Don Bosco Technical Institute

Tema, Ghana

SOLAR PV TRAINING DEPARTMENT

MODULE 6: DC COUPLED SOLAR PV SYSTEM
ADVANCE PROFESSIONAL PV SOLAR TRAINING

1
Brief review on system components

 PV Module: Converts sunlight in to Electrical energy

 Solar Charge controller: Protects the battery from
overcharging and deep discharging
 PWM

 MPPT

 Inverter: Converts DC in to AC
 Battery: Storage

2
DC coupled System

3
AC coupled System
MODULE 9 AC
coupled PV
system

4
AC/DC coupled System
MODULE 9 AC
coupled PV
system

5
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
6
DC Coupled 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 and Design
7
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
need 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…
8
 Example

 [Link] 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
9
Summery
 Mr. Adu 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
 Fluorescenttube 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.
10
Energy efficiency activities
Light bulb
Light bulb

Name Incandescent Compact Light Emitting Fluorescent

florescent Diode (LED) tube
(CFL)
Life span 750-1000 10,000 30,000-50,000 20,000
(Hrs.)
Cost Lowest Low High Medium

Efficacy lm/W 15 60 80 45

Comparison 40W 11W 7W 18W

11
Energy efficiency activities
Fridge

 Compressor is the most important part in the refrigeration cycle. most of

the electricity consumed by refrigerator is due to the operation of
compressor.
 Compressors requires huge amount of power during start-up.
 A lot of energy is wasted since non-inverter compressors stop and start
multiple times a day. This is where inverter compressor comes in.
What is an inverter compressor?
 Simply, special inverter is added that controls the frequency of the
incoming electrical current that goes to the compressor.
 This allows the compressor to operate at variable speeds.
12
Energy efficiency activities
Fridge

Non-inverter Compressor Inverter Compressor

13
Source [Link]
 Inverter vs. Non-inverter Refrigerator

Fridge Non- Inverter Inverter

Gross Capacity 189L 189L

Energy 0.55 kWh/24h 0.42 kWh/24h

Consumption
Price 2100GHC 3150GHC
Operation roaring Silent
Life span 5 years 10 years
14
DC Coupled 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
15
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.
16
Example
Let’s Determine inverter size for Mr. Adu’s apartment.
Total Power= 276W
Safety Factor 1.25-3
Inverter power= Total power * Safety factor Depending on the
= 276 W * 1.3 load type

= 359 W
We choose the next higher available size
Inverter Rated power= 400W
Voltage input = 12V DC
Voltage out put = 230VAC
Frequency = 50 Hz
Output wave form = Pure sine wave form
17
DC Coupled 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
18
 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
19
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
20
Note: The higher the system voltage => less current => less power loss.
 Example
 Let’s Determine battery size for Mr. Adu’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
21
110Ah 12V
 Example
 Let’s Determine battery size for Mr. Adu’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 = Single battery capacity = 200𝐴ℎ =1.65 ≅ 2 batteries in
parallel
Total number of batteries
= Number of batteries in series * number of batteries in parallel
= 1* 2 = 2 batteries each 200Ah, 12V
22
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
Exercise:
Determine battery size using
110Ah 12V 1) 6V, 200
2) 2V 400Ah
200Ah 12V

110Ah 12V
23
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

1 Energy Assessment
2 Inverter Sizing
3 Battery Sizing
4 Solar Array Sizing
5 Charge controller Sizing
6 Cable Sizing
7 System Layout
24
 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 Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
Total PV power required = equivalent sunshine hours per day∗ ᶯ battery∗ ᶯ inverter∗ ᶯ 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟

Component Efficiency
Battery 85% Lead acid, 95% Lithium(LifePO4) Output
Efficiency=
Inverter 90% 𝐼𝑛𝑝𝑢𝑡 25
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 26
48V PWM 100V 250/100 MPPT 250V
 Example

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

Total Energy Consumption/day= 1.6KWh/day
Total PV power required = Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
equivalent sunshine hours per day

1600Wh/day ∗1 .3∗1
= 4.5Hrs/𝑑𝑎𝑦 = 462Wp

27
 Note:

Example
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.
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 Voc= 22V
Number of PV modules = PV module maximum power (Pmax) Imp= 8.88A
462𝑊 Isc= 9.3A
= = 2.89 = 3 panels each 160W
160W(Pmax)
Charge controller Voltage input
Number of PV module in series = PV module voltage open circuit (V )
oc

28V
= 22V (Voc) = 1.2 round it down to 1=> only one panel per string
Total number of PV module 3
Number of PV module in parallel = Number of PV in Series = 1 = 3 panels in Parallel
28
Example

Let’s calculate number of panels required using 250W 36 cell PV module Pmax= 250W
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required Vmp= 18.6V
Number of PV modules = PV module maximum power Voc= 22V
(Pmax) Imp= 13.2A
462𝑊 Isc= 13.8A
= = 1.85 = 2 panels each 250W
250W(Pmax)
Charge controller Voltage input
Number of PV module in series = PV module voltage open circuit (V )
oc

28V
= 22V (Voc) = 1.2 round it down to 1=> only one panel per string
Total number of PV module 2
Number of PV module in parallel = Number of PV in Series = 1 = 2 panels in Parallel
29
Example
PV connection diagram
Option one 3* 160W Option two 2* 250W

