If you’re planning to convert a van for full-time living or even just for weekend getaways, a reliable and well-designed electrical system is an essential component. Without a dependable power source, you may find yourself stranded with a dead battery, or unable to use your appliances and lighting when you need them most.
In this guide, we’ll show you how to design and install an electrical system that will meet your needs and keep you powered up on the road. Whether you’re a complete beginner or have some experience with electrical work, this guide has something for everyone.
We know from first hand experience just how convoluted and daunting this part of your van conversion process is which is why we want to give you all the information and tools you’ll need to make this important step as easy to complete as possible.
We’ll start by outlining a general overview of the various components you will need that make up a van electrical system, including batteries, an inverter, and a charge controller. We’ll explain the purpose of each component. We’ll also touch on other electrical components that you may want to consider, such as lighting, outlets, and appliances. And how you can calculate the size of the electrical system you will need by calculating the power usage you plan on needing.
Next, we’ll delve into the wiring process, walking you step-by-step through the process of connecting all the components of your electrical system. We’ll include detailed instructions and illustrations to help make the process as clear and straightforward as possible. We will also show you how to correctly size your wiring.
Proper maintenance is also crucial for a reliable electrical system. In this guide, we’ll provide tips on how to keep your system running smoothly, including how to check and replace batteries and other components as needed. We’ll also discuss safety considerations, such as proper grounding and the use of properly rated fuses and circuit breakers.
Finally, we’ll address common electrical problems and provide guidance on how to troubleshoot them. We’ll also point you to additional resources for further information and support.
By the end of this guide, you’ll have a solid understanding of how to design and install an electrical system in your van conversion that will meet your needs and keep you powered up on the road. Let’s get started!
General Overview
The electrical system in a van conversion is made up of two main parts: the AC system and the DC system. The AC (alternating current) system is what powers your household appliances, such as laptops, TVs, and induction hobs, while the DC (direct current) system is what powers your 12V appliances, such as lights and water pumps.
There are several inputs that can feed into the electrical system, including solar panels, 240V shore power (when you’re plugged into a campsite’s electricity supply), and a DC to DC charger that draws power from the starter battery to charge the leisure battery.
The leisure battery acts as the “brains” of the system, storing power from the various inputs and distributing it to the various outputs as needed. The inverter converts the DC power from the leisure battery into AC power, which can be used to run your household appliances.
The 240V charger is used to charge the leisure battery when you’re plugged into shore power. The MPPT (maximum power point tracking) charge controller helps to optimize the charging process from your solar panels and ensure that the leisure battery is charged efficiently. A battery monitor and battery balancer help to manage and maintain the health of the leisure battery.
There are several outputs that come from the power supply, including 12V outputs that go to your 12V appliances and 240V outputs that go to your household appliances. It’s important to choose the right size and type of components for your power needs and to wire everything correctly to ensure a safe and reliable electrical system.
Don’t worry if you still don’t understand yet we will get into a lot more detail later on in the guide when it comes to talking about what each component does and what it should be wired to.
So, in a common electrical set up you will need these components:
· Batteries
· Inverter
· Shore hook up point
· AC charge controller
· DC to DC charger
· Solar panels
· Mppt charge controller
· Shut off switch
· Positive and negative bus bars
· Shunt
· Battery monitor
· Battery balancer
· Breaker box 240v
· Fuse box 12v
· All electrical appliances that you plan on using
Now there is also a much simpler set up that you can install which would make your life a lot easier. The Bluetti AC300 And Bluetti B300. This is a modular plug and play battery and inverter set up that makes it extremely easy to design and put together your electrical system. We will go into a lot more detail on these later as they are an amazing solution for a quick, easy and powerful van build electrical system. I came across this amazing system when I was researching new technologies for my second van conversion.
Here is an overview of components you will need in this setup:
· Bluetti B300 (battery)
· Bluetti AC300 (inverter, Charger, MPPT, Breaker Box 240v)
· Bluetti D050S (if you want to charge via starter battery)
· Fuse box 12v
· Shore power hook up
· All electrical appliances that you plan on using
Already I’m sure you can tell that the Bluetti system will be a lot simpler to install. We will go into more detail about the design and configuration and installation of both these systems later on.
But first we need to work out something extremely important in order to build out the optimal electrical system you require…
Calculating your power needs!
Calculating the total size of your electrical system in a van conversion will depend on your specific needs and preferences. There are a few key factors that you’ll need to consider in order to determine the size of your system:
Power consumption:
The first step in determining the size of your electrical system is to determine how much power you’ll need to run your appliances and devices. This is usually measured in watts (W) or amps (A).
