SolarFlex 400i components on Cougar 24SABWE TT

[PackFan]

I have a 2022 Cougar 24SABWE travel trailer and have a few questions on the factory installed SolarFlex 400i system:

1. The Smart Shunt is not visible in the Victron Connect app- only the Victron Charge Controller shows up and I am able to access it fine. Not so on the Smart Shunt- nothing.

Based on the routing of the negative battery cable (and the lack of any wiring diagrams I could find), I assume the Smart Shunt is in the junction box that contains the inverter switch. Is this correct? (I thought I would confirm this before digging into this box to confirm the Shunt is even there and how it is installed.)

2. Victron Charge Controller settings when removing the batteries for winter- as there is no battery disconnect switch between the solar panels and charge controller, I disabled charging in the Victron app to be safe. Is this OK? Or should I install a disconnect?

(Note: I currently have two Group 24 12 volt lead acid deep cycles, but will move to lithiums when these die- or sooner, as we boon dock regularly).

None of this was covered during the PDI at Camping World which was an awful experience where I knew more about the trailer than the PDI guy. I have an upcoming service appointment to handle some other items uncovered in the PDI, so I want to educate myself prior.

Any advice or info is appreciated!

[JRTJH]

Welcome to the forum...

I'm not sure if you've located the "very well hidden" SolarFlex 400i quick start guide on the Keystone website. It has some step by step directions to get your system up and running. You can find it here: https://keystone-rv-dealer-app.cdn.p...DF_QSG_WEB.pdf

There is not a "schematic or wiring diagram" in the guide, but hopefully it will help you get the system working. If you need further help, just post what you need help with.

[PackFan]

Thanks John. I was not provided this document, so I appreciate you forwarding it.

By trial and error, I have conducted the applicable steps identified in this document. The Victron Charge Controller is set up and is operating normally.

There appears to be a problem with my Smart Shunt as it does not show up on the Victron Connect app as the Charge Controller did. Therefore, I have not been able to complete the set-up for the Smart Shunt. I assume it is installed in the housing for the Inverter switch, but I have not confirmed that nor if it is installed correctly. I have also read on the forum that the wiring for the Shunt was installed incorrectly on some units that resulted in a service notice being issued.

In the document, there is a PV Disconnect switch referenced as (if equipped). My unit does not have one, so that may answer my question on whether to install one. My plan was to remove the + wire from the solar panels at the charge controller and add an appropriate switch like this one: https://www.amazon.com/gp/product/B0...KIKX0DER&psc=1

I may just have the Dealer work out the issue with the Smart Shunt, but I do not have a lot of confidence in their ability based on my PDI experience.

[PackFan]

I did find the attached wiring diagram for a 2022 Keystone Passport TT with the 400i package. Assuming it is a similar install on the Cougar TT, the Smart Shunt looks like it indeed may be in the junction box that contains the inverter switch- photo attached.

Has anyone ever opened this box?

It looks pretty straight forward with a number of allen screws to remove. I may give it a try when the weather warms up some later this week.

[jxnbbl]

It looks like that diagram has the shunt in the inverter shutoff and not shutoff switch. I have not shutoff switch from panel to the batteries in my install. For storage I take my batteries out and put them on a maintenance charger. Anyways the 'disconnect' is the removal of the terminal cable. In calling the actual solar panel provider, that is what they recommended and they said it would be safer/better if I cover the terminals with a non-conductive material.

[PackFan]

Thanks Jay.

I am with you, the shunt looks like it is in the inverter switch box, not the battery switch "Giggy Box".

Are you suggesting removing the positive cable from the solar panels to the charge controller? I also considered that until I discovered the option in the Victron Connect app for the charge controller to "disable" charging".

I am assuming this is an OK solution, but I still may install a disconnect switch to have a physical disconnect like you are proposing.

I also removed the batteries and put them on a trickle charger in the garage. It has been a cold winter here with lots of snow on the solar panels, so leaving them installed was not a good option.

[RollaMo]

Originally Posted by PackFan

Thanks Jay.

I am with you, the shunt looks like it is in the inverter switch box, not the battery switch "Giggy Box".

The shunt will not be in the "Giggy Box".
It should be a stand alone install very close to the batteries.

On 5th wheels, they are installed in the front storage compartment.
Not sure how the travel trailer setups are though.

Here is what mine looks like on my 2022 24RDS 5th wheel.
Screwed to wall next to the "Brock Box"
Travel Trailer = Giggy Box
5th Wheel = Brock Box
Same function
Click on picture for larger version

[PackFan]

Agreed.

It looks like the Shunt is in the switch box for the inverter on the travel trailers. That is the box in the previously attached picture. The ground cable from the battery goes into this box and I don't see the Shunt anywhere else.

If the Shunt is there, it must be either defective or installed incorrectly as it is not visible in the Victron Connect app as it should be.

[jxnbbl]

Originally Posted by PackFan

...

Are you suggesting removing the positive cable from the solar panels to the charge controller? I also considered that until I discovered the option in the Victron Connect app for the charge controller to "disable" charging".

...

