PV Design Basics

Aaron Liggett
Applications Engineer

Jan. 27, 2017

San Diego, CA
 PV Design Basics

The fundamentals of PV design; session will provide a basic

understanding of photovoltaic (PV) design.

What’s to come:

• Common practices
• String sizing
• Design considerations
• Safety
 Typical Grid Tied Solar System

Top Down Process

• Modules
• DC cabling
• Racking
• Inverter
• Monitoring
• Interconnection

Note: When grid power is lost the PV system will disconnect.

 Why Sizing and
Design is Important

• Do not want to exceed 100%

yearly offset
• Visually appealing
• Compensate for customers
needs/requests
• Comply with NEC and HOA
requirements
• Safety
 System Design Process

Customers usage:

• Yearly energy usage can be found

on utility bill.

Things to Consider:

• Inefficiencies in home
‒ Old appliances
‒ Lack of insulation
 System Design Process

• Total usage for the year is 10,298kWh

• Project address:
‒ 123 Main St.
Anytown, CA 95661
• Information needed for analysis:
‒ Azimuth
‒ Tilt angle
‒ Shade
‒ Customer requests
‒ System size that will fit on roof
• Remember FSB!!
• Ground mount
 PVWatts

• Now that we know the household usage

proceed to PVWatts

• Input site information

‒ Module type
‒ Array type
‒ System losses
‒ Tilt
‒ Azimuth
• http://tools.solmetric.com/Tools/RoofAzimuthTool
 PVWatts

• 1kW of solar will produce roughly 1,260kWh per year

• Take this value and divide it by the total household usage
10,298kWh/1,260kWh≈8kW solar array needed

But what can actually fit on the roof?..

 Roof Sizing

• ALWAYS account for Fire Setbacks (FSB)

‒ Roof Access—Residential with Single Ridge
‒ (IFC 605.11.3.2.2)
Single ridge needs two 3’ pathways on
array faces along edge of load bearing
exterior wall.

• After FSBs we can

only fit 18 modules

Note: FSB vary depending on structure;

please reference the IFC and consult your
local AHJ.
 Verifying Structure

• Lag screw length required

‒ Plywood decking, skip
sheathing
• Life of roof
• Snow load
• No fire damage or
broken/damaged rafters
• Confirm structure is adequate
‒ Can reference span tables
‒ Typ. Array will add 3-5 psf to
roof
‒ www.solarabcs.org/permitting
 Racking Selection

• UL 2703 for Bonding

‒ NEC Article 250 and 690 Part V
• Follow Panel manufacture spec. for
mounting
• Type of roofing
‒ Comp, Tile, Standing seam etc.,

Design tools
• actcouncil.org Source for wind and
snow loads
• SnapNrack Configurator

Don’t forget to add extra

attachments for conduit routing!
 Characteristics of Solar Modules

Temperature Effects

• PV module voltage has an

inverse relationship with
temperature, which means
that at lower temperatures,
PV modules’ voltage raises
and at higher temperatures,
PV modules’ voltage falls from
its nameplate rating.
 String Sizing Max. Voltage

Required Information Formula

REC280TP 𝑉𝑜𝑐 + 𝑅𝑒𝑐𝑜𝑟𝑑 𝑙𝑜𝑤 − 25 ∗ 𝑇𝑒𝑚𝑝 𝑐𝑜𝑒𝑓 ∗ 𝑠𝑡𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔ℎ𝑡

• Module Voc 39.2V

• Temp Coef. Voc -0.31%
o All found on module data
sheet
• Lowest record temp. -3°C
o SolarABC interactive map

Note: Residential system are not to exceed 600

VDC per NEC 690.7 (c)
 String Sizing Max. Voltage

Calculations

𝑉𝑜𝑐 + 𝑅𝑒𝑐𝑜𝑟𝑑 𝑙𝑜𝑤 − 25 ∗ 𝑇𝑒𝑚𝑝 𝑐𝑜𝑒𝑓 ∗ 𝑠𝑡𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔𝑡ℎ

• Convert temp coefficient from %/°C to V/°C

39.2*-0.31%= -0.122 V/°C

• Input all information

39.2 + −3 − 25 ∗ −0.122 ∗ 9
39.2 + −28 ∗ −0.122 ∗ 9
39.2 + 3.416 ∗ 9
42.62 ∗ 9
= 383.6𝑉 < 600V
 String Sizing Min. Voltage

