Flying Cloud

4/25/2017 – 2014 Airstream Flying Cloud, 30'

AM Solar installs a wide range of power equipment on RVs which gives us the flexibility to customize our systems to match a wide variety of customer preferences.  For example, this customer was familiar with the Bogart Engineering PWM charge controller interface and wanted it on his Airstream.  We were able to accommodate, and set him up with 400W of solar on an SC-2030 charge controller.

Equipment Added:   1x SP100 Solar Panel Kit 3x SF100 Solar Panel Kits 1x Roof C-Box 1x Bogart Solar Charger SC-2030

Equipment Added:
1x SP100 Solar Panel Kit
3x SF100 Solar Panel Kits
1x Roof C-Box
1x Bogart Solar Charger SC-2030

Planning panel layout

Planning panel layout

Bogart Charge Controller

Bogart Charge Controller

Inverter

Inverter

2/10/2017 - 2016 Airstream Flying Cloud FB, 25'

This client came to us with an existing 400W solar charging system using flexible panels (which we discourage due to reliability issues) and an additional 120W folding panel.  We replaced the original roof wiring because one of the four panels had stopped functioning, added two SP100 solar panels and upgraded the charge controller.  We also replaced the PWM charge controller on the folding panel and added a Victron MPPT charge controller with Bluetooth monitoring.  Next, we added a 600Ah Signature lithium battery bank and a 3000W inverter, which all fit tightly under the bed.  This is one of our most elaborate installs.
 

Equipment Added:  1x  600Ah Signature Lithium Battery Bank w/o Color Control Monitor 1x  Victron Multiplus 3000VA Inverter/Charger 2x  SP100 Solar Panel Kits 1x  Roof Mount Combiner Box 1x  Victron 100|45 charge controller 1x  Victron 100|15 charge controller 1x  Victron Bluetooth dongle

Equipment Added:
1x  600Ah Signature Lithium Battery Bank w/o Color Control Monitor
1x  Victron Multiplus 3000VA Inverter/Charger
2x  SP100 Solar Panel Kits
1x  Roof Mount Combiner Box
1x  Victron 100|45 charge controller
1x  Victron 100|15 charge controller
1x  Victron Bluetooth dongle

Lithium BMS components

Lithium BMS components

Charge Controller

Charge Controller

3000VA inverter and three 200Ah lithium batteries under the bed

3000VA inverter and three 200Ah lithium batteries under the bed

2/01/2017 - 2016 Airstream Flying Cloud 26U

Airstream systems are a substantial portion of our business.  This customer got 400W of roof mount solar and a 160W folding panel from our friends at Zamp Solar. Another common upgrade for Airstreams is to replace the charger with a Progressive Dynamics PD4655.

Equipment Added:  4x SP100 Solar panels 1x Roof C-Box 1x SunRunner Signature MPPT 40A system core 1x Zamp 160W Portable Panel with built in charge controller and portable case 1x PD4655 Charger Replacement/Upgrade

Equipment Added:
4x SP100 Solar panels
1x Roof C-Box
1x SunRunner Signature MPPT 40A system core
1x Zamp 160W Portable Panel with built in charge controller and portable case
1x PD4655 Charger Replacement/Upgrade

Blue Sky 3024IL charge controller being connected

Blue Sky 3024IL charge controller being connected

Blue Sky IPN Pro system monitor

Blue Sky IPN Pro system monitor

The system is installed in this cabinet.

The system is installed in this cabinet.

10/12/16 – 2015 Airstream Flying Cloud 25FB, 25'

A client brought in his 2015 Airstream with the following request of AM Solar:
Design an off-the-grid power system (for dry camping and boon-docking) that “runs itself” and requires as little maintenance and oversight as possible both when the trailer is being used and when it is stored.
Specifics:

  • Trailer is used for six weeks in the summer, often in shaded campgrounds, 95% of the time without electrical hookups. Stays range from 3-5 nights before moving to next location. Trailer is also used during the other three seasons typically for three-night stays.
  • Client has monitored his power usage in the trailer for the last year and a half and concluded that 40-50amp hours is the typical 24 hour energy usage.
  • Client doesn’t want to have to bring the batteries to a full charge after each use. Due to not utilizing campgrounds with electrical hook-ups, staying in shaded areas, and often driving short distances between destinations, there is often not enough time to fully recharge batteries via solar and vehicle alternator, especially in the off-season.
  • When sun is available, the client wants to utilize every watt possible from their panels to recharge the batteries as they often only travel 2-4 hours before stopping at their next destination. 
  • Client wants an option to add additional battery capacity and/or solar panels if desired for future energy needs.