Vm=18V
Im= 8.88A *3 =26.6A
Pt=18V* 26.6A= 3*160W= 480W Vm= 18.6V
Im=13.2A*2=26.4A 30
Pt= 2*250W= 500W
DC Coupled 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
31
 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

32
Online Link MPPT Calculator - Victron Energy
 Example

 Let’s calculate charge controller rating for Mr. Adu’s apartment

 We have calculated the panels size => current rating
Voc=22V
 System voltage (Battery voltage) => voltage rating Isc= 9.3A *3 =27.9A

Current rating of charge controller =Isc* Number of strings in parallel * safety factor
= CCcurrent rating= 9.3A*3*1.3= 36.3A
Round the value to the next available higher size which is 40A
Voltage rating = system voltage = 12V
Type= PWM
40A,12V, PWM charge controller 33
DC Coupled 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
34
 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 PV to CC CC to Battery to Inverter to

voltage Battery Inverter Load
0.5% 0.5% 5%
12V 0.06V 0.06V 11.5V
24V 4% 0.12V 0.12V For
230V
48V 0.24V 0.24V system
Voltage drop
35
 Example
Fuse rating
Mr. Adu’s PV to CC CC to Battery Battery to Inverter to PV to CC= Iarray *S.F
apartment Inverter Load 29.4A*1.3=38.2A
Available size 40A DC
8m 2m 2m 45m 30V(higher) slow blow fuse

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

PV to CC [P= 480W, Vbat= 12V, Distance 8m, 𝑉𝑑𝑟𝑜𝑝 =0.48V]

IArray=Imp ∗ numberof strin𝑔𝑠 = 9.8A*3=29.4A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.48𝑉
Rwire= = =0.016Ω
𝐼𝑙𝑜𝑎𝑑 29.4𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗8𝑚
Amm2= *2 = 𝑚
* 2 = 17.8mm2
𝑅𝑤𝑖𝑟𝑒 0.016Ω
36
Available size 16.0mm2 Wire.
Example
Fuse rating
CC to Battery= ICharging *S.F
29.4A*1.3=38.2A
Available size 40A DC
Let’s calculate cable size for Mr. Adu’s apartment 30V(higher) slow blow fuse
CC to Battery [Vbat= 12V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.06V]
ICharging= IArray = Imp ∗ numberof strin𝑔𝑠 = 9.8A*3= 29.4A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.06𝑉
Rwire= = =0.002Ω
𝐼𝑙𝑜𝑎𝑑 29.4𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 35.6mm2
𝑅𝑤𝑖𝑟𝑒 0.002Ω

Available size 35.0mm2 Wire.

37
Example
Fuse rating
Battery to Inverter= IDischarging *S.F
33.3A*1.3=43.3A
Available size 50A DC
Let’s calculate cable size for Mr. Adu’s apartment 30V(higher) slow blow fuse
Battery to Inverter [Vbat= 12V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.06V]
400𝑊
Idischarging= = 33.3A
12𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.06𝑉
Rwire= = =0.0018Ω
𝐼𝑙𝑜𝑎𝑑 33.3𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 39.5mm2
𝑅𝑤𝑖𝑟𝑒 0.0018Ω

Available size 35.0mm2 Wire.

38
Example
MCB rating
Inverter to load = ILoad *S.F
1.83A*1.3=2.38A
Available size 6A AC 230V MCB
Let’s calculate cable size for Mr. Adu’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

0.0178 Ωmm 2
ρcu ∗ Length ∗45𝑚
Amm2= *2 = 𝑚
* 2 = 0.23mm2
𝑅𝑤𝑖𝑟𝑒 6.82Ω

Available size 1.0mm2 Wire.

39
DC Coupled 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
40
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
 HelioScope
 Autocad

41
 Example
Let’s draw simple design layout for Mr. Adu’s apartment
3*160Wp

PWM Charge controller

40A 12V

Fuse Fuse

0 OFF 0 OFF 0 OFF 0 OFF

1.0mm2

35mm2
16mm2 0 OFF
C6

0 OFF

AC Load
35mm2 400W Pure sine wave inverter
35mm2

35mm2
12V DC Input 230VAC Output

110Ah 12V 110Ah 12V 110Ah 12V 42

AGM AGM AGM
Example 1
Summarized

 Step-1 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
Total Power= 276W
Total Energy consumption/day =1572Wh/day ≅ 1.6 KWh/day
43
Example 1
Summarized

Step 2: Inverter Sizing

Inverter power= Total power * Safety factor
= 276 W * 1.3
= 359 W
We choose the next higher available size
Inverter Rated power= 400W
Voltage input = 12V DC
Voltage out put = 230VAC
Frequency = 50 Hz
Output wave form = Pure sine wave form

44
Example 1
Summarized

110Ah 12V

 Step-3 battery sizing

1600wh∗1
Required battery capacity(Ah) = = 330Ah 110Ah 12V
12V∗ 0.85∗0.95∗0.5
System Voltage
Number of Battery in series = = 12V/12V = 1battery in series
Single Battery Voltage
110Ah 12V
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

