Build Your Own

Solar Panel Guide

Click Here to Watch the

Full Video Presentation

Build Your Own Solar Panel Guide: DIY

Off-Grid Solar System V2.0: Page 1
The prices of solar panels have been falling gradually but the cost of an off-grid solar system setup is
rising steadily. However, anyone with basic knowledge of Electricity and having a toolbox can install it on
their own. This will reduce the overall system cost substantially and you will learn a lot.

To build a basic off-grid solar system, you will need the following components:

1. Solar panel
2. Charge Controller
3. Battery
4. Inverter
5. Balance Of System ( Cable, Breaker, Meter, Fuses, and MC4 connectors )

In this book, you will know how to choose the appropriate components for your Off-Grid Solar System and
how to connect and set them up properly.

Components Required :

1. Solar Panel
2. Charge Controller
3. Battery
4. Inverter
5. Remote Meter
6. WiFi Adapter
7. Temperature Sensor
8. DC Breaker
9. AC Breaker
10. DC Busbar
11. Fuse Box
12. DIN Rail
13. Cables
14. MC4 Connector
15. Terminal Lugs
16. Cable Tie

Tools Required :
1. Wire Stripper
2. Crimping Tool
3. Pliers
4. Screwdriver
5. MC4 Spanner
6. Spanners

Build Your Own Solar Panel Guide: DIY

Off-Grid Solar System V2.0: Page 2
 Step 1: How It Works ?

The off-grid solar system means you are not connected in any way to the utility grid. The system utilizes
batteries to store energy produced from solar panels.

Solar Panel:
The solar panel converts sunlight into electricity. Photovoltaic cells on the solar panel absorb the
sun’s energy and convert it to DC electricity.
Charge Controller:
The current from the solar panel feeds into a charge controller, which controls how much current goes to a
battery. Charge controllers prevent batteries from being over-charged and over-discharged.

Battery:
It stores energy generated from the solar panel during the day.

Inverter:
It converts the DC (Direct Current) power from the battery bank or solar panels to AC (Alternating
Current) so that you can run your AC appliances, such as TV, Fan, Fridge, Water Pump, etc.

Click Here to Watch the

Full Video Presentation

Build Your Own Solar Panel Guide: DIY

Off-Grid Solar System V2.0: Page 3
 Step 2: Basic Electricity Rules

Ohms Law Relationship Current ( I ) :

Current ( I ) = Voltage (V ) / Resistance (R) I (amps) = V (volts) / R (Ω)

It is easier to remember the Ohms law relationship by Resistance ( R ) :

using the above picture ( Ohms Triangle). By knowing
any two values of the Voltage, Current, or Resistance R (Ω) = V (volts) / I (amps)
quantities we can use Ohms Law to find the third
missing value. Power ( Watt) = Voltage ( Volt) x Current (Amp)

Voltage ( V ) : Energy ( Watt-hours ) = Power (Watts) × Time ( Hours)

V (volts) = I (amps) x R (Ω) Capacity = Current (Amp) x Time ( Hours)

Build Your Own Solar Panel Guide: DIY

Off-Grid Solar System V2.0: Page 4
 Step 3: 6 Steps of DIY Off-Grid Solar

The following 6 steps are required for building a DIY Off-Grid Solar System:

1. Calculate Daily Energy Consumption

2. Select the Battery
3. Select the Solar Panel
4. Select Charge Controller
5. Select Inverter
6. Balance of System ( BOS )

In the next steps, we will discuss in detail the above points.

Step 4: Calculate Your Daily Energy Consumption

Figuring out your daily energy consumption ( Watt- Hours) is the 2rst step for designing an off-grid solar system.
Energy Consumption ( Watt-Hours ) = Power (Watts) × Time (Hours)

You can get the power rating from the power label ( Name Plate ) of the appliance or you can measure the actual power
consumption by using a wattmeter. I have used my wattmeter to measure the power consumption of a few appliances.

Manual Calculation:

If you’re running a 2 Nos of 6W LED bulb for 5 hours a day, 1 No of Fan (80W ) for 4 hours, 1 No of Laptop (65W )for 3 hrs,
and a WiFi Router (6W ) for 24 hours.

