Electrical Installation of a PV System

Making the Right Connections

Dr. Jeffery Lee Johnson CTO Todo-Solar Coahuila, Mexico
Email: jeff.johnson@todo-solar.com-mx Tele: (+52) 871 722 9522 www.todo-solar.com.mx

Agenda
Resources Assumptions and Background The DC side of things
Choosing and Connecting the Panels in Series Proper grounding String combiners

Meeting in the Middle

DC connection to the Inverter DC Disconnects, fusing and loading

The AC side of things

AC Connection to the Inverter AC Disconnects, fusing and safety Connecting to the grid

Summary and questions

Resources
Doc Solstices Seasoned Sentiments

Facts about Global PV installations

Global PV installations reached 27.7GW in 2011
http://www.pv-tech.org/news/global_pv_installations_reached_27.7gw_in_2011_industry_at_crossroads_says

That comes to 0.87 KW per second or 3 to 4 panels every second of the year
http://www.pvmarketresearch.com/press-release/Global_PV_Installations_to_Grow_by_up_to_21_Percent_in_2012_Predicts_IMS_Research/5

Global PV Installations to Grow by up to 21 Percent in 2012 Predicts IMS Research

For comparison , the entire grid capacity of the country of Mexico is 53 GW

INTRODUCTION, BACKGROUND AND ASSUMPTIONS ABOUT THE SYSTEM

Key Concepts and Assumptions

Follow the typical systematic Installation Procedures

Assemble and place racks Mount and connect panels (DC) Install combiner box (DC) Connect DC disconnect (may be integrated) (DC) Connect DC to inverter (DC) Mount and configure inverter (AC/DC) Install AC Disconnect (AC) Connect inverter to grid via electrical center (AC) Commission and test (AC/DC Install or activate Monitoring system

You have an approved wiring diagram meeting specifications and needs of Locations
Routing, cable lengths, junction locations, fusing etc a

You have a complete parts list with prepared components

Electrical diagram: Generic System

General Schematic

One-line diagram

Sample SMA Wiring Diagram with external DC Disconnect

Combiner Box

Sample SMA Wiring Diagram with integrated DC Disconnect

Combiner Box

Sample System

3 strings of 10 panels 250W Siliken SMA sunny Boy SB7000US

THE DC SIDE OF THINGS

Always use components rate for UL 1703 and IEC standards

Panel Characteristics
Must know VOC, ISC, Vmp Imp Pmp, tolerances under STC and NOTC (preferably)

Characteristics of Panels in Series

String is a series of panels with predetermined current and voltage output V = V1 + V2 + Vn = Vi I = I1 = I2 = In

Choosing Panels for Series layout

Issue Voltages for Panels in Series add linearly Ideally, every series has the same voltage output but generally not true When combining series into Parallel Arrays at a combination node (such as a combiner box or Inverter input), the voltage at that node is the weighted average of the series voltages favoring the lowest voltage present Important to balance your strings by equalizing the string voltages as best as possible !

Balancing String Voltage

Layout your panels in a similar environment of illumination & temperature Measure and Record VOC for each panel assign a numbering system
WHY measure VOC? Safer and varies little with changes in illumination

WHEN? Measure during peak hours near solar noon when solar radiation is changing slowly

With knowledge of panel characteristics, group them as best you can so each series will have equal or similar voltage mix and match high /low performers

Installing panels measure as you go!

RETURN LINE

Using return line measure VOC as you connect panels

Why? To ensure each connection is secure and voltage sums as you go! Panel interconnect issues are difficult to find after the fact Make Sure panel connectors and cables are secured to rack

Physical Ground
All panels must have common physical ground and be grounded to racks

Aluminum frames are anodized (resistive) Most panels provide a ground connection hole Other technique is to use WEEBs or lugs electrically connect panel frames to rack and then ground rack

Combiner boxes adding the current of strings

PV COMBINER BOXES ARE CURRENT ADDERS FOR STRINGS IN PARALLEL

Common buss bar DC positive inputs DC Negative inputs Ground Single outputs for Positive, Negative & ground

Each DC positive input (string) is fused before common output Fuse: 600 VDC with amp rating > 1.45 operating amps Acts as string switch

Recommendation: Pre-wire the box with negative/ positive cables with mated connectors

DC routing

Have a DC cable routing plan

DC is on the roof or remote from inverter

Best solar cables do not need conduit but bundle them nicely using UV resistant cable ties
For esthetics and some codes, use metal conduit to distribute DC cables

MEETING IN THE MIDDLE

CONNECTING DC TO THE INVERTER

DC Disconnects

Stand-alone DC Disconnect Switch Fuse: 600 VDC with Amp rating > 1.45 x operating amps for each positive lead

Integrated DC Disconnect Switch (Typically fused inside the inverter)

Connecting DC to Inverter

Disconnect all DC power Follow Inverter manual to connect positive, negative and ground cables*
*Note: some panels are positively grounded so pay attention

Turn on DC and measure voltage at all outputs and inputs Turn off DC

THE AC SIDE OF THINGS

Know your Grid

Know which type of grid you are connecting to

Most inverters are reconfigurable by dip switches or programming

Line voltages vary so choose the operating output range that fits your grid conditions

Inverter must be equipped with anti-islanding and must shutdown upon loss of grid power (grid connected systems)

The AC connection

AC Disconnect

Main Panel connection

AC Outputs

AC Disconnect
Fused style

Locate AC disconnect near the inverter -- must be accessible

Fuses or Breakers must be compatible with grid voltage (240 VAC) Amp repeating should be 1.45 x the output current under operating conditions

Breaker Style

Connecting to the Grid

Typical 240 VAC Connection
Phase 1
Phase 2

Outputs from Inverter are: L1, L2 are positive feed lines Neutral Physical Ground Shut off AC power at main switch Shut off all DC inputs to inverter

L1 L2

Connect Neutral and Physical Ground Connect L1 to Phase 1 using breaker Connect L2 to Phase 2 using breaker or use two pole breakers

** Phase numbering is for convenience

Commissioning

Check all connections Follow manual for startup Usual procedure is

For Startup: Turn on AC First then DC For Shutdown: Turn off DC first then AC

After shutdown, ALWAYS wait 5 to 10 minutes before opening or working on inverter !!! Capacitive load needs to discharge

SYSTEM MONITORING

Monitoreo de Bluetooth para Internet o iPhone, iPad

30

(Solar Energy made available to Everyone)

Twitter: @TodoSolar

Twitter: @TodoSolarKids

http://www.todo-solar.com.mx