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5kW 48V Workshop Solar Wiring Diagram PDF (5S2P)

Computed 5kW 48V workshop solar diagram: 5S2P array, wire gauges, OCPD, battery arrangement, routed parts and printable files.

5kW 48V Workshop Solar Wiring Diagram PDF (5S2P) showing 5S2P panels, MPPT controller, 4S1P battery bank, wire gauges and OCPD ratings
Computed from the values printed in the schedules below; not a permit set.
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View the scalable diagram inline5kW 48V Workshop Solar Wiring Diagram PDF (5S2P)Computed 5S2P schematic for a 5 kW 48 V workshop system, including wire and OCPD labels.FIG. OGA-LIBRARY-0935kW 48V Workshop Solar Wiring Diagram PDF (5S2P)COMPUTED FROM OGA CALC-CORE · NOT A PERMIT SET8 AWG · 40 A OCPD · 1.07% drop3/0 AWG · 150 A OCPD · 0.20% drop1 AWG · 110 A OCPD · 0.11% drop10 × 500 W panels5S2P · 260 Voc / 23.6 IscCombiner2 stringsDC disconnect40 A DC ratedMPPT controller131 A min · 400 V max150 A OCPDController output4 × 100 Ah LiFePO₄4S1P · 5120 Wh bank110 A OCPDInverter feed3600 W inverter7200 W surge · 83.3 A DCShunt83.3 A monitored returnGround busEquipment groundingarray → controller8 AWG · 40 A OCPD · 1.07% drop41 ft one way · Coppercontroller → battery3/0 AWG · 150 A OCPD · 0.20% drop6 ft one way · Copperbattery → inverter1 AWG · 110 A OCPD · 0.11% drop2 ft one way · CopperPOSITIVENEGATIVEEQUIPMENT GROUNDFAILING SEGMENTNEC 2023 Table 310.16 (60 C column) - conductor ampacityNEC Chapter 9, Table 8 - conductor DC resistanceNEC 240.6(A) - standard overcurrent-device ratingsNEC 210.19 / 215.2 - 125% continuous-load conductor sizingNEC 690.7 - maximum PV source-circuit voltageNEC 690.8 - PV source-circuit current sizingVerify equipment terminals, listings, ambient/bundling derates and local code before installation.

What this computed plan shows

Numbers, not decorative lines, define the 5kW 48V Workshop Solar Wiring Diagram PDF (5S2P). The 5S2P field connects 10 panels for 5 kW of nameplate power, 220 operating volts and 23.6 short-circuit amps. That combination gives a workshop builder a concrete starting case that can be changed in the linked customizer.

Controller sizing follows two separate limits in this workshop configuration. Power conversion calls for 131 A or more at the battery side, and cold-array allowance raises the PV check from 260 V nameplate Voc to 325 V. The selected MPPT envelope is 150 A and 400 V.

PV current is evaluated at 36.8 A for the 41 ft array run, which selects 8 AWG copper plus a 40 A OCPD. Charging current is 104.2 A across 6 ft, moving the recommendation to 3/0 AWG copper with 150 A protection. Each percentage in the table is a round-trip voltage-drop calculation.

For storage, the computed arrangement is 4S1P, assembled from 4 × 100 Ah LiFePO₄ batteries. Series connection establishes the 48 V nominal level, while parallel strings bring the bank to 100 Ah. The displayed 5,120 Wh is nominal capacity rather than a promise of daily usable energy.

The inverter contributes 83.3 A of continuous DC input at the engine’s efficiency assumption. Over a 2 ft one-way cable path, 1 AWG copper and a 110 A protective device keep calculated drop at 0.11%. Its 7,200 W surge label is recorded for equipment comparison, but the schedule must still be checked against the chosen inverter manual.

This page stays inside the verified engine boundary: every component and conductor currently returns a within verdict. A different panel label, longer run, hotter ambient or changed battery count can alter that result, so follow the customize link rather than scaling the picture by intuition. Local rules, equipment listings and inspection requirements take precedence over this planning aid.

