Lecture

Solar PV System Design, Installation, and

Performance
Solar Inverters, Cables, and System Design
Types of Inverters:-

 Off-Grid Inverters
 On-Grid Inverters
 Hybrid Inverters

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Inverters
OFF-Grid Sine Wave Inverters

RATING 4 KVA
Efficiency 90%
Surge Rating 8KVA
DC Input Voltage 24V ; 48V
DC Input Voltage Range 21-33V, 42-66V
Reverse, under and over
Input Protection
voltage
Sort Circuit, over load and
Output Protection
over temperature
Output waveform Pure sine wave
Output Frequency Selectable 50 or 60Hz
Remote control Power ON/OFF
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Inverters
Hybrid Inverters

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Inverters
Hybrid Inverters
• Pure sine wave inverter
• Efficiency = 90-93%
• Max PV array Voc = 500V DC
• MPPT Range = 140V to 450V
• Max PV Array Power = 5000W
• Battery Voltage =48V DC
• Surge Power = 1000VA
• Max Solar Charge Current = 60A and 80A
• Max AC Charging Current = 60A
• Display and Monitoring
Axpert VM III
• Parallel operation with up to 7 units 1.5/3/5KVA
• Overload, Reverse and short circuit
protection
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Inverters

ON-Grid Sine Wave Inverters

A Grid-tie inverter takes electricity generated by the renewable

energy system and sends it to the power distribution panel in
your home or office. From there, the power may be used by
loads within your home or if not needed it will be redirected to
the utility grid.

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 Inverter’s Standards
• IEC 62109-1:2010 (Safety of power converters for use in
photovoltaic power)
• IEC 60068-2 (Environmental Testing)
• IEC 62116 (Test procedure of islanding prevention
measures for utility-interconnected photovoltaic inverters)
• 2004/108/EC EMC (IEC 61000-6-2/4)

https://www.youtube.com/watch?v=Zla5vDsiKbo&t=551s

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Cables and Wiring

For DC systems, cable diameters are very important.

The bigger the load (W) and the longer the distance (m), the
bigger is the required cable diameter (mm²).
Losses increase:
• if the cable is too long or
• if the diameter is too small.
Losses must be limited in order to ensure proper functionality
of the system.

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 Cables and Wiring
General Rule:
• DC requires bigger cable diameters than AC.
• 12 requires bigger cable diameters than 24, 36 or 48 (for the
transmission of same power over the same distance)

Formula for the calculation of required cable diameter A in

insert here

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• If the calculated diameter is not exactly is fitting to available
for copper cables
(38 for aluminium)

standard cables, choose the next bigger standard cable.

Standard cables:
0.5 – 0.75 – 1.0 – 1.5 – 2.5 – 4.0 – 6.0 – 10 – 16 – 25 – 35 –
50 -70 – 95 ... mm².

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Solar PV Cables

Connector Fasteners Sealing caps

s

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Mounting Structures
GROUND MOUNTING STRUCTURE Galvanized Aluminium
WITH CONCRETE PADS Frame

ROOF MOUNTING STRUCTURE WITH

CONCRETE PADS
POLE MOUNTING STRUCTURE

Must withstand 120 km/hr Wind speed

Must withstand wind and snow loads 11
Solar System Integration

Site Survey and Solar Assessment:-

• Is the space sufficient for solar system

• Is there shading any time of the day
• Is it ground mounted system or roof mounted
• Is the roof plane or curved
• Is the roof stable to bear the modules load
• What is the distance from module to inverter
• Is grid available and what are voltages
• Will it be a Hybrid or ON-Grid system
• Is there any stair to go at roof
• Is the diesel generators already present and ATS

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Solar System Integration

Site Survey And Solar Assessment:-

• Is UPS already in place

• What are kinds of loads and load behavior
• The load usage in the day and night
• Any possibility of expansion or displacement

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Module Space Requirements
Comparison of different module types

Approx. Module
Module Efficiency
Module Type Surface Area for 1
(%)
kWp (SQF)

Monocrystalline
18 ~ 19 136 ~ 134
Silicon
Bifacial or Mono
23 ~ 24 130 ~ 132
PERC
Polycrystalline
17 ~ 18 140 ~ 136
Silicon

Thin film (CIS) 10 ~ 12 190 ~ 200

Module covered area depends upon the angle, the space between each row,
and module efficiency. 14
 Module Interconnections
PV Modules in Series.
• Serial interconnection of
cells of same type leads
to a multiplication of
voltage

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 Module Interconnections
PV Modules in Parallel.
• Parallel interconnection
of cells of same type
leads to a multiplication
of current.

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 Module Interconnections - Array

Modules can be connected in series and

parallel.

It is mandatory to use always the same type

of modules in an array.