To determine the power consumption of each item, you can check the label or sticker on the appliance, which will often have the power consumption listed in watts (W). For example, a laptop may have a power consumption of 60W, and a television may have a power consumption of 100W. If you can’t find the information on the label or sticker, you can also check the manual or look up the specifications online.
Once you have the power consumption of each item, add them up to get a total power consumption. For example, if you have a laptop with a power consumption of 60W, a television with a power consumption of 100W, and a few other small appliances with a total power consumption of 100W, your total power consumption would be 260W. This will give you a general idea of how much power you will need, this number might be a bit on the high side, so it’s important to also consider your own usage habits and how much time you spend with devices on.
It’s also important to note that not all devices are used at the same time, and some appliances have a higher consumption than others. You may want to prioritize the devices you want to be powered during the autonomy period, such as having a fridge on, or a device that you frequently use such as your phone charger.
It’s also essential to calculate power consumption during the different stages of your trip. For example, on a sunny day with your solar panels producing power you may use more power consuming appliances than on a cloudy day when you’re running your generator.
Keep in mind that it’s better to plan for a slightly larger electrical system than you think you’ll need, to ensure that you have enough power to run all of your appliances and devices, and to account for any unexpected usage or changes in your power needs
Autonomy
Another important factor to consider when determining the size of your electrical system is how long you want your system to be able to run without needing to be recharged. This is known as autonomy. The autonomy period can be affected by various factors such as the size of your battery bank, solar input, usage patterns and the power efficiency of your appliances.
The autonomy period is particularly important to consider as it will have an impact on the size of your battery bank and solar array. For example, if you’re planning to use your van for weekend trips, you may only need enough autonomy to last for a couple of days. In this case, a smaller battery bank and solar array would be sufficient. However, if you’re planning to live in your van full-time, you may need more autonomy to last for maybe up to a week without needing to be recharged. In this case, a larger battery bank and solar array would be needed.
When calculating autonomy, it’s important to consider the following factors:
· Power consumption: You should have an idea of the total power consumption and how many hours per day these appliances are going to be used.
· Battery capacity: Knowing the capacity of your battery, usually measured in amp hours (Ah) or watt hours (Wh), can help you estimate how long it will last, depending on your power consumption.
· Battery depth of discharge (DoD): This refers to the amount of energy that has been depleted from the battery and it’s commonly expressed as a percentage. The lower the DoD, the more cycles the battery will last, so it’s important to consider this factor when calculating autonomy. For example, if you want to ensure a long battery life, you may want to aim for a lower DoD, such as 50%.
· Solar input: If you’re planning to use solar panels as an input to your electrical system, you’ll need to consider how much solar power you can expect to generate during your autonomy period. This will depend on the size of your solar array, as well as the amount of sunlight you expect to receive. If you don’t have much space on your roof for solar yet you still want to travel off grid for a few days at a time you will need a larger battery bank as it wont be charged as often.
· Recharging options: You should also consider other recharging options available during your autonomy period, such as shore power or a generator.
By considering these factors and considering your own power usage and preferences, you can determine the size of your battery bank and solar array that is needed to achieve the desired autonomy period for your van conversion. Keep in mind that a higher autonomy will also require a larger and more expensive system, but it will also increase your flexibility and reduce the need to frequently search for charging options.
Battery type:
The type of battery you choose can also have a significant impact on the size of your electrical system. The most common types of batteries used in van conversions are lead-acid and lithium-ion batteries.
Lead-acid batteries are a traditional choice for van conversions and are relatively inexpensive compared to lithium-ion batteries. However, they also have a lower energy density, which means that you’ll need a larger lead-acid battery to store the same amount of energy as a smaller lithium-ion battery. They are also heavy, bulky and have a shorter lifespan. They have a lower depth of discharge threshold and requires maintenance such as equalization charging.
Lithium-ion batteries, on the other hand, are a newer technology and have a higher energy density, which means that they can store more energy in a smaller package. They are also significantly lighter and more compact than lead-acid batteries, which can be an advantage in a van conversion. They have a longer lifespan, higher depth of discharge threshold, and less maintenance requirements. However, they can be quite more expensive than Lead-acid batteries.
When considering which type of battery to use in a van conversion, it’s important to consider the following factors:
· Power consumption: As previously mentioned, you should have an idea of your total power consumption and how many hours per day these appliances are going to be used. This will help you determine how much energy storage capacity you’ll need.
