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400 Amp Hour – 400 Watt Camper Van Solar Kit

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400 Amp Hour – 400 Watt Camper Van Solar Kit

This DIY Camper Van Solar Kit features 400 watts of solar (4x100w Panels) and 400 Amp Hours of Lithium Batteries wired into a 12v battery bank. It also features a 2000w Inverter/Charger and alternator charging by way of a battery isolator.

THERE IS AN UPDATE TO THIS WIRING DIAGRAM THAT INCLUDES A DC-DC CHARGER AND A BUSBAR SYSTEM THAT DOES NOT REQUIRE CUTTING & DRILLING OF COPPER BAR. HERE IS THE LINK FOR THAT: https://www.explorist.life/2000w-inverter-200-400ah-lithium-200-to-700w-solar-camper-wiring-diagram/

Looking for a different size of system? Check here: https://www.explorist.life/solarwiringdiagrams

Not sure how big of a system you need? You need to do a power audit. Here’s a tutorial: https://www.explorist.life/what-size-of-solar-system-is-needed-to-power-a-camper/

Want more solar education in general? Check this: https://www.explorist.life/diy-campervan-solar

Want a high-resolution wiring diagram to print out? Get it here: COMING SOON

Here is a video that shows how this page works:

400Ah Lithium Battery Bank – 4x100W Solar – 2kW Inverter/Charger – Li-BIM Alternator Charging
EXPLORIST.life / Battle Born Solar Bundle [Affiliate Link] 100W Solar Panels [Affiliate Link] 50A ANL Fuse [Affiliate Link] Roof Entry Gland [Affiliate Link] 100A ANL Fuse [Affiliate Link] 250A ANL Fuse [Affiliate Link] 250A ANL Fuse [Affiliate Link] 15A Solar Disconnect [Affiliate Link] Master Battery Disconnect Switch [Affiliate Link] Exterior Shore Power Outlet [Affiliate Link] 250A Terminal Fuse [Affiliate Link] 300A Terminal Fuse [Affiliate Link] 30 A Shore Power Cord [Affiliate Link] 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 2/0 x 5/16 Wire Lug 8 AWG x 5/16 Wire Lug 6 AWG x 5/16 Wire Lug 8 AWG x 5/16 Wire Lug 8 AWG x 5/16 Wire Lug 6 AWG x 5/16 Wire Lug 8 AWG x 5/16 Wire Lug Tutorial: How to Wire the Li-BIM Battery Isolator Tutorial: How to Wire the AC Side of Your Electrical System Tutorial: How to Wire for Shore Power Tutorial: How to Wire a Battery Bank Tutorial: How to Wire a Busbar Tutorial: How To Wire DC Distribution Block & Accessories Tutorial: How to wire a power distribution panel

EXPLORIST.life / Battle Born Solar Bundle [Affiliate Link]

Battery, Inverter, Charge Controller, Battery Monitor Discount Bundle Coming June 1.

100W Solar Panels [Affiliate Link]

50A ANL Fuse [Affiliate Link]

Roof Entry Gland [Affiliate Link]

100A ANL Fuse [Affiliate Link]

250A ANL Fuse [Affiliate Link]

250A ANL Fuse [Affiliate Link]

15A Solar Disconnect [Affiliate Link]

Master Battery Disconnect Switch [Affiliate Link]

Exterior Shore Power Outlet [Affiliate Link]

250A Terminal Fuse [Affiliate Link]

300A Terminal Fuse [Affiliate Link]

30 A Shore Power Cord [Affiliate Link]

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

2/0 x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

8 AWG x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

6 AWG x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

8 AWG x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

8 AWG x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

6 AWG x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

8 AWG x 5/16 Wire Lug

Total wire lug quantities for this wiring diagram are totaled at the bottom of the shopping list below.

Tutorial: How to Wire the Li-BIM Battery Isolator

Tutorial: How to Wire the AC Side of Your Electrical System

Tutorial: How to Wire for Shore Power

Tutorial: How to Wire a Battery Bank

Tutorial: How to Wire a Busbar

Tutorial: How To Wire DC Distribution Block & Accessories

Tutorial: How to wire a power distribution panel

IMPORTANT!!! This diagram is, indeed, pretty detailed. YOU MUST STILL READ AND FOLLOW YOUR USER/INSTALLATION MANUAL WHEN INSTALLING THIS EQUIPMENT. In case of an error in the diagram above, your user manual will always superscede the diagram you see on this page.

