Photography – Cameras, Gear, Tips and Resources

Note: This page was written in 2016 and reflects the gear we used and what was on the market at that time. Our current gear is all professional quality and includes Nikon Z8 and Nikon D850 camera bodies, Nikon lenses, Nikon polarizing filters, Really Right Stuff tripod legs, Benro tripod legs, Sunway Foto table top tripod legs, Really Right Stuff ball heads and Wimberly gimbals, Think Tank camera backpacks, 14 inch Apple Macbook Pros with M2/Max CPU 64 GB memory and 4TB internal drives, and SanDisk G-Raid external hard drives for backups and archiving. We still highly recommend the resources we used for learning photography and post-processing described further down the page.

Since we began our full-time RV travels in 2007, photography has become a huge part of our lives. Photography is an ideal hobby for travelers, and it isn’t hard to learn. Our learning curve has played out on the pages of this website, and it is satisfying to see our improvement over the years. When we first started traveling, we each shot about 6,000 photos per year. Now we each shoot over 35,000 photos per year (a little under 100 per day per person!).

Camera on a tripod - photography

Photography is a lot of fun, and it’s not hard to learn.

People have asked us what cameras and equipment we use, and how we improved our skills. This page presents all of our gear choices over the years, from our camera bodies to our favorite lenses to our filters and tripods to the goodies we use to take our cameras out for a hike to the software we rely on for post-processing.

It also explains how we organize all our photos and lists all the books, eBooks and online tutorials we have studied to learn to take better photos. We are entirely self-taught, and the inspiring resources we reference here lay it all out in plain language.

We’ve invested in our camera equipment because photography is our passion and we do it all day long. What you’ll see here is our progression through good solid “value” gear, from the “entry level” gear we started with to the more professional quality gear we use today.

For easy navigation, use these links:

The best time to buy camera gear is during the lead up to Christmas or when a manufacturer discontinues a camera model. An inexpensive but good quality DSLR is the Nikon D3400 camera which is available in kits with one or two lenses, camera bags, filters, etc., here

CAMERAS and LENSES

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Our Current Cameras and Lenses

As of 2018, we both shoot with Nikon D810 cameras. This is a professional level, truly awesome, full-frame 36 megapixel camera. We use these primarily for landscape shots.

We also both have Nikon D500 cameras which are crop-sensor 20 megapixel cameras that can shoot 10 frames per second, ideal for fast moving objects like wildlife and our adorable puppy.

Prior to these cameras, we both used Nikon D610 cameras. This is a full-frame, 24 megapixel camera. It is considered a “pro-sumer” camera, not quite professional quality but at the high end of the hobbyist ranks.

Although we have a big collection of lenses, we typically take no more than two apiece with us when we are out and about on foot. It’s just too much stuff to lug around!

I have a Nikon 28-300 mm lens on my camera which I use almost exclusively, simply because I love the flexibility of having both wide angle and zoom options with the twist of my wrist without having to change lenses.

Photographer with camera tripod in the water

When we got into photography, we jumped in with both feet.

Mark likes to pick a lens for the day and work within its limits. His favorites are prime (non-zooming) lenses, and he uses the Nikon 50 mm and Nikon 85mm lenses a lot. These are a lot less expensive than zoom lenses, and they are much faster lenses too (meaning they can be used in lower light). However, they do not have vibration resistance (also known as “image stabilization”), a technology that reduces the inherent wiggle caused by hand-holding a lens.

He also uses the Nikon 24-120 and the Sigma 24-105. These are very similar lenses, and we would have just one of them, but I used to use the Nikon 24-120 all the time before I got the Nikon 28-300, so he got the Sigma 24-105 to have one with a similar range. They’re both terrific lenses, so we can’t decide which one to keep and which one to sell!

We have a Nikon 70-200, which is a truly beautiful lens. For a long time neither of us used it much, but after I commented to that effect when I first published this post, Mark put it into his regular arsenal and uses it frequently now. It is a fabulous lens with excellent color rendition. Another advantage is that the zoom feature doesn’t lengthen or shorten the lens — it is always one length and all the zooming is physically done inside the lens. This means that dust doesn’t sneak into the lens when it is zoomed in and out the way it does with other lenses (like the 28-300, 24-120 and 24-105 mentioned above).

For wide angles, we have a Nikon 16-35 and a Nikon Nikon 18-35 so we can each shoot very wide angles simultaneously. Mark LOVES wide angle photography, and he uses these all the time. The 16-35 is more expensive, and was purchased as an upgrade from the 18-35, but he can’t seem to part with the 18-35 now, so I inherited it.

For super wide angles like at Horseshoe Bend in Arizona or for shooting stars at night (like the final image in this post or the first image in this post), we turn to the Rokinon 14 mm lens (with the Nikon focusing chip) or our very cool fisheye lens, the Rokinon 12 mm lens.

A few years back we bought a Tamron 150-600 mm G1 lens for shooting birds (like wild peach faced lovebirds here) and for wildlife — or even for stationary cacti at a faraway distance as in this image here. We loved this lens so much we bought the upgraded Tamron 150-600 mm G2 lens. While we got lucky with the first one and it worked great right off the bat, we had to send back our first copy of the G2 and get a replacement because it didn’t focus well. Now both lenses are awesome. Frankly, if you are picky about testing the lens to make sure you have a good copy, we find we are getting just as good pics from the older G1 lens as from the newer G2, so you might save a few bucks and get the G1. We used both lenses as well as the Nikon D500 and the Nikon D810 to capture the eagle and moon images in this post: Magical Moments in the RV Life.

An alternative to this lens that is priced similarly is the Sigma 150-600 contemporary series lens. Another awesome option that has become available since our purchase is the Nikon 200-500 mm lens.

What about those third party lenses?? Some are better than others, although Sigma’s Art Series lenses are really great these days (and expensive). When I was casting about for a “do it all” lens, we initially bought a Tamron 28-300 mm lens. It had terrible color rendition and didn’t focus for beans, so we returned it to buy the Nikon 28-300, which I totally love.

Our Past Cameras and Lenses

Do you need all this crazy stuff when you first get started? No!

When we began traveling, we purchased two Nikon D40 cameras, which were 6 megapixel crop-sensor cameras. Each came with a Nikon 18-55 mm lens, and we got a Nikon 55-200 mm lens for distance. This was a great camera model to learn on, and we published five magazine cover photos taken with it.

Coast to Coast Cover Spring 2012

Do you need to spend a bundle on a camera? No!
I took this photo with a Nikon D40 that you can buy today (used) for $100.

The Nikon D40 (and its modern day equivalent Nikon D3400) are “crop sensor” cameras (or “DX” in Nikon lingo). This means the sensor is smaller than on a “full frame” camera (like our current Nikon D810 cameras which are “FX” in Nikon lingo). This, in turn, means the image quality is slightly lower and if you blow up the image to poster size it won’t look quite as good up close.

The D40 was discontinued long ago, but can be found on Craigslist and eBay for $100 with two lenses. One that has been lightly used will work just as well now as it did years back.

How do you tell how “used” a used camera is??

If you have a Mac, an easy way to find out how many shutter clicks a camera has is to take a photo, download it to your computer, export it or locate it in the Finder, and open it in Preview by double clicking on it. Then click on Tools > Show Inspector, click the “i” button and then the “Exif” button. The Image Number is the number of shutter clicks the camera has on it. This works only for cameras that have a mechanical shutter, not for pocket cameras with an electronic shutter.

My only frustration with the Nikon D40 was that there was no built-in cleaning system for the camera sensor, so every time we changed lenses the sensor was vulnerable to picking up dust — and it did! We used the Nikon D40 cameras fro 2007 until 2011.

Today’s “equivalent” entry level DSLR is the Nikon D3400. It is a 24 megapixel camera that is far more sophisticated than the D40 and not “equivalent” in any way except the price point. If you want to get it in a kit with multiple lenses, filters, camera bag, tripod, etc., there are lots of kits here.

The Tamron 150-600 lens can be hand held

The Nikon D610 and Tamron 150-600 mm lens.
I’m in camo to keep from scaring the birds away.
Think it will work when I point this huge scary lens at them? Not!!

In 2011, we upgraded to the Nikon D5100, a 16 megapixel crop-sensor camera. Like the Nikon D40, this camera was also a “crop sensor” or “DX” camera. It came with a Nikon 18-55 mm lens. We got a Nikon 55-300 lens, and I ran all over Mexico with both of those lenses, switching back and forth all day long.

In hindsight, I should have gotten the Nikon 18-300 lens and spared myself the hassle of carrying a second lens and switching lenses all the time (I missed so many great shots because I was fumbling with the camera!). But I had read some iffy reviews of the first edition of that lens and decided against it (the current model is its 3rd generation and I’ve met people who LOVE this lens. Oh well!).

The best thing about that camera was the built-in sensor cleaner. Living in the salty and dusty environment of coastal Mexico, this was huge. The other fun thing about that camera was the flip-out display on the back. You could put the camera in Live View, then set it on the ground or hold it overhead and still see your composition on the back of the camera.

We used the Nikon D5100 cameras from 2011 to 2013. The Nikon D5100 has been discontinued. Today’s “equivalent” level DSLR is the Nikon D5300. It is a 24 megapixel camera that, again, is far more sophisticated than the predecessor that we had. This is an outstanding “intermediate” camera and can be purchased in a Nikon D5300 camera and lens bundle.

If you have a few more dollars to spend, the Nikon D7200 is even better. It is still a crop sensor camera, but it is very sophisticated. Like the others, if you are starting out, getting a Nikon D7200 Camera and Lens Kit is very cost effective.

Pocket Cameras

Sometimes carrying a big DSLR camera is inconvenient. We both like having a pocket camera for times when a DSLR is too big.

I use an Olympus Tough TG-4 camera when I ride my mountain bike. I used its predecessor when I snorkeled in Mexico too.

This camera is very rugged. The bruises it has given me on my backside are proof that it holds up a lot better than I do when I fall off my bike and land on it. I like it because the lens doesn’t move in and out when it zooms, and you can drop it and not worry about breaking it. Here are a bunch of photos it took: Bell Rock Pathway in Sedona Arizona.

Mark has a Nikon Coolpix A that he is nuts about because it is just like a mini DSLR. He doesn’t do crazy things like take photos while riding his bike one handed the way I do (and he’s less prone to falling off), so he doesn’t mind having a more delicate camera in his pocket. It is a 16 megapixel camera that has most of the features of a the Nikon D610, except it is a crop-sensor camera that has a fixed 28 mm lens that can’t be changed. It has been discontinued.

Prior to that, he had a Nikon Coolpix P330 (also discontinued). It could shoot in raw format, which was the reason he chose it, but it didn’t produce nearly the quality images of the Coolpix A.

Lots of folks use a smartphone for all their photo ops or as an alternative to their DSLR. We don’t have a smartphone, but we have used a lot of them at scenic overlooks when groups of people pass their cameras around to get pics of themselves. One thing we’ve noticed is that there is a big difference in dynamic range (the rendering of bright spots and shadows) between Androids and iPhones, with iPhones being much better. This is probably common knowledge and not news to you at all, and it may be partly due to which generation of smartphone a person hands us to get their portrait taken.

 

ADDITIONAL PHOTOGRAPHY EQUIPMENT and ACCESSORIES

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Batteries – We have two batteries for each of our cameras, so we each always have a fully charged battery on hand besides the one in the camera. We’ve found the Watson batteries are a good alternative to the more expensive Nikon batteries. My Watson battery died shortly after the manufacturer’s warranty expired, and I was impressed that they honored it anyway and replaced it for me. However, note that the Nikon D500 camera can’t use third party batteries, so you have to spend the bigger bucks on a Nikon brand EL-15 battery for that camera.

Memory Cards – We also have two memory cards in each camera (the Nikon D610, D810 and D500 all have two card slots in them). We use Sandisk brand for all our memory cards. We like the SanDisk “Extreme Pro” 95 MB/second SD cards. We like these fast SD cards because when we start shooting in a burst (holding the shutter down and letting the camera take pics as fast as it can — for instance, when a bison jumps over a fence in front of us), the faster the card can be written to, the faster the camera’s internal memory buffer will empty, and the longer the camera can keep shooting at top speed. Faster SD cards are also faster when downloading photos to a computer. Our Nikon D500s use Sandisk XQD cards and our Nikon D810s use Sandisk CF cards.

Every evening we download all our photos onto our laptops and reformat the memory cards in the camera. We’ve heard that this reduces the chance of the card failing and losing all our photos (which happened to me once long ago with a Kingston card – ugh!).

The Hoodman Loupe – A Game Changer! The Hoodman Loupe revolutionized our photography because we were suddenly able to see our photos clearly on the back of our cameras and then retake the photo if necessary. The loupe fits over the LCD screen, blocking the glare and magnifying the image. The lens is adjustable, so no matter how good or bad your eyes are, you can adjust it until you can see the image perfectly clearly. We have the original hard sided loupe. A new model collapses down so it can be stored more compactly. In a lot of the photos of me on this website, you can see my Hoodman loupe hanging around my neck!

Hoodman Loupe on a Nikon D610 Camera

The Hoodman Loupe lets you see the image on the back of the camera clearly, adjusted for your eyes, and without glare.

Battery Grip – Mark occasionally uses a Vello Battery Grip on his camera. This grip can hold extra batteries and also makes it possible to take portrait oriented shots (vertical images) while holding the camera as if it were upright rather than twisting your right arm over your head. Mark absolutely loves his. I use mine only occasionally because I can’t use it with my tripod L-bracket (see below).

Camera Straps – We replaced the standard Nikon camera straps with the Optech Pro Strap. This strap is thick and cushy and is slightly curved to fit the curve of your shoulder. It also has quick release clasps so you can easily unclip it from the camera when you’re using a tripod.

 

LENS FILTERS

For a long time we preferred the B+W brand for all our filters, although we’ve used a lot of Hoya filters over the years too. We’ve also tried Tiffen filters, but find they are hit-and-miss. Often, if a “lens deal” includes a filter with the lens, it’s not a great one. Most recently, we have begun buying Nikon filters which seem to be the best quality all around. Just be sure you get the right size for your lens (52 mm or 77 mm, etc.).

Camera UV Filter, Polarizing Filter and Neutral Density Filter

UV filter (top), Polarizing filter (left) & neutral density filter (right)

UV Filters – We have UV filters for all our lenses to provide protection for them.

Polarizing Filters – We also have polarizing filters for all our lenses. A polarizer makes it possible to enhance the colors or reduce the glare in certain lighting situations. It is best around midday and has less effect at dawn and dusk. It is wonderful around bodies of water and for removing the dashboard glare on the windshield when taking photos from inside a car. A polarizer adds a lot of contrast to an image, however, so while it can enhance a landscape beautifully, I’ve found it makes street photography of people too contrasty.

Graduated Neutral Density Filters – We occasionally use a graduated neutral density filter when the sky is very pale and the scene we are shooting is dark. This kind of filter is half colored and half clear. By twisting it so the colored part lines up with the sky and the clear part lines up with the darker landscape, the sky and landscape come out more evenly exposed. They are also very helpful for sunrises and sunsets.

Neutral Density Filters – When shooting moving water, a neutral density filter darkens what the camera sees enough so the shutter speed can be increased to show silky movement in the water without it being blown out and all white. These filters are also helpful if you want to use a very big aperture (small “F number”) to blur out a background and the camera’s top shutter speed isn’t fast enough to get proper exposure. These filters come in different degrees of darkness. A 10-stop filter is good for shooting a waterfall in broad daylight while a 4-stop filter is good for the same scene at dawn or dusk. We had fun with moving water photography at Watkins Glen in Upstate New York, the Blue Ridge Parkway in N. Carolina, and Great Smoky Mountains National Park in N. Carolina.

Lee Filter System – Mark also uses a Lee Filter System and loves it. This is a multi-part system of square filters that can be placed on any camera lens. You need the Lee Foundation Kit, an adapter ring sized to your lens and some filters. The advantage of this system is that for graduated neutral density filters you can position the transition point between light and dark. So, if you are shooting a sunset and have very little land and lots of sky, you can darken the sky and lighten the land even if the horizon is just above the bottom of your photo. Likewise if you have a bright sky and a dark hillside – you can rotate the filter so the transition is on an angle and not a horizontal line right through the middle of the photo.

 

TRIPODS

It is really hard to invest in a tripod after blowing the bank account on a nice camera, a few lenses, spare batteries, memory cards and filters. And you can have loads of fun with photography without getting a tripod. But if you want to play with shooting (and showing) motion (i.e., a car going by with a blurred background, clouds streaking across the sky or silky water flowing) or you want to have perfect exposure in very low light (like a sunset) without a flash, or you want to do some timelapse videos (very cool at sunrise in a big canyon) then a tripod is a must.

Sunwayfoto XB-52DL Ballhead with T2C40C Tripod and DDC-60LR Quick Release Clamp

Sunwayfoto XB52-DL Ballhead with T2C40C Tripod and
Sunwayfoto DDC-60LR Quick Release Clamp

Most people end up upgrading their tripod several times because they just can’t believe, at first, that they have to spend good hard earned money on a tripod, and they go through a bunch of cheap ones before they bite the bullet and get a decent one! We did that, and lots of our friends did too.

The biggest difference between tripods is how much weight they can hold solidly, how easy they are to set up and adjust, and whether things drift or droop a little after you tighten the buttons. I have a Benro carbon fiber tripod that I absolutely love for hiking. The legs slide in and out really smoothly, and the adjustments are easy. I also have a set of super long Really Right Stuff tripod legs and a Wimberly gimbal which is awesome for letting me swing the Tamrom 150-600 lens around smoothly while shooting birds.

Mark has Sunwayfoto tripod legs and smaller ballhead for hiking and bigger ballhead that he loves and he uses a Sunwayfoto GH-01 gimbal head as well. We reviewed them in depth at this link:

Choosing a Tripod – Sunwayfoto Tripod and Ballhead Review

Sunwayfoto GH-01 Ballhead Review – Great Support for a Long Lens

We both have the SunWay Foto L-Bracket that attaches to the camera body and lets us set the camera in the tripod in either Landscape or Portrait orientation very easily. I keep my L-bracket on the camera all the time for simplicity in case I want to grab my tripod quickly, but it means I can’t use my Vello Battery Grip. Mark loves his battery grip, so he has to switch back and forth between the regular tripod bracket that fits on the camera along with the battery grip and the L-bracket that doesn’t.

 

FLASHLIGHT

We love doing night photography, photographing the milky way and the stars, and doing light painting on old buildings for ghostly effects. At Waterton Lakes National Park we did a timelapse video of the Milky Way.

When we are hiking on a remote trail in the middle of the night, or light painting a building to make it appear visible in a nighttime photo, we find that a good flashlight is essential.

We use the fabulous, super high powered LED flashlight from Lumintop, the Lumintop SD75 4000 lumen flashlight. It is like having a car’s headlight in your hand!

Lumintop SD75 4000 lumen tactical flashlight

Lumintop SD75 4000 lumen tactical flashlight next to a pocket Mag Light

Built with heavy duty aerospace aluminum, it has a military grade hard-anodized aluminum finish and is water resistant to 2 meters. Offering 3 power levels plus a strobe, there’s also an LED tail light that can be used as a night light when we’re setting up our camera gear in the dark. It also has threads on the bottom for mounting on a tripod.

The flashlight batteries are rechargeable and there is a battery level indicator. The flashlight ships with a wall charger and 12 volt car charging cords, and it comes in a suitcase! The batteries are so strong, it can be used to recharge other smaller devices like cell phones via 2 USB ports.

This is not a pocket flashlight, but it has slots in the end for a strap that makes it very easy to carry.

We love this flashlight and just wish we had had it when we cruised Mexico on our sailboat, as it is far more powerful than the emergency floodlight we had for rescuing a man overboard!

 

HAULING, STORING & MAINTAINING OUR CAMERA GEAR

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With all this camera stuff, it can be a challenge to figure out how to carry it to scenic spots and where to store it in the RV and truck when we’re not using it. Also, our camera gear takes a lot of abuse from dusty air out west, salty air on the coast, and sunscreen from our faces and hands. So it needs to be cleaned periodically. Here’s where we’re at with all this right now:

Hiking With Camera Equipment

When we go on a hike of a few miles, it is likely to take us four hours or more because we stop to take so many photos. So, we want to have water, snacks, our camera gear, tripods, and possibly a jacket with us. There are a lot of camera-specific backpacks and sling style camera bags on the market, but none we’ve seen is really designed for hiking.

After a lot of searching, we finally decided to use big Camelback hydration packs instead of bona-fide camera bags when we hike with all our photography stuff, and we’ve been really happy with this choice.

I have a Camelback H.A.W.G. and Mark has a Camelback Fourteener. Both can carry 100 ounces of water, and each has enough capacity for the Tamron 150-600 lens along with everything else if need be. (We never take more than two lenses with us — one on the camera and one in the pack).

Camelback H.A.W.G. camera bag

The Camelback H.A.W.G. can hold a big camera.

We generally hike with our cameras slung around our necks so we can take photos with them as we walk. I put the Camelback on first and then put the camera on afterwards so the camera straps aren’t trapped under the shoulder straps of the Camelback. There’s nothing like getting caught in the Tourist Tangle!

My main criteria for choosing a Camelback was that I wanted to be able to put my camera (with the 28-300 mm lens attached) inside the Camelback and then close that compartment so I could scramble over something gnarly that required two hands and not worry about the camera slipping out of the pack. And it had to do that with 100 ounces of water in the hydration pack.

My other criteria was that I wanted to be able to hang my tripod on one of the Camelback straps and hike without carrying it in my hand.

The straps on the sides of the H.A.W.G. aren’t designed to carry a tripod, and they may fatigue over time, but I’ve been really happy with how this Camelback has held up on the many hikes I’ve taken with it so far in two years of owning it.

The straps on the sides of the Fourteener are designed to hold ice picks and things like that, so they are probably a little more rugged. If I had known about the Fourteener before I bought my H.A.W.G., I probably would have bought that model instead. Mark has had it almost as long as I’ve had my H.A.W.G., and he is very happy with it as well.

Camelback H.A.W.G. with camera tripod

The tripod fits neatly on the side of the H.A.W.G., and the camera straps aren’t trapped under the Camelback straps.

One really nice feature of both of these Camelback models is that they have a waterproof rain sack that can be pulled out of a hidden pocket and slipped over the whole Camelback, keeping the contents dry if you’re caught in a downpour. This came in super handy at the Duggers Creek Falls on the Blue Ridge Parkway!

One of the tricks with backpacks in general is that, if they have a waist belt, you can loosen the belt a little, slip your arms out of the arm straps and then swing the pack around so it is in front of you. This way you can get something out of it without taking it off and putting it on the ground. This is fantastic when you want to swap filters, grab a snack, or change batteries without taking the whole darn thing off.

Once we get to an area where we’re going to take a lot of photos, we take the tripods off the Camelbacks and we carry them around in our hands until we’re ready to hike out again.

We carry a plastic bag (a shopping bag is fine) in our packs in case it sprinkles and we want to cover our cameras for a short time. We also carry rain ponchos so we can cover ourselves and our Camelbacks in the event of unexpected rain.

Short Walks With Photography Gear

If we are going to spend the day roaming around but not hiking, or if we’re taking photos a short distance from the truck, we don’t take the big Camelbacks. I use a small fanny pack to carry a spare battery and possibly a second lens. Mark likes to wear a photographer’s vest that has lots of pockets for all his goodies. He likes the one he has, but has his eye on the Phototools Photovest 14!

Storing All This Stuff

In the trailer we have Ruggard camera cases and Ruggard backpacks to hold the cameras and lenses. We also have camera cases in the truck. We’ve found good homes for the tripods in the truck too, and they generally stay there so they are with us if we arrive somewhere and suddenly wish we had them with us.

Cleaning

A great way to get the dust off the camera and lenses is to blow it off with the Giotto Rocket Blaster (the largest size is best). The Nikon LensPen Lens Cleaner is good for brushing dust off too. For smudges and smears, we use the Eclipse Camera Cleaning Kit which comes with a cleanser and pads.

Giotto Rocket Blaster & Camera Cleaning Kit

Giotto Rocket Blaster & Camera Cleaning Kit

Sometimes the camera’s built-in sensor cleaning system doesn’t quite do the trick, and getting debris off the camera sensor can be really intimidating. Rather than paying for an expensive cleaning at a camera shop, we’ve discovered that the Sensor Gel Stick sold by Photography Life does a phenomenal job (don’t get the cheap Chinese imitation ones). Check out the video under the product description here to see how to do it. It’s easy and we have done it many times.

 

PHOTO ORGANIZATION and POST-PROCESSING TOOLS

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We each have a plain MacBook Pro (no retina display) with 16 GB RAM and a 1 TB internal drive and slots for CD, SD card, Thunderbolt, etc. (2012-style case). We also each have a 4 TB external hard drive with a Thunderbolt dock that allows multiple drives to be daisy-chained.

We use Adobe Lightroom for most of our post-processing. The easiest way to learn Lightroom is the Julianne Kost Lightroom Videos. Julianne is Adobe’s “Lightroom Evangelist” (what a great title and job!) and her presentations are clear and concise.

Organizing photos is never easy, and everyone has a different method. Lightroom lets only one person work on a catalog at a time, so we each have separate Lightroom catalogs. We make use of the Smart Previews in Lightroom to get access to each other’s photos without transferring all the original photo files between our laptops. All we have to transfer is the catalog, previews and smart previews. It’s clunky — I know they could do better — but it works.

We also have a separate Lightroom catalogs for each year. The older catalogs are stored on external hard drives and the current year catalogs are on our laptops. We try to make sure all our photos are in two places (laptop and external drive or on two external drives). Some of our older photos are in Apple’s Aperture and our oldest are in Apple’s iPhoto, the two post-processing programs we used prior to Lightroom.

I don’t want to have to plug in an external drive every time I go into Lightroom, which is why we keep our current year’s photos and catalogs local to our laptops. We have our previous year’s catalogs and smart previews on our laptops so we can see and work with our older photos. If we need the full image of an older photo, we plug in the appropriate external hard drive, and the catalog on the laptop reconnects with the original images.

We don’t store anything in the cloud.

We organize our photos by location but like to have an overall sense of the chronological order in which we visited places, since that is the way we remember our travels. So, we label our folders with 2 digits followed by the state to bring up the states in the order in which we visited them.

Inside of each state folder, we name every download with a 4-digit date (month/day) followed by the specific location. For photos that aren’t location specific (like photos of our trailer disc brake conversion or fifth wheel suspension failure, we move them after downloading to a MISC folder and name a subfolder within it more appropriately or add them to an existing folder.

Lightroom Folder Organization

2 digits to order the states chronologically, then 4-digit dates on subfolders with the specific location.

We also use PHOTOSHOP for post-processing. The best instruction for learning Photoshop is offered by Brendan Williams. His free online tutorials on his YouTube channel are terrific. However, if your goal is to MASTER Photoghop, buy his video course and go through each of the videos slowly — and practice the techniques he teaches. His course is extremely well done and is worth every penny!

