Understanding of Selection of cable and cable size for a solar PV Plant

By Dr. Vashishta
In a solar PV plant selection of cable, cable size and its layout are as importa
nt as selection of modules and inverter. Cables are the medium to transfer elect
ricity from module to inverter. Even scientists has take science to another leve
l but still its is not possible on the industrial scale to transfer a good amoun
t of electricity without wire/cable. So, selection of cable and cable size is v
ery important while designing a solar PV plant.
It may be noted that a typical 5 MW solar project use about 5 KM of solar cable,
hence optimizing cable size and cable routing becomes important for system desi
gner. Even if we say, 1% of energy saved through reduces cable losses; it genera
ted extra energy worth 25 Lac per annum. While selecting cable, it s important, th
at we do a right selection of conductor size. For solar projects both copper and
aluminum conductors are used, however, using aluminum has its own demerits such
as low bending strength, higher thickens and higher losses. Although we can sav
e bit of money while using aluminum conductor, but it becomes, difficult to chan
ge broken cable In the solar field and the loss of generation due to cable failu
res become critical which should be consider while selecting a cable conductor t
ype.
The operating temperature of cable affects its current carrying capacity and hen
ce, the local site conditions play very important role while selecting right siz
e of cable. Typically, the cable should be design consider the highest temperatu
re observed at the site (worst case scenario). It has been observed that cable s
izing is done at STC of the 25o C, however, we have seen in various sites, the o
perating temperature of cable goes as high as 75o C. The system voltage is also
an important factor while deciding the cable size.
If a system voltage is 600 V, the cable size for a 8 A current and losses are 2%
then cable size is of the order of 6 mm2 and if with the same voltage and curre
nt value but with only 1% of loss, if the system voltage is increased to 1000V D
C cable size can be reduced to 2.5mm2 to carry the same power.