· Space constraints: Since lithium-ion batteries are more compact, they may be a better option if you’re working with limited space in your van.
· Budget: As mentioned, lithium-ion batteries are more expensive than lead-acid batteries. You should consider how much you’re willing to spend on your electrical system and decide which option is best for you.
· Lifespan: Lithium-ion batteries typically have a longer lifespan and require less maintenance than lead-acid batteries, making them a more efficient and cost-effective choice in the long run.
In general, lithium-ion batteries like Bluetti and Victron are a better option for van conversions due to their higher energy density and longer lifespan, as well as their ability to function in a wider range of temperatures, however it’s important to weigh the cost and space trade-offs when making your decision.
By considering these three factors (Power consumption, autonomy, and battery type) you can determine the size of your electrical system, including the size of the battery bank and the size of the solar array. It’s also important to plan for some extra power to account for unforeseen usage and rainy days.
Remember that the most important aspect of calculating the size of the system is to make it tailored to your needs and plan for some contingencies and future developments.
Use this excel spreadsheet to help you calculate the size of power system that you will need to use:
Link to excel
Battery
Batteries play a crucial role in a van conversion’s electrical system, as they store the power that is generated by inputs such as solar panels or shore power and make it available for use when needed. They are important because they provide a reliable source of power when the van is not connected to an external power source.
There are several types of batteries that can be used in a van conversion, each with their own advantages and disadvantages. The most common types are lead-acid and lithium-ion batteries.
Lead-acid batteries are the traditional type of battery used in vehicles and are relatively inexpensive. They have a lower energy density compared to lithium-ion batteries and need more space, weight more and have a shorter lifespan. They are also less efficient and require more maintenance.
Lithium-ion batteries, on the other hand, are a newer technology and have a higher energy density, which means that they can store more energy in a smaller package. They are significantly lighter, more compact and have a longer lifespan than lead-acid batteries. They also don’t require maintenance, and they can function in a wide range of temperatures. They are more expensive than lead-acid batteries.
Another type of battery that is commonly used in van conversions is AGM (Absorbed Glass Mat) which are a type of lead-acid battery that utilizes a glass mat separator that absorbs the electrolyte, AGM batteries are sealed, which means they do not require any maintenance and can be installed in any position. They are also more efficient and have a longer lifespan than traditional lead-acid batteries.
When choosing a leisure battery for your van conversion, it’s important to consider your power consumption, the desired autonomy period, the available space, the budget and the maintenance requirements. A proper battery selection will depend on the individual needs of the van converter.
If you have the budget, I would recommend everyone to get lithium batteries for all the reasons stated above and they will be cheaper in the long term when you don’t have to replace them every few years.
Recommended batteries:
Bluetti B300 (only compatible with Bluetti AC300) (3072Wh)
Price Per Wh: £0.72
Check price here:
USA:
Victron LiFePO4 Battery 12,8V/100Ah Smart (1280Wh)
Price per Wh: £1.02
Check price here:
USA: Link to US site
Inverter
Inverters are an important component of an electrical system in a van conversion. They are used to convert the Direct Current (DC) power stored in batteries into Alternating Current (AC) power, which is the type of power that is used by most appliances and devices. In this way, an inverter allows you to use standard household appliances in your van, even when you’re not connected to an external power source.
There are two main types of inverters: modified sine wave and pure sine wave. Modified sine wave inverters are less expensive than pure sine wave inverters, but they also produce a less smooth and less accurate AC power. This can cause some appliances, such as sensitive electronics and appliances with motors, to run poorly or even damage. Pure sine wave inverters, on the other hand, produce a smooth and accurate AC power, which is identical to the power supplied by utility companies. This allows you to use all your appliances and devices without any issues, including sensitive electronics.
Another important feature of an inverter is its power rating, which is measured in watts (W). The power rating tells you how much power the inverter can supply at one time. You’ll need to choose an inverter with a power rating that is high enough to handle the power consumption of all the 240v (110v in the US) appliances and devices that you plan to use in your van.
It’s also important to consider the type of battery used in your system, as some inverters are designed to work with specific battery types such as Lead-Acid or LiFePo4.
Inverters are important in a van conversion because they provide a convenient and reliable way to use standard household appliances and devices while on the road. They allow you to have the comforts of home, such as lighting, heating, and cooling, and to cook and charge devices, even when you’re away from external power sources. Furthermore, by using a pure sine wave inverter, you can ensure that sensitive electronics and appliances run safely and effectively, avoiding any damage.