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Module Interconnections - Array
Selection of modules and array design are first determined by the
specific application and power demand.

(1) Power demand: 600 W (2) Power demand: 600 W

Voltage required: 12 V Voltage required: 24 V
• PV Modules (12 V): • Array design:
– Option a: 12x50 W – 2 x (3 x 100 W) in serial
– Option b: 6x100 W (option b)
– Option c: 3x200 W
• Array design:
– All modules in parallel (option b)

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 Module Interconnections – Not Allowed
Parallel arrays which
are connected in serial
must be equal.
For example:
10 modules with 12 V /
50 Wp each

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 Factors Affecting Solar Performance

 Weather Conditions - Temperature, Wind load, Humidity, Clouds

 Shading and Dust
 Solar Module Orientation
 Irradiation levels
 Wrong design and Installations– Under or over design
 Quality of Solar PV Components
 User Behavior (Putting more loads than designed load, not cleaning
modules, not asking energy production, buying on cheap price, having
idea that solar is free and works for 24 hours etc.)
 Wrong cables selections and use
 Not following best practices, standards and codes
 Solar and inverter efficiency

3R ( Right Design, Right installation and Right Use) is the strategy for
long term Sustainability of the solar system.

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 Effect of Radiations
Electrical output and the current produced are directly proportional
to the level of solar irradiation.

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 Effect of Temperature
Increasing module temperature leads to decrease in power
output

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 Effect of Dust and Stints
In regions with little rainfall or with long dry seasons, dust may
accumulate on the modules and reduce efficiency by 10-25%.

Module efficiency may drop by more than 50% if 3% of module

surface are covered with dirt.

Example:
PV modules after 2 months without rain in the area of Los Angeles. Efficiency
dropped at approx. 10% (estimated by the owner).
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 Effect of Shading
Shading must be avoided !!!
• Shading from distant trees, roofs, chimneys etc. creates “soft”
or “diffuse” shadow which reduces irradiation and reduces
power output of the whole module.
When cells are connected in series, overall output is adjusted to
the output of the weakest cell.
• Hard shadow, bird drops etc., which prevent light from
reaching individual cells or groups of cells may bring power
output down to zero.

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 Failures in Solar Cells and Modules

 Broken interconnects
 Broken cells
 Corrosion
 Encapsulant discoloration
 Broken glass
 Hot Spots
 Ground faults
 Junction box and module connection failures
 Structural failures
 Bypass Diode failures
 Open circuiting leading to arcing

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 Lead Acid Batteries
Energy storage is required in most off-grid and Hybrid PV Systems.
Rechargeable lead-acid batteries are the most com common type of
batteries used for PV systems.
• Storage capacities in the range of
0.1 kWh to 100 kWh.
• Batteries are built from 2 V cells
(e.g., 6 cells for a 12 V block).
• Charging voltage is higher than battery voltage
( e.g., up to 14.5 V charging power for a 12V battery).

Grid-plate battery - AGM

Tubular plate
solar batteries Solar gel
(cell design) battery 26
 Battery Parameters
Battery capacity
The storage capacity of the battery is represented in Ampere hour or Ah. If V
is the battery voltage, then the energy storage capacity of the battery can be
Ah x V = Watt-hour. Usually, battery capacity will be specified for a given
discharge/charge rating or C rating. The actual capacity depends on operating
conditions such as load, temperature, etc.

Battery voltage
The terminal voltage during operating condition is known as nominal voltage or
working voltage. This voltage will be specified by manufactures. It may be 3V,
6V, 12V, 24V etc.

Depth of discharge (DOD) and State of charge (SOC)

It gives a measure of energy withdrawn from a battery as a percentage of its
full capacity. The state of charge of a battery is the difference between the full
charge and the depth of discharge of the battery in percentage. If the DOD is
25% then the state of charge is (100 - 25) = 75%.

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Battery Parameters

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Battery Parameters

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Battery Parameters

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 Types of Batteries
Lithium-ion battery

• The energy density of Li-ion batteries is 3

times that of Pb-acid batteries.

• The cell voltage will be 3.5V, and few cells

in series will give the required battery
voltage.

