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campervan solar10 MIN

How to Size a Solar Setup for a Campervan Based on Your Daily Power Use

Calculate a campervan solar array and battery bank from real daily energy use, autonomy, seasonal peak sun hours and battery-recovery needs.

By CarCody Team

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The defensible way to size a campervan solar system is to start with your daily energy use in watt-hours (Wh), then size the battery for the number of no-sun days you want and size the array for the peak-sun hours (PSH) on your route’s difficult season. A panel wattage that covers today’s appliances may still be too small to restore a depleted battery, and the final design also depends on roof space, shade, wiring, controller limits, temperature and other charging sources.

Use the workflow below as a first-pass design. The arithmetic examples come from Victron Energy’s guide dated 4 May 2026 and are illustrative, not a guarantee of what your particular appliances or location will produce.

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1. Measure a realistic day in watt-hours

Make an appliance-by-appliance load list before choosing a panel. For each device, estimate its running watts and the hours it operates in a typical day:

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daily Wh = watts × hours per day

For a device that cycles, use its average duty cycle rather than its nameplate wattage for the entire period. A refrigerator, for example, may draw its rated power only while the compressor runs. Use measured energy from a plug-in meter, shunt monitor or the appliance manufacturer’s daily figure when available; an optimistic guess is the quickest way to undersize a system.

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Load Illustrative calculation Energy
Laptop 60 W × 3 hours 180 Wh/day
12 V, 70 L refrigerator Daily figure in the guide 500 Wh/day
Lights 10 W × 4 hours 40 Wh/day
Total 180 + 500 + 40 720 Wh/day

Those three figures are Victron’s worked example, not a promise that every 70 L refrigerator or laptop will consume the same amount. Add every meaningful load: phones, cameras, routers, fans, water pumps, diesel-heater controls, cooking equipment, entertainment and standby draw. Include inverter idle consumption if any appliance is powered through an inverter.

Account for inverter losses

If you run a 230 V appliance from a battery through an inverter, the energy taken from the battery is higher than the appliance’s wall-plug consumption. Victron’s example allows about 10–15% extra for 230 V appliances. Apply that allowance to the relevant loads rather than adding it blindly to every 12 V device.

For example, a 230 V load that uses 200 Wh at its outlet would represent roughly 220–230 Wh from the battery under that illustrative allowance. In a real installation, inverter efficiency varies with load, voltage and model, so measured consumption is preferable.

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Separate average and worst-case days

Write down at least two totals: an ordinary travel day and the heaviest day you expect, such as a remote-work day with a computer, monitor, communications equipment and longer refrigerator operation. Size around the operating pattern you need to sustain, not a holiday day when almost everything is switched off. If another charging source will run regularly, record when it operates and how much energy it can reliably add; do not count an occasional alternator or campsite hookup as guaranteed solar production.

2. Convert daily use into battery capacity

Battery sizing answers a different question from panel sizing: how long must the van operate when solar is weak or unavailable? Choose an autonomy period in days, convert your energy requirement to amp-hours (Ah), and then allow for the fraction of the battery you intend to use.

daily Ah = daily Wh ÷ system voltage

required rated Ah = (daily Ah × autonomy days) ÷ usable fraction

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At 12 V, the 720 Wh/day example is about 60 Ah/day. Three days of autonomy therefore requires about 180 Ah of usable energy. Using the example fractions in Victron’s guide gives the following planning figures:

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Assumption Calculation for 720 Wh/day and three days Approximate rated bank
Usable energy needed 60 Ah/day × 3 180 Ah usable
Lead-acid, 50% usable 180 Ah ÷ 0.50 360 Ah rated
Lithium, 90% usable 180 Ah ÷ 0.90 200 Ah rated

The 50% and 90% figures are illustrative assumptions from that guide, not universal operating limits. The usable fraction depends on chemistry, the manufacturer’s permitted depth of discharge, temperature, discharge rate, battery-management system and the life you expect. Follow the exact battery manual, including low-temperature charging restrictions and required fusing.

Choose autonomy deliberately

  • One day: a small bank may work if you have dependable daily solar or frequent alternator charging and can reduce loads in bad weather.
  • Two to three days: a common planning range for remote travel, but it increases weight, cost and the time needed to recharge.
  • More than three days: often makes sense only when loads are essential, weather is uncertain and roof area or other charging sources cannot be expanded.

Autonomy is not the same as running the battery flat. It is the energy you want available before deliberately reducing loads or starting another charging source. Keep reserve for battery-protection cutoffs and unexpected consumption.

