Electrical System Install for MH (Solar, Batteries, MPPT)

Complete Motorhome Solar & Electrical Installation Guide

🔋 Complete Motorhome Solar & Electrical Installation Guide

🚛 Mazda T3500 - Specifications, Components and Legal

🚚 Vehicle Specifications

  • Model: 1990 Mazda T3500 Diesel
  • Configuration: 6-berth Motorhome
  • Engine: Diesel 3.5L Non-Turbo
  • Transmission: Manual 5-speed
  • Gross Vehicle Weight: 4500kg (est. with motorhome body)
  • Alternator Output: 80A @ 14.4V

📚 T3500 Resources

🏷️ Registration Details (PE2417)

  • Plate Number: PE2417
  • Vehicle Type: Passenger Service Vehicle (Motor Caravan)
  • Make: Mazda
  • Model: T3500
  • Year: 1990
  • Engine Size: 3455cc

⚡ Electrical Systems (Click items for details)

  • Inverter: Power Train PT1000WL
  • Batteries: 4X PowerTech 100Ah SB2215
  • Solar Controller: OLYS MPPT5025A-DUO-BT
  • Solar Panels: 2x AtemPower Flexible Shingled Solar Panel 200W
  • Dual Battery Charging: BEP Digital Voltage Sensitive Relay
  • Car Alarm: Steel Mate 838G Car Alarm System

💧 Water Systems (Click items for details)

  • Water Heater: Airxcel SW4DA
  • Water Pump: Ozito PTP-012A 600L/H 12V Portable Pressure Pump
  • Fresh Water Tank: 75L Capacity
  • Grey Water Tank: 75L Capacity

🔥 Heating & Cooking (Click items for details)

  • Diesel Air Heater: LF Bros Air Heater
  • Gas Hotplate: Dometic 2 Burner Hob with Glass Lid
  • Fridge: Iceco BC49 Fridge/Freezer 49L

📊 System Overview (Click for details)

  • Total Solar: 400W (2 x 200W panels)
  • Battery Bank: 400Ah LiFePO4 (4 x 100Ah)
  • Inverter Power: 1000W Pure Sine Wave
  • Water Capacity: 150L Total (75L Fresh + 75L Grey)

📋 Legal Compliance & Camping Requirements

🔍 Certificate of Fitness (COF)

  • Frequency: Annual inspection required
  • Applies to: Vehicles over 3500kg GVM (T3500 qualifies)
  • Covers: Brakes, steering, lights, tyres, structure
  • Cost: $150-300 depending on location
  • Where: VTNZ, AA, or authorised testing stations

🔥 Gas Compliance Certificate

  • Frequency: Every 4 years
  • Covers: LPG bottles, regulators, hoses, appliances
  • Required for: Gas hotplate, gas heating systems
  • Cost: $200-400 depending on complexity
  • Who: Certified gas fitter (LPG endorsement)

🏕️ Self-Containment Certificate

  • Validity: 4 years from issue date
  • Blue Sticker: Enables freedom camping in designated areas
  • Requirements: 75L fresh water, 75L grey water, toilet
  • Cost: $100-200 for inspection
  • Standard: NZS 5465:2001 compliance required

🏞️ NZMCA Parks Access

  • NZMCA Membership: Annual fee $85 (2025 rates)
  • Benefits: Access to 400+ NZMCA parks nationwide
  • Self-Containment: Required for most NZMCA parks
  • Stay Limits: Usually 2-3 nights per location
  • Additional: Magazine, rally access, discounts

🌲 DOC Camping Requirements

  • DOC Camping Pass: Annual pass $65 (family $120)
  • Site Types: Basic ($6-15), Standard ($15-25), Serviced ($25-35)
  • Booking: Online at doc.govt.nz (peak season recommended)
  • Self-Containment: Required for most conservation areas
  • Restrictions: Vehicle length limits may apply

🗺️ Freedom Camping Legal Requirements

  • Self-Containment: Mandatory for freedom camping (Blue Sticker)
  • Location Rules: Check local council bylaws before parking
  • Time Limits: Usually 1-3 nights maximum per location
  • Apps: CamperMate, Rankers Camping for legal sites
  • Fines: $200-1000 for illegal camping

📜 Additional Legal Requirements

  • Driver Licence: Class 2 required for vehicles over 4500kg
  • Road User Charges (RUC): Required for diesel vehicles over 3500kg
  • Insurance: Third party minimum, comprehensive recommended
  • Warrant of Fitness: Every 6 months for vehicles over 18 years
  • EWOF: Only if 240V mains electrical system installed

📅 Compliance Calendar & Services

📍 Find Services Near You: Use your current location or search by address to find the nearest compliance services.

