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Fuses protect your system from catching on fire in the case of mishaps such as a wire rubbing through
Quick note before we get started. This is just one part of an overarching “How to Install a DIY Camper Van Electrical System” series. If you’ve just stumbled on this article directly without seeing that, there are likely some things we’ve already covered. If you want to check out that step by step guide, you can do that here: https://www.explorist.life/diy-campervan-solar
Also, we have interactive solar wiring diagrams that are a complete, A to Z solution for teaching you exactly what parts go where, what size wires to use, fuse size recommendations, wire lug sizes, and all kind of other stuff to help save you time and frustration. You can check that out here: https://www.explorist.life/solarwiringdiagrams/
TYPES OF FUSES
ANL fuses come in sizes from 35 – 750 amps. They are typically less expensive than Re-settable Breakers. They are more reliable than re-settable breakers as they have no moving parts. If they blow/trip, they must be replaced. They require tools to connect/disconnect.
Re-Settable Breakers come in sizes from 25 amps up to 200 amps. I prefer these on circuits that I know I may have to regularly ‘disconnect' for maintenance and or troubleshooting. Honestly, the only time I don't use these is when I need a fuse/breaker that is bigger than is available.
HOW TO CHOOSE THE SIZE OF YOUR FUSES
A lot of components will tell you how big of wire and what kind of fuse to use. If this is the case, follow it.
- Find the continuous amperage of the device you are trying to power and multiply that number by 1.5, then round up to the nearest fuse size you can find.
- Cross check that fuse size with the maximum fuse size chart below and verify that your fuse size is below the maximum fuse size listed in the chart.
(more info: ABYC E-911)
Fuse & Wire Sizing Example
For this example, we are going to wire the 12v distribution block to the bus bar then wire a string of lights to the 12v distribution block. All with appropriately fused with properly sized wires.
Step 1: Find the wire size for the 12v fuse block.
Next, we use our wire size chart to determine how big of wire we need.
100 amps over 10ft calls for a 1ga wire.
Now that we know how big of wire we are going to use, we need to determine how big of a fuse we need.
Oh, lookie there, Blue Sea tells us in the instructions how big of a fuse to use.
Now, double check that the 125A fuse requested by the fuse block in within the safe threshold for 1ga wire:
The 125 amp fuse requested by the fuse block is WELL within the maximum fuse size tolerance for our wire.
Next, we are going to determine how big of wire and fuse we need to wire a string of lights. These 12v lights are the lights we are basing our example on. We are going to install 2 packs of these 12v lights which will be a total of 8 lights. The product page says these are 3 watts each.
8 x 3 = 24 total watts
24 watts / 12.6 system voltage = 1.9 amps for the whole string (which we will round up to the nearest whole number)
2 amps at 15 feet is calling for 12ga wire.
Find the size of fuse by multiplying the amps required by the device (2) by 1.5.
2×1.25 = 2.5 then we will round up to the nearest fuse size (in multiples of 5 amps) which would call for a 5 amp fuse.
Cross Reference that fuse size to verify that it's below the Maximum fuse size called out by this chart. As you can see, 5 amps is well within the 52.5 maximum fuse size threshold.
And there you go! There are a lot of steps to this and trust me, you'll get faster at it with practice. As always leave any questions you have in the comments below and subscribe for updates.
Now that you know how to size the fuses in your DIY Camper Van electrical system, it’s time to put everything you’ve learned to work.
Everything that you are learning here is put to use in our FREE Interactive Solar Wiring Diagrams. If you haven’t yet, check them out as they are a complete solution for a camper van electrical system. Check them out here: https://www.explorist.life/solarwiringdiagrams/
Remember, this is just one part of a full camper van electrical educational series. To see all of the individual guides, click here: https://www.explorist.life/diy-campervan-solar