Complete repair guide for the Outside Van Aterra – 12V Lithium Battery Bank & Solar Upgrade. Follow these steps to diagnose and fix the issue yourself.
Parts & Tools You’ll Need
- 100Ah LiFePO4 drop-in lithium battery
- Victron SmartSolar MPPT charge controller
- Victron BMV-712 battery monitor
- 40A DC-DC battery-to-battery charger
- 200W flexible solar panel
- ANL fuse holder + 200A fuse
- 4/0 AWG welding cable (battery interconnect)
- Bus bar / power distribution terminal block
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Step-by-Step Repair Guide
Step 1: Diagnose Current Electrical System
Begin by documenting your existing 12V system setup, including your current battery type, amp-hour capacity, and any existing charge controllers or monitoring equipment. Disconnect the negative battery terminal and allow the system to fully de-energize for at least 5 minutes to ensure your safety before proceeding with any installations or modifications.
Step 2: Install Battery Disconnect Switch
Mount the ANL fuse holder with the 200A fuse directly to your positive battery terminal using the 4/0 AWG welding cable, keeping the run as short as possible to minimize voltage drop. This fuse will protect your entire system from catastrophic short circuits and provides a safe disconnect point for maintenance work.
Step 3: Mount Lithium Battery Securely
Position your 100Ah LiFePO4 battery in a secure, level location within your van, preferably in an insulated battery box to maintain optimal operating temperatures between 32°F and 104°F. Secure the battery with heavy-duty straps or a mounting bracket, ensuring it cannot shift during driving or rough terrain navigation.
Step 4: Connect Battery To Bus Bar
Run the positive and negative 4/0 AWG cables from your battery through the ANL fuse holder to your bus bar terminal block, maintaining proper cable management and strain relief throughout the run. Double-check all connections are tight and corrosion-free before proceeding, as loose connections will create excessive heat and potential failure points.
Step 5: Install Solar Panel And Controller
Mount your 200W flexible solar panel to your van roof using appropriate adhesive or mechanical fasteners, then run the panel leads to your Victron SmartSolar MPPT charge controller mounted near your battery bank. Configure the controller settings via the integrated display for LiFePO4 chemistry to ensure proper charging profiles and prevent battery damage from overcharging.
Step 6: Wire Battery Monitor And Charger
Install the Victron BMV-712 battery monitor across your main bus bar to provide real-time data on state of charge, voltage, and current draw throughout your system. Connect your 40A DC-DC battery-to-battery charger from the van’s alternator output to your lithium battery, with all positive and negative connections properly fused and routed away from high-heat areas.
Step 7: Test Complete System Operation
Reconnect the negative battery terminal and power on all components, verifying that the BMV-712 displays correct voltage readings and the SmartSolar controller shows active charging from your solar panel. Monitor the system for 30 minutes under load to confirm proper voltage regulation, absence of fault codes, and stable operation of all connected devices and appliances.
Recommended Parts
| Part | Link |
|---|---|
| 100Ah LiFePO4 drop-in lithium battery | View on Amazon |
| Victron SmartSolar MPPT charge controller | View on Amazon |
| Victron BMV-712 battery monitor | View on Amazon |
| 40A DC-DC battery-to-battery charger | View on Amazon |
| 200W flexible solar panel | View on Amazon |
| ANL fuse holder + 200A fuse | View on Amazon |
| 4/0 AWG welding cable (battery interconnect) | View on Amazon |
| Bus bar / power distribution terminal block | View on Amazon |