
The 5-Step Solar Sizing Process
- Audit your loads. List every appliance with its wattage and daily hours of use. Multiply watts by hours for each to get watt-hours. A 60W fridge running 8 hours per day (compressor duty cycle) uses 480Wh. A 10W LED running 5 hours uses 50Wh. Add them all up for your total daily usage.
- Account for the inverter and the losses. If your loads run on AC, divide your daily usage by the inverter efficiency: at the default 92%, 3,000Wh / 0.92 = 3,261Wh a day for the array and the bank to supply. The array then loses 14% to wiring and other system losses (PVWatts' printed default), 2% in the charge controller (Victron's printed 98% maximum) and the cell-temperature factor 302 / 320: Trina's datasheet for its TSM-DE09.05 series prints 302W at NOCT (800W/m²) in its TSM-400 DE09.05 column, the module rated 400W at STC (1000W/m²), and 400 x 800 / 1000 = 320W. This chain derates the array by 1 - 0.86 x 0.98 x 0.94375 = 20.5%, beside Renogy's x1.2 for a kit it supposes is 80% efficient (a 16.7% derate) and Battle Born's additional 20 to 30 percent solar capacity (a 16.7% to 23.1% derate). Check your results against your product data or a licensed professional before acting.
- Calculate solar array size. Divide the inverter-adjusted usage by your worst-month peak sun hours and by the derated fraction: 3,261Wh / (3.83 x 0.86 x 0.98 x 0.94375) = 1,070W of solar panels at the default 3.83 sun hours. Round up to whole panels: three 400W panels give 1,200W, which make 3,656Wh a day against the 3,261Wh need, 12% above it.
- Size the battery bank. Multiply daily usage by autonomy days, then divide by the bank's nominal voltage, the depth of discharge and the inverter efficiency. A 12V LiFePO4 bank is 12.8V nominal, so 3,000Wh x 2 days / (12.8 x 0.80 x 0.92) = 637Ah, 8.2kWh of bank energy.
- Verify your charge controller. Your charge controller must handle the total panel current. Three 400W panels make 1,200W, which at the 12.8V nominal voltage of a 12V LiFePO4 bank is 1,200 / 12.8 = 94A, inside the rating of a 100A MPPT controller.

Example: Sizing a Weekend Cabin System
Consider a small cabin with these loads: LED lights (40W for 5 hours = 200Wh), a compressor fridge (50W average, runs 10 hours = 500Wh), phone and laptop charging (60W for 3 hours = 180Wh), and a water pump (100W for 0.5 hours = 50Wh). Total daily usage: 930Wh.
Take 4.5 worst-month peak sun hours as this example's input (your own site's figure is on pvwatts.nlr.gov) and the page's other defaults: a 92% inverter, 14% system losses, the 98% charge controller and the 302 / 320 cell-temperature factor. The array supplies 930 / 0.92 = 1,011Wh a day, and one 200W panel makes 200 x 4.5 x 0.86 x 0.98 x 0.94375 = 716Wh, so the calculator sizes two 200W panels (400W), which make 1,432Wh a day, 42% above the need.
For batteries, 2 days of autonomy at 80% DoD on a 12V LiFePO4 bank (12.8V nominal): 930 x 2 / (12.8 x 0.80 x 0.92) = 197Ah. Two 100Ah LiFePO4 batteries (200Ah total) meet this target with a small margin.
Total cost estimate as of early 2026: two 200W panels ($200-300), two 100Ah LiFePO4 batteries ($400-600), an MPPT controller rated for at least 400 / 12.8 = 31.25A, the array's current at the bank's nominal voltage ($100-150), and a 1,000W pure sine inverter ($100-200). Prices and rates on this page are our own estimates as of the date shown; they change often. Enter your own figures for a current result. Complete system: roughly $800-1,250.
Example Off-Grid System Sizes
| Array | Daily Usage | Daily Output (3.83 / 5.18 sun hours) | Battery Bank (2 days) | Example Use |
|---|---|---|---|---|
| 1 x 400W, 12V | 1,000Wh | 1,219 / 1,648Wh | 212Ah LiFePO4 (2.7kWh) | Small cabin, shed, or boat |
| 2 x 400W, 12V | 2,000Wh | 2,437 / 3,296Wh | 425Ah LiFePO4 (5.4kWh) | Full-time RV or van life |
| 5 x 400W, 24V | 5,000Wh | 6,093 / 8,240Wh | 531Ah LiFePO4 (13.6kWh) | Off-grid tiny house |
| 10 x 500W, 48V | 13,000Wh | 15,232 / 20,601Wh | 690Ah LiFePO4 (35.3kWh) | Full-size off-grid home |
Each row is this calculator at the daily usage, panel wattage and voltage shown, with its other defaults: 3.83 worst-month peak sun hours, 14% losses, a 92% inverter, LiFePO4 at 80% DoD and 2 days of autonomy. The array is the panel count it returns. Daily Output is that array's output at 3.83 sun hours and at 5.18, the annual figure PVWatts prints for Kansas City.
