DC coupled System

DC Coupled system sizing

• Solar PV system includes different components that should be

selected according to your system requirement.
• Steps to determine the system sizing
1. Energy assessment
2. Inverter Sizing
3. Battery Sizing
4. Solar Array Sizing
5. Charge Controller Sizing
6. Cable sizing
7. System layout
DC Coupled system sizing
Step 1: Energy assessment

• The first step in designing a solar PV system is to find out

the total Power and energy consumption of the loads that
needs to be powered by the PV system.
• To get accurate values it is a good practice to use energy
logger device to get a clear idea. Also having recent energy
bills can help a lot.
• MS Excel and other sizing programs can be used.
• Energy Efficiency action
• Site survey: Shade, Surface area, Rooftop, Routes, Roof
integration…
 Example
• Mr. Eric is planning to have a solar installation for his house.
In his one bed room apartment he is having 4 Lamps, 1 TV
and 2 Fan. Can you do energy assessment?

No Load Power No of Total Running Energy

Loads Power hours/ day consumption
/day
1 Lamp 9W 4 36W 12h 432Wh
2 TV 100W 1 100W 3h 300Wh
3 fan 70W 2 140W 6h 840Wh
Total 276W 1572Wh
Summery
• Mr. Eric Single bed room Apartment energy assessment result
• Power= 276W
• Energy/day =1572Wh/day ≅ 1.6 KWh/day

• Note: when you do energy assessment consider replacing loads to

energy efficient solution.
• Example
• Fluorescent tube should be replaced by LED tubes
• Incandescent light bulb and CFL should be replaced by LED
• Electric stove in to induction stove.
• Consider replacing an old non inverter fridge in to inverter fridges.
DC Coupled system sizing
Step 2: Inverter Sizing

• The output rating of the inverter must be sized to meet the AC load
demand.
• The inverter should be able to handle all loads that switched on at the
same time.
• In addition, the inverter size should be 30% higher than the load
demand in order to handle surge current during starting of inductive
loads like pump, compressor and Fluorescent light bulb.
• DC input voltage should be same as system voltage.
• Incase of appliance type involves motor then invertor size should be
able handle inrush current during starting otherwise it need to be
oversized by factor 3-5 times the rated current.
Example
Let’s Determine inverter size for Mr. Eric’s apartment.
Total Power= 276W
Inverter power= Total power * Safety factor Safety Factor 1.25-3
Depending on the load
= 276 W * 1.3 type

= 359 W
We choose the next higher available size
Inverter Rated power= 400W
Voltage input = 12V DC
Voltage output= 230VAC
Frequency = 50 Hz
Output wave form = Pure sine wave form
 ηBat
DC Coupled system sizing = 85% Deep cycle Lead acid battery
Step 3: Battery Sizing =95% Lithium battery
ηInv = 85-95%
DoD
= 50-60% for Deep cycle Lead acid
Steps to calculate battery size in Ah = 80-90% for Lithium battery
3.1 Calculate the total energy (Wh) consumption per day.
3.2 Divide the answer obtained from 3.1 by battery efficiency(ηBat).
3.3 Divide the answer obtained from 3.2 by Depth of discharge (DoD).
3.4 Divide the answer obtained from 3.3 by Nominal Battery voltage and Inverter
SOC 100% SOC 60%
efficiency. DOD 0% DOD 40%
3.5 Multiply the answer obtained from 3.4 by Days of autonomy.
Mathematically
Energy consumption per day(Wh) ∗Autonomy days
Battery capacity(Ah) =
Voltage system(V) ∗ ᶯ battery∗ ᶯ inverter∗DOD
DC Coupled system sizing
Step 3: Battery Sizing
System Voltage
• Number of Battery in series =
Single Battery Voltage
Total battery capacity
• Number of Battery in parallel =
Single battery capacity
Total number of batteries
= Number of batteries in series * number of batteries in parallel

