Certification Training Course

SESSION – 2
1. On site Survey and Sizing
2. Design of a Solar PV system
3. Connection of a PV plant to the grid
 Certification Training Course

SESSION - 2: Design of a Solar PV Plant

1. The PV Systems Family
2. Sizing the PV Array
3. Effects of the Partial Shading
4. Safety of PV Inverters
5. Efficiency Measurement of PV Inverters
6. EMC Main Issues
7. Standards on PV Connectors and PV Cables
8. Design Requirements and Safety of PV Systems
9. Lightning Main Issues
10. Further Standards
11. Electric Safety and PV Systems
12. PV Array Configuration
13. PV Arrays with a Pole Earthed
14. PV Earth Fault Detection and Alarm Requirements
The PV systems
Family

3
 Design of solar PV systems
The PV systems family

SYSTEMS FOR THE POWER SUPPLY TO EQUIPMENT

4
 Design of solar PV systems
The PV systems family

PUMPING SYSTEMS FOR HOUSEHOLDS AND AGRICULTURE

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 Design of solar PV systems
The PV systems family

SOLAR HOME SYSTEMS (SHS)

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 Design of solar PV systems
The PV systems family

VILLAGE POWER SYSTEMS (DC BUS)

Indonesia
• 20 kWp PV
• 10 kW Wind
• 150 Households

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 Design of solar PV systems
The PV systems family

VILLAGE POWER SYSTEMS (AC BUS)

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 Design of solar PV systems
The PV systems family

GRID CONNECTED PV SYSTEMS

DC AC
SWITCH GRID
AC GEAR WH WH

In this Training Course only

USERS
Grid connected PV systems
are considered

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 Certification Training Course

SESSION - 2: Design of a Solar PV Plant

1. The PV Systems Family
2. Sizing the PV Array
3. Effects of the Partial Shading
4. Safety of PV Inverters
5. Efficiency Measurement of PV Inverters
6. EMC Main Issues
7. Standards on PV Connectors and PV Cables
8. Design Requirements and Safety of PV Systems
9. Lightning Main Issues
10. Further Standards
11. Electric Safety and PV Systems
12. PV Array Configuration
13. PV Arrays with a Pole Earthed
14. PV Earth Fault Detection and Alarm Requirements
Sizing the PV
Array

11
 Design of solar PV systems
Limits to capacity of Renewable Generators
A Producer who wishes to connect one or more Renewable Generators to the Distribution
System shall ensure that the sum of the Maximum Capacity of Renewable Generators
connected by the Producer in a certain Plot does not exceed:
1) The applicable share of the Total Connected Load (TCL) resulting from the application of
the table below

As per the above table, the applicable share is 100% for the first 400 kW of TCL, and
gradually decreases for additional TCL slabs in excess of 400 kW. This implies that the
Maximum Capacity of Renewable Generators connected by the Producer in a certain Plot
cannot exceed 2,080 kW.

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 Design of solar PV systems
Limits on installation
As per Shams Dubai connection conditions, A Renewable Generator should be
located entirely in the Plot where the Hosting Account is located. Renewable
Generators shall be installed on rooftops, facades, and other existing structures.
Ground mounted installations are not envisaged.

Shams Dubai standard 2.1 General Rules, clause 3 - Arrays with voltages which
exceed the above mentioned value of 1,000 Vdc (but not exceeding 1,500 Vdc)
may be allowed only for ground mounted solutions*, canopies, urban design and
any other solutions that does not involve the installation of PV modules, inverters
or other related equipment on buildings. In any case, all the equipment must
withstand the maximum voltage reached for the system, as calculated at the
minimum outdoor temperature of 0 °C.
* Ground mounted installations are not envisaged

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 Design of solar PV systems
Sizing the PV array

• PV modules are connected in series to form strings

• Strings are connected in parallel to form a PV array
• In a PV system more than one array may be present
• PV arrays may be divided into sub-arrays

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 Design of solar PV systems
Sizing the PV array

It is important that in a PV array of a grid-connected PV system:

• Each module is equipped with by-pass diodes
• PV modules have the same characteristics
• Each string has the same number of PV modules

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 Design of solar PV systems
Sizing the PV array

• By convention, the nominal power of a PV system is equal to

the sum of the nominal power of the modules in that system
• The number of modules per string depends on the
characteristics of the inverter along with the maximum system
voltage of the modules
• In PV system it is sometimes necessary to split the DC circuit in
more than one array in order to properly use all the PV modules
• Large PV systems usually make use of several inverters and
therefore in these cases several PV arrays are used

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PV Plants – Central vs. String Inverters (1)
• Single-inverter plants (also called «Central Inverter»)
 Single inverter for the whole PV array  when the PV modules are of the
same type and have the same azimuth and tilt
 Problems with shading and overcurrent protection increased
 Down of the whole PV generator, in case of failure

