10 Essential Tips for Overland Solar Setup

flexible solar panel on roof of camper

Overlanding is a thrilling way to explore the great outdoors, and many enthusiasts opt to use solar power to keep their equipment charged and ready to go. However, setting up an effective solar system for overlanding can be a daunting task, especially for those new to the hobby. To help make the process easier, we’ve compiled a list of 10 essential tips for overland solar setup.

First and foremost, it’s important to consider your power needs when setting up a solar system for overlanding. This includes not only the amount of power you’ll need to keep your equipment charged, but also the type of equipment you’ll be using. For example, if you plan to use a refrigerator or other high-powered devices, you’ll need a larger solar system than if you’re only charging phones and cameras.

Another important factor to consider is the size and weight of your solar panels. While larger panels will generally provide more power, they can also be more difficult to transport and set up. It’s important to strike a balance between power output and portability, especially if you plan to travel to remote locations. With these factors in mind, let’s dive into our list of 10 essential tips for overland solar setup.

Section 1: Solar Setup Basics

When it comes to overland solar setup, it’s important to understand the basics of solar panels, charge controllers, batteries, and inverters. In this section, we’ll cover each of these components and their functions.

1.1: Solar Panels

Solar panels are the backbone of your solar setup. They convert sunlight into electricity, which can then be stored in your battery system. There are three main types of solar panels: polycrystalline, monocrystalline, and thin-film.

Polycrystalline panels are cheaper than monocrystalline panels, and basic Thin-film panels are the least efficient but are also the lightest and most flexible. But if you want the best efficiency and lightweight you should look into CIGS solar panels, but it’s going to be the most expensive option.

When choosing a solar panel, it’s important to consider your power needs and the available space on your vehicle. A 100-watt solar panel can produce around 30-amp hours per day. Estimating the power use from each of your devices that will be assisted by solar will give you an idea of which panel to choose and how many you need. Pick a panel that does not exceed the amperage of the controller.

1.2: Charge Controllers

Charge controllers are responsible for regulating the amount of charge that goes into your battery system. They ensure you get the proper voltage to safely charge your battery and that you don’t overcharge and damage your battery. There are two main types of charge controllers: PWM and MPPT.

PWM (Pulse Width Modulation) controllers are cheaper and simpler but are less efficient than MPPT (Maximum Power Point Tracking) controllers. MPPT controllers are more expensive but can increase the efficiency of your solar panel by up to 30%.

When choosing a charge controller, it’s important to match it with your solar panel’s voltage and current rating. Renogy offers a range of charge controllers suitable for different solar setups.

1.3: Batteries

Batteries are where your solar energy is stored. There are two main types of batteries: lead-acid and lithium. Lead-acid batteries are cheaper but heavier and less efficient than lithium batteries. Lithium batteries are more expensive but are lighter, more efficient, and have a longer lifespan.

When choosing a battery, it’s important to consider your power needs and the available space on your vehicle. Deep cycle batteries are designed for continuous discharge and recharging and are suitable for overland solar setups.

1.4: Inverters

Inverters convert the DC power stored in your battery system into AC power, which can then be used to power 110-volt appliances. There are two main types of inverters: pure sine wave and modified sine wave.

Pure sine wave inverters are more expensive but produce a cleaner and more stable AC power output. Modified sine wave inverters are cheaper but produce a less stable AC power output that can damage sensitive electronics.

When choosing an inverter, it’s important to consider your power needs and the available space on your vehicle. Renogy offers a range of inverters suitable for different overland solar setups.

Section 2: Choosing the Right Solar Setup for Overlanding

When it comes to choosing the right solar setup for overlanding, there are several factors to consider. From the type of overland rig to the power output and efficiency of the solar system, each decision will impact the overall success of your adventure. Here are a few essential tips to help you choose the right solar setup for your overlanding needs.

