Solar Trailer: Part 7 – DC Breaker/Combiner Box

Solar Trailer: Part 7 - DC Breaker/Combiner Box

Author: BenjaminNelson via YouTube
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Solar Trailer: Part 7 - DC Breaker/Combiner Box

on today’s video, I wire up DC circuit breakers and combine them in a box with the output going to the solar charge controller.
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00:00 Introduction
00:17 DC Breaker and DIN rail components
2:13 Combining Outputs
3:20 Panel to mount components to
5:35 Wiring
6:50 Mounting Panel to Tool Box
7:42 Next Time

This project will have two sets of solar panels – 3 connected in series – on either side of the trailer. Those need disconnects to be able to safely work on the system and NOT have voltage from the panels present. Since there are two sets of panels, we’ll use two DC circuit breakers on the input of the system. The outputs of the two breakers will be combined and then feed the input of the solar charge controller.

I installed the components on a pre-finished wood panel for ease of installation, and then mounted that panel to the side of the aluminum enclosure.

Please note: In close-ups, you might see in some shots that they are AC circuit breakers! With this brand, the AC breakers and DC breakers look nearly identical! I ordered these breakers by mail, but accidentally got the AC version. Since this was the next step in my building process, I installed the breakers anyways, so that I would have the correct spacing the breaker box, etc. I then swapped in the DC breakers once I got those. Alternating Current and Direct Current arc differently. Always make sure to use DC rated breakers on the DC side of a solar project.

This project is a bit of an experiment in building a portable, off-grid solar system using mostly what I already have. The Charge Controller is one that I’ve already had for years. The battery is made from 7 Nissan Leaf Cell modules. See the video on building the battery at:…
The inverter is a repurposed Uninterruptable Power Supply (UPS) which ran on 48V and would have originally been used in a computer server room. I’m just using the inverter portion of this unit, but it could also be used as a battery charger if I connected it to wall AC power. I used this same unit to power my house during a blackout from my motorcycle. Learn more about that at:…

Tools and Materials used in this project:
Xantrex C40 Solar Charge Controller:
(I later upgraded the charge controller to an Outback Flexmax80. Find out why in a future video: )
14S Lithium Battery (Leaf Cell Modules)
2200 Watt UPS (Recycled, Repurposed)
DC Circuit Breakers:
Circuit Breaker DIN Box:
Solar Cable:
Replacement tool box gas lifts:
DC Current/Power/Energy Multimeter Display:
Stainless Steel Cable Clips:
Anderson Disconnects:
Plug-In Electric Usage Monitor:
3/4" Pillow Block Bearings:
Weather-proof cord grip Cable Glands:
DIN Rail Terminal Block Kit:
Stainless Steel Zip Ties:
Outdoor Rated Metal 2-gang electric box:
Two-Gang Weather-proof outlet cover:
Ryobi 18V Drill:
Step Drill Bits:

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Music by:
"Shaving Mirror" Kevin MacLeod (
Licensed under Creative Commons: By Attribution 3.0 License…

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Solar Trailer: Part 7 – DC Breaker/Combiner Box
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