Photomatix Pro is an excellent program for creating HDR (high dynamic range) effects from several identical photos taken at different exposures, and Topaz Adjust and Topaz Detail in the Topaz Suite of software are great for getting a little wild with crazy effects at the click of a button.

For panoramas, we use Panorama Maker to stitch together a series of photos.

We use the X-Rite Color Checker Passport to create custom color profiles calibrated to specific camera and lens combinations. It also comes with a gray card that we sometimes use to set a custom white balance for particular light conditions.

 

RESOURCES FOR LEARNING PHOTOGRAPHY

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Photography is something you can spend the rest of your life learning. We’ve been reading and studying photography books and blogs for a few years now, and we have found the following printed books and ebooks and online resources to be really helpful in conquering both the technical aspects of understanding what all those buttons on our cameras do and the artistic aspects of how to capture the essence of what we’re seeing.

Photography Books

Some of our Favorite Photography Books

BOOKS ON PHOTOGRAPHY

 

eBOOKS ON PHOTOGRAPHY

 

ONLINE TUTORIALS

Steve Perry of Backcountry Gallery offers incredibly thorough and detailed camera reviews and photography tutorials on his YouTube channel, Backcountry Gallery. We were very fortunate to meet Steve and photograph prairie dogs and bison with him in South Dakota in 2017. In 2023 Steve was honored as one of the Top 40 wildlife photographers in the world. His eBooks are worth every penny and his videos offer outstanding and easy-to-follow instruction. He also leads wildlife photogrpahy tours to the far corners of the world where the most exotic wildlife live!

The website that taught us the most in the beginning was Photography Life written by Nasim Mansurov and his very talented team. He has super detailed gear reviews and his site is read by many of the top professionals in the photography world. His tutorials are excellent, and he has two pages with links to them all:

We were very fortunate to meet Nasim at his 2012 fall foliage photography workshop in Ridgway Colorado. Those extraordinary three days were a real turning point for our photography.

 

BLOGS, TIPS and GEAR REVIEWS

The photography blogs we read regularly are these:

  • Nikon Rumors – The latest info about everything related to Nikon cameras: future products, recalls, Nikon deals and specials
  • Photography Life – The most comprehensive camera/lens reviews anywhere and a top team of writers producing tutorials
  • Ken Rockwell – The first online photography resources we found. We’ve been following ever since
  • Ming Thein – Excellent and detailed camera reviews and truly inspiring photographs
  • DigitalRev TV – Hilarious (and very informative) videos on all kinds of photography topics.
  • Thom Hogan – Interesting photography-related essays as well as gear reviews
  • Dreamscapes – Phenomenal, jaw-dropping photography that makes us want to keep learning, plus tutorials & eBooks
  • DxO Mark – A laboratory that uses industrial testing equipment to do comparative camera, sensor and lens ratings

 

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RV Tips and Tricks – Make RVing EASY and FUN!

There are a million RV tips and tricks to make the RV life easier, and this page offers some little jewels we’ve discovered since we started RVing full-time in our fifth wheel trailer in 2007. We’ve broken them down into:

RV Tips and Tricks for making RVing and the RV Life easy

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OUTDOOR RV TIPS and TRICKS

High Powered “Search” Flashlight

We often camp in areas that are quite remote, and getting to and from and around the rig at night is much easier with a very high powered flashlight!

Lumintop SD75 LED flashlight

Lumintop SD75 Flashlight compared to a pocket Maglite

We have a Lumintop SD75 Flashlight which is downright phenomenal. We have hiked Bryce Canyon and the Grand Canyon at night to photograph the stars and the Milky Way, and this flashlight is literally like holding a car headlight in your hand.

Here is more info about this flashlight:

Lumintop SD75 Flashlight Review

Getting Parked Without Damaging Anything

The most basic element in RVing is learning to hitch up and unhitch, whether you are driving a car pulling a popup, a diesel truck towing a fifth wheel or a Class A motorhome towing a car. Of course, lots of people have loads of fun in their motorhomes without towing a car behind, but getting hitched up and unhitched is part and parcel of the RV lifestyle for an awful lot of us.

The most important thing for the driver and the person standing outside of the rig is to stay in eye contact with each other. This is entirely up to the person running around outside. If you can see the driver’s face in the rear view mirrors, you are golden. If you can’t, then any kind of gesture you make, including jumping up and down and waving your arms because the driver is about to drive the rig right off a cliff, will never be seen.

We use two-way radios to give us a way to talk to each other and to lessen the impact if I inadvertently end up in a position where Mark can’t see me in the rearview mirror. We use the longest distance radios we can get, to make sure the signal is decent. Right now we have 36 mile GMRS radios, which are realistically good to about 3-5 miles. We used these on our boat (a godsend when anchoring) and we’ve used them ever since we started RVing. We’ve gone through three sets so far, because the salt air ate up two pairs during our cruising years.

Two-way radios for backing up an RV

We use our two-way radios all the time…

Besides the radios, it’s really helpful to have good hand signals. I indicate the distance until disaster by spreading my arms wide and then bringing my hands closer and closer together until I give a “halt” sign (palms forward). Shaking my head and waving my hands and giving a few slices to the neck can help too if it starts to look really bad.

Midland 36 mile GMRS radios

36 mile GMRS radios

It is royally embarrassing to make all these gestures when you’ve got an audience of people watching, but I’ve learned that there’s no ego in getting the rig parked well. Every RVer who has been around a while has made a huge blunder of some kind while parking, and they’ve all lived through it. So a few members of your giggling audience will probably be very sympathetic to whatever mistakes you have up your sleeve.

My worst gaffe was in front of two very special friends we hadn’t seen since we’d moved into our fifth wheel a year earlier. They had come out to camp with us, and we were all excited. I had just finished telling them (with great pride) that we didn’t need their help parking because we parked our rig all the time, we had a system, and we had gotten pretty darn good at it.

Mark began to back up as our friends watched, and I began to warn him that he needed to go more towards the driver’s side to avoid a tree. He adjusted, but again, I told him, he needed to go more towards the driver’s side! I kept repeating my instructions louder and louder as our good friends watched in bewilderment. When Mark was just about to cream the tree, we all started shouting STOP!!! Mark got out of the truck, calmly assessed the situation, and then said to me: “Ahem…. which side does the driver sit on?”

Our friends smiled weakly and I looked for the nearest rock to crawl under…

So, don’t be embarrassed and don’t be shy. Make your gestures big and strong, and remember which side of the rig the driver sits on!

Hitching and Unhitching a Fifth Wheel Trailer

Some folks drive their RVs solo, and although I can’t say much about hitching and unhitching a motorhome and car combo, our good friend Bob has found a great way to hitch and unhitch a fifth wheel trailer solo. He marked the front landing leg that’s near the extend/retract button at regular intervals all the way up and down the leg.

Fifth wheel landing leg marked with hash marks

Hash marks on a landing leg help get the rig back to the right height before hitching up.

Then he numbered each hash mark. He keeps a pad and pen in the hatch near the landing legs button. When unhitching, once he’s raised the trailer to where he can drive the truck out from under it, he jots down the hash mark number that is visible on the leg. Then he drives out, parks, and returns to the trailer and raises or lowers the landing legs as necessary to get the trailer level.

When he hitches up again to leave, he adjusts the trailer height to the exact position where he unhitched. That way, when he gets in the truck to hitch up, he knows the trailer will be at the correct height as he backs the truck up into the hitch pin (and he doesn’t have to get in and out of the truck several times to check and adjust the height of the trailer).

We marked our landing legs at 1.5″ intervals and have not numbered them. There are only 6 hash marks, and I make a mental note of what mark we were at when we unhitched. Frequently, by the time we leave, I’ve forgotten where we were at before we leveled the trailer, but I’ve developed a good eye for knowing how much to raise or lower the rig as Mark backs the truck towards the trailer.

We also marked the centerline of the fifth wheel pin box and pin plate so it is easy for Mark to line up the hitch with the pin box and king pin when he is backing the truck into the trailer.

Leveling the Trailer

There are many methods for getting a trailer level, and hydraulic leveling is a blessing that takes all the excitement out of it. For those without hydraulic leveling, we found in our early years that with two 5′ lengths of 2″x8″ board and one 5′ length of 1″x8″ board we could always find a combination that worked to get the trailer level from side to side. A 5′ board is relatively easy to drive onto and provides a solid platform for the trailer’s wheels.

We store the boards in the bed of the pickup. When using two boards, we stagger them a few inches so the trailer is driven first onto one level and then up a step to the next. We have to remember to back up when coming off stacked boards or the upper one will tip up and hit the bottom of the trailer while driving off it (think of a sailor walking the plank).

Leveling boards fifth wheel RV trailer

This was an extremely unlevel spot where we used quite a few boards and strips of horse stall mat.

If you don’t like the idea of hauling long boards around in your truck, there are nifty plastic leveling board kits (here’s another type) that are very popular.

We also use plastic wheel chocks whenever we park on a steep incline to prevent the trailer from rolling, especially while unhitching and hitching up.

Our friend Ken introduced us to using a sliced up horse stall mat rather than pine boards. We cut a 4’x6′ sheet of horse stall mat into five 1×5 strips and four 1×1 squares, and those have worked really well for us. They hold up to the elements really well and they roll along with the contour of whatever crazy surface we might park on. It is also possible to drive off of them either forwards or backwards because they don’t slap the underside of the trailer.

The only disadvantage is that they are much heavier than pine boards, but we can drag them around and they don’t disintegrate. We use the 1’x1′ squares under the landing legs and scissor jacks for cushioning.

We also have four large blocks made of three 1′ lengths of 2″x8″ boards screwed together. We put handles on the ends to make them easy to lug around. In a really unlevel site in the Smoky Mountains we had to stack them on top of each other AND extend the jack legs all the way!

RV fifth wheel landing legs

A very unlevel spot that required two blocks plus all the leg length.

What Is Level and How Do You Know?

Determining what constitutes “level” inside an imperfectly constructed RV is an interesting trick. We used a carpenter’s level on our kitchen floor, in several directions, and on our table, and on the bedroom floor. Of course, none agreed! But we found a good compromise and then mounted some RV levels on the outside of the rig to give us a reasonable guess when we’re setting up.

There are two different types of levels: Bubble Levels that have an air bubble that floats to the high side, and Ball Levels that have a ball that drops to the low side. Bubble levels are more responsive (the bubble moves more quickly as the RV moves). Ball levels take a few seconds to react. If you use both types, you can get confused because they move in opposite directions.

We have a large Level Master level on the fifth wheel pin box that is easy to see from inside the truck. We also have two small bubble levels on the trailer on the corner by the landing jack power button, one facing forward (for left to right leveling) and one facing sideways (for front to back leveling).

RV Fifth wheel hitch level and center mark

The ball style level (visible from inside the truck) shows which side of the rig is low.
We painted a line on the pin box to help with hitching up.

Our pin box mounted Level Master, a ball level, is easy to see from inside the truck. When the trailer is higher on one side than the other, the Level Master ball falls to the low side.

Our smaller levels on the front corner of the fifth wheel are bubble levels, so the one on the front of the rig showing the side-to-side level has a bubble that rises to the high side. This is the opposite of the ball level on the pin box, and sometimes, when we are struggling with white line fever from hours on the road, this messes us up.

RV bubble levels on a fifth wheel trailer

Small bubble levels show left/right and front/rear level near the landing jack power button on our fifth wheel.

I’d recommend sticking to either ball levels or bubble levels and not mixing and matching like we did! A good solution might be to mount a ball level like this on both the pin box and on the front of the trailer near the landing jack power button.

Why do you need two side-to-side levels? When I’m running around placing the boards in line with the wheels for Mark to drive onto, I want to see a level on the fiver easily myself, and the front of the pin box is impossible to see from the side of the truck when we’re hitched up.

However, lots of folks rely on a single pin box mounted level that has both side-to-side and forward-back levels in it. There are a few from Camco and Hopkins that are very popular.

You can forego all this nonsense with a slick hydraulic leveling system. However, this does introduce a complicated and expensive system into your life, and we’ve heard many stories of the jacks falling down while driving, or not retracting properly and systems failing in other ways. On the plus side, though, you can easily jack up the trailer to change a flat!

 

Cordless Drill for Easy Jack Setup

We don’t have electric stabilizer jacks on our fifth wheel trailer (nor did we on our travel trailer). However, we use an 18 volt cordless drill, and it’s very easy.

Cordless drill set up for RV stabilizer jacks

Ready for action with the drill, extension and socket for the stabilizer jacks

We use the following setup to crank the scissor jacks:

We keep the 1/4″ Hex to 3/8″ Socket Adapter in the drill. Mark glued the extension and 3/4″ socket together with JB Weld, making it ultra easy to grab the extension, jam it in the drill and go.

18 volt cordless drill, 8" extension and socket for RV scissor jacks

18 volt cordless drill, extension, socket and adapters for RV scissor stabilizer jacks

This setup worked on both the four stab-jacks on our travel trailer and the two rear scissor jacks on our fifth wheel. We keep the drill right inside a basement hatch door so it’s easy to find during both setup and breakdown of the trailer.

RV stabilizer jacks with cordless drill

Raising and lowering the jacks takes 2 seconds!

Rigid Drill Set Radio

This goofy radio is in the Rigid Drill Kit (along with an impact driver & regular drill & lithium ion batteries and charger). We love it even more than the other stuff!

Camco makes a special Leveling Scissors Jack Socket that replaces those three pieces, but there is no 8″ extension. Personally, I like the long extension because you don’t have to crawl in so far to make contact with the scissor jacks.

Last year we bought a Rigid drill kit which includes a regular 18 volt drill, an impact driver (awesome for the lug nuts when changing a tire) and a radio as well as two rechargeable lithium-ion batteries and a charger.

After going through three different 18 volt drills during our years of RVing and sailing, we’ve been really impressed with this Rigid kit. The Lithium-Ion battery charges up in about 15-20 minutes and it’s good for a really long time.

The kit comes with two batteries, so we use one for the drill and one for the radio. And what a hoot it is to have a portable radio. In this day and age of slick electronics, we’ve gotten such a kick out of this thing…

 

Cleaning the RV

No matter where we park, the slide roofs need attention before we bring them in. Either they are dusty, in the desert, or they are covered with twigs and leaves, in the woods, or they are wet from rain. Slide toppers might help with this, although I have heard that they tend to make noise in high winds, sag over time, and sometimes end up with leaves and twigs trapped underneath.

Mark has a long handled squeegee he uses to get the water off, a broom for the leaves and branches, and a California Duster and/or broom for the dust. Getting up on the roof is also useful for checking out all the rooftop items like hatches, TV antenna, solar panels and wiring. His favorite cleaning tool for all this is a telescoping scrub brush that we used for cleaning our boat.

Scrub brush on RV roof

Our telescoping brush from our boat is a favorite for cleaning the rig.

He just loves this soft bristled brush. Murphy’s Oil Soap mixed with water is a good solution to wash the roof. To get rid of black scuff marks on the outside of the rig, he uses Mr. Clean Magic Eraser sponges.

Telescoping Ladder

Telescoping ladder on an RV

A second ladder is really helpful!

Telescoping ladder

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The first trailer we lived in full-time didn’t have a walk-on roof, and the signature of an RV without a walk-on roof is that it doesn’t have a built-in ladder.

We got a telescoping ladder so we could get up on the roof, and we have kept that ladder and used it ever since, even though our fifth wheel has a built-in ladder.

You may not think you need a second ladder when you’ve got one on the rig already, but polishing the front cap is one job where you do.

Washing or working on any part of the rig that is high up and out of reach of the ladder on the back is much easier with a second ladder, including the high corner of the rear end opposite the built-in ladder!

 

RV Patio Mats

A beautiful patio mat extends your living space and defines your outdoor area in an elegant way, and we love ours.

RV Patio mat defines outdoor space while camping

A classy patio mat extends your living space into the outdoors.

But they can be pricey if you’re just getting started with weekend RVing. An alternative is to get some green indoor/outdoor carpeting. We had this with our popup tent trailer, and it fit the bill perfectly (and our friends who now own our popup still use it!).

Popup tent trailer indoor-outdoor carpet patio mat

Save a few bucks and use green indoor/outdoor carpeting!

Waxing the Fifth Wheel Cap

Unfortunately, there’s no quick fix for getting the fifth wheel cap to have a deep shine. It’s made of ABS plastic and shows every swirl mark of a first-pass at waxing. The only way to bring back the luster it had when it was new is to use an orbital buffer and fiberglass polish and a whole lot of elbow grease.

Polished front cap on RV fifth wheel trailer

An orbital buffer and 3M Marine Cleaner Wax give the front cap a nice shine
but leave Mark’s shirt speckled with white spots!

Mark likes the 3M Marine Cleaner & Wax that we used on our sailboat. Unfortunately, you’ve gotta do this a bunch of times, and the worse condition the front cap is in, the more times it takes. But eventually you can get the shine back. Just be sure you keep the buffer moving lightly across the surface at all times so you don’t dig a hole in the plastic!

We have more cleaning tips for giving an RV that extra shine while boondocking here: Tips for Washing an RV While Boondocking

 

Truck Overloads

Timbren SES Suspension System for truck

Timbren SES Suspension

Our 14,000 lb. fifth wheel was right at the weight limit of what our 2007 Dodge 3500 could tow, and the pin weight of the trailer along with all the things we carry in our truck loaded down the bed of that truck quite a bit.

When hitched up, although the rig looked quite level, the truck sagged a bit, leaving the front wheels a little light and giving the truck a tendency to wander.

To alleviate this, we installed a Timbren Suspension Enhancement System between the axles and leaf springs of the truck. These are solid rubber donuts (not airbags) that fit between the axle and the leaf springs. That made the truck sit better and wander less.

We had that setup for eight years. In 2016 we purchased a 2016 Dodge Ram 3500 dually truck which had a much higher weight capacity in the truck bed and could handle the pin weight of the trailer along with the additional weight of the water jugs and leveling boards we carry in the bed of the truck much better.

How to Put Diesel Exhaust Fluid (DEF) in a Truck

Our 2016 Dodge Ram 3500 has a five gallon Diesel Exhaust Fluid tank which needs to be refilled every thousand miles or so. We’ve got some tips for where to get this stuff cheap and how to get it in the truck without spilling here:

How to Put Diesel Exhaust Fluid (DEF) in a Truck and Which Brand is Cheapest

How to put Diesel Exhaust Fluid (DEF) in a truck without spilling

Putting DEF in a diesel truck is a new necessary evil, but there are tricks to make it cheap and easy…

RV Grill Operating on the RV’s Propane Tanks

Mark loves to barbecue, and ever since our first popup trailer, we’ve had a wonderful, small RV barbecue, the “RV sidekick grill.” It comes with a mounting kit to hang it on the side of an RV. Flipped sideways, this same kit becomes legs so the grill can stand up off the ground.

RV grill attached to fifth wheel trailer

The RV sidekick grill is designed to hang on the side of an RV or stand on its own.

We had this grill installed on the side of both our popup tent trailer and travel trailer, but with the fifth wheel, Mark installed an extra gas line and valve coming from the RV’s propane tanks so it can run from them. A quick disconnect LP gas hose goes from the grill to this gas line.

RV grill gas pipe connection

An extra gas line and valve lets the grill runs from the trailer’s propane tanks.

We’ve had this little grill since 2005 and it still makes a great meal!

 

RV Water Toys – Water Spigot Connections

In many dry camping campgrounds where there are water spigots available but no water hookups at the campsites, the water spigots don’t have threads. We’ve found a water bandit makes it possible to thread our water hose onto the spigot so we can fill up with water easily.

Water Bandit spigot adapter for RV fresh water at campgrounds

The water bandit makes it possible to connect a fresh water hose when there are no threads on the spigot.

In cases where we get water hookups and leave the water hose connected to the trailer, we screw a 90 degree elbow onto the trailer so the hose can hang straight down rather than come out of the our city water connection horizontally and then droop down towards the ground, putting pressure on the connection and potentially causing drips. We discovered this nifty little elbow when we lived on our boat in a marina before our cruise.

In addition, a water pressure regulator keeps the water pressure down to a level inside the rig that prevents any unexpected damage or leaks. A quick release makes it easy to connect and disconnect the fresh water hose. Mark also keeps a Y valve in his water hose arsenal. This is handy if the rig is connected to city water and we want to fill pails with water for washing the truck, or if an RV dump station has only one water spigot and we want to fill our fresh water tanks and run the black water flush at the same time.

Lots of folks like to attach a water filter as well. We used various filters at first, but no longer use any, although we periodically add a cap full of bleach to the fresh water tank. When we got a new fresh water tank, we were surprised that there was no sludge of any kind inside the old tank, even after 7 years of use.

Changing the Inner Rear Tire on a Dually Truck

We have a Dodge Ram 3500 dually truck with a B&W fifth wheel hitch, and wouldn’t you know it, the first time we had to change a tire on it, it was the inner rear tire. Ugh!

We had always wondered exactly how you went about doing this, and we found out. Here is a blog post that explains the entire process:

How to Change the Inner Rear Tire on a Dually Truck

 

INDOOR RV TIPS and TRICKS

Creating STORAGE SPACE with Seating for Four in the Dinette

We replaced the two chairs in our dining area with two wonderful storage ottoman benches, and this has increased our storage space by quite a bit. The storage ottomans we chose have a nice faux leather padded top that is really comfy to sit on, and they have voluminous storage space inside.

Storage benches in RV dinette

Our dining area – lots of storage and seating for four.

We have his-and-hers benches, and we keep our camera gear in them. The great thing is it got rid of all our clutter and gave us a place that is low down in the trailer and slightly ahead of the trailer’s axles (a smoother ride) where we could make custom padded storage for this delicate gear.

For more info and more pics of our benches, see this blog post about our setup: Making STORAGE SPACE in an RV.

You can buy the storage ottomans we purchased HERE, and you can get ideas of other brands and sizes of storage ottomans on the market HERE.

Protecting the Carpets Under the Slide-Outs

The carpets take a beating as the slide-outs roll in and out. Some slide-outs aren’t quite square and one wall or the other presses particularly hard on the floor while driving. You can buy fancy carpet protectors that fit under the slides. We went a cheaper route and bought a package of four flexible plastic cutting boards.

RV tips - cutting boards under RV slide-out

Flexible cutting boards taped together protect the carpet under the slide-outs.

We used packing tape to tape two of these together, end-to-end, and each pair fits under the slide-out walls perfectly yet are thick enough to protect the carpets. I keep one pair under one slide-out wall while driving, because that slide is crooked and its one wall gets wedged against the floor pretty tightly. The other slide-out walls hover above the carpet as we drive, so I pull the plastic cutting boards out from under them so they don’t get lost underneath while in transit.

Keeping the Cabinets Closed

After having a cabinet door fly open while driving over a bumpy road, causing two unbreakable Corelle bowls to fly across the trailer and break in half, we now latch every cabinet door with 6″ bungee balls. For drawers we use mini 10″ bungee cords with a hook at each end, hooking the top and bottom drawer handles.

RV tips bungee balls and bungee cord on RV cabinet doors and drawers

Bungee balls and bungee cords ensures the cabinets and drawers all stay closed.

Rolled up Carpets

We have a large pots-and-pans drawer that occasionally likes to open. We roll up our throw rugs and place them so they can’t unroll in front of the drawer to keep it closed.

How to keep RV drawer closed in kitchen

Rolled up throw rugs keep this big pots and pans drawer closed while driving.

Rubber Shelf Liners

Rubber Shelf liners are invaluable, keeping everything in its place on each shelf as we travel. We try to make sure no plates, mugs or glasses are touching each other when we set out.

Shelf liner for RV shelves

Shelf liner keeps things in place when we drive

Closet Organization with Plastic Drawers

Our bedroom has a marvelous 8′ wide closet with sliding doors on it, but the interior is just open space with a rod for hangers. We don’t use it as a hanging closet (we have a different closet for that). Instead, we put stacked plastic drawers inside to give us more drawer space as well as a horizontal surface on the top.

RV closet plastic drawer organizer

We created more drawer space in one closet with lightweight, inexpensive plastic drawers.

These drawers don’t latch closed, so Mark drilled a hole through each drawer and the frame, and we simply slip a screw through each hole to keep it closed as we drive.

How to keep RV drawers closed

A screw through each drawer keeps it from opening in transit

Book Organization with Special Bins

We like to keep our heaviest items, like books, on the floor, as shelving in an RV tends to be quite flimsy. I found an awesome line of Rubbermaid “All Access” bins that have a clear plastic latching door on the front. Ours fits neatly under our desk (which we never use as a desk, so it’s wasted space). We can move the whole thing easily, can load it from the top easily and can get at the books from the front easily.

Rubbermaid All Access storage in RV

Rubbermaid’s “All Access” bins have clear front opening doors!

Dish Drying Mat

We do several small loads of dishes everyday, and I just love our little dish drying mat. It soaks up all the water, and once I move the dishes off of it I can hang it up to dry. Every so often I throw it in the laundry with the dish towels, and it comes out just fine.

RV dish drying mat

A dish drying mat sops up water, can be hung out to dry and thrown in the laundry.

How to Defrost an RV Refrigerator in 20 Minutes!

Propane RV refrigerators build up a lot of frost very quickly. After trying many different methods for defrosting our fridge over the years, we’ve outlined the steps we use to get this job done quickly:

How to Defrost an RV Refrigerator in 20 Minutes!

How to defrost an RV refrigerator

Defrosting the fridge doesn’t have to be a big nasty chore…

LED Wax Pillar Candles

I love romantic lighting, and there’s nothing like candles for that. But having an open flame isn’t great. Sailing friends of ours introduced us to pillar shaped LED candles made of real wax, and they are delightful. We’ve had ours for five years now, and we’ve had to change the batteries just once. They are wonderful for dim lighting in the pre-dawn hours or late at night, and they are a nice light around the rig when we watch a movie. The best part is they really look and feel like real candles, but you don’t have the risk that comes with an open flame.

RV tips LED flameless wax pillar candles in RV

LED pillar candles add warmth and create romantic mood lighting

Departure Checklist

RV Departure Checklist

All our mistakes on one page
with the worst ones underlined!

We thought we could memorize all the things that need to be done when we pack up the rig for towing, but a few mishaps taught us otherwise.

We now have a checklist taped inside the same cabinet that houses the main slide-out controls.

A quick glance before we leave ensures us that indeed all the hatches are closed, the shower door is latched, the window-mounted hummingbird feeder is not stuck on a window somewhere, etc.

This list is a comedy of errors made over several years of RVing. I’m sure more items will be added in the future!

 

Simmons Beautyrest Mattress

An RV can be outfitted with ordinary residential furniture, and we have upgraded our recliners to comfy La-Z-Boys.

More important for full-time RVers, there is no need to sleep on some funky RV mattress every night. We upgraded our mattress to a Simmons Beautyrest and just love it.

