Cloning: Premium Victron 48V homestead
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Solar array
Panels + how they are wired (series x parallel)
Charge controller
MPPT/PWM between array and battery
Battery bank
Identical batteries in parallel
Inverter / all-in-one
DC to AC. All-in-one units include the charge controller.
Wire runs
One-way distances for wire and fuse sizing.
| Segment | Continuous | Run (one way) | Copper wire | V-drop | Fuse/breaker |
|---|---|---|---|---|---|
| Array to charge controller | 28.0A | 50 ft | 10 AWG | 1.68% | 35APV-rated (gPV) fuse or DC breaker |
| Charge controller to battery bank | 100.0A | 6 ft | 1 AWG | 0.31% | 125AClass T |
| Battery bank to inverter | 83.3A | 6 ft | 2 AWG | 0.33% | 110AClass T |
Array to charge controller: show the math
Continuous current = 28A Design current = 28A x 1.25 (NEC continuous) = 35A Wire: 10 AWG copper (75C ampacity 35A); voltage drop 1.68% over 100ft round trip at 166.8V (target <= 3%) Fuse/breaker: 35A - two criteria, both required: carry the load: fuse >= design 35A -> next standard size = 35A protect the wire: fuse 35A <= 10 AWG ampacity 35A - OK construction: PV-rated (gPV) fuse or DC breaker
Charge controller to battery bank: show the math
Continuous current = 100A Design current = 100A x 1.25 (NEC continuous) = 125A Wire: 1 AWG copper (75C ampacity 130A); voltage drop 0.31% over 12ft round trip at 48V (target <= 3%) Fuse/breaker: 125A - two criteria, both required: carry the load: fuse >= design 125A -> next standard size = 125A protect the wire: fuse 125A <= 1 AWG ampacity 130A - OK bank BMS continuous 300A >= fuse 125A: the bank can hold the fuse's rated load construction: Class T (interrupt rating matters on battery mains)
Battery bank to inverter: show the math
Continuous current = 83.3A Design current = 83.3A x 1.25 (NEC continuous) = 104.2A Wire: 2 AWG copper (75C ampacity 115A); voltage drop 0.33% over 12ft round trip at 48V (target <= 3%) Fuse/breaker: 110A - two criteria, both required: carry the load: fuse >= design 104.2A -> next standard size = 110A protect the wire: fuse 110A <= 2 AWG ampacity 115A - OK bank BMS continuous 300A >= fuse 110A: the bank can hold the fuse's rated load construction: Class T (interrupt rating matters on battery mains)
Mount the fuse close to the battery positive terminal - it protects the wire run, so the unprotected stub should be as short as possible.
Sized for 75C copper ampacity with the NEC 1.25 continuous factor and a 3% voltage-drop target. Round up when between sizes and verify against local code.
Balance of system - shopping list
| Item | Qty | For |
|---|---|---|
| 10 AWG copper wire | 1 | ~115 ft total (50 ft one way, round trip + slack) - Array to charge controller |
| 35A PV-rated (gPV) fuse or DC breaker | 1 | Array to charge controller |
| 1 AWG copper wire | 1 | ~15 ft total (6 ft one way, round trip + slack) - Charge controller to battery bank |
| 125A Class T | 1 | Charge controller to battery bank - include the matching fuse holder/block |
| 2 AWG copper wire | 1 | ~15 ft total (6 ft one way, round trip + slack) - Battery bank to inverter |
| 110A Class T | 1 | Battery bank to inverter - include the matching fuse holder/block |
Derived from the wire and fuse guidance above. Wire lengths include round trip plus slack - verify against your actual layout, and verify ratings against local code. Buy fuses and wire from reputable electrical suppliers; marketplace listings for these items are a common source of counterfeit or mislabeled parts.
Parts list
| Part | Qty | Est. price | Where to buy |
|---|---|---|---|
Canadian Solar HiKu6 CS6W-550MS 550W Mono PERC | 8 | $2,240 | no merchant links yet |
Victron Energy SmartSolar MPPT 250/100-Tr VE.Can controllerdatasheet | 1 | $1,000 | |
Pylontech US5000 48V 100Ah batterydatasheet | 3 | n/a | |
Victron Energy MultiPlus-II 48/5000/70-95 120V inverterdatasheet | 1 | $1,459 | |
| Estimated total | $4,699(some prices unknown) |
15 passing checks - expand to see the math
passBattery matches the 48V systemSystem voltage coherence
Pylontech US5000 48V 100Ah (48V nominal) is a 48V-class battery.
