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Lithium Battery Installation

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fandj

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Lithium Battery Installation
« on: August 12, 2021, 04:20:52 pm »


To begin with let me say I have no financial interest in Lithium or any other type of battery supplier.

As most of you who have travelled very much in the last couple of years have no doubt seen is the increase in the number of people RVing and how it has in many areas overwhelmed the available supply of campsites.  This coupled with new Federal rules forcing many campgrounds to be reservation only has made serendipitous camping challenging.  I always enjoyed the ability of “first come/first served” to adjust your stay from one night to multiple nights if you found the area interesting and you needed more time to explore.  Also if I wanted to adjust my route on the fly there were no reservation systems that made it more difficult.

To enjoy the less structured mode of traveling has forced many of us to utilize boondocking on BLM and National Forest areas and campgrounds.  These frequently have little to no services available.  This has encouraged me to look at electrical power improvements for my PC.

While our Phoenix units have the ability to supply power directly and/or charge our batteries from the generator I for one despise the noise.  I am sure my neighbors like it even less than I do when running my generator.

My original two 6 volt Interstate flooded lead acid batteries were going on 6 year old.  While still functioning I could tell they were loosing some of their energy storage capacity.  I expected perhaps 1-2 years of remaining life albeit at reduced performance, which for the occasional user might have been fine.  Since I was planning a prolonged trip with no anticipated shore electrical service I started reviewing my options. 

I could replace with new flooded lead acid or the AGM lead acid but with little gain in terms of performance from what I originally had.  I could continue with my old somewhat compromised batteries for however long they may last.  It appeared Lithium Iron Phosphate was becoming more and more popular for RV and marine applications.  I researched this forum, YouTube, other RV forums, and Lithium battery vendor websites in attempt to better understand the requirements and the plusses and minuses for Lithium.  The Lithium Iron Phosphate chemistry is more stable than what is being used in electric propelled vehicles (Lithium-Nickel-Manganese-Cobalt) and is considered much safer.

For Lithium the number one hurdle for me was initial cost. When compared with AGM the Lithium cost typically runs about two to four times the initial cost per unit of rated energy storage capacity.  When compared to useable energy storage amp hours the Lithium costs about two to three times the cost of AGM.  The generally accepted guide for lead acid is to never discharge below 50% state of charge or battery life will be severely compromised whereas the full rated capacity for Lithium is typically stated as useable.  Like many other claims I am sure this is arguable.  Similar arguments on full recharge cycles are made.  Lithium’s are claimed to have a 3,000-5,000 cycle life whereas Lead acid is on the order of 300-500 charge cycles thus only about 10% of the charge cycle life.  If the Lead acid battery’s available recharge cycles was doubled the Lithium expected cycle life would still be three to five times greater.  Bottom line is it appears that Lithium can be competitive on a cost per kilowatt hour over the life of the competing technologies.

As to the need to upgrade ancillary equipment (converters, chassis to house battery charging, battery monitor, etc.) this needs to be evaluated on a case by case basis.  When I ordered my PC in 2016 I had a Progressive Dynamics 70 amp converter with Charge Wizard installed.  Discussion with both the Lithium battery and converter supplier said it was acceptable.  I previously installed a Victron battery monitor which also could be reused.  The PC supplied chassis to house charge system worked though slower to recharge than the Victron DC to DC converter that is often recommended.  I decided to give my PC installed system a try and reevaluate later based on my typical usage mode.  Phoenix I understand when supplying their Lithium option relies on their standard alternator charge setup.  So far while not optimum the PC system charges the Lithium batteries at a faster rate than the previous lead acid units.  I may upgrade in the future but at this point I doubt it being justifiable based on my travel/camping style.  So in my case no upgrading of the ancillary equipment hardware was required.  However the programming of the solar controller and battery monitor did require adjustment.  The battery supplier provided me with the new parameters for the programs.

After about a month and a half of camping without shore power I am very impressed with the Lithium batteries.  Faster charge time means running the generator very infrequently and for a shorter periods, more efficient use of my solar array system,  not being concerned that I need to get back to full charge everyday to prevent shortening battery life, not as concerned as to how much power I am consuming, no checking electrolyte level, more consistent voltage output, and hopefully longer battery cycle life (time will tell).

