10kW Solar PV System Proposal
10kW Solar PV System Proposal
DATE: 27.07.11
INDEX
I. COMPANY PROFILE.................................................................................................................................. 4
I.1. CONERGY ENERGY SYSTEMS INDIA PVT LTD (FORMERLY KNOW AS SUNTECHNICS ENERGY SYSTEMS PVT.
LTD) 4
II. AIM OF THE DOCUMENT ......................................................................................................................... 6
III. SYSTEM DESCRIPTION............................................................................................................................ 6
III.1. STAND ALONE SPV POWER SYSTEM: HOW IT WORKS............................................................. 6
III.2. SIZINNG ........................................................................................................................................... 7
IV. MAJOR COMPONENTS OF SOLAR PV SYSTEM ..............................................................................10
V. TECHNICAL DESCRIPTION ....................................................................................................................11
V.1. PV MODULES ................................................................................................................................ 11
V.2. MODULE MOUNTING STRUCTURE ............................................................................................ 14
V.3. ARRAY JUNCTION BOX (AJB)...................................................................................................... 15
V.4. ISOLATOR ..................................................................................................................................... 16
V.5. PROTECTION PANEL ................................................................................................................... 16
V.6. DUAL REDUNDANT SOLAR CHARGE CONTROLLER ............................................................... 16
V.7. DC DISTRIBUTION BOARD .......................................................................................................... 19
V.8. 415V AC, 3 PHASE, BATTERY CHARGER ................................................................................... 20
V.9. BATTERY BANK ............................................................................................................................ 21
V.10. DC-DC CONVERTER .................................................................................................................... 22
V.11. CABLES ......................................................................................................................................... 23
V.12. LIGHTNING PROTECTION SYSTEM............................................................................................ 24
V.13. EARTHING SYSTEM ..................................................................................................................... 24
VI. ANNEXURE- II ............................................................................................................................................24
VII. ANNEXURE- III ...........................................................................................................................................28
VIII. ANNEXURE- IV...........................................................................................................................................29
VIII.1. CHECK LIST.......................................................................................................................... 29
IX. SCOPE OF SUPPLY..................................................................................................................................32
X. ASSUMPTIONS & EXCULSIONS ...........................................................................................................33
X.1. ASSUMPTION................................................................................................................................ 33
X.2. EXCLUSION................................................................................................................................... 34
Conergy Energy Systems India Pvt Ltd (formerly known as SunTechnics Energy Systems Pvt. Ltd) a
company incorporated under the laws of India and having its registered office at #660/1; 100ft Ring Road,
Indranagar, Bangalore – 560 038 (hereinafter called “Conergy”).
I.1. Conergy Energy Systems India Pvt Ltd (formerly know as SunTechnics Energy Systems Pvt. Ltd)
Conergy is an affiliate brand of the stock-listed Conergy AG, a global leader in the field of solar system
integration. Headquartered in Hamburg, Germany and listed on the Frankfurt Stock Exchange - Conergy
is an international leading supplier of turnkey systems. Whether dealing with grid connect photovoltaic,
off-grid or hybrid systems, extensive engineering know-how has been acquired from constructing
thousands of systems worldwide for more than 10 years. This makes it possible for Conergy to optimally
adapt the renewable energy technology to respective local conditions, while offering its various customers
the optimum system solution for their individual needs with the highest level of quality, superior support
and consulting services.
The solar array comprises of solar modules that generate DC electricity in proportion to the amount of
sunlight available, generating the most power on a clear day when the sun is at a normal angle to the
array.
The DC power produced from Solar Array is fed in to a Battery Bank through a charge controller for
storage. This stored energy will be utilized to operate the DC loads of 24Volt DC or 48V DC with total load
of 800 Watt.
The solar array is anchored on the ground using special material and equipment supplied by Conergy.
The solar array comprises of solar modules interconnected electrically in series and parallel. These solar
modules are fastened to a support structure, which is fixed on to concrete foundations.
III.2. SIZINNG
PV ARRAY SIZING
Average Solar Insolation at
(kWh/Sqm/Day) 5.2 (F)
site
De-rating of Module Output 0.7 (G)
Battery Efficiency
0.95 (G-1)
(Charge/Discharge)
Charge Controller Efficiency 0.9 (G-2)
DC-DC Converter Efficiency 0.9 (G-3)
Capacity of Chosen Modules Wp 210 (H)
Maximum Voltage/Module V 34 (I)
Charging Current of 210Wp
Amps 6.18 (J)
Module
No. of Module in Series
Nos. 4 (K)
(Nos.)