45
Example 1
Summarized

 Step-4 PV array sizing

Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
Total PV power required =
equivalent sunshine hours per day
1600Wh/day ∗1 .3∗1
= = 462Wp
4.5Hrs/𝑑𝑎𝑦
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required
Number of PV modules =
PV module maximum power (Pmax)
462𝑊
= = 2.89 = 3 panels each 160W
160W(Pmax)
Charge controller Voltage input
Number of PV module in series =
PV module voltage open circuit (Voc)
28V
= = 1.2 round it down to 1=> only one panel per string
22V (Voc)
Total number of PV module 3
Number of PV module in parallel = = = 3 panels in Parallel
Number of PV in Series 1
46
Example 1
Summarized

 Step 5- Charge controller sizing

Current rating of charge controller =Isc* Number of strings in parallel * safety factor
= CCcurrent rating= 9.3A*3*1.3= 36.3A Voc=22V
Isc= 9.3A *3 =27.9A
Round the value to the next available higher size which is 40A
Voltage rating = system voltage = 12V
Type= PWM
40A,12V, PWM charge controller

47
Example 1
Summarized
3*160Wp

PWM Charge controller

40A 12V

Fuse Fuse

0 OFF 0 OFF 0 OFF 0 OFF

1.0mm2

35mm2
16mm2 0 OFF
C6

0 OFF

AC Load
35mm2 400W Pure sine wave inverter
35mm2

35mm2
12V DC Input 230VAC Output

110Ah 12V 110Ah 12V 110Ah 12V 48

AGM AGM AGM
 System efficiency
PWM charge controller
 Since PWM charge controller works at the same voltage level with battery voltage, Array
voltage surly drop closer to battery voltage. As a result the maximum charging power is
80%.

Output
Efficiency=
Input

V= 14.4V 80𝑊
ᶯ 𝑃𝑊𝑀 𝐶 . 𝐶 = = 0.8
I=5.56A 100W
P=80W

Vm= 18V
49
Im=5.56A
14.4V
P=100W
System efficiency
Battery

 Not all of the charging energy transferred into the battery is available when the battery is
being discharged.
 The charge efficiency of a lead acid battery is approximately 85% at 25°C

Heat out
Gas out

Electricity in Electricity out

Chemical reaction
E=100Wh E=85Wh
Output
Efficiency=
Input 50
 System efficiency
Inverter
 The efficiency of an inverter refers to the amount of AC output power it provides for a
given DC input. This normally falls between 85 and 95 percent, with 90 percent being
the average.
 How to test inverter efficiency? 67W
 Let say we are powering 60W AC bulb.
 You have to measure power on both side. 5.1A
0.0wh
13V
67W

Output
Efficiency=
Input
60W
60𝑊
ᶯ 𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 = = 0.9
67W
51
13V
 On the previous example we didn’t consider system
Example 1 efficiency. Due to that we end up with less energy.
Without Considering System Efficiency
400W INVERTER
PWM 40A/12V
12V DC IN, 230V AC OUT

Eout=Ein * ᶯ Battery
= 1723Wh*0.85=1465Wh
Vmp=18V
Imp= 8.88A *3 =26.6A
P=3*160Wp= 480Wp

110Ah
110Ah12V
Vbat=14.4V, I=26.6A 12V

P=14.4V*26.6A=383W P=276W
P=276W
E=383W*4.5Hr=1723Wh Eout=Ein * ᶯ Inverter
E=1572Wh
E=1572Wh
Or Simply = 1465Wh*0.90=1318Wh
110Ah 12V
Eout=Ein * ᶯ C.C
480w*4.5Hrs*0.8 Initially we calculated that 52
=1728Wh Total daily Energy consumption
110Ah 12V =1572Wh
 Example 1
Summarized

 Initially we calculated daily energy consumption 1572Wh/day

 Due to losses finally we end up 1318Wh/day which is not sufficient to cover daily energy
demand.
 Power loss in individual devices must be accounted.
 When we do PV estimate we have to consider losses in every component from source up to
the load point.
Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days
Total PV power required =
equivalent sunshine hours per day ∗ ᶯ 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟 ∗ ᶯ battery ∗ ᶯ inverter

Component Efficiency @ 25°C

Battery 85% Lead acid, 95% Lithium(LiFePO4)
Output
Inverter 90% Efficiency=
Input 53
Charge controller 80% PWM, 95% MPPT
Example 1
Summarized

Let’s calculate Total PV Power required one more time.

Total Energy consumption(Wh/day) ∗ safety factor ∗ Autonomy days Pmax= 160W
Total PV power required = Vmp= 18V
equivalent sunshine hours per day∗ ᶯ battery∗ ᶯ inverter∗ ᶯ 𝑐ℎ𝑎𝑟𝑔𝑒 𝑐𝑜𝑛𝑡𝑟𝑜𝑙𝑙𝑒𝑟
1572Wh/day∗ 1.3∗1 Voc= 22V
Total PV power required =
4.5h/day∗ 0.85∗0.9∗0.8
= 742Wp Imp= 8.88A
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required Isc= 9.3A
Number of PV modules =
PV module maximum power (Pmax)
742𝑊
= = 4.63 = 5panels each 160W
160W(Pmax)
Charge controller Voltage input
Number of PV module in series =
PV module voltage open circuit (Voc)
28V
= = 1.2 round it down to 1=> only one panel per string
22V (Voc)
Total number of PV module 5
Number of PV module in parallel = = = 5 panels in Parallel
Number of PV in Series 1

