Chapter 6 Solar Photovoltaic System Design (Non-Pumping Applications)

6.2 Module /Array Sizing

The goal of array sizing is to balance the usually opposing goals of maximum
reliability and minimum cost. The mechanics of the calculations are quite simple, but
the judgment on the part of designer and the user about the efficiency and
appropriateness of the loads that make a system cost effective.
The basic information required for array sizing is:
A. Environmental Information: The environmental information required for
proper array sizing is Insolation in the given location, ambient temperature
extremes, latitude, longitude, module mounting techniques and autonomy
days. Usually the insolation is recorded on a horizontal surface. A
mathematical model of the movement of the sun must be used to translate
the data to what would be incident on a tilted surface. The average daily
maximum and minimum temperatures for each month must be known. The
maximum temperatures will be needed to predict the loss of voltage by the
array and can impact the choice of modules. The minimum temperatures
are needed to calculate battery size to prevent freezing. Latitudes and
longitudes are needed to identify optimum tilt angle of the array. Finally
module-mounting technique (fixed at one angle, adjustable during the year
or with a sun tracker) is to be known as it can have a large impact in
overall array output and sizing.
B. Load information: Total Wh and Ah consumed per day, any seasonal
distribution of load pattern.
C. Other information likes ground cover, permissible voltage loss in cables,
load surge etc.

The first step in sizing the array is to determine the estimated design insolation or the
peak sun for given locality. For Nepal, the solar radiation data sheet for various parts
of the country can be used (see Annex). To be in safer side, the minimum insolation
(monthly average) should be considered as estimated design insolation. For most part
of Nepal a value between 4.5 to 5.5 could be consider safe. The required total array
output current can be calculated using the following formula:

I array = Total average daily load in Ah @ system voltage /

(peak sun x derating factor x Columbic efficiency) (6.2.1)

Here, the derating factor is generally taken equal to 0.9 and the Columbic efficiency
equal to 0.95.

If a single module cannot deliver the current (here we refer to I mp of the module)
calculated using formula (6.2.1) above, then number of modules have to be connected
in parallel to produce the required level of current. The number of modules to be
connected in parallel can be found by using the following formula:
I array
Np  (6.2.2)
I mp

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Chapter 6 Solar Photovoltaic System Design (Non-Pumping Applications)

It is to be noted that Np may not be the whole number. The actual value of Np should
always be rounded up to the next highest integer value.

Example 6.2.1
Suppose the daily load requirement is 575 Ah and the peak sun
(minimum monthly average) for the locality is 5. The total array
current required, as per formula (6.2.1) would be:
I array = 575 / 5 x 0.9 x 0.95 = 134.51 A
Now a module with Imp = 3.1 A is selected to form an array, then the
number of modules to be connected in parallel would be:
Np = 134.51 /3.1 = 43.39 rounded to 44.
Now if we consider the peak sun to be 5.5, the number of modules
will drop down to 40 only. And if we take the value of peak sun to be
4.5, the number of modules will increase to 49.

As we see from the above example, slight increase or decrease in design insolation
value significantly affects the number of modules required to meet the daily load
demand. Therefore it will be the responsibility of the designer to consider most
optimum and safe value of insolation and the tilt angle to arrive at optimum number
of modules required.

The required number of modules is also a function of I mp. Higher the value of Imp,
lower will be the number of modules required. But modules with higher I mp cost more.
And again, the judgment and market knowledge of the designer will play critical role
in optimizing the cost of the array.

The next step is to determine the number of strings of parallel-connected modules to

obtain desired system voltage. This number is found by using the following formula:
Ns = nominal system voltage / nominal module voltage (6.2.3)
The total number of modules required to deliver the daily average energy (in Ah) at
the system voltage is:
Nt = Np x Ns (6.2.4)

It is to be noted here again that if sun-tracking system is used, the insolation level
could be greatly increased (by 30% in average). By increasing the insolation level, the
number of modules required is decreased. Moreover, the ground reflectivity also plays
not less significant role in the availability of solar radiation in the inclined surface.
However the effect of reflection from the ground (called 'Albedo effect') usually been
considered while calculating insolation in inclined surface.

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