One important note is that many RV mattresses are non-standard sizes. An “RV Queen” is shorter than a standard Queen, and an “RV King” is narrower than a standard King. Here’s a chart showing the differences:

Standard “RV” Size
Queen 60″ x 80″ 60″ x 74″
King 76″ x 80″ 72″ x 80″
Simmons Beautyrest Plush Pillowtop mattress for RV

A good night’s rest…

In most rigs that have a Queen bed, the floorplan clearly states whether it is an RV Queen or a regular Queen. However, in virtually all RVs that have a king bed, it is an RV king. If you are buying an RV with a king bed and think you might want to upgrade to a residential mattress someday, make sure there are 4″ of extra width on the sides so the mattress can fit, even if it hangs over a little.

 

Laptop Lap Insulator

I mentioned that we don’t use our desk, and that’s because we use our dining room table for writing things out by hand and we use our laptops on our laps in our recliners. To keep from frying our legs with our laptops, we each have a laptop sized thin piece of foam that was part of the packaging of a solar panel. If you don’t have that handy, there are laptop lap insulators that can do the trick.

Laptop on thin foam insulation

A thin piece of foam keeps our legs from cooking under our laptops

Cleaning the Ceiling

We have a fabric ceiling liner and twice we’ve had to clean a stain from it. Each time we used spray bleach and the results were miraculous. You couldn’t see where the stain had been. Just make sure you cover everything nearby before spraying bleach in the air or you’ll have not just a clean ceiling but white spots on the rugs and upholstery too.

 

HEALTH and COMFORT in the RV LIFE

Living in an RV is not all that different than living in a stick-built house, so anything you enjoy in a conventional life is more than likely going to be something you can enjoy in your RV life. Here are some goodies that we use everyday, that have made a significant difference in our lives, and that we will continue to use daily no matter what kind of home we live in:

Amazing Grass

Amazing Grass powdered wheat grass drink

Helps keep fair haired people with thin skin from bleeding!

Mark has found that when he works around the rig, it is really easy for him to get little cuts and blood spots on the backs of his hand his hands. This turns out to be common with fair haired (red haired) formerly freckle-faced guys over 50. After some research, we found that the remedy is bunches of Vitamin K, and it turns out that wheat grass is loaded with Vitamin K! It has lots of other beneficial nutrients as well.

As long as Mark drinks a small dose of wheat grass everyday, his hands are as tough as when he was 20. But miss that wheat grass for a few days, and the next time he does any work around the rig, the slightest flick of his hand against something breaks the skin and he’s bleeding again. The best brand we’ve found is Amazing Grass.

Sound weird or too good to be true? We’ve suggested this crazy remedy to formerly red-haired friends, and they are now big believers and wheat grass connoisseurs too. Mark mixes it with fruit juice and actually loves the flavor! For those who don’t like veggies, the claim is that a spoonful of this wheatgrass powder is akin to a bushel basket of veggies. I don’t believe that myself, and I keep putting broccoli on our plates, but I think this stuff is worth its weight in gold when it comes to toughening up thin skin.

Hand-held Electric Massager

As former athletes, we’ve both spent a lot of time looking for ways to soothe aching muscles. We’ve owned a lot of different hand-held massaging tools over the years, including the very popular massager, and they’ve all been okay. But many of them ultimately wound up in yard sales because they had bad habits of pinching skin or were awkward to use.

 electric massager

electric massager

We’ve found that the hand-held massager is really fantastic. Because it has just one ball head on it (rather than the more common and goofy twin ball heads), you can place it over any sore spot and get instant relief. Rub it slowly on your leg muscles after a hike or bike ride or rub it on that weird spot in your neck after you sleep funny and wake up unable to turn your head, and you’ll feel better right away.

This massager was a lifesaver for me after a bad cycling accident I had years ago that messed up my shoulders and collar bone for a very long time, and Mark recently relied on it heavily when he wrenched his back. We’ve never had it pinch our skin at all.

The neat thing about these massagers is that they increase the blood and fluid flow in the sore area, which is really helpful for getting nutrients into the injured spot and getting waste fluids out. You don’t need to press hard on it — just place it on the sore area and you’ll feel the muscle relax instantly.

We have had ours for four years now, and we used it both on the boat and in our RV. It’s amazing just how kinked up you can get living in a small space, and it is so helpful to be able to get unkinked in a matter of minutes. We keep it in our living room so it’s always handy.

Sonicare Toothbrush

Sonicare toothbrush

Sonicare toothbrush

If only these Sonicare toothbrushes (and toothbrush heads) had been around when we were kids! It may seem ridiculous to spend a bunch of money on an electric toothbrush, but brushing your teeth with one of these makes your mouth feel like you just came from a cleaning at the dentist’s office. I’ve used a Sonicare toothbrush for 13 years now, and what a difference it has made in the overall health of my teeth.

One note for boondockers and off-the-grid RVers living on solar power, Phillips, the manufacturer of Sonicare toothbrushes has noted that the rechargeable batteries do not like modified sine wave inverters very much. I read this years ago, and have always charged ours on our pure sine wave inverter. Perhaps the batteries are better in newer models, I don’t know.

Also, for tech junkies who like to collect tech goodies, the magnet inside the Sonicare toothbrush heads is incredibly strong. Mark has saved a few of the magnets from our discarded Sonicare toothbrush heads and has found all kinds of interesting uses for them, including gluing one onto a long stick to retrieve tiny metal objects from hard to reach spots in the bowels of something.

Other RV Tips & Tricks

We have loads of other tips and tricks for RVers on this website. Many of the links can be found here:

RV Tech Tips and Product Reviews

A small sampling is below:

A wonderful website dedicated to RVing tips and tricks is RVtravel.com

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2008 Hunter 44DS Sailboat

Hunter sailboats are the best kept secret in the boating industry.  Here's a review of our 2008 Hunter 44DS

Groovy - '08 Hunter 44DS

sv Groovy layout

Hunter 44DS Floor Plan

s/v Groovy main salon

Main salon.

SV Groovy nav station

Navigation station.

s/v Groovy galley

Galley.

sv Groovy Master stateroom.

Master stateroom.

This page describes our Hunter 44DS sailboat, including all the equipment we have added for full-time liveaboard cruising in Mexico.

Long settee for napping.

We have a large cockpit, a nice feature on a liveaboard sailbot, and great for sailing too.  SV Groovy cockpit

Spacious cockpit.  We can sit face-to-face with our legs

stretched out, and our feet don't touch.

On a cruising sailboat it is essential to have large uncluttered decks.  s/v Groovy deck.

On deck.

When we sail on overnight passages while cruising Mexico we appreciate our forward looking windows.  sv Groovy forward looking windows.

Sitting inside on the companionway stairs, you can see where you're going, a wonderful feature on a

cold overnight passage.

s/v Groovy - it's just a groovy boat.

It's just a groovy boat.

The twizzle rig is a twin headsail rig that we have flown on our boat during our cruise to Mexico.  SV Groovy - twizzle rig

Twizzle Rig - twin headsails flown on

matching whisker poles.

Sailing down the Pacific Baja coast on our cruise to Mexico we anchored s/v Groovy in Bahía Sant Maria, Mexico

At anchor in Bahía Santa Maria, Mexico.

Hunter Marine sailboats are the best kept secret in the boating industry.

Under sail.

One of the finest anchorages in Pacific Mexico isin Zihuatanejo, Mexico -  s/v Groovy.

At anchor in Zihuatanejo, Mexico.

Three 185 watt solar panels provide

awesome shade over the jump seats

Hunter 44DS Sailboat: s/v Groovy

Groovy has been sold. Pics, listing and Sales Spec Sheet here!!

Groovy (named for Simon & Garfunkel's song Feelin' Groovy)** is a

Glenn Henderson designed 2008 Hunter 44DS (Deck Salon).  A

fractional sloop, it is 44 feet long and 14' 6" feet wide with two

staterooms and two heads.

Hunter 44DS Model History

First introduced by Hunter Marine in 2002 as the Hunter 426, the aft

cabin was changed a little and the model name changed to "44DS" in

2003.  Production ran from 2003 to 2008.  In 2008 the the deck and

cabin were modified to accommodate twin helms instead of a single

helm, the forward berth was changed from a v-berth to a pullman style,

and the window pattern was changed to a wraparound band to match

the popular Hunter 45CC.  These changes saw the model name change

to "45DS," and as of 2012 it is still in production.

Along with the Hunter 426 and 45DS, the 44DS shares its hull with the

Hunter 44AC (Aft Cockpit) and Hunter 45CC (Center Cockpit).  Each of

those boats has the same hull but a different deck and cabin layout.

Groovy is hull #252 for the 44DS model line, where the numbering

started at #101.  Built in May, 2007, it was the last Hunter 44DS ever

built.  Click here for more information on the Hunter 44DS.

Groovy is a stock boat with Hunter's "Mariner Package," a collection of upgrades sold as a unit.  Because the boat was built after

the replacement model (45DS) was in production, it features a few of the components that are standard on that model, including

a laminate cherry interior, which we love, and a larger fuel tank, which has come in very handy.

Specifications

Length Overall (LOA)

43' 4"

Waterline Length (LWL)

39' 2"

Beam

14' 6"

Draft

6' 6"

Displacement

22,936 lbs

Ballast

7,237 lbs

Mast Height

60' 8"

Sail Area

975 sq. ft.

Fuel Capacity

66 gallons

Water Capacity

140 gallons

Holding Tank Capacity

45 gallons

Water Heater Capacity

11 gallons

Yanmar Diesel Engine

54 hp

CE Classification

A/10

We installed many upgrades to enable comfortable cruising where we can stay at anchor for months at a time without having to

rely on marinas for water or electrical connections.

House Batteries

640 Amp Hours (Four AGM 4D 12 volt) - plus one 70 Amp Hour AGM start battery

Charging

555 Watts Solar / 100 Amp Alternator on engine / 130 Amp 110v Charger (via shore power)

Inverters

600 Watts Pure Sine Wave / 2500 Watts Modified Sine Wave / 2 portable Modified Sine Wave

Watermaker

60 Gallon per hour engine-driven Echotech watermaker*

Downwind Sailing

Twin jib "Twizzle Rig" set on two fixed length whisker poles.

Anchors

60 lb Ultra primary with 300' 5/16" G4 chain

32 lb Fortress FX-55 secondary with 20' 5/16" BBB chain and 300' 7/8" Nylon Rode

15 lb Manson Supreme stern anchor w/ 5' 3/8" G4 chain and 230' 1" Nylon Rode

Dinghies

10' Porta-bote with a Suzuki 6 hp outboard

Hobie i14t tandem inflatable kayak

A GAZILLION BOATS FOR SALE... WHICH ONE

WOULD MAKE US HAPPIEST?

When we set about buying a boat, the major trade-offs we found

were age, size, price and manufacturer's prestige.  In an earlier life I

owned two boats back to back that were the exact same model, the

Nonsuch 36.  This is a wonderful boat for cruising and living aboard,

and I lived aboard for four years in Boston, Massachusetts in the

early 1990's (brrrr...those winters were cold).  The first year I was on

a 1984 model that had been ridden hard and put away wet.  After

watching in great distress as my then-husband repeatedly chased

down a spider web of unmarked cables and miles of smelly plumbing

hoses in a putrid bilge, we upgraded to a 1991 model of the same

boat that had been lavishly commissioned and meticulously

maintained.

What a world of difference.  You would never know they were the same

model boat.  Instead of him spending hours kinked up in impossible

positions in noxious nooks and crannies fixing problems and spending

boatloads of money on spare parts at West Marine, we enjoyed three

terrific summers of boating together.  We watched sunsets and sunrises

in pretty anchorages and experienced countless utterly brilliant days of

sailing.  There is nothing like an almost-new boat made up of sparkling

clean parts that work.  Therefore, when Mark and I started thinking about

buying a boat, our first two criteria were that it be in superior condition

and as new as possible.

After living in trailers full-time for so long, we also knew that size

mattered to us.  For full-time liveability, we found bigger is better.

With age and size the top priorities, and a maximum budgeted

price, there were only three manufacturers whose boats we could

afford: Hunter, Beneteau and Catalina.  These are the Ford-Chevy-

Dodge of the sailboat industry (not in any particular order).  All

three are American made.  Beneteaus are French designed but

built in South Carolina.  Hunters and Catalinas are designed and

built in Florida.

Our top priorities for livability included a huge cockpit where we could

stretch out to sleep, a long settee in the main salon where we could

nap, and two good sized staterooms (rather than three as in many

models).  Brokers thought we were crazy when the first thing we did

as we stepped aboard a prospective boat was to lie down in the

cockpit to see if the benches were long and wide enough to sleep on.

But hey, this boat would become our home, and we like to be

comfortable and relax!

Next in importance was a large swim platform and cockpit shower, as

we envisioned frequent swims off the back of the boat and we knew

we would need easy access to the dinghy when we lived at anchor,

especially hauling groceries, daypacks, trash and laundry bags in and

out.  Lastly, we wanted an airy, spacious interior.  Other than that, we

weren't fussy, but after attending dozens of boat shows, visiting fifty

or more boats with brokers, and many Caribbean charters, we found

that the Hunter models spoke to us more than the others, and of

those only the Hunter 41DS and 44DS made the cut.  The faltering

economy worked in our favor, suddenly making the larger of the two

boats a viable option.

A visit to the Hunter factory assured us that not only are their boats

cleverly designed and chock full of innovative features, but they are well

built to boot.  We came away from every contact we had with Hunter

impressed that it is a quality company that employs a loyal group of

happy employees.  Their phenomenal customer service since we

purchased Groovy (15 minute turnaround time on almost every emailed

question we've ever sent) has driven that point home to us time and

again.  Hunter sailboats are the boating industry's best kept secret.

Best of all, Groovy is a dream to sail.  With an easily driven hull,

the boat is light on its feet, easy to reef, responsive and

forgiving.  A delight to live in and fun to sail, it is an excellent

platform for extended cruising.

** When we named our boat, it was the only boat with the name Groovy in the US Coast Guard Documentation database.  So we

were quite surprised when we discovered over a year later that she has a sistership of the same name bearing a non-US flag:

Jimmy Buffet of Margaritaville fame races his Groovy in the Caribbean.  Far out!!

*Echotec's official "rating" is 40 gph, but since we installed high capacity membranes, our timing measurements have never

been less than 58 seconds to fill a one-gallon jug in the tropics (the speed is 44 gph in San Diego's cooler water).

More info in the links below...

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

The following clip is a VIDEO WALKTHROUGH of our boat which we did before it was sold:

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Our 555 watt solar power system is described in detail here: Sailboat Solar Power System. There is lots more info about solar power solutions for boats and RVs here: Solar Power Articles for Sailboats and RVs.

Our 60 gallon per hour engine driven watermaker was featured in an article we wrote for Cruising World Magazine. The article can be read at this link: Water, Water Everywhere – Installation of a 60 gph engine driven watermaker.

Our cruising itinerary and all of our blog posts from our cruise can be found at this link: A Groovy Cruise of Mexico.

There is a ton of info on this website about planning a Mexico cruise and anticipating what to expect. To get oriented and find out where we keep all the good stuff, visit this link: Cruisers Start Here

.

To help you plan your cruise and get you inspired, we created the video series, "Cruising Mexico Off the Beaten Path - Volumes 1-3," shown below. This is a fun-to-watch and easy-to-digest introduction to Mexico from a cruiser's perspective, giving you lots of valuable information that isn't covered by the cruising guides. Each video is available individually at Amazon, either as a DVD or as a download. For discount package pricing on the whole series, visit our page Cruising Mexico Video Series.

Volume 1 reviews the geography, weather and seasons in Mexico and shows you what the best anchorages between Ensenada and Manzanillo are like.

Volume 2 gives detailed info that can't be found in any of the guidebooks about the glorious cruising ground between Manzanillo and the Guatemala border.

Volume 3provides all the info you need to get off the boat for an adventure-filled trip to Oaxaca.

Our Gear Store also has a boatload of ideas for your cruise!

 

RV Solar Panels – Flexible or Rigid? 12 or 24 volt? Mono or Poly? Yikes!

There are a lot of decisions to make when you install solar panels on an RV or boat. Some of the most basic are: what size solar panels to buy, whether to go with flexible solar panels or aluminum framed rigid panels, whether the solar cells should be monocrystalline or polycrystalline, and whether to install nominal 12 volt or 24 volt panels.

We have done several RV and marine solar panel installations, and we have used not only 12 volt and 24 volt panels of various sizes but we have also used both aluminum framed rigid solar panels and the newer semi-flexible solar panels. We have also worked with both monocrystalline and polycrystalline solar panels. This article outlines the pros and cons of the various types and sizes of solar panels and offers some things to think about when you are deciding which solar panels to buy for your RV or boat.

RV solar panel selection

.

Our article RV Solar Power Made Simple explains how to determine the overall wattage for an RV solar power installation. In general, a weekend / vacation RV can get by with 200 watts or less while a full-time solar power system is best with 500 watts or more.

SOLAR PANEL SIZE and PLACEMENT

Once you decide on overall capacity for your solar panel array, the next thing to think about is solar panel placement and wiring. The panels should be a matched set of identical or nearly identical panels. If you have a lot of real estate on the RV roof, then you can get a few big panels. If you have a truck camper or your RV roof is cluttered with a lot of things on it already (hatches, vents, antennas, etc.), then you may need to go with smaller panels that can be squeezed in and around everything else.

Solar panel installation on a ffith wheel RV

Our fifth wheel trailer is powered by four 120 & 130 watt 12 volt rigid polycrystalline solar panels wired in series

WHAT VOLTAGE IS THAT SOLAR PANEL?

Solar panels are constructed internally with DC wiring, and they are sized to work on 12 or 24 volt circuits. So, they are commonly referred to as 12 or 24 volt solar panels. What’s confusing is that while the nominal voltage of a solar panel may be 12 or 24 volts, the open circuit voltage is higher. So, for a nominal 12 volt solar panel that is 100 watts, the open circuit voltage (“Voc“) will be 17 or 18 volts. Likewise, for a nominal 24 volt panel, the Voc will be 34 to 36 volts.

Also, smaller solar panels (both physically and in terms of watts) are typically nominal 12 volt panels while larger panels are typically 24 volts. Solar panels under about 150 watts in size are usually 12 volt panels. Solar panels over about 150 watts are usually 24 volt panels.

Solar panel installation on a sailboat

For nearly four years, we sailed our boat on Mexico’s coast relying on three 185 watt 24 volt
polycrystalline rigid solar panels, wired in parallel, for all our electrical needs.

Solar panels work best when they are a matched set. The electrical characteristics of all the solar panels in the array need to be very similar, preferably identical. When upgrading a solar power array this can make things complicated as you try to mix and match old small panels with new big ones.

One technique for upgrading is to wire two 12 volt solar panels in series to work on a 24 volt circuit. For instance, if you have two 100 watt 12 volt panels and you are buying a 200 watt 24 volt panel, you can wire the two 100 watt panels in series and then wire that pair in parallel with the new 200 watt solar panel.

This will work as long as the electrical characteristics of the pair of solar panels in series match the electrical characteristics of the single panel that is wired in parallel with them.

THE EFFECT OF SHADE ON SOLAR PANELS

Shade is the biggest enemy of any solar power installation. Unbelievable as it seems, a tiny bit of shade will effectively shut down a solar panel. The impact is dramatic: a few square inches of shade can drop a solar panels current production down from 8 amps to 2 amps. A few more square inches of shade can drop the current production to 0.

Before deciding on the size of the panels, it is worthwhile to take some time to study the various things that might cast shade across them once they are in place. A closed hatch may cause little shade, but when it is open on a hot day, depending on where the sun is in the sky, it might cast a big shadow across a nearby solar panel. Satellite dishes, air conditioners and even holding tank vents can cast sizable shadows as well.

We put a book in one corner of a 120 watt 12 volt panel and discovered that even though it was a small percentage of the surface area of the panel, that 8.5″ x 11″ book was enough to knock down the current production of a 120 watt solar panel by 80%. Rather than producing 7 amps, it produced a measly 1.4 amps. Egads!

Shade on one corner of solar panel

Just 8.5″ x 11″ of shade from this book reduced current production by 80%!

Similarly, shade wreaked havoc on our three185 watt 24 volt panels on our sailboat. The shade from our mast traveled across the panels as the boat swung at anchor, and the current production dropped by 1/3 and then by 2/3 as the shade first crossed one of the three panels and then straddled two of them. It did this over and over, with the current rising and falling repeatedly, as the boat slowly swung back and forth at anchor.

Effect of shade on solar panels installed on sailboat

A line of shade from the mast on our sailboat reduced our solar panel array to 65% and then 35% of its capacity as it traveled across the panels and occasionally straddled two of them.

Shade is a huge concern in the solar power industry, and there are several white papers (here’e one) about the impact of shade on commercial solar panel installations. The gist is the importance of spacing the rows of commercial solar panel arrays in such a way that one row of panels doesn’t accidentally shade the bottom inch or so of the next row behind it when the sun is low in the sky.

If it does, the second row of panels shuts down. If there are rows and rows of solar panels spaced like this, none of the panels except the ones in the first row can function until the sun rises a little higher in the sky.

Solar panels are most sensitive to shade along the longest part of the panel, so in the case of our sailboat, when the sun was over our bow, the mast would shade the panels in a strip that had a maximum impact on current production (as you can see in the above photo)!

For RVers, besides rooftop obstructions, shade comes into play primarily if you park near a building or trees. Snowbirds boondocking in the southwest deserts of Arizona and California during the wintertime have little concern with shade from trees and buildings. But summertime RV travelers who boondock in wooded areas need to be cognizant of where the shade from the trees will fall during the course of the day.

WIRING SOLAR PANELS IN PARALLEL vs. IN SERIES

One of the big decisions for a solar power installation on an RV or boat is whether to wire the solar panels in series or in parallel. There are several things to consider when making this decision.

When the solar panels are wired in series, then the developed voltage across all the panels is additive while the current remains constant from panel to panel. That is, if there were four 120 watt 12 volt panels producing 7 amps each, then the developed voltage across all the panels would be 48 volts (12 x 4) while the current would be just 7 amps.

In contrast, when the solar panels are wired in parallel, then the voltage of the panels remains constant through the circuit while the current is additive from panel to panel. For instance, for those same four panels, the developed voltage across them would be 12 volts but the current would be 28 amps (7 x 4).

The solar charge controller takes care of balancing everything out by ensuring the circuit between it and the batteries is 12 volts. In the case of the above solar panels wired in series, the solar charge controller steps down the voltage from 48 volts to 12 volts (if they are 12 volt batteries). The current then increases from 7 amps to 28 amps in the wire run going between the solar charge controller and the batteries.

In the case of the above solar panels wired in parallel, the voltage is already 12 volts, so the solar charge controller does not need to step it down for the batteries.

SHADE EFFECTS on SOLAR PANELS WIRED IN SERIES vs. WIRED IN PARALLEL

When solar panels are wired in series, if shade hits one panel and shuts it down (caused by that solar panel’s internal circuitry building up a massive amount of resistance), then the entire string of solar panels shuts down. For instance, if a tree shaded 1/3 of one solar panel in the string of four panels given above, wired in series, the current production of the entire array of four panels would be reduced to to 0 amps, even though the three other solar panels were in full sun.

In contrast, if the panels are wired in parallel, when shade knocks one panel out, the other panels are unaffected. So, even if 1/3 of one solar panel were shaded, reducing it to 0 amps of current production, the other three would be working just fine. The total current production would be 3/4 of what it could be if that one panel were in full sun (in this case, 21 amps), rather than 0 amps.

So, it would seem that the best way to wire solar panels is in parallel.

Unfortunately, it’s not that easy, and here’s why:

CURRENT and WIRE SIZE in a SOLAR PANEL INSTALLATION

The more amps of current there are flowing in a circuit, the thicker the wire needs to be to ensure that no energy is lost to heat. Unfortunately, thicker, heavier gauge wire is a pain to work with. It’s stiff and doesn’t bend around corners easily. It is hard to tighten down in the solar charge controller connections and it’s hard to crimp ring terminals onto. It is also more expensive per foot.

So, when the solar panels are wired in series, a thinner gauge wire can be used for a given distance than when they are wired in parallel.

Of course, the thickness of the wire is also dependent on the length of the wire. The longer a wire is, the more energy is lost along its length. So, if you are installing the solar panels high on an arch off the aft end of a 50′ sailboat and the batteries are located at the bottom of the hull over the keel, the wire must be a lot heavier gauge than if you are installing the panels on an RV roof directly above the battery compartment.

What is the price difference in the cable? We like to use Ancor Marine Cable because it is tinned and it is very supple (the copper is fine stranded). Here are the price differences for 25′ of 2 gauge wire as compared to 25′ of 10 gauge wire.

Ultimately, there is a dilemma: Is it better to go for thinner, cheaper wire and an easier installation, and wire the panels in series, risking that the whole array will shut down whenever a corner of one panel is shaded by a nearby tree? Or is it better to pay the extra bucks for heavier gauge wire and endure a more challenging installation but have a system that will be more tolerant of partial shade?

What to do?

SOLAR PANEL VOLTAGE and WIRE SIZE

Luckily, there is another option: higher voltage solar panels can be wired with thinner gauge wire. Remember, Watts = Current x Voltage. So, for the same number of watts in a panel, a higher voltage panel will produce a smaller amount of current.

Rather than using four 120 watt 12 volt panels wired in parallel that would produce 28 amps at 12 volts, you can use two 240 watt 24 volt panels wired in parallel that produce 14 amps at 24 volts. The net effect on the battery bank will be the same, but the bigger panels can be wired with smaller gauge wire.

As mentioned above, the wiring that is most affected by these solar panel choices is the wiring that runs from the solar panels to the solar charge controller. The wiring from the solar charge controller to the batteries is the same in either configuration, as the same amount of current will be flowing in that wire regardless of how the solar panels are wired. In the case of solar panels wired in parallel, the voltage will be stepped down in the solar charge controller. So, in our example, the solar charge controller will step down the voltage from 48 volts to 12 volts, ensuring that the circuitry between the solar charge controller and the batteries is at operating at 12 volts.

CHOOSING THE OPTIMAL WIRE GAUGE

The thickness of the wire, or wire gauge, depends entirely on how long the wire is going to be. That is, the wire gauge is determined by how far apart the solar panels and the solar charge controller and the batteries are.

Why is this? The more current that flows in a wire, the more the conductor in the wire will warm up. The more it warms up, the more energy is lost to heat. Eventually, this becomes measurable as a voltage loss between the two end points.

