Design of PV System

Major system components

• Solar PV system includes different components that should be selected according
to your system type, site location and applications.
• The major components for solar PV system are solar charge controller, inverter,
battery bank, auxiliary energy sources and loads (appliances).
• PV module
– converts sunlight into DC electricity
• Solar charge controller
– regulates the voltage and current coming from the PV panels going to battery and prevents
battery overcharging and prolongs the battery life.
• Inverter
– converts DC output of PV panels or wind turbine into a clean AC current for AC appliances or
fed back into grid line.
• Battery
– stores energy for supplying to electrical appliances when there is a demand.
• Load
– is electrical appliances that connected to solar PV system such as lights, radio, TV,
computer, refrigerator, etc.
• Auxiliary energy sources
- is diesel generator or other renewable energy sources.
 1. Determine Power
Consumption Demands
• The first step in designing a solar PV system is to find out
the total power and energy consumption of all loads that
need to be supplied by the solar PV system as follows:
• 1.1 Calculate total Watt-hours per day for each
appliance used.
Add the Watt-hours needed for all appliances
together to get the total Watt-hours per day which must be
delivered to the appliances.
1.2 Calculate total Watt-hours per day needed from the
PV modules.
Multiply the total appliances Watt-hours per day
times 1.3 (the energy lost in the system) to get the total
Watt-hours per day which must be provided by the panels.
 2. Size the PV modules
• Different size of PV modules will produce different amount of power.
• To find out the sizing of PV module, the total peak watt produced needs.
• The peak watt (Wp) produced depends on size of the PV module and climate of site location.
• We have to consider “panel generation factor” which is different in each site location. For
Thailand, the panel generation factor is 3.43. For Pakistan, it has to be defined
• To determine the sizing of PV modules, calculate as follows:
• 2.1 Calculate the total Watt-peak rating needed for PV modules
Divide the total Watt-hours per day needed from the PV modules (from item 1.2) by 3.43 to
get the total Watt-peak rating needed for the PV panels needed to operate the appliances.
• 2.2 Calculate the number of PV panels for the system
Divide the answer obtained in item 2.1 by the rated output Watt-peak of the PV modules
available to you.
• Increase any fractional part of result to the next highest full number and that will be
the number of PV modules required.
• Result of the calculation is the minimum number of PV panels. If more PV modules are
installed, the system will perform better and battery life will be improved. If fewer PV
modules are used, the system may not work at all during cloudy periods and battery life will
be shortened.
 3. Inverter sizing
• An inverter is used in the system where AC power output is needed.
• The input rating of the inverter should never be lower than the total
watt of appliances.
• The inverter must have the same nominal voltage as your battery.
• For stand-alone systems, the inverter must be large enough to
handle the total amount of Watts you will be using at one time.
• The inverter size should be 25-30% bigger than total Watts of
appliances.
• In case of appliance type is motor or compressor then inverter size
should be minimum 3 times the capacity of those appliances and
must be added to the inverter capacity to handle surge current
during starting.
• For grid tie systems or grid connected systems, the input rating of
the inverter should be same as PV array rating to allow for safe and
efficient operation.
 4. Battery sizing
• The battery type recommended for using in solar PV system is deep cycle
battery.
• Deep cycle battery is specifically designed for to be discharged to low
energy level and rapid recharged or cycle charged and discharged day
after day for years.
• The battery should be large enough to store sufficient energy to operate
the appliances at night and cloudy days. To find out the size of battery,
calculate as follows:
• 4.1 Calculate total Watt-hours per day used by appliances.
4.2 Divide the total Watt-hours per day used by 0.85 for battery loss.
4.3 Divide the answer obtained in item 4.2 by 0.6 for depth of discharge.
4.4 Divide the answer obtained in item 4.3 by the nominal battery voltage.
4.5 Multiply the answer obtained in item 4.4 with days of autonomy (the
number of days that you need the system to operate when there is no
power produced by PV panels) to get the required Ampere-hour capacity
of deep-cycle battery.
• Battery Capacity (Ah) = Total Watt-hours per day used by appliances x Days
of autonomy (0.85 x 0.6 x nominal battery voltage)
 5. Solar charge controller sizing
• The solar charge controller is typically rated against Amperage and Voltage
capacities.
• Select the solar charge controller to match the voltage of PV array and
batteries and then identify which type of solar charge controller is right for
your application.
• Make sure that solar charge controller has enough capacity to handle the
current from PV array.
• For the series charge controller type, the sizing of controller depends on
the total PV input current which is delivered to the controller and also
depends on PV panel configuration (series or parallel configuration).
• According to standard practice, the sizing of solar charge controller is to
take the short circuit current (Isc) of the PV array, and multiply it by 1.3
• Solar charge controller rating = Total short circuit current of PV array x 1.3