54
Example 1
Summarized

 Now we are going to have five modules in parallel (5 strings) the current is going to be
higher.
 We have to calculate charge controller current rating as well.
Current rating of charge controller
=Isc* Number of strings in parallel * safety factor
CCcurrent rating= 9.3A*5*1.3= 60.45A
Round the value to available size which is 60A
Voltage rating = system voltage = 12V
Voc=22V
Isc= 9.3A *5 =46.5A Type= PWM
60A,12V, PWM charge controller
Note: it might be impossible to find 60A,12V PWM charge
controller in such case we can use another alternative by 55
combining multiple charge controllers in parallel. Eg. 2* 30A,12V
 Example 1
Considering System Efficiency
400W INVERTER
PWM 60A/12V 12V DC IN, 230V AC OUT

Eout=Ein * ᶯ Battery
= 2877Wh*0.85=2445Wh
Vmp=18V
Imp= 8.88A *5 =44.4A
P=5*160Wp= 800Wp

Vbat=14.4V, I=44.4A 110Ah 12V

P=14.4V*44.4A=639.4W P=276W
E=639.4W*4.5Hr=2877Wh Eout=Ein * ᶯ Inverter
E=1572Wh
Or Simply = 2445Wh*0.90=2200Wh
110Ah 12V
Eout=Ein * ᶯ C.C
800w*4.5Hrs*0.8 Now our customer is satisfied!
56
=2880Wh We have 30% more energy due to
110Ah 12V the safety factor 1.3 we put.
Example 2
Determine the PV sizing for the following loads given below

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

57
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 = 276 W * 1.3
≅ 1.6 KWh/day = 359 W
We choose the next higher available size
Inverter Rated power= 400W
Voltage input = 24V DC
Voltage out put = 230VAC
Frequency = 50 Hz
Output wave form = Pure sine wave form
58
 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) = = 165Ah
24V∗ 0.85∗0.95∗.5
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
59
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) = = 165Ah
24V∗ 0.85∗0.95∗.5
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
60
200Ah 12V
Example 2 Which one do
you like?

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 61
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)

62
Example 2

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 5 Pmax= 160W
Number of PV module in parallel = = = 2.5 round it
Number of PV in Series 2 Vmp= 18V
up => 3 panels in Parallel Voc= 22V
 Total number of PV Modules= Number of PV module in series * Number of PV Imp= 8.88A
Isc= 9.3A
module in parallel
 =2*3= 6 PV modules panels each 160W

63
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
Number of PV modules =
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required Imp= 13.2A
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) Pmax= 190W
Total number of PV module 3 Vmp= 36.6V
Number of PV module in parallel = = = 1.5 round it up
Number of PV in Series 2
Voc= 22V
=> 2PV string.
Imp= 5.1A
 Total number of PV Modules= Number of PV module in series * Number of PV
module in parallel Isc= 5.3A

 =2*2= 4 PV modules panels each 250W 64

Exercise
190W 72Cell
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 65
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

66
 Example 2
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to PV to CC= Iarray *S.F
measurement Inverter Load 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

0.0178Ωmm
2
ρcu ∗ Length ∗8𝑚
Amm2= *2 = 𝑚
* 2 = 5.8mm2
𝑅𝑤𝑖𝑟𝑒 0.05Ω

Available size 6.0mm2 solar cable.

67
 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
ICharging= IArray = Imp ∗ numberof strin𝑔𝑠 = 8.88A*3= 26.6A Available size 20A DC
50V(higher) slow blow fuse
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= = =0.0045Ω
𝐼𝑙𝑜𝑎𝑑 26.6𝐴

0.0178Ωmm
2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 15.8mm2
𝑅𝑤𝑖𝑟𝑒 0.0045Ω

Available size 16.0mm2 Cable.

68
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
Idischarging= = 16.6A 50V(higher) slow blow fuse
24𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= = =0.007Ω
𝐼𝑙𝑜𝑎𝑑 16.6𝐴

0.0178Ωmm
2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 9.8mm2
𝑅𝑤𝑖𝑟𝑒 0.007Ω

Available size 10.0mm2 Wire.

69
Example 2
MCB rating
Inverter to load = ILoad *S.F
Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝 =11.5V] 1.83A*1.3=2.38A
VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC Available size 6A AC 230V MCB
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 400𝑊
ILoad= = = 1.83A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉
Rwire= = =6.82Ω
𝐼𝑙𝑜𝑎𝑑 1.83𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗45𝑚
Amm2= *2 = 𝑚
* 2 = 0.23mm2
𝑅𝑤𝑖𝑟𝑒 6.82Ω

Available size 1.0mm2 Wire.