Overall, an inverter is a crucial component of a van conversion electrical system as it provides the necessary conversion to power all the appliances and devices, providing comfort, convenience and reliability.
Recommended inverters:
Bluetti AC300 (Only compatible with B300)
Check Price here:
US Price:
Victron Phoenix Inverter 12/3000 230V Smart
Check Price here:
US Price:
Shore hook up point
Shore power hook up, also known as “park power,” is a feature that allows a campervan or motorhome to connect to a source of electricity when parked at a campground or RV park. It is important because it provides a reliable and convenient way to power appliances and devices while the vehicle is stationary.
Shore power hook up typically consists of an external power source, such as a power pedestal at a campground, and a plug or cord that connects the campervan’s electrical system to the power source. The most common type of plug used for shore power hook up is the 120/240-volt AC, 30-amp plug (RV type). This plug can supply power to the campervan’s electrical system, which can then be used to power appliances and devices such as lights, air conditioner, microwave, refrigerator and even charge the leisure battery.
When designing an electrical system in a campervan conversion, it is important to consider the potential use of shore power hook up. If it is an important feature, it may be necessary to install a transfer switch or automatic transfer switch (ATS) in the electrical system. This allows the campervan to switch seamlessly between the shore power and the battery or generator power, preventing damage to the electrical system, appliances and devices.
Additionally, installing a voltage regulator and a surge protector will help to protect the electrical system and appliances from voltage spikes and surges that may occur when connecting to the shore power.
Having the ability to connect to shore power can be a valuable feature when planning a campervan conversion. It allows for the use of more power-hungry appliances and devices, providing more comfort and convenience while stationary. Furthermore, it can also be used to charge the batteries and run appliances while the vehicle is parked, which can save on generator fuel and provide more autonomy.
In summary, Shore Power Hook up is a valuable feature in a campervan conversion, it allows for a reliable and convenient way to power appliances and devices while the vehicle is parked and provides an alternative power source to the batteries and generators. Careful planning and installation of the appropriate components can ensure that the electrical system is protected and functions seamlessly when using shore power.
Recommended shore power hook up point:
Eazy 240v Plug & Play Electric Hook Up Conversion Kit – Black Inlet
AC charge controller
An AC to DC charger is an electronic device that is used to convert alternating current (AC) power from an external source, such as shore power or a generator, into direct current (DC) power that can be stored in the batteries of a van. It is an important component in a van’s electrical system because it allows the van to charge its batteries while connected to an external power source.
There are different types of AC to DC chargers available, but they all perform the same basic function of converting AC power to DC power and charging the batteries. Some chargers are designed to work with specific types of batteries, such as lead-acid or lithium-ion, and may have different charging algorithms for each type.
In summary, an AC to DC charger is an electronic device that converts AC power from an external source into DC power that can be stored in the batteries of a van. It is an important component of a van’s electrical system as it allows the van to charge its batteries while connected to an external power source. AC to DC chargers have different charging algorithms and stages, providing a safe and efficient way of charging the batteries. Built-in BMS also help in monitoring and protecting the battery during the charge process.
A lot of modern inverters are inverter chargers as well, meaning that they can charge from ac to dc when the shore power is plugged into the van. Therefore, we haven’t recommended any solo ac to dc chargers as both the Victron and Bluetti inverters act as both an inverter and a charger. This saves a lot of time and energy wiring and connecting these systems together. We would highly recommend you buy an inverter charger
DC to DC charger
In a van conversion, a DC-to-DC charger is an essential component of the electrical system that allows for the transfer of power from the starter battery to the leisure battery when the van is running. The starter battery is typically used to start the engine and power the vehicle’s electrical systems, such as the lights and radio, while the leisure battery is used to power appliances and other devices in the living space of the van.
A DC-to-DC charger is essentially a device that converts the DC power from the starter battery to the correct voltage and current needed to charge the leisure battery. This is done by using a process called voltage regulation, which ensures that the voltage of the power being supplied to the leisure battery is within a safe range for charging.
When the van is running and the alternator is generating power, the DC to DC charger transfers power from the starter battery to the leisure battery, keeping it charged and ready to use. When the van is not running, the leisure battery can be used to power appliances and other devices, allowing for off-grid camping and other activities.
In addition to providing a reliable source of power for the leisure battery, a DC-to-DC charger also helps to protect the electrical system of the van by preventing the leisure battery from being overcharged or undercharged. This prolongs the life of the battery and prevents damage to the electrical system of the van.
