The system begins with two solar panels mounted on the roof. The panels convert solar energy (sunlight) into electric current. Wires carry the current to a controller. The controller is also wired to three deep-cycle "house" batteries. All electronic items in the sleeper (lights, microwave, fans, computer, etc.) are wired to and powered by the house batteries.
Expediter Bill Allen had two problems. He did not like idling his Sprinter van to stay comfortable in the sleeper, and he did not like generators. He solved both problems by rigging his van to use solar power.
Bill, 52, has been hauling expedited freight for 18 months. He drove big trucks for 16 years and then went to work for Halliburton as a truck driver in Iraq. In November 2005, he was second in command of a fuel tanker convoy and was severely wounded by an IED (roadside bomb). He returned home to Monroe, Michigan, and moved in with his sister. She took a leave of absence from work and cared for Bill for a year while he re-learned how to walk.
With a cheerful tone and some pride, Bill said, “I went from a wheelchair to a walker, to a four-point cane, to a single-point cane, to finally just walking without a cane.” Then he wanted to go back to work. “I was going nuts sitting around the house.” he said.
He called Express-1 to see if he could find someone who had a van. He wanted to try it to see if it would work and if he could do it with “all the metal in me.” Express-1 put Bill in touch with a fleet owner, Richard Calame. Bill drove one of Mr. Calame’s vans for a year and then bought a van of his own, in April, 2008.
The van is a diesel-fueled 2007 Sprinter, purchased from Bob Caldwell Chrysler Jeep Dodge in Columbus, Ohio. The sleeper conversion was done by Midway Specialty Vehicles, LLC. in Elkhart, Indiana.
Expedite NOW caught up with Bill on the road. In a parking lot behind a strip mall in Knoxville, Tennessee, he happily provided a van tour and answered our questions. While the Espar heating and cooling components are yet to be installed, Bill knows their power requirements and believes that once they are installed, he will never again have to idle to stay comfortable in his sleeper.
***image1***Bill guided us around his van and showed the components. The system begins with two solar panels mounted on the roof. The panels convert solar energy (sunlight) into electric current. Wires carry the current to a controller. The controller is also wired to three deep-cycle “house” batteries. The controller converts the voltage to 12 volts and regulates the amps going into the batteries. Twelve-gauge wires come out of the panels and controller. Between those connections, thicker (eight-gauge) wire is used to minimize voltage drop.
All electronic items in the sleeper (lights, microwave, fans, computer, etc.) are wired to and powered by the house batteries. An isolator separates the house batteries from the starting (engine) battery. Two house batteries are mounted under the van, in a custom-made rack; another is under the hood. Bill installed all the components himself, except the custom-made battery rack.
EN: What got you started on solar power?
Bill: It costs $40 a night to idle. I didn’t want the hassles of putting a generator underneath. You have to drop it down for oil changes and all that maintenance. And there is the added noise of having it right under you. I didn’t like the idea of carrying a portable generator with me. And carrying gasoline … I didn’t think that was such a great idea. I didn’t want to carry a portable generator in back because it will get in the way of the freight. I didn’t want to mount one on the front bumper or on the back of the van. And I didn’t want to have to worry about the generator while I was sleeping.
So I needed something to replenish the batteries while I was sitting, especially during the day. I was finding that I was using too much current during the day. With even the two fans, after a couple of days I was losing power. I would have to idle. So I wanted to get at least to a power break-even point during the day.
EN: Does it work?
Bill: Right now (parked in the sun), I can charge the batteries while using things in the sleeper. At night, the batteries provide the power. With this controller and the panels, I am getting 12 to 14 amps during the day.The Espar 12 volt air conditioner I am looking at is going to draw about 8 amps when it is on half power, after everything is cooled down. I’ll be cooling things down with the regular truck air conditioner anyway, so I’ll only be drawing about eight amps to keep the sleeper cool after the truck is turned off.
EN: Twelve to 14 amps does not sound like much power.
Bill: The van came from Midway Sleeper with a refrigerator, and a TV/DVD player, and a microwave. Everything is 110 volts so you have to run the inverter. If you run the inverter, you have to keep the engine running because the sleeper only came with one deep-cycle battery. And that inverter, because it’s so large, is not very efficient.
So I wanted to go all to 12 volts. The refrigerator came out. A 12 volt cooler from TA went in. The TV, I picked up at Pilot. That’s a flat-screen TV and DVD player, but it is also 12 volts. Instead of having a regular stand, I just got a wall-mounted stand and freed up another compartment.
The sleeper came with lights underneath the cabinets. I added LED light bars. They draw less current, and that way I can leave lights on longer without drawing much current. My LED reading lamp is mounted overhead and powered by a battery.
I have another inverter, but a small one. It’s a 100 watt inverter that I use for my printer. I turn it on. The printer powers up, I print or scan, and I turn it off. It’s a lot more power-efficient.