70
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 71
 Example 3 will take you to optimum way of
calculating battery size considering only night
Example 3 time energy consumption.
Step 1. Energy assessment

hours / Night
Item No. power day time Power Energy night time Energy
TV 1 80 3 80 240 4 320
Fridges 1 150 2 150 300 6 900
freezer 1 200 3 200 600 7 1400
Blender 1 150 1 150 150 1 150
Bulbs LED 5 12 3 60 180 5 300
Out side lamp 3 12 0 36 0 8 288
LED Bowser outside 3 30 0 90 0 8 720
Ceiling fan 3 60 4 180 720 5 900
Computer 2 150 4 300 1200 1 300
Laptops 1 60 4 60 240 3 180
printer/ Scanner / copier 1 1,100 3 1100 3300 3 3300 72
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
Voltage input = 48V DC
 Total Energy/day
=6930Wh/day + 8758Wh = Voltage out put = 230VAC
15688Wh Frequency = 50 Hz
Output wave form = Pure sine wave form
≅ 15.7 KWh/day
73
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
74
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
75
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

76
 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

77
Example 3

Pmax= 380W
Let’s calculate number of panels required using 380W PV module. Vmp= 40.5V
Number of PV modules =
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required Voc= 48.9 V
PV module maximum power (Pmax) Imp= 9.39A
=
5579𝑊
= 14.7 = 15 panels each 380W Isc= 9.75 A
380W(Pmax)
Charge controller Voltage input
Number of PV module in series =
PV module voltage open circuit (Voc)
250V
= = 5.1 round it down to 5=> five panels per string
48.9V (Voc)
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

78
 10* 380W

Example 3 5* 380W
Step 5: Charge controller Sizing
Using 15*380W panel
Voltage rating = system voltage = 48V
Type= MPPT MPPT1 MPPT2
250/85 250/60
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 15∗380𝑊
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)

79
 Example 3
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to PV1 to CC1= Iarray *S.F
measurement Inverter Load 18.6A*1.3=24.18A
25m 2m 2m 45m Available size 25A DC
60V(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

0.0178 Ωmm 2
ρcu ∗ Length ∗25𝑚
Amm2= *2 = 𝑚
* 2 = 2.22mm2
𝑅𝑤𝑖𝑟𝑒 0.44Ω

Available size 2.5mm2 Wire.

80
 Example 3
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to PV2 to CC2= Iarray *S.F
measurement Inverter Load 9.39A*1.3=12.2A
25m 2m 2m 45m Available size 16A DC
60V(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

0.0178 Ωmm 2
ρcu ∗ Length ∗25𝑚
Amm2= *2 = 𝑚
* 2 = 1.03mm2
𝑅𝑤𝑖𝑟𝑒 0.86Ω

Available size 1.5mm2 Wire.

81
 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
ICharging= =79A 60V(higher) slow blow fuse
48𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.003Ω
𝐼𝑙𝑜𝑎𝑑 79𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 23.7mm2
𝑅𝑤𝑖𝑟𝑒 0.003Ω

Available size 25.0mm2 Wire.

82
 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
ICharging= =39.5A 60V(higher) slow blow fuse
48𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.006Ω
𝐼𝑙𝑜𝑎𝑑 39.5𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 11.86mm2
𝑅𝑤𝑖𝑟𝑒 0.006Ω

Available size 16.0mm2 Wire.

83
Example 3
Fuse rating
Battery to Inverter= IDischarging *S.F
104.6A*1.3=135A
Available size 150A DC
Battery to Inverter [Vbat= 48V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.24V] 60V(higher) slow blow fuse
5000𝑊
Idischarging= = 104.16A
48𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.002Ω
𝐼𝑙𝑜𝑎𝑑 104.16𝐴

0.0178Ωmm
2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 35.6mm2
𝑅𝑤𝑖𝑟𝑒 0.002Ω

Available size 35.0mm2 Wire.

84
 Example 3

Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝 =11.5V=5%230V]

VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC MCB rating
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 5000𝑊 Inverter to load = ILoad *S.F
ILoad= = = 22.8A 22.8A*1.3=29.6A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉 Available size 32A AC 230V MCB
Rwire= = =0.5Ω
𝐼𝑙𝑜𝑎𝑑 22.8𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗45𝑚
Amm2= *2 = 𝑚
* 2 = 3.2mm2
𝑅𝑤𝑖𝑟𝑒 0.5Ω

Available size 4mm2 Wire.

85
Example 3
Step 7 System layout
10* 380W 5* 380W

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

86
 Example 4
Step 1. Energy assessment
N Load Power No of Total Running Energy Running Energy
o W Loads Power hours consumptio hours/Night consumptio
W during n during n during
day day night

1 6 300 6 300
Light 10 5 50
2 8 288 12 432
Fans 18 2 36
3 4 384 3 288
Tv 48 2 96
4 3 1080 0.5 180
Laptop 90 4 360
5 12 3600 12 3600
Fridge 300 1 300
6 0.5 600 0.5 600
Microwave 1200 1 1200
Total 6252 5400 87
2042
Example 4

Step 2: Inverter Sizing

Step 1. Energy assessment
Total Power= 2042W
 Power= 2042W Inverter power= Total power * Safety factor
 Energy during daytime = 2042 W * 1.3
=6252 Wh ≅ 6.3 KWh = 2655 W
 Energy during night time We choose the next higher available size
=5400Wh ≅ 5.4KWh Inverter Rated power= 3000VA
Voltage input = 24V DC
 Total Energy/day
=6252Wh/day + 5400Wh = Voltage out put = 230VAC
11652Wh Frequency = 50 Hz
Output wave form = Pure sine wave form
≅ 11.7 KWh/day
88
Example 4
Step 3 – Battery sizing

Energy consumption per night ∗Autonomy days

 Battery capacity required =
Voltage system ∗ ᶯ battery∗ ᶯ inverter ∗DOD

5400Wh
=
24V ∗ 0.85 ∗ 0.90 ∗ 0.5

5400Ah
=
9.18𝑉

= 588.2Ah
89
Example 4
 Available Battery in Market
Capacity = 686Ah C10
Voltage = 2V OPzS
System Voltage
 Number of Battery in series = sun power V L 2-1820
Single Battery Voltage C100 1820 C50 1715
C24 1591 C10 1370 C5 1185
24V
=
2V sun power V L 2-910
C100 910 C50 860
= 12 Batteries C24 797 C10 686 C5 590