No. of strings in Parallel Nos. 12 (L)
Total No. of Modules in Nos. 48 (M)=(K)*(L)
Battery Sizing
Battery required Type Ni-Cd
Nominal System Voltage V 96 (A)
Loads in Watts W 800 (B)
Loads in Amps Amps 8.3 (C)=(B)/(A)
Back Up Time in Hours Hours 72 (D)
Unadjusted Capacity Amp-Hour 600 (E)= (C) * (D)
Temperature correction
factor at minimum of 10 1.09 (F)
deg. C
Discharge Adjustment(DOD
0.70 (G)
Factor)
Charge controller and DC-
1.20 (H)
DC converter efficiency
Aging factor 0.80 (I)
Battery State of Charge
0.88 (J)
Factor
The calculated battery (K) = (E)*(F)*(H) /
Ah 1592.53
capacity (G)*(I)*(J)
Equivalent load current in
Amps 22.12 (L) = ((K)/(D)
amps (A)
End Cell Voltage (ECV) 1.10 (M)
Number of cells 80.00 (N)
50% load of battery bank in
11.06 (0) = (L)/2
amps (A)
Battery selected as per
performance table in the HSL+830
catalogue
Battery model (for 50%
80 HSL+830
capacity)
The capacity of Battery
768.00 Ah
bank @ C5
The following are the major systems, sub systems & components that are used for these projects:
SunTechnics/
1 Solar photo voltaic module-210Wp 48 No.
Conergy India
SunTechnics/
2 24 Module mounting structure/Suitable For Above Qty 2 Set
Conergy India
Polycab/Advance/
3 FRLS Aromoured Cables & Accessories 1 Set
Ravin Cable/Equivalent
SunTechnics/
4 Array Junction Box 1 Set
Conergy India
1 SunTechnics/
5 Isolator Junction Box No.
Conergy India
2x100% Solar charge Controller Suitable 96V/100A DC 1 Chabbi/Universal/
6 No.
Solar Array Input Conergy
2x50% Low Discharge Pocket Plate Nickel Cadmium
7 Battery of capacity 2 x 96V 768 AH = 96V/1536Ah At C5 1 No. HBL/AMCO/Equivalent
rate of Discharge.
SunTechnics/
8 Battery Protection Panel with Common Bus 1 No.
Conergy India
1 Chabbi/Universal/
9 2x100% - 96V-24V/ & 48V DC-DC Converter. No.
Conergy
150A Cell Booster Suitable To Charge 6 Cells of 768AH Chabbi/Universal/HBL/
10 1 Set
Ni-Cd BATTERY Conergy
SunTechnics/
11 DC Distribution board 1 No.
Conergy India
2x50% - 415AC, 3Ph Charger
Chabbi/Universal/HBL/
12 2 x 96V/200A Float Cum Boost Charger Suitable For 1 No.
Conergy
2X50% - 96V/768AH NI-CD Battery.
SunTechnics/
13 Earthing systems 1 Set
Conergy India
SunTechnics/
14 Lightening Arrester 1 Set
Conergy India
SunTechnics/
15 Installation Accessories 1 Set
Conergy India
V.1. PV MODULES
Solar cells produce direct current electricity from light, which can be used to power equipment or to
recharge a battery. Cells require protection from the environment and are usually packaged tightly behind a
glass sheet. When more power is required than a single cell can deliver, cells are electrically connected
together to form photovoltaic modules, or solar panels. A photovoltaic module is a packaged interconnected
assembly of photovoltaic cells, which converts sunlight into electrical power. The cells are hermitically
sealed between glass and back cover (Tedlar) to protect them from harsh environments.
The modules being offered are IEC 61215 Edition II and IEC 61730 (Part I and Part II) compliant
Each module will have 72 solar cells connected in series.
Each module will be tested using Sun-simulator to find out modules output parameters at standard test
conditions (STC) of irradiance of 1000 W/m², AM1.5 and cell temperature of 25˚C. The module will be
tested by connecting a load with minimum possible resistance to very high resistance to find out the module
parameters from short circuit to open circuit condition.
Each PV module will have RF identification tag. The following information will be mentioned in the RFID
used on each module.