As to what I ultimately chose I went with two 100 ah 12 volt Battleborn Lithium Iron Phoshate batteries.  They provide 200 ah of useable power.  Being conservative I am not expecting to use the full capacity before recharge.  They weigh less than half the previous flooded lead/acid golf cart batteries and easily fit the original PC slide out  battery tray.  I had multiple conversations by phone and email with Battleborn and another popular supplier.  Battleborn batteries typically are premium priced.  I have found their technical and commercial service was first class.  The other popular supplier though cheaper I found was not very responsive and sorely lacking as to their technical support.  Battleborn is currently running a sale though still premium priced they are becoming more attractive for anyone that truly relies on their batteries to make RVing more enjoyable.  Battery technology is making major improvements in terms of performance and cost with more and more applications getting away from the dated lead acid designs and going to the new chemistries.  On the flip side if your RVing means going to campsites with electrical hookup or you and your neighbors don’t mind the generator noise it is tough to beat the initial cost of two 6 volt GC2 flooded lead/acid golf cart batteries sold at Sam’s Club for about $90 apiece.  It should also be pointed out that solar in the right conditions and/or frequent moves so as to allow the alternator to recharge the coach batteries can also minimize generator run time.

Initially at least for me there seemed an aura of complexity associated with the use of Lithium.  What I am finding is yes there are some unique requirements for Lithium but probably no more complex than the requirements to properly apply lead acid technology, just different.  If you are considering the Lithium option and are not familiar with Lithium requirements I recommend finding a reputable battery supplier with skilled application tech support that can and will guide you in the proper use of Lithium technology.

In conclusion there is no single “right answer” for every application.  Several factors need to be considered when choosing a battery system.

Sorry for the lengthy post but I hope this might be helpful to anyone needing for whatever reason to replace their current coach batteries.  I would also be curious what others that have already made the switch to Lithium have found.

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Ron Dittmer

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Re: Lithium Battery Installation
« Reply #1 on: August 12, 2021, 08:55:42 pm »
Hi fanjj,

It sounds like you have a sweet lithium situation with your 2016 PC with solar plus lithium-compatible on-board charging.

We have always sought primitive camp grounds for the wilderness experience as well as dramatically lower camping fees.  With our 2007 2350, we struggled in such places with two 12V wet acid batteries.  I looked into two 6V lithium batteries but the cost of the batteries along with the required change of our on-board Tripp-Lite converter/inverter, was enough deterrent to go with lithium.  As you recall, I ended up with two 6V AGM batteries that work with our reconfigured Tripp-Lite along with modifying the battery compartment for fitment.  Another improvement with battery reserves was converting all our incandescent and florescent lighting to LED.  But still with all I had improved upon, we still need to run the generator for 1 to 1.5 hours per day when the PC stays parked for a 24 hour period with no plan to drive the rig.  And that is with us out all day long in our tow vehicle, not hanging around the campsite using more energy.

So I surely understand your effort and investment in changing to lithium technology and are pleased with the results.  Thanks for sharing that.
« Last Edit: August 14, 2021, 04:53:49 am by Ron Dittmer »
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donc13

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Re: Lithium Battery Installation
« Reply #2 on: August 12, 2021, 09:16:12 pm »
For what it's worth, I replaced the 2 6v wet cell interstate batteries with 2 Lifeline 4CT 6v AGM Deep Cycle batteries.   220 amp hours and no changes to my stock converter.   They fit the battery tray just fine.

I am very happy with them, at the time, they were $300ea delivered.
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Ron Dittmer

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Re: Lithium Battery Installation
« Reply #3 on: August 13, 2021, 12:56:42 am »
For what it's worth, I replaced the 2 6v wet cell interstate batteries with 2 Lifeline 4CT 6v AGM Deep Cycle batteries.   220 amp hours and no changes to my stock converter.   They fit the battery tray just fine.

I am very happy with them, at the time, they were $300ea delivered.
I believe 6V batteries, whether wet acid or AGM will have the same physical height.  In my case, I was changing from 12V to 6V.  The only solution to gain the required additional height for the 6V was to replace the battery tray with a flat plate.  Doing so made it impractical to check fluid levels, so installing sealed AGM batteries was an easy decision.  Fortunately our 2007 Tripp-Lite converter/inverter has a setting for AGM batteries.  When driving, the E350 chassis alternator also seems to charge them effectively.
« Last Edit: August 14, 2021, 04:50:54 am by Ron Dittmer »
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mikeh

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Re: Lithium Battery Installation
« Reply #4 on: August 13, 2021, 08:31:06 am »

Sorry for the lengthy post but I hope this might be helpful to anyone needing for whatever reason to replace their current coach batteries.  I would also be curious what others that have already made the switch to Lithium have found.


fandj---

Thanks a lot for your well-crafted post describing your analysis and experience transitioning to the lithium setup.  That type of detailed first-hand information from a fellow PC owner is very helpful to someone that might be considering such a move.  My own factory AGM/Progressive Dynamics/solar/Bogart TriMetric system is only 2.5 years old, and works flawlessly.  But.....tack another 3 years onto that and I'll be at the same point from where you started your debate.  Hard to imagine that I won't want to strongly consider making the change given the several advantages of lithium technology.  Given my existing equipment, your experience tells me I can likely do that by just ponying up the extra money for the batteries, and making some adjustments.  Thanks again for taking the time to outline your experience.

Mike

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donc13

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Re: Lithium Battery Installation
« Reply #5 on: August 13, 2021, 03:04:37 pm »
I can't tell you about the newer models, but my 2015 1800 watt inverter will auto shutoff if voltage (from batteries) drops too low (below 11v I *believe*).  Which means your TV outlets will shut off, but other 12v things should keep going for a bit longer.

I don't believe that would be an issue with lithium batteries as my understanding is their voltage doesn't drop much until they are almost depleted.
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fandj

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Re: Lithium Battery Installation
« Reply #6 on: August 13, 2021, 03:56:24 pm »
I have noticed in actual use the voltage changing very little with use in contrast to my previous lead-acid batteries.  As you state this is an advantage where inverters shutdown if the voltage drops too low.  This is a percent charge vs resting voltage chart supplied by Battleborn which also shows this.

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mikeh

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Re: Lithium Battery Installation
« Reply #7 on: August 13, 2021, 04:28:20 pm »
Hadn't seen that chart.  Huge difference from the lead-acid profile, flooded or AGM!  Definitely another point for the lithium!
« Last Edit: August 13, 2021, 04:33:42 pm by mikeh »

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Engineerlt

Re: Lithium Battery Installation
« Reply #8 on: August 13, 2021, 06:46:17 pm »
You said that you haven't installed a DC to DC converter yet. If I remember correctly the alternator voltage regulator will be put to its maximum charging state when charging the lithium batteries. The lithium batterie's accept a higher amperage charge then lead acid achieving the short charging time. So I believe that the voltage regulator of the alternator will have a considerable shortened life expectancy. I believe it has something to do with the low internal resistance of the lithium batteries.

I have been slowly changing my electrical system so I can use lithium batteries as well. I have the Victron monitor, my converter is a WIFCO 9855, which has a charging profile for lithium batteries. I removed my battery compartment tray and increased its size for a single 8D battery. I am currently using an 8D AGM with 250 AMP Hour rating.   Battle Born has recently introduced there 270 amp hour 8D replacement battery. There are a couple other battery manufacturers saying there 8D batteries are over 400 amp hours. I am not so sure that those manufacturers claims are accurate. I do know that the industry is working hard to make the 8D size battery for commercial vehicles, which will be a large source of revenue.

If you were to install a DC to DC converter which one would you chose and what amperage rating?  I am very curious to know if you have noticed any charging issues when the alternator is charging. Curious to know if there is any increase in physical temperature above what it was before the lithium battery install. I wish you the very best and maybe one day I will get off my wallet and do the lithium conversion.

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fandj

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Re: Lithium Battery Installation
« Reply #9 on: August 13, 2021, 07:32:29 pm »
I agree the internal resistance of the Lithium batteries are significantly less than Lead-acid units.  I too was concerned about overloading the Ford alternator and electrical system.  On my 2552 I measured the resistance of the charging wire, etc. that Phoenix installed initially and found it significantly limits the amount of current that can be carried to the coach batteries at a given voltage drop.  My alternator appears to max out in the 14.2 - 14.4 volt range.  The Lithium batteries would be about 13.1 - 13.3 volts so the delta V would maybe as much as 1.3 volts.  Whatever voltage loss in the wiring, etc. further reduces the emf potential. The small wire PC installed significantly limits how much current that will flow into the coach batteries.


I have measured the current a couple of times and it varies but it is about 10 amps which is fairly small in relation to the alternator.  I am not positive but I think the Ford alternator rating is about 140 amps.


If I find I would need to upgrade to a DC to DC charger (which I doubt) I would probably go with the 30 amp Victron.  I have found the Victron equipment reliable and it also is the unit Battleborn recommends. If I did that I would rewire from the chassis battery/alternator to the DC to DC charger with probably a 6 awg wire.


If I am missing something in my approach I would certainly like to be made aware before I damage my alternator.  I am comforted to a degree that Phoenix apparently has installed Lithium batteries without the DC to DC charger. I am not aware of any alternator issues this may have caused. 

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Engineerlt

Re: Lithium Battery Installation
« Reply #10 on: August 14, 2021, 08:17:38 am »
Great to know information, I really appreciate your response.  It seems you have dove into this further than I have and will help me proceed further in my installation. Thanks for your post and great explanation. Happy travels and hope you are enjoying your PC as much as I am.
Very Respectfully
Lance

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fandj

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Re: Lithium Battery Installation
« Reply #11 on: August 19, 2021, 10:30:47 am »
Hi fanjj,

It sounds like you have a sweet lithium situation with your 2016 PC with solar plus lithium-compatible on-board charging.

We have always sought primitive camp grounds for the wilderness experience as well as dramatically lower camping fees.  With our 2007 2350, we struggled in such places with two 12V wet acid batteries.  I looked into two 6V lithium batteries but the cost of the batteries along with the required change of our on-board Tripp-Lite converter/inverter, was enough deterrent to go with lithium.  As you recall, I ended up with two 6V AGM batteries that work with our reconfigured Tripp-Lite along with modifying the battery compartment for fitment.  Another improvement with battery reserves was converting all our incandescent and florescent lighting to LED.  But still with all I had improved upon, we still need to run the generator for 1 to 1.5 hours per day when the PC stays parked for a 24 hour period with no plan to drive the rig.  And that is with us out all day long in our tow vehicle, not hanging around the campsite using more energy.

So I surely understand your effort and investment in changing to lithium technology and are pleased with the results.  Thanks for sharing that.


Ron,   I made an effort shortly after taking delivery of my PC to determine the sources and the amount of power each appliance and accessory required.  While my PC came with LED lights I found that some of them put out too much light and consequently required too much power. On these I replaced the light switch and one of the “bulbs” in each fixture with a lower output size.  This enabled me to select a still very bright light or a moderate amount of light.  At the lower setting I reduced the power draw by about 75% from the OEM configuration.


I installed a Victron battery monitor that provided a very accurate measurement of the amount of power going into or coming out of the battery.  This enabled me to not only measure how much power each item required by turning them on an off and checking the monitor but it also was helpful in tracking down “phantom” power users when I thought everything was turned off.


So like you I think optimizing your power system when living “off grid” comes down to knowing how much available power you can store, how much power you can produce (generator, solar, etc.), and where and how much power is being consumed.

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Re: Lithium Battery Installation
« Reply #12 on: August 19, 2021, 02:46:07 pm »
FANDJ- what are your solar array and charge controller specs? Whats the average battery level in the morning, and how long does it  take to fully charge a 200ah Li-ion battery bank?
TIA
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fandj

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Re: Lithium Battery Installation
« Reply #13 on: August 19, 2021, 04:31:45 pm »
CalCruiser,
I have a Victron 100/30 controller connected to 4 panels with a max theoretical output of 520 watts.  Since I installed the Lithium batteries I have been staying in sites that are partially tree shaded.  Also I expect the heavy forest fire smoke also hinders the solar output. My typical maximum solar array output has been less than 300 watts.  My morning state of charge will be 80 - 85% which will be replenished by about noon or earlier.

I recently added two 100 watt panels to my original two 160 watt panels for a total of 520 watts.  I did that knowing I didn’t need 520 watts but with several years of experience I realized because of shading and inclement weather, low sun angle, etc. my actual average output would be significantly less.


With relatively limited experience with the 4 panels I think I will be fine but time will tell.  I had tentatively planned to add the two 100 watt panels prior to the Lithium install.  However what I was seeing with the higher internal resistance of the lead acid units was the batteries would not accept all the power being put out by the 320 watts during the peak solar production mid day time period so I usually could, but not always bring the batteries up to 100% state of charge.  In essence the batteries/controller was throttling the output of the array. 


I hope that answers your question.  I am still learning myself with the Lithium batteries and the added solar array capacity.
« Last Edit: August 19, 2021, 04:43:44 pm by fandj »

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Re: Lithium Battery Installation
« Reply #14 on: August 19, 2021, 05:38:51 pm »
Thank you. That’s exactly what I wanted to know  2o2

I purchased  a 40A MPPT controller and 2 180W mono-crystalline panels. For now the goal is  not rushing back to the rv  at 5pm to run the generator for 2 hrs before curfew.  I  spec’d a 40A controller so I could add more panels later, so it’s good to know that lead acid batteries can’t fully utilize all of the available charging capacity.

Where are you running into heavy smoke? I am seriously considering cancelling our plans for Lake Tahoe if conditions don’t improve next week.
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