Small Battery Based PV System Design

48 Volt System

Appalachian State University

Christian Houpe

TEC4608-102

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I] Introduction
This is a design for a photovoltaic array that would provide electricity to my two bedroom one
bath apartment located in Boone, North Carolina. Currently two college students and a large dog reside
in the apartment using very little electricity, about 2,158 watt hours per day. I have selected a 48 V
system to offset this load. The system requires 4, 24V, 335 watt PV modules that will charge 8, 12V,
200 Amp hour, Trojan batteries.

II] Load Calculation and Sizing Results

a) Electrical Loads
Our small apartment electrical load only consists of 16 LED lights, a refrigerator, a TV, a wireless router,
a modem, an Apple TV, a record player, a fan, two iPhone chargers, and a computer charger. (All the
loads are AC loads.) Our daily apartment living on a day to day basis requires 2,158 watt-hours per day
and 50 amp-hours per day not including system efficiencies.,

Load Analysis
AC Loads
Device Hours of Days of Average
AC Device Watts daily use use per watt-hour
week per day
LED Lighting ( 16 Lights) 184 4 7 736
Refrigerator 100 7 7 700
TV 66 2 2 38
Wireless router 5 24 7 120
Modem 5 24 7 120
Apple TV 1 24 7 24
Stereo 3.5 24 7 84
Fan 43 7 7 301
Phone charger 10 3 7 30
Computer charger 40 1 1 6
Total AC watt-hrs/ day: 2158
AC to DC watt-hrs/day: 2398
(divide by inverter efficiency of 90% or .90)
Table 1: Load Analysis calculated with the Load Analysis Spreadsheet by Benjamin Root, modified by John F. Robbins 7-1-
99

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II] Solar array
a] Module Description
For this array I chose to use 4 Canadian Solar,
monocrystalline, 24Volt, 335 Watt modules that were priced at
$219.00 per module. The array itself will cost $876.00 before taxes
and tax credits. This module has the following electrical
characteristics:

Specifications
STC CS6U-335M
Nominal Max Power (Pmax) 335 watts
Optimum Operating Voltage (Vmp) 37.8V
Optimum Operating Current (Imp) 8.87A
Open Circuit Voltage (Voc) 46.1V
Short Circuit Current (Isc) 9.41A
Module Efficiency 17.23%
Maximum System Voltage 1000V (IEC/UL)
Maximum Series Fuse Rating 15A
Cell Type Mono-crystalline
Cell Arrangement 72 (6 x 12)
Dimensions 77.2 x 39.1 x 1.57in
(1960 x 992 x 40mm)
Weight 49.4lbs (22.4kg)
Connectors MC4 or MC4 Comparable
Table 1: Canadian solar CS6U module spcifications

b) Array Description
To achieve the required amperage for our apartment 2 series strings of modules must be
wired in parallel to surpass 60 amp hours per day. With 2 modules, each rated at 8.87 Imp, wired
together in parallel the array will produce 17.74 amps per hour. Boone receives about 4.5 hours of
full sun a day bringing the system amperage to 79.83 amps per day, 19.83 more amps than the
required 60A.

8.87 2
| || | = 17.74

Boone receives about 4.5 hours of full sun a day bringing the system amperage to 79.83
amps per day, 19.83 more Amps than the required 60A.

17.74 4.5
| || | = 79.83

The array will have 2, 24V modules wired in series to raise the system voltage up to 48V. These
series strings will be wired in parallel at the junction box to bring the system amperage to 17.74A.

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The PV array will wired as such:

17.74 A

TO DC JUNCTION BOX

Figure 1: PV array wiring schematic

III] Battery Bank

I have chosen to use 28 Trojan J200-RE 12V, 200AH (20HR) Premium Line Flooded Batteries.
This system will have a reserve battery life of 5 days without dropping below a 25% percent charge to
avoid damaging the cells within the batteries. To size this system I found the minimum battery
capacity (in amps) by calculating the amperage load for all five days and dividing it by 75% to ensure
the charge never drops below 25%.

60 5 300
| || |= 75% = 400

I must have a total of 400 amp hours stored in my battery bank to last 5 days without
sunlight. Because I am using 200 AH batteries I will only need 2 of them wired together in parallel

400 200
| || | = 2

Because I have a 48 volt system and my batteries are only 12 volts, I must wire four of them
together in series for each string to have a nominal voltage of 48V.

