Van Solar Panel Install

Van Solar Panel Install. One of the ultimate goals of van life is true independence – the ability to pull over, set up camp, and power all your essentials without a single thought about shore power.

For our Weekender Van Life Ram Promaster conversion, achieving this meant one crucial upgrade: solar power. We’d already laid the groundwork for a robust DIY Van electrical system, and the time finally came to add the sun-catching muscle.

Unleash Off-Grid Freedom: Installing a Renogy 200W Solar Panel on Our Promaster Van (Above a Roofnest Tent!)

But our setup had a unique challenge: a bulky Roofnest rooftop tent already occupied prime real estate on our Promaster’s roof. We didn’t want to forgo the tent, so we devised a custom solution to mount our new Renogy 200-Watt solar panel above it. Read on to see how we did it!

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Why Add Solar to Your DIY Van Electrical System?

If you’re still debating solar for your van, let us convince you. The benefits are game-changing:

True Off-Grid Freedom: Power lights, charge devices, run a fridge, and even operate small appliances without needing external hookups.

Sustainability: Harness clean, renewable energy, reducing your carbon footprint.

Cost Savings: Eliminate campground electrical fees and reduce reliance on noisy, fuel-guzzling generators.

Quiet Operation: Enjoy the peace of nature without the hum of an inverter or generator.

Battery Longevity: Keep your house batteries topped up daily, extending their lifespan by preventing deep discharges.

Component Selection: Powering Our Promaster

Choosing the right components is key to a reliable solar setup. For our needs, we opted for straightforward, dependable parts:

Solar Panel

We landed on the Renogy 200-Watt 12-Volt Monocrystalline Solar Panel. Renogy is a trusted name in the van life community, and this panel offered a great balance of power output and physical size to fit our custom mounting solution. Monocrystalline panels are known for their efficiency, perfect for maximizing power even in less-than-ideal sun conditions.

Solar Charge Controller

We had already pre-installed our Renogy Rover Li 20 Amp MPPT Solar Charge Controller into our electrical system. MPPT (Maximum Power Point Tracking) controllers are highly efficient, converting more of the sun’s energy into usable power for your batteries compared to PWM controllers. Our 20A model was perfectly sized for the 200W panel.

Wire Sizing

For a 25-foot wire run from the panel to the controller, we chose 10-gauge wire. This gauge minimizes voltage drop over that distance, ensuring efficient power transfer.

Where to Buy Your Renogy Gear

For convenience and competitive pricing, we sourced all our Renogy products, including the solar panel and related accessories, directly from Amazon. Their fast shipping made getting started on our project a breeze.

The Design Challenge: Mounting Above a Roofnest Rooftop Tent

This was the unique puzzle of our installation. Our Weekender Van Life Promaster has a Roofnest Rooftop Tent securely mounted on its roof. We wanted to add solar without sacrificing the tent.

While we could have purchased roof racks specifically designed by Roofnest to mount accessories, we opted for a more customized and robust approach: we decided to build custom roof rack brackets and crossbars ourselves. This allowed us to precisely position the solar panel directly above the tent, ensuring optimal sun exposure and a durable attachment. All our wiring, from the panel down to the interior, would be meticulously run and protected within split loom conduit for maximum durability against the elements.

Van Solar Wiring Diagram

(….Wiring Diagram …)

Now Let’s Get To The Fun Part – Installing Our Van Solar Panel

THE VIDEO

How-To Steps: Our Renogy 200W Solar Panel Installation

Here’s a breakdown of the steps we took to get our solar panel up and running:

1. Unboxing and Inspection

First things first: we carefully unboxed the Renogy 200W solar panel. It’s crucial to inspect for any shipping damages immediately upon arrival. Better to catch a ding or crack now than after you’ve started the laborious mounting process. Our panel arrived in perfect condition.

2. Building Custom Mounting Brackets and Crossbars

This was the most involved step due to our unique Roofnest situation.