Known issues with the diagram above:

  • The shunt in the diagram is backwards. On the side of the shunt, there is a label that says which side goes to the battery and which side goes to the load. Please follow the orientation on the side of the shunt.
  • The shore power cord has a male plug on both ends. Shore power extension cords do not have male plugs on each end. This would be incredibly dangerous. Please do not splice a shore power cord so there is a male on each end. The shore power cord in the parts list below is accurate and has a male end on one side and a female end on the other.
EXPLORIST.life Battery, Charge Controller, Inverter Bundle
Solar Charging System:
  • Qty: 4 – 100 Watt Solar Panel
    • Put these in the sun
  • Qty: 4 – Solar Panel Mounting Feet
    • Help mount solar panels to the roof
  • Qty: 1 – MC4 Connectors
    • Connecting Solar Panels to Wires going to Charge Controller
  • Qty: 40 – 10 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Solar Panel to Charge Controller
  • Qty: 40 – 10 AWG Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Solar Panel to Charge Controller
  • Qty: 1 – Roof Entry Gland
    • Waterproof Box for Running Wires through Roof
  • Qty: 1 – 1″ Wire Grommet
    • Mounted in roof under Roof Entry Gland
  • Qty: 1 – 15 Amp Solar Disconnect Switch
    • Mounted on Din Rail Between Solar Panels & Solar Contoller
  • Qty: 1 – Din Rail
    • To mount the Solar Disconnect Switch
  • Qty: 1 – Victron Smartsolar MPPT 150 | 35 – Bundle
    • Included in Bundle at Top of List
    • Solar Charge Controller
  • Qty: 5 – 8 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Charge Controller to Busbar
  • Qty: 5 – 8 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Busbar & Charge Controller Equipment Ground
  • Qty: 5 – 8 AWG Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Charge Controller to Busbar
  • Qty: 2 – 5/16″ x 8 AWG Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Positive & Negative Wires from Charge Controller to Busbar
  • Qty: 2 – 5/16″ x 8 AWG Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Connecting Busbar to Charge Controller Equipment Ground
  • Qty: 1 – 50 Amp ANL Fuse
    • Check Wire, Lug, and Fuse List at Bottom of List
    • On Positive Busbar Protecting Red Wire to Charge Controller
  • Qty: 1 – ANL Fuse Holder
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Mounted to Busbar under each ANL fuse
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

Battery Bank, Busbar, & Inverter
  • Qty: 1 – 2000W Victron MultiPlus Compact Inverter Charger 12V – Bundle
    • Included in Bundle at Top of List
    • This Converts Your 12v DC Power to 120v AC Power
  • Qty: 1 – 400Ah Battle Born Lithium Battery Bundle
    • Included in Bundle at Top of List
    • These Store Your Power
  • Qty: 6 – 2/0 Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Batteries & From Batteries to Busbar
  • Qty: 6 – 2/0 Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Batteries & From Batteries to Busbar
  • Qty: 16 – 5/16″ x 2/0 Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Wires to Batteries & to Busbar
  • Qty: 1 – 300 Amp Terminal Fuse
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attached to Battery Protecting Red Wire to Busbar
  • Qty: 5 – 2/0 Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Busbar & Inverter
  • Qty: 5 – 2/0 Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Busbar & Inverter
  • Qty: 5 – 2/0 Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Busbar & Inverter Equipment Ground
  • Qty: 5 – 2/0 Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Busbar & Chassis Ground
  • Qty: 2 – 5/16″ x 2/0 Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Positive Wire from Busbar to Inverter
  • Qty: 2 – 5/16″ x 2/0 Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Negative Wire from Busbar to Inverter
  • Qty: 2 – 5/16″ x 2/0 Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Black Wire from Negative Busbar to Inverter Equipment Ground
  • Qty: 2 – 5/16″ x 2/0 Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Black Wire from Negative Busbar to Vehicle Chassis Ground
  • Qty: 1 – 250 Amp ANL Fuse
    • Check Wire, Lug, and Fuse List at Bottom of List
    • On Positive Busbar Protecting Red Wire to Inverter
  • Qty: 1 – ANL Fuse Holder
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Mounted to Busbar under each ANL fuse
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