• Remark: For MPPT charge controller sizing will be different. (See Basics of
MPPT Charge Controller)
 Example
• A house has the following electrical appliance
usage:
• One 18 Watt fluorescent lamp with electronic
ballast used 4 hours per day.
• One 60 Watt fan used for 2 hours per day.
• One 75 Watt refrigerator that runs 24 hours
per day with compressor run 12 hours and off
12 hours.
• The system will be powered by 12 Vdc, 110
Wp PV module.
 1. Determine Power
Consumption Demands
Total appliance use = (18 W x 4 hours) +
(60 W x 2 hours) + (75 W x 24 x 0.5 hours)
= 1,092 Wh/day
Total PV panels Total PV Panels Needed =
energy needed =
1,092 x 1.3
= 1,419.6 Wh/day.
 2. Size the PV panel
2.1 Total Wp of PV = 1,419.6 / 3.4
panel
capacity needed

= 413.9 Wp

2.2 Number of PV
= 413.9 / 110
panels needed

= 3.76 modules

Actual requirement = 4 modules

So this system should be powered by at least
4 modules of 110 Wp PV module.
 3. Inverter sizing
• Total Watt of all appliances
= 18 + 60 + 75 = 153 W
For safety, the inverter should be considered
25-30% bigger size.
The inverter size should be about 190 W or
greater.
 4. Battery Sizing
• Total appliances use = (18 W x 4 hours) + (60
W x 2 hours) + (75 W x 12 hours)
Nominal battery voltage = 12 V
Days of autonomy = 3 days
• Battery capacity = [(18 W x 4 hours) + (60 W
x 2 hours) + (75 W x 12 hours)] x 3
(0.85 x 0.6 x 12)
Total Ampere-hours required 535.29 Ah
So the battery should be rated 12 V 600 Ah
for 3 day autonomy.
 5. Solar Charge Controller Sizing
• PV module specification
Pm = 110 Wp
Vm = 16.7 Vdc
Im = 6.6 A
Voc = 20.7 A
Isc = 7.5 A
Solar charge controller rating = (4 strings x
7.5 A) x 1.3 = 39 A
So the solar charge controller should be
rated 40 A at 12 V or greater
 TIPS
• A solar project smaller than 2.5 kW takes only a few
days to design and install.
• The freedom and sense of accomplishment that such a
project grants the home owner lasts for years.
• Photovoltaic systems give individuals the ability to
become self-sustaining and to control the cost of their
electricity - PV systems also teach a fundamental
lesson of local production and consumption unlike any
other experience.
• The California Energy Commission published "A Guide
to Solar PV Design and Installation (pdf)" to enable
more citizens to go solar on their own .
• Don't be intimidated, it's easy if you are fully prepared!
 Tips
• We will list the basic steps for do-it-yourself
solar enthusiasts. You don't have to be an
engineer, nor do you have to actually purchase
equipment at this stage. Just as a starting
point, follow these 10 easy steps:
 1) Know how much electricity (kWh) you
consume and know your electricity rate
• To understand the economics of installing a solar system it is
important that you determine how much electricity you consume in
a year.
• A summary of your electricity usage is on your utility bill.
• Please note that a solar PV system would offset your electricity
demands mostly in the summer months (Not because of the
temperature, rather because the path of the sun varies with the
seasons, it is optimal for PV systems during the summer).
• Also, note that most utility companies have a tier rate structure
based on consumption patterns and state mandates. A small PV
system could reduce your electricity needs enough to move you to
a different tier, lowering your rates and saving you a large amount
of money.
 2) Know how much available roof
space (sq-ft) you have
• To determine how many solar panels you can actually use,
it is important that you know how much roof space you
have.
• Based on the size of your house, draw a diagram of your
roof on a piece of paper. If you'd like to be more technical,
you can use the free tool Google SketchUp or a free CAD
program DraftSight.
• Once you have determined the size of your roof it is
important to know how much of your roof faces towards
the equator (South in the northern hemisphere [USA,
Canada, etc.], north in the southern hemisphere [Australia,
South America etc.]).
• Solar irradiance is strongest coming from the equator and