90
91
Example 4
Total battery capacity required
 Number of Battery in parallel =
Single battery capacity
588.2Ah
=
686Ah
= 0.86 ≈ 1 Battery

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

= 12 battery * 1 batteries
= 12 battery
95mm2

2V 2V 2V 2V 2V 2V

2V 2V 2V 2V 2V 2V 92
Example 4
Step 4: Solar Array Sizing

Total Energy Consumption/day= 1.6KWh/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

11652Wh/day ∗1 .3∗1
= 4.5Hrs/𝑑𝑎𝑦 ∗0.85 ∗ 0.9 ∗ 0.95 = 4632Wp

93
Example 4

Pmax= 380W
Let’s calculate number of panels required using 380W 120 cell half-cut PV module. Vmp= 34.7V
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required
Number of PV modules = Voc= 41.62 V
PV module maximum power (Pmax)
4632𝑊
Imp= 10.93A
=
380W(Pmax)
= 12.1 = 12 panels each 380W Isc= 11.41 A
Charge controller Voltage input
Number of PV module in series =
PV module voltage open circuit (Voc)
150V
= = 3.6=> 3 panels per string
41.62V (Voc)
It is wrong to round 3.6 to 4 because 4*41.6V=166.4V which above 150V MPPT rating
Total number of PV module 12
Number of PV module in parallel = = = 4 Strings in Parallel
Number of PV in Series 3
 Total number of PV Modules= Number of PV module in series * Number of PV module in parallel
 =3*4= 12 PV modules panels each 380W
94
 Available size:
Example 4 150/35, 150/45, 150/60,
150/70, 150/100
Step 5: Charge controller Sizing

Voltage rating = system voltage = 24V

Type= MPPT
In Sizing MPPT we have to calculate charging current
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 12∗380𝑊
Charging current = = = 190A
𝑉 𝑏𝑎𝑡 24V

Now we are to the limit there is no single charge controller which can charge 150/190. so that
we are required to combine two charge controllers.
150/100 and 150/100
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 6∗380𝑊
 150/100 will get two strings, Charging current = = = 95A
𝑉 𝑏𝑎𝑡 𝑓𝑢𝑙𝑙 24V
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 6∗380𝑊
 150/100 will get two strings, Charging current = = = 95A
𝑉 𝑏𝑎𝑡 𝑓𝑢𝑙𝑙 24V

95
Example 4
Step 5: Charge controller Sizing
6* 380W 6* 380W

MPPT1 MPPT2
150/100 150/100

96
 Example 4
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to PV to CC= Iarray *S.F
measurement Inverter Load 21.86A*1.3=28.4A
10m 2m 2m 45m Available size 32A DC
30V(higher) slow blow fuse

PV1 to CC1 [P= 6*380W, VPV= 34.7V, Distance 10m, 𝑉𝑑𝑟𝑜𝑝 =4.16V 4%(3*34.7Vm)]
IArray=Imp ∗ numberof strin𝑔𝑠 = 10.93A*2=21.86A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 4.16𝑉
Rwire= = =0.19Ω
𝐼𝐴𝑟𝑟𝑎𝑦 21.86𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗10𝑚
Amm2= *2 = 𝑚
* 2 = 1.87mm2
𝑅𝑤𝑖𝑟𝑒 0.19Ω

Available size 2.5mm2 Solar Wire.

97
 Example 4
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to PV to CC= Iarray *S.F
measurement Inverter Load 21.86A*1.3=28.4A
10m 2m 2m 45m Available size 32A DC
30V(higher) slow blow fuse

PV2 to CC2 [P= 6*380W, VPV= 34.7V, Distance 10m, 𝑉𝑑𝑟𝑜𝑝 =4.16V 4%(3*34.7Vm)]
IArray=Imp ∗ numberof strin𝑔𝑠 = 10.93A*2=21.86A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 4.16𝑉
Rwire= = =0.19Ω
𝐼𝐴𝑟𝑟𝑎𝑦 21.86𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗10𝑚
Amm2= *2 = 𝑚
* 2 = 1.87mm2
𝑅𝑤𝑖𝑟𝑒 0.19Ω

Available size 2.5mm2 Solar Wire.

98
 Example 4
Fuse rating
CC1 to Battery= ICharging *S.F
CC1 to Battery [Vbat= 24V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.12V] 95A*1.3=123.5A
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 6∗380𝑊 Available size 125A DC
ICharging= = = 95A 30V(higher) mega fuse
𝑉 𝑏𝑎𝑡 24V
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= = =0.0012Ω
𝐼𝑙𝑜𝑎𝑑 95𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 59.3mm2
𝑅𝑤𝑖𝑟𝑒 0.0012Ω

Available size 70.0mm2 Wire.