When wiring solar power circuits, you can choose how much voltage loss you are willing to have. Somewhere between 2.5% and 5% is typically considered okay. There are voltage loss tables that will help you decide on the proper wire gauge size for the distance you are spanning between the solar panels and the solar charge controller and between there and the batteries. Here’s a good one:

AWG Voltage Loss Table

An Example: 480 watts of solar power located 27′ from the batteries

  • Say we have four 120 watt 12 volt panels wired in series. If the distance is going to be 27′, then by looking at the third chart at the above link (the 12 volt chart) and going to the line for 8 amps flowing in the wire, it shows a wire run of up to 27′ can be done with 10 gauge wire.
  • Now, imagine putting those same panels in parallel. 32 amps will flow at 12 volts. For that same 27′ distance you’ll need 2 gauge wire.
  • Lastly, instead of using four 120 watt 12 volt panels, use two 240 watt 24 volt panels wired in parallel. For this you use the 2nd chart down (24 volt chart). There will be 16 amps flowing in the wire at 24 volts. You will be able use 8 gauge wire.

Of course, due to the nature of multi-stage battery charging and the changing position (and angle) of the sun in the sky, the solar panels will be operating at full tilt for a very short time each day. They may produce max current for 30 minutes near noon as they wrap up the Bulk Stage, however, as the Absorb stage takes over and continues in the afternoon, the solar charge controller will gradually hold the panels back so they produce far less than max current.

With less than peak current flowing in the wires, less energy will be lost to heat.

If this is confusing, see our articles:
RV and Marine Battery Charging Basics
How Solar Charge Controllers Work

So, although it may seem dire that you’re wiring is on the hairy edge size-wise, it is only that way for a little while each day. Depending on the overall size of the solar power array, the size of the battery bank, and the state of discharge when the batteries wake up in the morning, your system may not even hit the theoretical maximum current production or even come close.

MULTIPLE SOLAR CHARGE CONTROLLERS

Another method of keeping the wire size down is to install more than one big solar charge controller. For instance, you might install several smaller charge controllers for each pair of panels wired in series, or perhaps even one for each panel. Of course, this adds complexity and expense, and you will probably buy less sophisticated solar charge controllers that have fewer programming options than a single big one.

You must run more wires between the RV roof and the location in the coach where the solar charge controllers are installed (preferably next to the batteries), and so you must not only pay for additional solar charge controllers, but you must buy more wire and install it all. However, this design option does deserve mention and consideration.

TILTING THE SOLAR PANELS

Solar panels perform a whole lot better in the summer than in the winter. This is because the sun rides much higher in the sky and its rays hit the panels at a nearly perpendicular angle in the summertime. The days are also a whole lot longer. In the winter, the sun’s rays hit the panels at an angle and the sun is only out for a short while.

Solar panels on a fifth wheel RV roof

Tilting solar panels in winter can improve current production by 30%
Or…install more panels and save yourself from climbing up and down the RV ladder!

To get around this, rather than using ordinary Z-brackets to mount their solar panels on the roof, many RVers use tilting brackets. By tilting the panels towards the sun at about a 45 degree angle (technically, at the angle of your latitude), then the sun’s rays hit the panels at a nice 90 degree angle if they are oriented to face south. This can increase the overall power production by about 30% on a sunny winter day.

The only problem is that you have to climb up on the roof to tilt the panels each time you set up camp and then climb up again later to lay them flat when you are packing up before you drive away. We’ve seen many a winter snowbird driving their RV around with the solar panels still raised.

An alternative is simply to install more solar panels and to keep them lying flat all the time. This is easy for a big RV that has a huge roof but is not so easy for a little trailer with a small roof. We have not installed tilting brackets on our trailers.

MONOCRYSTALLINE vs. POLYCRYSTALLINE SOLAR CELLS

Monocrystalline solar panel

Monocrystalline
solar panel

There are lots of different kinds of solar panels on the market today. There are two primary types of solar cells used in the manufacture of solar panels: monocrystalline and polycrystalline.

Monocrystalline solar panels are more efficient and more expensive, but they are also extremely intolerant of shade. Polycrystalline panels are slightly less efficient and less expensive, but they handle partial shade just a smidge better.

The way to tell if a solar panel is monocrystalline or polycrystalline is to look at the pattern of rectangles on the panel itself.

If the circuitry between the rectangles has large silver diamond shapes, it is monocrystalline. If the pattern of rectangles is just intersecting lines, it is polycrystalline.

Polycrystalline solar panel

Polycrystalline
solar panel

Examples of popular monocrystalline solar panels are here:

Examples of popular polycrystalline solar panels are here:

RIGID ALUMINUM FRAMED SOLAR PANELS vs. SEMI-FLEXIBLE SOLAR PANELS

Flexible solar panel

Flexible solar panel

Solar panels can also be rigid or flexible.

Rigid panels are built with an aluminum frame surrounding tempered glass that covers the solar cells.

Flexible solar panels are built with the solar collecting material impregnated into a thin mylar film that is affixed to an aluminum substrate.

Flexible solar panels are not flimsy, they are simply bendable up to about 30 degrees.

 

There are a number of manufacturers selling flexible solar panels:

FLEXIBLE SOLAR PANEL ADVANTAGES

Flexible solar panels have several advantages over rigid panels. They are a little lighter than framed solar panels and you can glue them onto an RV roof using Dicor Lap Sealant, or something similar. This saves you from the complexity of drilling holes into a perfectly watertight roof and risking creating leaks. This is especially helpful with a fiberglass roof. It takes just a few minutes with a caulk gun to attach these panels to the RV roof.

Another nice feature is that on a rounded roof, like an Airstream travel trailer or Casita travel trailer, the panels can bend to follow the contour of the roof.

Installing solar panels on a motorhome roof

Mark uses Dicor Lap Sealant to affix flexible solar panels to a friend’s fiberglass roof.

One of the most important things for solar panels to work well is heat dissipation. Rigid aluminum framed solar panels stand up off the roof of the RV by about an inch, allowing air to flow underneath and for heat to dissipate. Air can’t flow underneath flexible solar panels. The aluminum substrate serves to dissipate the heat instead. This may or may not be as efficient a method of heat dissipation, and I have heard of a case where all the flexible solar panels on a sailboat had to be replaced after two years because they did not dissipate the heat sufficiently in the tropics and the panels self-destructed.

FLEXIBLE SOLAR PANEL CONSTRUCTION and INSTALLATION

Our RVing friends Dick & Katie asked us to install six 100 watt 12 volt flexible solar panels made by Eco-Worthy on the roof of their motorhome, along with all the other projects involved in an RV solar power installation. Ironically, the hardest part of the entire installation was removing the plastic protection from the aluminum substrate of each panel (it kept ripping!). We all ended up working on this together.

Flexible solar panel installation on an RV

We had a tough time getting the plastic off the back of the Eco-Worthy flexible solar panels

Removing plastic from flexible solar panel

With all of us working together, we got the job done!

Once we got up on the roof, and got past a cute warning from Winnebego, the installation was straight forward.

Warning slippery roof on RV

Hmmm…I wonder what sage advice the manual suggests for this problem?

Solar panel installation on a motorhome RV

Flexible solar panels are lighter than their rigid counterparts

The plastic protection needed to be removed from the face of the panels as well. Interestingly, at one point Mark found himself picking at the corner of the mylar that has the solar collection circuitry embedded in it and almost began to peel that whole layer off the aluminum substrate! But once he got a hold of just the most superficial layer of plastic, it came off easily.

Removing plastic from flexible solar panel

Mark removes the plastic from the face of the flexible solar panels

He used Dicor Lap Sealant to tack down the corners of the panels and then ran a bead around each side of each panel.

FLEXIBLE SOLAR PANEL DISADVANTAGES

Flexible solar panels are less efficient than rigid aluminum framed solar panels, which means you may want to get a few more total watts of solar panels than you would if you were buying framed panels. Bendable panels also can’t be installed on tilting brackets. So, again, buying more total watts may be the best solution.

Flexible solar panels are not as rugged as rigid aluminum framed solar panels built with tempered glass. Overhanging branches can scratch them. This is important for anyone that will be boondocking or dry camping a lot on public lands and in rustic public campgrounds, as it is often impossible to get in or out of a site without ducking under some low lying tree branches.

Some RVers have found that flexible solar panels installed on flat motorhome roofs tend to pool water when it rains. This can lead to debris building up and taking root and damaging the panels.

Perhaps for all these reasons, flexible solar panels are sold with a much shorter warranty than rigid solar panels. Whereas many solar panel manufacturers warranty their tempered glass aluminum framed rigid solar panels for 25 or 30 years, bendable solar panel manufacturers generally warranty their panels for 5 years or less.

This may or may not be relevant for RVers, as the fine print in almost every solar panel manufacturer’s warranty states that their solar panels are not warrantied for use on mobile vehicles.

Also, there has been a huge problem across the entire solar power industry with rigid solar panels failing prematurely in large numbers in big commercial installations (see a May 2013 NY Times article here). Apparently, just because those lovely rigid solar panels are warrantied for decades doesn’t mean they will last that long. We have already had a failure of one of our framed solar panels that was warrantied for 25 years, and we discovered the manufacturer’s warranty did not apply to RV installations.

However, as a general rule, when manufacturers warranty a product for 5 years versus 30 years, it says something about how they think their product will hold up over time.

Flexible solar panels installed on a motorhome RV roof

Nice job! (but don’t fall off that roof!)

CONCLUSION

There are many ways to go about installing solar power on an RV roof, and the solar panels that work best in one installation may not be the same as those that are best for another. Not only is every RV roof different, but every RVer’s needs are different.

If you have loads of space on a big motorhome roof or fifth wheel trailer roof, and you are setting it up for full-time use, you may be best off with three or four 200+ watt 24 volt rigid solar panels wired in parallel. If you have a little tear drop camper you use on weekends and store in the garage, a single flexible 100 watt 12 volt panel may be just the ticket for you.

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RVers Jason and Nikki Wynn have written about the condition of their flexible solar panels after a year of use HERE

Wet Cell vs. AGM Batteries & Wiring Tips for Installation on an RV or Boat!

There is a world of difference between wet cell batteries (also called flooded batteries) and AGM batteries for use in an RV or marine battery bank, because AGM batteries are totally sealed, maintenance free and keep the user from coming into contact with battery acid (electrolyte). In a nutshell, the advantages of AGM batteries over wet cell batteries are the following:

  • AGM batteries are maintenance free, which means:
    • They don’t need periodic equalizing to clean the internal plates and never need the electrolyte topped off with distilled water.
    • They do not release gasses during charging, so they don’t need special venting in the battery compartment.
    • Since gasses are not released, the terminals and battery cables do not corrode over time and don’t need to be cleaned.
  • AGM batteries discharge more slowly than wet cells, so an RV or boat can be stored for a few months without charging the batteries.
  • AGM batteries charge more quickly than flooded batteries because they can accept a higher current during the Bulk charging phase.
  • AGM batteries can be installed in any orientation, which is helpful if installation space is limited.
  • AGM batteries can’t spill battery acid if they are tipped over. This is especially important when a boat heels excessively or capsizes. (Not that you’d be too concerned about spilling electrolyte if your boat were upside down!)
RV battery upgrade from 6 volt wet cell batteries to AGM batteries

.

OUR ORIGINAL BATTERY INSTALLATION

We used Trojan T-105 wet cell (flooded) batteries for nearly six years in our fifth wheel trailer, and they worked great. They were installed in our basement compartment, all lined up in a row. This was a custom installation that was done by H&K Camper Sales in Chanute, Kansas, when we purchased our trailer new from the NuWa factory in 2008.

Fifth wheel RV battery boxes in basement

Four 6 volt golf cart batteries installed in our fifth wheel basement

The original battery compartment was designed at the NuWa factory to hold two 12 volt Group 24 batteries. Group 24 batteries have the same footprint as 6 volt golf cart batteries but are about an inch shorter. We had 2″ angle iron bolted onto our fifth wheel frame so the four batteries could stand side by side in battery boxes.

Angle iron supports under an RV fifth wheel battery bank

2″ angle iron is bolted onto the fifth wheel frame
to support the batteries.

There were four venting flex hoses that ran from the battery boxes to four individual louvered vents on the front of the basement on either side of the hatch door.

RV 5th wheel basement with 6 volt battery boxes

Each battery box is vented to the outside with flex hose going to a louvered vent cover.

These batteries worked well, but because we put our RV in covered storage for 4 to 20 months at a time during the four years we cruised Mexico’s Pacific coast on our sailboat, we were not actively present to take care of the the battery charging and maintenance duties. Despite our best efforts to have someone do this while we were gone, when we moved off of our boat and back into our fifth wheel, we found our four Trojan wet cell batteries were completely dead and unrecoverable.

We replaced these batteries with four inexpensive 6 volt golf cart flooded batteries from Costco. These new batteries did not last. Within 18 months, the internal plates had sulfated badly, they took forever to charge, and they discharged extremely quickly.

6 volt wet cell batteries in fifth wheel RV basement

Upgrade time! We removed the old wet cell batteries and replaced them with AGMs.

In April, 2015, while staying in beautiful Sarasota, Florida, we replaced our wet cell batteries with four fabulous new Trojan Reliant T105-AGM batteries that Trojan had just begun manufacturing and selling. We replaced all the wiring as well.

CORROSION CAUSED BY WET CELL BATTERIES

One of the biggest problems with wet cell, or flooded, batteries is that the battery terminals and ring terminals on the battery cables get corroded easily due to the gassing that goes on when the batteries are being charged. When Mark removed the battery cables from our old batteries, he measured as much as 20 ohms of resistance from the end of each cable to its ring terminal.

Corrosion on battery cable

We measured 20 ohms of resistance between the end of the cable
and the end of the ring terminal.

Flooded batteries need to be held at 14.5 or more volts during the Absorption charging stage (depending on the battery), and at this voltage the electrolyte in the batteries begins to release gasses into the air. These gases are both explosive and corrosive, and venting them protects everything around them. However, inside the battery box these gases can corrode the battery terminals and wiring.

The best way to clean off the corrosion is with a solution of baking soda and distilled water. Put it in a disposable cup and then use a cheap paintbrush to paint it on and smooth it around the terminals and cable ends. Let it sit for a few minutes and then pour a little distilled water over it to rinse the baking soda and crud off. Dry it with paper towels.

Also, while driving down the road, the electrolyte can splash around inside the battery cells and drip out the vent holes. Dust can settle on the spilled electrolyte and can cause a minute trickle discharge across the top of the battery. So, it is important to wipe down the tops of the batteries regularly and keep them clean.

It’s a good idea to wear rubber gloves for all of this too!

6 volt wet cell RV house batteries

These batteries did not hold up well and corroded badly every few weeks.

Watch out for drops of liquid settling on your clothes when messing with the batteries. It’s nearly impossible to avoid, and Mark has holes in some of his jeans from drops of battery acid landing on his pants while he either checked the state of charge of the batteries with a hydrometer or poured distilled water into the battery terminals or cleaned the corrosion from the battery terminals and cable connections.

Battery hydrometer not used with AGM batteries

Now that we have nifty new AGM batteries, we no longer need the hydrometer!

OUR NEW RV BATTERY INSTALLTION

We chose the new Trojan Reliant T105-AGM batteries to replace our old flooded batteries because these are a completely redesigned battery from one of the top battery manufacturers, Trojan Battery. Rather than being dual purpose batteries, like othe AGM batteries on the market, the new Trojan Reliant AGM batteries are single purpose deep cycle batteries.

Trojan Reliant AGM 6 volt RV batteries

Our new Trojan Reliant T105-AGM batteries ready to go.

TRUE “DEEP CYCLE” – START BATTERIES vs. HOUSE BATTERIES

Large RV and marine batteries can be used both to start big engines and to run household appliances. However, these functions are polar opposites of each other! A start battery gives a big but short blast of current to get an engine started and then does nothing. In contrast, a house battery provides a steady stream of current to power lights and household appliances for hours on end.

Most deep cycle AGM batteries on the market today are actually dual purpose start and deep cycle batteries, largely due to the history of how batteries have developed and what they have been used for. The new-to-market (in 2015) Trojan Reliant AGM batteries were engineered from the ground up to be strictly deep cycle batteries, and the design is not compromised with start battery characteristics.

Installing Trojan 6 volt Reliant AGM battery in RV fifth wheel

Mark installs the new batteries in the old plastic battery boxes.

12 volt batteries come in many sizes: Group 24, Group 27, Group 31, 4D, 8D and more. As the battery sizes increase, they provide more and more amp-hour capacity. 6 volt batteries come in various sizes too, and the golf cart size is one of several.

The Trojan Reliant T105-AGM 6 volt golf cart style batteries (68 lbs. each) are rated to have a capacity of 217 amp-hours when two of them are wired in series to create a 12 volt battery bank. In comparison, our sailboat came with three Mastervolt 12 volt 4D AGM batteries (93 lbs. each), and we added a fourth. These batteries were rated to have a capacity of 160 amp-hours each.

The advantage of using two 6 volt golf cart batteries instead of enormous 4D or 8D 12 volt batteries is that they are smaller, lighter and easier to carry around and to put in place during the installation and easier to remove in the event of a failure.

BATTERY WIRING

We wired our four new 6 volt batteries in series and in parallel. We wired two pairs of batteries in series to create two virtual 12 volt battery banks. Then we wired those two 12 volt banks in parallel with each other.

Four 6 volt batteries wired in series and in parallel

Four 6 volt batteries: two pairs wired in series to make virtual 12 volt batteries.
Those pairs are wired in parallel with each other (red / lavender circles explained below).

Trojan Battery recommended the following wire sizes for this battery configuration:

  • 4 gauge wire between the batteries that are wired in series
  • 2 gauge wire between the pairs of 12 volt battery banks wired in parallel

This is thicker wire than many RVers and sailors typically select for their battery banks.

Because we were wiring batteries that would be physically lined up in a row, we drew out a wiring diagram to be sure we got it right.

Four 6 volt batteries in a row wired in series and in parallel

Same wiring but with the batteries lined up in a row (red and lavender circles explained below).

WIRING THE BATTERY CHARGERS and INVERTER

Because AGM batteries have a lower internal resistance, they can accept a higher bulk charging current than wet cell batteries.

Trojan Reliant AGM batteries can accept a bulk charge current of 20% of their 20 hour amp-hour rating. For the T105-AGM batteries, the 20 hour amp-hour rating is 217 amps per pair of batteries wired in series. So the max current the batteries can accept is 20% of 217 amps, or 43 amps, per pair. The wiring for each charging system should be sized for a max current flow of 43 amps.

In contrast, Trojan’s wet cell batteries can accept only 10%-13% of their 20 hour amp-hour rating. For the T105 battery, the 20 hour amp-hour rating is 220 amps per pair of batteries wired in series. So the max current the batteries can accept is 13% of 220 amps, or 28 amps.

It is important when wiring both the battery charging systems and inverter systems into the battery bank (that is, the solar charge controller, the engine alternator on boats and motorhomes, the inverter/charger or the individual DC converter and inverter), to ensure that the wiring going to those devices is connected across the entire battery bank and not to just one 12 volt battery (or 6 volt pair) in the bank.

If the charging systems are connected to the battery terminals of just one 12 volt battery, whether it’s an individual Group 24 or 4D battery or is a pair of 6 volt golf cart batteries wired in series, then the batteries in the system will not charge equally. Likewise, if only one battery of the parallel bank is wired to the DC side of the inverter, the batteries will not discharge equally.

In the above drawings, the two optimal connection points for the charging and inverter systems are shown in red and in lavender. Either pair of terminals works equally well.

We found that with individual devices for our converter, our inverter and our solar charge controller, there were a lot of ring terminals getting piled up on two of the battery terminals. So we chose the inner pair of battery terminals for the inverter and the outer pair for the converter and solar charge controller.

Since we dry camp 100% of the time and rarely use our converter except when we have to pull out our generator after days of storms or to run our air conditioning, this division means that our primary charging system spans the batteries one way while the inverter driving the AC household systems that discharge the batteries span the batteries the other way.

NOT ALL BATTERY CABLE IS CREATED EQUAL

We chose Ancor marine wire for our battery cables because it is very high quality cable. The individual strands of wire inside the casing are thin, which makes this cable very supple, despite being thick overall. It is easy to work with and to snake around tricky areas. The individual strands inside the cable are tinned as well.

This is expensive wire, but after all the wiring projects we have done on our RVs and on our sailboat, we felt it was well worth the extra cost.

We also used Ancor marine tin plated lugs made of high-grade copper with flared ends for our ring terminals (available here).

Ring terminal on battery cable

Mark slips a ring terminal onto the new battery cable.

It was critical to get a good solid connection between the ring terminals and the 2 gauge and 4 gauge wire we were using.

We don’t own a crimper of that size, but West Marine Stores often have a crimper for heavy gauge wire that customers can use, and we got an excellent crimp from a workbench mounted crimper.

Crimping ring terminal on battery cable

Crimping 2 and 4 gauge wire requires a large crimper.

With Mark hanging onto the ring terminal and me hanging onto the wire, we both pulled with all our might and we couldn’t pull the lug off the wire.

Good crimp on battery cable

A good, solid crimp.

As these projects always go, we needed to return to West Marine for crimping a few days later when we wired in our solar charge controller. We went to a closer West Marine store this time, and they had a different crimper that wasn’t quite as nice.

Using a hand crimper to crimp ring terminal onto battery cable

This wire is so thick you need a huge wire cutter!

Mark wasn’t as confident that these crimps were as good electrically as the ones made with the first crimper, even though we couldn’t pull the lugs off the wire. So he fluxed the wire and used a propane torch to flow solder into the connection. This way we had not only a solid physical connection but an excellent electrical connection as well.

Soldering ring terminal crimp on battery cable

Mark flows solder into the connector to make a superior electrical connection.

Then he slipped shrink tubing over the connection and used a heat gun to shrink it in place.

Heat gun shrink wrap over ring terminal on battery cable

Shrink tube covers the whole connection, and a heat gun tightens it up.

After our installation, we discovered that Camco makes 2 and 4 gauge battery cable and you can get them here.

Back at the RV, Mark wired the batteries up. He placed the batteries in the battery box bottoms to keep them from sliding around and put the battery box tops on as well so that if anything fell over in the basement while we were driving, it wouldn’t accidentally land on the battery terminals and short something out. We keep that area clear, but you never know when you’ll hit a huge bump and things will go flying.

Trojan Reliant AGM 6 volt batteries in fifth wheel basement

The batteries are ready for their battery box tops.

The AGM batteries do not need to be vented, so he removed all the vent flex hoses. This gave us much better access into the fifth wheel basement from the front hatch door.

Trojan Reliant AGM 6 volt batteries in fifth wheel RV battery compartment

The new batteries are installed, wired and labeled.

Without any flex hose behind the louvered vents, dust and road grime could now flow into the basement, so Mark removed the vent covers and placed a piece of solid plastic behind each one.

Replacing battery vents on fifth wheel RV

The louvered vents are open to the basement in the back and will let dust in.

RV battery vent

Mark puts a thin plastic sheet behind each louvered vent to keep dust out.

We then went on to wire in our new converter, inverter and solar charge controller (installations to be shown in future blog posts).

HOW DO THE NEW TROJAN RELIANT AGM BATTERIES WORK?

The performance of these new batteries is nothing short of outstanding. We are floored everyday by how quickly they get charged, and not one bit of corrosion has appeared anywhere.

Mark is happy not to have to check the electrolyte levels in the batteries any more or to remember to equalize them every month. The new AGM batteries are winners all around.

RV battery boxes in 5th wheel basement

Even though AGM batteries don’t have to be installed in battery boxes,
ours are because our basement is large and open and we want to protect them from falling objects!

WHY WOULD ANYONE USE FLOODED BATTERIES?

Our Trojan T-105 wet cell batteries worked just fine for us for years, and flooded are actually advantageous over AGM batteries in two significant ways:

  1. Flooded batteries are much cheaper than AGM batteries.
  2. Well maintained wet call batteries can be cycled more times than AGM batteries

Flooded batteries cost 30% to 40% less than AGM batteries. This can add up to a savings of hundreds of dollars. Depending on the value of the RV or boat, it just may not make sense to have a huge investment in batteries on board.

Also, perfectly maintained wet cell batteries can be cycled more times than AGMs. “Perfectly maintained” means staying on top of equalizing the batteries to keep the battery plates clean and also checking each cell in each battery regularly to ensure that the electrolyte is completely topped off with distilled water at all times.

Under these ideal conditions in the laboratories at Trojan Battery, the Trojan T105 flooded batteries can survive 1,200 cycles where they are discharged to 50% (12.06 volts) and then fully recharged. The Trojan Reliant T105-AGM batteries can survive only 1,000 cycles.

Of course, battery cycling in real world conditions is very different than in laboratory conditions. The degree to which RV and boat batteries are discharged and recharged day to day is far from regular (partial discharging and partial recharging are common). Also, batteries on RVs and boats that are left in storage for any period of time can be difficult to maintain and may degrade despite good intentions (like ours did).

So, the ultimate performance and value of flooded versus AGM batteries is going to vary widely from one RVer or sailor to the next. However, for us, we will not be going back to wet cell batteries any time soon!

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RV Refrigerator Replacement – How an RV Warranty Saved Our Bacon!

We’ve been reporting on whether or not an RV warranty is a good investment for RVers, and this page — the second of four installments — presents our latest findings.
(Hint: the answer is a resounding YES!)

Ten days ago, after a fabulous two weeks in Maysville, Kentucky, and a long day of driving, we set up camp, grabbed a beer, and kicked back to enjoy a cold one. But to our dismay, the beer was kinda warm. We ratcheted the RV refrigerator up a notch and went about our business. After dinner and a movie in our RV, we decided to have a bowl of ice cream. When Mark lifted the lid on the Haagen Dazs, what he found inside could only be described as cool chocolate soup.

Oh no! Our 8 year old RV refrigerator had died.

RV extended warranty repair RV refrigerator replacement

Do something quick! We’re going to lose everything in the fridge and freezer!!

As the clock neared midnight, we began a frantic search for RV repair shops in the area. We put together a list of them, went to bed quite distressed, and first thing the next morning we started making phone calls. Mark threw bags of ice in the fridge and freezer and we didn’t dare open either door after that. We lamented sadly that all our frozen meats — all those nice burgers and steaks, and even our bacon, darn it — were quickly defrosting.

After about 15 phone calls, we were still nowhere. Everyone told us it would be a two week wait to get a fridge and that it would probably cost upwards of $1,500. Finally, we called Camping World just south of Indianapolis. They had an identical unit in stock and they could squeeze us in for service the next morning. They told us they always try to make an extra effort for desperate travelers passing through.

Well, we weren’t exactly passing through. We were in Kentucky driving west towards Tennessee, and they were 150 miles to the north in the totally wrong direction. But what can you do? We were absolutely thrilled to find an RV repair facility that had an RV refrigerator in stock and could install it quickly, so a 150 mile detour was not a problem!

This would be our second major repair in just over a month. We had just had our 36′ fifth wheel trailer axle replaced. What’s worse, we were actually on our way to an RV repair appointment in Kansas to fix a leak in our fresh water tank. What kind of luck was that?

