Section 5

DC system electrical design

5.1 General
DC system-general requirements

Module class (BS EN IEC 61730)

● Open circuit voltage between 30 V and 1,500 V DC
● Casa A Modules thall be used

DC cables
● Cables shall be selected and erected so as mice the risk of the faults and short-circuit.
● Cable shall be double insulated, or have equivalent performance according to BS 767

Access to PV array and associated wiring and protection

● In systems with Uoc_stc>1000Vdc access to the entire PV atay and associated wiring
and protection shall be restricted to a on defined in BS IEC 62548

DC connectors
● Shall be class or equivalent construction and selected in accordance with RS EN 62852

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5.2
DC system voltage and current ratings

5.2.1
General

In the design of a PV system to determine two values.

● Maximum voltage (Udc_max)
● Current (ldc_max)
Note 1:
To account for the peaks in module voltage and current that occur due to variations in
environmental conditions (temperature etc.)
Note 2:
A multiplier is applied to the STC module parameters.
Note 3:
For systems fitted with DC power optimizers, the voltage or current output from the optimizer
may be greater than the module STC value.

5.2.2
 Voltage and current rating: crystalline silicon modules

Formula
The values of (Udc_max) and (ldc_max)can be calculated as follows

● (Udc_max) x1.2
● (ldc_max)×1.25

5.2.3
Voltage and current rating: other module types

Due to their differing characteristics, it is not possible to provide a simple pair of multipliers to
apply to modules that are not constructed using crystalline silicon cells. For such modules
installed in the UK individual calculations need to be performed as follows

Systems with other module types:

Using manufacturer's data, the values of (Udc_max) and (ldc_max) shall be calculated
assuming a minimum temperature of 15'C and a maximum irradiance of 1.250 W/m².

5.2.4
Voltage and current rating: Modules fitted with DC power optimizers

Where modules are fitted with a DC power optimizer, the voltage or current output of the DC
power optimizer may be higher than that from the individual module

Where DC power optimizers are fitted to the modules:

● Current did shall be taken as either the output of the DC power optimizer or (ldc_max)
calculated in Section 5.2.2 whichever is the greater.
● Voltage (Udc_max) shall be taken as either the output of the DC power optimizer or the
value of Upon es calculated in Section 5.2.2 whichever is the greater.
● For other systems (strings with M optimizers connected in series) the circuit shall be
rated (MxUopt_max).

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5.3
DC system: voltage considerations

The DC voltage encountered in a PV array is set by the maximum voltage of the (Udc_max)
and the number of modules connected in series. All parts of the DC array must be rated for this
voltage. All parts of the DC array circuit shall be rated to the maximum system voltage. It can be
calculated by formula.

Voltage rating: Mx (Udc_max)

where M is the number of modules connected in series.

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5.4
DC system: current considerations

The DC current encountered in a PV array is set by the current of the modules and the number
of PV strings connected in parallel.

In the subsequent calculations, the following symbols are used:

● Isc_mod: the module short-circuit current at STC
● Isc_sub_array: the sub-array short-circuit current at STC,
● Isc_areay: the array short-circuit current at STC,
● N: total number of strings connected in parallel in an array (or sub-array);
● In_string: the current rating of the string overcurrent protection device; and
● In_sub_array: the current rating of the sub-array overcurrent protection device.

For a system using standard crystalline modules where no power optimizers are fitted all parts
of the circuit (to include cables, isolators, switchgear and connectors) shall be rated to the
current values described in following formula.

● Array formed of single PV string

System part: All parts of DC circuit

Minimum current rating required:
Isc_mod x 1.25

● Multiple PV strings connected to inverter

System part: All parts of PV array circuit

Minimum current rating required:
(String)
Isc_mod x 1.25 x (N-1)
(Array)
Isc_mod x 1.25 x N
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5.5
Overcurrent protection

5.5.1
General

This Section relates to a system where the PV array provides the only source of fault.
In the subsequent calculations, the following symbols are used
● Isc_mod: the module short-circuit current at STC
● N: total number of strings connected in parallel in an array (or sub-array)
● Imod_max_ocpr: the module maximum overcurrent protection rating.