2.1 Types of Overland Rigs

Overland rigs come in various shapes and sizes, from trucks and vans to trailers and campers. The type of rig you have will impact the size and type of solar system you need. For example, a small van may only require a 100-watt solar panel, while a larger truck may need a 300-watt panel or more. Consider the size and weight of your rig when choosing a solar system.

2.2 Solar System Size

The size of your solar system will depend on your power needs. Determine what appliances and devices you will be using on your trip and calculate how much power you will need. A good rule of thumb is to have a solar system that can produce at least twice the amount of power you will need. This will ensure that you have enough power to run your devices and appliances, even on cloudy days.

2.3 Power Output and Efficiency

The panel voltage and the charge controller can both increase efficiency and be the largest expense. MPPT charge controllers are the most efficient on the market but only if you’re able to utilize higher voltage panels. Larger voltage panels are generally large panels used on houses. Their size doesn’t make them the best choice for an overland rig. However, a PWM controller is the least efficient and loses about 20+% of the power output of the panel from the top. So a 100-watt panel will really only be kicking out closer to 80-watts.

The balance of panel size and charge controller efficiency should be considered for the space and power needs. Sometimes it’s better to go with smaller panels on a PWM controller as a smaller lower voltage system won’t have much of an efficiency boost on an MPPT charge controller. A rule of thumb is if your system is smaller than 300-watts, PWM is a good option. Larger than 300-watts and a higher voltage system with MPPT is best.

2.4 Quality and Reliability

When it comes to overlanding, quality and reliability are crucial. Look for solar kits, models, and manufacturers with a good reputation for quality and reliability. You don’t want to be stranded in the middle of nowhere with a faulty solar system. Invest in a high-quality solar setup that will last for years to come.

Section 3: Components of an Overland Solar Setup

When it comes to setting up an overland solar system, there are four main components that are essential to consider. These components include solar panels, charge controllers, batteries, and inverters. Each of these components plays a crucial role in the overall functionality of the solar system.

3.1: Solar Panels

Solar panels are the backbone of any solar system. They capture the sun’s rays and convert them into electrical energy. There are three main types of solar panels that are commonly used in overland solar setups: polycrystalline, monocrystalline, and thin-film.

Polycrystalline panels are the most affordable option and are suitable for those on a budget. Monocrystalline panels are more efficient than polycrystalline panels and are a great option for those who have limited space. But this just means that a monocrystalline will be smaller than a poly by about 15%. So don’t pass by a poly panel thinking mono is best. A 100-watt panel is 100-watt.

Thin-film panels are the most lightweight and flexible option. There are mono and poly thin-film panels that are most commonly sold, but I’d avoid these as they don’t last. If you do get one just be ready to replace it in 3 to 5 years. But there is a think film tech that is really good, but pricy, it’s called CIGS solar panels. There aren’t many suppliers but if you did want a flexible solar option that will last I’d look into CIGS flexible solar panels.

3.2: Charge Controllers

Charge controllers are responsible for regulating the amount of power that goes into the batteries. They prevent overcharging and ensure that the batteries are charged efficiently. There are two main types of charge controllers: PWM and MPPT.

PWM charge controllers are the most affordable option and are suitable for small solar systems, 300-watts and smaller. MPPT charge controllers are more efficient than PWM controllers and are a great option for larger solar systems. If your system is over 800-watts, you’ll not only want MPPT but you’ll also want higher voltage panels, 24-volts or more for best efficiency.

3.3: Batteries

Batteries are the key component in the solar power storage system. There are two main types of batteries that are commonly used in overland solar systems: lead-acid and lithium.

Lead-acid batteries are the most affordable option and have been used in solar systems for many years. They are reliable and have a long lifespan. Lithium batteries are more expensive than lead-acid batteries but are more efficient and have a longer lifespan.

Check out our RV Battery Basics Guide for more info on types of batteries, how to care for them, size them, and wire them.

3.4: Inverters

Inverters are responsible for converting the DC power stored in the batteries into AC power that can be used to power appliances. There are two main types of inverters: pure sine wave and modified sine wave.