As it turns out, Lady Luck was following us very closely. Our RV extended warranty had covered the bulk of the trailer axle repair, and we were pretty sure it would cover this one too.

Where we stood on our trailer warranty at this point was the following:


We were 11 months into a 4 year RV extended warranty
Cost of RV warranty: $1,904
Reimbursements (less deductibles) to date: $1,036
Remaining Reimbursements to Break Even: $868

You can see the current status of our warranty HERE.

It looked like this RV warranty repair would not only bring our total reimbursements to the point of covering the original cost of the RV extended warranty but would go well beyond that.

18 hours after we’d discovered our fridge was dead, Camping World service manager Rick Helvey was in our trailer examining its hulking carcass. He told us that propane RV refrigerators typically last only 10 years.

What??!!

It was no surprise to him that our 8 year old unit had kicked the bucket. He opened the fridge vent on the outside of the trailer and showed us the telltale signs of a dying RV refrigerator: greenish or yellowish dust.

The presence of this dust meant the ammonia was leaking out and the cooling unit had given up the ghost. The crazy thing is that the price of a cooling unit is nearly the same as the price of a new RV refrigerator — Not Cheap!

RV warranty repair on a refrigerator - inside the vent

Yellowish dust in the fridge vent area is proof positive that the fridge is dying.

RV warranty repair RV refrigerator installation

Here is a closer look at the greenish – yellowish dust.

He called our warranty provider, Portfolio Protection, to get approval to proceed with the repair the next morning. To his astonishment (and ours), they said they wouldn’t reimburse us for a replacement refrigerator. They would reimburse us only for the replacement of the cooling unit to save themselves a little money. Here’s the breakdown:

Install New RV Refrigerator Parts: $1,389.99
Labor: $267.00
Tax: $97.00
Total: $1,753.99
Replace Cooling Unit Only Parts: $1,049.00
Labor: $356.00
Tax: $73.43
Shipping: $100.00
Total: $1,578.43

DIFFERENCE IN OVERALL COST: $175.56

This was a problem — for us and for Camping World!!

If we got our refrigerator replaced, we would be in and out of Camping World in 3 hours the next morning and they could go back to business as usual with their local customers. If we had to have the cooling unit replaced, we would have to wait a week or two for the part to come in and Camping World would have to reshuffle their appointments the next morning, once again, because our appointment was already on the books. We had all assumed the approval of a replacement refrigerator would be a slam-dunk.

New RV fridge ready for installation

Our new refrigerator is ready and waiting — all we need is approval to install it!

What to do?

Well, here’s one reason we are becoming more and more enamored of our RV extended warranty through Wholesale Warranties. Unlike most warranty brokers who wash their hands of the deal once you’ve purchased the contract and signed on the dotted line, they are willing to go to bat for you if the warranty reimbursement process isn’t going as smoothly as it should.

We called Wholesale Warranties and told them what was going on. The difference in cost between repairing and replacing was not astronomical. Couldn’t the warranty company allow us to go ahead with the refrigerator replacement?

Within an hour they had called our warranty company, Portfolio Protection, explained to them why it made more sense for everyone involved to install the new fridge Camping World had in stock and, magically, our refrigerator replacement had been approved. We were floored that Wholesale Warranties would do this and that they could be such effective facilitators. Yet it turns out that making these calls is business-as-usual and is routine customer support for them.

Early the next morning we parked the fifth wheel in front of Camping World, and service technician Raymond and his assistant José got started on it right away. Unfortunately, our old refrigerator was 1/4″ too wide and could not fit through our front door. RV refrigerators are installed at the factory before the doors and windows are in place!

RV warranty repair Removing RV refrigerator from fifth wheel trailer

Good heavens, the old fridge can’t go out the front door!

So, the dining room window had to come out!

RV extended warranty Removing an RV window from fifth wheel trailer

The dining room window has to be removed
so the refrigerators can be hoisted in and out.

RV extended warranty repair RV window removed

It would have been so much easier if the refrigerators could have gone through the door!

RV warranty refrigerator replacement gets through window

The new fridge is ready for some strong person to pick it up!

A forklift was used to remove the old fridge and hoist up the new one. It was at this point that I realized just what a challenging DIY project this would have been for Mark!

RV warranty refrigerator replacement New RV fridge on forklift

Thank goodness for fork lifts! This is not an easy DIY installation for one guy!

Then the new RV refrigerator was put in place.

RV warranty repair New RV refrigerator installed in fifth wheel trailer

Raymond settles the new refrigerator into place.

The pretty oak panels from our old refrigerator were slipped into place on the new door.

Under warranty Oak panel installed on RV refrigerator door

Our oak panels from the old fridge slide neatly into place.

Then Raymond ran around back to hook everything up in the refrigerator vent.

RV extended warranty repair new RV refrigerator installation

The back of the new fridge is exposed in the vent area where Raymond hooks it all up.

Meanwhile, his assistant José removed the silicone remnants from the wall around the window opening using a scraper and wiping the wall down with Acrysol

Removing silicone seal on RV window

José scrapes the old silicone sealant off the outside wall
around the window opening.

Removing silicone from RV window

The wall has to be completely clean for a good seal on the window.

Raymond lifted the window into place, and he and José screwed it in place.

RV warranty refrigerator replacement Installing RV window

Raymond puts the window back in place.

Installing RV window on fifth wheel trailer

The guys work together to get the window screwed into place.

Then they remounted the window valence and reinstalled the day-night shades.

Installing valence on RV window

The window valences are reinstalled over the windows.

Installing day-night shades on RV window

The day-night shades are reinstalled on both windows.

Raymond gave us instructions not to put a bead of silicone around the window frame for about a week because he had used caulk tape that would ooze a little for the next few days.

We were impressed with how quickly these guys worked and got the job done, and we were really grateful to Rick for making an opening for us. In just 36 hours from the time we had soup for ice cream, we had a brand new RV refrigerator up and running. Now we just had to wait for it to cool down (about 9 hours).

In the meantime, our frozen meats had fully defrosted but were still cold. We couldn’t re-freeze any of them when the refrigerator finally cooled down. Arghhh!

As we hitched up the fifth wheel, I noticed Mark had a twinkle in his eye as he drove it around to the back lot. He hopped out and instantly set up the barbecue, right there in the Camping World parking lot. He happily began grilling burgers, hot dogs, steaks, chicken and brats.

“We can’t let all this good meat go to waste!” He said to me as he handed me the bacon and sent me inside to fry it up.

It turned out he’d invited the service guys to come on over to our place for a barbecue lunch, and when the yummy smells from our grill began to waft across the Camping World parking lot, they quickly showed up in a golf cart and began chowing down.

The crew enjoys a barbecue lunch

The Camping World service team stops by for an impromptu barbecue. Thank you guys for a super job!

At last it was time to settle up the bill with the service manager, Rick. Our RV warranty deductible was $100. Indiana charges sales tax on deductibles, so our total out of pocket cost for this phenomenal repair was only $107. Wow!!

Our RV warranty (less our $107 deductible + tax) covered $1,647 on this one repair alone — that is nearly the cost of the entire four year RV extended warranty itself!

Shockingly, this RV refrigerator replacement was just one of a slew of major repairs our trailer needed in a four month period in 2015:

Here's a summary of what our four year RV warranty through Wholesale Warranties cost, what our repairs WOULD HAVE cost, and what our warranty reimbursements have been to date:

Cost of Warranty $1,904
Total Cost of Repairs we've had done $7,834
Total Out of Pocket Costs for those repairs $1,145
Repair Reimbursements:
Trailer Axle Replacement $1,036
RV Refrigerator Replacement $1,647
Plumbing Issues & Window Leak $1,142
Suspension Replacement $2,550
RV Toilet Replacement $314
Total Repair Reimbursements $6,689

Our trailer warranty has paid for itself 3.5 times over!
Confused about the nitty gritty fine print buried in RV Extended Warranties? Here's an excellent detailed explanation!!

Are we happy with our extended trailer warranty? OMG Yes!!

Having suffered four major repairs in four months, we have come to the conclusion that anyone with an RV older than four or five years should seriously consider getting an RV extended warranty, especially if they don’t like unexpected financial surprises.

What a shock it was to find out that RV refrigerators are expected to fail by their tenth year of service. All you need is that one repair plus another one or two (air conditioner, water heater, furnace, slide-out mechanism, hydraulic leveling system, etc.) to cover the cost of a four year warranty and even wind up ahead.

Do I sound enthusiastic and excited about our trailer warranty? I am!! I was hugely skeptical about RV warranties before our trailer axle and RV refrigerator replacements, and all I can say is that this has been an amazing process!!

If you want to find out what a warranty would cost for your rig, Wholesale Warranties is offering a $50 discount to our readers. Call our contact, Missi Emmett at (800) 939-2806 or email her at missi@wholesalewarranties.com. Or go to this link:

Wholesale Warranties Quote Form

The discount comes off of the quoted price at the time of purchase — just be sure to ask!

To learn how RV warranties work and how they differ from RV insurance, see this article:

What Is An RV Warranty and Is It A Good Investment?

If propane RV refrigerators are so prone to failure, why don’t we have a residential refrigerator? — It takes a huge solar panel array and big (heavy) battery bank to power a residential refrigerator along with everything else in an RV. See the following:

Can a Residential Refrigerator Run on Solar Power in an RV?

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What Is An RV Warranty – Do You Need One? Is It A Good Investment?

An RV Extended Warranty (or “RV Warranty“) is a mechanical breakdown protection product that you can purchase for your RV to give you a financial boost in the event that a system on your RV suddenly fails. By their very nature and reputation, RV warranties are contracts that most RVers either swear by or swear at, and for those of us whose eyes glaze over when reading legal documents, it can be really hard to figure out whether or not buying an RV extended warranty is a worthwhile investment.

This article is the first in a series of articles about RV extended warranties that present our personal case history with our RV warranty on our 2007 NuWa Hitchhiker II LS fifth wheel trailer (four year warranty cost: $1,904). This first article begins by explaining what RV extended warranties are, how they work, and how they differ from RV insurance. It also explains what to look for when buying an RV extended warranty contract. Then it goes on to show our own RV warranty in action during our first claim which was an axle replacement on our fifth wheel trailer ($1,136 reimbursement).

The rest of the articles in this series show our warranty in action. How valuable is this extended trailer warranty to us?

Here's a summary of what our four year RV warranty through Wholesale Warranties cost, what our repairs WOULD HAVE cost, and what our warranty reimbursements have been to date:

Cost of Warranty $1,904
Total Cost of Repairs we've had done $7,834
Total Out of Pocket Costs for those repairs $1,145
Repair Reimbursements:
Trailer Axle Replacement $1,036
RV Refrigerator Replacement $1,647
Plumbing Issues & Window Leak $1,142
Suspension Replacement $2,550
RV Toilet Replacement $314
Total Repair Reimbursements $6,689

Our trailer warranty has paid for itself 3.5 times over!
Confused about the nitty gritty fine print buried in RV Extended Warranties? Here's an excellent detailed explanation!!

What is an RV Warranty and should you have one?

To buy or not to buy an RV warranty?

You can navigate through this article using these links:

 

RV Extended Warranty Overview

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All RVs come with a manufacturer’s warranty when they are purchased new, and these warranties are good for a year or two.

After the manufacturer’s warranty expires, you can purchase an RV Extended Service Contract, commonly known as an RV Warranty, from an independent warranty company for another few years. Or you can just hope for the best.

RV extended warranties are contracts that describe in detail what is covered and what is not covered by the policy, and they have a specific start date and end date. You can pay for the warranty outright when you sign the contract or you can purchase it over time with payments. These contracts are designed to cover the mechanical working components on and in your RV.

If you have an RV extended warranty, when there is a system failure on your RV, you begin the process of filing a claim with your warranty provider by finding an RV repair shop of your choice to diagnose the problem. The shop then calls the warranty company’s administrator for authorization to do the repair. The claims adjustor then reviews the details of your failure to determine if the failure falls under the coverage offered by the contract you purchased. After a covered repair is completed, the RV repair facility contacts the warranty company to present them with the bill, and the warranty company pays for the covered items immediately with a corporate credit card. You then pay for the items that were not covered by the warranty plus a deductible.

The real sticking point comes with what is covered and what is not covered by the warranty. It is up to you to determine the likelihood that enough items on your RV will break during the time period that the warranty is in place to cover the cost of the warranty. Obviously — and hopefully — it will cover a bit more than that, just to make you feel like you made a smart decision by buying a warranty in the first place.

What Is The Difference Between Insurance and A Warranty?

In a nutshell, the difference between an insurance policy and a warranty is that insurance covers damage caused by an incident or accident happening, while a warranty covers the failure of something mechanical that shouldn’t have broken.

Insurance is there for damage that can be pinpointed to an event on a particular date: a fire, a theft, a tree falling on the rig, a tornado. Warranties are there for systems that die without an obvious cause: the hot water heater can’t warm the water any more, the fridge can’t keep the food cold any more, the air conditioning is on the fritz, or a slideout room refuses to budge in or out.

Insurance is something we all understand pretty well since we’ve all had to have car insurance since we bought our first car. Warranties are a little less familiar because, for most of us, our only experience is with manufacturers’ warranties or with a home warranty we got as part of the deal when buying a house. There are no laws that say we have to purchase a warranty of any kind for any big asset we own, so many folks (like us) steer clear of them!

Risks

The value of an RV warranty all boils down to risk. Just like insurance, you pay some money up front in the hopes that something major goes wrong that will cost a lot more than the money you paid for the contract. It’s a way of protecting yourself from having to come up with a massive amount of money to pay for an unexpected repair — a way of hedging your bets by paying a little now instead of (possibly) a lot later.

Just like playing the slot machines at the casino, you put in quarters — either with regular payments or by paying for the whole contract at the beginning of the warranty — and you hope the bells suddenly go off and a huge pile of quarters lands in your lap. Unfortunately, in the back of our minds, we all know that when it comes to casinos, “the house” always wins. And who owns the biggest and fanciest office buildings in most major cities? The insurance companies!

So, while we consumers are betting that something bad will happen when we buy insurance or a warranty, the insurance and warranty companies are successfully betting that it won’t.

Our RV warranty Personal Case History

RV extended warranties provide the most value for folks that have a rig that is two or more years old. Our fifth wheel trailer that we live in full-time is a 2007 model, and its aging equipment could be very costly to repair. The hot water heater, RV refrigerator and air conditioning systems are all more and more prone to failure as the days pass. Sometimes older rigs like our develop cracks in the frame or the big slide-outs fail (we have three slides). We’ve heard heard horror stories from fellow RVers of broken trailer axles and unexpected $1,700 refrigerator replacements. We realized that an RV warranty could make a lot of sense for us.

As we did our research, we had no idea that we would soon experience both trailer axle AND RV refrigerator failures!

We decided to work with Wholesale Warranties, an RV extended warranty broker. We gave them the details about our rig, and they got quotes from the warranty companies they work with and chose the one that was best suited to our situation. We signed a contract with Portfolio Protection for a $1,904 four year Exclusionary RV Extended Warranty with a $100 deductible.

Fifth wheel trailer RV at Harvey RVs in Bangor Maine

Our fifth wheel peeks out from the its hospital room at Harvey RVs in Bangor Maine

Some warranty companies are fly-by-night operations that might go out of business before the contract period ends, and others have top ratings with the Better Business Bureau and are backed by A-rated insurance companies that will step in and take over if the warranty company fails.

Wholesale Warranties makes it their business to sort out which companies are the best ones and to establish relationships with them. Wholesale Warranties has been growing by leaps and bounds and was named one of Inc 5000’s Fastest Growing Companies in 2014, and one of San Diego’s fastest growing companies in 2015. More important, they have made many clients very happy.

What is unusual about Wholesale Warranties is that they don’t simply sell a contract and walk away. They are there for their clients to help smooth the process, if necessary, when a claim is filed. In fact, they are willing to pay for a client’s claim themselves, if they believe it was wrongly denied, and then fight with the warranty company behind the scenes after the fact.


Little did we know that before the first year of our contract was up, we would need FOUR major repairs on our trailer and we’d end up almost $4,500 AHEAD of the cost of our trailer warranty!

.

The RV Warranty In Action – Trailer Axle Replacement!

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About three weeks ago, in mid-July, 2015, Mark noticed some serious and irregular wear on the passenger side tire on our rear trailer axle. Our tires were just 14 months old, had been properly cared for, and had less than 10,000 miles on them. Oddly, one half of the tire had okay tread while the opposite half, 180 degrees out, was a mess. On the bad half, the tire was severely cupping on the outside tread and was nearly bald. The other three tires looked great. Much research and many phone calls later, we realized that our problem was probably a bent axle.

Bald tire

Weird tire wear: bald on one side, on one half of the tire

Bald tire other side

Same tire spun 180 degrees – bad but not bald!

We were wrapping up our travels in Nova Scotia at the time. We weren’t sure what was involved in replacing an axle, and even though our warranty covered repairs in Canada as well as the US, we had friends in Bangor, Maine, and felt better about doing the repair there. Lippert Components helped us locate a phenomenal RV repair facility in Bangor — Harvey RVs — and we nervously drove 450 miles to Bangor on the faulty tire and took the buggy in.

The diagnosis was exactly what we had expected: a bent axle. The bizarre wear on the tire was due to the tire “dribbling” like a basketball as it rolled down the road. Unfortunately, by the time we got to Bangor, the driver’s side tire on the bad axle was also beginning to cup, and we needed both tires replaced.

We decided to take advantage of our RV warranty to have some other broken items repaired as well. This way, one deductible payment would cover all the different warranty repairs. The extender on one of our awning arms had sheered off, and we had just developed some kind of leak in the fresh water tank during the last few weeks.

Brent Horne, the service manager at Harvey RVs, called our warranty company’s administrator and got same-day authorization to do all three repairs, with the water tank repair pending a full diagnosis.

The axle replacement and awning arm replacement went like clockwork, although we did have to wait ten days for the new axle to be built and shipped from Indiana. A minor complication with the replacement was that the new axle came with electric drum brakes pre-installed and we had to move our new disc brakes from the old axle to the new one.

The diagnosis on the water tank was inconclusive. The leak was at the top of the tank, and we would have to drop the tank out of the trailer frame to determine the cause. Because it was at the top of the tank, it leaked only when the tank was totally topped off, not when it was less than full. We decided to defer that repair to the service folks at the Kansas RV Center (which used to be NuWa, the manufacturer of our trailer) rather than delay our travels waiting for a replacement tank to be shipped to northern Maine. Kansas would be in our general direction as we headed west in the fall.

Old trailer axle new fifth wheel RV axle

The new axle (left) has electric drum brakes and old axle (right) has our nifty new disc brakes.
The challenge with this repair was moving the disc brakes from the old axle to the new one.

When the bill for the repairs came, it was the following:

Awning Arm, tax and labor 46.73
Trailer axle, tax and labor 1,089.42
Freight for trailer axle 219.90
Tires, tax and labor 417.78
Total Repairs: 1,773.83

The Service Manager, Brett, called the warranty company and was immediately paid by credit card for the following:

Awning Arm, tax and labor 46.73
Trailer axle, tax and labor 1,089.42
Total Covered by Warranty: 1,136.15

Our bill was the following:

Freight for trailer axle 219.90
Tires, tax and labor 417.78
Deductible 100.00
Total Out of Pocket: 737.68

 
So, on a total bill of $1,773.83, our savings was $1,036.15.

 

RV Warranty Analysis

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As mentioned above, RV warranties are intended to reimburse the parts, tax and labor expenses for repairing system failures, and the trailer axle and awning arm piece were clear system failures.

However RV warranties do not cover the freight costs for shipping large replacement parts from the manufacturer to the RV repair facility, and they don’t cover “maintenance items” that wear out or need regular maintenance to operate correctly. There is also a very large gray area when it comes to items that were damaged by the failure of something else, like the tires being damaged by the failed axle. Similarly, water damage due to plumbing or roofing failures may or may not be covered.

In our case, even though the tires were very obviously disintegrating because of the bent axle, they are classified as a maintenance item so they weren’t covered. We learned later that Wholesale Warranties has a separate policy for tire failures due to road hazards, but it wouldn’t have helped us in this case either.

So, we paid for the tires out of pocket.

Has our RV warranty done the job so far?

Absolutely! 10 months into our 4 year warranty contract, here’s where we stand:

 
Cost of warranty: $1,904.00
Reimbursed so far: $1,036.15
Remaining to break even: $867.85

We are 20% of the way through our warranty contract period.
We are 54% of the way through our contract cost.

So, we are ahead of the game at this point. $867.85 more in repairs in the next 38 months, and we will have matched the cost of the warranty.

NOTE: We did not know at the time we wrote this that we’d have a bunch more major repairs in the next THREE MONTHS!

A financial breakdown of all our repairs is at the top of this page HERE

Harvey RVs Bangor Maine

All smiles at Harvey RVs after the repair is finished
Expert Technician Steve and Service Manager Brett join me in front of our rolling home.

Could An Insurance Policy Have Done The Job?

Usually, insurance and warranties don’t overlap in the kinds of things they cover. Insurance generally requires an event that caused damage while a warranty generally requires a system to fail on its own. In this particular situation of a bent trailer axle, however, if we could have pinned the axle failure to a particular event, perhaps when we hit one particuarly gargantuan pothole of the thousands we encountered in Nova Scotia, then we could have filed an insurance claim based on hitting that pothole.

Using insurance, our claim would have been:

Trailer axle, tax and labor 1,089.42
Freight for trailer axle 219.90
Tires, tax and labor 417.78
Total Claim: 1,721.10

Note that we couldn’t have slid the awning repair into the insurance claim.

If the claim were approved, all of those items would have been covered. However, we have a $500 deductible on our trailer insurance and we would have had to pay the $46.73 awning repair out of pocket.

Here’s the breakdown for comparable repair work (axle and awning) using our warranty versus our insurance policy:

Covered Out Of Pocket
Warranty 1,136.15 737.68
Insurance 1,721.10 546.73

 

Why Use a Warranty When Insurance Works Too?

If we had filed an insurance claim, there would have been a wait for an insurance adjuster to assess the damage. With the warranty, the authorization for the repair is given to the service provider as soon as they call. Also, our “reward” for filing the insurance claim would have been a ding on our insurance record which would have affected our insurance premium in the future.

If we had had one of those nifty insurance policies that has a “disappearing deductible” that decreases each year that no claim is filed, the clock would have started over again at the maximum deductible amount the next year after we filed the claim.

I’m not sure if the difference in out of pocket costs of $190.95 ($737.68 in the case of using the warranty minus $546.73 in the case of using the insurance policy) would have been made up in the next three years of insurance premiums (the time period that the warranty will continue to be in effect), but it’s easy to imagine this claim resulting in an increase in our annual insurance premium of $66.67 ($190.95 / 3 years).

Of course, this particular system failure — a bent trailer axle — is unusual in that it is even possible that an insurance policy might have been used to pay for it. In most cases, RV systems die on their own without a specific event causing the failure (an accident, road hazard, theft, etc.), and those failures are not eligible for insurance coverage at all.

 

Is An RV Warranty A Good Value?

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RVs are notorious for system failures, and sooner or later big expensive stuff is going to break on every RV.

If you don’t like large, unexpected financial outlays, an RV extended warranty can mitigate or eliminate the cost completely when a major system on board goes on the blink. There’s a lot to be said for that when you are suddenly jerked off the road and away from your travels and dumped into the waiting room at an RV repair shop while you nervously wonder if the service guys are any good and if your rolling home is going to be repaired correctly.

Bicycle riding in Nova Scotia Canada

It’s a shock to be dragged away from your happy travels to deal with an RV repair

Obvioiusly, you could simply bank the amount you would have put into buying an RV warranty and use that cash as needed when things fail. It is easy to go that route when you remember that, on average, RV warranties must work out in favor of the warranty companies or they couldn’t stay in business.

However, an intangible in all of this is peace of mind when chaos reins. Abandoning your travels to take care of an ailing RV is really stressful. Believe me! And there are lots of stresses involved in any repair that is big enough to be warranty-worthy.

There is stress in finding a repair facility that has the right equipment and the right skill set and a good reputation, especially when you are traveling in a part of the country you don’t know. There’s stress in taking a detour to get your RV to the shop if it’s not in totally safe driving condition (like ours was). There’s stress in figuring out where you’re going to stay while your RV is in the shop, if you can’t stay in it. And there’s stress as you wait, first for a shop appointment, and then for the necessary parts to come in.

Going through all that stress while also knowing in the back of your mind that the repair is going to put a big hole in your bank account makes it even worse.

Directions to Everywhere

It’s all fine and dandy to be traveling in remote areas,
but where do you find a top quality RV service repair shop?

The purpose of an RV warranty is to pay up front to cover potential costs later. Where they get the bad rap is when you pay up front to cover potential costs that never materialize or that materialize but aren’t covered. However, if you think about it, in many ways the devil that you don’t know may be worse than the devil that you do.

What I mean is that paying a fixed amount for an RV warranty, an amount that you know up front, may save you more or less cash for repairs in the end, but at least you’ve lessened the surprises and you know your costs. Plus, you may save far more than just cash when all is said and done. Even if having the warranty doesn’t save you all the cash you spent on it, you can view the difference as the price of peace of mind. If it saves you more than it cost you, you’re ahead.

 

What to Look For in an RV Extended Warranty

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It is easiest to turn to a company like Wholesale Warranties to get a warranty. When you work with them they will evaluate which warranty product is the best fit for your RV. Whichever warranty company they recommend for you, one of their requirements is that the warranty company call them if you file a claim that is over $500 so they can be part of the claims process and help it be as smooth as possible.

Since we got our RV warranty (our warranty company is Portfolio Protection), Wholesale Warranties has grown a lot and has begun providing their own warranty protection in addition to brokering for warranty companies like Portfolio Protection. This is a new and exciting development, because they have been through the claims process with their clients so many times that they know what RVers really need. The name of their warranty company is Viking Protection.

However, if you want to research RV warranty companies on your own, here are some things to think about:

Inspection and Age of RV

With the better warranty companies you will need to make your RV available for an inspection to determine the condition of everything at the start of the contract. This way, when you file a claim, there is no question as to whether the problem was a pre-existing condition. The warranty companies that Wholesale Warranties works with will send an agent to your RV, wherever it is parked, to do the inspection, and you don’t have to lift a finger.

If your RV is older than a 2001 model or has over 100,000 miles on the odometer, it may be difficult to find a warranty company. In some cases, a motorhome with more than 100k miles can get a “coach only” warranty for everything except the engine and drive train.

Warranty Types

There are two major warranty types: Stated Components and Exclusionary Contracts. Stated Component contracts cover only what is listed in the contract. Exclusionary Contracts cover everything EXCEPT the items listed. Definitely get an Exclusionary Contract, as many more things are covered in that type of contract.

You Choose the RV Repair Shop

Make sure there’s no clause that restricts who can do the work. You want to choose the best repair facility you can find and not be forced into using one that is not up to your standards.