• The lithium electrode reacts with the

electrolyte creates a passivation film
during every discharge and charge
operation. This is compensated by the
usage of thick electrodes. Because of this
fact, the cost of Li-ion battery is higher
than NiCd batteries. Further overcharging
damages the battery. 31
 Solar Battery Standards
• IEC 60896 – Stationary Lead Acid Batteries – Valve Regulated
Batteries
• IEC 61427 For Renewable Energy Applications

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 Charge Controller
Matching voltage of the PV array and the systems to that of the battery.
During times of high irradiance &
– Charge voltage must be higher low temperature (e.g. 0°C), MPP of
than battery voltage. the PV array may increase up to ~21
– Standard example: V, MOC up to ~25V.
Therefore, the battery must be
• Battery nominal voltage:12V protected
• Charge voltage: up to 14.5 V against overcharging.
• PV nominal voltage: 15-18 V During times of low / no irradiance,
PV voltage breaks down and the
(e.g., NOCT = 45°C) battery starts to discharge via the PV
– Discharge voltage is decreasing array.
while the battery is discharging Protection against self-discharging via
(discharge current stays almost the PV array, increases overall
constant). efficiency of the system.
Deep discharge is reducing battery
lifetime dramatically.
Therefore, a specific discharge cut-
off voltage is to be respected in
order to save battery life.
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 Charge Controllers
MPPT Charge Controllers:

• An MPP tracker essentially consists of a regulated DC/DC

converter.
• MPP power is determined every few minutes.
• The DC/DC converter is the set so that it takes the optimum
power from the PV array and adjusts it to the charge voltage of
the battery.
• In this way, optimum use is made of the available solar energy.
• MPP charge controllers are useful in combination with larger PV
arrays or when using high voltage modules/arrays

MPP Tracking Solar Charge Controller 10

Amp 12/24V 34
 Charge Controllers
MPPT 60A Charge Specifications Data
Controllers Nominal System Voltage 12/24/36/48 AUTO
12/24/36/48V Nominal Battery Current 60A
Battery Input Voltage range 8V to 68V
Maximum PV Open 180V
Circuit Voltage
Max input Power 1600W/24V
2400W/36V
3200W/48V
Self Consumption 1.4 to 2.6W
Ambient temp range -25C to + 55C
Efficiency 99%
Protections Over temp,
Over voltage

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 Charge Controllers
Characteristics 80A 60A
Nominal Battery Voltage 12, 24, 36, 48 or 60V DC 12, 24, 36, 48 or 60V DC
Maximum Output Current 80A at 40 Degree C 60A at 40 Degree C

PV Open Circuit Voltage 150VDC 150VDC

Maximum Array STC 24V ( 2000W), 48V ( 24V ( 1500W), 48V (
4000W) and 60V(5000W) 3000W) and 60V(3750 W)

Power Conversion 97.5% 98.1%

Efficiency

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 Charge Controller Standards
• IEC 62509:2010 (Battery charge controllers for photovoltaic systems
- Performance and functioning)
• IEC 62093:2005 (Balance-of-system components for photovoltaic
systems)

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Hybrid System Design
Total Operational Total Watt
APPLIANCE Watts QTY
watts Hours hours
FANS 100 6 600 8 4800
Energy
24 7 168 8 1344
Savor
AC 1-ton
600 1 600 6 3600
Inverter
Pump 600 1 600 2 1200
Laptop and
800 1 800 6 4800
TV
Total 2760 15740
Power 2760
Energy 15740
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 OFF-Grid System with Separate Charge Controller
Variable
DC Energy
Source PV Module
Power
and Energy Load
Solar Cable from Module to CC

Charge
Controller Battery safety
Solar Cable from CC TO
BAT
DC to AC
DC Energy Distribution
Storage Battery Inverter Board
DC Cable from AC Cable from
BAT TO INV Inverter to
load
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OFF-Grid Design

(in market 5KVA)

insert here

56
for copper cables
(38 for aluminium)
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Solar Hybrid Design
(in market 5kVA)

insert here

56
for copper cables
(38 for aluminium)

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 OFF-Grid System with Separate Charge Controller

VOC =49.5
ISc = 10.3 A

400W
Each Energy = 15740 Wh
VOC =99 V
& 2760W
ISc = 51.50A
VOC = 150 V LOAD
I Max = 60A
CC
80A/48V

5kVA

Inverter
4000W MODULE

4*200AH
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Solar PV Grid Hybrid System with Built-in Charge
Controller
Variable DC Grid
Energy Source
Energy = 15740 Wh
At 2760W
PV Module

Solar Cable from Module to Power Load

CC and Energy

DC to AC
Inverter

SC Inverter GC

DC Cable from
Battery Battery to Inverter Distribution
Board
DC Energy Storage AC Cable from
Inverter to Load
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Hybrid Solar System with Built-in Charge Controller

VOC =49.5 ISc = 10.3 A

400W
Each
4000 Wp

Grid
VOC = 300-600V Inverter
Input max = 40A Load
Output AC = 20A 5KVA
Energy = 15740 Wh
At 2760W

4 x 200 AH
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ON-Grid Solar System

Variable DC
Energy Source

PV Module
Net
Solar PV Cable Meter Grid

SOLAR
Inverter
Meter

DC TO
AC

From PV to Energy Load

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Thank You!

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