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PV Plants – Central vs. String Inverters (3)
• String inverter plants
 Each string is connected to its own inverter (string conversion)
 Each string operates according to its own Maximum Power Point (MPP)
 Coupling between PV modules and inverters improved
 Losses due to shading reduced
 Overcurrent protections and blocking diodes can be omitted  diode
losses cancelled
 Efficiency and reliability improved

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PV Plants – Central vs. String Inverters (4)

• Multi-string inverter plants

 More than one string is connected to the same inverter

 Inverter provided with more than one MPPT (management of single string
indipendently of the others, e.g. because made of a different number of modules -
different module layout or tilt – shading on one string)

 Only one AC output

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PV Plants – Central vs. String Inverters (5)
• Multi-inverter plants (large plants)
 PV array divided into sub-arrays
 Still possibility to group string with similar characteristics (number of
modules, layout)
 Installation and maintenance cost reduced (lower number of inverters
with respect to string inverters)
 Loss of production of only one single sub-array, in case of inverter failure

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 Design of solar PV systems
Sizing the PV array

• The voltage of the PV array shall not exceed the MPPT limits of
the inverter in any condition of irradiance and cell temperature

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Coordination between inverter and PV generator (1)

 4 Conditions must be checked, with reference to a string of NM modules:

 Uoc max (PV generator) @ 0 °C ≤ UMAX (Inverter)

The Maximum Open-Circuit (no-load) Voltage of the string, at minimum expected working
temperature (T = 0 °C  see Connection Standard), must be smaller than the maximum
input DC voltage of the inverter, but also:

 Uoc max (PV generator) @ 0 °C ≤ UMAX (PV modules)

 Umin (PV generator) @ 80 °C ≥ UMPPT min (Inverter)

The voltage at the MPP of the string, calculated at the maximum operating temperature (T =
80 °C) with G = 1000 W/m2, must be higher than the inverter working voltage at MPPT

 Umax (PV generator) @ 0 °C ≤ UMPPT max (Inverter)

The voltage at the MPP of the string, calculated at the minimum operating temperature (T =
0 °C  see Connection Standard) with G = 1000 W/m2, must be smaller than the inverter
working voltage at MPPT

22
Coordination between inverter and PV generator (3)

• Maximum Open-Circuit (no-load) Voltage

The open-circuit voltage is higher at low temperatures. The maximum open-circuit

voltage can be calculated using the module open-circuit voltage and the temperature
coefficient. The lowest expected temperature at installation site must be considered:

Uoc max = NM   Uoc + Uoc  [CtUoc  (min - 25)/100]  ≤ UMAX_INV

≤ UMAX_MOD
Uoc max = NM  [Uoc +   (min - 25)]

where:
Uoc max : Maximum PV string open circuit voltage @ min T (0°C)

Uoc: Open-Circuit (no-load) voltage of PV module

NM : number of modules for each string

CtUoc: Temperature coefficient of Open-Circuit (no-load) voltage (%/°C)

 : Temperature coefficient of Open-Circuit (no-load) voltage (V/°C)

(min - 25): Variation between minimum expected cell temperature (0 °C) and STC (25 °C)

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Coordination between inverter and PV generator (4)

• Minimum MPP Voltage

The voltage is lower at high temperatures. The minimum PV module voltage can be calculated
from the MPP voltage using the module open-circuit voltage and the temperature coefficient. The
highest expected operating temperature must be considered.

Umpp min = NM   Umpp  (0.9~1) + Uoc  [CtUoc  (max - 25)/100] 

≥ UMPPT min INV
Umpp min = NM  [ Umpp  (0.9~1) +   (max - 25)]

where:
Umpp : Voltage of PV module at maximum power
Uoc: Open-Circuit (no-load) voltage of PV module
NM : number of modules for each string
CtUoc: Temperature coefficient of Open-Circuit (no-load) voltage (%/°C)
 : Temperature coefficient of Open-Circuit (no-load) voltage (V/°C)
(max - 25): Variation between maximum expected cell temperature (80 °C) and STC (25 °C)

• Maximum Temperature
Approximately max = air_max + (NOCT – 20) / 0.8
NOCT: Nominal Operating Cell Temperature
24
Coordination between inverter and PV generator (4)

• Maximum MPP Voltage

The voltage is higher at low temperatures. The maximum PV module voltage can be calculated
from the MPP voltage using the module open-circuit voltage and the temperature coefficient. The
lowest expected cell operating temperature must be considered.