Pure sine wave inverters are more expensive than modified sine wave inverters but are more efficient and produce a cleaner power output. Modified sine wave inverters are more affordable but can produce a distorted power output that can damage sensitive electronics.

Section 4: Installing an Overland Solar Setup

When it comes to installing an overland solar setup, there are a few key decisions to make. In this section, we’ll explore the pros and cons of a roof rack versus a portable setup, wiring and connector options, and protection and maintenance considerations.

4.1: Roof Rack vs. Portable Setup

One of the first decisions to make is whether to mount the solar panels on a roof rack or use a portable setup. A roof rack can be a convenient option if you have a sturdy, flat surface to mount the panels on. However, it can also add weight to your vehicle and make it more top-heavy, which can affect handling and fuel efficiency.

A portable setup, on the other hand, can be more versatile and easier to set up and take down. You can position the panels to maximize sun exposure, and you can move them around if you need to park in the shade. However, a portable setup can take up valuable storage space in your vehicle, and you’ll need to secure the panels when you’re driving.

4.2: Wiring and Connector Options

When it comes to wiring and connector options, there are a few things to consider. Most solar panels use MC4 connectors, which are a standard in the industry. You’ll need to make sure your wiring and connectors are compatible with your solar panels and charge controller.

You can use clamps or plug-n-play systems to connect the panels to your vehicle’s battery. Make sure you use the appropriate gauge wire for your setup, and consider using a fuse or fuse box to protect your system from overloading.

4.3: Protection and Maintenance

Finally, it’s important to think about protection and maintenance for your solar setup. You’ll want to make sure your panels are securely mounted and protected from damage while you’re driving. You may also want to consider adding a cover or shade to protect the panels from harsh weather conditions.

Regular maintenance is also important to ensure your system is working properly. Check the wiring and connectors for signs of wear or damage, and clean the panels regularly to maximize their efficiency.

Section 5: Maximizing the Benefits of Overland Solar Setup

When it comes to overland solar setup, maximizing the benefits is key. Not only does it provide access to electricity in remote locations, but it can also help with food and water preservation, navigation and communication, shelter and sleep, first aid and emergency, and entertainment and comfort. Here are some tips to help you make the most of your overland solar setup.

5.1: Access to Electricity

One of the main benefits of overland solar setup is access to electricity. This can be used to power a variety of devices, including laptops, cell phones, and portable solar power stations. By having a reliable source of power, you can stay connected and productive even in remote locations.

5.2: Food and Water Preservation

Overland solar setup can also help with food and water preservation. By using a fridge or fridge-freezer powered by solar power, you can keep your food and drinks cold and fresh for longer periods of time. This is especially important when traveling in hot and dry climates where access to fresh food and water may be limited.

5.3: Navigation and Communication

Navigation and communication are also important when traveling off-road. By using GPS and cell phone technology, you can stay on track and communicate with others even in remote locations. Text messaging is a great way to stay in touch without using too much battery power.

5.4: Shelter and Sleep

Overland solar setup can also help with shelter and sleep. By using a solar-powered air compressor, you can inflate your air mattress and sleep comfortably in your tent. Solar-powered lights can also help illuminate your campsite and provide a sense of security.

5.5: First Aid and Emergency

First aid and emergency preparedness are crucial when traveling off-road. By having a solar-powered fire starter and emergency radio, you can quickly start a fire and communicate with others in case of an emergency. A dual battery setup can also provide backup power in case of an emergency.

5.6: Entertainment and Comfort

Finally, overland solar setup can provide entertainment and comfort. By using solar-powered speakers and charging stations, you can listen to music and charge your devices while enjoying the great outdoors. The Yeti line and solar generators from Renogy are great options for those who want to bring some of the comforts of home with them on their overland adventure.

Overall, overland solar setup can provide a variety of benefits for those who love to travel off-road. By following these tips and using the right equipment, you can make the most of your overland solar setup and enjoy a comfortable and convenient adventure.

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