Overall, a DC-to-DC charger is an essential component for any van conversion, providing a reliable source of power for the leisure battery and protecting the electrical system of the van. Without one, the van’s leisure battery would not be able to be charged while the van is running, limiting the amount of time the van can be off-grid, and would have a shorter lifespan, which would result in more frequent replacement of the batteries.
Mppt Charge Controller
MPPT (Maximum Power Point Tracking) solar charge controllers are a type of device that are commonly used in van conversions to optimize the charging of the vehicle’s battery system using solar power. They are designed to efficiently convert the power from the solar panels into a form that can be used to charge the battery system.
When solar panels are connected to a battery system, the voltage and current that the panels produce will vary depending on factors such as the intensity of the sunlight and the temperature. A standard solar charge controller is only able to charge the battery system at a fixed voltage, which means that it may not be able to fully utilize the power that the solar panels are producing.
An MPPT solar charge controller, on the other hand, uses a technique called Maximum Power Point Tracking to constantly monitor the voltage and current that the solar panels are producing and adjust the voltage of the battery system accordingly. This allows the controller to charge the battery system at the highest possible efficiency, ensuring that the maximum amount of power from the solar panels is being used to charge the battery.
MPPT charge controllers also have built-in temperature compensation, which will adjust the charging voltage based on the temperature of the solar panels. This ensures that the panels are not damaged by overcharging and prolongs the life of the battery system by preventing overcharging or undercharging.
In addition to their efficiency, MPPT solar charge controllers also offer a number of other benefits for van conversions. For example, they can be used with a wide range of solar panel types and sizes, and they are often designed to be compact and lightweight, making them easy to install in a van.
Overall, MPPT solar charge controllers are an essential component for any van conversion that wants to make use of solar power to charge the vehicle’s battery system. They allow for maximum efficiency in charging, protecting the battery and solar panel from damage, and are easy to install, making them a versatile solution for van dwellers looking for a sustainable energy source.
Solar panels
Solar panels are an increasingly popular addition to van conversions, as they provide a sustainable and reliable source of power for the vehicle’s electrical systems. There are two main types of solar panels that are commonly used in van conversions: rigid and flexible.
Rigid solar panels are the traditional type of solar panel, and are made from a solid material, such as glass or plastic. They are typically more efficient and durable than flexible solar panels, and are able to withstand more severe weather conditions. They can be mounted directly to the roof of the van and are relatively easy to install. One of the downsides is that they are quite heavy and can be difficult to work with when trying to optimize the angle and positioning for the best solar exposure.
Flexible solar panels, on the other hand, are made from a flexible material such as plastic or rubber, which allows them to be bent or flexed without breaking. They are often thinner and lighter than rigid solar panels, which makes them easier to install and work with. They can also be mounted on various surfaces, like the roof or the side of the van, which allows for more flexibility in positioning them for optimal solar exposure. However, they are not as efficient and durable as rigid solar panels, and may not perform as well in extreme weather conditions.
When deciding on which type of solar panels to use in a van conversion, it’s important to consider the specific needs and constraints of the van, as well as the intended use. For example, if the van will be used for long-term travel and will be exposed to a wide range of weather conditions, rigid solar panels may be the better choice. However, if weight and space are concerns, flexible solar panels may be a better option.
Regardless of the type of solar panel used, it is important to have a proper charge controller such as MPPT (Maximum Power Point
Tracking) solar charge controller to optimize the charging of the battery system. This will ensure that the solar panels are charging the battery efficiently, and also protect the battery and solar panel from damage.
Another important factor to consider when installing solar panels in a van conversion is the size of the solar panel array. The size of the array will depend on the specific power needs of the van, as well as the available space for installation. A larger array will typically be able to produce more power, but will also take up more space. It’s important to carefully calculate the power needs of the van and the available space before deciding on the size of the solar panel array.
Overall, solar panels are a valuable addition to any van conversion, providing a sustainable and reliable source of power for the vehicle’s electrical systems. Both rigid and flexible solar panels have their own advantages and disadvantages, and the choice of which one to use will depend on the specific needs and constraints of the van and the intended use. It is important to consider the efficiency, durability, weight, space, and cost when choosing solar panels for a van conversion.
Shunt and Battery Monitor
In a van conversion, a shunt and battery monitor are important components of the electrical system that help to ensure the efficient and safe operation of the battery system.
A shunt is a device that is used to measure the current flowing in and out of a battery. It is essentially a large resistor that is connected in series with the battery, and it works by measuring the voltage drop across the resistor. This allows the shunt to measure the current flowing in and out of the battery with high accuracy.
A battery monitor, on the other hand, is a device that is used to monitor the state of charge of the battery, as well as other important information such as voltage, current, and temperature. It typically includes a digital display that shows the current state of charge of the battery, as well as other information such as the voltage, current, and temperature. Some battery monitors also include alarms that will sound if the battery is overcharged or undercharged.
When used together, a shunt and battery monitor work to provide a detailed understanding of the state of the battery system, allowing for efficient and safe operation. The shunt allows for accurate measurement of the current flowing in and out of the battery, which can be used to determine the state of charge and estimate the remaining battery capacity. The battery monitor, on the other hand, provides detailed information about the state of the battery, such as the voltage, current, and temperature. This information can be used to prevent overcharging or undercharging of the battery and prolong the battery life.
In a van conversion, it is important to have a good understanding of the state of the battery system, as this is the main source of power for the electrical systems. A shunt and battery monitor are essential components that allow for efficient and safe operation of the battery system, by providing detailed information about the state of charge and preventing overcharging or undercharging.
Overall, a shunt and battery monitor are key components in a van conversion electrical system, they allow for accurate monitoring of the state of charge of the battery, and prevent overcharging or undercharging, providing a reliable and safe source of power for the van’s electrical system.
Battery balancer
In a van conversion, a battery balancer is a device that is used to ensure that all of the batteries in the electrical system are being charged and discharged at the same rate. This is particularly important when using multiple batteries in parallel, as this can cause imbalances in the state of charge of the batteries over time.
A battery balancer works by constantly monitoring the state of charge of each battery in the system, and adjusting the charging and discharging of the batteries as necessary to ensure that they are all at the same state of charge. This is done by diverting some of the charging current from the overcharged batteries to the undercharged batteries, and also by diverting some of the discharging current from the over-discharged batteries to the under-discharged batteries.
Battery balancers are particularly useful for van conversions that rely on multiple batteries for their electrical systems. This is because, when batteries are connected in parallel, each battery will have different characteristics and will age differently, which will cause an imbalance in the state of charge over time. A battery balancer will help to prolong the life of the batteries by ensuring that they are all being charged and discharged at the same rate, which will prevent overcharging or undercharging of any of the batteries.
There are different types of battery balancers available, some are stand-alone devices, and others are built-in to battery management systems. Some of them can also be connected to a digital display to give you an overview of the state of each battery.
It is important to note that, while a battery balancer can help to prolong the life of the batteries, it is still important to keep an eye on the overall state of the batteries and to replace them when necessary.
Bluetti AC300 and B300 system
After reading about all the components that go into designing and building this electrical system in your van you might be feeling a little overwhelmed at the complexities of everything. And you will probably be asking yourself some of these questions: How will I connect all these components together? How will I size the cables correctly for each stage of the system? How do I integrate both an AC and DC circuit together in the same system?
Don’t worry we will help you answer these questions and guide you on designing this complicated system but before that I want to introduce you to a product that will eliminate a lot of the headaches that these electrical systems will cause you…
The Bluetti AC300 And B300’s
The Bluetti AC300 and B300 electrical system is a great option for van conversions and other off-grid applications. This system offers several benefits that make it a high-quality, easy, and quick solution for powering your van.
The Bluetti AC300 is a multi-functional device that is designed to be used in conjunction with the B300 batteries to create an off-grid electrical system. The AC300 is a combination of an inverter, a charger, and a MPPT charge controller all in one. It has a built-in inverter that can convert DC power from the batteries into AC power that can be used to power appliances and devices. The built-in AC-DC charger allows the system to charge the batteries using a standard AC power source, such as a generator or shore power. The built-in MPPT charge controller optimizes the charging of the batteries by constantly adjusting the charging voltage and current to match the batteries’ needs.
The B300 is a high-performance, portable and rechargeable lithium-ion battery that can be used to store energy for off-grid applications. It has a total capacity of 3072 watts, which makes it one of the most powerful portable batteries on the market. The B300 is designed to be highly durable and can withstand a wide range of temperatures and conditions. Multiple B300 batteries can be connected together to increase the total power storage capacity of the system.
One of the main benefits of the Bluetti AC300 and B300 system is its compact size and lightweight design. The AC300 and B300 are designed to be small and lightweight, which makes them easy to install and transport. This is especially useful for van conversions, where space is often limited, and weight is a major consideration. The compact design of the system allows for easy integration into your van without taking up too much space.
