Solar panel installation roof wiring

Hi

Quite a few posts recently have mentioned the removal of the roof lockers to route wiring from roof mounted solar panels. This seems to me to be very invasive for routing just a couple of wires, indeed, if I really wanted to avoid what is coming next, I'd route through the tops of them rather than remove them, especially if paying AS to do so!!

See pics below, some will have seen them before....

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I have used half round cable ducting, the type for routing TV aerial/broadband etc cables. I used half round to keep it neat and, where running at 90degs to the roof, for at least some aerodynamics!

It comes self adhesive, but I run a fine bead of sikoflex either side of the self adhesive strip. With that in place it'll never move.

The first pic shows the routing on my Duo, the cables then run through the roof gland behind the microwave, then down to the leisure battery.
Other layouts will differ, of course, but the aim should be to achieve a near vertical run behind the driver seat down to the footwell in the door.

Second pic shows the bend radii of the cables being strictly adhered to. The bend radius will be quoted for the cables used will be somewhere in the spec, in my case 30mm. The cable trunking is also seen in this pic. There is no attempt to use corner joiners, they are available but too small a bend radius, instead the bends are open as seen, the two cables held together with cable ties.

My cable run is quite short, if yours needs to be longer, then running the cable trunking along the base of the roof rail would be a good place, and, near invisible too. Incidentally, my Duo is silver, so I sprayed the trunking wheel silver in the garage before installation, this makes it even less visible.

I used extension cables, also from my supplier, Photonic Universe, this gave me the correct plugs/sockets for the join, and, of course, totally waterproof, they are internally sealed with O rings. The other end of these is bare wire.

The cable gland is also glued down with sikaflex, the holes through the roof have rubber grommets in them where the cables run through, this is essential to prevent the insulation being abraded in future.

Once inside the vehicle, the wires run behind the microwave, it has to be removed which is a great opportunity to fasten it back down in a more civilised way then running thin self tapping screw through its bottom as done by AS. Where they emerge, pics 4&5, is the only place they are currently seen, this will, one day, be hidden by a trim part yet to be made!. They then run into more cable trunking, this time square in section to run them down vertically behind the driver seat then into the door footwell, en route to the leisure battery, via, of course, the solar controller.

Other models will vary, but, as far as I know, all the Boxer vans have the LB under the driver seat, so the final routing can be the same as mine. For those with the Sussex Duo, with the roof mounted AirCon, Photonic do long and narrow 50w solar panels, "

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 which can fit either side of the aircon, connected in series to give 100w. Then the wiring will be more complex hence this post which would make it much easier than internal invasion!

From the footwell to the battery is another post if anyone wants me to include it, but it is simple and fairly obvious.

Hope this helps

IanH  

I ran my cables almost the same way, but later Duo's if like mine have the LB under the bed at the rear of the van. A quick call to Mark and I was given the best route, without removing any lockers, just ran down inside one and then tucked the cable behind the side trim, I did have to remove it, but a simple job.

I did find a connection already on the inbuilt solar controller, which when I enquired was told to discard it as the other end is behind the wardrobe! and was advised not to try and remove it.

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Richard

Thank you IanH for the comprehensive explanation of how you routed your SP cables etc. I take your point of routing through the top of the roof locker, if necessary, rather than having the pain of removing them. Same as Richard, the LB is under the o/s bed but thankfully near the front, near and behind the drivers’ seat. So no problems there

Thanks IanH for your post.
It's given me the information I need but to move the round arial on the roof from the off  side to the near side. I'll use the ducting, gland and sikaflex ideas that you've used So thanks.

Windy

Just thought I'd add to the thread following installation of solar panel at AS factory. The only empty space on the roof of a Sussex, due to air con unit and aerial at front drivers side, was behind the air con and forward of rear rooflight. Expecting to have lockers removed, as was explained by Mark at AS, the fitters have routed it down behind the offside rear corner upholstered pillar, through the floor and then run cabling under van bringing it back into the battery compartments. Controller is mounted on the inside of back panel of sofa. Tried to take photo of roof but cannot get good view of whole roof, just the location of the panel...

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