Cloning: Skoolie conversion 1200W 24V
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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 | 23.2A | 15 ft | 10 AWG | 1.26% | 30APV-rated (gPV) fuse or DC breaker |
| Charge controller to battery bank | 60.0A | 5 ft | 4 AWG | 0.58% | 80AClass T |
| Battery bank to inverter | 156.3A | 5 ft | 3/0 AWG | 0.38% | 200AClass T |
Array to charge controller: show the math
Continuous current = 23.2A Design current = 23.2A x 1.25 (NEC continuous) = 29A Wire: 10 AWG copper (75C ampacity 35A); voltage drop 1.26% over 30ft round trip at 55.2V (target <= 3%) Fuse/breaker: 30A - two criteria, both required: carry the load: fuse >= design 29A -> next standard size = 30A protect the wire: fuse 30A <= 10 AWG ampacity 35A - OK construction: PV-rated (gPV) fuse or DC breaker
Charge controller to battery bank: show the math
Continuous current = 60A Design current = 60A x 1.25 (NEC continuous) = 75A Wire: 4 AWG copper (75C ampacity 85A); voltage drop 0.58% over 10ft round trip at 25.6V (target <= 3%) Fuse/breaker: 80A - two criteria, both required: carry the load: fuse >= design 75A -> next standard size = 80A protect the wire: fuse 80A <= 4 AWG ampacity 85A - OK bank BMS continuous 400A >= fuse 80A: 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 = 156.3A Design current = 156.3A x 1.25 (NEC continuous) = 195.3A Wire: 3/0 AWG copper (75C ampacity 200A); voltage drop 0.38% over 10ft round trip at 25.6V (target <= 3%) Fuse/breaker: 200A - two criteria, both required: carry the load: fuse >= design 195.3A -> next standard size = 200A protect the wire: fuse 200A <= 3/0 AWG ampacity 200A - OK bank BMS continuous 400A >= fuse 200A: 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 | ~35 ft total (15 ft one way, round trip + slack) - Array to charge controller |
| 30A PV-rated (gPV) fuse or DC breaker | 1 | Array to charge controller |
| 4 AWG copper wire | 1 | ~15 ft total (5 ft one way, round trip + slack) - Charge controller to battery bank |
| 80A Class T | 1 | Charge controller to battery bank - include the matching fuse holder/block |
| 3/0 AWG copper wire | 1 | ~15 ft total (5 ft one way, round trip + slack) - Battery bank to inverter |
| 200A 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
13 passing checks - expand to see the math
passBattery matches the 24V systemSystem voltage coherence
LiTime 24V 100Ah LiFePO4 (25.6V nominal) is a 24V-class battery.
battery nominal 25.6V is in the 24V class == system 24V
passInverter matches the 24V systemSystem voltage coherence
Giandel PS-4000QAR 4000W 24V Pure Sine Wave Inverter DC input is 24V-class.
inverter DC input 24V is in the 24V class == system 24V
passCharge controller supports 24V banksSystem voltage coherence
Victron Energy SmartSolar MPPT 150/60 supports 12/24/36/48V battery banks.
controller battery voltages [12, 24, 36, 48] include 24V
passString Voc stays at 72.7V at -15C - cannot reach the 150V limit at any temperatureCold-temperature string voltage
3 x Rich Solar MEGA 200 200W 12V Monocrystalline Solar Panel in series stays below the Victron Energy SmartSolar MPPT 150/60 max PV input voltage at your design low temperature. This string cannot reach 150V at any physically possible temperature.
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))
= 21.80V x 3 x (1 + (-0.28%/100) x (-15 - 25))
= 21.80V x 3 x 1.1120 = 72.7V
Controller max PV input: 150V
Crossover: string Voc reaches 150V at T = 25 + (150/65.4 - 1) x 100/-0.28 = -437C (below absolute zero - never reached)passString Vmp 55.2V has healthy margin over the 24V bankMPPT voltage margin
Clears the start floor cold and the hot-weather floor with sag included.
Vmp_string = 18.40V x 3 = 55.2V Start floor = V_batt + 5V = 24 + 5 = 29V Hot Vmp (~11% sag) = 55.2V x 0.89 = 49.1V vs hot floor 32V
passArray short-circuit current 23.20A is within the 50A limitArray current vs controller input limit
Within the Victron Energy SmartSolar MPPT 150/60 published max PV short-circuit current.
Isc_array = 11.60A x 2 parallel = 23.20A Controller max PV short-circuit current: 50A = 50A (manufacturer-specified, compared directly)
passController can pass the array's full output (46.9A of 60A rated)Array size vs controller charge output
No clipping at rated conditions.
Array = 200W x 6 panels = 1200W Potential charge current = 1200W / 25.6V = 46.9A Controller rated charge current: 60A
passArray 1200W is within the controller's 1720W rating at 24VMax array wattage for battery voltage
Within the published maximum array wattage.
Array = 200W x 6 panels = 1200W Controller max array wattage at 24V: 1720W
passVictron Energy SmartSolar MPPT 150/60 supports LiFePO4 chargingBattery chemistry support
Controller has a lithium profile or user-adjustable charge voltages.
battery chemistry = lifepo4; controller lifepo4_profile = true
passBank BMS limit 400A comfortably covers the inverter's 156.3A drawInverter draw vs battery BMS limit
Healthy headroom at full inverter load.
Inverter draw = 4000W / 25.6V = 156.3A Bank BMS limit = 100A x 4 batteries = 400A Headroom band starts at 80% of limit = 320A
passBank BMS peak 1120A covers the inverter's 312.5A surgeInverter surge vs battery peak limit
Surge loads within the bank's published peak rating.
Surge draw = 8000W / 25.6V = 312.5A Bank BMS peak = 280A x 4 batteries = 1120A
pass4 in parallel is within the manufacturer limit of 4Battery parallel count
Supported parallel configuration.
4 in parallel vs manufacturer max 4
passCharge current 60A is within the bank's 400A capacityCharge current vs bank capacity
Charge rate within limits.
Controller rated charge = 60A Bank max charge = manufacturer max charge 100A x 4 = 400A
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