System Voltage Maximum system size

12V 3000W
24V 5000W
48V Above 5000W

Note: The higher the system voltage => less current => less power loss.
 Example
 Let’s Determine battery size for Mr. Eric’s apartment using 110Ah-12V battery
Total Energy Consumption/day= 1.6KWh/day
Energy consumption per day(Wh) ∗Autonomy days Round it to 3
Battery capacity(Ah) =
Voltage system(V) ∗ ᶯ battery∗ᶯinv ∗DOD
1600wh∗1
Required battery capacity(Ah) = 12V∗ 0.85∗0.95∗0.5 = 330Ah
System Voltage
Number of Battery in series = = 12V/12V = 1battery in series
Single Battery Voltage
Requieed battery capacity (Ah) 330Ah
Number of Battery in parallel = Single battery capacity = 110𝐴ℎ ≅3 batteries in parallel
Total number of batteries
= Number of batteries in series * number of batteries in parallel
= 1* 3 = 3 batteries each 110Ah, 12V

110Ah 12V
 Example
 Let’s Determine battery size for Mr. Eric’s apartment using 200Ah-12V battery
Total Energy Consumption/day= 1.6KWh/day
Round it to 2
1600wh∗1
Required battery capacity(Ah) = = 330Ah
12V∗ 0.85∗0.95∗.5
System Voltage
Number of Battery in series = = 12V/12V = 1battery in series
Single Battery Voltage
Requieed battery capacity (Ah) 330Ah
Number of Battery in parallel = = =1.65 ≅ 2
Single battery capacity 200𝐴ℎ
batteries in parallel
Total number of batteries
= Number of batteries in series * number of batteries in parallel
= 1* 2 = 2 batteries each 200Ah, 12V

200Ah 12V
Example
Battery connection layout
Using 110Ah/12V 200Ah/12V
Note: It is not
recommended to connect
multiple battery strings in
parallel more than four.

110Ah 12V

200Ah 12V

110Ah 12V

200Ah 12V

110Ah 12V

Etotal = 12V*330Ah = 3960Wh=4Kwh Etotal = 12V*400Ah = 4.8Kwh

Useful capacity 50%DOD = 2KWh Useful capacity 50%DOD = 2.4KWh
 DC Coupled system sizing
Step 4: Solar Array Sizing
4.1 Multiply total energy consumption/day by safety factor (1.3)
4.2 Divide the answer obtained from 4.1 by equivalent sunshine hours(4.5-5Kwh/m2/day
for Ghana), battery efficiency, inverter efficiency, charge controller efficiency.
4.3 Multiply the answer obtained from 4.2 by Days of autonomy.

Mathematically it is expressed as
Total PV power required =
Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
equivalent sunshine hours per day∗ ᶯ battery∗ ᶯ inverter∗ ᶯ 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟

Component Efficiency
Battery 85% Lead acid, 95% Lithium(LiFePO4) Output
Efficiency=
𝐼𝑛𝑝𝑢𝑡
Inverter 90%
Charge controller 80% PWM, 95% MPPT
 DC Coupled system sizing
Step 4: Solar Array Sizing Charge controller
maximum input voltage
depend on the
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required manufacturer
Number of PV modules =
PV module maximum power (Pmax)

Charge controller Voltage input

Number of PV module in series = PV module open circuit voltage(V )
oc

Total number of PV module

Number of PV module in parallel = Number of PV in Series

S/m Voltage(Battery) Maximum input voltage MPPT C.C Rating Maximum input voltage
12v PWM 28V 75/10 MPPT 75V
24VPWM 47V 150/45 MPPT 150V
48V PWM 100V 250/100 MPPT 250V
 Example

 Let’s Determine PV Array size for Mr. Eric’s apartment.

Total Energy Consumption/day= 1.6KWh/day
•Let’s calculate Total PV Power required
•Total PV power required =
Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
equivalent sunshine hours per day∗ ᶯ battery∗ ᶯ inverter∗ ᶯ 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟
1572Wh/day∗ 1.3∗1
•Total PV power required =
4.5h/day∗ 0.85∗0.9∗0.8
= 742Wp
 Note:
Since our demand is less than 3000W we choose system voltage 12V,
In 12V system we have to use 36 Cell solar panel not 60 cell or 72 cell.
Example Also we choose PWM charge controller.
a 12V PWM C.C can handle 28V no series connection of PV modules.

