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10 Basic Components for DIY RV Camper Solar System

John Marius
John Marius
—
09/06/2023

When it comes to powering electrical components in your RV, a solar system can be an efficient and convenient solution. However, understanding the individual components that make up a solar system can be overwhelming. In this article, we will break down and explain the most essential components you’ll need to know about.

1. Solar Panels 

Solar panels are the most conspicuous and essential element of a solar system. They serve the purpose of collecting solar energy from the sun and transmitting it via wires to the solar controller. The two primary categories of solar panels are monocrystalline and polycrystalline.

Monocrystalline and polycrystalline solar panels are both effective in collecting solar energy. However, there are some significant differences between these two types.

The first difference is in their appearance. Monocrystalline panels are usually black and have a more uniform color and appearance. On the other hand, polycrystalline panels are blue and have a speckled appearance.

Another main difference is their efficiency. Monocrystalline panels have a higher efficiency rate compared to polycrystalline panels. This is because monocrystalline cells are created from a single, pure silicon crystal, minimizing energy loss. Polycrystalline cells are made of multiple silicon crystals, which can lead to some loss of energy during the manufacturing process, resulting in lower efficiency. 

Finally, the cost is another notable difference. Monocrystalline panels are generally more expensive than polycrystalline panels. However, in terms of long-term performance and efficiency, monocrystalline panels may be the better investment. 

2.Charge Controller

Replacing the charge controller is one of the more challenging tasks to undertake in the future. It is advisable to do it correctly the first time. The role of the charge controller is to convert solar power from the panels into an organized and useful form. The solar panels produce power at varying voltages, ranging from 16 volts up to the hundreds of volts, depending on the set-up. The charge controller regulates this voltage down to the 12 to 15-volt range required to charge a 12-volt battery bank.

Types of Charge Controller 

There are two types of charge controllers in the market- MPPT and PWM. PWM is an older technology that is less efficient than MPPT, which is a more sophisticated and newer technology. While MPPT controllers have a higher buy-in fee, they have more processing power that enables them to optimize the output voltage to store the maximum amount of amps possible in the batteries for use.

LiTime solar mppt charge controller

MPPT controllers can be referred to as a Tesla while PWM is like a traditional gasoline-powered car. The buy-in cost for a Tesla may be higher, but it offers more advanced technology and better energy efficiency, ultimately providing greater satisfaction and long-term benefits. Similarly, an MPPT controller's initial investment may be higher, but it has superior processing power and optimization capabilities, allowing maximum storage of amps in batteries for later use. In contrast, the older technology of PWM is less efficient and offers fewer advanced features, much like traditional gasoline-powered vehicles compared to electric cars.

Therefore, it is recommended to get the MPPT controller unless you are short on cash.

3.Batteries 

On the current market, there are three primary battery varieties available: lead-acid, AGM, and LiFePO4 lithium battery. Although they were once the norm, advancements in technology have rendered them more troublesome than they're worth due to issues such as corrosive hydrogen gas and maintenance requirements. By contrast, AGM and lithium batteries are the two most frequently adopted battery types for campers.

 Despite the fact that lithium batteries call for a greater upfront investment, they are ultimately less expensive and offer higher power output. In light of this, it is recommended to go for lithium as they are more lightweight, robust, and cost-effective over the long haul.

 If you are unable to afford lithium batteries at present and require an operational electronic system, AGM batteries may be purchased in the meanwhile, but it is recommended to choose a size that can be switched out for lithium in the future in case your preference changes.

In the event that you need to opt for AGM batteries at the moment, a proposal would be to purchase three and store them, then replace them with three lithium batteries directly in their place, fasten them together, modify some parameters on your charge controller, and then enjoy your upgraded power capacity when they reach the end of their usage. By adopting this upgrade plan, you can reduce future expenses and make the upgrade process more manageable when the time comes. Learn more about the advantages of upgrading the RV batteries to LiFePO4.

4.Inverter 

In a solar system, an inverter is a crucial component that converts the direct current (DC) produced by the solar panels into alternating current (AC) for use in households and other electrical devices. 

The battery in a solar system typically stores power at 12 volts, but many household appliances and devices require 110 volts, which is where the inverter comes in. It takes the 12 volt power stored in the batteries and converts it into 110 volt power, allowing you to power those household appliances.

There are various types of inverters, such as square wave and modified sine-wave inverters, but these do not produce a clean power output and can damage electronic equipment. Therefore, it is highly recommended to use a pure sine wave inverter since it best mimics the power that comes through a standard plug.

For moderate usage such as running a coffee maker, instant pot, or induction stove, a 2000 watt inverter is sufficient.

diy rv solar system with inverter

In addition, the inverter charger combo also allows you to charge your batteries via shore power or an external plug from a camp ground power pedestal or someone's house. These units typically charge your batteries at a rapid rate of 40 to 70 amps.

Ultimately, whether or not you require an inverter depends on the appliances you plan on powering and how much you want your setup to feel like home. The device also allows you to charge your solar battery bank via your engine alternator, preventing you from draining your starting battery as you use your solar batteries.

5. Battery Isolator 

A battery isolator is a device that effectively disconnects or separates multiple batteries in a system, enabling each battery to be charged individually. This protects the batteries from discharging into one another and provides a way to utilize multiple batteries in a single system without any interference. This device proves to be highly beneficial in vehicles or boats equipped with multiple batteries for starting and running various electronics or appliances. By incorporating a battery isolator, one can prevent one battery from draining the others and assure optimum charging of each battery when required.

