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DIY DC combiner box
#1
On request of some people a more indepth post of my DIY solar combinerbox.
This box is designed for my solar array which is still in a building phase.
Finally I will have 12 panels in a 3S - 4P combination.
The DC combinerbox will combine all the DC currents and add some extra safety features.

It all starts with a box...



Drill 14mm holes to fit the MC4 connectors.


Installing the MC4 connector with 10 gauge wire/2.5mm.


Preparing the schottky diodes and drill holes 3.5mm and taper 4mm thread into the heat sink.



Use some coolpaste before installing them on the heat sink.


A test layout...


Wire it all up, the terminal blocks are awesome, I found it by coincidence while browsing on AE.
I used Solar cable (6mm) between terminal block and DC breaker & terminal block and surge protection device.


Terminal block, 6 in - 2 out.


Don't forget to install the fuses....



Diagram....sorry I'm not that good at it, if not clear don't hesitate to ask me a question.


Data sheet schottky diode.

These are the links to all hardware I used to build this unit. Except the enclosure & heatsink which I had lying around from previous projects.

Cap fuse holder
https://www.aliexpress.com/item/32695643760.html

I use 10A fuses
https://www.aliexpress.com/item/32946610764.html

DC breaker:
https://www.aliexpress.com/item/32940325595.html

Surge protection
https://www.aliexpress.com/item/32890590691.html

Terminal block
https://www.aliexpress.com/item/32946942889.html

High power zener diodes
https://www.aliexpress.com/item/1412597935.html

MC4 connector
https://www.aliexpress.com/item/32835142335.html

Cupper lugs between fuse holders/zener & zener/terminal block
https://www.aliexpress.com/item/32846486368.html

Used tools:
MC4 crimptool
https://www.aliexpress.com/item/32882304975.html

Wire stripper:
https://www.aliexpress.com/item/32955348322.html

Good luck building your own, and again, don't hesitate to ask questions. Feedback appreciated too.

Frank
hbpowerwall, wim, RikH And 3 others like this post
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#2
Great job, I will be copying this design, due to the price of a commercial combiner box
Franky Beuselinck likes this post
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