you will want to maximize the efficiency of your system.
3) Know your solar radiation data and calculate
how much energy you could generate
• You can consult the NREL website (National
Renewable Energy Lab) for official government
statistics on your area. You can also use PV
Watts’ or Solmetric's solar calculators.
 4) Know your shading issues
• If there are obstacles like trees or buildings in
the vicinity of your roof that might create
shade, you need to be careful.
• Shading can reduce the output of your system
and may also damage the solar cells.
• You can use Solar Pathfinder or Solmetric Sun
Eye for detailed shading analysis. Some
utilities rent or loan these devices.
5) Select an appropriate solar module
• There are hundreds of different solar panel on the market,
determining which is the perfect fit for you can be
complicated.
• The size (surface area) of the module and the solar rating
are the most important factors.
• Please note, although the solar ratings might be the same
for some modules, the voltage and current output might
vary
• It is advised to select a lower voltage module for smaller
projects [less than 4 kW].
• Other differences, such as color and financial limitations
may also be a factor.
•
 6) Select an inverter
• Similar to choosing a solar panel, selecting an
inverter out of the many available is not easy.
Consider using micro inverters that are easy to
install and that generate AC power directly
from the module.
• If you want to use a central inverter please
read the linked article and use the string sizing
tools.
7) Choose a racking system to mount your solar
PV system on your roof
• Remember that 10% to 25% of the total costs will be the racking system.
• Pay attention and take your time to decide which racking system is most suitable
for your budget and for your roof.
• The racking system is going to last for at least 20 years and it's one of the key
components since it protects both the roof and the modules.
• A small mistake with the racking can permanently damage the roof or injure
people or property.
• There are a number of different racking and mounting systems available in the
market for roof mounted solar systems.
• Check the manufacturer's websites, read the installation manual.
• Be aware of the codes and plan how you are going to mount the racking system on
the roof. Learn about flashing solutions; I mentioned some options in the linked
article.
• Using an inexpensive racking solution does not mean lower quality, it might
require more effort to install it or the materials may be different.
• To have a glimpse on how to design a roof mount system, you can either refer to a
previous article or you can useUnirac's roof mount part estimator.
• Additionally, as the solar PV field matures unique racking solutions, such as
hanging panels vertically along an exterior wall, become more applicable.
 8) Learn your local and state incentives,
calculate how much money ($) you could save
• Check the DSIRE (Database of State Incentives) website.
• There are also a number of other financial calculators
available online.
• Most importantly, you need to estimate your electricity
generation and compare it to your utility rate.
• Note that different tier rates might apply depending on
your energy consumption.
• Call you utility company and learn about their solar
programs. Learn the applications process.
• Make use of incentives and tax cuts.
•
 9) Get your documents ready

• Every city has a different permitting process. In order to

apply for an incentive or to receive a construction permit,
you will need to obtain the equipments' (module, inverter,
racking) data sheets, and submit a roof drawing and
electrical drawing.
• You can draw those on your own using the programs
mentioned above, or ask a professional to draw them for
you.
• The electrical diagram requires some electrical knowledge
in order to determine the wire sizes, voltage drops, AC and
DC disconnects. Contact an electrician if you don't feel
confident about it.
•
 10) Go Solar!