Let’s calculate number of panels required using 160W 36 cell PV module. Pmax= 160W
Vmp= 18V
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required
•Number of PV modules = PV module maximum power Voc= 22V
(Pmax) Imp= 8.88A
742𝑊 Isc= 9.3A
•= 160W(Pmax)
= 4.63 = 5panels each 160W
Charge controller Voltage input
•Number of PV module in series = PV module voltage open circuit (Voc)
28V
•= 22V (Voc) = 1.2 round it down to 1=> only one panel per string
Total number of PV module 5
•Number of PV module in parallel = Number of PV in Series = 1 = 5 panels in Parallel
 DC Coupled system sizing
Step 5: Charge controller Sizing
PWM charge controller
5.1 To select PWM charge controller, we need to know the system voltage 12V/24/48V
5.2 Current rating: PV array short circuit current or maximum load current (the highest)
5.3 It is a good practice to oversize a charge controller current rating by 30%
Safety factor = 1.3
Mathematically it is expressed as
Current rating of PWM charge controller =Isc* Number of strings in parallel * safety factor

MPPT Charge controller

PV input voltage= Voc * Number of modules in series
Battery voltage: 12V/24V/48V
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑉 𝑚𝑜𝑑𝑢𝑙𝑒𝑠 ∗𝑃𝑚𝑎𝑥
Charging current=
System Voltage
 Example
Voc=22V
Isc= 9.3A *5 =46.5A
• Let’s calculate charge controller rating for Mr. Eric’s apartment
• We have calculated the panels size => current rating
• System voltage (Battery voltage) => voltage rating
Current rating of charge controller =Isc* Number of strings in parallel * safety factor
= CCcurrent rating= 9.3A*5*1.3= 60A
Round the value to the next available higher size which is 60A
Voltage rating = system voltage = 12V
Type= PWM
60A,12V, PWM charge controller
 DC Coupled system sizing
Step 6: Cable Sizing
International standard wire sizes
0.5 mm² 0.75 mm² 1 mm² 1.5 mm² 2.5 mm² 4 mm²
6 mm² 10 mm² 16 mm² 25 mm² 35 mm² 50 mm²
70 mm² 95 mm² 120 mm² 150 mm² 185 mm² 240 mm²
300 mm² 400 mm² 500 mm² 630 mm² 800 mm² 1000 mm²

System voltage PV to CC CC to Battery Battery to Inverter Inverter to

0.5% 0.5% Load
5%
12V 0.06V 0.06V 11.5V
24V 4% 0.12V 0.12V For
230V
48V 0.24V 0.24V system
Voltage drop
 Example
Fuse rating
Mr. Adu’s PV to CC CC to Battery Battery to Inverter to Load PV to CC= Iarray *S.F
apartment Inverter 44.4A*1.25=55.5A
Available size 60A DC
8m 2m 2m 45m 30V(higher) slow blow fuse

Let’s calculate cable size for Mr. Eric’s apartment

PV to CC [P= 720W, Vbat= 12V, Distance 8m, 𝑉𝑑𝑟𝑜𝑝 4%Vm=0.72V]

IArray=Imp ∗ numberof strin𝑔𝑠 = 8.88A*5=44.4A You can also use Victron tool kit
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.72𝑉 app
Rwire= = =0.016Ω Download it from Play store
𝐼𝑙𝑜𝑎𝑑 44.4𝐴
Ωmm 2
ρcu ∗ Length 0.0178 ∗8𝑚
𝑚
Amm2= 𝑅𝑤𝑖𝑟𝑒
*2 = 0.016Ω
* 2 = 17.8mm2
Available size 16.0mm2 Wire.
 Example
Fuse rating
CC to Battery= ICharging *S.F
46.5A*1.25=58.1A
Available size 60A DC 30V(higher) slow
Let’s calculate cable size for Mr. Eric’s apartment blow fuse
CC to Battery [Vbat= 12V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.6V]
ICharging= IArray = Imp ∗ numberof strin𝑔𝑠 = 8.88A*5=44.4A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.6𝑉
Rwire= =1.35*10-3Ω
=
𝐼𝑙𝑜𝑎𝑑 44.4𝐴
Ωmm 2
ρcu ∗ Length 0.0178 𝑚 ∗2𝑚
Amm2= *2 = − * 2 = 52.7mm2
𝑅𝑤𝑖𝑟𝑒 1.35∗10 Ω3

Available size 50.0mm2 Wire.