48 12
| || |=4

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 With two series strings of four batteries each this bank requires a total of 8 batteries. These
batteries cost $297.77 each bringing the battery bank cost to $2,382.16, almost three times as much
as the array itself. The batteries have the following characteristics:

Model J200-RE
Volts 12V
Capacity (A-H) 200A-H
Number of Batteries 28
Cost (without taxes) $297.77
Total Cost of Battery Bank $2,382.16
Table 3: Characteristics of J200 RE-A battery

The following drawing shows the batteries wiring:

Drawing 2: Batteries wiring

IV] Wire & OCPD Sizing

The amperage of the system must never exceed the ampacity of the wire gauge being used,
to prevent fire hazards. This happens by carefully selecting wire sizes that can handle the system
amperage at its maximum production potential and selecting over current protection devices that
dont exceed the ampacity of the wire. But the OCPD also should not limit the system by tripping or
blowing so measures must be taken to insure the devices also can handle the amperage of the
system at its maximum production potential. I will be using the Midnite Solar touch safe fuses that

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are rated for 1,000 volts with this touch safe fuse holder.
Item code Brand name Model number Volts Amps Fuse Type
MIDMNFH Midnite Solar, MNTS 1000V 30A 1000V
Inc.

a) Wires from Modules to Combiner Box

The wire connecting the modules in a series string will be #14-gauge copper wire rated at 90oC.
To determine the wire size, I calculated the amperage the modules will produce by multiplying the Isc
of 9.41 by the temperature modification factor of 1.56 to give a total of 14.68 amps in each series
string.

9.41 1.56
| || | = 14.68
.

Number 14 AWG can handle 35 Amps in a free air environment according to table 310.15(B)
(17) of the NEC, but the wires will be making a connection in the combiner box that can reach
temperatures of 141oF-158oF. To find the wires true ampacity at this temperature I multiplied the
rated amperage of 35 Amps by the temperature correction factor of .58 and figured it was 20.3
Amps, this is well over the required 14.68 Amps.

35 . 58
| | = 20.3

b) OCPD in Combiner Box

Item code Brand name Model number Volts Amps Fuse Type
MIDMNFUSE201000 Midnite MN1000FUSE- 1000V 20A Ferraz
Solar, Inc. 20 Shawmut

The over current protection device inside the combiner box must not exceed the amperage
rating of the #14 gauge wire but must have a high enough ampacity that it does not limit the system.
Number 14 gauge wire can safely handle up to 20.3 Amps at temperatures of 141oF-158oF, so our
OCPD can be no greater than 20 Amps. The modules can produce up to 14.68 Amps at maximum
efficiency, so our OCPD cannot be less than 15Amps or they will trip at peak performance and stop
the flow of electricity to the grid.

20.3 14.68
| |<| | = 15 20

c) Wires from Combiner Box to BOS Components

The wires running from the combiner box to the rest of the BOS componets will have to be larger
because they have a higher current flowing through them and they will be in conduit buried
underground. The two series strings will be wired together in parallel inside the combiner box
doubling the amperage of the system.

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 14.68 2
| || | = 29.36

Number 8 AWG can handle 55 Amps inside of conduit based on table 310.15(B) (16) of the
NEC. The parallel connection will be in the combiner box that reaches temperatures of 158oF so its
ampacity will also have to be multiplied by the temperature correction factor of .58 to find its true
limit of 31.9 Amps, which is more than the required 29.36 Amps.

55 . 58
| || | = 31.9

d) OCPD Sizing For Charge Controller Wiring

Item code Brand name Model number Volts Amps Fuse Type
MIDMNFUSE201000 Midnite MN1000FUSE- 1000V 20A Ferraz
Solar, Inc. 20 Shawmut

The over current protection devices in the DC junction box, on either side of the charge
controller, must not exceed 25 Amps (#14 AWG max ampacity) while still being able to handle 17.74
Amps (system maximum current). Because the two series strings will be wired in parallel inside the
combiner box the amperage will double calling for a circuit breaker twice the size. The breakers must
not exceed 31.9 Amps while allowing for 17.74 Amps to flow through it, bringing me to a 30 Amp
Breaker.
31.9 29.36
| |<| | = 20

e) Wire Sizing Inside DC Junction Box

The wires inside the DC junction box can be a smaller gauge because they do not have to be
temperature rated because the box will not be in the sun. The wires inside the junction box have
to be able to handle 17.74 Amps (system maximum current), #16 AWG can handle 18 Amps but I
will use #14AWG that can handle 25 Amps just to be safe.

f) OCPD Sizing for Inverter Wiring

The minimum breaker size between the inverter and the battery bank must be greater than the
maximum potential amperage of the system at the inverters cutoff voltage, but less than the
ampacity of #14 AWG wire. I chose the Context SW 4048 230 inverter. This is a true sine wave
inverter rated for 3800 watts. This inverters cutoff voltage is 40V. To size the OCPD between the
inverter and the battery bank I divided the wattage of my array (1340W) by the cutoff voltage of
the inverter (40V) and got a maximum amperage of 33.5A. This amperage is very low due the
high voltage of my array and battery bank.

