DIY Solar Combiner Box

Installing an array of solar panels for a dwelling is a smart move as the cost of traditional energy production and provision gets ever higher. Creating a significant solar energy system will usually involve a large number of photovoltaic panels and hence more string inputs. This wiring connects the solar panels to the inverter or the charge controller in the system. A solar combiner box is a simple construction that is used to collect multiple wiring, combine them and then convert them into a single set of wires that can be fed into the next part of the electrical circuit.

Ground Bar
Plastic box with ¾-inch openings at either end
Plastic box top with screws
Color-coded electrical wiring
Hacksaw
Superglue

Instructions

- 1
  Evaluate the best position for the placement of your combiner box. Usually, this would be as close as feasibly possible to the solar panels, allowing you to cut down on the amount of wiring needed.
- 2
  Work out how many input strings you have and acquire the necessary size of ground bar needed for the job. Cut ground bar into two equally-sized lengths to fit inside the plastic box.
- 3
  Mark the positions of where you want to place the ground bar before glueing.
- 4
  Glue the two pieces of ground bar into the box. Place them parallel to each other onto the base of the box in vertical orientation to the two box holes.
- 5
  Gather all positive wiring from the solar panels and run through the top of the plastic box, securing all to the same piece of ground bar. Ensure there is at least one ground bar hole left over for the combining wire.
- 6
  Repeat the process with the negative panel wires, but this time connect the wiring to the "negative" ground bar.
- 7
  Seal the box by screwing on its plastic top and then secure in your chosen location. Finally, run the single negative combined wire and positive combined wire down to your inverter or charge controller.

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