Packing list, cable cuts, wiring diagram, and quick settings for the 400–800 W suitcase. Check it off, build it clean.
Packing List (tick what you packed)
| Item | Spec / Notes | 400W | 800W |
|---|---|---|---|
| “~200 W 24 V-class”, matched model | ×2 | ×4 | |
| 24 V profile, 60 A, PV Voc max 100–150 V | ×1 | ×1 | |
| String fuses 15 A each string (if parallel) | — | ×1 | |
| ≥150 V DC, lockable preferred | ×1 | ×1 | |
| MC4 inline 15 A (per string as required) | — | ×2 | |
| 80 A ANL/Class-T near bus | ×1 | ×1 | |
| 10 AWG PV wire + MC4s | see cuts | see cuts | |
| 6–4 AWG copper to bus (short runs) | see cuts | see cuts | |
| Hinges, handle, tilt leg, glands, labels, fasteners | ✔ | ✔ | |
| MC4 tool, crimper, heat-shrink, multimeter, step bit | ✔ | ✔ |
Cable Cut List (fill, then cut)
| Run | Gauge | Length | Notes |
|---|---|---|---|
| Panel A → Panel B series jumper (2S) | 10 AWG PV | ________ | MC4 male→female |
| String home-run → Combiner | 10 AWG PV | ________ | Per string (800 W only) |
| Combiner → PV Disconnect | 10 AWG PV | ________ | Keep short; label polarity |
| PV Disconnect → MPPT PV+/PV− | 10 AWG PV | ________ | Strain relief at entry |
| MPPT BAT+ → Fuse (near bus) | 6–4 AWG | ________ | Ring lugs, torque to spec |
| Fuse → Station Bus+ | 6–4 AWG | ________ | ≤3% drop target |
| MPPT BAT− → Station Bus− | 6–4 AWG | ________ | Straight run |
Voltage-drop sanity check: keep MPPT→bus runs short and size for ≤3% drop. Use Blue Sea charts or a calculator. Absorb ~28.4–28.8 V; Float ~27.0–27.6 V (or per your battery).
Wiring Diagram (topology)
[Panel A]+--MC4--. (If 2S2P)
+--[ Combiner ]-- 15A fuse/str --[ PV Disconnect ]--> MPPT PV+
[Panel B]+--MC4--' MPPT PV- <--
MPPT BAT+ -- 80A fuse --> Station Bus+ MPPT BAT- --------------> Station Bus-
Settings & Sequence
- Battery type: LiFePO₄ (custom if needed)
- Absorb: 28.4–28.8 V • Float: 27.0–27.6 V (or per maker)
- Connect: Battery → MPPT first, then close PV disconnect
- Shutdown: Open PV first, then battery if needed
Cold Voc Check (worksheet)
Keep string Voc (cold) below MPPT PV Voc max.
| Panel Voc @ STC (V): | ________ |
| |Temp coeff Voc| (%/°C): | ________ |
| ΔT from 25°C (°C): | ________ |
| Calc Voc_cold per panel = Voc × (1 + coeff×ΔT): | ________ V |
| Series count (Ns): | ________ |
| String Voc_cold = panel Voc_cold × Ns: | ________ V |
| Controller PV Voc max: | ________ V |
String Fusing Notes
- Fuse each string when paralleling if back-feed can exceed module’s max series fuse rating.
- Use MC4 inline 15 A (typical) or per module datasheet.
- Place fuses in the combiner ahead of the disconnect.
Final Checks
Sticker spot / QR to full guide: _______________________________