DIY solar installation

[Efficacious]

HI all,

I just came across this thread and having done a very similar job thought that it may be useful to add photos of my panel installation. It is a 200W single panel (Allpowers) which by positioning it asymmetrically across the roof rails towards the awning side fits in nicely.

I used some aluminium strips across the roof and bonded to the panel with U extrusion end caps. It is secured by drilling through the panel and strips and use of M6 T nuts. I also used neoprene strips to pad from the roof. The finished assembly is nice and solid with no wind noise or vibration.

I created my own curly cable by winding some 12AWG 2 core cable tightly around a pole. I secured it with tape and left it in the warm sun for a couple of days, then steamed it for good measure. It held the shape nicely when I removed it and after a month or so and a bit of roof use now shows no sign of loosing the coil/shape. Cost £10.

The junction box was a bargain - quoted as being IP68 rated and 2 for £6.99 from Amazon. I removed the MC4 connectors from the panel wiring and solder joined to the curly cable inside the box.

 

[Ads1234567890]

Thanks almost bought a California used your detailed info 2 panels installed I used the mc4 plugs but crimped Solar to curly flex

 

[Van Diesel VW]

Thank you all for this really helpful thread, after some thought decided to go down the DIY route for solar on my California, mainly cost reasons, but also learning and flexibility of install. Currently managed to purchase 2 x Renogy 100w panels for £75 each in Black Friday offers.

100W Solar Panels for Campervan,Solar Panels UK|Renogy

The Renogy 100W Flexible Lightweight Solar Panel enhances module efficiency while minimizing its weight.It is the perfect solar panels for campervan.

uk.renogy.com

First question is cable size from panels to MPPT controller, will use 4mm cable from MTTP to battery, do I also need 4mm from panels to MPPT or is 2.5 mm cable adequate, highly unlikely that I will add anymore panels in the future.

 

[Efficacious]

Thank you all for this really helpful thread, after some thought decided to go down the DIY route for solar on my California, mainly cost reasons, but also learning and flexibility of install. Currently managed to purchase 2 x Renogy 100w panels for £75 each in Black Friday offers.

100W Solar Panels for Campervan,Solar Panels UK|Renogy

The Renogy 100W Flexible Lightweight Solar Panel enhances module efficiency while minimizing its weight.It is the perfect solar panels for campervan.

uk.renogy.com

First question is cable size from panels to MPPT controller, will use 4mm cable from MTTP to battery, do I also need 4mm from panels to MPPT or is 2.5 mm cable adequate, highly unlikely that I will add anymore panels in the future.

I used 2 core 12AWG cable (3.3mm^2) which is easily adequate with my 200W and would allow a further 200W if we needed it.

The current Amazon price of £6.89 for 2m is actually a good bit less than I paid earlier in the year.

https://www.amazon.co.uk/dp/B0B7WNS21H

 

[Almost bought a california]

HI all,

I just came across this thread and having done a very similar job thought that it may be useful to add photos of my panel installation. It is a 200W single panel (Allpowers) which by positioning it asymmetrically across the roof rails towards the awning side fits in nicely.

I used some aluminium strips across the roof and bonded to the panel with U extrusion end caps. It is secured by drilling through the panel and strips and use of M6 T nuts. I also used neoprene strips to pad from the roof. The finished assembly is nice and solid with no wind noise or vibration.

I created my own curly cable by winding some 12AWG 2 core cable tightly around a pole. I secured it with tape and left it in the warm sun for a couple of days, then steamed it for good measure. It held the shape nicely when I removed it and after a month or so and a bit of roof use now shows no sign of loosing the coil/shape. Cost £10.

The junction box was a bargain - quoted as being IP68 rated and 2 for £6.99 from Amazon. I removed the MC4 connectors from the panel wiring and solder joined to the curly cable inside the box.

View attachment 137014

View attachment 137015

View attachment 137016

Love the curly cable - considerably cheaper than mine and it looks great!

 

[Almost bought a california]

Thank you all for this really helpful thread, after some thought decided to go down the DIY route for solar on my California, mainly cost reasons, but also learning and flexibility of install. Currently managed to purchase 2 x Renogy 100w panels for £75 each in Black Friday offers.

100W Solar Panels for Campervan,Solar Panels UK|Renogy

The Renogy 100W Flexible Lightweight Solar Panel enhances module efficiency while minimizing its weight.It is the perfect solar panels for campervan.

uk.renogy.com

First question is cable size from panels to MPPT controller, will use 4mm cable from MTTP to battery, do I also need 4mm from panels to MPPT or is 2.5 mm cable adequate, highly unlikely that I will add anymore panels in the future.

Hi Mr Diesel, I used a 4 core 2.5mm2 cable between the solar panel and the controller and used 2 cores for both pos and neg - 1.5mm2 would be OK for the current from a 200W panel but 2.5mm2 would give a safety margin and less volts drop when the suns out. I only used a 4 core cable because I expect I'll add a 2nd panel at some point and I wanted the option to connect both in parallel and series - probably over the top and it made the curly cable a lot more expensive!
I have a 15A MPPT controller and soused 2.5mm2 cable between this and the rear battery but your choice will depend on max current, cable type and cable length - Chat GPT will give you an accurate answer.

 

[Almost bought a california]

Thanks almost bought a California used your detailed info 2 panels installed I used the mc4 plugs but crimped Solar to curly flex

View attachment 139884

Very nice work!

 

[Carl_______________]

This guy on eBay makes the cables up to whatever your specification requirements are

4 CORE 1.5sqmm COILED BLACK LSZH 13amp POWER CABLE. 500mm (20") COIL LENGTH # | eBay UK

500mm (20") Black Coiled 13amp Power lead. This is a 4 core 1.5sqmm flexible spiral LSZH H05Z1Z1-F cable. Due to the bend in the black cable, these may appear grey. Coil length of approx.

ebay.us

I have had a couple of different sizes made up, the 4c 2.5mm is a Chucky cable