DC Busbar
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AC Circuits & Shore Power
  • Qty: 1 – 30 Amp Shore Power Cord
    • Connecting 30A Flanged Power Inlet to Shore Power
  • Qty: 1 – 30 Amp Shore Power Extension Cord
    • If your Shore Power Cord is too Short
  • Qty: 1 – 30A to 15A Adapter
    • For plugging your 30A shore power cord into a 15/20 amp standard outlet.
  • Qty: 1 – 30A Flanged Power Inlet
    • Connected to Outside of Camper
  • Qty: 10 – 10 AWG 3 Conductor Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From 30A Flanged Power Inlet to Inverter
  • Qty: 5 – 6 AWG 3 Conductor Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Inverter to Power Distribution Panel
  • Qty: 1 – Power Distribution Panel
    • For Distributing Power & Housing Breakers/Fuses
  • Qty: 1 – 50A AC Breaker
    • Check Wire, Lug, and Fuse List at Bottom of List
    • For AC Branch Circuits
  • Qty: 1 – 20A HOMT Tandem AC Breaker
    • Check Wire, Lug, and Fuse List at Bottom of List
    • For Standard 120V Outlet Circuits
  • Qty: 1 – 20A / 30A HOMT Tandem AC Breaker
    • Check Wire, Lug, and Fuse List at Bottom of List
    • For Circuits that include large loads (hot water heater)
  • Qty: 50 – 12 AWG 3 Conductor Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • For AC Branch Circuits
  • Qty: 6 – 120V GFCI Outlet
    • For plugging 120V Appliances into
  • Qty: 6 – Single Gang Electrical Box
    • For 120V GFCI Outlet
  • Qty: 6 – GFCI Wall Plates
    • For 120V GFCI Outlet
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

12v Distribution
  • Qty: 1 – Power Distribution Panel
    • For Distributing Power & Housing Breakers/Fuses
  • Qty: 1 – 100 AMP ANL Fuse
    • Check Wire, Lug, and Fuse List at Bottom of List
    • On Positive Busbar Protecting Red Wire to the Power Distribution Panel
  • Qty: 1 – ANL Fuse Holder
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Mounted to Busbar under each ANL fuse
  • Qty: 2 – 5/16″ x 6 AWG Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Positive & Negatives Wires to the Busbar from the Power Distribution Panel
  • Qty: 5 – 6 AWG Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Positive Wire From Busbar to Power Distribution Panel
  • Qty: 5 – 6 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Negative Wire From Busbar to Power Distribution Panel
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

Alternator Charging
  • Qty: – LI-BIM 225 Isolator
    • Connects and Disconnects House and Starting Battery Banks
  • Qty: 5 – 2/0 Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between LI-BIM 225 Isolator & Start Battery
  • Qty: 20 – 2/0 Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between LI-BIM 225 Isolator & House Battery Bank
  • Qty: 1 – 250 Amp Terminal Fuse
    • Check Wire, Lug, and Fuse List at Bottom of List
    • On Starting Battery Protecting Red Wire to LI-BIM 225 Isolator
  • Qty: 1 – 250 Amp ANL Fuse
    • Check Wire, Lug, and Fuse List at Bottom of List
    • On Positive Busbar Protecting Red Wire to LI-BIM 225 Isolator
  • Qty: 1 – ANL Fuse Holder
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Mounted to Busbar under each ANL fuse
  • Qty: 4 – 5/16″ x 2/0 Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Attaching Positive Wire to Starting Battery, Isolator x2, & House Battery Bank
  • Qty: 5 – 16 AWG Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Isolator Ign to Ignition Positive
  • Qty: 1 – Add-a-Fuse Kit
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Used to piggyback power for Ignition+ Wire
  • Qty: 5 – 16 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Isolator Gnd to Chassis Ground
  • Qty: 10 – 16 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Isolator Sig to Momentary Switch & from Momentary Switch to Chassis Ground
  • Qty: 1 – Momentary Switch
    • Placed in-line on Isolator Sig Wire
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Misc Tools & Accessories (As Needed/Optional)
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

Wires, Lugs, Breakers, and Fuses

Wires
Add Wires Individually to Verify Quantities

Lugs
Add Lugs Individually to Verify Quantities

Fuses & Breakers
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

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Scot

Tuesday 20th of October 2020

Hola Nate! I bought your 400ah bundle from Battle Born with the LiFePO4 Battery Isolation Manager, however your updated wiring diagrams use the DC-to-DC charger. Do you recommend the DC-to-DC charger or would BIM work fine? I have a 2019 Sprinter, if that helps. Thanks for your time.