The charger for the computer is a 12 volt mobile charger. My computer can stay plugged in all the time and I don’t have to worry about the batteries going dead.
EN: What else do people who want to do something like this need to know?
Bill: I don’t know. It’s a lot of trial and error. I go to a lot of RV stores. Camping supplies is where I find most of my things.
EN: When you go to web sites to read up on this, are there any you find to be good?
Bill: It’s kind of hit and miss. I’ll put in key words and start Googling them, and then just narrow it down from there.
EN: On a bright, sunny day, what do the solar panels produce?
Bill: I’ll get about 12 to 14 amps with the boost. Without the boost, I’m getting 10 to 12. The boost is giving me about an additional two amps.
EN: Where does the boost come from?
Bill: From the Blue Sky controller, it’s not a standard controller. That’s why I have to use the lower wire gauges for thicker wire.
EN: What about wattage?
Bill: The panels will generate 120 watts apiece, and they’re 17.6 volts. The controller brings it back down to 12. I can equalize the batteries through this controller, but I was told not to because these are the AGM batteries, the sealed batteries. You don’t want to equalize them because it will increase the gases that may explode.
EN: Who told you this?
Bill: I used a book. Managing 12 Volts is a book for RV’s and for sail boats, for putting 12 volt systems in. Amazon.com and most of the RV stores have it.
EN: What about your microwave?
Bill: The microwave is 110. Turn on the big inverter that came with the sleeper, and cook what you want. It’s only going to be on about five minutes, then turn it back off. That’s the only time I use that big inverter. Other than that, it would waste power.
EN: Not for the van, but for the solar system, how much money do you figure you have into this?
Bill: Each panel was a little over $600. And for the controller … I paid $289. The brackets were 50 bucks for the two sets.
EN: And the wires? ***image3***
Bill: Wires? I was surprised. That copper wire at Lowe’s was $40 for 20 feet.
EN: So brackets and wires were around $100?
Bill: Yea, OK. We can put it that way. Actually, it was $104 because I also used stainless-steel washers and screws and that. The whole deal I’m thinking $1,200 … almost $1,500.
EN: What about the batteries? Does that include the batteries?
Bill: No. Batteries … those are 100 amp-hour, deep-cycle, AGM batteries; $250 apiece.
EN: What about the custom-built battery rack under the van?
Bill: Camping World charged $300 to fabricate the rack.
EN: So the grand total is?
Bill: About $2,400, plus the cost of the bunk heater and air conditioner.
EN: If you were to go the old-fashioned way with a gasoline generator, how much would that cost?
Bill: A lot cheaper. The generator would have been $600, maybe. A roof-mounted air conditioner for a camper is another six. So the whole thing would have been $1,200. This is more expensive but the thing is, I’ll have no maintenance. I’ll have zero maintenance. Once the system is in, the system should take care of itself … and be quiet.
EN: You were driving someone else’s van and thinking about one of your own. When did the solar idea come into your mind?
Bill: When I was roasting in his van. I needed to have an air conditioner going when I was sitting. And even in the van at idling, it wasn’t keeping the van cool. I figured there’s gotta be a better way.
At the 2007 truck show in Wilmington, Ohio, the Expedite Expo, I saw the gentleman from Espar heater. He had just got the air conditioners in. They are made in Spain. There are two compressors and it runs on 12 volts.
EN: And the heater?
Bill: Yea. I’m planning before winter starts to get an Espar heater. I’ve already talked to him. He can mount it underneath the bunk. It has its separate exhaust and runs off diesel fuel and a glow plug.
EN: You were a truck driver for 16 years and then a truck driver in Iraq. How did you become an “electrical engineer?”
Bill: I’m a ham radio operator. I’ve been a ham radio operator since I was 14.
EN: Where is your ham radio?
Bill: Up front on the dash; two meters and 440.
EN: Your call sign?
Bill: KN8AA
EN: Your antennas?
Bill: There are two solar panels and two antennas on the roof; one antenna for amateur radio and one for the CB. I wanted to make sure I could take the roof fan out and leave enough room for the air conditioner, because it is going to stick out farther than the fan. On the back, I had the Qualcomm moved over because eventually I want to get a VuCube that will mount next to that.
EN: What happens if you have a week of cloudy days?
Bill: You’re not going to be using the air conditioner, most likely. So, that power will not be used. Every time you move the truck, the alternator charges the batteries. If you are sitting under clouds for days at a time and not moving the truck, the batteries will last, I’m thinking, two to three days.
EN: So, you have eliminated the need for a generator and kept the creature comforts, but at a cost higher than using a gasoline generator. Is it worth it?
Bill: Yea, I think so. Every once in a while, my knee and wrist hurt from the metal pins inside. I won’t have to mess with maintenance, and changing oil, and filters, and filling up gas cans, and carrying gas cans with me. With no generator, I have one less thing to maintain. And I’m emission-free, so if I went into California I would be CARB-compliant.
For additional information, contact Bill Allen at [email protected]