If your intent is not to use the solar to charge the batteries I would assume putting them in nocharge mode would accomplish this. If that is your decision then I will assume that you intend to put the batteries into "inplace storage" (not remove from the trailer).



I wouldn't trust just the gigi box shutoff anyways and I would disconnect the battery entirely and wrap up the connectors.

[PackFan]

I removed the batteries and I used the "disable charging" setting in the Victron Connect app to stop any current from going into the battery connections from the charge controller. Even though there was no current I still insulated the positive battery terminals as a precaution.

The charge controller is still energized in a standy mode so I still want to install a disconnect to totally turn it off in the future.

I still need to troubleshoot the Shunt.

[jxnbbl]

Originally Posted by PackFan

I removed the batteries and I used the "disable charging" setting in the Victron Connect app to stop any current from going into the battery connections from the charge controller. Even though there was no current I still insulated the positive battery terminals as a precaution.

The charge controller is still energized in a standy mode so I still want to install a disconnect to totally turn it off in the future.

I still need to troubleshoot the Shunt.

This (bolded) is exactly what I do

[Kaylodad]

Having had the issue with the Smart Shunt disappearing/not working I emailed Keystone support. Here's their response, tbh not confident in the solution but it does confirm the SS location:

The smart shunt can be found in the black box at the disconnect. If you have lost power for whatever reason, you may have to reload the program or shut the unit down and start it back up to see if it resets everything. If that doesn’t work, you’ll need to contact an authorized dealership for assistance. To fully shut down your unit, you’ll need to unplug from shore power, shut the battery disconnect off, and wait 30 seconds then you’ll power everything back on, meaning plug the unit back in and turn the disconnect switch back to the on position.

[PackFan]

Thanks Kaylodad.

The restart procedure listed did not work in my case. I have followed the steps indicated on a number of occasions and still no response from the Shunt.

I currently have the batteries out, but plan on re-installing them this week if the weather warms up. I will also dig into the inverter switch box and see if the Shunt is there and in what state it is in.

Did you ever get your issue with the Shunt sorted out?

[Kaylodad]

I haven't resolved the issue. Can't get the Bluetooth connection to the shunt even though my phone remembers it. I'm going to open up the disconnect box as soon as I can dig the snow out from around the trailer. Have to believe it's a fuse.

[PackFan]

Mine never worked from the get-go so I was never able to activate it on the app. I am with you- it looks like there is an in line fuse on the power lead. Hopefully that is the problem.

[PackFan]

Hey Kaylodad:

I looked at the switch box this morning and it doesn't look very easy to access. The allen head screws visible look like they secure the switch and the shunt to the box, not for any access. There are 4 phillips head screws that attach the box to the frame, so that looks like the only way to get in. Managing all the cables present may be challenging.

My box has a "1 Amp Fuse Max" sticker on it and I confirmed that is the recommended fuse size for the shunt- so make sure you have one of those handy.

If you dig into it, please let me know how it goes and I will do the same. Mine is going into the dealer for some other warranty work soon, so I may just have them deal with it.

I still want to understand how everything works and how to maintain everything when the warranty lapses. This doesn't appear to be easy with Keystone as they don't readily provide a lot of service info on systems, wiring diagrams, parts, etc. It looks like they want everything to go through the dealer. I had a Winnebago motorhome previously and most of this is on line which makes it much easier to figure things out on your own.

[PackFan]

I am also re-thinking the type of switch to disconnect the solar panels from the charge controller. A dual pole switch/breaker that disengages both the positive and negative leads, like the one attached, keeps coming up.

There is a lot of debate on this versus using a simple battery switch, but the main reasoning is that the solar panel negative is not grounded and the higher voltage that MPPT chargers employ.

Here is a video that covers this:

[JVan]

I had a problem with the smart shunt on our 2022 Cougar 22MLS. Victron app said I needed to update the firmware, tried the update and it failed. After hours of reading and trying different recommended procedures on the Victron website I found that I would need the Product Unlock Key (PUK) from the shunt. Victron said that there are two PUK numbers with each shunt, one should be in the owners manual the other is on the shunt. Nothing in the owners manual, so I decided to look on the shunt which is located in the box with the inverter shutoff switch. When I took apart the box I was surprised to find that it was literally full of water. The trailer is still under warranty so I took it back to the dealer, Keystone is replacing the box. We have had the trailer four months, it has been at the dealer for nearly two of those months for various problems.

[PackFan]

Hey JVan:

That sucks. I never got an owners manual for the shunt and got zero training or info from Camping World on the Solar Flex system. Heck, I didnt even know there was a shunt until I educated myself on the system.

Am I on the right track in removing the 4 Phillips screws that appear to hold the inverter box switch to the frame?

Mine looks like there may be some sealant between the box and the frame. Based on your experience, if this isn't sealed, it should be.

[JVan]

My box was attached with two screws to a bracket that is attached to the frame directly behind the battery rack. When the box is removed you can access the six very small Philips screws holding the back cover on. Then you can see the Shunt and the back of the switch. My original dealer was clueless about the shunt or how it worked. We never received a manual for the shunt I got the information from the Victron website. I don't know how mine filled with water, there were some gaps where the cables from the battery and to the inverter entered the box.