Where string overcurrent protection devices are fitted:

● For systems with one of the active conductors functionally earthed: the overcurrent
protective devices shall be installed in all unearthed conductors
● For systems without any functional earth connection: the overcurrent protective devices
are only required in one of the active conductors.

5.5.2
String overcurrent protection

String Overcurrent protection shall be fitted to all PV arrays (and sub-arrays) where:

1.35 x Imod_max_ocpr < (Ns-1) x Isc_max

Note:
This calculation applies to an array with parallel connected strings.

i. Device selection

The string overcurrent protective device shall be selected with a rated current (In) such that
following conditions are met

(a) To meet the requirements of BS ITC-62548

● In > 1.5 x Isc_mod
● In < 2.4 x Isc_mod
● In <= Imod_max_ocpr
and
(b) To meet the requirements of BS 7671
● 1.1 x Isc_max of the string <=In <=Imod_max_ocpr

ii. Device location

String overcurrent protective devices shall be located at the end of the PV string cables at the
where the strings are paralleled and overcurrent protective devices shall be readily
accessible-for example, at the string combiner box or inverter.

5.5.3
Sub-array overcurrent protection
Sub-ray overcurrent protection shall be provided if more than two sub-arrays are single inverter

i. Device selection

The sub-array overcurrent protective device shall be selected with a rated curent (such the
following conditions are met:
● In > 1.25 x Isc_sub_array
● In <= 2.4 x Isc_sub_array

ii. Device location.

Sub-array overcurrent protection devices shall be located at the end of the sub-array cabl point
where the sub-arrays are paralleled andovercurrent protective devices shall be readily
accessible-for example, at the sub-array combiner box or inverter.

5.5.4
Array overcurrent protection

Array overcurrent protection is required where the array is connected to a battery (DC coupled).

Section 5 - DC system electrical design

i. Device selection

The array overcurrent protective device shall be selected with a rated current (I.) such that both
of the following conditions are met:
● In > 1.25 x Isc_sub_array
● In <= 2.4 x Isc_sub_array

ii. Device location

Array overcurrent protection devices shall be located where the array connects to the source of
the fault current-le, at the battery connection in battery systems.Array overcurrent protective
devices shall be readily accessible.

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5.6
Overcurrent protection of grouped strings
Where the overcurrent protection rating of a PV module is much larger than its normal operating
current, it may be possible to group a number of PV stings under the protection of a single
overcurrent protective device.

This is a special case and is not possible for most typical modules.
Grouping of strings can generally only be performed where
Imod_max_ocpr > 4 x Isc_mod

Condition

Np x 1.1 x Isc_max <= In<= Imod_max_ocpr - (Np-1) x Isc_max

where:

● Isc_max: is the module short circuit current at STC.

● Np: is the number of strings in the group protected by the overcurrent protective device.
● Imod_max_ocpr: is the module maximum overcurrent protection rating.
● lg: is the current rating of the grouped string overcurrent protection device.

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5.7
Isolation and switching

5.7.1 General

The PV array shall be equipped with devices for isolation and switching according to following
conditions.

i. PV string
● For small systems isolation is achieved by suitably located plug and socket connectors.
● For large systems isolation is typically achieved using removable strings fuses in the
array combiner box

ii. Sub-array
● For small systems N/A
● For large systems isolation is typically achieved using a removable sub-array fuse or
switch disconnector.
iii. Array
● For small systems isolation is typically achieved using a switch disconnector or circuit
breaker.
● For large systems isolation is typically achieved using a switch disconnector or rated
suitably circuit breaker.
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5.8
Combiner boxes

String or sub-array combiner boxes need to be selected and erected to maintain the insulation
class afforded by the rest of the circuit. The design of the box also needs to take into
consideration segregation between positive and negative parts, so as to permit safe installation
and maintenance and to minimize the risks of arcs. The combiner box shall be rated for the
voltage and current maxima calculated for the circuit (see Section 5.2, 5.3 and 5.4).

