How To Build A DIY Solar Battery Box
Building a DIY solar battery box is your best cost-saving option if you’re looking for a portable power station that matches your solar panels. You may already be familiar with brands like Bluetti, Jackery, or EcoFlow and their bestselling product — the solar generator. These components are designed to store solar energy on demand, but their high price can be off-putting. Fortunately, you can circumvent this costly investment by building your very own DIY plug-and-play solar battery box at a fraction of the price! The building process takes only 2 hours over 7 steps. Our DIY guide also includes a cost estimate for two DIY solar battery boxes of 640 Wh and 1200 Wh for a short camping trip or a more extended off-the-grid vacation.
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What Is A DIY Solar Battery Box?
Here is a simplified electrical diagram for a solar battery box:
Solar Charger
The solar charge controller ensures safe and efficient charging of the battery with a solar panel. It ensures that the battery receives the correct voltage (12V, 24V, or 48V) and follows the proper charging profile.
We recommend the MPPT models; they are the most efficient.
Inverter
The inverter supplies power to the loads. It converts DC electricity from the battery into AC electricity usable by our appliances.
We recommend a Pure sine wave inverter. It provides clean and reliable electricity, similar to utility standards (110V, 60Hz).
Lithium Battery Pack
A lithium battery pack stores and supplies electrical energy. It consists of several modules connected in parallel and/or series to reach the desired voltage and capacity.
Lithium batteries are reliable and durable; they offer several advantages:
- Modular design
- Long life duration (4000 cycles, 10 years)
- Fast charging/discharging
- High energy density
Our build uses prismatic LiFePO4 (LFP) modules, each with a rated voltage of 3.2V. These 4 modules will link up in series to create a 12.8V lithium battery.
Material Needed For A DIY Solar Battery Box
Here are the components you’ll need for your DIY build:
Tools Needed For A DIY Solar Battery Box
Here are the tools you’ll need to build your solar battery box:
Inverter Trolleys
An integral component of a home inverter system is an inverter trolley. The spillage from your inverter battery could harm your flooring or any other items that come into contact with the battery. By housing the battery inside the trolley, an inverter trolley guards against any such harm. It is strong, roomy, effective, and constructed of durable material. The trolley typically has wheels, making it simple to move. Trolleys for inverter batteries have no screws, making installation simple. An inverter trolley also provides optimum ventilation and saves space. We at Moglix provide high-quality and durable battery trolleys from renowned brands such as Luminous, Diamond, and Microtek.
Choose the Right Inverter Trolley by Considering the Following Factors
The Size and Weight of your Inverter Battery Combo: Inverter battery combinations come in a variety of forms, dimensions, and weights. For instance, someone will need a larger inverter trolley if they have a tall tubular battery. Similar to this, you should get a larger trolley if you anticipate needing to add a battery to your current configuration. When choosing an inverter trolley, the weight of your inverter battery is also crucial. Purchase a strong trolley that can support your inverter battery combination with ease.
Material of the Trolley: Make sure your inverter trolley is made of sturdy, long-lasting material. It is significant in terms of weight but also because you want your battery to be strong enough to withstand any spills. We advise you to consider inverter trolleys made by various brands, compare the qualities and choose the one that produces high-quality trolleys utilising high-grade plastic.
Wheel Quality: Moving them is challenging since inverter batteries are constructed of heavy metals. If necessary, the inverter battery combination should be able to be transferred easily from one area to another by being placed on a sturdy-wheeled inverter trolley. In addition to making the trolley more mobile, the wheels make it simple to clean and check for leaks on the surface underneath the trolley.
Ventilation: Invest in an inverter trolley with sufficient ventilation. This is due to the fact that inverters often become hot when in charging mode. The inverter battery combination’s performance can be impacted by excessive heat, potentially damaging or breaking. Therefore, adequate ventilation is essential. Lead-acid batteries also release fumes that could be harmful to your health. The opening on inverter trolleys ensures proper airflow. By doing this, the heated air is forced to exit the system. This allows the inverter to cool down and improve the efficiency of your inverter and batteries, ensuring your family’s security.