1. LED Bulb: 2 x 6W x 5 hr = 60WH

2. LED TV: 1 x 65W x 3 hr = 195WH

3. Ceiling Fan: 1 x 80W x 4 hr = 320WH

4. WiFi Router: 1 x 6W x 24 hr = 144WH

-------------------------------------------------------
Total = 719WH
You can calculate the energy consumption manually as shown above or use an Online Calculator

Build Your Own Solar Panel Guide: DIY

Off-Grid Solar System V2.0: Page 5
Step 5: Select the Battery of current is needed to turn the engine over during
starting. Therefore lots of thin plates are employed to
The battery is used to store the energy produce by the
achieve maximum surface area and as a result higher
Solar Panel during the day. It is an essential part of an
starting current in starting batteries.
off-grid solar system, and provide a constant source of
stable and reliable power that allows to power devices
Application: Automobiles ( Car & Bike )
when the sun is down.

Deep-Cycle Battery:
The cost of the battery is contributing a large portion of
the entire project cost. here we will discuss in detail so
A deep cycle battery is designed to provide a steady amount
that you can select the right battery for your off-grid
of current over a long period of time. This type of battery is
solar installation.
also designed to be deeply discharged over and over again.
To accomplish this, a deep cycle battery uses thicker plates.
Batteries are categorized according to 1. Application &
This will lead to lower surfaces and accordingly less instant
Construction 2. Chemistry
power, unlike the starting batteries.

1. Applications: Automotive and Deep-Cycle

Application: Renewable Energy
2. Chemistry: Lead Acid, Lithium, and NiCd

Automotive Battery:

This type of battery is designed to provide a very large

amount of current for a short period of time. This surge

DIY Off-Grid Solar System V2.0: Page 6

Step 6: Lead-Acid Battery Vs Lithium-Ion Lithium is a premium battery technology with a longer
Battery lifespan and higher efficiency, but you’ll pay more
Two of the most common battery chemistry types are money for the boost in performance.
lithium-ion and lead-acid. Apart from these NiCd is also
used for the renewable application. The Lithium batteries that are employed in solar systems
are Lithium Iron Phosphate (LiFePO4) which have great
Lead-acid batteries are made with lead, while Lithium thermal stability, high current ratings, and a long life
batteries are made with the metal lithium. Lithium and cycle. This new technology lasts longer and can be put
lead-acid batteries can both store energy effectively, but through deeper cycles. They also require no
each has unique advantages and drawbacks. maintenance or venting, unlike lead-acid batteries. The
main downside for lithium batteries is their higher price
1. Lead-acid Battery: compared to lead-acid batteries at the moment.

The lead-acid battery is a tried-and-true technology that Which Battery Should You Choose?
costs less, but requires regular maintenance and doesn’t
last as long. If you need a battery backup system, both lead-acid and
lithium-ion batteries can be effective options. However,
Flooded Lead-Acid (FLA) : it’s usually the right decision to install a lithium-ion
battery given the many advantages of the technology –
These types of batteries are submerged in water. These longer lifetime, higher efficiencies, and higher energy
must be checked regularly and refilled every 1-3 months density.
to keep them working properly. It also needs to be
installed in a ventilated place to allow battery gases to If you are planning to live off the grid full-time, you
escape. should go with Flooded Lead Acid (if you don’t mind
regular maintenance) or the premium Lithium option for
Sealed Lead-Acid (SLA): heavy use.

SLA batteries come in two types, AGM (Absorbent Glass If you want to install the solar in a small cabin or a
Mat) and Gel, which have many similar properties. They vacation home, you’ll only be there a few times a year. In
require little to no maintenance and are spill-proof. The this case, you won’t be able to provide the regular
key difference in AGM vs. gel batteries is that gel maintenance which is required for Flooded Lead-acid
batteries tend to have lower charge rates and output. batteries. Then, I will recommend spending some extra
Gel batteries generally can’t handle as much charge amount to buy a Sealed Lead Acid battery instead.
current, which means they take longer to recharge and
output less power.

2. Lithium Battery:

DIY Off-Grid Solar System V2.0: Page 7

Step 7: Factors Determine the Battery Bank Size

The following factors determine the battery bank size:

1. Daily power consumption

2. System voltage ( 12V / 24V /48V )

3. Depth of Discharge ( DOD )

In the previous step, we have already calculated the daily power consumption. In the next few steps, we will learn more
details above factors.

Click Here to Watch the

Full Video Presentation

DIY Off-Grid Solar System V2.0: Page 8

Step 8: System Voltage

A battery is recognized with its voltage (V ) and capacity Parallel Connection:

measured by amp-hours (AH). To provide the desired
system voltage, one can wire the batteries in series and Parallel connections will increase your current rating
parallel. (Amp-Hours ), but the voltage will stay the same. It's
important to note that because the amperage of the
Series Connection: batteries increased, you may need a heavier-duty cable
to keep the cables from burning out.
Connecting batteries in series add the voltage of the two
batteries, but it keeps the same amperage rating (also Example: Connecting two 12V /100AH batteries in
known as Amp-Hours). parallel will produce 12V, but the total capacity will be
increased to 200AH.
Example: Connecting two 12V /100AH batteries in series
will produce 24V, but the total capacity remains the
same (100AH).