 Example
Fuse rating
Battery to Inverter= IDischarging *S.F
33.3A*1.25=43.3A
Available size 50A DC 30V(higher) slow
Let’s calculate cable size for Mr. Eric’s apartment blow fuse
Battery to Inverter [Vbat= 12V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.6V]
400𝑊
Idischarging= = 33.3A
12𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.6𝑉
Rwire= = =0.018Ω
𝐼𝑙𝑜𝑎𝑑 33.3𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗2𝑚
Amm2= *2 = * 2 = 39.5mm2
𝑅𝑤𝑖𝑟𝑒 0.018Ω
Available size 35.0mm2 Wire.
 Example
MCB rating
Inverter to load = ILoad *S.F
1.83A*1.25=2.38A
Available size 6A AC 230V MCB
Let’s calculate cable size for Mr. Eric’s apartment

Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝 =11.5V]

VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 400𝑊
ILoad= = = 1.83A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉
Rwire= = =6.82Ω
𝐼𝑙𝑜𝑎𝑑 1.83𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗45𝑚
Amm2= *2 = * 2 = 0.23mm2
𝑅𝑤𝑖𝑟𝑒 6.82Ω
Available size 1.0mm2 Wire.
DC Coupled system sizing
Step 7: System Layout

• Small scale installation layout can be done by hand but for large scale
we might required to use computer software.
• There are many PV design software that can be used to simulate
shading analysis, system performance, Cost analysis and so on.
• Examples
• PVSyst
• Open Solar
• PVSOL
• HelioScope
• Autocad
Example 1
400W INVERTER
12V DC IN, 230V AC OUT

110Ah 12V

P=276W
E=1572Wh
110Ah 12V

Now our customer is satisfied!

We have 30% more energy due to the
110Ah 12V safety factor 1.3 we put.
Example 2
Determine the PV sizing for the following loads given below

No Load Power No of Loads Total Power Running hours/ Energy

day consumption /day

1 Lamp 9W 4 12h
2 TV 100W 1 3h
3 fan 70W 2 6h
4 Frige 150 1 276W 24h
Considering

Voltage System = 48V

DC Coupled system sizing

• Solar PV system includes different components that should be

selected according to your system requirement.
• Steps to determine the system sizing
1. Energy assessment
2. Inverter Sizing
3. Battery Sizing
4. Solar Array Sizing
5. Charge Controller Sizing
6. Cable sizing
7. System layout
Example 2
Determine the PV sizing for the following loads given below

No Load Power No of Loads Total Power Running hours/ Energy

day consumption /day

1 Lamp 9W 4 36W 12h 432Wh

2 TV 100W 1 100W 3h 300Wh
3 fan 70W 2 140W 6h 840Wh
Total 276W 1572Wh
Example 2
Step 2: Inverter Sizing

Step 1. Energy assessment Total Power= 276W

• Power= 276W Inverter power= Total power * Safety factor
• Energy/day =1572Wh/day ≅ 1.6
KWh/day = 276 W * 1.3
= 359 W
We choose the next higher available size
Inverter Rated power= 400W
Voltage input = 24V DC
Voltage output= 230VAC
Frequency = 50 Hz
Output wave form = Pure sine wave form
 Example 2
 Step 3: Battery sizing using 110Ah, 12V(Case one)
Total Energy Consumption/day= 1.6KWh/day
Energy consumption per day(Wh) ∗Autonomy days
Battery capacity(Ah) =
Voltage system(V) ∗ ᶯ battery∗ᶯinv ∗DOD
1600wh∗1
Required battery capacity(Ah) = 24V∗ 0.85∗0.95∗.5 = 165Ah
System Voltage
Number of Battery in series = = 24V/12V = 2 battery in series
Single Battery Voltage
Required battery capacity (Ah) 165Ah
Number of Battery string in parallel = Single battery capacity = 110𝐴ℎ =1.5≅ 2 battery
string in parallel
Total number of batteries
= Number of batteries in series * number of battery strings in parallel
= 2* 2 = 4 batteries each 110Ah, 12V

