400 Amp Hour – 525 Watt Camper Van Solar Kit

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This DIY Camper Van Solar Kit features 525 watts of solar (3x175w 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 – 3x175W Solar – 2kW Inverter/Charger – Li-BIM Alternator Charging
EXPLORIST.life / Battle Born Solar Bundle [Affiliate Link]175W Solar Panels [Affiliate Link]80A 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]DIN Rail Terminal Blocks [Affiliate Link]2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug2/0 x 5/16 Wire Lug6 AWG x 5/16 Wire Lug6 AWG x 5/16 Wire Lug6 AWG x 5/16 Wire Lug6 AWG x 5/16 Wire Lug6 AWG x 5/16 Wire Lug6 AWG x 5/16 Wire LugTutorial: How to Wire the Li-BIM Battery IsolatorTutorial: How to Wire the AC Side of Your Electrical SystemTutorial: How to Wire for Shore PowerTutorial: How to Wire a Battery BankTutorial: How to Wire a BusbarTutorial: How To Wire DC Distribution Block & AccessoriesTutorial: How To Install a Roof Entry GlandTutorial: How to wire a power distribution panelPower Distribution Panel - Amazon Affiliate Link

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

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

175W Solar Panels [Affiliate Link]

80A 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]

DIN Rail Terminal Blocks [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.

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.

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.

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.

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.

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.

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.

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.

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 Install a Roof Entry Gland

Tutorial: How to wire a power distribution panel

Power Distribution Panel - Amazon Affiliate Link

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: 3 – 175 Watt Solar Panel
    • Put these in the sun
  • Qty: 3 – 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 | 60 – Bundle
    • Included in Bundle at Top of List
    • Solar Charge Controller
  • Qty: 5 – 6 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Charge Controller to Busbar
  • Qty: 5 – 6 AWG Black Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Between Busbar & Charge Controller Equipment Ground
  • Qty: 5 – 6 AWG Red Wire
    • Check Wire, Lug, and Fuse List at Bottom of List
    • From Charge Controller to Busbar
  • Qty: 2 – 5/16″ x 6 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 6 AWG Lug
    • Check Wire, Lug, and Fuse List at Bottom of List
    • Connecting Busbar to Charge Controller Equipment Ground
  • Qty: 1 – 80 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
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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
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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)
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Wires, Lugs, Breakers, and Fuses

Wires
Add Wires Individually to Verify Quantities

Lugs
Add Lugs Individually to Verify Quantities

Fuses & Breakers
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16 thoughts on “400 Amp Hour – 525 Watt Camper Van Solar Kit”

  1. Hey Nate, thanks so much for all your useful resources. Is the charge controller not oversized here? With 175w x3 to Victron specification I’m expecting max amps out to be 45A and max amps in to be be 15A (if wired in series). Is that wrong?

    1. It’s borderline. If the temperature is cold out, the panels could exceed 50A output from the charge controller, but that would not damage the charge controller; that power would just be missed out on as the 100/50 would just limit the output amps. Either way.

  2. Thanks so much for your reply, I didn’t see it until checking back the page today, thought I might get notified! Thanks for the info, I have a MPPT 100|50 for my 525w and just questioned my choice after seeing your diagram, but no harm done, as you have mentioned: there just might be some wasted power if operating in optimum conditions .

  3. Hi Nate,
    Thanks for the information! I am a little confused by the 16A DC Breaker between the panels and the charge controller. Shouldn’t the breaker be higher than 15A in a 525W Solar array using a 60A charge controller? I may just be a little confused.

    Thank you!

    1. Each of those panels has a maximum current output of 10.29 amps. All four of the panels wired in series still just has an output current of 10.29 amps (as wiring in series boosts the voltage, not the amperage). So… that 16A dual pole breaker will be just fine there. Now…on the other side of the charge controller. As the MPPT regulates the 525w down to 12-14V, the current will be closer to 40 Amps, which is why I have spec’d a 6 AWG Wire with an 80A fuse. More info about how a change controller regulates all of this: https://www.youtube.com/watch?v=MxziHKvTRh8

  4. Hi Nate,
    Your diagram has 6 gauge wire running from Inverter to AC side of distribution panel. That panel has a 50A maximum capability, according to manufacturers specs. If that wire is 10 feet, one would only need 12 gauge wire, according to your wire sizing calculator. At 50A, one would not need 6 gauge wire until wire length reaches 100 feet. Why did you choose 6 gauge? What am I missing? Thanks.

    1. The fuse size is determined by the wire that the fuse is protecting. For this sytem, the largest load is the 2000w Inverter/Charger. Victron specs 2/0 wire and a 300 Amp fuse for this particular Inverter, so we use 2/0 wire through the whole path from batteries to Inverter and protect the main wiring with a 300 amp fuse.

      1. It looks like there is a 300amp fuse on the batteries, and then a 250amp fuse on the inverter/charger. I’m looking at how to hook up a 3000w samlex 12v to my 4×100 battle borns. I believe I need a 400amp t fuse, which will go near my batteries, but then what amp fuse do I need on my inverter line? another 400amp?

  5. Nate, I’m basically building this system – 3 x 175w Renogy panels into a 400Ah BattleBorn battery bank….I thought I sized the MPPT correctly w/ the Victron 150/35, but maybe not based on this and a comment I see above, sounds like you went with the 150/60 because the panels can produce up to 40Amps? Shoot!

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