DIY Off-Grid Solar System V2.0: Page 9

Step 9: Depth of Discharge

The battery’s Depth of Discharge ( DOD ) is the but are recommended to choose a value of around 50%
percentage of the battery capacity that can be safely as a good trade-off between longevity, cost.
drained without damaging the battery.
For a deep cycle battery, 50% and for a lithium battery
As you can see in the above 2gure, the more a battery is 80% DOD is considered as good practice.
allowed to discharge, the shorter its lifespan. Deep cycle
batteries are designed to discharge 80% of their capacity

DIY Off-Grid Solar System V2.0: Page 10

Step 10: Battery Sizing

Battery Capacity ( AH ) = Daily Energy Consumption ( Battery Capacity = 719WH / ( 12V x 0.5 ) = 119.8AH
Watt-Hour ) / ( System Voltage x DOD )
You have to select a battery with a capacity of more than
Example: 119.8AH. The nearest value available in the market is
120AH.
Daily energy consumption =719WH ( Calculated in the
earlier step ) Battery Selected: 12V / 120AH

System Voltage = 12V I have purchased 150AH by considering future

expansion.
DOD = 50% for Flooded Lead Acid Battery

DIY Off-Grid Solar System V2.0: Page 11

Step 11: Select the Solar Panel

Solar Panel converts the sunlight into electricity. A 3. Thin Film:

speci2c amount of sun’s energy can be converted to
electricity by the solar panel since they are not 100% Thin-2lm solar panels are made by depositing a thin
efficient and they cannot trap the full energy of sunlight. layer of a photovoltaic substance onto a solid surface,
Most of the solar panels are less than 20% efficient, like glass. Examples of these photovoltaic substances
which means that they can just trap about 20% of include Amorphous silicon (a-Si), Cadmium telluride
sunlight energy. (CdTe), Copper indium gallium selenide (CIGS), Dye-
sensitized solar cells (DSC).
Commonly they are 3 types: Monocrystalline,
Polycrystalline, and Thin Film . The main advantage of amorphous solar cells is that they
can generate electricity in weak light conditions.
1. Monocrystalline: However, the main problem of amorphous solar cells is
the low photoelectric conversion efficiency, which is
Monocrystalline solar cells are more efficient because about 10-13% only.
they are cut from a single source of silicon.
Which One You Should Choose?
As monocrystalline solar cells are made out of a single
crystal of silicon, electrons are able to Now easier For most residential solar panel installations, it makes
through the cell, which makes the efficiency higher than the most sense to install monocrystalline panels.
other types of solar panels. The efficiency can range from Although you have to pay a higher price, you get better
17% to 22%. efficiency and a sleeker aesthetic than you would with
polycrystalline panels.
Because of the way that monocrystalline panels are
manufactured, they end up costing more than other If you’re on a tight budget, however, polycrystalline
kinds of solar panels. panels might make more sense for you.

2. Polycrystalline: Thin-film solar cells are mostly used in large scale

operations, such as utility or industrial solar installations
Polycrystalline solar cells are blended from multiple because of their lower efficiency ratings.
silicon sources and are slightly less efficient. The multiple
silicon crystals in each solar cell make it harder for I will always recommend purchasing a good brand solar
electrons to Now. This crystal structure makes the panel. A good brand solar panel company always invests
efficiency rate of polycrystalline panels lower than heavily in the quality of its manufacturing process, as
monocrystalline panels. Polycrystalline panel efficiency well as in its reputation.
ratings will typically range from 15% to 17%.

Polycrystalline solar panels are cheaper to produce than

monocrystalline panels. Most of the residential
installations use Polycrystalline solar panels.

DIY Off-Grid Solar System V2.0: Page 12

Step 12: Factors to Determine the Solar Panel Sizing

The sizing of the solar panel used in an off-grid system depends on the following factors:

1. Daily energy consumption

2. Number of Peak sun hours

3. Solar panels efficiency

DIY Off-Grid Solar System V2.0: Page 13

Step 13: Peak Sun Hours

The first step for sizing the solar panel is to determine The following factors affect the number of peak sun
the amount of sunlight received where you live. While hours:
the amount of sunlight your panels receive is important,
a more accurate representation of the amount of energy 1. Geographical Location: Solar panels installed at a
your panels can produce is peak sun-hours. different location, receive different amounts of sunlight.
The panel installed near the equator receive maximum
What is Peak Sun-Hours? sunlight, as it is closer to the sun.