Worked Examples
Off-Grid Shed Workshop in Oregon
Context
Calculation
Daily usage = (1800×1) + (80×5) + (15×6) + (10×2) = 1,800 + 400 + 90 + 20 = 2,310Wh
Through a 92% inverter: 2,310 / 0.92 = 2,511Wh
Loss-adjusted: 2,511 / (0.80 × 0.98 × 302 / 320) = 3,394Wh (20% losses, a 98% MPPT controller and the cell-temperature factor 302 / 320 = 0.944)
Solar array: 3,394 / 3 PSH = 1,131W → 3 × 400W panels (1,200W)
Battery bank (2 days autonomy): 2,310 × 2 = 4,620Wh ÷ (25.6V LiFePO4 nominal × 0.80 × 0.92) = 245Ah at 24V
Interpretation
Three 400W panels provide a 6% buffer over minimum in Oregon's overcast winters. The 245Ah requirement at 24V means three 100Ah 12V batteries in series pairs (6 batteries total for 24V 300Ah) gives comfortable headroom.
Takeaway
For a workshop with intermittent high-draw tools, make sure your inverter handles the table saw's startup surge. Use our battery size for inverter calculator to confirm the battery bank can deliver peak current without voltage sag.
Grid-Down Emergency Backup in Texas
Context
Calculation
Daily usage = (150×10) + (30×24) + (60×6) + (20×3) = 1,500 + 720 + 360 + 60 = 2,640Wh
Through a 92% inverter: 2,640 / 0.92 = 2,870Wh
Loss-adjusted: 2,870 / (0.78 × 0.98 × 302 / 320) = 3,978Wh
Solar (winter): 3,978 / 3.5 = 1,137W → 3 × 400W panels (1,200W)
Battery (3 days autonomy): 2,640 × 3 = 7,920Wh ÷ (12.8V LiFePO4 nominal × 0.80 × 0.92) = 841Ah at 12V
Interpretation
For 3 days without sun, the battery bank is substantial: nine 100Ah batteries at 12V. That's heavy and expensive. Reducing autonomy to 2 days cuts the bank to 6 batteries. At 3.5 winter sun hours the 1,200W array makes about 3,030Wh a day against the 2,870Wh the loads draw through the inverter, a surplus of about 160Wh a day, so after an outage the bank refills slowly in winter.
Takeaway
An emergency backup system with 3 autonomy days needs serious battery capacity. After sizing, check the solar battery charge time calculator to verify your panels can recharge fully between outage events.
Frequently Asked Questions
Glossary
Autonomy Days
The number of days a battery bank can power your loads without any solar input. Higher autonomy means more batteries and cost, but greater resilience during extended cloudy periods or storms.
System Voltage
The nominal voltage of the battery bank. Victron's RV solar sizing article lists 12V, 24V or 48V. The same power draws half the current at twice the voltage.
Loss-Adjusted Usage
The energy your panels must be rated to make: your daily usage divided by the inverter efficiency and by the array's derate for the system loss, the charge controller and cell temperature. At the defaults that is 1 / (0.92 x 0.86 x 0.98 x 0.94375) = 1.37 times the raw usage: 1.09 for the 92% inverter and 1.26 for the array chain.
Charge Controller
An electronic device between the solar panels and battery bank that regulates charging voltage and current. In Victron's worked example, a 100W panel at 25°C cell temperature charging a 13V battery, with 0.5V lost in the cabling and controller, gives 81W through a PWM controller, 19% less than the 100W through an MPPT controller. At 75°C cell temperature Victron finds the difference negligible.
Check whether your planned battery bank can handle your loads with our battery runtime calculator.
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A properly sized off-grid system balances panel output, battery storage, and realistic loss factors. Undersizing any one component creates a bottleneck that drags down the whole system. When in doubt, round up: some spare panel capacity costs far less than running a generator every cloudy week. To convert your panel wattage into the amps your wiring and fuses need to handle, run the numbers through the solar watts to amps calculator.
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Last updated:
Written and maintained by Dan Dadovic, Commercial Director at Ezoic Inc. & PhD Candidate in Information Sciences. On the energy side, Dan has hands-on experience with residential solar panel installation, DIY battery bank construction, off-grid power systems, wind power, and EV ownership/driving, all from building, maintaining, and operating his own systems.
Disclaimer: Calculator results are estimates based on theoretical formulas. Actual performance varies with temperature, battery age, load patterns, and equipment condition. For critical electrical work, consult a licensed electrician.
Methodology reviewed by Doc. dr. sc. Damir Topić, Assistant Professor, FERIT Osijek.