110Ah 12V
 Example 2
• Step 3: Battery sizing lets try with different battery using 200Ah, 12V (Case two)
Total Energy Consumption/day= 1.6KWh/day
Energy consumption per day(Wh) ∗Autonomy days
Battery capacity(Ah) =
Voltage system(V) ∗ ᶯ battery∗ᶯinv ∗DOD
1600wh∗1
Required battery capacity(Ah) = 24V∗ 0.85∗0.95∗.5 = 165Ah
System Voltage
Number of Battery in series = = 24V/12V = 2 battery in series
Single Battery Voltage
Required battery capacity (Ah) 165Ah
Number of Battery strings in parallel = Single battery capacity = 200𝐴ℎ = 0.82 ≅ 1
battery string in parallel
Total number of batteries
= Number of batteries in series * number of battery strings in parallel
= 2 * 1 = 2 batteries each 200Ah, 12V

200Ah 12V
Example 2
Case one Case two

110Ah 12V 110Ah 12V

200Ah 12V 200Ah 12V

110Ah 12V 110Ah 12V

V= 2*12V=24V
V= 2*12V=24V Capacity(Ah)= 1*200Ah=200Ah
Capacity(Ah)= 2*110Ah=220Ah Etotal = 24V*200Ah = 4800Wh=4.8Kwh
Etotal = 24V*220Ah = 5280Wh=5.3Kwh Useful capacity 50%DOD = 2.4KWh
Useful capacity 50%DOD = 2.6KWh
 Example 2
Step 4: Solar Array Sizing

Total Energy Consumption/day= 1.572Wh/day

Total PV power required =
Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
equivalent sunshine hours per day∗ᶯ 𝑏𝑎𝑡𝑡𝑒𝑟𝑦∗ ᶯ 𝑖𝑛𝑣𝑒𝑟𝑡𝑒𝑟∗ ᶯ " 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟
1572Wh/day∗ 1.3∗1
Total PV power required = = 742Wp
4.5h/day∗ 0.85∗0.9∗0.8

𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required

Number of PV modules =
PV module maximum power (Pmax)
742𝑊
= = 4.63 = 5 panels each 160W
160W(Pmax)
Example 2
Pmax= 160W
Vmp= 18V
Voc= 22V
Charge controller Voltage input Imp= 8.88A
•Number of PV module in series =
PV module voltage open circuit (Voc) Isc= 9.3A
47V
•= = 2.1 round it down to 2=> only two panel per string
22V (Voc)
Total number of PV module 5
•Number of PV module in parallel = = = 2.5 round it up => 3 panels in
Number of PV in Series 2
Parallel
• Total number of PV Modules= Number of PV module in series *
Number of PV module in parallel
• =2*3= 6 PV modules panels each 160W
 Example 2 PV array open circuit voltage shouldn't
exceed the voltage that the charge controller
able to handle
Pmax= 250W
Vmp= 18.6V
•Let’s calculate number of panels required using 250W 36 cell PV module. Voc= 22V
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required Imp= 13.2A
•Number of PV modules =
PV module maximum power (Pmax) Isc= 13.8A
742𝑊
= = 2.97 = round it up => 3 panels each 250W
250W(Pmax)
Charge controller Voltage input
•Number of PV module in series =
PV module voltage open circuit (Voc)
47V
•= = 2.1 round it down to 2=> only two panel per string
22V (Voc)
Total number of PV module 3 Pmax= 190W
•Number of PV module in parallel = = = 1.5 round it up
Number of PV in Series 2 Vmp= 36.6V
=> 2PV string. Voc= 22V
• Total number of PV Modules= Number of PV module in series Imp= 5.1A
* Number of PV module in parallel Isc= 5.3A
• =2*2= 4 PV modules panels each 250W
Example 2
PV connection diagram
Option one 3* 160W
Option two 2* 250W

Vm=18V*2=36V Vm= 18.6V*2=37.2V

Im= 8.88A *3 =26.6A Im=13.2A*2= 26.4A
Pt=36V* 26.6A= 6*160W= 960W Pt= 2*250W= 37.2*26.4A=1000W
 Example 2
Step 5: Charge controller Sizing

using 6*160W panel

Current rating of charge controller =Isc* Number of strings in parallel * safety factor
= CCcurrent rating= 8.88A*3*1.3= 34.6A
Round the value to the next available higher size which is 40A
Voltage rating = system voltage = 24V
Type= PWM
40A,24V, PWM charge controller
 Example 2
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to Load PV to CC= Iarray *S.F
measurement Inverter 13.2A*1.3=17.2A
8m 2m 2m 45m Available size 20A DC
50V(higher) slow blow fuse