The peak sun hours is the number of hours per day 2. Time of Day: The amount of sunlight falling on the
during which the average solar irradiance (sunlight) is solar panel, varies throughout the day, based on the
1000 watts per square meter (W/m2) or 1 kilowatt per sun’s position in the sky. It receives maximum at noon
square meter (kW/m2). and a minimum during the morning and evening.

One peak sun hour = 1000 W/m2 or 1kWh/m2 of sunlight 3. Season: Maximum amount of sunlight received
during the summer and minimum amount during the
Example: If a given location receives a total of 6,650 winter.
Wh/m2 of solar radiation over the course of a day, then
that location gets 6.65 peak sun hours. You can see the Image source: Solar Energy International and Global
above picture for a clear understanding. Solar Atlas

DIY Off-Grid Solar System V2.0: Page 14

Step 14: How to Calculate Total Peak Sun Hours?
Peak Solar Radiation = 1 kW/m2 ( Solar Panels are rated
The solar irradiance map can show you the amount of at an input rating of 1kW/m2.)
solar energy your location receives on an average day
during the worst month of the year. Peak Sun Hours = 5.093/1 = 5.093 Hours

To find out the amount of solar insolation in your area, If we consider the worst scenario, we have to choose a
you can use the Global Solar Atlas. Follow the following number lesser than that obtained in the above. So here I
steps: have chosen 4.5 Hours.

Step-1: Search your location If you are situated in North America, you can use this
reference chart, to get the number of peak sun hours.
Step-2: Choos the PV system configuration ( e.g - Small
residential )

Step-3: Click on Annual Average ( Daily Average in

kWh/m2 per day)

Step-4: The number is the peak sun hours

DIY Off-Grid Solar System V2.0: Page 15

Step 15: System Efficiency

You will never get the rated power from the solar system 3.Wiring Loss: Loss arises in the inter panels
because there are few losses associated with it like : cabling and cable from panels to the battery
bank.
1. Soiling Loss: Loss due to dust deposition on the solar
panel The typical efficiency is 70% ( considered the worst
situation )
2. Shading Loss: Loss due to shadow by trees and
building near to the panels

Click Here to Watch the

Full Video Presentation

DIY Off-Grid Solar System V2.0: Page 16

Step 16: Solar Panel Sizing

You can use the below formula to determine the solar

panel wattage:

Solar Panel Watt = Daily energy consumption ( WH) / ( HowMany Solar PanelsRequired?
Peak Sun Hour x system efficiency )
If the power calculated in the above higher than a single
Daily energy consumption = 719WH panel, you have to purchase more panels, in that case:

Peak Sun Hour = 4.5Hrs Number of solar panels=Required solar panels (Watts) /
Selected panels Watt
Panel Watt = 719 / ( 4.5 x 0.7 ) = 228.25W
Example:
We have to buy a solar panel with a rating more than the
above-calculated value. The nearest value of the panel Required panel watt = 1320W
available in the local market was 250W or 260W.
Solar panel selected = 330W
I have purchased a 260W because the price between the
two panels was not much different. Number of panels = 1320 /330 = 4

Final Rating: 250W / 12V You have to purchase 4 numbers of 330watt panels.

DIY Off-Grid Solar System V2.0: Page 17

 controller ( PWM or MPPT ).
Step 17: How to Wire Solar Panels?
To connect the solar panels in the above 3
You can connect the solar panels in the following 3 configurations, you need MC4 Connectors and spanners
ways: to connect and disconnect them.

1. Series: Current remains the same while the voltage of Note: Every charge controller has limits on how much
the panels will be added to each other. voltage it can accept (maximum input voltage). You must
ensure that the power coming in from your solar panels
2. Parallel: Voltage remains the same while the number never exceeds this number.
of currents will be added.

3. Series-Parallel: Strings of series panels connected in

parallel

When deciding between the above three con2gurations,

two important facts to consider are the maximum input
voltage of your charge controller and the type of charge

DIY Off-Grid Solar System V2.0: Page 18

Step 18: Charge Controller Selection when the battery is discharged.

