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Designing a solar array for a 12-volt battery bank requires calculating panel open-circuit voltage, short-circuit current, and max series fuse ratings to select the appropriate MPPT charge controller and wiring gauge. Using a charge controller calculator, designers can determine whether to wire panels in series, parallel, or a series-parallel combination to optimize efficiency and cost. For a 400-watt array using four 100-watt panels, a series-parallel configuration—two panels in series per string, with two strings in parallel—provides sufficient voltage for a Victron Smart Solar MPPT 100/30 controller. When the array short-circuit amperage exceeds the panel's max series fuse rating, PV fuses must be installed on the positive wires at the combiner. For larger arrays, such as 700 watts or 1,050 watts, higher-capacity controllers like the Victron Smart Solar MPPT 150/85 are required to handle increased output amperage and voltage. Ten-gauge wire is generally sufficient for these solar runs, ensuring minimal voltage drop while remaining compatible with standard PV connectors.

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