In a camper van, a battery isolator serves the same purpose as in other vehicles, to segregate and safeguard multiple batteries in a system. Camper vans usually have more than one battery, such as a starting battery for the engine, a house battery for powering appliances and electronics, and potentially a solar battery for charging the system. With the aid of a battery isolator, each battery can be efficiently charged and utilized without disrupting others, hence prolonging the lifespan of the batteries and avoiding potential issues such as drainage or overcharging. Additionally, some battery isolator systems enable connection of a camper van's charging mechanism to external power sources, such as shore power or a generator, resulting in more flexible and effective battery charging when stationary.

6. Busbar 

A busbar in an RV solar system is a metal strip or bar that serves as a common connection point for multiple electrical wires. Essentially, it allows for the connection and distribution of power from the solar panels to the various components of the electrical system, such as the batteries, charge controller, and inverter.

 A busbar provides a cleaner and more organized electrical setup, allowing for easier maintenance and troubleshooting in the event of an issue. It is an essential component in any RV solar system to ensure efficient and reliable power distribution.

shapes of busbar

There is a wide range of electrical busbars available, varying in shape, size, and material used in different industries.

Rectangular busbars are a popular choice due to their easy assembly operations, such as cutting, bending, and joining, and are capable of handling high current.

Square-shaped busbars are less favored due to poor ventilation and more challenging assembly possibilities.

Tubular-shaped busbars are primarily used in electrical substations for very high voltages, providing excellent ventilation and mechanical resistance. Despite their superior qualities, the installation of tubular-shaped busbars is complex and requires particular care, with cost being a significant disadvantage.

Wired busbars, on the other hand, are more flexible and ideal for connecting equipment terminals subject to vibration and shocks, including transformers, induction voltage regulators, circuit breakers, and others.

Round or circular shape busbars are suitable for limited applications in which the current is minimal and the service voltage is low, such as the interconnection of instruments on boards and synchronization bars.

7. Shunt 

In an RV solar system, a shunt is a device used to measure the flow of electrical current in a circuit. It is typically installed between the battery bank and the charge controller, and allows for precise monitoring of the state of charge (SOC) and battery capacity.

A shunt works by measuring small changes in voltage across a low-resistance resistor, which is placed in line with the current being measured. By measuring the voltage drop across the shunt, the current flowing through the circuit can be accurately calculated. This information can then be used to monitor the battery bank's charging and discharging cycle, as well as provide vital information such as battery voltage, current, power, and capacity.

shunt

Having an accurate shunt measurement in an RV solar system is crucial for ensuring optimal performance and longevity of the battery bank.

Some battery monitors come equipped with a shunt, integrating the measurement functionality directly into the monitoring system. This allows users to easily access real-time data on their battery status, helping to prevent overcharging or deep discharging, which can damage batteries. Additionally, these monitors often feature user-friendly displays that present information clearly, making it easier for RV owners to manage their energy usage efficiently.

8. Fuse Block  

A fuse is a safety device used to protect electrical circuits from an excess of current flow. It is made up of a metal wire or filament with a low resistance that is designed to melt or break when the current flowing through the circuit reaches a certain level, known as the current rating. When a fuse "blows," it interrupts the flow of current and prevents damage to other components in the electrical system.

fuse

picture souce: electricaltechnology.org

Fuses come in various shapes, sizes, and ratings, and are typically rated according to the maximum voltage and current they can safely handle. They are commonly used in homes, vehicles, and electronic devices to protect the circuits from overloading or short-circuiting, which can lead to fires or other hazards. In short, a fuse is an essential safety component that helps to prevent electrical mishaps and keep the electrical system functioning properly.

9. Wire

What is wire gauge?

Wire gauge is a measurement that indicates the diameter of a wire. It is typically expressed as a numerical value, with a lower number indicating a thicker wire and a higher number indicating a thinner wire. The most commonly used wire gauge system is the American Wire Gauge (AWG) system, which ranges from 0000 (4/0) to 40.

The gauge of a wire is important because it affects the amount of electrical current that can flow through the wire without causing damage or overheating. Generally speaking, thicker wires can handle higher amounts of electrical current than thinner wires. The wire gauge is also important when selecting connectors and other components, as they must be compatible with the wire size.

size of wire guage

picture source: electronicshub.org

10. Switch

A switch in an RV solar system refers to a device that is used to connect or disconnect electrical components within the system. In the context of an RV solar system, a switch is typically used to connect or disconnect the solar panels, battery, and load (such as lights, fans, or appliances).

In a basic RV solar system, a switch may be used to connect the solar panels to the charge controller, which regulates the amount of charge going into the battery. The switch may also be used to disconnect the battery from the load when not in use or to switch between multiple battery banks.

switch in rv solar system

Switches in an RV solar system are an important component for controlling the flow of electricity and ensuring the system operates safely and efficiently. They are available in various types, such as manual on/off switches, toggle switches, and automatic switches that can be controlled remotely.

 

Conclusion

In conclusion, an RV solar system can greatly benefit those seeking to live off the grid or reduce their carbon footprint. Understanding the basic components required, such as solar panels, charge controllers, batteries, inverters, battery isolators, busbars, shunts, fuses, wires, and switches, is essential to creating an effective and efficient system.

While there are multiple options and varieties to choose from, making a well-informed choice and investing in quality components will ultimately lead to long-term satisfaction and savings. With the help of this article, we hope we have provided valuable insights into the basic components required for an effective RV solar system and simplified the process of creating your own.

John Marius
John Marius
John Thompson, an automotive engineer with 15+ years of EV and lithium battery experience, holds a Master’s in Electrical Engineering from Stanford. He’s passionate about advancing battery tech and promoting green energy.

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