Required Information Formula

REC280TP 𝑉𝑚𝑝 + (𝑀𝑎𝑥 𝑡𝑒𝑚𝑝 + 𝐴𝐷𝐷𝐸𝑅) − 25 ∗ 𝑇𝑒𝑚𝑝 𝑐𝑜𝑒𝑓

∗ 𝑠𝑡𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔ℎ𝑡

• Module Vmp 31.9V

• Temp Coef. Vmp -0.39%
o All found on module data
sheet
• Location high temp. 28°C
o SolarABC
o Use rise adder for cell temp

Note: Be sure that Min string voltage is above

inverter Min operating voltage.
 String Sizing Min. Voltage

More Calculations
𝑉𝑚𝑝 + (𝑀𝑎𝑥 𝑡𝑒𝑚𝑝 + 𝐴𝐷𝐷𝐸𝑅) − 25 ∗ 𝑇𝑒𝑚𝑝 𝑐𝑜𝑒𝑓 ∗ 𝑠𝑡𝑟𝑖𝑛𝑔 𝑙𝑒𝑛𝑔𝑡ℎ

• Max temp 28°C+25°C= 53°C

o Use Vmp coefficient -0.39%/°C or -0.124

• Input all information

31.9 + 53 − 25 ∗ −0.124 ∗ 9
31.9 + 28 ∗ −0.124 ∗ 9
31.9 − 3.472 ∗ 9
28.43 ∗ 9
= 255.8𝑉 > inverter startup voltage
 Selecting an Inverter

Inverter Data

DC input information
• 5.04kW DC
• 383.6V Max
• 255.8V Min
• ≈1:1 DC/AC ratio

AC information is provided
• 30A OCP for 240V
• NEC 690.8(B)(1)
 BOS placement

Considerations

• Don’t place inverters in direct

sunlight w/o shade covers
• Confirm with AHJ and utility
for special requirements
• Verify if Rapid Shutdown is
required NEC 690.12
• Working spaces NEC Table
110.26(A)(1)
 Interconnection

Interconnection Methods

• Breaker tie-in
o 120% rule
• NEC 2014 705.12(D)(2)
• Install breaker opposite to
main breaker.
o 100% rule
• Supply side connection
o Requires service-rated disco
• Min. 60 amp rating
o Equipment must have AIC
rating sufficient for the max.
available fault current
o IPC, double-lugged panels
 System Conclusion

Final Design

• (2) strings of (9) REC280TP

modules
o Min 255.8 VDC Max 383.6 VDC
o PV STC DC size 5.04kW
• (1) Fronius Primo 5.0-1
o DC/AC ratio ≈1:1
o OCP- 30A breaker

• Offset
o 5.04kW*1260kWh=6,350kWh/yr
o ≈61.7%
 Module Level Electronics

Microinverters SolarEdge String

Cost $$$ $$ $
Rapid Shutdown   o
Shade mitigation   -
Module level monitoring   -
Variable string lengths   oo
Max DC Voltage 60 350 600
Strings with varing tilt and azimuth   -
o Requires more equipment
oo Variable string lengths possible with multiple MPPTs
 Safety

Green Job Hazards

• Always comply with OSHA

regulations
• Only a qualified person should
perform electrical work
• Green Job Hazards
o Fall
o Electrical shock
o Heat/cold stress
• Always wear proper PPE
• Hazardous materials on site
o Asbestos
• Vermiculite
• Siding

https://www.osha.gov/dep/greenjobs/solar.html
 Resources and References

Learn More References

• NABCEP • National Electric Code (NEC)

o Reference Guide o CEC
• Imagine Solar • IFC
• Solar Living Institute • IBC
• USGBC • AEE Catalog
• UL
 Questions?

Aaron Liggett
Office: (916) 559-8823
Mobile: (916) 806-4896

Aaron.Liggett@aeesolar.com
Lumber Grade Stamp
String Sizing Max. Voltage Using
NEC Table 690.7

• Module Voc: 39.2

• Max low temp: -3°C

39.2*1.12=43.9VDC/module

43.9*9(string length)= 395VDC