Umpp max = NM   Umpp + Uoc  [CtUoc  (min - 25)/100] 

≤ UMPPT max INV
Umpp max = NM  [ Umpp +   (min - 25)]

where:
Umpp : Voltage of PV module at maximum power
Uoc: Open-Circuit (no-load) voltage of PV module
NM : number of modules for each string
CtUoc: Temperature coefficient of Open-Circuit (no-load) voltage (%/°C)
 : Temperature coefficient of Open-Circuit (no-load) voltage (V/°C)
(min - 25): Variation between minimum expected cell temperature (0 °C) and STC (25 °C)

25
Coordination between inverter and PV generator (5)

• Maximum PV Module Current

The PV module current is higher at high temperatures. The maximum PV module

current can be calculated using the MPP current and the temperature coefficient. The
highest expected operating temperature must be considered. Due to the series
connection of PV modules within a string, the PV module current is the same as the
string current

IDCmaxSTR = IDCmppMOD(80°C) =1.25  Impp  (1 + (CtIsc  ΔT/100))

where:

IDCmaxSTR: Maximum string current

Impp: MPP current of the PV module @ STC

CtIsc : Temperature coefficient of short circuit current

26
Coordination between inverter and PV generator (6)

• Maximum Number of PV Modules per String

A string consists of a number of PV modules which ensures that the string voltage is
always below the maximum input voltage of the inverter. If the string voltage exceeds
the input voltage of the inverter, yield losses can occur due to delayed starting or to
inverter damage for overvoltage. Likewise, the maximum string voltage must not
exceed the maximum permitted system voltage of the PV modules and the maximum
MPPT voltage of the inverter

min nmaxMODSTR ≤ Umax INV / Uoc max ; nmaxMODSTR ≤ UMPPT max INV / Umpp max 
where:
nmaxMODSTR: Maximum number of PV modules per string
Umax INV: Maximum input voltage of inverter
Uoc max: Maximum PV module voltage (= Uoc as referred to min )
UMPPT max INV: Maximum MPPT Voltage of inverter
Umpp max: Maximum MPP Voltage of PV generator (as referred to min )
27
Coordination between inverter and PV generator (7)

• Minimum Number of PV Modules per String

A string should consist of that number of PV modules which ensures that the string
voltage is always above the minimum MPP voltage of the inverter. If the string voltage
falls below the minimum MPP voltage of the inverter, yield losses can occur through
suboptimal MPP tracking, or MPP tracking is not possible at all

nminMODSTR ≥ UMPP min INV / UminMOD

where:

nminMODSTR: Minimum number of PV modules per string

UMPP min INV: Minimum input voltage of inverter

UminMOD: Minimum PV module voltage (= Umpp min/ NM)

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Coordination between inverter and PV generator (8)

• Number of PV modules per string

The optimum number of PV modules must not be less than the minimum number of
PV modules per string and must not exceed the maximum number. As a rule of thumb:
the more PV modules per string, the more viable the planning of the PV array

nminMODSTR ≤ nMODSTR ≤ nmaxMODSTR

where:

nminMODSTR: Minimum number of PV modules per string

nMODSTR: Number of PV modules per string

nmaxMODSTR: Maximum number of PV modules per string

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Coordination between inverter and PV generator (9)

• String Number

With a defined total power of the PV array and a predefined number of PV modules
per string, it is possible to calculate the minimum number of strings required to
achieve the total power. The minimum number of strings can be calculated from the
ratio of the total PV array power and the power of all the PV modules of a string

nminSTR = PDCGEN / (PmaxMOD  nMODSTR)

where:
nminSTR: Minimum number of strings
PDCGEN: PV array power
nMODSTR: Number of PV modules per string
PmaxMOD: Maximum power of PV module 30
Information on Equipment Data Sheet

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 Example 1: 100 kW PV Plant

Gen PV
Total N of modules 312
N of strings 24
Modules / string 13
P module (Wp) 335
P array(Wp) 104520
Uoc single module (Vdc) 67.9
Umpp single module (Vdc) 57.3 (Voltage @ Pmax point)
Sunpower X21-335
Ct Uo %/K -0.246
Isc (A) 6.23
Ct Isc %/K 0.056
Impp (A) 5.85
UMAX Inv (Vdc) 1000
Udc activation inv (Vdc) 485
N MPPT / inv module 1
Pmax (W) 110000 ABB PVI-110.0 (2x55 kW) OK
Max Input current /MPPT (A) 123
UMPPT min 485
UMPPT max 950
String check
UocxNtot (Vdc) 882.7
N of strings 1
Modules / string 13
Uoc max @ STC 882.7 OK

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 Example 1: 100 kW PV Plant

UOC max @ 0 °C ≤ UMAX

T STC °C 25
Tese min °C 0
Uoc @ 0°C 72.08 Each module
Uoc @ 0°C TOT 936.9861 OK Condition 1
Umpp min @ 80 °C ≥ UMPPT min
Tese max °C 80
Umpp min @ 80°C 48.11 Each module
Umpp min @ 80°C TOT 625.4707 OK Condition 2

