Low Voltage Disconnect and Power Converter

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skyl4rk

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I have a SunSaver 20 charge controller with low voltage disconnect and am wondering if I can connect the load to my 120VAC to 12VDC power converter?  This is in a RoadTrek, with a stock power converter.  My goal is to use the low voltage disconnect to protect my batteries.  The power converter has my fusebox/breakers for AC and DC.

https://www.solar-electric.com/ss-20l.html

I am concerned if plugged into 120VAC, the power converter will try to charge the "batteries" through the solar charge controller.  Would this damage something?  I rarely plug into 120VAC, but would not want to connect two incompatible systems.  Perhaps I should buy a separate low voltage disconnect?
 
Makes no sense.

The SC output is DC only.

Converter (charger) produces DC output, but only from mains or genny AC.

OT but note the SC LVD section is also very limited amps.
 
I am talking about disconnecting the battery from the converter, and using the load from the solar charge controller to power the converter.
 
you could never plug the converter into 120vac. also what's the load limit on the solar controller? highdesertranger
 
20 amps is the rating on the charge controller load.
 
I do not understand what you are asking. A converter is powered by 120V AC current. It supplies 12 volt dc current to charge the battery and operate other 12 volt items. My inverter is powered by 12V DC current. It supplies a limited amount of 120V AC current for such other devices such as my microwave. There are combination converter/inverter. My controller takes DC current from the panels and provides adjusted DC current to charge my battery. Some do use the output from a controller directly to a DC load, such as a fan.
 
Yes rather than asking "what if" questions, first learn the basic functionality of what your different devices do.

Your SC does not output AC, only DC

DC cannot supply your converter, only AC.

Use the gear as it's designed, as you learn more, you can tweak things.

Yes separate LVDs **for DC consumers** can help protect your batteries.

Or put a big one on the bank itself, but they get expensive with greater ampacity.
 
I think the OP is talking about when you are not hooked up to 120vac the converter takes power from the battery to power the 12v loads in the house. they want to take the battery out of the loop and use the load of the solar controller in it's place. highdesertranger
 
Yes, good call, I think you're right.

Some converters include distribution / circuit protection panels that go between the bank and DC loads.

But I don't think the actual converter's electronics play any role actively stabilizing voltages etc, I believe those connections are just "pass-through" passive wiring infrastructure.

If that issue is what was indeed confusing the OP question:

Whatever loads you want to get cut off by the SC's LVD terminals, rewire them there instead.

Treat the DC wiring panels included with your converter as direct to the battery supply.

You have to make sure total amps does not exceed the SC's LVD limit.

And there are restrictions on what type of loads those terminals will support.

Standalone LVDs can give more flexibility and greater capacity, as outlined in my previous post.
 
skyl4rk said:
I am talking about disconnecting the battery from the converter, and using the load from the solar charge controller to power the converter.

Do you mean that you want to use the solar charge controller "load" output  to power all the loads that are currently connected with fuses inside the converter box? 

The converter box fuses are all in a row connected to the fat wires that go from the battery charger part of the converter box to the battery.  You may be able to disconnect the whole bunch of fuses and supply them with a new wire connected to the low voltage disconnect "load" output of the charge controller. 

Upon further review, the pictures in the Morningstar PDF files show a fuse on the minus side of the load output.  My cheap controller turns off the load by disconnecting the minus side so all switched loads have their minus wire run back to the charge controller.  That works.  With your loads already all connected to the battery minus directly this will be an obstacle if your solar controller works like mine.  The fuse on the minus side in the pictures may be an error or there may be text explaining, I didn't read all the documents. 

One way to determine this is to disconnect all wires from the charge controller then use an ohm meter.  If battery minus and load minus are connected, no problem.  If battery plus and load plus are connected (like they are with mine), problem.  Check with the ohm meter then reverse the leads and check again. 

The Morningstar PDF installation manual shows an optional chassis ground connection on the solar panel minus wire.  That means to me that your chances are better than 50 / 50 that it can work and that the minus side fuse means nothing.
 
So lets do some RV power 101 here.

A converter is powered by shore power or a generator. It takes 120 Vac and creates 12 volt power to supply the 12 volt loads in the RV ( pump, lights, control boards, furnace fan, exhaust fans, etc.) It also provides charging for the RV's battery bank. It can only raise the voltage so no LVD is needed in this instance. Off grid it sits idle.

The inverter takes 12 volt from the battery or solar and provides 120 Vac to the outlets that normally would be powered by plugging in to shore power or a generator. It has a low voltage disconnect built in not so much to protect the battery but because it can not function if the voltage of the battery gets too low.