Deductible

Deductibles can vary. Make sure you know what it is!

Fair Treatment of the RV Repair Shop

Be sure the warranty company guarantees to pay the RV repair shop quickly, preferably immediately with a corporate credit card, and make sure they pay the shop’s standard prices for the parts rather than wholesale or some amount to be negotiated. RV repair shops are often little outfits, and they can’t afford to be toyed with by a warranty company.

What Happens if the RV is Sold

Be sure the contract will be valid for another owner, just in case you decide to sell before it expires. A warranty is a nice perk to offer the buyer that may set your rig apart from others they are considering.

Cancellation, Missed Payments and Refund

Find out what happens if you decide to cancel the contract prematurely, and whether the purchase price will be refunded in whole or in part, and find out what happens if you miss a payment. Some warranty companies offer a month-to-month payment arrangement, but in the event that you miss a payment the contract terminates. Wholesale Warranties goes the extra mile and will work with you if you have extenuating circumstances that make it hard to make a payment, and if you cancel before the contract is up, you will be refunded the unused portion of the contract.

Hotel & Lodging Reimbursement

Some warranties cover a certain amount of lodging if you can’t stay in the RV during the repair. This is where Wholesale Warranties is really taking care of RVers with their new Viking Protection contracts. You will be reimbursed for “trip interruption” expenses of: $150/day in hotel rooms (up to $750), $50/meal for 2 meals a day (up to $500), $75/day for a rental car (up to $450), up to $100 towards boarding your pet and up to $200 to cover a mobile mechanic’s upfront fee for coming out to your RV.

Towing and Roadside Assistance

Some warranty companies offer reimbursements for some amount of towing and/or roadside assistance. Wholesale Warranties‘ new Viking Protection reimburses up to $750 in towing expenses.

Canadian RVers and RVing in Canada

If you plan to travel to Canada, make sure the warranty company covers repairs done in Canada. Also, not all warranty companies cover RVs that are registered in Canada. Wholesale Warranties’ new Viking Protection does!

 

Final Notes

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We couldn’t be happier with our RV warranty so far, and have been convinced in the value of purchasing an RV warranty.

At this point we still have three years to go on our warranty, and we have a big repair looming as we tackle the problem with our fresh water tank. We have no idea how our RV warranty will come into play on that repair, or if it will at all, and of course, we will be posting and analyzing that repair!

It’s a pain to feel that you have to buy yet one more big ticket item for your RV, and I am the last person to say you need to do this or that in your RVing adventures. However, if you are interested, Wholesale Warranties is offering a $50 discount to our readers. Mention that you heard about them through our website, Roads Less Traveled, and they will deduct $50 from the quoted price at the time of purchase. Just be sure to ask! You can get a quote for your RV (not including the discount) at this link:

Wholesale Warranties Quote Form

Or you can call them at 800-939-2806. Ask for our contact, Missi Emmett. Or email her at missi@wholesalewarranties.com.

NOTE: We had no idea during this first repair that in the next few months we would have a slew of major failures after our trailer axle was replaced. The summary of our warranty reimbursements to date is below:

Here's a summary of what our four year RV warranty through Wholesale Warranties cost, what our repairs WOULD HAVE cost, and what our warranty reimbursements have been to date:

Cost of Warranty $1,904
Total Cost of Repairs we've had done $7,834
Total Out of Pocket Costs for those repairs $1,145
Repair Reimbursements:
Trailer Axle Replacement $1,036
RV Refrigerator Replacement $1,647
Plumbing Issues & Window Leak $1,142
Suspension Replacement $2,550
RV Toilet Replacement $314
Total Repair Reimbursements $6,689

Our trailer warranty has paid for itself 3.5 times over!
Confused about the nitty gritty fine print buried in RV Extended Warranties? Here's an excellent detailed explanation!!

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RV / Marine Battery Charging – Solar & Shore Power Combined!

What happens when two RV or marine battery charging systems attempt to charge the batteries at the same time? The interactions between solar charge controllers, converters, inverter/chargers and engine alternators can be complex, and in our lives off the grid in a sailboat and RV, we have observed them working together in many different kinds of circumstances.

This page offers some insights into what goes on when two battery charging systems operate simultaneously, specifically: solar power and shore power, and solar power and an engine alternator. It is the fourth post in our series on RV and Marine Battery Charging Systems. The previous articles in this series are:

  1. RV and Marine Battery Charging Basics
  2. Converter, Inverter/Charger and Engine Alternator Battery Charging Systems
  3. Solar Charge Controllers – Optimizing Battery Charging from the Sun

This is a long post and you can navigate to the various sections using these links:

 

WHAT HAPPENS WHEN TWO CHARGING SYSTEMS OPERATE AT ONCE?

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When two battery charging systems are working side by side simultaneously, each follows its own internal algorithms to get the job done. However, when this happens, and the two charging systems measure the battery voltage to determine which charging stage they should each be in, they don’t see a “real” value. They see an artificially elevated battery voltage due to the presence of the other charging system. This can throw one or the other or both systems off of their normal Bulk-Absorb-Float cycle.

Because solar charging systems operate 24/7, the most common scenario in which two charging systems work simultaneously is solar charging and some form of artificially powered charging, either a converter or inverter/charger when the RV or boat is plugged into shore power or the generator is turned on, or an engine alternator when the boat or motorhome is under way.

The bottom line with two charging systems working simultaneously is that each will do a little work, but one will do more work than the other. Higher end solar charge controllers are designed to ensure that the batteries are never overcharged. As explained in the previous post about solar charge controllers, they are the gate keepers for the solar panels and will reduce the current coming in from the panels to 0 amps if need be.

There are many factors to consider when running an artificially powered charging system alongside a solar charging system. And in reality, just letting the two systems do their thing without worrying about how they get along is probably fine. But for those who want to ponder the relationships, here are some things we’ve learned.

SETTING COMMON BASELINE CHARGING STAGE VOLTAGES

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In order for all the charging systems on an RV or boat to work together truly harmoniously, it is helpful for the voltages at which the systems change charging stages to be the same across all the systems. For instance, each charging system should be set up with one common set of voltages similar to the following:

  • Bulk 14.7 volts
  • Absorb 14.7 volts
  • Float 13.5 volts

If these terms are confusing, have a peek at Battery Charging Basics.

Obviously, these voltages should be whatever values you have determined are optimal for your battery type. Unfortunately, some charging systems don’t allow you to enter specific voltages, so you may be stuck with whatever defaults the manufacturer chose or whatever “set” of voltages they provide that is closest to the values you want.

Flexible solar panels on a motorhome RV roof

Soaking up the sun:
600 watts of flexible solar panels we installed on a friend’s motorhome roof.

As you can see, if one system has an Absorb target voltage of 14.7 volts and another has an Absorb target voltage of 14.1 volts, there is going to be a conflict. What will happen is that the system that is aiming for the higher voltage will win out and raise the batteries to or towards the higher voltage. The reaction of the other system will depend on how it was designed to handle a situation where the battery voltage is higher than the stage it was in. This is true for all the target voltages (Bulk, Absorb and Float).

Similarly, all the charging systems on the RV or boat should be set up with the same algorithm for switching from one stage to the next. However, as shown in the posts about converters, inverter/chargers and engine Alternators and about solar charge controllers, this is not possible, because every product made by the many manufacturers who build these things has a unique charging algorithm.

There are some similarities, however. All multi-stage charging systems remain in the Bulk stage, pouring the maximum current they can into the batteries, until the Bulk voltage is reached. Then they switch to the Absorb stage. However, no two charging systems use the same criteria to exit the Absorb stage to go into Float. The Float stage is also handled differently by different chargers and manufacturers.

 

EFFECTS OF VOLTAGE LOSS IN THE WIRING

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Every RV and marine battery multi-stage charging system monitors the battery voltage to decide which stage to be in. How and where this voltage is measured and how each device is internally calibrated can make quite a difference.

For instance, the solar charge controller in a sailboat may be located as much as 20′ from the battery bank if the batteries are strung out from bow to stern in the bottom of the bilge and the charge controller is mounted in an aft compartment. Unless the charge controller is connected to the batteries with fairly beefy wires, there will be some voltage loss between the batteries and the charge controller, and the charge controller will get inaccurate readings of what the battery voltage actually is.

This can happen even if the distance is just 10′ but the wire used is too small for that distance. It can also happen if the engine alternator or the converter or the inverter/charger is a long distance from the batteries. Wire gauge sizes, distances and percentages of voltage lost are given in the following chart:

Wiring Gauge vs. Voltage Loss Chart

EFFECT OF DIFFERENCES IN CALIBRATION

Higher end solar charge controllers are complex pieces of electronic engineering that are likely to be calibrated pretty well coming out of the factory. However, a cheapie single stage converter, like the factory installed units that come with so many RVs, may not be calibrated as well, and may be off in its measurement of the battery voltage by a tenth of a volt or more. Likewise with a simplistic engine alternator.

It was a big surprise to me to read in the user manual for our boat’s engine alternator/regulator (a Balmar ARS-4 multi-stage regulator) that the voltages may be off by +/- 3%. That means that a target Bulk voltage of 14.4 volts could vary between 14.0 volts and 14.8 volts. Hmmm. Not a lot of precision there!

Solar panels on a sailboat

Our solar panels catch some tropical rays on the back of our sailboat during our cruise in Mexico.

If the two charging systems that are working simultaneously are detecting different voltages on the batteries — for instance, the solar charge controller is measuring the batteries to be 14.5 volts while the converter is measuring them to be 14.7 volts — they will each react according to their own internal charging algorthims.

For instance, say both the solar charge controller and converter are in Bulk mode, trying to attain a voltage of 14.7 volts before switching to Absorb. When the batteries reach 14.7 volts according to the converter, the converter will think they have achieved the Bulk voltage already and will switch to the Absorb stage, while the solar charge controller will remain in the Bulk stage because it sees only 14.5 volts, and it will continue aiming for 14.7 volts, according to its internal measurements and algorithm.

What does this mean? It simply means that the solar charge controller will continue to let as much current in from the solar panels as they can produce while the converter will already be backing off how much current it puts into the batteries to hold them steady at what it perceives to be 14.7 volts (and which the solar charge controller sees as 14.5 volts). Not a big deal. The solar charge controller will keep pushing while the converter keeps backing off, and the job will eventually get done.

 

LESSONS LEARNED FROM OUR ENGINE ALTERNATOR AND SOLAR CHARGE CONTROLLER

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The most challenging relationship we’ve had between charging systems was on our sailboat, and it was the one that forced me to investigate this whole business more deeply and to learn how to program a solar charge controller — and to discover, in the process, the value of programming one!

The two systems were our Balmar ARS-4 engine alternator/regulator and our Xantrex XW-MPPT-60-150 solar charge controller. The charging algorithms for these systems are described in detail here (for the alternator) and here (for the solar charger).

When I first observed them working together, I noticed two things right away.

1) Whenever we turned on the engine, the solar charge controller went into the Float stage soon afterwards.

2) Once the solar charge controller was in the Float stage, if we turned the engine off, it remained in the Float stage, even if the batteries hadn’t been fully charged by the engine alternator.

For instance, if the solar charge controller had been in the Absorb stage when we turned the engine on, and then we ran the engine for just 15 minutes and turned it off (not nearly long enough to charge the batteries), the solar charge controller would wind up in the Float stage and remain there for the rest of the day, depriving the batteries of a proper charge.

Engine Alternator Causes the Solar Charge Controller to Switch from Absorb to Float

The thing about batteries in a complex vehicle like a motorhome or a boat is that they are running many different systems that are continually turning on and off. In the case of our boat, when we were underway, any or all of our big systems might be in use at any one time: fridge and freezer compressors, radar, chartplotter, autopilot, anchor windlass, and even the microwave.

Marine diesel engine alternator Balmar ARS-4 100 amp

100 amp Balmar diesel engine alternator

Worst case, all of those things might be on at once for several minutes as we raised or lowered 200′ of stainless steel anchor chain with a 60 lb. anchor attached to the end of it (well, maybe not the microwave!).

Plus, there was no guarantee we’d run the engine long enough for the alternator to go through its Bulk and Absorb stages and charge the batteries completely.

We might run it for as little as a few minutes while moving from one anchoring spot to another, or for half an hour while we motored out of the bay to go daysailing.

We wouldn’t want to idle the engine at anchor just to charge the batteries, because the engine RPMs have to be fairly high for the alternator to generate a good charging current. These high RPMs happen naturally while driving the boat, but unfortunately, conventional wisdom says that revving the engine to high RPMs while not in gear (i.e., without a load on it) risks glazing the cylinder walls.

Besides it being random as to how long we might run the engine, it was also random as to what state the solar charge controller would be in when we started the engine up.

We might start the engine in the dark to raise the anchor, and in that case the solar charge controller would be asleep. Or we might do it early in the morning when the solar charge controller was in the Bulk stage and gamely trying to get whatever current it could from the wimpy sun on the horizon. Or we might do it later in the day when the solar charge controller was in the Absorb stage and cranking away.

We used a clamp-on ammeter to find out exactly what was going on at various points in the system. We put it around the alternator’s battery cable to see how much current the alternator was putting into the batteries. We also used it on the solar charge controller’s battery cable to verify that the current it displayed on its LCD screen was correct (it was).

Sperry Clamp-On Ammeter measures current from engine alternator

The alternator is pouring 77.9 amps into the batteries – WOW!!

Whenever we turned on the engine, regardless of what the solar charge controller was doing, the engine alternator would immediately go into the Bulk stage and dump as much current into the batteries as they needed to reach the alternator’s Bulk voltage.

If the solar charge controller had been in the Bulk stage already, its job would suddenly become much easier as it got a huge boost from the alternator.

If it had been putting 21 amps into the batteries and had been slowly raising the voltage towards 14.4 volts (the setting we had for the boat’s batteries), the engine alternator might contribute another 40 amps for a while, getting the batteries up to the Bulk voltage a whole lot faster than if the solar panels had continued working by themselves.

If the solar charge controller had been in the Absorb stage already, putting something like 18 amps into the batteries to hold the Absorb voltage of 14.4 volts, the engine alternator would begin its own Bulk stage regardless, and it would remain in the Bulk stage for 36 minutes as it followed its own internal algorithm.

The solar charge controller would react by backing off and delivering less current.

To make things more complicated, as these two systems worked through their charging stages, the loads on the batteries would be fluctuating widely as Mark and I went about our business of living on a boat.

If the fridge and freezer compressors were both running, and the autopilot was maintaining our course and the radar and chartplotter were on and we were making burritos in the microwave, the batteries would need a lot of current.

However, if neither compressor was on and someone was hand steering the boat, etc., then the batteries would need a whole lot less current. During those lulls in current demand, the solar charge controller would suddenly scale things way back and put just 8 or 9 amps from the panels into the batteries.

As soon as that happened, the solar charge controller would suddenly switch to the Float stage!

Huh?!

After some sleuthing, as described in the previous post, I realized that the charge controller was switching from Absorb to the Float stage because the current needed to maintain the Absorb voltage had dropped below 2% of the capacity of the battery bank.

2008 Hunter 44DS Sailboat Groovy in Tangolunda Bay Huatulco Mexico

In Tangolunda Bay (Huatulco, Mexico) we motored back and forth across the bay every few days to anchor out of the swell as it changed its flow.

Since I had entered the true value of the battery bank (710 amp-hours), the controller switched from Absorb to Float when the current dropped below 14 amps (2% of 710).

So, I lied to the controller and told it the battery bank was just 250 amp-hours. Then it would remain in Absorb down to 5 amps.

What I found (by trial and error) was that the solar charge controller pretty much always needed more than 5 amps when it was in Bulk or Absorb.

I don’t know why the alternator didn’t produce that last 5 or so amps on its own, but I suspect it was because the alternator’s Absorb voltage was set to 14.2 volts while the solar charge controller’s Absorb voltage was set to 14.4 volts (the alternator had “sets” of values for the three target voltages, and 14.2 volts for Absorb was in what I felt at the time was the most appropriate set).

The Solar Charge Controller Gets Stuck in the Float Stage

The second problem I encountered was that in the event that the solar charge controller went into the Float stage prematurely, then, after the engine was turned off it would remain there until the next morning.

Xantrex XW MPPT 60-150 Solar Charge Controller

Xantrex solar charge controller
(bottom plate removed)

Yet the batteries may not have been fully charged by the alternator, and they may have really needed to remain in Absorb with the solar panels charging them at a fast clip for another hour or two.

In this case, the solar charge controller needed either to resume the Absorb stage or cycle back through the Bulk stage as soon as the engine was turned off.

The only way the Xantrex XW MPPT 60-150 would cycle back through the Bulk stage is if the battery voltage dropped below a certain level.

I experimented with different voltages. The Float voltage was 13.4 volts, so if I set the “ReBulk” voltage to be 13.5 volts or higher, then the charge controller would never get into the Float stage at all, because it would keep cycling back to Bulk.

According to the user manual, this is actually a valid way to operate this solar charge controller, and they even provide a programming parameter that sets the charge controller up to be a “two stage” charger that has no Float stage and has just the Bulk and Absorb stages.

I wasn’t comfortable with not having a Float stage (although in hindsight that probably would have been just fine given the intermittent heavy loads that were on the batteries all day long). In the end, I settled on a ReBulk value of 12.9 volts.

So, if the solar charge controller was in the Float stage after the engine was turned off, and a big load came on some time afterwards that drew the battery voltage down from 13.4 volts to below 12.9 volts (microwave plus fridge and freezer, for instance), then the solar charge controller would cycle back through the Bulk stage and start the charging cycle all over again.

Programming For Storage

Periodically, we left the boat for a month or several months at a time when we traveled inland or went back to our RV for hurricane season. Since the fridge and freezer would be turned off, and there would be no loads on the batteries at all, I would undo these two programming changes. I would reprogram the solar charge controller with the true size of the battery bank so it would switch from Absorb to Float at 14 amps rather than 5, and I would change the “ReBulk” voltage back to 12.5, the factory default.

 

SOLAR CHARGING AND ELECTRIC HOOKUPS

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Sometimes There Are Good Reasons Not To Plug In!

Solar power is free, however, the electricity from shore power hookups may not be. If your shore power electricity is “free” (i.e., built into the overnight fee you are paying for your RV site or boat slip), then it doesn’t really matter which charging system is dominant.

If you have metered electricity (a common situation if you are renting your RV site or your boat slip on a monthly, seasonal or annual basis), and you are paying for your electricity, then you may want to ensure that your solar charger is running the show and doing the bulk of the work while your converter or inverter/charger is playing second fiddle.

One easy way to do this is just to flip off the electric switch on the shore power post. Flip it on only as needed when the batteries get low and need a boost.

We did this a lot when we lived on our sailboat. We lived at a slip in Paradise Village Marina in Puerto Vallarta, Mexico, as well as at slips at Hotel Coral and at Cruiseport Marina in Ensenada Mexico for months at a time without plugging in the shore power cord at all. During hurricane seasons, we also left our boat in a slip in Marina Chiapas for seven months without plugging it into shore power.

It was nice when we settled up the bills for these places at the end of each stay to have a big ol’ “$0” on the line item for electricity.

What Happens If You DO Plug In?

If your RV or boat is plugged into shore power, and the switch at the post is turned on, it is hard to get the solar power system to be dominant because its power source is flakey (as explained here).

We plugged our sailboat into shore power for several months while we lived aboard at Kona Kai Marina in San Diego at the end of our cruise.

Schneider Electric 2500 watt inverter charger Xantrex

Schneider Electric (Xantrex)
2500 watt Freedom inverter / charger

Our Xantrex inverter/charger went through the Bulk and Absorb stages the first time we plugged in, and then it remained in the Float stage forever after (except when we unplugged to go day sailing and plugged back in again upon returning)!

Each morning when our Xantrex solar charge controller woke up, it zipped through the charging stages and went into the Float stage after just a few minutes, because it saw the batteries were already fully charged.

In our RV, we plugged into shore power for 48 hours during rainy and stormy skies while we stayed at Narrows Too RV Resort in Maine. It was overcast when we plugged in. Our Outback solar charge controller was in the Bulk stage putting about 6 amps into the batteries at around 13.9 volts (it was aiming for 14.7 volts).

Ordinarily, since we live a solar power only lifestyle, our Outback solar charger is set up with Bulk and Absorb values of 14.7 volts, a minimum Absorb time of 2 hours and a maximum Absorb time of 4 hours. However, our Iota DLS-90 / IQ4 Converter has a fixed (non-modifiable) Bulk voltage of 14.6 volts and Absorb voltage of 14.2 volts and Absorb time of 8 hours.

I temporarily changed the solar charge controller to have Bulk and Absorb voltages that matched the converter, and minimum and maximum Absorb times of 0 hours so it would remain in Absorb only as long as it took to get to Bulk (the charging algorithm of the Outback solar charge controller is explained in detail here).

Iota DLS 90 IQ4 Converter and smart charger

Iota DLS 90 IQ4 Converter and smart charger ready for installation in our RV

As soon as we plugged in, the converter began dumping 49 amps into the batteries which zoomed the battery voltage up to the converter’s Bulk stage value of 14.6 volts. Then it backed way off to 30 amps, then 20, then 15 as it held the converter’s and solar charger’s Absorb voltage of 14.2 volts (our new Trojan Reliant AGM 6 volt batteries charge up extraordinarily quickly!).

The Outback solar charge controller responded by putting in a few amps at first, but then it displayed “Bat Full” and went to sleep!

From there, the Outback solar charge controller went through its usual Sleeping and ZZZZ stages as the Iota DLS-90 / IQ4 Converter quietly slipped from Absorb (14.2 volts) to Float (13.6 volts). When the Outback solar charge controller went through its wakeup sequence after being in the ZZZZ stage for 3 hours, it saw the batteries were fully charged, so it rolled over and went back to sleep in the ZZZZ mode.

Outback FlexMax 60 Solar Charge Controller

We catch our RV’s solar charge controller sleeping on the job at midday!
The solar panels are in full sun and are at 68 volts
The converter is in control and has elevated the batteries to 13.5v
But the controller sleeps soundly as 0 amps go from the panels to the batteries!

In fact, the whole rest of the time we were plugged into shore power, the Outback solar charger stayed in the ZZZZ mode, even in bright afternoon sunshine. Every 3 hours it would lazily open its eyes, yawn, look at the state of the batteries, see that they were fully charged and go right back to dreamland in the ZZZZ mode.

To summarize, these are two examples of how different solar charge controllers handled the presence of full-time shore power:

Do The Different Charging Voltages Have To Match?

No. On another occasion, while getting repairs done at an RV dealership, we plugged in our trailer for an afternoon while it was out on the lot next to the building on a cloudy day. The solar charge controller was putting in 6 amps at 13.8 volts in the Absorb stage (trying to keep the batteries at 14.7 volts) at mid-afternoon.

As soon as the shore power cord was plugged in, the converter began dumping 55 amps into the batteries and the battery voltage zoomed to 14.6 volts. The solar charge controller kept putting in around 6 amps.

For the next few minutes, the total current going into the batteries dropped from 61 amps to 33 amps and then settled there. If the solar charge controller could put in 8 amps, as the sky lightened, the converter put in 25 amps. If the solar charge controller could put in only 2 amps as the sky darkened, the converter put in 31 amps.

Suddenly, the converter switched to its Absorb stage where it holds the batteries at 14.2 volts, and the total current going into the batteries dropped to 20 amps. The solar charge controller was still in its own Absorb stage where it wanted to hold the batteries at 14.7 volts, so it kept putting in as much current as it could (5 to 8 amps and even as high as 12 when the sun came out for a few minutes) while the converter made up the difference, keeping the total at around 20 amps.

We didn’t stay plugged in long enough to see the solar charge controller switch to Float (the converter stays in Absorb for 8 hours), but at that point the converter would have held the batteries at 14.2 volts while the solar charge controller wanted them at 13.5 volts. It also would have been dark, so the converter would have been in complete control and the solar charge controller would have gone to sleep.

 

GETTING THE MOST OUT OF A BACKUP GENERATOR

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If you are using a generator to give the batteries a boost of charge because you’ve been in cloudy conditions or don’t have enough solar power to run everything on board indefinitely, then you’ll want the generator to charge the batteries as quickly as possible, saving you a few dollars in fuel (gas or diesel) and saving yourself from the loud noise and obnoxious fumes of the generator itself.

Yamaha 2400i Portable Gas Generator

Yamaha 2400i generator — our backup

In essence, the goal with a generator is to run it for as short a time as possible to get the batteries charged up.

With solar power, at the end of the day, before nightfall, the batteries are in their most charged state.

During the evening and into the darkest hours of the night, the batteries get depleted from running the lights, the TV, the computers, the microwave and whatever else your household uses until bedtime.

By dawn, the batteries are at their lowest state of charge. This is also a time when the sun is low in the sky and the solar panels are operating weakly and producing minimal current.

Early morning is the ideal time to turn on the generator!

An Example of Generator Use at Midday versus Dawn

The first time we fired up our generator to charge our batteries via the Iota DLS-90 / IQ4 converter, we’d had several overcast days in a row. It was mid-afternoon, and the batteries were fairly depleted from days of cloudiness. However, they had already gotten about 25 amp-hours of charge during the morning and noon hour, so they weren’t as depleted as they had been at dawn.

The solar panels were limping along in the Bulk stage with the batteries at about 13.5 volts. The solar charge controller was aiming at a Bulk voltage of 14.7 volts and the panels were valiantly trying to produce enough current to get there, but all they could muster was about 6 amps. It wasn’t likely the batteries would reach the Float stage before dark.

As soon as we turned on the generator, the the Iota converter went into the Bulk stage and began delivering about 60 amps to the batteries. It quickly got them up to 14.6 volts and switched to Absorb, dropping to about 20 amps. Great! But this converter is capable of putting 90 amps into the batteries, so why run it when Bulk mode delivers just 20 amps?

Solar panels on a fifth wheel RV roof

We let the solar panels do their job during the day.

We decided turn off the generator and let the solar panels do whatever they could for the rest of the day.

Early the next morning when the batteries were depleted from several days of inadequate charging plus a night of activity in the RV (they were down to about 12.3 volts), we fired it up again.

I did not modify the settings on the Outback solar charge controller to match those of the converter because we were just going to run the generator for a few hours and probably wouldn’t need it again for a few months.

This time the converter rolled up its sleeves and got to work, pumping 67 amps into the batteries as it aimed for its target Bulk voltage of 14.6 volts. The solar charge controller was in Bulk mode too and was busy putting in 1-2 amps of its own (it was early morning), and with the converter’s assistance, it briefly hit 14.7 volt Bulk target and switched to Absorb.

With both the converter and solar charge controller operating in the Absorb stage, the converter dropped the current to maintain the target Absorb voltage. The solar charge controller could still bring only 1-2 amps to the party due to the low light, so the converter was in control and doing virtually all the work.

