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400 Amp Hour – 600 Watt Camper Van Solar Kit

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400 Amp Hour – 600 Watt Camper Van Solar Kit

This DIY Camper Van Solar Kit features 600 watts of solar (2x300w 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 – 2x300W Solar – 2kW Inverter/Charger – Li-BIM Alternator Charging
EXPLORIST.life / Battle Born Solar Bundle [Affiliate Link] 300W 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] 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 6 AWG x 5/16 Wire Lug 6 AWG x 5/16 Wire Lug 6 AWG x 5/16 Wire Lug 6 AWG x 5/16 Wire Lug 6 AWG x 5/16 Wire Lug 6 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 Install a Roof Entry Gland Tutorial: How to wire a power distribution panel Power Distribution Panel - Amazon Affiliate Link

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

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

300W 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]

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: 1 – 300 Watt Solar Panel – 2 Pack
    • Put these in the sun
  • Qty: 1 – 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
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)
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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
CLICK HERE TO ADD ALL AMAZON PRODUCTS TO AMAZON CART

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Ryan

Sunday 2nd of August 2020

I'd love your thoughts on using the Lithium batteries you recommend with the Smart Solar MPTT 100|50, but with a bigger solar setup - 630 W from 2 of https://www.ecodirect.com/HanwhaQ-CELLS-315-W-Mono-Solar-Panel-p/hanwha-q.peak-duo-blk-g5-315.htm.

These have VOC 40.29V each, and I'd wire them in parallel to ensure avoiding issues from partial shading. Checking your calculator seems to imply a maximum amps in array of 52 A (at -8deg F, which I doubt I'd ever be in). My understanding is those extra 2A would be lost, but no safety issue, if I did go that cold.

I would appreciate your input on sizing the fuse or breaker for the positive PV lead to the positive bus bar on these. The negative lead shouldn't need a breaker/shutoff, right (I ask only as on your diagrams it looks like both PV + and - are running through the circuit breaker, but I assume that's just an image thing)? If amps per panel are 26 A, and in parallel, 52 A would be the output, so a 60 A breaker/fuse? I believe that works well with the MPPT that lists PV short max amps as 60 A. Does that make sense/help provide protection to have it there?

Nate Yarbrough

Sunday 9th of August 2020

The 2A would simply be lost, as you suggested. No harm would come from that.

The disconnect between the panels and the charge controller does, indeed, disconnect both the positive and negative wires. This is in compliance with NEC 690.17 (B) regarding ungrounded PV arrays. For those two panels, you do not need any overcurrent protection, you will just need the Dual Pole Din Rail Breaker as listed in the parts list.

Logan

Wednesday 8th of July 2020

For the 600w system, do you think it's worth grabbing Renogy's new 320w panels since they're roughly the same size and only and extra $16 bucks? https://www.renogy.com/320-watt-monocrystalline-solar-panel-120-cell/ Happy to use affiliate link if they're on Amazon.

Nate Yarbrough

Monday 13th of July 2020

Sure! Looks like an update to their 300w panels. Keep in mind when pricing, though, those 320w panels don't have free shipping, so take that into consideration when pricing them out.

Matt Hardy

Thursday 25th of June 2020

Can you explain why you have chosen the following fuse sizes? 300amp - Battery terminal 250amp - between busbar and alternator 250amp - between inverter and busbar

Nate Yarbrough

Sunday 5th of July 2020

Fuse sizes are determined by a combination of manufacturer recommendations, expected amp output, and size of wire the fuse is protecting. https://www.youtube.com/watch?v=5y-yDMEgV70

MrVanGlamping

Saturday 20th of June 2020

Hey Nate, So I've just built out the 400amp hr with 6oowatt solar setup using Lithium ion Battle Born batteries. Now, do I have to configure my Victron inverter to work with the lithium batteries? The only thing I found was a short youtube video from Battle Born stating I needed to purchase the (MK3 to USB) to configure my devices using Victrons software?

Chris Kelly

Monday 25th of May 2020

Hey Nate, How do you connect wires to your two pole breaker shown in the diagram above between solar panels and charge controller? Midnite solar’s 2 pole breaker comes with a jumper on one side which doesn’t make sense to me. How do you know where to place positive and negative cables?

Nate Yarbrough

Sunday 5th of July 2020

Positive to one side, negative to the other. Which side is which doesn't matter.