Nate Yarbrough

Wednesday 21st of October 2020

This should answer your questions: https://www.explorist.life/how-to-charge-diy-camper-van-batteries-with-vehicle-alternator/

herve

Sunday 23rd of August 2020

Hello Nate, I have used this wiring diagram to build my van electrical system....with the exception I have a 3000 watts inverter (AIMS Power 3000 WATT Pure SINE Power Inverter 12 VDC to 120 VAC -). I also purchased your superb busbar main switch system. I emailed you a picture of my setup a month ago.

Maybe here I can find some help because I currently have an electrical issue with the 2/0 wire (between the 3000 inverter and the busbar) gets overheat when I run my water heater (1440 watts). It has even melted down the connection inside the busbar.

I do understand This has nothing to do with your design. But I'm puzzled about what could cause the overheat. I believe 2/0 wire (between the 3000 inverter and the busbar) should handle 1440 watts knowing no others devices were using the inverter during the test.

Does it mean a 3000 inverter needs a 4/0 wire even if the load is lower than 2000 watts ?

Any insights would be appreciated.

Nate Yarbrough

Friday 28th of August 2020

Overheating at the fuses usually means there is a loose connection somewhere. Weather that means that the lug crimp was bad, the lug to fuse connection was loose, or the fuse to copper bar connection was loose. This was, indeed, likely compounded by the 2/0 wire as a 3000w Inverter requires 4/0 wire. But I'm going to guess a loose connection is the main point of the heat generation.

Brian Anglin

Tuesday 28th of July 2020

Hey Nate! Thank you so much for all this awesome info! I followed your specs for most of my build and it came out great! However, I've been having some trouble with Alternator charging--I keep blowing my 250 Amp fuse for some reason. I usually keep my Battle Born batteries charged bout 50% via solar. I also have the LI-BIM 225 Isolator between my alternator and bus bar (via the 250 Amp fuse) Any ideas what might be causing me trouble here? My first thought was size up my fuse but that seems like a bandaid fix. I have a 2019 Sprinter w/ a 220 Amp alternator. On my BMS I will routinely see 100 Amps going into my batteries but that's no where near the 250 Amp fuse have in place. Thinking about setting up a DC-DC charger but that maxes out at 40 Amps and would mean ditching the expensive isolator I already bought. I would really appreciate any ideas you have. Thank you again for all the effort you've put into building out these guides!!

Nate Yarbrough

Thursday 30th of July 2020

I suspect there is a loose connection somewhere. I'd go back through all of your wire lugs and make sure all of the bolts are nice and tight.

Nick Andrea

Sunday 28th of June 2020

Hi Nate,

In the process of building our off-grid skoolie system. Thank you for all your resources and guidance, it's very helpful. We plan to 'chase' snowy/cloudy climates that come with snowboarding so we are going to include alternator and shore power charging capabilities. But the dream is to live completely off-grid.

Quick question: When we did our power audit your system recommends that we do 400 watts of power, 200 ah lithium battery. So we've compared that diagram with this one and it seems the only difference is the addition of 2 more lithium batteries and their appropriate connectors. Would a 400 watt solar system appropriately charge 4 lithium batteries? I thought the rule of thumb was always to double your solar intake to your total battery capacity.

Any guidance/advice you can provide would be greatly appreciated.

Nate Yarbrough

Sunday 5th of July 2020

The rule of thumb for charging is to take the amp hours of power you use every day and multiply that number by two to get the watts of solar you'll need to replinish. For example - 400Ah used per day x 2 = 800W solar needed.

herve your big fan

Friday 19th of June 2020

Hello Nate, I plan to order your components from this affiliates page. I might be mistaken but It seems you are missing one 250amp ANL fuse. The One installed between the batteries and the positive bus bar. It shows in your diagram but not in the description.

Nate Yarbrough

Sunday 21st of June 2020

Sure! Try this: https://amzn.to/2zRbmm3