99
 Example 4
Fuse rating
CC1 to Battery= ICharging *S.F
CC2 to Battery [Vbat= 24V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.12V] 95A*1.3=123.5A
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 6∗380𝑊 Available size 125A DC
ICharging= = = 95A 30V(higher) mega fuse
𝑉 𝑏𝑎𝑡 24V
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= = =0.0012Ω
𝐼𝑙𝑜𝑎𝑑 95𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 59.3mm2
𝑅𝑤𝑖𝑟𝑒 0.0012Ω

Available size 70.0mm2 Wire.

100
 Example 4
Fuse rating
Battery to Inverter [Vbat= 24V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.12V] Battery to Inverter= IDischarging *S.F
125A*1.3=162A
3000𝑊
Idischarging= = 125A Available size 100A*2 DC
24𝑉
30V(higher) Mega fuse
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.12𝑉
Rwire= = =0.001Ω
𝐼𝑙𝑜𝑎𝑑 125𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 74.1mm2
𝑅𝑤𝑖𝑟𝑒 0.001Ω

Available size 95mm2 Wire.

101
 Example 4

Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝 =11.5V=5%230V]

VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC MCB rating
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 3000𝑊 Inverter to load = ILoad *S.F
ILoad= = = 13.7A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉 13.7A*1.3=17.8A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉 Available size 25A AC 230V MCB
Rwire= = = 0.83Ω
𝐼𝑙𝑜𝑎𝑑 13.7𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗45𝑚
Amm2= *2 = 𝑚
* 2 = 1.9mm2
𝑅𝑤𝑖𝑟𝑒 0.83Ω

Available size 2.5mm2 Wire.

102
Example 4
Step 7 System layout 6* 380W
6* 380W

2.5mm2
2.5mm2

MPPT2
150/100
MPPT1
3000VA
150/100
INVERTER/CHARGER
24VDC IN
70mm2 230V AC OUT
70mm2
95mm2

95mm2

2V 2V 2V 2V 2V 2V

2V 2V 2V 2V 2V 2V
103
 Same load profile with example 4
Example 5 But system voltage =48

Step 1. Energy assessment

N Load Power No of Total Running Energy Running Energy
o W Loads Power hours consumptio hours/Night consumptio
W during n during n during
day day night

1 6 300 6 300
Light 10 5 50
2 8 288 12 432
Fans 18 2 36
3 4 384 3 288
Tv 48 2 96
4 3 1080 0.5 180
Laptop 90 4 360
5 12 3600 12 3600
Fridge 300 1 300
6 0.5 600 0.5 600
Microwave 1200 1 1200
Total 6252 5400 104
2042
Example 5

Step 2: Inverter Sizing

Step 1. Energy assessment
Total Power= 2042W
 Power= 2042W Inverter power= Total power * Safety factor
 Energy during daytime = 2042 W * 1.3
=6252 Wh ≅ 6.3 KWh = 2655 W
 Energy during night time We choose the next higher available size
=5400Wh ≅ 5.4KWh Inverter Rated power= 3000VA
Voltage input = 48V DC
 Total Energy/day
=6252Wh/day + 5400Wh = Voltage out put = 230VAC
11652Wh Frequency = 50 Hz
Output wave form = Pure sine wave form
≅ 11.7 KWh/day
105
Example 5
Step 3 – Battery sizing

Energy consumption per night ∗Autonomy days

 Battery capacity required =
Voltage system ∗ ᶯ battery∗ ᶯ inverter ∗DOD

5400Wh
=
48V ∗ 0.85 ∗ 0.90 ∗ 0.5

5400Ah
=
18.36𝑉

= 294.1Ah
106
Example 5
 Available Battery in Market
Capacity = 320Ah C10
Voltage = 2V OPzS
System Voltage
 Number of Battery in series = sun power V L 2-1820
Single Battery Voltage C100 1820 C50 1715
C24 1591 C10 1370 C5 1185
48V
=
2V sun power V L 2-429
C100 420 C50 395
= 24 Batteries C24 370 C10 320 C5 273

107
108
Example 5
Total battery capacity required
 Number of Battery in parallel =
Single battery capacity
294.1Ah
=
320Ah
= 0.91 ≈ 1 Battery

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

= 24 battery * 1 batteries
Negative Busbar Positive Busbar
= 24 battery
95mm2

2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V

2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 109
Example 5
Step 4: Solar Array Sizing

Total Energy Consumption/day= 1.6KWh/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

11652Wh/day ∗1 .3∗1
= 4.5Hrs/𝑑𝑎𝑦 ∗0.85 ∗ 0.9 ∗ 0.95 = 4632Wp

110
Example 5

Pmax= 380W
Let’s calculate number of panels required using 380W 120 cell half-cut PV module. Vmp= 34.7V
𝑇𝑜𝑡𝑎𝑙 𝑃𝑉 𝑃𝑜𝑤𝑒𝑟 required
Number of PV modules = Voc= 41.62 V
PV module maximum power (Pmax)
4632𝑊
Imp= 10.93A
=
380W(Pmax)
= 12.1 = 12 panels each 380W Isc= 11.41 A
Charge controller Voltage input
Number of PV module in series =
PV module voltage open circuit (Voc)
150V
= = 3.6=> 3 panels per string
41.62V (Voc)
It is wrong to round 3.6 to 4 because 4*41.6V=166.4V which above 150V MPPT rating
Total number of PV module 12
Number of PV module in parallel = = = 4 Strings in Parallel
Number of PV in Series 3
 Total number of PV Modules= Number of PV module in series * Number of PV module in parallel
 =3*4= 12 PV modules panels each 380W
111
 Available size:
Example 5 150/35, 150/45, 150/60,
150/70, 150/100
Step 5: Charge controller Sizing