🔧 Every 6 Months: Warrant of Fitness (WoF)

Required for vehicles over 18 years old

ℹ️ WoF Info

📋 Annual: Registration Renewal & COF Inspection

Registration renewal online or at agents • COF at certified stations

💳 Renew Rego

🔥 Every 4 Years: Gas Compliance & Self-Containment

Certified gas fitters • Self-containment inspectors

⛽ As Required: RUC Purchases & EWOF

Diesel RUC purchases • Electrical WoF if 240V system

💳 Buy RUC Online

🚗 Ongoing: Licence, Insurance & Camping

Driver licence renewal • Insurance quotes • Camping permits

🆔 Licence Renewal

📝 Complete System Electrical Schematic

⚡ Professional Electrical Schematic Diagram

Diagram Legend:

This is a complete electrical schematic showing all connections, fuses, switches, and wire paths.

  • ⎯⎯⎯ Red lines = Positive (+)
  • ⎯⎯⎯ Black lines = Negative (-)
  • Cable Types:
  • ⎯⎯⎯
  • 2/0 AWG - Main Power (200A)
  • ⎯⎯⎯
  • 10 AWG - Solar Cable (30A)
  • ⎯⎯⎯
  • 12 AWG - Branch Circuit (20A)
  • ⎯⎯⎯
  • 14 AWG - Branch Circuit (15A)

System Specification:

  • System Voltage: 12V DC
  • Solar Capacity: 400W (2 x 200W Panels)
  • Engine Battery: 100Ah Lead Acid
  • House Battery Bank: 400Ah LiFePO4 (4 x 100Ah)
  • Alternator: 80A @ 14.4V
  • Dual Battery Isolator: Cut-in 13.7V, Cut-off 12.8V
  • MPPT Controller: 20A Rating
  • Individual Battery Protection: 100A Fuses

Safety Critical:

  • Master load switch disconnects all 12V appliances
  • Always disconnect battery negative before servicing
  • All fuses must be properly sized and rated
  • Battery connections require proper torque
  • Solar panel isolation required during installation

SYSTEM SPECIFICATIONS

Solar Array:
  • 2x 200W panels = 400W total
  • Voltage: 20-25V open circuit
  • Current: 20A max output
Engine Battery:
  • 100Ah Lead Acid
  • Voltage: 12.6V nominal
  • Cranking Amps: 800A
House Battery Bank:
  • 4x 100Ah LiFePO4 = 400Ah
  • Voltage: 12.8V nominal
  • Energy: 5.12kWh usable
Charging System:
  • Alternator: 80A @ 14.4V
  • Isolator: Smart, voltage sensing
  • Cut-in: 13.7V | Cut-off: 12.8V
Protection:
  • Battery fuses: 4x 100A (individual protection)
  • Master load switch: Disconnects all 12V appliances
  • Solar breaker: 20A DC
  • Inverter fuse: 200A
Wire Gauges:
  • Main: 2/0 AWG | Solar: 10 AWG
  • Loads: 12-14 AWG
MPPT Connection:
  • Always connect to battery BEFORE solar

⚠️ SAFETY CRITICAL

  • Main fuse MUST be within 7" of battery positive terminal
  • All fuses must be DC rated for system voltage
  • Connect MPPT to battery BEFORE solar panels
  • Use proper wire gauge for current capacity
  • Test all connections

Important Reminder:

Battery fuses protect each battery's positive connection to the system.

Motorhome Electrical System Schematic

PANEL 1 200W + - PANEL 2 200W + - SOLAR COMBINER 20A ISOLATION SWITCH BREAKER 20A DC MPPT CONTROLLER 20A - 12V Solar Charge Controller S+ S- B+ B- BATT 1 100Ah + - BATT 2 100Ah + - BATT 3 100Ah + - BATT 4 100Ah + - 100A BATT 1 100A BATT 2 100A BATT 3 100A BATT 4 POSITIVE BUS +12V NEGATIVE BUS GND MASTER LOAD SWITCH FUSE BLOCK 12-Circuit Distribution 10A 15A 20A 15A Lights Outlets Fridge Fans + - ENGINE ALTERNATOR 14.4V 80A + ENGINE BATTERY Lead Acid 100Ah + - DUAL BATTERY ISOLATOR Cut-in: 13.7V | Cut-off: 12.8V ENGINE AUX MPPT to Battery Connection Always connect BEFORE solar panels LED LIGHTS 10A 12V OUTLETS 15A 12V FRIDGE 20A FANS 12V 15A Smart Charging Auto-Connect CHASSIS GROUND 10 AWG Solar Cable 12-14 AWG Branch Circuits SOLAR: 20-25V DC ALTERNATOR: 13.8-14.4V DC BATTERY: 12.8V DC LOADS: 12V DC Solar: 20A Max Alternator: 80A Max DIAGRAM LEGEND Positive (+) 12V DC Negative (-) / Ground Wire Types: 2/0 AWG - Main Power (200A) 10 AWG - Solar Cable (30A) 12 AWG - Branch Circuit (20A) 14 AWG - Branch Circuit (15A) Fuses & Protection Ground Symbol Current Flow Direction 2000W INVERTER 12V DC → 230V AC Pure Sine Wave + - AC INVERTER SWITCH 200A INVERTER 4/0 AWG Inverter Cable