PV to CC [P= 960W, Vbat= 24V, Distance 8m, 𝑉𝑑𝑟𝑜𝑝 =4% of Vm=

1.44V]
IArray=Imp ∗ numberof strin𝑔𝑠 = 8.88A*3=29.4A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 1.44𝑉
Rwire= = =0.05Ω
𝐼𝑙𝑜𝑎𝑑 29.4𝐴 2
Ωmm
0.0178 𝑚 ∗8𝑚
ρcu ∗ Length
Amm2= *2 = * 2 = 5.8mm2
𝑅𝑤𝑖𝑟𝑒 0.05Ω
Available size 6.0mm2 solar cable.
 Example 2
Fuse rating
CC to Battery= ICharging *S.F
CC to Battery [Vbat= 24V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.12V] 13.2A*1.3=17.2A
Available size 20A DC 50V(higher) slow
ICharging= IArray = Imp ∗ numberof strin𝑔𝑠 = 8.88A*3= blow fuse
26.6A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= =
=0.0045Ω
𝐼𝑙𝑜𝑎𝑑 26.6𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗2𝑚
Amm2= *2 = * 2 = 15.8mm2
𝑅𝑤𝑖𝑟𝑒 0.0045Ω
Available size 16.0mm2 Cable.
 Example 2
Fuse rating
Battery to Inverter= IDischarging *S.F
Battery to Inverter [Vbat= 24V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.12V]16.6A*1.3=21.5A
400𝑊 Available size 25A DC 50V(higher) slow
Idischarging= = 16.6A blow fuse
24𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= = =0.007Ω
𝐼𝑙𝑜𝑎𝑑 16.6𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗2𝑚
Amm2= *2 = * 2 = 9.8mm2
𝑅𝑤𝑖𝑟𝑒 0.007Ω
Available size 10.0mm2 Wire.
 Example 2 MCB rating
Inverter to load = ILoad *S.F
1.83A*1.3=2.38A
Available size 6A AC 230V MCB
Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝 =11.5V]
VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 400𝑊
ILoad= = = 1.83A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉
Rwire= = =6.82Ω
𝐼𝑙𝑜𝑎𝑑 1.83𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗45𝑚
Amm2= *2 = * 2 = 0.23mm2
𝑅𝑤𝑖𝑟𝑒 6.82Ω
Available size 1.0mm2 Wire.
Example 2
Step 7: System Layout
6*160Wp

PWM Charge controller

40A 24V

6 mm2

hager
hager

0 OFF 0 OFF
0 OFF 0 OFF

1.0mm2

16 mm2 16 mm2
10 mm2 hager

6 mm2 0 OFF 0 OFF

400W Pure sine wave inverter

25 mm2

25 mm2
24V DC Input 230VAC Output
25 mm2 AC Load

200Ah 12V 200Ah 12V

AGM AGM
 Example 3 will take you to optimum way of calculating
battery size considering only night time energy
consumption.
Example 3
Step 1. Energy assessment

hours
hours //
Item
Item No.
No. power
power day time Power
day time Power Energy
Energy night time
night time Night Energy
Night Energy
TV
TV 1
1 80
80 3
3 80 240 4
4 320
Fridges
Fridges 1
1 150
150 2
2 150 300 6
6 900
freezer
freezer 1
1 200
200 3
3 200 600 7
7 1400
Blender
Blender 1
1 150
150 1
1 150 150 1
1 150
Bulbs LED
Bulbs LED 5
5 12
12 3
3 60 180 5
5 300
Out
Out side lamp
side lamp 3
3 12
12 0
0 36 0 8
8 288
LED Bowser outside
LED Bowser outside 3
3 30
30 0
0 90 0 8
8 720
Ceiling
Ceiling fan
fan 3
3 60
60 4
4 180 720 5
5 900
Computer
Computer 2
2 150
150 4
4 300 1200 1
1 300
Laptops
Laptops 1
1 60
60 4
4 60 240 3
3 180
printer/ Scanner // copier
printer/ Scanner copier 1
1 1,100
1,100 3
3 1100 3300 3
3 3300
Total
Total 2406 6,930 8,758
Example 3