Check physical and electrical constraints

Before committing to a bank, verify compartment dimensions, ventilation requirements, cable length, fuse ratings, battery weight and the maximum charge and discharge current accepted by the battery-management system. A bank that fits the energy calculation can still be unsuitable if it cannot accept the expected solar current or if the installation cannot safely support its fault current.

3. Estimate the solar array from peak sun hours

Peak sun hours (PSH) express solar irradiation as equivalent hours at 1,000 W/m². They are not the number of daylight hours. Use a location- and month-specific PSH value for the route and season that matter most, then begin with:

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minimum array watts = daily Wh ÷ PSH

Victron’s Alpine-summer example uses 720 Wh/day and 5 PSH:

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720 Wh ÷ 5 h = 144 W

That 144 W is an idealized daily-energy minimum. It assumes the panels deliver their rated output during the equivalent sun hours and does not fully represent shading, panel temperature, dirt, orientation, cable loss, controller conversion or battery-charge inefficiency. A 144 W nameplate array should therefore not be treated as a guaranteed 720 Wh/day supply.

Use the difficult season, not an annual average

Solar yield changes with latitude, weather, roof orientation, season and route. A summer average can hide a winter shortfall, while a clear desert estimate can fail on a shaded forest road. Select PSH for the months in which you need the van to be self-sufficient. If the route spans regions, use the lower relevant value or model each travel segment separately.

No route-specific PSH dataset is provided, so obtain current location and month figures from a reputable solar-irradiance source or a qualified installer. Treat any single PSH number as an assumption to document, not as a universal campervan constant.

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Apply a loss and weather margin

Panel ratings are measured under best-condition test assumptions. Real output falls when a panel is shaded, dirty, hot, poorly angled or connected through inefficient wiring. MPPT conversion and battery charging also consume some energy. Rather than pretending a fixed loss percentage works everywhere, show your assumptions and test the result against the worst month you intend to travel. A larger array can compensate for mediocre weather, but only if the roof, controller and wiring can handle it.

4. Decide whether solar must refill the battery

An array sized merely to replace that day’s consumption may leave a multi-day deficit after cloudy weather. Add a second calculation for recovery: how much energy must be returned to the battery, and in how many good-solar days?

In the 720 Wh/day example, a three-day reserve is about 2,160 Wh usable. Victron’s guide says that recovering this reserve in one sunny day changes the target to roughly 450–500 W under a 4–5 PSH assumption—around three times the 144 W daily-use minimum. That is an approximate planning illustration, not a guaranteed recharge time.

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Actual recovery depends on the battery’s state of charge, charge-acceptance limits, weather, shade, simultaneous loads, controller clipping and whether alternator or mains charging contributes. A practical design therefore states both targets:

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  • Daily replacement target: enough harvest to cover expected loads on an ordinary day.
  • Recovery target: enough additional capacity to restore the chosen reserve after poor weather within the number of sunny days you consider acceptable.

If the recovery array will exceed roof capacity, plan an explicit backup: drive often enough for alternator charging, use campsite mains, reduce loads, carry portable panels or accept a longer recovery period.

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5. Match panels, wiring and the charge controller

Panel wattage alone does not prove that a system is electrically compatible. The controller must tolerate the array’s open-circuit voltage (Voc), short-circuit current (Isc), operating voltage and total power at the battery voltage.

Series versus parallel

Layout Electrical effect Practical implications
Series Voltages add; current remains approximately that of one panel Higher voltage can help an MPPT controller start earlier and continue later. A shaded panel can reduce output from the string, especially when panels share one current path.
Parallel Voltage remains approximately that of one panel; currents add Some layouts tolerate partial shade better, but higher current requires appropriately larger conductors, fusing and connectors.

These are system-level tendencies, not guarantees. Bypass diodes, panel orientation and the exact shade pattern matter. Put panels with materially different shade or orientation conditions on separate controller inputs when the equipment supports it, or choose a layout that limits the effect of the shade you actually encounter.

Verify controller voltage and current limits

Use the exact panel datasheet and the exact controller manual. The MPPT manual guidance cited by Victron requires that:

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  • the array’s maximum Voc, including the increase caused by cold temperatures, stays below the controller’s absolute PV-voltage limit;
  • the array’s nominal PV voltage is at least 5 V above battery voltage so the controller can charge;
  • the controller’s maximum PV current and charging-current rating are not exceeded; and
  • the panel arrangement, battery voltage and protective devices match the manufacturer’s wiring instructions.

For product discovery, Victron describes its SmartSolar MPPT 100/30 as accepting up to 100 V PV input and providing up to 30 A charging current. That specification is not a recommendation for every van: the actual array’s cold-weather Voc, Isc, power and battery voltage must be checked against the current manual and the manufacturer’s calculator.