Material: We started with robust aluminum stock material. Aluminum is lightweight, strong, and corrosion-resistant – perfect for outdoor van applications.

Fabrication: Using basic tools (saws, drills, files), we cut and shaped the aluminum into the desired bracket and crossbar designs. Precision was key here to ensure a level mount for the panel.

Welding: Once all the pieces were cut and test-fitted, we took them to a local welder to have them professionally welded together. This ensured incredible strength and durability for the entire structure.

Powder Coating: To give them a professional finish and provide further weather protection, we had the custom brackets and crossbars powder-coated black. This step not only looks great but adds longevity.

3. Connecting The Solar Panel To The Cross Bars

With our custom rack built, mounting the panel itself was straightforward. We used custom U-bolts to securely fasten the Renogy panel to our newly fabricated crossbars. This method provided a very strong connection, capable of withstanding highway speeds and vibrations.

4. Prep Solar Panel Wiring

Before hoisting the panel onto the van, we prepped its wiring:

Inline Fuse: Crucially, we installed an inline fuse on the positive wire coming from the solar panel. This is a vital safety measure to protect your system from potential short circuits or power surges. Always size your fuse appropriately for your panel’s maximum current output.

Crimp Terminal Lugs: We then crimped appropriate terminal lugs onto the ends of the positive and negative wires. This ensures a clean, secure, and reliable connection to the charge controller.

5. Mount the Panel on Top of the Van

With the panel prepped and attached to its custom rack, it was time for the final lift! With careful planning and an extra set of hands, we positioned the entire assembly (panel + custom rack) directly above our Roofnest tent and securely bolted it to the existing tent mounting points on the van’s roof rails.

6. Wire Run: From Panel to Charge Controller

This step involved carefully running the now-fused and terminated 10-gauge wires from the solar panel down into the van’s interior. We routed the wires strategically, utilizing existing openings or drilling new, properly sealed holes, ensuring the wire run was clean, protected in split loom conduit, and away from any potential pinch points or abrasion.

7. Terminate Wiring

The final electrical connections were made inside the van:

Panel to Controller: We connected the positive and negative wires from the solar panel to the designated “PV Input” terminals on our Renogy Rover Li 20 Amp MPPT Solar Charge Controller.

Controller to Battery: We then connected the “Battery Output” terminals of the charge controller to our main house battery bank. (Ensure your battery is disconnected during this entire process to prevent accidental shorts!)

Once all connections were confirmed secure and correct, we reconnected the battery, and watched our Renogy controller light up, indicating it was receiving power from the sun – a truly satisfying moment!

Conclusion: Is the Renogy 200-Watt 12-Volt Monocrystalline Solar Panel Suitable for Vanlife?

Absolutely, yes! The Renogy 200-Watt 12-Volt Monocrystalline Solar Panel, paired with an MPPT controller, has proven to be an excellent choice for our Ram Promaster van conversion. Its efficiency and solid build quality make it a reliable source of power, keeping our batteries topped up even on partially cloudy days. For a typical van life setup with a fridge, lights, and device charging, 200 watts is a fantastic starting point, offering a great balance between power output and roof space consumption.

Our custom mounting solution above the Roofnest tent allowed us to maximize our usable roof space without compromising on solar power. If you’re undertaking a similar build with unique roof challenges, don’t be afraid to think outside the box and fabricate your own solutions! The freedom a well-integrated solar system provides is simply unparalleled in the world of van life.

Happy adventuring, and may your batteries always be full!

Share Your Thoughts

Have you installed a Solar in your van or RV, or are you planning to do so? Have some knowledge to share? Drop a comment in the box 👇👇

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Unleash Off-Grid Freedom: Installing a Renogy 200W Solar Panel on Our Promaster Van (Above a Roofnest Tent!)

Scroll Down For The Video👇

Why Add Solar to Your DIY Van Electrical System?

If you’re still debating solar for your van, let us convince you. The benefits are game-changing: