Solar panels and wiring

rmaddy said:

Putting your 6 panels in series is trivial and does not require any fusing. But you will be working with deadly high voltage. Treat it with respect and care.

The PV disconnect should be a DC rated 2-pole breaker that can handle 600VDC. I suggest such a high voltage because your all-in-one's charge controller can handle up to 500V which means you want a breaker that can handle at least that much voltage. Going to 600V means the breaker isn't being pushed to its limits all of the time.

I would make sure the PV disconnect breaker is in the OFF position any time you attempt to connect or disconnect the MC4 connectors of your panels. A quality breaker should work just fine even if switched on or off midday.

When I setup the 3 panels in series for my trailer I did things in the following order (make sure there is no power to the charge controller/all-in-one until stated):

1. I mounted the PV disconnect breaker and made sure it was in the OFF position.
2. I ran the long wires that will go to the panels (but not yet connected to the panels) to the PV disconnect breaker.
3. I ran the wires from the PV disconnect breaker to the PV input connections of the charge controller (all-in-one in your case).
4. Connect the solar panels together is series. Connect the string to the long wires coming from the PV disconnect breaker.
5. Provide power to the charge controller/all-in-one and make sure it is configured as needed.
6. Switch the PV disconnect breaker to the ON position.

Now you should have working solar.

If you ever have a need to work on the solar panels, be sure you turn the PV disconnect breaker to the OFF position before doing anything.

You should have little reason to be connecting and disconnecting the panels after the initial installation. Do it once when ready and be done with it.

You will be working with deadly high voltage. Treat it with respect and care.

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