It is a device that is placed between the Solar Panel and Types of solar charge controllers
the Battery Bank to control the amount of electric There are currently two types of charge controllers
energy produced by Solar panels going into the commonly used in PV power systems :
batteries. The main function is to make sure that the
battery is properly charged and protected from 1. Pulse Width Modulation (PWM) Controller
overcharging.
2. Maximum Power Point Tracking (MPPT) Controller
As the input voltage from the solar panel rises, the
charge controller regulates the charge to the batteries
preventing any overcharging and disconnect the load

DIY Off-Grid Solar System V2.0: Page 19

Step 19: PWM Solar Charge Controller the MOSFET at a high frequency with various pulse
widths, a constant voltage can be maintained. The PWM
PWM stands for Pulse Width Modulation, which stands controller self-adjusts by varying the widths (lengths)
for the method it uses to regulate charge. Its function is and frequency of the pulses sent to the battery.
to pull down the voltage of the solar array to near that of
the battery to ensure that the battery is properly When the width is at 100%, the MOSFET is at full ON,
charged. In other words, they lock the solar panel allowing the solar panel to bulk charge the battery.
voltage to the battery voltage by dragging the Solar When the width is at 0% the transistor is OFF open
panel Vmp down to the batteries system voltage with no circuiting the Solar panel preventing any current from
change in the current. Nowing to the battery when the battery is fully charged.

It uses an electronics switch ( MOSFET ) to connect and

disconnect the solar panel with the battery. By switching

DIY Off-Grid Solar System V2.0: Page 20

Step 20: MPPT Solar Charge Controller system.

MPPT charge controller extracts the maximum power The performance advantage of an MPPT controller is
from the PV module by forcing the PV module to operate substantial (10% to 40%) when the solar cell
at a voltage close to the Maximum Power Point (MPP). It temperature is low (below 45°C). They are more efficient
has been designed to adjust its input voltage to utilize than the PWM controller. The efficiency of a typical MPPT
the maximum power output of the solar array and then controller is around 94-99%.
transform this power to supply the varying voltage
requirement. The input voltage is varied by using a To fully exploit the potential of the MPPT controller, the
DC/DC converter. array voltage should be substantially higher than the
battery voltage. The MPPT controller is the best solution
MPPT controllers do this via an adaptive algorithm that for higher power systems.
follows the maximum power point of the Solar
panel/array and then adjusts the incoming voltage to
maintain the most efficient amount of power for the

DIY Off-Grid Solar System V2.0: Page 21

Step 21: Sizing of Charge Controller : Charge controllers have an upper voltage limit. This
refers to the maximum amount of voltage they can
Choosing the most suitable charge controller requires handle from the solar array. Make sure you know what
two steps: the upper voltage limit is and that you don't exceed it or
you may end up burning out your solar charge
1. Voltage Selection: The charge controller voltage controller.
shall be matched with the system voltage. The standard
configurations are 12, 24, and 48 volts. If you are wiring Sample Calculation
your batteries for 12 volts you need a charge controller
that is rated at 12 volts. Example

Some controllers are voltage speci2c, meaning that the Consider a 260W solar panel is used to charge a 12V
voltage cannot be changed or substituted. Other more battery bank.
sophisticated controllers include a voltage auto-detect
feature, which allows it to be used with different voltage 1. Voltage Rating:
settings.
The voltage rating of the charge is controller shall be
2. Current Selection: To select the proper Charge equal to the system voltage i.e 12V in this case.
Controller, you have to know the maximum output
current of the solar panel and Battery Voltage. 2. Current Rating:

The maximum possible current in the system = ( Solar Rating = ( Solar panel Wattage / System voltage ) ×
panel Wattage / System voltage ) × Safety factor Safety factor (1.3)

Safety Factor : Rating = ( 260W / 12V ) x 1.3 = 28.16A

We use a standard factor to account for all Solar panel So, the solar charge controller rating is selected as 30
output-boosting circumstances like a sunny day with a Amps /12 Volt
very clear snowpack. (additional light reflected off the
snow). That factor is 1.3 or 130%

PV Charge Controller - Upper Voltage Limit

DIY Off-Grid Solar System V2.0: Page 22

Step 22: PWM or MPPT ? 12%.
With a PWM controller, the current is drawn out of the
panel at just above the battery voltage, whereas with an Then the power drawn by the MPPT will be 5.75A * 15.3V
MPPT controller the current is drawn out of the panel at = 88W
the panel maximum power voltage ( Vmp). To
understand this concept, let's take an example. Power loss = 88-66.6 =21.4W, i.e. 21% more power than
the PWM controller.
Example: Consider a 100 Watt panel with a current(Imp)
of 5.75A & voltage (Vmp) of 17.40V connected to a 12 V Which One Should I Purchase?
lead-acid battery.
When you are finding which type of solar charge
PWMController controller to purchase, you need to know about their
functionality and features.
With a PWM controller, the panel voltage would be
dragged down near to the voltage of the battery but the 1. PWM controller is best for small off-grid power
current stays the same at 5.75 amps. This happens applications that don’t need any other features and has
because Solar Panels behave like a current source, so the no much budget. If you just want the basic and
current is determined by the available sunlight. economical charge controller then the PWM controller is
the best option for you.
Now the power (P)= Vbat x Imp = 12V x 5.75A = 66.6W.
So the Solar panel is now behaving like a 66-watt panel.2. MPPT controller is best for a larger system ( Off-grid
power station, RV Solar Power, Boat, Hybrid Solar Power,
MPPTController etc.) . When the solar array voltage is substantially higher
than the battery voltage, then MPPT is the best
With an MPPT controller, the panel voltage will operate controller. e.g. Connecting a 72cell solar panel, for
at voltage close to the Maximum Power Point (MPP), and charging a 12V battery.
the current stays the same at 5.75 amps.
Now the Power = Vmp x Imp = 17.4 x 5.75 =100W This You can look at the above comparison table for PWM
equates to a loss of 100W-66.6W = 33.4W and MPPT Solar Charge Controllers.
However, the above calculation is overly-optimistic as
the voltage drops as temperature increases; so assuming
the panel temperature rises to say 30°C above the
standard test conditions (STC) temperature of 25°C and
the voltage drops by 4% for every 10°C, i.e. a total of

DIY Off-Grid Solar System V2.0: Page 23

Step 23: Inverter Selection

Solar inverters are one of the most important 3. Pure Sine Wave
components of a solar panel system. They’re responsible
for converting direct current (DC) electricity from your Square wave inverter is cheaper among the all but not
solar panels to alternating current (AC) electricity to suitable for all appliances. Modified Sine Wave output is
power your appliances. also not suitable for certain appliances, such as a fridge,
microwave oven, sensitive electronic equipment, Laser
If you are only running DC loads straight off your battery printers, and most kinds of motors.
bank, you can skip this step. But, if you are powering any
AC loads, you need to convert the direct current from Typically modified sine wave inverters work at lower
the batteries into alternating current for your appliances. efficiency than pure sine wave inverters.

Common Types Of Inverter:

1. Square Wave

2. Modified Sine Wave

DIY Off-Grid Solar System V2.0: Page 24

Step 24: How Inverters Are Rated?

The inverter is rated for Continuous Watts and Surge 2. Surge Watts ( Peak Watts ):
watts
Surge watts is the amount of power the inverter can
1. Continuous Watts : support for a very short time, usually momentary. A
2000 watt inverter rated at 4000 surge watts can handle
Continuous watts is the total amount of watts the up to 4000 watts momentarily while starting things like
inverter can support inde2nitely. A 2000 watt inverter motors.
can power up to 2000 watts continuously. It is also called
the nominal AC output power of the inverter. In the above picture, you can see the drill draws 471.6W
for a short time period.
If you want to run multiple appliances at the same time,
just add up the power rating of the equipment that is In our case, the surge power is applicable for the ceiling
running together at the same time. fan during the starting which is approximately 200W.

Example: Running a Fan (80W /200W ), 2 nos of LED Total surge watt = 200+12+65+6 = 283W
Light (6W ), Laptop (65W ), and WiFi Router (6W ) at the
same time total Continuous Watts = 80+12+65+6= Select the inverter that should support both of these
163W values.

DIY Off-Grid Solar System V2.0: Page 25

 Output voltage:
Step 25: Inverter Voltage & Frequency
The common output voltage of an AC outlet is
The next rating you have to look at when sizing an
120/240VAC, based on the location.
inverter is the input /output voltage and output
frequency.
Output Frequency:
Input Voltage / System Voltage:
The two common Inverter output frequencies are
50/60Hz, based on the location.
For correct solar system sizing, your solar panels,
inverter, and battery bank all need to use the same
Before buying the inverter check your country's
voltage. i.e system voltage.
voltages/frequencies used for domestic appliances.
In the earlier steps, we have selected 12V battery and
solar panel, so the input voltage of the inverter must be
12V.

