 2DC Load line to the 12VDC input to the Inverter.
Test:
Check all wiring correct and safety
No Shore Power input
Generator OFF
Make sure Battery is the full of charge
Program Inverter
Un-plug 110VAC outlet.
Test Inverter output from 12VDC load-input:
Enable AC output in Inverter
Check 110VAC outlet and normal AC operation (measure value AC Voltage outlet)
test Generator output: Unplug shore power
running Generator
Check 110AC outlet and normal AC operation
Measure Battery voltage battery should be in charged mode.
Repeat step 9 with Air Conditioning ON and Microwave Open ON
Figure 22: Operation: Tapping AC input to the inverter between Generator out put and Transfer Switch.
Figure 22: Operation: Tapping AC input to the inverter between Generator out put and Transfer Switch.
NOTE:
NOTE:
1 - The 110VAC is provided by Inverter when Generator and no shore power plug-in.
1 - The 110VAC is provided by Inverter when Generator and no shore power plug-in.
2 - When Generator or Shore-Power plug-in, Battery is charged.
2 - When Generator or Shore-Power plug-in, Battery is charged.
Figure 22: Connecting Inverter.
Figure 22: Connecting Inverter.
Option 2: Upgrade Converter
Do I need to upgrade Converter for LiFePO4 battery:
Depend on your need if - there is no harm to Lithium battery.
There are 4 sources to charge the Batteries:
1 Solar Panels (Setup for Lithium Bat.)(Solar charger active when no other power sources:Shore Power plug in, Generator ON or Engine ON)
2 Alternator (General )
3 Generator or (Converter setup for Lead Acid Bat . profile)
4 Shore-power
Shore-Power Plug-in override the Generator.
Priority the 3 energy sources can charge the battery:
MPPT output Vmax =~14.7V ( Solar charger charge only engine stop or no shore power)
Alternator output Vmax = ~14V (Stop the Solar power)
Generator/shore power Vmax = (Lead Acid charging profile) (Generator override the shore power input by transfer box)
Figure 23: SOC for LiFEPO4 battery
Figure 23: SOC for LiFEPO4 battery
Figure 24: SOC for Lead Acid-AGMCell
Figure 24: SOC for Lead Acid-AGMCell
Figure 25: Histogram of the Result of Solar Charging System after 2 months (it is raining and cloudy in my area)
Figure 25: Histogram of the Result of Solar Charging System after 2 months (it is raining and cloudy in my area)
SmartSolar charged from 275 Watts of Solar panels. Display from Victron MPPT
SmartSolar charged from 275 Watts of Solar panels. Display from Victron MPPT
Figure 26: Add more Solar Energy with the design details
Each panel is 200W Totally 675Watts MAX
Figure 27: Analyze State Of Charge for Batteries Current Input:
I = i1+i2+i3; i3 active only i1 or i2 not active.
Figure 28: Version 2 of dual battery type design
ADD 300W Inverter for 27" Computer Monitor and for Portable Air Compressor.
Installed 300W Inverter inside the bench
Installed 300W Inverter inside the bench
Figure 29: tap 12VDC for 300W Inverter
65W 110VAC for 27" Monitor
65W 110VAC for 27" Monitor
Figure 30: 65W for 27" Monitor
Report System Status after 6 months
Early in the morning no sunshine yet
Daily Status of Solar Charging System (with 310Ah Lithium and 100Ah Lead Acid Batteries
Redesign the system with LiFePO4 Lithium House Batteries
Upgrade 2024-25 : Redesign the Couch Power System
1. Install 3 LiFePO4 batteries:
Bat-1 310Ah BMS 300A
Bat-2 304Ah BMS 200A
Bat-3 320Ah BMS 200A Proprietary
Bus Bar for +12VDC and GND
VEVOR BIM (Batteries Isolation Manager). Replaced BIM LI-225(no longer worked).
Add 3Kw Inverter
2. Mouseproof and soundproof the cavity behind the chairs
3. Fixed the awning due to the design defect.
Electrical System Version 2
Mouseproof and Soundproof:
Mouse sneaks in through the electrical wires. Using steel wool and spray foam (like popcorn) the cavity.
Electrical Wire Size Reference Table for 12VDC system
2025 Upgrade (Cont...)
Recommendation for the Upgrade Lithium Batteries:
Lithium is the new battery technology - the research about this technology is incompleted before the product available.
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