Another benefit of the Bluetti AC300 and B300 system is its ease of use. The system is designed with a user-friendly interface and automatic controls, which make it simple to manage and monitor your power usage. The AC300 also has a built-in MPPT charge controller, which automatically adjusts the charging voltage and current to match the batteries’ needs, ensuring the batteries are charged as efficiently as possible. This makes it easy to keep track of your power usage and ensure that your batteries are always charged and ready to use. You can link up your batteries and inverter via Bluetooth on Bluetti’s app and keep track of everything on your phone.
The system also provides an extremely large power output. The B300 battery has a power output of 3072 watts, and multiple batteries can be connected to increase the total power output up to 12,288 watts. This allows you to have a large power storage capacity which can be used to power a variety of appliances and devices.
The Bluetti AC300 and B300 systems are extremely easy to install. The system comes with provided cables that are already sized for the B300 batteries, which makes it easy to connect the batteries together and to the AC300 inverter. All you need to do is plug in the provided cables into the correct ports, making the installation process simple and straightforward.
In summary, the Bluetti AC300 and B300 electrical system is a great option for van conversions and other off-grid applications. The system offers a number of benefits such as a compact size and lightweight design, ease of use, high-quality power output, and easy installation. These features make it a high-quality, easy, and quick solution for powering your van.
However if this system doesn’t sound like your cup of tea and you don’t mind the added complexities of designing and building out your own system don’t worry, we’ll show you exactly what you need to install and what components connect with each other!
But first, here is a quick price comparison for those who are interested in Bluetti’s system.
Price of Bluetti compared to Victron system of similar quality
Bluetti AC300 + 2 B300s + D050S + 610Watts of Solar
DC – DC Charger compatible with system
Storage Capacity: 6144Wh
Inverter: 3000W pure sinewave inverter, 6000W surge output
Solar: 610W
Battery type: LiFePO4
Battery Life Cycle: 80% DoD 3000 cycles
Total Price of system: £6,756
Price Per Wh: £1.10
Victron system from Energy Monkey
Entire Kit Provided by Energy Monkey
Storage Capacity: 5120Wh
Inverter: 3000W pure sinewave inverter
Solar: 610W
Battery Type: LiFePO4
Battery Life Cycle: 70% DoD 3000 Cycles
Total cost of system: £8,546
Cost per Wh: £1.67
Now both kits are extremely high end and designed for use in van conversions that require a lot of power that is why they are rather expensive. You probably won’t need this much power especially if you plan on using a gas powered stove and hot water heater. But if you have worked through the power consumption spreadsheet and you do need around this much power storage then this might be a helpful comparison of what you’ll need to spend.
As you can see both of these examples are very similar in specification and quality (If you want to save more money you can find cheaper systems, but you will sacrifice quality). The Bluetti system in this example has a slightly larger storage capacity, but apart from that they are very similar and do the same job. You can save a lot of time, money and headaches installing the Bluetti system, but the choice is up to you.
There are still advantages to a normal electrical system. You can mix and match different brands, so you have a lot more flexibility than Bluetti’s battery system. This allows you to save money if you find good deals. You can add as much power as you’d like as well, you’re not capped at 12,288Wh (I can’t see how you’d need more than that mind you).
If you’d like to install a normal system I’ll show you in this next section how you can properly size your cables to make sure it is safe.
How to calculate cable size
Sizing your cables correctly is one of the most important steps to consider when designing your electrical circuit. If you size them too small then the current running through them may be too large and can cause a fire so it is imperative to get this correct. It is ok to oversize cables if you are unsure, it is not ok to undersize cables. If you have any concerns then I would urge you to speak to a qualified electrician on the matter.
You can use this simple formula to correctly size the cables all across your van conversion:
Cable size (mm²) = (Current (A) x Voltage drop (V)) / (Allowable Voltage drop (V) x Current carrying capacity (A/mm²))
The current (A) is the amount of electrical current that will be flowing through the cable. This can be calculated by adding up the power consumption (W) of all the appliances and devices that will be connected to the cable, and then dividing that total by the voltage (V) of the system.
The voltage drop (V) is the amount of voltage that will be lost as the current flows through the cable. It is affected by the length of the cable, the current flowing through it and the cable size. A common allowable voltage drop for most applications is 3%.