1340 40 33.5
| || |=

This means the breaker between the inverter and the battery bank inside the DC junction box
must be greater than 33.5A and less than the ampacity of #10AWG (40).

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 33.5 40
| |>| |

This brings me to the Midnite Solar 40 amp fuse.

Item code Brand name Model number Volts Amps Fuse Type
MIDMNFUSE401000 Midnite MN1000FUSE- 1000V 40A Ferraz
Solar, Inc. 40 Shawmut

V] Charge Controller
I chose the morning star TriStar MPPT charge controller, priced at $478.00 before taxes that
has the following characteristics:

Morningstar TriStar PMW Charge Controller TS 45

Cost1(without
Description System Voltage Charge amps
taxes)

TriStar 45 charge
48 V 45 A $478.00
controller

VI] Inverter
I chose the Context SW 4048 230 inverter by Schneider electric, it has the following
characteristics :

Context SW Off-Grid Inverter Model SW 4048 230

DC
No Cost2
Continuous Battery AC out Input Charger
Efficiency Load (without
Power Voltage volts/ hertz Voltage amps
Draw taxes)
Range
40 to 68 <11
3800 W 48 VDC 120V/60Hz 94% 45 A $1,550
VDC W

VII] Mounting System

I have chosen the Iron ridge Flashfoot roof mounting system for my small 4kW array. This mounting
system is designed to be mounted to asphalt shingles which my apartment complex has. The
mounting points of this system have flashing that slides under the shingles to prevent leaks. This is
very important to property owners because they expect their roof to last for many tenants. The
mounting system is also equipped with grounding connections between different parts eliminating

1 Charge Controller Price: http://www.wholesalesolar.com (website visited on October 15, 2013 )

2 Inverter Price: http://www.gogreensolar.com (website visited on October 15, 2013 )

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 the need for expensive copper wires. The mounting system will cost a total of $1,045.10 or $0.26 per
watt.

BILL OF MATERIALS
Part Number Description Quantity Price/EA Total Price
XR-100-132B XR100, Rail 132" (11 Feet) Black 8 $61.20 $489.60
FM-FF2-001-B Kit, 4pcs, FlashFoot 2 (Black) 5 $72.00 $360.00
XR-100-SPLC-BD Kit, XR100 Bonded Splice 4 $8.00 $32.00
UFO-CL-001-B Kit, 4pcs, Universal Module Clamp 7 $15.00 $105.00
FM-SQ-BHW Kit, 4pcs, Square-Bolt Bonding Attachment Hardware 5 $8.00 $40.00
GD-LUG-003 Kit, 2pcs, Grounding Lug, Low Profile 1 $14.00 $14.00
UFO-STP-40MM-B Kit, 4pcs, Stopper Sleeve, 40MM, Black 2 $2.25 $4.50
Total Price $1,045.10
$/Watt $0.26

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VII] Cost of the PV system
Item Qty. Price Cost
Modules 4 $ 219.00 $ 876.00
Inverter 1 $ 1,550.00 $ 1,550.00

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 Fuse Holder 5 $ 6.88 $ 34.40
20 Amp Fuse 4 $ 4.12 $ 16.48
40 Amp Fuse 1 $ 4.12 $ 4.12
Mounting System 1 $ 1,045.10 $ 1,045.10
Lightining Arrestor 1 $ 40.00 $ 40.00
Combiner Box 1 $ 73.51 $ 73.51
Charge Controller 1 $ 478.00 $ 28.96
Batteries 8 $ 297.77 $ 2,382.16
Total $ 6,050.73

Here is a recap chart made with the PV System Sizer to summarize the solar array and battery
Array Sizing
Total DC watt-hours/ day 2398
System Nominal Voltage (12, 24, 48) 48
Total DC amp-hours/ day 50
Total daily amp-hour requirement 60
(corrected for battery/ wiring
xxxxxxxx
losses, safety factor)
Estimated insolation 4.5
(hours of full sun per day or KWH/m2/day) xxxxxxxx
Total required PV array currrent (amps) 13
Selected PV module nominal voltage 24
Selected PV module rated power (amps) 8.87
Number of Series Strings required in parrallel 2
Number modules required in series 2
Total modules required 4

Battery Sizing
Reserve time desired (days) 5
Fraction of useable battery capacity (50%-80%) 75%
Minimum battery capacity (in amp-hours) 400
Selected battery amp-hour capacity 200
Number of series strings required in parrallel 2
Selected battery voltage (usually 6 or 12) 12
Number of batteries required in series 4
Total number of batteries required 8

Total modules required 4

sizing, Total number of batteries required 8

Table 4: Recap chart of solar array and battery sizing. (Red Cells are calculated data & green cells are entered data)

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