For later comparison, keep the 5 kW array, 4S1P bank and the 41/6/2 ft one-way routes together when requesting equipment quotes or an inspection review.

Wire, protection and battery schedules

Wire schedule

SegmentDesign currentOne-way runComputed conductorVoltage dropSizing basis
array → controller36.8 A41 ft8 AWG copper1.07%156% of array Isc (NEC 690.8)
controller → battery104.2 A6 ft3/0 AWG copper0.2%controller output at 125% continuous-load ampacity
battery → inverter83.3 A2 ft1 AWG copper0.11%inverter continuous DC input at 90% efficiency and 125% ampacity

Overcurrent protection

Protected segmentRequired ampacityOCPDConductor ampacityVerdict
array → controller36.8 A40 A40 Awithin
controller → battery130.2 A150 A165 Awithin
battery → inverter104.2 A110 A110 Awithin

Battery arrangement

ArrangementChemistryUnitsUnit capacityBank capacityNominal energyNominal voltage
4S1PLiFePO₄4100 Ah100 Ah5,120 Wh48 V

Static routed parts list

Parts are computed from this passing configuration. A route appears only when the verified catalogue record proves every displayed numeric rating; all uncertain matches stay local for verification. Routed links may earn Off Grid Authority a commission at no extra cost to you.

10 × 500 W solar panelVoc 52 V, Vmp 44 V, Isc 11.8 AVerify locally — no proven catalogue match
1 × MPPT charge controllerat least 131 A output and 325 V PV inputVerify locally — no proven catalogue match
4 × 100 Ah LiFePO₄ battery4S1P bank, 5120 Wh nominalVerify locally — no proven catalogue match
1 × 3600 W inverter7200 W surge, 48 V DC inputVerify locally — no proven catalogue match
90 ft × 8 AWG Copper cableTHHN/THWN-2 copper (or UL-listed battery cable), 75°C+Verify locally — no proven catalogue match
2 × Ring/lug terminalstinned, sized for 8 AWGVerify locally — no proven catalogue match
1 × 40 A breaker / fuseDC-rated, 220 V system — must not exceed the wire's 40 A ratingVerify locally — no proven catalogue match
1 pr × Heat-shrink + ferrulesadhesive-lined, color-codedVerify locally — no proven catalogue match
20 ft × 3/0 AWG Copper cableTHHN/THWN-2 copper (or UL-listed battery cable), 75°C+Verify locally — no proven catalogue match
2 × Ring/lug terminalstinned, sized for 3/0 AWGVerify locally — no proven catalogue match
1 × 150 A breaker / fuseDC-rated, 48 V system — must not exceed the wire's 165 A ratingVerify locally — no proven catalogue match
1 pr × Heat-shrink + ferrulesadhesive-lined, color-codedVerify locally — no proven catalogue match
10 ft × 1 AWG Copper cableTHHN/THWN-2 copper (or UL-listed battery cable), 75°C+Verify locally — no proven catalogue match
2 × Ring/lug terminalstinned, sized for 1 AWGVerify locally — no proven catalogue match
1 × 110 A breaker / fuseDC-rated, 48 V system — must not exceed the wire's 110 A ratingVerify locally — no proven catalogue match
1 pr × Heat-shrink + ferrulesadhesive-lined, color-codedVerify locally — no proven catalogue match

Pre-install review steps

  1. Confirm the array and controller window: Verify that the 5S2P string plan produces 260 V open circuit and that the equipment is rated above the 325 V cold-design value.
  2. Lay out the protected DC runs: Measure the one-way paths before ordering cable, then compare them with the computed 41 ft, 6 ft and 2 ft runs shown here.
  3. Build complete battery strings: Arrange all 4 battery units as 4S1P; do not leave a partial series string in a 48 V bank.
  4. Commission against equipment instructions: Check polarity, terminal torque, DC interrupt ratings, conductor temperature ratings, ambient correction and local inspection requirements before energizing the 3,600 W inverter.

Customize or compare

Customize this diagram →

Open the parent build guide for the surrounding design context, safety notes and installation discussion.

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