Off-grid from zero · lesson 6 of 12

Wire it so it does not burn

Learn the fusing, wire gauge, and grounding rules that make a DC system safe, and draw the diagram before you buy a single part.

The difference between a solar system and a fire is a few fuses in the right places and wire that is thick enough. This is the lesson people skip because it is not exciting, and it is the one inspectors and insurers care about most. The principles are few and they are firm: a lithium bank needs overcurrent protection with enough DC interrupt capacity for the short-circuit current it can deliver (Class T is the common high-interrupt choice; other fuse types can be acceptable when their continuous-current, DC voltage, and interrupt ratings are right and the battery maker permits them), a fuse on every string once there are three in parallel, wire sized for the current plus margin, and one grounding point.

The planner now draws the one-line diagram from your numbers, with the fuse ratings and gauges on it. Print it, take it to whoever will inspect or insure the place, and keep two of every fuse on the shelf.

Numbers to carry
  • Class T fuses are rated to interrupt 20,000 A of DC fault current, which is why they are the default recommendation for lithium banks; common ANL fuses carry far lower interrupt ratings and may fail to clear a big lithium short. Whatever fuse type you use, check its DC interrupt rating against what your bank can deliver.
  • PV wire is sized from Isc times 1.25 (and again times 1.25 for continuous duty).
  • String fuses: use the maximum series fuse rating printed on the module label, often 15 A but check each panel, and fusing is generally required from three parallel strings up.
Read
Do before the next lesson
  • Generate the wiring diagram from your saved plan and check every fuse rating against the spec tables.
  • Size the generator from running watts plus the biggest surge, and decide between propane and gasoline for storage.
  • Buy the crimper and the real MC4 connectors before you buy the panels.
The newsletter

One useful off-grid email a week.

One useful off-grid email a week: practical gear rundowns, honest how-tos, and plain-English guides. No spam, unsubscribe anytime.

Want more of this site in your Google results?

I respect your inbox. See my privacy policy and affiliate disclosure.