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5.9
PV array plug and socket connections

Correctly selected and erected plug and socket connections provide a quick safe and durable
Interconnecting PV string circuits. The majority of PV modules come with a plug and socket
connection Many inverters also come with plug and socket connections as standard. The plug
and socket shall be rated for the voltage and current maxima calculated for the circuit
(see Section 5.2, 5.3 and 5.4).

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5.10
DC cables

5.10.1
Cable ratings

Within the DC circuits of a PV array shall comply with the following basic requirements;

i. Voltage rating
PV array cables shall be rated for the DC voltage maxime calculated for the circuit (Section 5.3)

li. Current rating

● PV amay cables shall have a DC current-carrying capacity of greater than the current
maxime calculated for the circuit (see Sections 5.2 and 5.4, and as required by BS 7671.
● Appendix 4 of BS 7671 contains further guidance to determine the current carrying
capacity Izc(dc) of cables under the event conditions.

iii. Environment rating

 ● Cables shall be selected to ensure that they are rated for the environment in which they
will be installed (temperature, UV, water resistance etc).
● Cables routed behind a PV array shall have a temperature rating of at least 70°C.

5.10.2
PV string cables

The cables used to interconnect PV modules (PV string cables) shall comply with BS-EN-50618
Electric cables for photovoltaic systems.

5.10.3
Cable installation

As discussed earlier in this Code of Practice, the particular nature of PV circuits (current limiting)
means that additional protective measures need to be applied to provide for fire and shock
protection.
Cables Installed within buildings may need to meet additional requirements, such as use of low
smoke and fume (LSF) cable types.

Note:
1. Solar PV DC cables (cables to BS EN 50618) shall not be directly buried in walls or
otherwise encased in the fabric of the building. Where burial in walls cannot be avoided.
2. Conductors shall be suitably protected from mechanical damage; and a plan showing
cable locations shall be provided in the system Operation and Maintenance (O & M)
manual.

Procedure for buried Solar PV DC cablels

● BurIed in the ground at a suitable depth considering the use of the area under which the
buried ( see Section E2).

NOTE 1: Standard PV cables are not suitable for direct burial as mechanical damage would be
very difficult to detect and could lead to a fire risk.

NOTE 2:Direct burial in walls or building fabric is taken to mean where cables are cast into part
of the building (for example,within plaster or concrete).

NOTE 3: Suitable methods of mechanical protection for cables concealed in walls or building
fabric may include the use of earthed metallic conduit or trunking. Cables within the metallic
containment are still required to meet the requirements for double or reinforced insulation.
NOTE 4: The requirement for double or reinforced insulation on the DC side and separation of
L+ and L- conductors (see Regulation 712.521.101 of BS 7671) precludes the use of certain
wiring systems.

5.10.4
Cable labelling

The DC cables in a PV array remain energized whenever the PV array is generating, particularly
during daylight, and much of the DC circuit will stay live even after DC isolators have been
operated. As a result DC cables need to be clearly identified.
"DC cables shall be balled PV array cable-live during daylight for equivalent)".

5.10.5
Cable sizing

To maximize the output of the solar PV system and losses in the PV array DC cables need to be
minimized.

Note: For systems of up to 50 kWp, DC cables shall be sized such that the voltage drop at the
rated power ( Vmmp, Impp) is less than 3%.

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5.11 Protection against the effects of DC insulation faults

5.11.1
Insulation faults can be the result of a wide variety of causes, including:

● Water ingress into junction boxes or PV laminates.

● Rodent or abrasion damage to cables.
● Insulation damage due to thermal, UV or wind cycling of cables or other components.
● Impact or storm damage.

5.11.2
Earth insulation resistance

A PV array needs an insulation resistance to Earth that is sufficiently high to minimize the extent
of earth leakage currents. Earth leakage currents will naturally occur in all PV arrays, primarily
from the PV modules but also from other parts such as the wiring system.

NOTE: The extent of naturally occurring leakage currents is determined largely by the size of
the PV array the larger surface area the lower the insulation resistance) Earth insulation
resistance is determined, using the principle of Ohm's Law, by applying a voltage.