The load terminals on the Solar charge controller can be set to turn off at a certain voltage and this IS to protect the battery. Load terminals provide 12 volt power and usually have low amp capacities. Outside of LVD to keep you from running your battery down there really is no advantage and it puts a extra job on the controller and may introduce heat doing so.

So off grid you can not use the converter plugged in to the inverter because it will drain the battery by trying to charge the battery at the same time. Power comes out of the battery, some is loss in the inverter creating 120 Vac, more is loss in the converter creating 12 volt to go back into the battery. It is a bad loop of out, loss, loss, in. The two losses will drain the battery. Also its purpose of providing 12 volt power is covered by the battery and solar charge controller all ready.

Using the load terminals to power a small inverter, (very small) would be better done with the inverter connected to the battery directly with a switch and fuse. This way it puts no stress on the controller and you can use any size that the battery can handle with the proper wiring.
 
Yes, the intent is to protect my batteries with the low voltage disconnect in the solar charge controller. I think the key issue is heat build up in the charge controller if high loads are being passed through the charge controller load. I want a simple reliable system, so the heat issue alone is enough for me to not use the charge controller low voltage disconnect for all 12V loads. It is rated for 20A load and would be fused for 20A but on a hot sunny day with a lot of solar power and a lot of DC draw, it might get too hot.

Someone mentioned a post about another low voltage disconnect, I did a search but did not find it. help?

I am now looking for a low voltage disconnect that can handle about 35 amps and can be installed between the battery and power converter (which is my 12V fuse bank). I need to check my power converter to see what it is rated. Probably 35A, but I need to check.
 
Okay, I am beginning to understand. You want to power the 12 volt loads of the RV from the bank which already happens now when you are off grid. All you need then is a LVD on the line running from the battery to the fuse box. The converter is on the fuse box but would not be in play.
 
I still don't under stand what you wish to do. Your solar controller will only feed the battery the controller's settings. There should be no difference if the battery is providing larger loads to your 12 volt devices. Your controller will supply 20 amps to the battery if the panels produce enough power, even if something is using 50 amps from the battery. If you have LiFePo batteries you need low and high voltage disconnects, but not if you have any lead acid chemistry. If you have LiFePo, don't use a cheap solar controller as a disconnect.
 
I think HDR had it right.

Where the OP mentions "my converter" substitute "DC distribution panel attached to my converter".

wrt LVDs, I would prefer to use voltage-adjustable ones and put smaller-amp ones on high-usage less-essential consumers, leaving lower-amp more critical devices running longer.

Also, there should be some delay, since large loads can pull voltages down temporarily even when the bank is still at a high SoC.
 
Here’s another take on it, I’ll try to describe things as simply as possible.
So go refill your coffee cup, make a sandwich, go to the bathroom, then sit down and get comfortable. This may be a long reply - [emoji23]

So let’s set this example - You have this RV. With its original standard power arrangement of:
120v plug to feed the 120v side of your power panel. The 120v a/c side feeds a set of circuit breakers (or fuses if your rv is really old). Those circuits feed the air conditioning, microwave, 120v side of refrigerator, etc. all your 120v sockets that were shipped in the rv as originally built.
In that “standard” arrangement there would be a “Converter” that is taking power from the 120v a/c source (it may be on its own circuit or possibly just on the same circuit as your 120v receptacles) it is almost always located in the power panel (Probably in the lower section). It’s job is converting the incoming 120v to feed 12v d/c output to the 12v side of the distribution panel to power all the 12v items in the RV while you are hooked to 120v shore power. This same 12v circuit in the power panel is also connected to the house batteries. This is keeping your 12v house battery (or batteries if you have more than one) topped off - or fully charged.
On a side note if your standard 12v converter is rated at 30 amps or 60 amps (either is a common size) but for my example we’ll use 60: then whenever you are on shore power and using your 12v systems at a rate of less the 60amps load which ever your system is rated at, it will continue to charge your house batteries. If you have a larger load that is over the rated converter output, say over 60 amps in this example , maybe your running every light, you have a 12v tv, your running water (and not hooked to shore water) so your pump is running - in other words, every 12v device is on. Then you may be using more 12v power (more amp draw) more than 60amps in this example or more than your converter is supplying.
Then in that scenario you will be also pulling from your house batteries at the same time to supplement the demand and not be charging your battery.
That is an extreme case but I just wanted to illustrate how your 12v standard system is charging while on shore power.

So far all a normal standard RV setup.