Click Here to Watch the

Full Video Presentation

DIY Off-Grid Solar System V2.0: Page 26

 3. Cable Length from Solar Panel to Battery
Step 26: Selecting the Solar Cable
4. The expected loss in percentage

The current generated from the solar panels should The 2rst two parameters ( Vmp and Imp) can be easily
reach the Battery with minimum loss. Each cable has its found from the speci2cation sheet on the backside of
own ohmic resistance. The voltage drop due to this the solar panel or from the datasheet. The cable length
resistance is according to Ohm’s law depends on your installation. The loss percentage
considered for good design is around 2 to 3%.
V = I x R (Here V is the voltage drop across the cable, R is
the resistance and I is the current). In the earlier step, we have already 2nalized the Solar
panel, the rating. From the Solar panel speci2cation
The resistance ( R ) of the cable depends on three sheet Vmp = 36.7V and Imp = 6.94A ( rounded off to next
parameters: higher number i.e 37V and 7A). Let the distance
between the Solar panel and the Battery is 30 feet and
1.Cable Length: Longer the cable, the more is the the expected loss is 2%.
resistance

Note: The voltage grade of the cable should be matched

2. Cable Cross-section Area: Larger the area, the smaller
with the Solar Panel maximum system voltage.
is the resistance

3. The material used: Copper or Aluminum. Copper has

lesser resistance compared to Aluminium In this
application, copper cable is preferable.

You need to enter the following parameters :

1. Solar Panel Operating Voltage (Vmp)

2. Solar Panel Operating Current (Imp)

DIY Off-Grid Solar System V2.0: Page 27

Step 27: Selecting the Correct Size Power battery bank. (1500 W )/(24 Vdc)=62.5 A So, 62.5 A is the
Inverter Battery Cables maximum current that the cable needs to support in
order to properly provide the current to the inverter. The
It is very important to be sure you are using the next higher size available on the table is 100A.
appropriate cable size for your inverter/battery. Failing
to do so could lead to your inverter not supporting full Use the above chart as a guide to determine which size
loads and overheating, which is a potential 2re hazard. cable will be best for your application.
Use this as a guide for choosing the proper cable size,
and be sure to contact a professional electrician or our In our example, we can see that 2/0 AWG cable would be
tech team with any additional questions you may have. appropriate.

1. What size inverter do you have? NOTE: For distances over 10 feet, the voltage drop over
2. What is the DC voltage of your battery bank? the cables will occur due to resistance through the
wiring. If you will need to run cables longer than 10 feet,
3. Now divide the inverter’s wattage by your battery it is recommended that you increase the cable size in
voltage; this will give you the maximum current for your order to compensate for voltage loss. If you are unsure
cables. about your application feel free to give us a call and we
will be able to assist you in 2nding the right cable.
Sample Calculation:

Current (Amps ) = Power (Watts ) / Voltage (Volt)

Consider 1500 Watt inverter connected to the 24V

DIY Off-Grid Solar System V2.0: Page 30

 Example-2:
Step 28: Sizing of Fuses / Breakers
Fuse between the battery bank and inverter =
(continuous Watts / Battery Voltage ) x 1.56
Fuses and circuit breakers are primarily used to protect
the system wiring from catching 2re or getting damaged
A 1000W /12V inverter draws = 1000/12 =83.3A,
if a short circuit occurs. They are not necessary for the
system to run properly, but it is recommended for safety
Circuit Ampacity = 83.3 x 1.56 = 130A, round up to the
purposes only.
next standard trade size which will be 150A.

There are three different locations where fuses or

ACBreaker/Fuses:
breakers must be installed:

AC Breaker is placed at the inverter output and the

1. Between the charge controller and solar panel
Outlet for AC appliance.

2.Between the charge controller and battery bank

The above NEC ampacity formula also changes on the
AC side of the circuit. Instead of 1.56, the multiplier is
3.Between the battery bank and inverter
1.25. And in place of the short-circuit current, you must
use the maximum or continuous output current listed on
You can add one more breaker at the inverter output.
the inverter speci2cation sheet.

DCBreaker/Fuses:
Circuit Ampacity = Inverter AC output current X 1.25

As per NEC, the DC fuse or breaker size can be

Example-3:
determined as per the following equation:

let's assume a 1500W inverter with an AC output of 6.5A

Circuit ampacity = Short Circuit Current (Isc) X 1.56
max.

Example-1:
Circuit Ampacity = 6.5 x 1.25 = 8.12A, round up to the
next standard trade size which will be 10A.
A 315 Watt module with an Isc rating of 9.12A.

To calculate the fuse size required between the string

and the charge controller, you take 9.12 x 1.56 = 14.7 and
round up to the next trade size of 15A.