To accomplish the above client goals we spec’d one of our Lithium Battery Systems, solar panels, solar charger, and battery charger.

  • Because the customer has light AC loads, we chose a 200Ah Essential Lithium Battery system. This will comfortably give them the five nights of camping desired with almost no solar panel input if they are camping under trees in the winter. If the client desires greater battery capacity in the future, this system can be expanded easily with an additional 200Ah bringing the total to 400Ah. Additionally, unlike lead-acid battery based systems, the lithium battery does not need to be recharged to 100% after each use.
  • Due to the potential for tree cover, we chose 400W of solar panels to give the client ample solar charging capacity.
  • We chose a 50A charger to maximize all available power (solar and vehicle alternator) to recharge the batteries as quickly as possible.
  • We chose a three-stage battery charger so that the client can leave the trailer plugged in when stored without having to be concerned about the batteries being charged correctly.
Equipment Added:  4x SP100W Panels 1x Roof C-Box 2x 15.5" Tilt Bar Sets 1x SunRunner Victron MPPT 30A 1x Victron MPPT Control 1x 200Ah Essential Battery Bank 1x Phoenix Charger 12/50 1x Phoenix Charger Control/Monitor

Equipment Added:
4x SP100W Panels
1x Roof C-Box
2x 15.5" Tilt Bar Sets
1x SunRunner Victron MPPT 30A
1x Victron MPPT Control
1x 200Ah Essential Battery Bank
1x Phoenix Charger 12/50
1x Phoenix Charger Control/Monitor

Because the BMS on the Essential system acts on the negative side of the batteries (ground control), the negative (or chassis) from the tow vehicle with the alternator is at a slightly different voltage than the negative output of the lithium system. This creates a design challenge since shorting the negative output of the lithium system to the tow vehicle chassis would damage the BMS.  

In a van conversion or coach, the issue of having two different negatives is easily resolved by routing the output of the lithium battery through the Orion 12/12 DC converter.  The negative output of the Orion converter can then be tied to the chassis and all positives for the DC loads get re-routed to the positive output of the Orion.  If the total DC load is more than 30A, multiple Orion converters can be connected in parallel.  Inverters, or anything else that can have their negative isolated from the chassis will just connect directly to the output of the lithium battery system without going through the Orion converter.

In trailers, the issue of having two different negatives is solved differently.  In this situation, the Orion converter goes on the input side of the lithium system, thus isolating the trailer from the tow vehicle’s chassis.  When this is done, the Orion converter has to be modified so it’s output voltage is 14.2V instead of the factory 12.0V.  This is accomplished by carefully tuning a potentiometer inside the converter that is accessible when the cooling fan is removed.  This design will limit alternator charging current to 30A, but it will protect the BMS from having it’s input and output short circuited.

Victron Orion 12/12 Converter customized to 14.2V output and connected on the input to the lithium battery system

Victron Orion 12/12 Converter customized to 14.2V output and connected on the input to the lithium battery system

200Ah Lithium Battery and Solar Charge Controller

200Ah Lithium Battery and Solar Charge Controller

Essential Lithium BMS and Battery Monitor

Essential Lithium BMS and Battery Monitor

Charge Controller and Battery Monitor Displays

Charge Controller and Battery Monitor Displays

Installation Video

7/8/2016 - 2015 Airstream Flying Cloud 20'

We installed a 300W solar panel system with an MPPT charge controller and a 300Ah AMS Generation 1 Lithium Battery System.  In order to install the battery bank and access the existing inverter we had to very carefully remove the bed and then put it back once everything was connected.

Equipment Added:  3x  SP100 solar panels  1x  Roof C-Box  1x  SunRunner Signature MPPT 25A system core  1x 300Ah Lithium Battery Bank

Equipment Added:
3x SP100 solar panels
1x Roof C-Box
1x SunRunner Signature MPPT 25A system core
1x 300Ah Lithium Battery Bank

Blue Sky 2512iX-HV MPPT Charge Controller and AMS Lithium BMS

Blue Sky 2512iX-HV MPPT Charge Controller and AMS Lithium BMS

Blue Sky IPN Pro Remote Monitor

Blue Sky IPN Pro Remote Monitor

AMS Generation 1, 300Ah Lithium Battery Bank

AMS Generation 1, 300Ah Lithium Battery Bank