battery nominal 48V is in the 48V class == system 48V
passInverter matches the 48V systemSystem voltage coherence
Victron Energy MultiPlus-II 48/5000/70-95 120V DC input is 48V-class.
inverter DC input 48V is in the 48V class == system 48V
passCharge controller supports 48V banksSystem voltage coherence
Victron Energy SmartSolar MPPT 250/100-Tr VE.Can supports 12/24/36/48V battery banks.
controller battery voltages [12, 24, 36, 48] include 48V
passString Voc stays at 224.2V at -25C - safe down to -75C (-103.1F)Cold-temperature string voltage
4 x Canadian Solar HiKu6 CS6W-550MS 550W Mono PERC in series stays below the Victron Energy SmartSolar MPPT 250/100-Tr VE.Can max PV input voltage at your design low temperature. The string would not reach the 250V limit until the temperature drops below -75C (-103.1F).
Why this matters: Panel voltage rises as temperature falls. A string that measures fine in summer can exceed the controller's absolute maximum input voltage on the first cold clear morning, which can permanently destroy the controller - and at these DC power levels, failures can start fires. This is the mistake experienced builders catch most often in DIY parts lists.
Voc_string = Voc x N_series x (1 + tempCoeff/100 x (T_design - 25))
= 49.60V x 4 x (1 + (-0.26%/100) x (-25 - 25))
= 49.60V x 4 x 1.1300 = 224.2V
Controller max PV input: 250V
Crossover: string Voc reaches 250V at T = 25 + (250/198.4 - 1) x 100/-0.26 = -75CpassString Vmp 166.8V has healthy margin over the 48V bankMPPT voltage margin
Clears the start floor cold and the hot-weather floor with sag included.
Vmp_string = 41.70V x 4 = 166.8V Start floor = V_batt + 5V = 48 + 5 = 53V Hot Vmp (~11% sag) = 166.8V x 0.89 = 148.5V vs hot floor 56V
passArray short-circuit current 28.00A is within the 70A limitArray current vs controller input limit
Within the Victron Energy SmartSolar MPPT 250/100-Tr VE.Can published max PV short-circuit current.
Isc_array = 14.00A x 2 parallel = 28.00A Controller max PV short-circuit current: 70A = 70A (manufacturer-specified, compared directly)
passController can pass the array's full output (91.7A of 100A rated)Array size vs controller charge output
No clipping at rated conditions.
Array = 550W x 8 panels = 4400W Potential charge current = 4400W / 48V = 91.7A Controller rated charge current: 100A
passArray 4400W is within the controller's 5800W rating at 48VMax array wattage for battery voltage
Within the published maximum array wattage.
Array = 550W x 8 panels = 4400W Controller max array wattage at 48V: 5800W
passVictron Energy SmartSolar MPPT 250/100-Tr VE.Can supports LiFePO4 chargingBattery chemistry support
Controller has a lithium profile or user-adjustable charge voltages.
battery chemistry = lifepo4; controller lifepo4_profile = true
passVictron Energy MultiPlus-II 48/5000/70-95 120V charger supports LiFePO4Battery chemistry support
Inverter/charger has a lithium charge profile.
battery chemistry = lifepo4; inverter charger lifepo4_profile = true
passBank BMS limit 300A comfortably covers the inverter's 83.3A drawInverter draw vs battery BMS limit
Healthy headroom at full inverter load.
Inverter draw = 4000W / 48V = 83.3A Bank BMS limit = 100A x 3 batteries = 300A Headroom band starts at 80% of limit = 240A
passBank BMS peak 600A covers the inverter's 187.5A surgeInverter surge vs battery peak limit
Surge loads within the bank's published peak rating.
Surge draw = 9000W / 48V = 187.5A Bank BMS peak = 200A x 3 batteries = 600A
pass3 in parallel is within the manufacturer limit of 16Battery parallel count
Supported parallel configuration.
3 in parallel vs manufacturer max 16
passCharge current 100A is within the bank's 300A capacityCharge current vs bank capacity
Charge rate within limits.
Controller rated charge = 100A Bank max charge = manufacturer max charge 100A x 3 = 300A
passClosed-loop comms available via pylontechClosed-loop battery communications
The inverter can read state of charge and limits directly from the battery BMS. Enable closed-loop per both manuals.
inverter speaks [victron, pylontech, generic-can]; battery speaks [pylontech, generic-can, rs485]; overlap [pylontech, generic-can]
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