3. Month and year of the manufacture (separately for solar cells and module)
10. Other relevant information on traceability of solar cells and module as per ISO 9000 series.
Note:
The Performance of the solar modules is measured at STC: Irradiance 1000 W/m²,
Module Temperature at 25°C and AM 1.5G spectrum
Refer Technical Data sheet in Annexure- II
The module mounting structure is designed for holding suitable number of modules in series. The frames
and leg assemblies of the module mounting structures is of Mild Steel hot dip galvanized of suitable
sections of Angle, Channel, Tubes. All hardware considered for fastening modules with this structure are
of very good quality of Stainless Steel (SS304). The module mounting structure is designed in such a way
that it will occupy minimum space without sacrificing the output from SPV panels at the same time it will
withstand severe wind speed up to a maximum 200kmph.
PCC ARRAY FOUNDATION BASE: The legs of the structures made with GI will be fixed and grouted in
the PCC foundation columns made with [Link] mix of cement concrete. The minimum clearance of the
lowest part of any module structure shall not be less 500 mm from ground level. While making the
foundation design, due consideration shall be given to weight of module assembly, maximum wind speed
of 200 km/hr.
PV MODULE MOUNTING STRUCTURE TECHNICAL SPECIFICATION
Parameters Specifications
Type Fixed Type
Configuration 24 Module Structure/12 Module Structure
Material MS Galvanized
Coating Hot dip (galvanized) Minimum of 100 Micron thick
Wind rating 200 km/hr (Horizontal)
Tilt angle Suitable to site
Foundation PCC ([Link])
Fixing type Using SS 304 fasteners
V.4. ISOLATOR
An isolator is used to make sure that an electrical circuit can be completely de-energized for service or
maintenance purpose. This can be used for isolating the solar array inputs coming from two different
AJBs.
This protection panel will act as central controlling unit, connecting the solar charge controller output,
Battery connection and DC-DC converter input. Any of the battery banks can be isolated in this panel for
servicing or maintenance.
Solar Charge Controller will be floor/wall mounting type housed in a cubicle, made out of PVC coated
hairline finish stainless steel of 2/1.6mm thick. Input and Output terminals shall be provided for the
incoming and outgoing cables. The charge controller shall be suitable for bottom cable entry with front
and rear access and shall confirm to IP:31 degree of Protection. The following are the details of the
equipment the solar power controller acts as an interface among photovoltaic (PV) array, battery, battery
charger and load. This unit controls the power output from PV array, protects battery from overcharge /
deep discharge and gives a regulated output to load. The various system parameters are monitored to
ensure a reliable and optimum system performance.
SPECIFICATIONS:
Nominal Voltage: 96V DC
Output Voltage: 96V DC
Load regulation: +5%, -3%
PV array current: 100A max (Please confirm)
Battery charger current: 150A
Load current: Suitable for 24V/1000W
SYSTEM DESCRIPTION:
The control system is designed to perform the following main functions:
a. Protect the battery from both overcharge and deep discharge.
b. Monitor various system parameters with necessary indications and alarms.
c. Maintain output voltage within specified regulation limits.
Enclosure protection IP 31
Mounting Floor/Wall
Efficiency >80%
TECHNICAL SPECIFICATION
Parameters Specifications
Make Conergy
Type Non draw-out type, Front operation & maintenance type
with Voltmeter and Ammeter.
Degree of protection IP 41
Mounting Wall mounted
Battery Charging Equipment comprising of 2x50% Float cum Boost Charger housed in a common cubicle,
made out of suitable sheet steel of 2mm/1.6mm. Cabinet shall be painted in shade 631 as per IS:5.
Louvers will be provided for ventilation, backed-up by fine wire mesh to make the cabinet vermin-proof
and dust-proof to the extent possible.
Input and Output terminals shall be provided for the incoming and outgoing cables. The charging
equipment shall be suitable for bottom cable entry with front access and shall conform to IP: 31 degree of
Protection.
The following are the details of the equipment: -
EACH FLOAT CUM BOOST CHARGER intended to operate off a three phase four wire AC supply of
415V±10%, 50Hz±5% and suitable to charge 80 Ni-CD cells and capable of the Following two modes of
operation:-
i) CONSTANT CURRENT MODE (BOOST MODE):- In the constant Current mode, the charger is capable
of Boost charging the Batteries at any Constant Current settable from 25% to 100% of 150A. The Current
will remain stabilized within ±2% of the set current. The DC output voltage range of 1.42V to 1.7V per cell
required for Boost charging will be automatically selected by the Charger in this Constant Current Mode.
ii) CONSTANT VOLTAGE MODE (FLOAT MODE):- In Constant Voltage Mode floats the battery at 1.3V
to 1.45V per cell with a voltage stabilization of ±1% and feeds the DC continuous load of 100A.
