11/2/22, 9:30 PM 4 Ways of reverse power flow protection in grid-connected PV systems

Yakub Ansari Dec 5, 2020 5 min read

4 Ways of reverse power flow protection in grid-

connected PV systems
Updated: Aug 10, 2021

On-gird (gird-tie/gird connected) solar power (PV) plant generates excess power when the connected load is
lesser than the power generated by the solar power plant (Power generation > Power required).

This excess power is synchronized with grid power hence it can revere the power flow. In simple words, power will
flow from the PV plant owner’s home to the connected grid [when Solar power generation > Power required by
connected load].

And if the net-meter is not installed at the PV plant owner’s home. This excess power will increase the electricity
bill of the PV plant owner.

The reason behind this is that a normal energy meter measures only the power flow through it, irrespective of the
direction of power. So normal energy meter will measure both imported and export power (reverse power) and
sum them up.

Whereas net-meter measure the input power form the gird and subtract the surplus power injected back to gird
from an on-grid solar power plant.

Also if PV plant owner is using DG (diesel generator) as reference power source [in place of gird] for on-grid (grid-
tie) inverter. This excess power of the on-gird PV plant will damage the DG set or trip its breaker [if there is any
breaker].

Related post: Why generators are rated in kVA

Do you want to learn how to synchronize DG set with an On-gird solar power plant? Here is my whole page on
"DG synchronization with grid-tie PV plant".

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11/2/22, 9:30 PM 4 Ways of reverse power flow protection in grid-connected PV systems

4 ways of reverse power flow protection for gird connected

(gird tie) PV system

#1 Use RPR (relay power relay) to isolate PV plant from the gird by means of tripping breaker or releasing
contactor, if there is any reverse power detected.

#2 Use Export limiter to limit the power generation of the grid-tie solar inverter concerning the power required by
the load.

#3 Use of PLC as an export limiter.

#4 Use Mini PLC to isolate PV plant from the gird by means of tripping breaker or releasing contactor, if there is
any reverse power detected.

Conclusion: the best solution for reverse power flow protection

These methods of reverse power flow protection for grid-tie solar power plant works with any makes of grid-tie
solar inverters like ABB, SMA, Hitachi, Consul Neowatt, Huawei, Solar Edge, Kaco, Delta, Solis, Kirloskar, polycab,
Sungrow, Growatt, Fronius, REFU Sol, Schneider, Zever solar and many more.

Solution#1

Reverse power relay for solar/ Reverse power relay protection for solar

Reverse power relay (RPR) sometimes also called as Reverse power protection relay]

Reverse power relay (RPR) for solar is used to eliminate any power reverse back to gird from on-grid (grid-tie) PV
power plant to grid or to generator by tripping either on-grid solar inverter or breaker or any contactor depends
upon the type of power distribution and a control circuit.

RPR (Reverse Power Relay) is connected at the coupling point of grid and load [In simple words between energy
meter and load].

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11/2/22, 9:30 PM 4 Ways of reverse power flow protection in grid-connected PV systems

When RPR sense any reverse power it will generate a signal, which can be used to trip any contactor or breaker or
gird-tie solar inverter [if there is an option available in solar inverter].

In simple words, the solar power plant will be completely shut down as long as there is a trip signal from RPR
(Reverse power relay).

The manual operation will be required to turn on [start] the solar power plant. In simple words, you need to start a
solar inverter on your own.

So if the load varies frequently, the solar power plant will be completely shut for most of the daytime. To use RPR
as reveres power protection successfully, you will be required and good manual monitoring on the load demands.

Also, the use of RPS will increase ROI [return of the investment] time for grid-connected solar power plants.
Because it continuously switching on and off the solar power plant.

Solution#2

Export Limiter (a.k.a Zero Export Device)

The Export limiter also is known as Zero export device or solar export limiter

The export limiter is a programmable controller with set points, which can detect reverse power flow (from home
to the grid) and control the power generation of the solar power plant.

When the export limiter detects reveres power [solar power generation > Load demand] it ramps down the power
generation of the grid-connected PV plant.

To match, load demand = solar power generation

And when the load increases, the export limiter will ramp up the solar power production accordingly.

As long as solar power generation is lower than the load demand, export limiters won't affect any change in solar
power generation. But it keeps monitoring the system.

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11/2/22, 9:30 PM 4 Ways of reverse power flow protection in grid-connected PV systems

Setpoints of Export limiter can be set between 0% to 100%. Where 5% means that the minimum 5% of load will be
served by the grid.

If the frequency of load variation is very high, we need to fix the setpoint above 0%. the suitable setpoints are 5%,
10% and 15%.

Solution#3

Use of PLC as an export limiter

PLC (like Siemens, Rockwell etc) can also be used as an Export limiter, but the problem is that they are like 3 times
expensive than export limiters and required experience in PLC to handle.

Similarly, the spare cost of PLC is much more expensive than the export limiter.

Solution#4

Use of Mini PLC as RPR

Mini PLCs are less expensive than PLC and they can also be used as a reverse power relay. You will require one
multi-function meter for the load measurement at the grid connection point. And one contactor for isolation solar

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11/2/22, 9:30 PM 4 Ways of reverse power flow protection in grid-connected PV systems

power plant from load/grid.

Mini communicate with MFM via LAN cable. And you can program mini PLC in such a way, that if any reverse
power flow is detected it [mini PLC] will send a trigger signal contactor to open it.

By opening the contactor, the solar power plant will be isolated from the grid/load.
Closing of the contactor can either be manual or a timer in the program can be used to close the contactor after
some time.

Mini PLC's are much more expensive than RPR, but they are slightly more reliable than RPR.

With Mini PLC RIO of the solar power plant will be slightly better than RPR, but you won't get much improvement
in overall operation for the plant.

Conclusion:

1. RPR are the cheapest solution, but also the most unreliable solution for reverse power protection in a grid-
connected solar power plant.

2. Mini PLC is somewhat better than RPR but still, the ROI of the solar plant will be too much higher than you
expected.

3. Since most of the reputed companies didn't make Mini PLC, it's hard to select the best Mini PLC for your
PV project.

4. Export limiter and PLC both are reliable solutions for reverse power protection in a grid-connected solar
power plant. But PLC's are 3 times expensive than an export limiter.

5. The export limiter has an inbuilt remote monitoring system, so it also saves the cost of a remote monitoring
system for a solar power plant.

If you are looking for reveres power protection for your grid-
connected solar power plants. Then Export limiters are the best
option available in the solar market.

We make a whole page on “Export limiter (a.k.a Zero Export Device)” go and checkout and it will help you will be
able to select the correct solution for your need.

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11/2/22, 9:30 PM 4 Ways of reverse power flow protection in grid-connected PV systems

Use our below Export Limiter simulator to understand the function of the Export Limiter

1. The first slider represents the amount of PV panels that can generate.

2. The second slider represents the load demand

3. The third slider represents the set point of Expoler Limiter

You can vary all these three variables and you will get

1. Output power at Solar inverter

2. Load demand

3. And Load share by grid

Power can be generated by PV Panles

0 10 20 30 40 50 60 70 80 90 100

Load Demand [kW] 

0 20 40 60 80 100 120 140 160 180 200

FORM ISN'T PAID FOR

Set Point of Export Limiter [Zero Export Device]
If you are a form owner, log in to the service
in percentage % and purchase the plan.

0 10 20 30 Create
40 a Survey
50 on WEBASK
60 70 80 90 100

Solar inverter Output [kW] 38 kW

Load Demand [kW] 40 kW

Load on Grid [kW] 2 kW

Here are some screenshots of the Remote monitoring system

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