Voltage rating = system voltage = 48V

Type= MPPT
In Sizing MPPT we have to calculate charging current
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 12∗380𝑊
Charging current = = = 95A
𝑉 𝑏𝑎𝑡 48V

MPPT 150/100 *1

112
Example 5 12* 380W
Step 5: Charge controller Sizing

MPPT
150/100

Negative Positive
Busbar Busbar 113
 Example 5
Step 6: Cable Sizing
Fuse rating
Distance PV to CC CC to Battery Battery to Inverter to PV to CC= Iarray *S.F
measurement Inverter Load 43.72A*1.3=56.83A
10m 2m 2m 45m Available size 63A DC
60V(higher) slow blow fuse

PV to CC [P= 12*380W, VPV= 34.7V, Distance 10m, 𝑉𝑑𝑟𝑜𝑝 =4.16V 4%(3*34.7Vm)]

IArray=Imp ∗ numberof strin𝑔𝑠 = 10.93A*4=43.72A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 4.16𝑉
Rwire= = =0.095Ω
𝐼𝐴𝑟𝑟𝑎𝑦 43.72𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗10𝑚
Amm2= *2 = 𝑚
* 2 = 3.7mm2
𝑅𝑤𝑖𝑟𝑒 0.095Ω

Available size 4.0mm2 Solar Wire.

114
 Example 5
Fuse rating
CC1 to Battery= ICharging *S.F
CC to Battery [Vbat= 48V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.24V] 95A*1.3=123.5A
𝑡𝑜𝑡𝑎𝑙 𝑃𝑉 𝑝𝑜𝑤𝑒𝑟 12∗380𝑊 Available size 125A DC
ICharging= = = 95A 60V(higher) mega fuse
𝑉 𝑏𝑎𝑡 48V
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.0025Ω
𝐼𝑙𝑜𝑎𝑑 95𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 28.2mm2
𝑅𝑤𝑖𝑟𝑒 0.0025Ω

Available size 35.0mm2 Wire.

115
 Example 5
Fuse rating
Battery to Inverter [Vbat= 48V, Distance 2m, 𝑉𝑑𝑟𝑜𝑝 =0.24V] Battery to Inverter= IDischarging *S.F
62.5A*1.3=81.25A
3000𝑊
Idischarging= = 62.5A Available size 100A*2 DC
48𝑉
60V(higher) Mega fuse
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 0.24𝑉
Rwire= = =0.0038Ω
𝐼𝑙𝑜𝑎𝑑 62.5𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗2𝑚
Amm2= *2 = 𝑚
* 2 = 18.5mm2
𝑅𝑤𝑖𝑟𝑒 0.0038Ω

Available size 25mm2 Wire.

116
 Example 5

Inverter to load [VSource= 230V, Distance 45m, 𝑉𝑑𝑟𝑜𝑝 =11.5V=5%230V]

VLoad = Vinverter - 𝑉𝑑𝑟𝑜𝑝= 230V-11.5V=218.5V AC MCB rating
𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑃𝑜𝑤𝑒𝑟 3000𝑊 Inverter to load = ILoad *S.F
ILoad= = = 13.7A
𝑉𝐿𝑜𝑎𝑑 218.5𝑉 13.7A*1.3=17.8A
𝑉𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑤𝑖𝑟𝑒 11.5𝑉 Available size 25A AC 230V MCB
Rwire= = = 0.83Ω
𝐼𝑙𝑜𝑎𝑑 13.7𝐴

0.0178 Ωmm 2
ρcu ∗ Length ∗45𝑚
Amm2= *2 = 𝑚
* 2 = 1.9mm2
𝑅𝑤𝑖𝑟𝑒 0.83Ω

Available size 2.5mm2 Wire.

117
Example 5
Step 7 System layout
12* 380W

4mm2

3000VA
MPPT INVERTER/CHARGER
150/100
48VDC IN
25mm2 230V AC OUT
35mm2
25mm2

50mm2

2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V

2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V 2V

118
Final result comparison Example 4 Vs Example 5

component 24V 48V Comment

PV 380W 12pcs 12pcs same

MPPT 2 x 150/100 1 X 150/100 24V is expensive
Battery KWh 24V X 686Ah 48V X 320Ah Nearly same
Inverter 3000VA, 24V 3000VA,48V same
Cable size
PV to CC 2 X (2X2,5mm2) 1 X (2X4mm2) 24V system
requires thicker
cable size
CC to Battery 2 X (2X70mm2) 1 X (2X35mm2)
=>expensive

Battery to 2 X (2X95mm2) 1 X (2X25mm2)

Inverter 119
 Exercise
No Load Power No of Total Running Running Energy Energy Total
Loads Power hours hours consumptio consumptio energy
during during n during n during
day night day night

1 Lamp 15W 4 60W 1h 8h 60Wh 480Wh 540Wh

2 TV 100W 1 100W 3h 3h 300Wh 300Wh 600Wh

3 Fridge 150W 1 150W 10h 6h 1500Wh 900Wh 2400Wh

4 fan 70W 2 140W 10h 3h 1400Wh 420Wh 1820Wh

450W 3260Wh 2100Wh 5360Wh

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To be continued

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