Installing a 450 Watt Solar system in TC 8.4S Camplite help

[Biewers on the Go]

Thanks for all of the awesome suggestions and recommendations and links.  I so appreciate the help.  Next, how do I set up this forum to email me when I get an answer to one of my posts?  LOL.
Thanks,
Rayne


I have 2 12v AGM 31 batteries that I need to put in my truck camper to store the solar energy for non solar generating hours, and I am trying to figure out how to work the necessary wiring with minimal distruption to my camper of course, but also to allow the straightest and shortest run possible from some of the components as I read in an article somewhere in one of these forums, and on some solar installation sites last fall.  This shorter straight run is supposed to reduce any voltage fluctuations.  Also, where in this whole system would I incorporate a surge protector for my electronics?  Anyone know? 

My system is the SunSparks Solar charging system made by Zebra Energy. 

So, I want to install the solar panels using the roof rack that is already installed on the camper, but cannot figure out from the kit I got exactly how to do that?  Can anyone direct me to a video that shows that part only? 

Next, how does this system with its Charge controller interface with the camper's inverter too, or doesn't it? 

Lastly, it seems to me that this system has to tie into the campers system somehow for me to be able to use the camper's installed outlets using the solar energy the system generated and stored in my special batteries, right?  So, will I still need the regular 12 volt battery battery to be in the loop of the system too?  The camper's battery compartment is on the non-slide out side of the camper, and is so small that no way can either of my AG batteries fit in it.  That's why they have to go on the opposite side, and in the lowest compartment in the rear overhang of the camper.  Not too happy about adding 120 pounds of battery there, but I can't deal with the mess and noise of a generator so I have to hope this this will not throw off my camper's balance too much either. 

I am really praying that my dealer's guys know what they are doing with this installation, because I don't really, so that worries me.  I'm also making them use plastic rigid wiring conduit to run the wires through the walls too.  I don't want the aluminum cutting it at all anywhere. 

Say a prayer it works when we are done with it. 

Thoughts, directions and suggestions are all appreciated. 
Raye

[MitchB]

I can't answer your question on how the panels will attach although I'm sure you'll be able to find something on youtube about that. Generally speaking, your panels will connect to the charge controller that will then connect to your batteries. Nothing new will connect directly to the camper inverter. The wiring of the camper stays intact as is, you'll be adding "stuff" from the batteries out.  If you're going to add 2 AGM batteries I would remove the existing 12 volt battery, you don't really want batteries of different size and type in the same charging set up. If you are moving the batteries you will need to add wire from the new battery location to the inverter.  Regarding wire size, I'd google search best wire size for solar setup, there are a ton of really good installer sites.  Bigger is better within reasonable constraints.

[DavidM]

In addition to MitchB's advice here are some specific answers to your questions:

"Also, where in this whole system would I incorporate a surge protector for my electronics?  Anyone know?"

Your DC system which is what a solar panel hooks up to, does not need surge protection.

"Next, how does this system with its Charge controller interface with the camper's inverter too, or doesn't it?"

I think you are confusing the terms "inverter" with "converter". A converter is just another name for a battery charger that takes AC power and converts it to DC to charge the batteries. Your solar panel's charge controller will probably hook up directly to the batteries and then to the converter. The converter also has fuses and breakers to protect the AC and DC wiring that goes to the outlets and appliances.

"Lastly, it seems to me that this system has to tie into the campers system somehow for me to be able to use the camper's installed outlets using the solar energy the system generated and stored in my special batteries, right? "

Yes and no. By installed outlets I assume you mean the AC outlets that power small appliances that you plug in like a hair dryer. It takes another, rather expensive device to this: an inverter. An inverter takes DC power and converts it to AC. The inverter will also have an automatic switch to change from shore power to the AC produced from the inverter. These devices start at about $500.

Most campers don't have inverters to produce AC because everything else with the exception of the air conditioning and microwave is designed to run on DC. You can even buy DC hair dryers.

And if I could disagree slightly with MitchB: I would leave the small battery that you already have but change it to an AGM type to be compatible with the new batteries. All three should be wired in parallel so that their outputs are combined and all will be charged by the solar system.

David

[Diversteve]

Follow this link for all you need to know about solar.
Be very careful if you decide to cut corners or you will be wasting your money.

https://handybobsolar.wordpress.com/

[Merlin]

Great project!  There is basic info on solar and electricity in last fall's forum newsletter.

https://mailchi.mp/fc579d244794/aluminum-camper-forum-newsletter?e=098d190c6d

The location of the batteries sounds challenging in your truck camper. Make sure you use large enough wire and fuses to handle the current. The current from your (150 watt?) panel won't be much, but under full load (lights, fans, TV, etc.) the current from the batteries to the camper should probably have at least 10AWG wiring and a 30A fuse. By the way, did you really mean 450 watts of panels? That's a LOT of power! If that's the case, you'll need a big charge controller and very large wire for all those amps!

Mounting the panel will need attention to wind. The force of the wind increases as the square of the speed, so don't wimp out and use tiny sheet metal screws to hold that panel to the rack. Get brackets that bolt all the way through the frame and use blue Loctight on the threads. The wires will need to be held down securely too. Self-leveling caulk will hold wires down on the roof and screwed down zip ties everywhere else.