Step 2: Inverter Sizing

Step 1. Energy assessment
Total Power= 1166W
• Power= 2406W
Inverter power= Total power * Safety factor
• Energy during daytime = 2406 W * 1.5
=6930Wh ≅ 6.9 KWh
= 3609 W
• Energy during night time We choose the next higher available size
=8758Wh ≅ 8.8KWh
Inverter Rated power= 5000VA
• Total Energy/day Voltage input = 48V DC
=6930Wh/day + 8758Wh =
Voltage output= 230VAC
15688Wh
Frequency = 50 Hz
≅ 15.7 KWh/day
Output wave form = Pure sine wave form
Example 3
Step 3 – Battery sizing

Energy consumption per night ∗Autonomy days

• Battery capacity =
Voltage system ∗ ᶯ battery∗ ᶯ inverter ∗DOD

8758Wh
=
48V ∗ 0.95 ∗ 0.90 ∗ 0.80
8758Wh
= 32.83V

= 266.7Ah
Example 3

• Available Battery in Market

 Capacity = 320Ah BYD battery
 Voltage = 48V
System Voltage
• Number of Battery in series =
Single Battery Voltage
48V
=
48V
= 1 Battery
Example 3

Total battery capacity

• Number of Battery in parallel =
Single battery capacity
266.7Ah
=
320Ah
= 0.8 ≈ 1 Batteries

• Total number of batteries = Number of batteries in series * number of batteries in parallel

= 1 battery * 1 batteries
= 1 battery
 Example 3
Step 4: Solar Array Sizing

Total Energy Consumption/day= 15688Wh/day

Total PV power required
Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
= equivalent sunshine hours per day∗ᶯ 𝑏𝑎𝑡𝑡𝑒𝑟𝑦∗ ᶯ 𝑖𝑛𝑣𝑒𝑟𝑡𝑒𝑟∗ ᶯ " 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟

15688Wh/day ∗1 .3∗1
= 4.5Hrs/𝑑𝑎𝑦∗ 0.95∗0.9∗0.95 = 5579.6Wp
 Example 3
Pmax= 380W
Vmp= 40.5V
•Let’s calculate number of panels required using 380W PV module.
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required
Voc= 48.9 V
•Number of PV modules = Imp= 9.39A
PV module maximum power (Pmax)
5579𝑊 Isc= 9.75 A
•= = 14.7 = 15 panels each 380W
380W(Pmax)
Charge controller minimum input Voltage Charge controller Max. Input Voltage
• ≤ Number of PV module in series ≥
PV module open circuit voltage(Voc) PV module open circuit voltage(Voc)
60V 250V
•= ≤ 𝑛𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑃𝑉 𝑚𝑜𝑑𝑢𝑙𝑒𝑠 𝑖𝑛 𝑠𝑒𝑟𝑖𝑒𝑠 ≥
48.9V (Voc) 48.9V (Voc)
• ∴ 𝑇ℎ𝑢𝑠, 𝑎 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑜𝑓 𝑡𝑤𝑜 𝑎𝑛𝑑 𝑎 𝑚𝑎𝑥𝑖𝑚𝑢𝑚𝑢𝑚 𝑜𝑓 𝑓𝑖𝑣𝑒 𝑃𝑉 𝑚𝑜𝑑𝑢𝑙𝑒 𝑐𝑎𝑛 𝑏𝑒 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑒𝑑 𝑖𝑛 𝑠𝑒𝑟𝑖𝑒𝑠.
Total number of PV module 15
•Number of PV module in parallel = = = 3 Strings in Parallel
Number of PV in Series 5

• Total number of PV Modules= Number of PV module in series * Number of PV

module in parallel
• =5*3= 15 PV modules panels each 380W
 10* 380W

Example 3 5* 380W
Step 5: Charge controller Sizing
Using 15*380W panel
Voltage rating = system voltage = 48V
Type= MPPT MPPT1 MPPT2

𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 15∗380𝑊

250/85 250/60

Charging current = = = 118.75A

𝑉𝑏𝑎𝑡 48V
We don’t have such big size charge controller so we have to look
for another alternative.
• Available size:
250/60, 250/70, 250/85, 250/100. Which one??? 250/85 and
250/60
MPPT 1 will share two strings(2X5) and MPPT 2 will share one
string(1X5)
 Example 3
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to Load PV1 to CC1= Iarray *S.F
measurement Inverter 18.6A*1.3=24.18A
25m 2m 2m 45m Available size 25A DC
250V(higher)DC CB or slow blow
fuse
PV1 to CC1 [P= 3800W, VPV= 5 X 40.5V, Distance 25m, 𝑉𝑑𝑟𝑜𝑝 =8.1V
4%(5*40.5Vm)]
IArray=Imp ∗ numberof strin𝑔𝑠 = 9.39A*2= 18.6A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 8.1𝑉
Rwire= = =0.44Ω
𝐼𝐴𝑟𝑟𝑎𝑦 18.6𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗25𝑚
Amm2= *2 = * 2 = 2.22mm2
𝑅𝑤𝑖𝑟𝑒 0.44Ω
Available size 2.5mm2 Wire.
 Example 3
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to Load PV2 to CC2= Iarray *S.F
measurement Inverter 9.39A*1.3=12.2A
25m 2m 2m 45m Available size 16A DC
250V(higher)DC CB or slow blow
fuse
PV2 to CC2[P= 00W, VPV= 5 X 40.5V, Distance 25m, 𝑉𝑑𝑟𝑜𝑝 =8.1V
4%(5*40.5Vm)]
IArray=Imp ∗ numberof strin𝑔𝑠 = 9.39A*1= 9.39A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 8.1𝑉
Rwire= = =0.86Ω
𝐼𝐴𝑟𝑟𝑎𝑦 9.39𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗25𝑚
Amm2= *2 = * 2 = 1.03mm2
𝑅𝑤𝑖𝑟𝑒 0.86Ω
Available size 1.5mm2 Wire.
 Example 3
Fuse rating
CC 1to Battery= ICharging *S.F
CC1 to Battery [Vbat= 48V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.24V] 79A*1.3=102.2A
3800𝑊 Available size 125A DC 60V(higher)
ICharging= =79A slow blow fuse
48𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.003Ω
𝐼𝑙𝑜𝑎𝑑 79𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗2𝑚
Amm2= *2 = * 2 = 23.7mm2
𝑅𝑤𝑖𝑟𝑒 0.003Ω
Available size 25.0mm2 Wire.
 Example 3
Fuse rating
CC2 to Battery= ICharging *S.F
CC2 to Battery [Vbat= 48V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.24V] 39.5A*1.3=51.4A
1900𝑊 Available size 63A DC 60V(higher) slow
ICharging= =39.5A blow fuse
48𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.006Ω
𝐼𝑙𝑜𝑎𝑑 39.5𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗2𝑚
Amm2= *2 = * 2 = 11.86mm2
𝑅𝑤𝑖𝑟𝑒 0.006Ω
Available size 16.0mm2 Wire.
 Example 3
Fuse rating
Battery to Inverter= IDischarging *S.F
104.6A*1.3=135A
Available size 150A DC 60V(higher)
Battery to Inverter [Vbat= 48V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.24V]slow blow fuse
5000𝑊
Idischarging= = 104.16A
48𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.002Ω
𝐼𝑙𝑜𝑎𝑑 104.16𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚
∗2𝑚
Amm2= *2 = * 2 = 35.6mm2
𝑅𝑤𝑖𝑟𝑒 0.002Ω
Available size 35.0mm2 Wire.
 Example 3

Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝

=11.5V=5%230V] MCB rating
Inverter to load = ILoad *S.F
VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC 22.8A*1.3=29.6A
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 5000𝑊 Available size 32A AC 230V MCB
ILoad= = = 22.8A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉
Rwire= = =0.5Ω
𝐼𝑙𝑜𝑎𝑑 22.8𝐴
Ωmm2
ρcu ∗ Length 0.0178 𝑚 ∗45𝑚
Amm2= *2 = * 2 = 3.2mm2
𝑅𝑤𝑖𝑟𝑒 0.5Ω
Available size 4mm2 Wire.
Example 3
Step 7 System layout
10* 380W 5* 380W

5000VA
MPPT1 MPPT2
250/85 250/60
INVERTER/CHARGER
48VDC IN
230V AC OUT