The AC ripple content in the DC output voltage of the charger shall not be more than 2% RMS.
Refer Technical Data sheet in Annexure- II
Make HBL/AMCO-SOFT
Self discharge of battery <3% per month at 20 deg C <6% per month at 30 deg C
Type-1: A dual redundant DC-DC converter is used to stabilize 48 volts supply to the indicated loads.
Nominal Input voltage of 96 volts from battery shall be fed to the DC-DC converter input through
protection panel.
Type-2: A dual redundant DC-DC converter is used to stabilize 24 volts supply to the indicated loads.
Nominal Input voltage of 96 volts from battery shall be fed to the DC-DC converter input through
protection panel.
TECHNICAL SPECIFICATION
Parameters Specifications
Make Chabbi/Universal/Conergy/Equivalent
Type Parallel redundant (2x100%)
Input Voltage 96V DC (As per design)
Output voltage 24V DC and 48 V DC
Accuracy +/-1%
Efficiency >80%
V.11. CABLES
These copper Cables are insulated with a special grade PVC compound formulated and manufactured in-
house. The skin coloration offers high insulation resistance and long life. The sizes of the cables between
array interconnections are selected to keep the voltage drop and losses to the minimum. The bright-
annealed 99.97% pure bare copper conductors that offer low conductor resistance, they result in lower
heating thereby increase in life and savings in power consumption.
Cables are suitable for high temperature resistance and excellent weatherproofing characteristics which
provides a long service life to the cables used in large scale projects. The connectors/lugs of copper
material with high current capacity and easy mode of assembly are used. The used cables are of FRLS
(Fire Retardant Low Smoke) type.
A lightning arrester is a device used on electrical power systems to protect the insulation of the system
from the damaging effect of lightning. When a lightning surge or switching surge travels down the power
system to the arrester, the current from the surge is diverted to Ground and protect the system.
The Earthing system incorporated shall provided necessary safety for the entire Solar PV system in the
field.
VI. ANNEXURE- II
4.8 End cell volt. At specified discharge rate (V/ cell) 1.1 V/Cell
4.10 Recommended Float charging voltage per cell Float(1.4 – 1.42 V/Cell)
4.12 Recommended Boost charging voltage per cell Boost(1.5 – 1.70 V/Cell)
4.15 Dimension of battery bank stand (WXDXH) 4005 (L) X 1500 (W) X 1550 (H)
6.4 3Ph Grid Charger 2200 (H) X 3200 (W) 800 (D) mm
2.0 BATTERY
SunTechnics/
1 Solar photo voltaic module-210Wp 48 No.
Conergy India
SunTechnics/
2 24 Module mounting structure/Suitable For Above Qty 2 Set
Conergy India
Polycab/Advance/
3 FRLS Aromoured Cables & Accessories 1 Set
Ravin Cable/Equivalent
SunTechnics/
4 Array Junction Box 2 No.
Conergy India
1 SunTechnics/
5 Isolator Junction Box No.
Conergy India
1 Chabbi/Universal/
9 2x100% - 96V-24V/ & 48V DC-DC Converter. No.
Conergy
SunTechnics/
14 Earthling systems 1 Set
Conergy India
SunTechnics/
15 Lightening Arrester 1 Set
Conergy India
SunTechnics/
16 Installation Accessories & Spares 1 Set
Conergy India
NOTE: The above mentioned qty. may vary depending on the actual site condition.
X.1. ASSUMPTION
• Clear mounting area is available for the PV on the roof without shading/obstruction.
• Assumed terrace area can withstand the dead + live load of modules.
• The maximum cable length from the solar array to the control room is considered as 25mtrs.
• Assumed sufficient space is available for Controllers, Battery bank, distribution boards etc. in the
control room.
• The mounting structures are selected considering significant flat space available in the roof area.
X.2. EXCLUSION
• Lying of the output cables to the loads (load distribution) and grid power required for Battery Charger
is in customer scope
• All the civil works except foundation for module mounting structure is beyond SunTechnics scope.
Note: Due to continual improvement and development the data mentioned above may change, some
photos are for indicative purpose and for Tender purpose only.