Now let’s add in the option of solar.
Let’s say you add 4 - 100 watt panels on the roof. You are boondocking (not plugged in to 120v) to power your batteries and 12v side of power panel.
You are running off your solar and battery bank.
Using the standard power conversion formula: Watts = Volts times Amps
Just like in high school algebra you can flip that around: Amps = Watts divided by Volts
So on a sunny day your 400 Watts of solar is putting out about 33.3 Amps of 12v power. 400 / 12 = 33.3
In this example you should have at least a 40 amp charge controller. (Always larger than the output of your solar array. Now your batteries are receiving 33 Amps (less any line loss in wiring or the power the charge controller needs to operate etc.) so you will likely be getting something less that 33 amps actually feeding your batteries and 12v side of power panel.
While in this sunny condition, you should be able to use 33amps of 12v power load and not drain batteries, again like above greater than the solar supply - at this point >33 and you would be pulling batteries down. Less than <33 and the surplus should be charging batteries. Any charge controller worth having will have a display showing this condition, usually by showing a + or - , or maybe a happy face when charging battery bank & frown when draining bank.
So now you want to power up a few of your 120v appliances. Maybe your laptop, phone charger, coffee pot etc.
You can use the same formula to size those loads.
1st off forget trying to run air conditioning, you would need an extremely large solar system and many batteries for that. Also any heating appliance will consume a lot of power.
So in order to power these 120v items while you’re out in the boondocks you will need an “inverter” that will take in 12v power from your battery bank and supply 120v power out for these devices.
Your inverter will also consume some amount of power itself for internal circuits while doing this conversion. (Remember it has to change over from direct current to alternating current so even if you don’t have anything 120v plugged or on, as long as your inverter is powered it’s using some small amount of power.

So if you have a 1000 watt inverter and you max it out, say you have your 400 watt coffee maker on, your 200 watt tv, computer using 100, and a 120v lamp, phone chargers, whatever (these numbers are not real) Just examples, but let’s say your using your full 1000 watt inverter power.
If you are powering 1000 Watts of load:
1000 divided by 12 = 83 Amps
Over twice (almost 3 times) the power being supplied by your solar array.
And that is just using straight math. Not taking into account line losses, transformer losses, start up surged (like for motors, like on a blender etc.).
AND you still have the other 12v circuits if on like your 12v pump, or lights, or vent fan etc. all also pulling power from your battery bank.
Per the Radarc electronics web site www.redarc.com you really should use a multiplier of .85 when sizing your inverter.
In other-words, use a 1000watt inverter for an 850watt load.

There’s a lot of math to consider when sizing your solar system.

Someone earlier addressed the issue of powering your standard rv “converter” from your inverter! Hopefully now it should be clear that if you tried to just power your 120v side of your standard rv power panel from your inverter, that you would create a power consuming loop whereas your inverter is transforming 12v to 120v while powering your converter that is taking 120v to convert to 12v to feed battery - all the while each device is consuming power itself! So through line losses and device consumption you are loosing!!!!

This not to say you can’t power your onboard 120v systems using your inverter, but you would need to eliminate (or disconnect) your converter from the system.
Most people take a simpler approach and just have dedicated 120v plugs that are isolated to just the inverter to eliminate potential crossover.

Another option: there are some solar charge controllers out there that can also receive a 120v input to charge batteries from shore power. If your charge controller was large enough ( say 80 amps maybe larger) then there would be the option to just eliminate the standard converter all together since it’s function could be replaced by your multi power type charge controller. This example assumes that you have a basic 60 amp converter. As long as your charge controller is big enough to power your needs on the 12v side of your power panel.
Naturally efforts to minimize that need would greatly help reduce 12v power requirements. Example replacing all your 12v incandescent lights to the way more efficient LED lights is a big step. Really nothing you can do about your water pump but the good thing is it’s intermittent. Running your refrigerator on gas while boondocking will make a big difference (the 120v part on an ammonia refrigerator is a heating element) remember heating devices like coffee pots, hair dryers, space heaters will all consume a lot of power, so anything you can remove from the inverter to gas will help use less power from battery bank or solar charge requirements.

One thing I’m not so sure about are the effects (good or bad) or potential problems if any about having 2 separate charging sources for your battery bank.
Like for example: your solar charge controller trying to charge your batteries while at the same time your standard rv system 12v converter is also trying to charge your batteries at the same time (assuming you have them all connected together).
Are there any consequences to this arraignment?

Comments welcome on that!

So now that this post is almost as long as a war & piece novel, I’m sure I still haven’t covered near enough. I’m sure there will be a few complaints or corrections or criticisms about my rant. And I always welcome those. Besides my fingers are getting calluses!

But hopefully this helps someone understand things a little better.



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Maybe diodes should be employed if your batteries are being charged by 2 sources?
Like your solar charge controller at the same time your plugged into shore power and 12v converter is also trying to charge batteries?

2 - 12v power sources at same time - comments welcome.


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