DIY Off-Grid Solar System V2.0: Page 31

Step 29: Gather the Components and Tools

In the previous steps, we have already f i nalized the main 7. Temperature Sensor
components required for our Off-Grid Solar System. Now,
it is time to gather the components, It’s a good practice to Tools Required:
buy all the components from a reputed brand. I have
used the charge controller, inverter from EPEVER, solar To successfully install the off-grid solar system, you need
panel from Waree, and battery from Luminous. a few basic tools like:

Apart from the 4 main components, there are few other 1. Wire Stripper
components that are required for the off-grid system.
2. Crimping Tool
They are listed below:
3. Plier
1. Solar Cables
4. Screwdriver
2. Breakers / Fuses
5. MC4 Spanner
3. DC Busbars / Fuse Box
6. Spanners
4. MC4 Connectors
After purchasing all the components and tools, we can
5. Cable Ties
move for the installation.
6. Metering Device

DIY Off-Grid Solar System V2.0: Page 32

Click Here to Watch the
Full Video Presentation

DIY Off-Grid Solar System V2.0: Page 33

Step 30: Wiring Diagram During connection ensure the polarity is correct.

Solar Panel : Protection :

The connection of solar panels depends on the Though the charge controller and inverter have inbuilt
maximum input voltage and current of the charge fuses for protection, you can put external fuses and
controller. MC4 connectors are used to connect the solar breakers for more safety and reliability of the system.
panels in series/parallel. You can see the above picture for different locations of
the breakers/fuses.
Battery Bank :
For a larger system, you need lighting protection..
Battery banks should be wired to match your system
voltage, which is the voltage allowed by your DC SAFETY :
appliances or AC inverter. Copper cable or busbars are
used to connect the battery in series and parallel. It is important to note that we are dealing with the DC
current. So the positive (+) is to be connected to positive (+)
Charge Controller: and negative (-) with negative (-) from Solar Panel to
Charge Controller. If it gets mixed up, the equipment can go
The charge controller has 3 terminals: 1. Solar 2. Battery burst and may catch 1re. So you need to be extremely
3. DC Load. careful when connecting these wires. It is recommended to
use 2 color wires i.e. red and black color for positive (+) and
You have to connect the wires from the solar panel, negative (-). If you don't have a red and black wire you may
battery bank, and DC load to the respective terminal. wrap red and black tap at the terminals.
During connection ensure the polarity is correct.

Inverter :

Connect the inverter input terminal to the battery bank.

DIY Off-Grid Solar System V2.0: Page 34

Step 31: Power Distribution

If you want to use a single DC load, you can connect output terminals of the distribution box.
directly to the Charge controller load terminal. Ensure
the voltage rating of the load is matching with the load Note: The total load current shall not cross the
terminal voltage. maximum limit of the charge controller load terminal. If
the load current exceeds the charge controller load
But If you want to run multiple DC loads at the same terminal limit, you have to connect the
time, then you need a DC busbar or Distribution Box. busbar/distribution box directly to the battery.
Connect the busbar/ distribution box input to the charge
controller load terminal and connect the loads to the

DIY Off-Grid Solar System V2.0: Page 35

Step 32: Metering and Data Logging In this project, I have used an Epever TRIRON Series MPPT
If you are interested to know how much energy is charge controller and an IPower-Plus Series Inverter both
produced by your solar panel or how much energy is of which have an LCD display for monitoring. Apart from
consumed by the appliances you have to use meters. this, there is provision for remote monitoring through the
Besides this, you can monitor the different parameters in RJ45 communication port. For remote monitoring, I have
your off-grid solar system by remote data logging. used a remote meter MT75 and eBox-WIFI-01.

Most of the good charge controller and Inverter have You can follow the above wiring diagram to connect the
their inbuilt LCD display to monitor the parameters. MT75 and eBox-WiFi.
Besides this, you can monitor the same parameter by
using a remote meter or WiFi adapter.

DIY Off-Grid Solar System V2.0: Page 37

Step 33: Battery Temperature Monitoring The temperature sensor will measure the battery
temperature, and the Solar Charge Controller uses this
Why is Temperature monitoring Required? input to adjust the charge set point as required.

The battery’s chemical reactions change with I have used a remote temperature sensor for measuring
temperature. As the battery gets warmer, the gassing the battery temperature. Connect it to the temperature
increases. As the battery gets colder, it becomes more port given in the charge controller.
resistant to charging. Depending on how much the
battery temperature varies, it is important to adjust the
charging for temperature changes. So it is important to
adjust charging to account for the temperature effects.

Step 34: Watch the Full Video Presentation on How to

Build Your Own Solar Panel Step-By-Step

Click Here to Watch the Video

DIY Off-Grid Solar System V2.0: Page 38