Calculation methodology.
Every number the calculator produces comes from a named formula. This page documents each one — the derivation, the assumptions behind it, and where those assumptions break down.
Design philosophy
Most off-grid sizing tools give you a number without showing the reasoning. Amperage Labs takes the opposite approach — every output is traceable to a formula, every formula is visible on screen, and every assumption is documented here.
The calculator uses the standard off-grid sizing methodology taught in power electronics and renewable energy engineering: size the battery bank for autonomy and depth-of-discharge, size the solar array for daily energy replenishment with a system-loss margin, and derive the charge controller rating from the resulting array output current. This approach is conservative by design — it produces systems that perform reliably in real conditions, not just on paper.
Formulas & derivations
Battery Bank Energy
storageWh = (Daily Load × Autonomy Days) / DoD
The battery bank must store enough energy to power your load for the chosen number of autonomy days — the consecutive days of little or no solar generation your system can survive without running flat.
Dividing by Depth of Discharge (DoD) accounts for the fact that not all of a battery's rated capacity is safely usable. A 100 Ah LiFePO4 battery at 80% DoD delivers 80 Ah of usable energy; the remaining 20 Ah is held in reserve to protect the cells from over-discharge and extend cycle life. Without this correction, you would be sizing for the usable portion only and inadvertently over-stressing the battery on every cycle.
1,200 Wh/day × 2 days = 2,400 Wh needed. At 80% DoD: 2,400 / 0.80 = 3,000 Wh total bank size required.
Battery Capacity in Amp-Hours
batteryAh = storageWh / System Voltage
Battery datasheets specify capacity in amp-hours (Ah) at a given voltage. This formula converts the watt-hour requirement from Formula 1 into the Ah figure you need when specifying or purchasing batteries, using the fundamental electrical relationship Wh = Ah × V.
System voltage has a practical engineering implication beyond the maths: a 24V system stores the same energy as a 12V system using half the current. Lower current means thinner, cheaper wiring, reduced resistive losses, and smaller fuse ratings. For systems above roughly 500W, 24V or 48V is the standard choice.
3,000 Wh at 24V: 3,000 / 24 = 125 Ah. The same energy at 12V would require 250 Ah.
Solar Array Rating
solarWatts = (Daily Load × 1.3) / Peak Sun Hours
Peak Sun Hours (PSH) is the key input here. It is not the number of daylight hours — it is the equivalent number of hours per day during which solar irradiance averages 1,000 W/m², which is the standard test condition for panel wattage ratings. A 390W panel in a 4.5 PSH location produces approximately 390 × 4.5 = 1,755 Wh on a clear day before losses.
The 1.3× multiplier represents a 30% gross margin for real-world system losses that are unavoidable in practice:
- —Wiring resistance losses — current travelling through cables generates heat proportional to resistance, reducing useful power.
- —MPPT conversion efficiency — charge controllers operate at roughly 93–97% efficiency; some energy is lost in the conversion process.
- —Temperature derating — crystalline silicon panels lose approximately 0.4% of output per °C above 25°C. In warm climates, panels routinely operate at 50–65°C, reducing output by 10–16%.
- —Soiling and shading — dust, haze, bird droppings, and partial shading reduce effective panel area and output.
- —Battery charging inefficiency — lithium batteries absorb charge at roughly 95–98% efficiency; lead-acid at 80–85%.
Note that the solar array is intentionally sized to replenish one day's load. It is not scaled up to match autonomy days — that would oversize the array unnecessarily. The battery bank covers multi-day cloudy periods; the array covers the average daily replenishment requirement.
1,200 Wh/day at 4.0 PSH: (1,200 × 1.3) / 4.0 = 390 W array rating.
MPPT Charge Controller Size
mpptAmps = solarWatts / System Voltage
This formula derives the output-side (battery-side) continuous current rating — the amperage the charge controller must be capable of delivering into the battery bank at the chosen system voltage. This is the figure used to select a controller model (e.g., a 20A, 30A, or 40A unit).
MPPT (Maximum Power Point Tracking) controllers accept a higher panel string voltage and step it down to battery voltage, transferring as much power as possible during the conversion. Because of this, the panel-side input current is lower than the battery-side output current — the controller trades voltage for current. The formula above gives the output current, which is what the controller's amperage rating refers to.
Always round up to the next standard commercial rating. Running a controller at its maximum rated current continuously shortens its service life; a 20–25% headroom is good practice.
390W array at 24V: 390 / 24 = 16.25A → round up to a 20A controller.
Battery Recharge Time
rechargeDays = Autonomy Days / 0.3
This metric answers: after the battery bank has been fully drawn down over the autonomy period, how many days of average sun does it take to fully recover — while the daily load continues to run?
The derivation follows from Formula 3. Because the array is sized at 1.3× the daily load, it generates 30% more energy each day than it consumes. That daily surplus of 0.3 × Load Wh is what goes toward recharging the depleted battery. The total energy to recover is Load × Autonomy Days. So:
rechargeDays = (Load × Autonomy) / (0.3 × Load) = Autonomy / 0.3
Notice that Load cancels out — recharge time depends only on the number of autonomy days and the 30% margin built into the array sizing. This is a direct consequence of the design choice in Formula 3: a larger load with a proportionally larger array recovers at the same rate as a small system.
2 days of autonomy: 2 / 0.3 = 6.7 days of average sun to full recovery. For Lead-Acid systems with 2+ days of autonomy, this extended partial-discharge period accelerates plate sulfation — consider a generator for faster recovery.
Scope & limitations
Amperage Labs is a system-level sizing estimator. It answers the question: "how large does my battery bank and solar array need to be?" It is not a component-level design tool. The following are explicitly outside its scope:
- — Panel string configuration. Open-circuit voltage (Voc), minimum power point voltage (Vmp), temperature-corrected voltage rise, and maximum series string voltage for a given charge controller. These require your specific panel datasheet values.
- — Shading and orientation losses. Panel tilt angle, azimuth correction, inter-row shading, and horizon obstruction all affect real-world yield and require site-specific modelling.
- — Inverter sizing. VA (volt-ampere) rating, surge capacity for motor loads, and power factor correction are separate calculations based on your specific AC load profile.
- — Grid-tied and hybrid systems. Net metering, feed-in tariffs, backup power switching, and generator integration require grid-specific calculations not covered here.
- — Battery wiring configuration. How individual cells or batteries are wired in series and parallel to achieve the target system voltage and amp-hour rating is a separate step after this sizing exercise.
For accurate Peak Sun Hours specific to your location and panel orientation, use the free EU JRC PVGIS tool or Global Solar Atlas.