Price: Price is a crucial consideration when looking for an inverter trolley. Choose the inverter battery that delivers the most value for money by comparing inverter trolleys from various brands. Just because an inverter battery is less expensive than others does not mean you should buy it.
Take a Look at Various Brands Selling Efficient Battery Trolley
Luminous Inverter Trolleys : Luminous introduces ultra-durable, premium-quality inverter battery trolleys, which save on storage space and improve the appearance of homes. They are roomy, effective, and built of durable, long-lasting material that remains unaffected by battery spills. Their trolley has wheels to make moving around easier. Installation is simple thanks to the screw-less design, and the open back side supports ventilation. Their sturdy, simple-to-install, and small inverter box can be installed anywhere in your house.
Diamond Inverter Trolleys : Diamond inverter trolleys are a superior collection manufactured with the assistance of their proficient specialists. Their inverter stands are renowned in the market for their great performance and extended working life. These products are created by their skillful engineers using the best materials and cutting-edge technologies. You can make your home lovely by using Diamond inverter battery trolleys, which are of the highest quality and durability. They are roomy, secure, and composed of durable, long-lasting materials that are unaffected by battery spills.
Microtek Inverter Trolleys : Microtek battery trolleys are composed of durable materials that are attractive, mobile, and safe. They give a house a classy appearance, prevent acid spills, safeguard kids’ safety, and protect the environment. Their quick-thinking experts combine premium raw materials and cutting-edge technology to create high-quality inverter stand products. Customers can purchase Microtek inverter battery trolleys at economical rates. These characteristics make these battery trolleys a fantastic choice for everyone.
Purchase Inverter Stands from Moglix for a Reasonable Price
We at Moglix work hard to provide our clients with the best goods and services. They can choose from a large selection of dependable battery trolleys for homes from reputed and well-known firms. We provide amazing deals and discounts to make sure you can purchase high-quality battery trolleys at an affordable price. You may browse our products easily and conveniently thanks to our user-friendly software. Customers can use our user-friendly website to compare the features and of several brands prior to making a purchase. We provide you with affordable inverter boxes from top manufacturers in India.
Frequently Asked Questions about Inverter Trolleys
How do you find the maximum load on a trolley?
The load weight and tare of the trolley are taken into account while calculating the loading capacity of one wheel. Even with a 4-wheel trolley, dividing by 2 or 3 depends on the fact that not all 4 wheels are always in touch with the ground.
What is the use of trolley in inverter?
The trolley is a stylish, mobile, secure object made of durable material. It is also known as an inverter battery cover or case. A trolley gives a home a classy appearance, prevents acid spills from damaging flooring, and ensures the safety of kids.
SES Large Outdoor Enclosure Standard Features
- Built to NEMA 3R design specifications
- Bright white polyester powder-coat inside and out (other colors available)
- Fabricated from.125” thick 5052-H32 aluminum
- Heavy duty stainless steel continuous hinge
- Seams are continuously welded and then sanded smooth
- Filtered or screened ventilation louvers
- Adjustable tension stainless steel padlock hasp
- Chest style, pad- or ground-mounted, and hinged-lid battery boxes feature welded skid channels Swing out door and top opening designs
- Heavy-duty, extra-thick Styrofoam insulation
- Conduit knockouts for easy connections of grid, solar or loads
- Can accommodate: Deka Unigy II, GNB Absolyte, Deka 8D Gel, Discover and SimpliPhi LiPO4 batteries.
- NEMA 4 electronics compartment available
- Pull out trays for easy installation and removal of batteries
- Mil finish aluminum, stainless or galvanized steel
- DC to AC inverters pre-wired
- DC to DC converters pre-wired
- Solar controllers pre-wired
- Polyphaser surge protection for radios
- DIN Rail for equipment loads
- Additional DC load breakers
- POE’s and other load equipment can be pre-wired and installed on backplate
Over 20 Years of Remote Off-Grid Solar Experience
Solar Electric Supply’s years of PV expertise allow us to offer a wide variety of time-tested heavy-duty aluminum outdoor rated battery enclosures for remote industrial applications including solar and UPS.
