This page is the start of a description of a 525 W solar power system containing both AC and DC loads in a Ford Transit van named Dusty and made by Tressie George.

Parts[edit | edit source]

Below are the list of parts, supplies, and tools you will need. Depending on sourcing, you will likely be buying slightly different components.

Assembly Instructions[edit | edit source]

The following section contains step-by-step instructions on how to assemble this 535 W photovoltaic system.

1
Panels in parallel.png
Connect panels in parallel

Use the panel adaptor cables and connectors to connect the 3 solar panels. Start by joining the adaptor cables to the positive and negative terminals on each panel. Then use the connectors to attach the three panels in parallel. To do this, use the connectors to join all the negatively charged wires. Then do the same thing but with all of the positively charged wires. Each wire carrying a negative charge should only be connected to other wires that are also negatively charged. Similarly, each wire carrying a positive charge should only be connected to other wires that are also positively charged.

2
Panel and fuse.jpg
Connect panels to 40A fuse

Once all the positively charged wires are joined to one wire, connect this wire with a 40A fuse to prevent power surges to the system. Next, connect a red wire coming out of the same 40A fuse, this will attach to the charge controller in a later step.

3
Batteries in Parallel.jpg
Connect the 2 batteries

Warning: Do not let the positive and negative terminals of the batteries touch each other. Using the red wire, attach that to the positive terminal of the battery. Use that same wire and connect it to the positive terminal of the second battery. Repeat this same process for the black wire, except attach it to the negative battery terminals.

4
Battery with wires to inverter.jpg
Prep to connect battery to inverter

Connect a red wire to the battery terminal, then connect that same wire to a 150A fuse. Next connect another red wire to the opposite side of the same fuse, this will attach to the inverter in a later step. Then, connect a black wire to the negative terminal of the battery, this will attach to the inverter in a later step.

5
Battery with wires to inverter and charge controller.jpg
Prep to connect battery to charge controller

Connect another red wire to the positive battery terminal, this same wire will connect to a 40A fuse. Next, connect another red wire to the opposite side of the same fuse, this will connect to the charge controller in a later step. Then, connect a black wire to the negative terminal of the battery, this same wire will connect to the charge controller in a later step.

6
Fuse Box Labeled.jpg
Prep to connect fuse box to charge controller

Connect the positively charged red wires to one side of the fuse box, in a later step those same wires will be connected to the charge controller. Then, connect the negatively charged black wires to the fuse box above the red wires that were just installed. Those same black wires will be connected to the charge controller in a later step. Repeat this process for the other side of the fuse box, except those wires will be connected to the loads.

7
Battery to inverter.jpg
Connect inverter to battery

Using a red wire, connect the positive terminal of the inverter to the 150A fuse from step 4. Then, connect the black wire from step 4 into the negative terminal of the inverter.

8
Battery to charge controller.jpg
Connect charge controller to battery

Install the red and black wires from the battery in step 5 to the charge controller battery terminals. This is done by unscrewing the terminals, inserting the black wire into the negative terminal labeled Bat- and the red wire into the positive terminal labeled Bat+, and closing and securing both terminals with the screwdriver.

9
Fuse box to charge controller.jpg
Connect fuse box to charge controller

Install the red and black wires from step 6 to the charge controller load terminals. Unscrew the terminals and insert the red wire into the Load+ terminal and the black wire into the Load- terminal. Close and secure both terminals with the screwdriver.

10
Panel to charge controller.jpg
Connect panels to charge controller

Install the red an black wires from steps 1 and 2 to the charge controller PV terminals. Unscrew the terminals and insert the red wire into the PV+ terminal and the black wire into the PV- terminal. Close and secure both terminals with the screwdriver.

To Catch the Sun is the first book created from this much exclusive Appropedia content on photovoltaics. It is was successfully crowdfunded on Kickstarter. See http://tocatchthesun.com to get your own copy.

Safety and Disclaimer[edit | edit source]

This guide is provided as a free reference. Electricity is dangerous. Batteries have stored energy and can be very dangerous if you short them (i.e., connect the positive and negative terminal with something conductive like metal). You can even hurt yourself with a screwdriver if you try hard enough. Please proceed at your own risk. Appropedia (and any authors) shall not be held responsible for any damages as a result of any activities contained within this guide.

Notes[edit | edit source]

  1. https://www.amazon.com/Vmaxtanks-Vmaxslr125-rechargeable-Solar-Inverters/dp/B00ACNO2AO/ref=sr_1_1?crid=2BYWWIL5YHHLZ&keywords=vmax+tanks+12v+battery+125ah+SLA+rechargeable+deep+cycle+battery+for+use+with+pv+solar+panels&qid=1669504655&sprefix=vmax+tanks+12v+battery+125ah+sla+rechargeable+deep+cycle+battery+for+use+with+pv+solar+panel%2Caps%2C137&sr=8-1&ufe=app_do%3Aamzn1.fos.08f69ac3-fd3d-4b88-bca2-8997e41410bb
  2. https://www.amazon.com/Vmaxtanks-Vmaxslr125-rechargeable-Solar-Inverters/dp/B00ACNO2AO/ref=sr_1_1?crid=2BYWWIL5YHHLZ&keywords=vmax+tanks+12v+battery+125ah+SLA+rechargeable+deep+cycle+battery+for+use+with+pv+solar+panels&qid=1669504655&sprefix=vmax+tanks+12v+battery+125ah+sla+rechargeable+deep+cycle+battery+for+use+with+pv+solar+panel%2Caps%2C137&sr=8-1&ufe=app_do%3Aamzn1.fos.08f69ac3-fd3d-4b88-bca2-8997e41410bb
  3. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  4. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  5. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  6. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  7. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  8. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  9. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268
  10. https://www.homedepot.com/p/Renogy-8-ft-10-AWG-Charge-Controller-and-Battery-Connector-Tray-Cables-RNG-TRAYCB-8FT-10/310330268

Authors[edit | edit source]

  • Lonny Grafman
  • Joshua Pearce
FA info icon.svg Angle down icon.svg Page data
Keywords solar, photovoltaics, how-to
SDG SDG07 Affordable and clean energy
Authors Lonny Grafman, Joshua M. Pearce
License CC-BY-SA-4.0
Organizations To Catch the Sun/525W solar van
Language English (en)
Related 0 subpages, 0 pages link here
Impact 67 page views
Created November 17, 2022 by Lonny Grafman
Modified February 28, 2024 by Felipe Schenone
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