The current carrying capacity (A/mm²) is a value that represents the maximum amount of current that a cable of a specific size can safely handle. This information can be found in tables that are provided by cable manufacturers and are based on the temperature rating of the cable and the installation conditions. The most common type of cable used in van conversions are Automotive Cables, these are flexible, multi-stranded and protected with an insulation to handle the harsh conditions of a van life. These cables will have a current carrying capacity of around 30-40 A/mm² at 30°C (86°F) and 35-45 A/mm² at 70°C (158°F) ambient temperature.
It’s important to always consult the cable’s manufacturer documentation or consult a qualified electrician to confirm the current carrying capacity of the cables you plan to use, as well as to confirm which temperature rating applies to your specific situation and usage.
Keep in mind that this is just an example and there may be other types of cables and/or different situations and applications where the current carrying capacity may be different. Additionally, you may need to take into account other factors like cable routing, installation conditions and ambient temperature in your calculations.
By using this formula, you can calculate the appropriate cable size for your van conversion’s electrical wiring. You can always choose a cable size larger than calculated if you have the space for it or if you expect to have a higher current in the future.
Note that this formula is a general guide, and it’s important to consult the manufacturer’s specifications and follow the local regulations and codes. Always consult a qualified electrician if you are not sure of the calculations or if you feel unsure about the safety of your wiring.
How to connect cables and wires
Sizing and connecting lugs to cables correctly is crucial for ensuring a safe and reliable electrical connection. Improperly sized lugs or connections can lead to arcing, overheating, and even fires.
Here are some guidelines on how to properly size lugs and connect them to
different sized cables:
· Determine the correct size of lug for the cable: Lugs come in different sizes, and it is important to select the correct size for the cable being used. Generally, the lug should be no smaller than the cable it is connecting. For example, a 2/0 AWG cable requires a 2/0 AWG lug. It’s always recommended to consult with the manufacturer’s specifications to determine the correct lug size.
· Strip the cable: Carefully strip the insulation off the end of the cable to reveal the conductors. The amount of insulation to be removed will depend on the size of the lug and the type of connector being used. It’s recommended to strip no more than 1/4 inch of insulation for most applications.
· Insert the cable into the lug: Carefully insert the exposed conductors into the lug, making sure that they are inserted all the way to the bottom of the lug. The conductors should be straight and not twisted or damaged in any way.
· Crimp the lug: Once the cable is inserted, use a crimping tool to crimp the lug onto the cable. Make sure to use a crimping tool that is compatible with the type of connector being used and that the jaws of the tool are properly aligned with the lug. It’s recommended to use a hydraulic crimping tool for best results.
· Inspect the connection: Inspect the connection to ensure that the conductors are properly seated in the lug and that the lug is securely crimped onto the cable. Check that the connection is tight, clean, and free of any damage.
Complete build
Hopefully now you will know the following things: What each component in your electrical system does and how they work, which components you need for your own electrical system, how to correctly size the wiring for each part of your electrical system, how to correctly connect and size your lugs and cable connectors, and the size of the electrical system that you need in your own van conversion.
Now you need to know which components fit together with each other and which wire goes where. This is extremely important and will vary for each individual use case.
I will start by showing you the simple wiring diagram for the Bluetti system in a van conversion. But if you are not using bluettis system i will direct you to an extremely useful diagram designed by Faroutride.com It is extremely detailed and gives you everything you need to know about connecting up each individual component in your electrical system.
Bluetti Wiring Diagram
Because Bluetti’s AC300 integrates an inverter, MPPT solar charge controller, AC-DC charger all into one the wiring process is very simple. Simply plug each battery into the inverter, plug your solar cables from your solar panels into the correct port, and connect the power lead from your ac hook up point into the correct port on the AC300.
If you want to charge via your starter battery you can buy the optional D050S charger that plugs into your vans cigarette lighter.
To connect your outputs to this system it is also very simple. For your 12v appliances, run a positive and negative cable from your 30amp 12v output on the AC300 to a 12v fuse box. Connect an inline fuse on the positive cable that leads to the fusebox to be extra safe and fuse it at 30 Amps. Then connect up each individual appliance to this fuse box and correctly fuse each device.
For your AC outputs, simply wire on a plug to the end of each AC cable and plug them into the correct sockets on the AC300. It is that simple and that is why I love Bluetti’s AC300 and B300 system.
Complex wiring Diagram
Farout Ride have created an extremely detailed and useful wiring diagram for those of you who have opted for a traditional electrical system. It covers everything you need to wire and i would urge you to check it out on their blog:
Farout ride link: https://faroutride.com/product/wiring-diagram/
