Kannon Fodda
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- Feb 26, 2019
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- Autotrail V-line 540
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- I Make Schoolboy Errors!
Lithium prices have been dropping and it was time for more power! But what might fit into my 2019 Autotrail 540 V-line (a 5.4m long PVC)?
4 years ago, I had Vanbitz replace the pathetic rear under benchseat mounted 75ah lead acid with a 120Ah Sterling Lithium fed by a Sterling 60A B2B through 25mm2 cables whilst also tweaking stuff like the solar controller. There were a few neat tricks involved including pulling a fuse in the EM40 fusebox behind the driver's seat that stopped the useless Sargent EC176 relay based charger, and a small loop linking the solar feed that could have charged the engine (until that fuse was pulled), so the step could still operate. Best of all the installation was squished into a space behind the Sargent unit in front of the Truma heater, in the underbench seat on the drivers side, releasing all of the passenger seat for storage (the lead acid battery box took a lot of space).
Having seen what Vanbitz achieved, and as time moved on, I was able to develop ideas. A hydraulic crimper became an invaluable tool. I added a Victron Smartshunt (the early Sterling batteries BMS was fine but the bluetooth got killed by some update). A battery master was fitted. I added circuits for USB sockets (Autotrail provided nothing in the hab area). I fitted a small Victron VE Direct 375 inverter so I could charge my e-bike. The additions meant the space on the battery posts were too cramped so rewiring took place to add busbars. The original 100W solar panel was replaced with 150W and better wiring as some of the Autotrail stuff seemed pitifully thin. I got a separate Victron IP67 mains charger just in case as the Sargent thing was not even smart, let alone lithium compatible. Earlier this year I added a second solar controller and wiring for a fold out 200W panel. Recently the Sterling B2B was replaced with the new Victron Orion XS (the Sterling kept throttling for heat as the cooling fans were directing air straight at the battery case, the space being too tight). As far as possible all the new stuff completely bypassed the Sargent so stuff like inverter and USB can be used even if engine is running and without stressing the original cable thicknesses.
As a singleton, I can get through a fair bit of juice, especially if weather is poor so I don't want to venture out. If I've recharged the e-bike, with then a couple of cloudy days without EHU, watching TV, gaming on a laptop, there have been times I've been below 20%, and once was nearing only 5% of the 120Ah.
The space available was very tight indeed. I've had the tape measure out a number of times. Most things won't work. I looked at underseat type batteries but they were still too wide or deep even on side. Fitting a battery under the front seat was impractical as all the other wiring was in the wrong place for rear connections. Eventually I realised, just, the Fogstar Drift 280Ah would shoehorn in, if everything else was moved around and it laid on it's side. Fogstar confirm their batteries can be orientated almost any way up as the heaters pads are between the cells rather than just on the base of the battery.
Fitting the Fogstar was not straightforward. The bench seat bed frame had to come out just to give clearance. I have to say that under the base there is a whole mass of untidy cabling from the Autotrail pre-wired looms that are apparently one length fits all for their various vans.
But there was now access to for me really tidy up my previous spaghetti wires. The shunt is moved out of the way to the rear. Busbars are now more accessible (if I'm mad enough to make any future changes) The bus bar housings and aluminium angle frame I built for the inverter secure the battery from sliding about. There is more space around the Orion XS, albeit not the 10cm all round Victron recommend, but my last trip out suggests it is working well and not throttling heavily from temperature (I could always lift the cushion from seat above to increase airflow whilst driving along). I have a much better fusebox, Blue Sea ST 5045, for the added USB and other circuits, with crimped ring connectors rather than the previous cheapo push fit blades thing that were risking working loose or being knocked.
Now if only there was space for a bigger inverter so I could power the Autotrail fitted microwave that is more use as a bread bin .....
4 years ago, I had Vanbitz replace the pathetic rear under benchseat mounted 75ah lead acid with a 120Ah Sterling Lithium fed by a Sterling 60A B2B through 25mm2 cables whilst also tweaking stuff like the solar controller. There were a few neat tricks involved including pulling a fuse in the EM40 fusebox behind the driver's seat that stopped the useless Sargent EC176 relay based charger, and a small loop linking the solar feed that could have charged the engine (until that fuse was pulled), so the step could still operate. Best of all the installation was squished into a space behind the Sargent unit in front of the Truma heater, in the underbench seat on the drivers side, releasing all of the passenger seat for storage (the lead acid battery box took a lot of space).
Having seen what Vanbitz achieved, and as time moved on, I was able to develop ideas. A hydraulic crimper became an invaluable tool. I added a Victron Smartshunt (the early Sterling batteries BMS was fine but the bluetooth got killed by some update). A battery master was fitted. I added circuits for USB sockets (Autotrail provided nothing in the hab area). I fitted a small Victron VE Direct 375 inverter so I could charge my e-bike. The additions meant the space on the battery posts were too cramped so rewiring took place to add busbars. The original 100W solar panel was replaced with 150W and better wiring as some of the Autotrail stuff seemed pitifully thin. I got a separate Victron IP67 mains charger just in case as the Sargent thing was not even smart, let alone lithium compatible. Earlier this year I added a second solar controller and wiring for a fold out 200W panel. Recently the Sterling B2B was replaced with the new Victron Orion XS (the Sterling kept throttling for heat as the cooling fans were directing air straight at the battery case, the space being too tight). As far as possible all the new stuff completely bypassed the Sargent so stuff like inverter and USB can be used even if engine is running and without stressing the original cable thicknesses.
As a singleton, I can get through a fair bit of juice, especially if weather is poor so I don't want to venture out. If I've recharged the e-bike, with then a couple of cloudy days without EHU, watching TV, gaming on a laptop, there have been times I've been below 20%, and once was nearing only 5% of the 120Ah.
The space available was very tight indeed. I've had the tape measure out a number of times. Most things won't work. I looked at underseat type batteries but they were still too wide or deep even on side. Fitting a battery under the front seat was impractical as all the other wiring was in the wrong place for rear connections. Eventually I realised, just, the Fogstar Drift 280Ah would shoehorn in, if everything else was moved around and it laid on it's side. Fogstar confirm their batteries can be orientated almost any way up as the heaters pads are between the cells rather than just on the base of the battery.
Fitting the Fogstar was not straightforward. The bench seat bed frame had to come out just to give clearance. I have to say that under the base there is a whole mass of untidy cabling from the Autotrail pre-wired looms that are apparently one length fits all for their various vans.
But there was now access to for me really tidy up my previous spaghetti wires. The shunt is moved out of the way to the rear. Busbars are now more accessible (if I'm mad enough to make any future changes) The bus bar housings and aluminium angle frame I built for the inverter secure the battery from sliding about. There is more space around the Orion XS, albeit not the 10cm all round Victron recommend, but my last trip out suggests it is working well and not throttling heavily from temperature (I could always lift the cushion from seat above to increase airflow whilst driving along). I have a much better fusebox, Blue Sea ST 5045, for the added USB and other circuits, with crimped ring connectors rather than the previous cheapo push fit blades thing that were risking working loose or being knocked.
Now if only there was space for a bigger inverter so I could power the Autotrail fitted microwave that is more use as a bread bin .....