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Include protection and serviceability

A complete design normally includes a PV isolator, correctly rated DC fuses and holders, solar cable and lugs sized for the current and run length, panel brackets, weatherproof cable-entry hardware, battery protection and an accessible controller. Place protection where the manufacturer specifies, keep cable runs short where practical, and label both PV and battery circuits. A qualified RV or campervan electrician can verify crimp quality, polarity, earthing and over-current protection before the system is used.

6. A worked first-pass design

Starting assumptions

Suppose your audited daily load is the guide’s illustrative 720 Wh, your system is nominally 12 V, you want three days of autonomy and you are evaluating an Alpine summer period represented by 5 PSH.

  1. Battery energy: 720 Wh ÷ 12 V ≈ 60 Ah per day.
  2. Usable reserve: 60 Ah × 3 days ≈ 180 Ah usable.
  3. Rated bank: approximately 360 Ah with a 50% usable lead-acid assumption, or approximately 200 Ah with a 90% usable lithium assumption.
  4. Daily solar minimum: 720 Wh ÷ 5 PSH ≈ 144 W before real-world losses.
  5. Recovery-oriented array: roughly 450–500 W if the objective is to recover the three-day reserve in one 4–5 PSH day under the guide’s assumptions.

The two array figures answer different questions. The smaller figure addresses same-day energy in an idealized calculation; the larger figure addresses rapid recovery. Neither figure confirms that the roof can hold the panels or that a selected controller can accept them.

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Stress-test the result

  • Replace 5 PSH with the lower PSH for your critical month and rerun the division.
  • Increase the load total if your workday, refrigerator duty cycle or inverter usage is higher than the illustrative list.
  • Check whether shading on a morning or afternoon parking spot defeats the assumed harvest.
  • Confirm that the battery can accept the planned charge current and that cold-weather charging is permitted.
  • Recalculate controller Voc at the lowest expected panel temperature, not only at room temperature.

7. Common sizing mistakes and fixes

Choosing panels from roof wattage alone

Symptom: the label says the array is large enough, but the battery reaches a lower state of charge each day. Fix: return to the Wh audit, include inverter losses, use the relevant seasonal PSH and account for shade and temperature. Compare harvested energy, not only nameplate watts.

Ignoring autonomy

Symptom: one cloudy day forces immediate driving or campsite charging. Fix: multiply daily Ah by the number of no-charge days you actually require and divide by the battery’s permitted usable fraction.

Confusing daily replacement with recovery

Symptom: the system covers a sunny day but cannot rebuild the reserve after a storm. Fix: calculate a separate recovery target and decide whether to add panels, add another charging source, reduce loads or accept a longer recovery time.

Exceeding controller limits

Symptom: the controller faults in cold weather, clips output unexpectedly or cannot begin charging. Fix: check cold-corrected Voc, Isc, nominal PV voltage, battery voltage and controller current limits using the exact model manual.

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Using the wrong wiring for the shade pattern

Symptom: one shaded panel drags down a series string, or parallel wiring produces excessive voltage drop and hot cables. Fix: map shade by parking location, then select series, parallel or separate controller inputs with cable and fuse sizes calculated for the resulting current.

8. Final design checklist

  • Daily loads are listed in Wh, with realistic hours or duty cycles.
  • 230 V loads include an explicit inverter-loss allowance or measured battery-side consumption.
  • Average and worst-case days are separated.
  • Autonomy days and the battery chemistry’s permitted usable fraction are documented.
  • Battery size fits the physical compartment and its charging, temperature and management requirements.
  • PSH is specific to the route and critical season rather than an unexplained annual average.
  • Array size is checked for both same-day replacement and reserve recovery.
  • Roof area, mounting, dirt, orientation and shade are included in the decision.
  • Series or parallel wiring is selected for the shade pattern and cable-current limits.
  • Cold-weather Voc, Isc, nominal PV voltage, controller limits and battery voltage are checked from current manuals.
  • Fuses, isolators, cable sizes, connectors and entry hardware are specified before installation.
  • A backup charging plan exists for prolonged cloud or a failed component.

Use this calculation as a transparent first pass, then have the final installation checked against the current equipment manuals and local professional practice. Solar sizing is conditional: the right answer is the smallest system that meets your documented loads, autonomy, seasonal yield and recovery requirement without exceeding any electrical or physical limit.

Product prices and availability are accurate as of the date/time indicated and are subject to change. Any price and availability information displayed on Amazon at the time of purchase will apply.

campervan solarMPPT charge controlleroff-grid powerpeak sun hoursRV batterysolar sizing

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