We shut off the generator off after about two hours and let the solar charge controller take over. Now that the batteries were partially charged up, the solar charge controller was able to get the batteries up to its Absorb voltage target and finish the job, even in the overcast conditions, getting the batteries through its Absorb stage and going into the Float stage for the first time in a few days.

 

 

FINAL NOTES

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So, you can see, there are many ways to charge RV and boat batteries and many things to consider. Of course, it’s easy enough to leave the various charging systems at their factory settings after installing them, and there is nothing wrong with that!

But if you want to understand your system and get the most out of it — especially if you are using solar power and end up running a second charging system in conjunction with your solar power system — you may want to dig into the nitty gritty details buried in the user manuals and figure out what the charging algorithms are and how to program each system with the parameters that make the most sense for you.

All battery charging systems for mobile installations like RVs and boats have become increasingly more sophisticated over the years. A quick review of the older systems described in detail in the previous posts here and here show how the engineers designing these systems have become more and more knowledgeable about the real world applications of their products and what conditions they might encounter as they interact with other charging systems.

As the years go by from here forward, more and more solar charge controllers, inverter/chargers, converters and engine alternators will be designed with the understanding that they may not be the only charging system operating in the RV or boat.
 

This was the last article in our series on RV and Marine Battery Charging:

Related posts about batteries, solar power and living off the grid in an RV or boat:

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Solar Charge Controllers – Optimizing RV Battery Charging

The solar charge controller is the heart of any solar power installation on an RV or boat. It is the gatekeeper between the solar panels and the batteries, and it determines how much of the sun’s energy that is available to the solar panels will actually be converted into electrical current to charge the batteries.

Because solar power is a “set it and forget it” type of system, it is not “mission critical” to understand the inner workings of these complex pieces of gear. However, if you want to get the most out of your solar panels, you may want to fine tune your system to increase its battery charging capacity by programming the solar charge controller for optimal performance.

This page gives the low-down on how solar charge controllers work, presents ideas for how to size them, and explains what the typical input parameters are and how they affect performance. It then explores three specific charge controllers made by three different manufacturers, and compares the unique ways that each manufacturer has tackled the challenge of multi-stage charging via the sun.

Since we started traveling full-time in 2007, as of June 2019, we have used, worked with and lived with these particular units for over 4,000 nights of living off the grid in our RV and sailboat.

1200 Solar Charge Controllers and RV Battery Charging

An in depth look at solar charge controllers

This is the third part of our 4-part series on RV and marine battery charging systems.

So far in this series, we have reviewed the basic concepts involved in charging RV and marine batteries, including an in-depth review of multi-stage charging, and we also have looked at how “artificially powered” charging systems like converters, inverter/chargers and engine alternators go about the process of battery charging. The other parts in this series are:

This is a long post and you can read it in stages and navigate to the different sections by clicking on the links below:

 

SOLAR CHARGE CONTROLLER OVERVIEW

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Solar charge controllers are a lot more complex than all of the charging systems described so far in this series (converters, inverter/chargers and engine alternators), and they offer a lot more flexibility for programming too, usually through a menu driven screen interface. What makes these systems so complicated?

— The sun not a consistent power source like the local power plant or an engine

“Artificially powered” chargers like converters, inverter/chargers and engine alternators have unlimited power backing them, either from electricity at a power plant or an engine. This allows them to perform optimally no matter what the circumstances are. In contrast, solar charge controllers are dealing with a very flaky power source.

The sun — flaky? Yes! The energy available from the sun varies all day long. At noon when the sun is high in the sky there’s a lot more energy available than in the morning and evening when it is low. The sun also gets covered by clouds now and then, and sometimes it goes away all together or never comes out all day.

Storm clouds swirl above our RV

The solar panels COULD be working, but…

In summertime, the days are long and the sun is out for many hours. In winter, the days are short and the sun is out very little (if at all — think Alaska). And every night all year long the sun vanishes for hours. Trees and buildings can cast shadows on solar panels, affecting their ability to generate current. For boats at anchor, sometimes the mast or boom will shade the solar panels every few minutes as the boat swings back and forth, making the current coming in from the panels rise and fall repeatedly.

— Solar panels can’t always do the job at hand

The batteries on an RV or boat are charged by the sun as long as it is light, regardless of what kinds of electrical appliances you are running inside. Sometimes there’s enough extra energy from the sun that the panels can do two jobs: charge the batteries AND support things like hair dryers and microwaves. But at certain times of the day, the solar panels may not be able to produce enough current to power those appliances AND charge the batteries at the same time by holding them at their target Absorb or Float voltage.

Solar power is difficult when cloudy

The solar charge controller keeps busy as the sun comes and goes

The net effect may be that the batteries are actually be being discharged while those loads are running, even though the solar panels are actively charging them. Sure, the sun mitigates the discharge rate, but overall the batteries are giving up more current than they are receiving from the solar panels. This temporary period of discharging means the solar charge controller will need to keep the batteries in the charging state a little longer to make up for the lost charging time.

— Solar charge controllers operate 24/7

Another difference between artificially powered and naturally powered charging systems is that solar charge controllers do not get turned on and off or plugged in and unplugged. Solar charge controllers operate 24/7, and they are busy communicating with the solar panels all the time to see how the sun is affecting them. At night, solar charge controllers stop talking to the panels quite so frequently since they know the sun won’t shine again for many hours. They “sleep” for a few hours, waking up periodically to see if the sun has risen yet.

Because there is no on/off switch, there isn’t necessarily an easy way for a solar charge controller to be forced into Bulk mode other than by virtue of the “wake-up” phase first thing in the morning. If, for instance, you want to force a solar charge controller into the Bulk stage at 2:00 in the afternoon, you may or may not be able to, depending on the unit.

— No two solar charge controllers are alike

Each solar charge controller manufacturer has a different way of dealing with the inconsistencies of solar power production. Some are easy to program and some are more difficult. Some have many adjustable input parameters and some have just a few. Some can be forced to start a Bulk charge at any time, and some can’t.

 

 

CHARGING FROM THE SUN AS IT RISES AND FALLS

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Generally, a solar charge controller wakes up and immediately puts the batteries in the Bulk stage. Sounds great! However, the Bulk stage in low light may mean the batteries are getting just a trickle charge of an amp or two, because the solar panels can’t produce any more than that.

This means that frequently, for much of the morning, even though the solar charge controller is in Bulk and you’d expect the batteries to be getting blasted with current (which would be happening with an “artificially powered” charging system), the batteries are actually getting just a few anemic amps while the sun is slowly rising in the sky.

Depending on their state of charge at dawn and the size of the solar panel array, this trickle charge might actually be enough for the batteries to reach the Bulk voltage sometime before lunch. They will then switch out of the Bulk stage and into the Absorb stage before the sun has actually reached its peak in the sky where it can produce max energy.

Isn’t it ironic that by the time the solar panels are able to operate at full power, the batteries may not need it any more?!

However, having the batteries out of Bulk and into the Absorb stage during the hours that the sun is highest in the sky is actually optimal. The current delivered by the solar charge controller can slowly taper off as the sun falls lower during the afternoon. Once the Absorb stage is done, and the solar charge controller is operating in the Float stage, the low angle of the sun and the panels’ reduced ability to produce current is not a problem because the charge controller now wants to deliver less to the batteries anyway.

All this is great for sunny days… but not everyday is sunny!

On the other hand, it may be a cloudy morning until noon, or the RV may be in the shade of a mountain until noon, so by the time lunch rolls around, the batteries are still just as discharged as they were at breakfast — or even more discharged because you spent the morning playing on the computer or watching TV.

Lots of solar panels

Lots of solar panels

Now, when the sun comes out or the mountain’s shadow moves off the RV’s panels, the solar charge controller is still in Bulk mode. Suddenly the panels can run full blast and operate as close to their rated output current as possible (how close they can operate to their rated maximum depends on how close they are to being perfectly perpendicular to the sun’s rays).

In this case, having a bigger solar panel array is helpful because now it becomes a race with the clock to get the batteries through the Bulk stage and through the Absorb stage before the sun gets too low in the sky in the late afternoon.

And of course there are those cloudy days, or rainy days, and/or short winter days, when, try as they might, the solar panels just can’t produce the current needed to get the batteries through the Bulk and Absorb stages completely by the end of the day. On these days, you hope for more sun the next day or, if you get a bunch of these days in a row, eventually you turn to an artificially powered charging system like a converter or a inverter/charger ((via a portable gas generator or an onboard generator or shore power electricicity) or an engine alternator to finish the job.

 

 

SIZING A SOLAR CHARGE CONTROLLER

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The rule of thumb for sizing solar charge controllers is not the same as for sizing artificially powered chargers. Remember, in Part 1 of this series, we mentioned there is a rule of thumb that says a battery charging system’s max output current should be roughly 25% of the capacity of the battery bank. This means that, in very approximate terms, a 440 amp-hour battery bank needs a 110 amp charging system.

However, solar charge controllers are generally sized to a solar panel array rather than to a battery bank. The sizing parameters for a solar charge controller are the maximum number of watts coming in from the solar panel array and the maximum current going out to the batteries. Add up the total watts in the solar panel array and the maximum amount of current the array can produce, and make sure those numbers are within the specs of the solar charge controller.

The traditional rule of thumb for sizing a solar panel array to a battery bank is that the total watts should be more or less equivalent to the amp-hour capacity of the battery bank.

Conventional Rule of Thumb:

Total solar panel array watts = Total battery amp-hours

However, this may end up under-sizing the solar panel array just a bit. As an alternative, you might start by sizing the solar charge controller to the battery bank using the 25% rule of thumb for sizing battery chargers to batteries:

1 – Solar charge controller output current = 25% Total battery amp-hours

THEN size the solar panel array so it maxes out the total watts and total open circuit voltage specified for the solar charge controller.

2 – Total solar panel array watts = Maximum input watts for Solar charge controller

Here’s an example using a 435 amp-hour battery bank of four Trojan T-105 Reliant AGM golf cart style batteries as a starting point. This is our battery bank and is the maximum amount of battery capacity our 36′ fifth wheel trailer can carry comfortably due to weight and space constraints.

Using the Conventional Rule of Thumb above, the total wattage of the solar panel array would be approximately 450 watts. This is sufficient in the summer months in North America and might be sufficient at the equator or in the Land of the Midnight Sun in the winter months, but in our experience, our 490 watts of solar panels on our RV roof is inadequate during winters in the southern US when the sun is low in the sky, the days are short and winter storms create overcast skies for days on end.

Using the Two Step sizing method above instead, you would choose a solar charge controller that has a maximum current output of 25% of 435 amps = ~108 amps. The Outback FlexMax 80 is an 80 amp solar charger (relatively close to the 108 we’re looking for). It can support up to 1,000 watts of 12 volt solar panels (and more watts for higher voltage panels). Note that to get 80 amps of current, you’d need to have the solar panels facing 90 degrees to the sun, and the solar charge controller would need to be operating in the Bulk stage.

Sizing the solar charge controller this way, we are now looking at 1,000 watts of solar panels instead of the 450 watts that the Conventional Rule of Thumb came up with — twice as much!

This sizing method is probably overkill. However, it might make sense to size the panels and controller both ways and choose something in between. As I’ve said, in our case, 600 to 800 watts lying flat on our RV roof without tilting would be nice in winter.

Boat solar power installation

Our sailboat had 555 watts of solar power.
Note the shade on the panels from the mast and spreaders.

For us, on our boat (710 amp-hour battery bank) we could have used a 750 watt to 1,000 watt solar panel array instead of the 555 watts we had to run the systems we had on board, despite having ample sunshine throughout our cruise.

All of this is given here as food for thought. Sizing panels and batteries and solar charge controllers is all very flexible. More of everything is better, but the reality is that there are roof space constraints for the panels, and there are both weight and space constraints for the batteries, and those limitations will ultimately dictate your particular options for panels and batteries.

A truck camper and a Class A diesel pusher (or a Catalina 27 sailboat and a Nordhavn 62 trawler) obviously have different constraints and needs.

In very general terms, anything from a 450 amp-hour / 500 watt system to a 900 amp-hour / 1,200 watt system is fine for both boats and RVs that are used to boondock or anchor out for months on end, depending on whether you run electric refrigeration and how much you stay up at night watching TV with the lights on and/or stay home during the day using computers, electric appliances and power tools.

 

 

OUTBACK MX60 MPPT SOLAR CHARGE CONTROLLER

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Now that we’ve seen the challenges that solar charge controllers face, let’s look at a specific example.

We installed an Outback MX60 MPPT solar charge controller in our fifth wheel trailer. It’s been in operation all day everyday that we’ve been in our trailer since we purchased it new in 2008. Since then, the Outback MX60 model has been discontinued and replaced by the new and improved Outback FlexMax 60 solar charge Controller.

The Outback FlexMax 60 MPPT Solar Charge Controller has the following algorithm:

BULK: Deliver maximum current until the Bulk voltage is reached.

ABSORB: Deliver as much current as necessary for the batteries to maintain the Absorb voltage. Transition to the Float stage when one of the following things happens:

  • The charger has been in the Absorb stage for as long as it took for the batteries to reach the Bulk voltage.
  • The current coming from the batteries has dropped below a certain level

If the sun fades and the controller can’t deliver enough current to keep the batteries at the Absorb voltage, extend how long the batteries stay in Absorb by the length of time the voltage fell below the Absorb voltage.

FLOAT: Deliver enough current to keep the batteries at the Float voltage.

EQUALIZE: Equalization voltage and time parameters are programmable, and equalizing can be done automatically or started manual. If Equalizing can’t be completed in one day, the batteries will resume equalizing the next day until the equalizing time has been completed.

Everything in the Outback MX60 charge controller (and the Outback FlexMax 60/80 Solar Charge Controllers) is programmable on a four-line LED menu driven display. You enter the battery type (Flooded, Gel, AGM) and that gives you default values for Bulk, Absorb and Float voltages. You can then override those values with values of your own if you wish.

So, how does this solar charge controller compare to a converter, inverter/charger or engine alternator?

If you compare the Outback MX60’s charging algorithm shown above to that of any of the artificially powered charge controllers described in the previous article, you can see just how very much more complicated this solar charge controller is. Here’s a little more detail:

 

SWITCHING FROM ABSORB TO FLOAT BASED ON TIME

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The key part of any multi-stage charging algorithm is when to switch from the Absorb stage to the Float stage. (If you are unclear about those stages, read more here: RV and Maring Battery Charging Basics). All charging systems use TIME as a basic criteria. The question is how long?? Should the batteries stay in Absorb for 2 hours or 4 hours? Should it always be the same amount of time?

To be most amenable to the batteries’ needs, the state of charge of the batteries when they first start charging must be taken into account. If the batteries are nearly fully charged when charging starts, why keep them in Absorb for three hours? That’s like forcing down extra helpings of pie after a big Thanksgiving dinner. Maybe just a small piece is enough on a full stomach.

On the other hand, if the batteries are deeply discharged when the charging begins, they should stay in Absorb longer to make sure they really get full. If you didn’t nibble on hors d’oeuvres before dinner and you skipped lunch and breakfast, then extras helpings of everything at the Thanksgiving table might taste and feel great.

Outback tackles this conundrum by looking at how long it takes the batteries to reach the Bulk voltage. If they are well charged already, they’ll zip to the Bulk voltage quickly. In that case, they don’t need to stay in the Absorb stage for very long. On the other hand, if they are deeply discharged, it will take a long time for them to reach the Bulk voltage. In that case, they should hang out in Absorb for a long time until they are really and truly fully charged.

The way the Outback charge controllers accomplish this flexibility in the length of time of the Absorb stage is that they make the Absorb stage last for the same length of time as the Bulk stage did. If Bulk took 2 hours, then Absorb will last for 2 hours. If Bulk took 3 hours, Absorb will be 3 hours. Clever!

 

WHAT IF THE TARGET VOLTAGES CAN’T BE MAINTAINED?

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Unfortunately, the sun isn’t all that consistent for such a basic algorithm, and there is more to it than just a simple one-to-one relationship between Bulk and Absorb. What makes this business tricky is that the sun may not allow the charger to hold the batteries at the Absorb target voltage once they begin Absorbing. For instance, in the middle of the Absorb stage, the sky might cloud over. The charge controller will respond by instantly opening the floodgates for the batteries so it can get the necessary current from the panels to keep the batteries at the Absorb voltage. But if the panels can’t deliver, there’s nothing the solar charge controller can do, and the battery voltage will fall below the Absorb voltage.

Outback FlexMax 60 MPPT Solar Charge Controller

Outback FlexMax 60 MPPT Solar Charge Controller

In another scenario, someone in the RV or boat might turn on an electrical appliance that draws a lot of current — more than the panels can deliver — and this will temporarily lower the battery voltage below the target voltage. Running the vacuum or a hair dryer in addition to whatever else is running in the RV or boat might be just enough to draw more current from the batteries than the sun on the panels can produce.

In these cases, the solar charge controller will try to keep the batteries in the Absorb stage, but it’s failing. The thing is, if there isn’t enough current to keep the batteries at the Absorb voltage, are they really Absorbing? Not exactly. They’re getting as much current as possible, but the voltage has dropped below the Absorb stage threshold.

The Outback charge controllers view this as a kind of “timeout” period. So, for every minute of this “timeout,” they tack on a minute of extra time that the batteries must stay in Absorb before they switch to float.

For instance, if the batteries have been in Absorb for 53 minutes when the sky suddenly clouds over, the Outback charge controller will start counting how long the batteries stay below the Absorb voltage. If they stay below for 14 minutes, then once the sun comes back out and they get back to the Absorb voltage, they will need to stay in Absorb for an extra 14 minutes on top of the time period they were planning on (which is either the length of time that the Bulk stage took that day or a minimum amount of time programmed by the user). When they resume Absorbing, the Outback will resume counting from 53 minutes with a new target time that is 14 minutes longer than before.

This problem of the solar panels not being able to deliver enough current to keep the batteries at the target voltage exists in the Float stage as well as the Absorb stage. However, in the case of the Float stage there is no time consideration. Once they get into Float, the batteries will stay there (or attempt to stay there) until dark.

If you are confused, here is a real live example:

One day around noon our batteries had reached the Float stage (we’d gone to bed early the night before, so the batteries had charged up quickly). They were humming along getting about 4 to 10 amps or so to maintain a 13.5 Float Voltage with whatever stuff we had running in the RV (laptops, etc.).

I got out the vacuum, and when I turned it on, the charge controller jumped into high gear, demanding max output from the solar panels. The panels could deliver 25.6 amps, but that wasn’t enough to maintain the Float voltage of 13.6, and the battery voltage dropped to 13.1 until I finished vacuuming. Then everything went back to where it had been.

Lesson learned: use a broom not a vacuum!

You can see the display from the Outback charge controller here:

Outback MX60 Solar Charge Controller

Outback MX60 Charge Controller display at midday with vacuum & computers running.
Note the batteries have dropped to 13.1 volts (below Float) and the current coming from the panels to the batteries is a huge (for “Float”) 25.6 amps to support the load in the RV. “F-MPPT” means “I’m in the Float Stage but I need max power ’cause I can’t maintain the Float Voltage.”

Even if the sun is out all day long and the batteries reach the Float stage, at the end of the day when the sun begins to set, the charger will no longer be able to hold the Float voltage. As it gets darker and darker, the charger will try valiantly to hold the Float voltage, but the battery voltage will drop lower and lower while the charge controller delivers less and less current.

Eventually, when it gets completely dark outside, no current will be going to the batteries at all. If the batteries were in Float before the sun went down, they will settle out at 12.7 volts, fully charged. If they never reached the Float stage, however, you’ve gotta cross your fingers for good sunshine tomorrow!

 

 

SWITCHING FROM ABSORB TO FLOAT BASED ON CURRENT

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As I mentioned in the previous article in the description of the Xantrex Freedom 25 Inverter/Charger, a rule of thumb is to switch from Absorb to Float when the current that the batteries need to remain at the Absorb voltage drops below 2% of the amp-hour capacity of the battery bank.

For a 450 amp-hour battery bank, this would be 9 amps. For a 750 amp-hour battery bank, this would be 15 amps. So, for a 450 amp-hour battery bank, a reasonable time to switch from Absorb to Float is when the current drops below 9 amps. For a 750 amp-hour battery bank it is when the current drops below 15 amps.

The Outback FlexMax 60 (and 80) allow you to enter whatever number of amps seems right to you, whether it is 2% of your battery bank or some other number that you prefer.

Why is it important to switch from Absorb to Float when the amount of current the batteries need to remain at the Absorb voltage drops below a certain level?

The batteries may be nearly fully charged, but if the charging algorithm forces them to stay in Absorb for a set period of time — three hours for instance — they may need just 1 or 2 amps to maintain the Absorb voltage. It might be better for the batteries if they were allowed to slip back to the Float voltage at that point rather than forcing them to stay at 14.7 volts while accepting a minuscule amount of current until the 3 hours is up.

However, the reverse may also be true. There may be situations where you don’t want the batteries to be in the Float stage even though the charging current has dropped below 2% of the battery bank capacity. More on that further down.

 

WHAT HAPPENS AT NIGHT?

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Because solar charge controllers operate 24/7, there are three more states that the Outbacks can be in:

  • SNOOZING: The voltage of the solar panels is greater than the voltage of the batteries but there is no current coming in from them
  • SLEEPING: The voltage of the solar panel array is less than the voltage of the batteries
  • ZZZZZ…: The solar charge controller has been in the SLEEPING state for 3 hours or more

The controller has an algorithm for waking up as well. As the sun rises, once the voltage of the solar panels is more than 2 volts higher than the voltage of the batteries (i.e., the panels are at 14.7 volts or more if the batteries are fully charged at 12.7 volts), it looks for current coming in from the panels. If the current is still near 0, it SNOOZES in 5 minute intervals while it waits for the current to reach about an amp. Then it goes into Bulk and starts its work for the day. This happens each morning as the sky becomes light and the solar panel voltage rises from 0.

 

LOW LIGHT — FULL MOON and STREET LAMPS

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It doesn’t take much light to bring a 400+ watt 12 volt solar panel array up to 15 volts. A full moon with clear skies may raise the voltage on the panels to this level, and parking under a bright street light will definitely do it. This is not enough light for the solar panels to generate current, but it can sometimes be enough to fool the charge controller that the sun might be about to rise and give it a sleepless night.

We have seen our solar charge controller pull an all-nighter as it alternated between SNOOZING and WAKE-UP all night long because the solar panel array was steady at 15 volts from a street light overhead while the batteries were at 12.7 volts.

The charge controller couldn’t start the real SLEEPING phase because the panel voltage was higher than the battery voltage. But there wasn’t enough light to generate any current either. So, the controller would WAKE-UP, discover there was no current coming in from the panels, and then it would go back to bed and SNOOZE a little longer. It would repeat this unfortunate cycle all night long, never getting into the really good 3 hour long ZZZZ… sleep stage (poor thing!).

On the other hand, while staying in the Catskill Mountains about 120 miles from New York City, I crept out at 2:00 in the morning to see how the charge controller was doing. The city lights kept the sky from being very dark, and the panel voltage was elevated slightly to 9 volts rather than the usual 0 volts we see in more rural areas. However, the batteries were more than 2 volts higher than that at 12.7, so the charge controller was well into its REM sleep phase, dreaming of sunny days. (Mark crept out to photograph the fireflies…a much better reason to climb out of bed at 2 am!!)

Outback FlexMax solar charge controller sleeping near NYC

At 2:00 a.m. in the Catskills, the lights of NYC reflecting off low clouds raise the Panel Voltage to 9 volts. The previous day the batteries got 73 amp-hours of charge, so they are fully charged at 12.7 volts, more than 2 volts higher than the panels. The controller is sleeping soundly for 3 hours when it will check the panel voltage again.

 

XANTREX XW MPPT 60-150 SOLAR CHARGE CONTROLLER

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We installed a Xantrex XW MPPT 60-150 Solar Charge Controller on our sailboat. Xantrex is now Schneider Electric, and this unit has been replaced with the Schneider Electric XW MPPT 60-150 solar charge controller. I don’t know if this is just a name change on the unit or if the design of the unit has changed in any way.

This solar charge controller is about the same size as the Outback but has a two line LCD display instead of four, so you have to scroll through the menus a bit to get the same info you can see at a glance on the Outback.

The challenge for us on our boat was that we had a smaller solar panel array than we needed for our typical daily power consumption due to our electric (DC) fridge and standalone freezer. 555 watts of solar power was not enough. So, we needed the charge controller to get the solar panels to provide as much current as possible everyday.

Unfortunately, it took us a while to realize that the factory default settings on the Xantrex charge controller were preventing the solar panels from providing as much current as they could.

The Xantrex charge controller came with a factory default setting to switch from Absorb to Float when the current being delivered to the batteries dropped below 2% of the amp-hour capacity of the battery bank, or 14 amps.

Xantrex XW MPPT 60-150 Solar Charge Controller in a sailboat

Our Xantrex XW MPPT60-150 charge controller on our sailboat

The problem was that once the current going to the batteries dropped below 14 amps, the solar charge controller put them into the Float stage. In the Float stage they needed much less current to maintain the Float voltage, usually around 5 amps. That’s a lot less than the nearly 14 amps they had been getting in Absorb!

What this meant was that even if the sun was shining brightly, the batteries were being given less current than the panels were capable of delivering because the solar charge controller had put them in the Float stage. The gatekeeper had closed the gate most of the way!

We would watch the system go into the Float stage at 1:00 p.m. and waste the best sunshine of the day sitting in the Float stage all afternoon charging the batteries with a lot less current than it would have if the controller were still in Absorb.

So, because the Xantrex charge controller had the programming option available, we programmed it to switch into Float when the batteries needed only 5 amps to maintain the Absorb voltage instead of the 14 amps that was 2% of our battery bank size. This way we were able to charge the batteries up by an extra 25-30 amp-hours each day.

However, the Xantrex controller didn’t make this programming option obvious. Rather than having an input parameter for the current at which to switch from Absorb to Float like the Outback models have, you could enter only the size of the battery bank. The controller would then calculate what 2% of that value was and would use that value to switch from Absorb to Float.

So, we had to fool the controller by saying our battery bank was only 250 amp-hours rather than the 710 amp-hours that it actually was. Then it would switch from Absorb to Float when the current dropped to 5 amps (2% of 250) instead of at 14 amps (2% of 710).

This also could have been alleviated by throwing the system back into a Bulk charge, and in our first days of working with this system, there were many times when I wished there were a setting to force the charge controller to put the batteries back in the Bulk stage whenever I wanted. But unlike the Outback solar charge controllers, this Xantrex model did not have that option.

So, as you can see, the Xantrex XW MPPT 60-150 Solar Charge Controller takes a slightly different approach to the challenges of solar charging than the Outback models do. Here are the details:

The Xantrex XW MPPT 60-150 Solar Charge Controller charging algorithm is the following:

BULK: Deliver the maximum possible current to the batteries until they reach the Bulk voltage

ABSORB: Deliver as much current as necessary for the batteries to maintain the Absorb voltage. Transition to the Float stage when one of the following things happens:

  1. The current necessary to maintain the Abosrb voltage is 2% of the battery bank capacity
  2. The batteries have been in the Absorb stage for 2 hours (modifiable)
  3. The batteries have been at or above the Float voltage for 8 hours

FLOAT: Deliver enough current to the batteries to maintain the Float voltage.