Umpp max @ 0°C 61.48 Each module

Umpp max @ 0°C TOT 799.1861 OK Condition 3
Umpp max @ 0 °C ≤ UMPPT max
Inv Current withstanding @ Tmax
No. of strings/ MPPT input 12
Impp (A) 90.4527 OK

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Information on Equipment Data Sheet

34
 Example 2: 300 kW PV Plant

Gen PV
Total N of modules 936
N of strings 72
Modules / string 13
P module (Wp) 335
P array(Wp) 313560
Uoc single module (Vdc) 67.9
Umpp single module (Vdc) 57.3 (Voltage @ Pmax point)
Sunpower X21-335
Ct Uo %/K -0.246
Isc (A) 6.23
Ct Isc %/K 0.056
Impp (A) 5.85
UMAX Inv (Vdc) 1000
Udc activation inv (Vdc) 485
N MPPT / inv module 1
Pmax (W) 330000 ABB PVI-330.0 OK
Max Input current /MPPT (A) 123
UMPPT min 485
UMPPT max 950
String check
UocxNtot (Vdc) 882.7
N of strings 1
Modules / string 13
Uoc max @ STC 882.7 OK

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 Example 2: 300 kW PV Plant

UOC max @ 0 °C ≤ UMAX

T STC °C 25
Tese min °C 0
Uoc @ 0°C 72.08 Each module
Uoc @ 0°C TOT 936.9861 OK Condition 1
Umpp min @ 80 °C ≥ UMPPT
Tese max °C 80 min
Umpp min @ 80°C 48.11 Each module
Umpp min @ 80°C TOT 625.4707 OK Condition 2

Umpp max @ 0°C 61.48 Each module

Umpp max @ 0°C TOT 799.1861 OK Condition 3
Umpp max @ 0 °C ≤ UMPPT max
Inv Current withstanding @ Tmax
No. of strings/ MPPT input 12
Impp (A) 90.4527 OK

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 Certification Training Course

SESSION - 2: Design of a Solar PV Plant

1. The PV Systems Family
2. Sizing the PV Array
3. Effects of the Partial Shading
4. Safety of PV Inverters
5. Efficiency Measurement of PV Inverters
6. EMC Main Issues
7. Standards on PV Connectors and PV Cables
8. Design Requirements and Safety of PV Systems
9. Lightning Main Issues
10. Further Standards
11. Electric Safety and PV Systems
12. PV Array Configuration
13. PV Arrays with a Pole Earthed
14. PV Earth Fault Detection and Alarm Requirements
Effects of the
Partial Shading

38
 Design of solar PV systems
Effects of the partial shading

• Seasonal and persistent shading may give rise to side effects of

magnitude greater than that initially considered
• It is always important to take into account the partial shading
when it occur for a significant time in the day and especially
when the solar radiation is high
• A PV system should never be shaded, also partially, however it
is preferable to have shadows that cover strings equally in order
to avoid or limit the intervention of the protection devices.

39
 Design of solar PV systems
Effects of the partial shading

• The PV cells protected by the same by-pass diode behave as

the most shaded cell

40
 Design of solar PV systems
Effects of the partial shading

• In case of shading the production of a weak current persists in

the cell because of the diffuse radiation that is not completely
obstructed
• In case of total shadowing the current produced is almost equal
to zero
• In both cases the voltage of the PV cell is close to the nominal

41
 Design of solar PV systems
Effects of the partial shading

• We observe that the I-V curve of a shaded array is distorted

42
 Design of solar PV systems
Effects of the partial shading

• Depending on shading, the I-V curve may have 2 or more

maxima
• Inverters should be able to single out the absolute maximum
and work in that point

43
 Design of solar PV systems
Effects of the partial shading

• A particular case is represented by PV modules placed on

equally spaced rows on a plane
• In this case a reciprocal shading must be avoided but it is also
necessary to avoid a distance too large between rows

44
 Design of solar PV systems
Effects of the partial shading

• The maximum obstruction angle is L, while the azimuthal effect

of the shading has an extention equal to the angle L

45
 Design of solar PV systems
Effects of the partial shading
• As a rule, the reciprocal shading can be considered acceptable or negligible if In
the 2-3 hours around noon at 21 December the sun height angle h is greater or
equal to the obstruction angle L
• This angle may be calculated or read on a sun-paths diagram
• It can be also estimated considering that the sun height at noon of the 21
December is h_21_Dec_Noon = 90 –(+ 23.45)
This value should be decreased of 2-3° in order to take into account the
variations of h around noon

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