Not Just For Batteries
We offer enclosures for single and multiple batteries, solar controllers, DC to AC inverters, DC to DC Converters, POE’s and customer supplied loads.
US Air Force using MAPPS 1060AHr battery enclosures.
Utility company Class I Division 2 solar system
Solar Electric Supply specializes in supplying dealer, contractor, government and industrial accounts worldwide with reliable, cost-effective solar electric power solutions.
Contact us for sales, wholesale and expert reviews for any quantity of outdoor battery enclosures
Batteries in Series vs. Parallel: Which is Right for Me?
Stumped on whether to put your batteries in series vs. parallel? Ultimately, the method you use depends on the needs of the applications you’re trying to power.
Let’s take a look at the advantages and disadvantages of each method.
Batteries in Series: Advantages and Disadvantages
Putting batteries in series is usually the better choice for large applications that need high voltage. (Say, more than 3000 watts, for example). Higher voltage means a lower system current, so you can use thinner wiring. There will also be less voltage drop.
There’s one main disadvantage of connecting batteries in series vs. parallel. When you do this, all your applications have to function at the higher voltage. For example, if you connect two 12V batteries in series, you’ll end up with 24V. You won’t be able to power any 12V appliances unless you use a converter.
Batteries in Parallel: Advantages and Disadvantages
What’s the principal advantage of wiring batteries in parallel vs. series? Voltage stays the same, but you can run your applications longer because you’ve increased the capacity. Also, if there’s a problem with one battery, it won’t affect the others. The working batteries will continue to power your appliances.
As far as disadvantages, placing batteries in parallel can make them take longer to charge. Also, the lower voltage means higher current draw and more voltage drop. It may be difficult to power large applications, and you’ll need thicker cables.
Batteries in Series vs. Parallel… or Series-Parallel?
In the end, neither connection method is “better” than the other. Choosing to wire your batteries in series vs. parallel ultimately depends on what works best for your boat, solar setup, RV, or other power needs.
But there is one more choice. Series-parallel. This doesn’t mean you wire your batteries in both series and parallel. That would short your system!
A series-parallel connection is achieved by wiring several batteries in series. Then, you create a parallel connection to another set of batteries in series. By doing this, you can increase both voltage and capacity.
Questions about connecting batteries in series vs. parallel, or series-parallel? See if you can find the answers below, or contact our lithium battery experts here.
Series vs. Parallel Quick Answers
Does connecting batteries in parallel increase amp hours?
Yes. When you connect your batteries in parallel, you increase the amp-hour capacity of your batteries. The voltage stays the same.
For example, let’s say you connect two 12v 100ah batteries in parallel. It’ll stay a 12 volt system, but the amps will double to 200ah. And of course, the batteries will last a lot longer.
What happens when you put two 12 volt batteries in series? When you have two or more 12 volt batteries hooked up in series, you develop 24 volts, but your amps don’t change. On the other hand, if you have those 12 volt batteries wired in parallel, it’s still a 12 volt system, but the amps will increase. (See example in the section below.)
Do batteries last longer in series or parallel? Batteries last longer in parallel, because the voltage remains the same, but the amps increase. If you connect two 12v 50ah batteries in parallel, it will still be a 12 volt system, but the amps will double to 100ah, so the batteries will last longer. On the other hand, when batteries are connected in series, voltage is increased while capacity (ah) stays the same.
Can you put Lifepo4 batteries in series? It depends on the batteries – if you have Ionic batteries, chances are you can (double check though). Many Lifepo4 batteries can’t be hooked up in series, because they’ll get damaged. But most Ionic lithium batteries are capable of series connections. Not all of them are though, so please check your battery’s user manual to make sure.