EQUALIZE: The voltage and times for equalizing are user defined.

This charging algorithm is pretty straight forward, except for that odd 3rd way that the controller might switch from Absorb to Bulk. What’s going on there?

— What if the target voltages can’t be maintained — another technique!

That third trigger Xantrex uses for switching from Absorb to Float allows for the situation where the battery voltage has dropped below the Absorb voltage temporarily due to either clouds or shade or big loads in the RV or boat (vacuums or refrigerator compressors) drawing the voltage down for a while because the panels can’t deliver enough current. What it’s doing it that even if the batteries haven’t been at the Absorb voltage the whole time, as long as they have stayed above the Float voltage for at least 8 hours, they are considered ready to leave the Absorb stage and enter the Float stage.

Remember, the Outback solar charge controllers dealt with this same challenge of flaky sunshine by tracking how long the batteries fell below the Absorb voltage and then forcing the batteries to stay in Absorb for that same number of extra minutes to make up the lost time.

The Xantrex method is a little more simplistic than the Outback method, saying that as long as the battery voltage stayed above Float for 8 hours, they have been sufficiently charged and can switch to the Float Stage.

— Programming the charge controller for improved performance

As a recap, our goal was to keep the batteries in Absorb for as long as possible. So, I modified two of the Xantrex solar charge controller’s input parameters to allow this to happen:

  1. Pretend our battery bank was just 250 amp-hours instead of 710 so it would stay in Absorb down to 5 amps (modifying criteria #1)
  2. Increase the Absorb stage time limit from 2 hours to 8 hours (modifying criteria #2)

What these two programming changes ultimately did was they made the batteries stay in the Absorb stage for 8 hours, getting a healthy amount of current from the solar panels, unless the current happened to drop below 5 amps (2% of 250) before 8 hours was up.

This worked really well for 750 nights of anchoring out.

 

PROGRAMMING THE CHARGE CONTROLLER TO THE BATTERY MANUFACTURER’S SPECS

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We were extremely cautious with the AGM batteries in our boat and did not want to modify the solar charge controller’s default voltage settings for AGM batteries since AGM batteries are sealed and they can’t be charged at as high a voltage as flooded batteries (this is explained in more detail in Part 1 of this series).

The default charging voltages for AGM batteries on the Xantrex XW MPPT-60-150 Solar Charge Controller are:

  • Bulk: 14.3
  • Absorb: 14.3
  • Float: 13.4

* * * Lesson Learned * * *

Now that we have installed four Trojan T-105 Reliant AGM batteries in our fifth wheel and have been advised by the engineers at Trojan Battery to use Bulk and Absorb voltages of 14.7 volts on their AGM batteries instead of the 14.3 or 14.4 that most charging systems default to, I look back and realize I was probably too conservative with our boat’s AGM batteries.

If we had set the Bulk and Absorb voltage values to 14.7 instead of 14.4 (the setting I chose), then they would have charged faster (received more current from the charge controller) during those stages, and they would have won the daily race against the clock more easily. Obviously, more panels would have done the trick too, but finding unshaded deck space on a sailboat is tricky.

It only makes sense to program a battery charging system to the battery manufacturer’s specifications rather than assuming that the factory defaults on the charge controller are optimal. Afterall, charging system manufacturers — whether solar charge controllers, converters, inverter/chargers or engine alternators — will ALWAYS err far to the conservative side because they they are designing for a wide variety of battery brands and they don’t want to risk frying a customer’s batteries.

However, in the end, this might result in undercharging the batteries! Trojan Battery engineers have found that far more batteries die a slow death of chronic undercharging than a violent death of massive overcharging, so they prefer slightly higher charging voltages for their AGM batteries than are factory standard on many solar charge controllers, converters, inverter/chargers and engine alternators (with a caveat not to go to 14.8 volts or higher).

 

MORNINGSTAR TRISTAR TS-MPPT-60 SOLAR CHARGE CONTROLLER

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We recently did a complete full-timer solar power installation on a friend’s motorhome. He specified the Morningstar TriStar TS-MPPT-60 Solar Charge Controller for his installation, so we had a chance to program it and work with it. This solar charge controller uses yet another methodology.

Morningstar TriStar MPPT 60 amp solar charge controller

Morningstar TriStar MPPT 60 amp solar charge controller

This solar charge controller is programmed via dip switches and the charging stages are indicated by LED lights rather than a digital readout. You can also purchase the additional TriStar Remote Digital Meter that has a two line LCD display similar to the 2-line and 4-line displays on the Xantrex and Outback models described above.

Separating the charge controller from the display is a great idea. It allows you to install the display inside the RV or in the boat’s cabin where you can read it easily and mess with its buttons whenever you wish. Yet you can still place the charge controller itself right next to the batteries where it needs to be (the cable going from the batteries to the charge controller must be as short as possible).

Our friend did not purchase the remote meter, but we found the system was easy enough to set up without it. The dip switches were a clunky interface, but that would be improved with the buttons and digital display of the remote meter. The lack of a digital readout made it difficult to know the details about the voltages and currents of the panels and batteries in the system. However, our friend did not plan on programming the solar charger any further, and he already had a battery monitor in his coach, so he had a way to monitor the battery voltage easily.

Here are the details on the charging algorithm:

The Morningstar TriStar TS-MPPT-60 Solar Charge Controller multi-stage charging algorithm is the following:

BULK: Deliver the maximum amount of current possible until the batteries reach the Bulk voltage.

ABSORB: deliver as much current as necessary to keep the batteries at the Absorb voltage until the following thing happens:

  • 2 to 2.5 hours has gone by (depending on battery type)

If the batteries fell below 12.5 volts during the previous night, then extend the Absorb stage by 30 minutes.

FLOAT: Deliver as much current as necessary to keep the batteries at the Float voltage. If the batteries are drawn down below the Float voltage for an hour or more due to big loads in the RV or boat (vacuum, power tools, microwave) or due to sudden cloud cover, the charge controller will switch back to Bulk mode and start the cycle over again. If the batteries fell below 12.3 volts during the previous night, then the solar charger will not enter the Float stage the following day.

EQUALIZE: The voltage and duration of the Equalization stage is determined by the battery type selected and is started manually.

This is yet another creative approach to the various problems caused by the unreliability of sunshine. The idea of setting up the charging parameters today based on the lowest voltage the batteries reached overnight is cool, since that is truly the biggest determining factor for how much charging the batteries need right now.

However, note that there is no criteria for switching from Absorb to Float based on the current falling below a minimum value as with the other charge controllers. There is also no provision for lengthening the Absorb stage if the Absorb voltage can’t be maintained, although there is if the Float voltage can’t be maintained.

The Absorb, Float and Equalize voltages are assigned in this controller when you select the battery type. AGM batteries are assigned:

  • Bulk/Absorb: 14.4
  • Float: 13.7

There seemed to be an option to override those values with custom values, however, it wasn’t clear how to enter the actual voltages using the dip switches. The TriStar Remote Digital Meter might provide more programming flexibility.

The Morningstar does come with PC based software, and it is possible to connect the solar charge controller to your in-house ethernet network via the controller’s ethernet port or to connect it using a wireless router. However, for me, that adds a level of complexity that isn’t really necessary.

There are just a few parameters to enter on any charge controller, and just a few values to monitor, and those only need to be monitored occasionally. Having a menu driven screen interface built into the charge controller rather than getting my computer involved in the action is worth a lot to me.

 

FINAL NOTES

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As you can see, there is a significant variation in how the different manufacturers of solar charge controllers tackle the challenge of creating an algorithm to charge the batteries, given the vagaries of sunshine. All of the solar charge controllers described here get the job done, it’s just that the methodology varies and the ease of use and programmability of the units differ.

If you want to get the most out of your solar charge controller, the most important thing is to know what your battery manufacturer’s recommended charging voltages and time limits are, that is, what their preferrred Bulk, Absorb and Float voltages are and how long they want the batteries to remain Absorb. Then program the solar charge controller accordingly.

The reason I chose the Xantrex XW MPPT-60-150 Solar Charge Controller for our boat rather than purchasing another Outback charge controller like the one in our RV (the nice new FlexMax 60 was on the market by then) was that the Outback has a fan in it. I was concerned that in the hot tropical climates where we would be sailing, the fan would likely run a lot and might fail. I didn’t want any moving parts! I chose the Xantrex because it is cooled by large cooling fins instead of a fan.

In hindsight, the Outback charge controllers are rated to operate at up to 104 degrees, and the cabin of our boat never got that high. Probably an Outback charge controller would have held up just fine. The Morningstar with its Remote Digital Meter is a neat idea for separating the charge controller and the digital display. However it does require a few more installation steps to mount the remote meter and run the cable from the charge controller location to the remote meter location. It also has a simpler overall charging algorithm, which could be a pro or a con depending on your preference.

__________________

The next — and final — article in this series takes a look at what happens when two battery charging systems are running simultaneously. That is, what happens if you have solar power and you plug into shore power or turn on the boat engine?

To continue to the next article in this series, click here:

Solar and Shore Power or Engine Alternator Battery Charging Combined

4-Part Series on RV and Marine Battery Charging Systems:

Related posts about batteries, solar power and living off the grid in an RV or boat:

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RV Converter, Inverter/Charger, and Alternator Battery Charging Systems

This article discusses battery charging systems that are “artificially powered” by electricity or an engine (as opposed to sun or wind power) and the methods these systems use to chargeso RV and marine batteries. It is the second post in our four part series on RV and Marine Battery charging systems.

Converter Inverter-Charger Engine Alternator Battery Charging Systems

The first article in the series, RV and Marine Battery Charging Basics, explains how batteries are charged and describes the concepts of single stage and multi-stage charging. The third and fourth articles in this series are:

You can navigate to specific parts of this article with the links below:

 

“ARTIFICIALLY POWERED” versus “NATURALLY POWERED” CHARGING SYSTEMS

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There are two basic types of multi-stage chargers for RVs and boats: those that are “artificially powered,” either by electricity, by an engine or by a generator, and those that are “naturally powered” by the sun (or wind). Note: Although this series doesn’t discuss wind charging systems, the same principles apply.

What is the difference?

Ability to Deliver the Maximum Rated Current

The biggest difference between these two types of charging systems is that artificially powered charging systems — converters, inverter/chargers and alternators — can all deliver the maximum amount of current they are rated for as soon as they are turned on. In contrast, “naturally powered” chargers may or may not be able to deliver their maximum rated current when called upon to do so.

Yamaha 2400i portable gas generator

Yamaha 2400i portable gas generator
As long as there’s gas, it’s good to go.

Solar charge controllers can deliver their maximum rated current only if they are connected to a large enough solar power array and that array is exactly perpendicular to full sunshine. Unfortunately, no matter how big the solar panel array is, these charging systems spend most of their time operating in sub-optimal conditions when the sun is low in the sky or filtered by clouds or totally absent because it is nighttime.

In addition, if a big appliance is turned on in the RV or boat while the batteries are being charged, the artificially powered charging systems can meet the challenge and provide the current that is needed (up to their rated current output and up to the limits of the power source) to keep the batteries at their target charging voltage.

Sunshine

The sun’s out — yay!
We can start charging!

However, solar charge controllers may or may not be able to meet the challenge, depending on the time of day and amount of cloud cover. In fact, if the current draw is big enough, not only will the solar charge controller fail to keep up with the sudden demand, but the net effect on the batteries may be that they are temporarily being discharged a little bit rather than charged.

Therefore, solar charge controllers have a lot of extra complexity built into their charging algorithms so they can handle the situations where, for whatever reason (lack of sun and/or too much demand from the appliances in the RV or boat) they aren’t actually charging the batteries but are just slowing down the discharge rate!

Ability to Restart the Charging Process with the Bulk Stage

Artificially powered charging systems can all be turned on or off with the flick of a switch. Most systems will test the battery voltage to see if they should jump into the Bulk stage as soon as they are turned on. This gives you a way to force the batteries into the Bulk stage and start the charging process from scratch.

Solar charge controllers operate 24/7, and they rely on an internal algorithm to determine when it is morning and time to start the Bulk charging stage. Not all solar charge controllers are designed to have an easy way for the user to put the batteries in a Bulk charging stage at any time of day other than dawn.

 

 

PROGRAMMING A BATTERY CHARGING SYSTEM

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Many artificially powered charging systems are programmable, but usually the choices are minimal. If they can be programmed at all, it is generally done with dip switches or simple buttons. In contrast, big solar charge controllers are complex enough and have so many programmable options that they often have a screen display and a menu driven interface.

Some charging systems have preset groups of voltage values, and all you can select is whether your batteries are Flooded, AGM or Gel. The charger then assigns voltage values for the charging stages based on battery type. In this case, the charging system manufacturer is guessing what voltages are appropriate for your batteries. The battery manufacturer may have different specs!

The most sophisticated (and expensive) charging systems allow you to enter any value you want for the individual charging voltages as well as the length of time to remain in the Absorb stage and other values as well.

Even if you don’t study the charging algorithm that is used by the charging systems on your RV or boat, it is worthwhile to find out what the default voltages are for the Bulk, Absorb and Float stages are on each device.

 

WHAT VALUES DO YOU PROGRAM INTO A CHARGING SYSTEM?

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There are rules of thumb for what the charging voltages should be for the various battery types, with flooded batteries requiring higher charging voltages than AGM and Gel batteries. The general consensus I found in my research was that flooded batteries preferred a Bulk/Absorb voltage in the range of 14.6 – 14.8 volts while AGM and Gel batteries prefer to be around 14.4 volts.

Because of this general consensus, I set up all the charging systems on our boat with Bulk and Absorb values around 14.4 volts so we wouldn’t fry our four Mastervolt 4D AGM batteries house batteries and our Group 27 start battery.

Needless to say, I was quite surprised when we installed our four new Trojan T-105 Reliant AGM 6 volt batteries in our trailer, that the engineers I spoke with at Trojan Battery recommended we set the Bulk and Absorb stages of our charging systems to 14.7 volts. They said the vast majority of battery failures are from chronically undercharged batteries, so they preferred that their AGM batteries be charged at this higher voltage.

I never spoke with anyone at Mastervolt back in our cruising days, and their documentation didn’t specify charging voltages. In hindsight, perhaps we should have been charging the batteries on our boat to higher Bulk and Absorb voltages. They would have charged faster, which would have been awesome, especially on solar, because our solar panel array was a little small (555 watts), and getting the batteries fully charged by day’s end was a challenge unless we turned off our DC freezer.

Lesson learned: If you can’t find your battery manufacturer’s recommended charging voltages in their documentation, give them a call!

The next sections take a look at a few artificially powered charging devices we have used and the algorithms they employ for battery charging.

 

 

CONVERTERS

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Most trailers are equipped with a converter to charge the batteries from shore power (via electric hookups or a portable gas generator). The shocking thing about these converters is that many of them are just single stage trickle chargers. (Note: if you are confused about what converters and inverters are, click here).

We had never thought much about our converter, because we use it very rarely. We don’t ever get electrical hookups, so our converter is used only when we fire up our gas generator, which happens just a few times a year. We had always assumed that the Atwood SRV 55 amp converter that came with our Hitchhiker II LS fifth wheel was a multi-stage charger. However, we discvoered a few months ago that this converter is actually a single stage trickle charger. It brings the batteries up to 13.4 volts and leaves them there indefinitely, as long as the converter has AC power supplied to it.

This is startling for two reasons.

First of all, since we boondock all the time, this means that whenever we turn on our generator to charge our batteries (after a few days of stormy weather), rather than giving the batteries a fast blast of Bulk charge followed by Absorb and Float, the batteries are immediately put into a Float stage and left there. Rather than getting a quickie does of lots of current and then trailing off to less and less current, the batteries get an anemic amount of current the whole time the generator is running.

What a waste of fuel! And who wants to listen to that noisy thing for that long! Rather than taking an hour or two to charge the batteries completely, it could take 8 hours or more. Ugh!

Secondly, single stage converters like this Atwood don’t exercise the batteries at all when they are left on shorepower via electrical hookups, and the batteries deteriorate more quickly. This is an important consideration for an RV that is plugged into shore power month after month. It is important for batteries to go through the Bulk and Absorb stages periodically.

We decided to replace our factory-installed single-stage Atwood 55 amp converter with an Iota DLS 90 converter / IQ4 smart charger a few months ago so that on the days that we use our generator we could use it for a very short time rather than running it all day.

Besides wanting a true multi-stage charger that could load the batteries up with a lot of current at the beginning of the charge cycle, we also realized our old factory installed converter was too small.

Remember that 25% rule for sizing batteries and chargers from the last post? Our converter had been sized for the two Group 24 12-volt batteries (total capacity 140 amp-hours) that had come with our RV, and we had upgraded to four Trojan T-105 Reliant AGM 6 volt batteries which gives us a total capacity of 435 amp-hours.

Our new Iota DLS-90 / IQ4 is a 90 amp converter which is much more appropriately sized to the new battery bank.

And what a world of difference there is between these two converters!

The Iota DLS 90 / IQ4 is far more sophisticated. It puts the batteries into a true Bulk charge state as soon as AC power is available (for us, that is when we turn on the generator with the shorepower cord plugged into it). Then, after cycling through Absorb to Float, it keeps the batteries in the Float stage for seven days (not applicable to us with our generator, but important for folks who get electric hookups), and then it cycles them through Bulk and Absorb again.

The multi-stage algorithm that the Iota DLS 90 / IQ4 uses is the following:

BULK: Whenver the batteries are below 12.8 volts (i.e., when first plugging into shore power or when a bunch of appliances are turned on in the RV or boat) deliver the maximum current possible (up to 90 amps DC) until the batteries reach a voltage of 14.6 volts, then switch to Absorb. If they don’t reach 14.8 volts within four hours, switch to Absorb anyways.

ABSORB: For eight hours, deliver enough current to hold the batteries at 14.2 volts.

FLOAT: For seven days, deliver enough current to hold the batteries at 13.6 volts. Then go through the Bulk and Absorb stages before resuming the Float stage.

The system is fully automatic and none of these values or times are programmable.

Note: For readers who have studied the spec sheets on the Iota DLS-90/IQ4, this outline differs slightly from what you read. I had a lengthy conversation with an engineer at Iota who explained the details of how this converter works. The documentation refers to the weekly return to Bulk and Absorb as an “Equalization” stage, but the voltages and times are actually those of the Bulk and Absorb stages. As noted in the first post in this series, equalization is generally done at 15 volts or more for less than 8 hours. In addition, the documentation describes the converter’s power supply ramping up to 14.8 volts during Bulk, but doesn’t explain that the actual trigger point that switches the batteries from Bulk to Absorb is 14.6 volts.

Using the Iota DLS 90 / IQ4 The First Time

A few weeks ago we endured several days of gray skies and rain while we were driving from Florida into southern Georgia. Our solar panels were producing very little current, and our new Trojan T-105 Reliant AGM batteries were becoming depleted. There was no sign of sun in sight.

We set up our Yamaha 2400i portable gas generator and plugged our shore power cord into it. We clamped the jaws of our trusty clamp-on ammeter around one of the battery cables and were truly astonished to see 67 amps going into the batteries. Yowza!! Within two hours the batteries had accepted roughly 100 amp-hours of charge and we turned the generator off. Our old converter would have taken about 8 hours or more to do the equivalent.

 

 

INVERTER/CHARGERS

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Many motorhomes and cruising boats are equipped with an Inverter/Charger to charge the batteries when the RV or boat is plugged into shore power. Our Hunter 44DS sailboat was equipped with a Xantrex Freedom 25 inverter/charger which was factory installed in the boat. Xantrex has since become Schneider Electric, and a comparable model being sold today is the Schneider Electric 2500 watt inverter/charger. I haven’t found an online manual for it, so I don’t know if the charging algorithm or programmability of the unit has changed.

Schneider Electric 2500 watt inverter : charger

Schneider Electric 2500 watt inverter/charger
This is the updated model of our Xantrex Freedom 25 Inverter / Charger
(ours was buried under a settee and impossible to photograph!)

Unlike many converters, most inverter/chargers are multi-stage chargers. Our Xantrex Freedom 25 had minimal programming capabilities. You could enter the battery type (Flooded, Gel or AGM), and the voltages for the charging stages were automatically assigned according to the battery type you selected. You could not enter any other values. We had AGM batteries, and the Xantrex inverter/charger assigned them defaults of:

  • Abosrb: 14.3 volts
  • Float: 13.3 volts

If you wanted different voltages, you could select the Flooded or Gel values instead simply by indicating that your batteries were Flooded or Gel, even if they weren’t.

The multi-stage charging algorithm for the Xantrex Freedom 25 inverter/charger is the following:

BULK: Deliver the maximum current possible until the Absorb voltage is reached

ABSORB: For up to 3 hours, deliver as much current as needed to keep the batteries at the Absorb voltage. If the current necessary to keep the batteries at the Absorb voltage drops below 15 amps before the 3 hours is up, stop charging and let the battery voltage settle down to the Float voltage.

FLOAT: Deliver enough current to hold the batteries at the Float voltage., and keep the batteries at the Float voltage indefinitely.

EQUALIZE: Whenever you want to equalize the batteries, you can manually put them into an Equalize charging stage. The inverter/charger will deliver enough current to bring the batteries up to 16.3 volts and will keep them at that voltage for 8 hours.

Notice how different the Xantrex inverter/charger is than the Iota DLS 90 / IQ4 Converter!. Both the voltages and lengths of time are quite different.

Even more interesting, however, is where the heck did that 15 amp thing come from for switching from Absorb to Float?

As a rule of thumb, it is thought that when the batteries need less than 2% of the amp-hour capacity of the entire battery bank in order to maintain the Absorb voltage, then they are pretty close to full charge and can be put in the trickle charge Float stage.

This 15 amp switchover is an attempt at implementing this 2% rule. However, because the 15 amp value is not modifiable, the assumption is that the battery bank is 750 amp-hours (15 is 2% of 750). That’s quite an assumption! More sophisticated charge controllers allow you to program the current at which you want the system to switch from Absorb to Float.

Our boat’s battery bank was 710 amp-hours, so a more accurate number would have been 2% of 710, or 14 amps. 15 amps versus 14 amps — big deal, right? It’s true, for an inverter that is going to be running 24/7 when you are plugged into shore power, that slight difference is not significant.

But if you are using the inverter/charger with a generator (to supplement solar power during stormy days), you might want to stay in the Absorb stage for the full 3 hours rather than dropping into Float as soon as the current dips below 15 amps!

Also, as I’ll show in the next post in this series, 15 amps was still much too high a current — in our case — to switch from Absorb to Float when we charged our boat’s battery bank with our solar charge controller. We wanted the switch-over current from Absorb to Float to be only 5 amps.

 

 

ENGINE ALTERNATOR

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Cruising sailboats and motorhomes are equipped with an engine alternator that charges the batteries. Our sailboat had a 100 amp Balmar alternator with an ARS-4 Smart Charger which was a multi-stage voltage regulator.

Balmar 100 amp engine alternator

Balmar 100 amp diesel engine alternator

The multi-stage charging algorithm the ARS-4 Smart Charger uses is the following:

BULK: For 36 minutes deliver maximum current until the batteries reach the Bulk voltage. If the Bulk voltage is not attained in 36 minutes, then continue delivering that same current for 6 more minutes. If, again, the Bulk voltage has not been reached, continue for 6 more minutes and check again. Repeat this cycle until the Bulk voltage is reached.

ABSORB: For two hours, deliver enough current to keep the batteries at the Absorb voltage. If after two hours the batteries are not at the Absorb voltage (due to large current draws from systems on the boat or RV), check every six minutes until the Absorb voltage is achieved.

FLOAT: For six hours, deliver enough current to keep the batteries at the Float voltage. After six hours, increase the current being delivered to the batteries to bring them up to the Abosrb voltage and keep them at that voltage 36 minutes. Then return to Float for six more hours. Repeat this cycle indefinitely.

EQUALIZE: The equalizing stage is started manually and you can choose the voltage and time limit.

This charging system is quite programmable. The user can enter the length of time of each stage, and all the voltages can be programmed to any value as well. The factory default voltages are:

  • Bulk = 14.1 volts
  • Absorb = 13.9 volts
  • Float = 13.4 volts

Notice that with this particular engine alternator the batteries are not left in the Float stage indefinitely. Instead, they are put into Float for six hours and then in Absorb for 36 minutes, cycling between those two stages indefinitely.

How long is “indefinitely” when it comes to running a boat’s engine, anyway? Well, we had lots of 24 to 55 hour passages on our cruise where the engine ran nonstop. The alternator cycled between Absorb and Float quite a bit during those passages.

 

 

SIZING AN ENGINE ALTERNATOR TO A BATTERY BANK

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One really important aspect of using an alternator to charge a large battery bank, especially if the engine will be running when huge loads are put on the batteries (like the anchor windlass or power winches), is the 25% rule of thumb I mentioned in the first post of this series: the rated output current of a charger should be roughly 25% of the capacity of the battery bank.

Most cruising boats have very large battery banks. Ours was 710 amp-hours, and we knew lots of cruisers with 600 amp-hour banks all they way up to 1,000 amp-hour banks. For us, 25% of our 710 amp-hour battery bank calculates to 177, so our alternator needed to be a 180 amp alternator to be sized correctly.

The problem is that most alternators over 100 amps require a double pulley system on the engine. That’s complicated, and very few cruisers choose to go that route. Instead, they tend to limp along with undersized alternators.

And what is the most common system failure we saw sailors experiencing on their cruising boats? Alternators!

Not only are most cruising boat alternators undersized, most alternators are called upon to power the anchor windlass, lifting a 60 or 70 lb. anchor along with 100 to 300 feet of stainless steel chain from a depth of 20 or 30 feet. Frequently, it does this in pre-dawn hours of the morning, after the sailors have spent an evening with lights and laptops running and maybe watching a movie. The boat’s batteries are depleted and the solar panels are still asleep and aren’t helping out. It’s like asking a weak and starving person to move furniture.

 

FINAL NOTES

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The manufacturers of converters, inverter/chargers and diesel engine alternators each approach the methodology of multi-stage charging in unique ways, and the charging systems described on this page are just a few examples from our own personal experience.

If you have the time and the inclination, read the user manuals of the charging systems on your RV or boat, find out what your battery manufacturer gives for recommended settings, and set your charging systems up accordingly.

To continue to the next article in this series, click here:

Solar Charge Controllers – Optimizing Battery Charging from the Sun

4-Part Series on RV and Marine Battery Charging Systems:

Related posts about batteries, solar power and living off the grid in an RV or boat:

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Never miss a post — it’s free!

Our most recent posts:

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