Is series or parallel more powerful? A parallel circuit consumes more power. Compared to series (both having the same voltage), parallel causes much more power to be dissipated by each of the resistors.
Which is safer, series or parallel? Generally speaking, neither is safer than the other. They’re more or less equally safe. Supply voltage is the main thing that matters there.
Bison Heavy Duty Battery Enclosures
Heavy batteries demand a solar side-of-pole and chest type battery box with extra strength and durability. In some cases, ventilation is needed for not just cooling the enclosure, but also for the release of potential battery gases. Bison battery enclosures are approved by Underwriters Laboratories to provide UL certified products for both Canada and the US for NEMA 1, 3, 3R, 4 and 4X ratings.
Heavy Duty Plastic Battery Enclosures
Heavy Duty Plastic Battery Enclosures These battery enclosures are made from HDPE plastic, the same material used to manufacture the outside cases of batteries. A removable lid with handles allows easy access to the batteries for service. Enclosures for L-16s are made with a removable middle section that minimizes lifting when installing the batteries. The plastic is acid resistant and very strong, but easy to drill with a hole saw for adding conduit fittings or battery filling tubes. The hydrogen vent fitting on the lid should be extended to the exterior of the building.
Lead-acid batteries produce hydrogen gas when charging. But if the battery box is left open to vent gas in cold climates, the batteries get too cold and battery capacity is significantly reduced. A vent that solves this problem is especially important when battery boxes are placed in basements, garages and sheds. When heat rises in the structure, a low pressure area forms around the box, cool air flows into the box and gases vent into the structure. The Power Vent controls battery box venting, removing hydrogen gas while reducing cold air infiltration into the box. The Power Vent contains a gravity-operated damper that normally stays closed. When connected to a voltage-controlled relay, the fan operates only when the batteries are being charged and blows gas vapors out. Designed for battery banks under 2200 Ah and charge rates under 125 amps. Fan can be operated from the auxiliary relay on a Xantrex XW inverter, from the auxiliary relay of an OutBack FX inverter (use 12 volt-fan for all OutBack inverter voltages) or by a voltage controlled switch (sold separately). The 12/24-volt unit uses 3 watts and pushes air at 6 CFM with a 360° maximum change of direction. Dimensions: 4 diameter x 7.25 with a 2 PVC pipe socket on the inlet and outlet. The 48-volt unit uses 6 watts and pushes 8 CFM with a 360° maximum change of direction. Dimensions: 4 diameter x 10 long, with a 3 PVC pipe socket on the inlet and outlet.
Battery Enclosures / Racks Deep Cycle Batteries for off-grid or home backup.
NEC codes generally require that a battery bank has to be installed in some type of enclosure separate from the other electrical equipment. Your battery box should be sized and strong to hold the batteries allowing for air to move between the battery casing. If the battery box is located above the ground it should be in a location out of direct sunlight. Additionally the batteries should be stored in an area to avoid dramatic temperature swings if possible which will improve the life cycle of the batteries.
Batteries can be stored in appropriate boxes, on the deck (concrete) despite wives tails which advise otherwise. The battery box or enclosure may be insulated or there are cooling and or heating accessories available to protect the battery bank from extreme temperatures swings.
Battery racks should be made from ridged materials that are resistant to deterioration. If the battery bank is placed on racks, the rack should be of sufficient strength to support the bank with room to spare. Any parts in direct contact with the battery terminals should be electronically insulated. The battery storage system should also be constructed in such a way as to contain any potential spill. Pans or trays under the battery bank is a good idea if you plan on making a homemade battery box.
Because flooded lead acid (FLA) batteries produce toxic, corrosive and potentially explosive outgases, ventilation for the battery bank is a must for FLA batteries and are recommended by AGM battery manufactures. Under no circumstances should your battery bank be located in an unvented area or unprotected area where someone may accidently short circuit the battery bank.