• Once you feel confident with your system, you

can consult a sales person or distributor.
• If you want to install the system on your own,
read some books about it first. Or just contact a
local electrician and install it together.
• It will take 5 to 15 hours of work to install a small
solar system on your roof, which could be done in
one or two days. Then you can watch your meter
run backwards and enjoy clean energy.
 Things to Check Before Buying
Solar PV System in Pakistan
• Temperature Factors
• When it is said that this is a 1KW Panel, always check at what ambient
temperature.
• Chances are this will be rated at STC, which is 25ºC condition.
• In Lahore 25 is in February. What about summer temperatures 45-46 ºC.
• See derating charts of the manufacturer. You will see thirty percent drop in
output.
• It means panel output decreases with increase in temperature and if you
don’t know, by June or July, it will not give desired KW rating.
• A high temperature coefficient is a sign of a crappy panel.
• A reasonable number is about 0.5%. If you can get this down to 0.3% that
is the sign of an excellent panel. Over 0.7% is a warning sign
 Solar Panel Efficiency
• Unless you have a huge roof, you probably want
an efficiency of at least 14%.
• Otherwise if you ever want to upgrade in the
future, you’ll probably struggle to find any roof
space left over.
• However don’t fall into the trap of believing that
efficiency is the be all and end all of solar panel
quality.
• You can get great quality panels at the lower end
of the efficiency scale.
 Power Tolerance
• This is the amount that the actual power output of your solar
panel can vary from the output specified by the supplier.
• For example a 165W module with a tolerance of +/- 5% could
actually produce from 156.75W up to 173.25W.
• So be aware of this number, as it will directly affect the amount
of power you can get.
• Some manufacturers have a “positive only” power tolerance,
which means you are guaranteed to get at least the specified
output from the panel and usually more.
• For example: a 200W solar panel with a tolerance of +5%/-0%
will produce a minimum of 200W and a maximum of 210W.
•
 Bypass Diodes

• If your panel is mono or multi crystalline then

these are a must.
• They are diodes that cost a few cents each and
are put across neighboring of cells inside the
solar panel.
• If you don’t have bypass diodes then a small
shadow on a tiny part of your solar panel can
stop the entire panel from making electricity.
•
 Panel Type
• Is it a mono crystalline, multi crystalline or thin
film solar panel, or some wacky new technology?
• Make sure you are happy with the technology
that you choose.
• The Backsheet.
• All solar panels have a plastic back sheet glued on
the back of the panel to protect the solar cells.
• A flimsy back sheet with any air bubbles or signs
of coming unstuck is a sign of a crappy panel.
•
 Framing Quality

• The aluminum frame which goes around the solar

panel is a good indicator of the overall quality of the
solar panel’s manufacture.
• Look at the corners. Are they tidy joins? Are they
anodized after the cut, or before.
• Anodizing after the cut is more time consuming, but
means that the 45 degree edge is anodized too, helping
protect from corrosion. Are the panels glued (bad),
screwed or welded at the corners.
• If looks are important to you – then you may want to
look for a black anodized frame – they look good when
mounted in a solar array on a roof.
 Manufacturer
• Do a quick Google of the manufacturer –
What’s their website like?
• Is there a “warranty” section?
• Is there a Pakistan dealer.
• How long have they been around?
• Has anyone had any bad experiences with
them on the forums?
• Cost
• Typical prices for solar power systems of different KW sizes are available at almost all suppliers’
sites. If the cost offered to you for solar system is substantially less, then make sure you are getting
a bargain.
• If the price is much more expensive than those shown, then either you have a particularly difficult
install, or you are paying too much. Get multiple quotes to check which is the case.
•
• Warranty.
• All panels claim to have a minimum 25 year Power Output Warranty.
• But the main criteria is to check that the Warranty is backed by an “on site replacement” warranty.
• You really don’t want to be removing the panel from your roof and going down the post office to
send it back to China!
• There are some excellent solar panels, made in China, these days and also some shocking ones –
the best way to know if the supplier believes in their quality is to see what responsibility they take
for the warranty they offer on them.
•
 Home Assignment date 20/4/18
1. 1. Design a PV home system for your selected
household load as per lecture slides.
2. Find out the pricing of each component used in the
design which should be used in your calculation.
3. Compare it with the rates provided by Classmates. (in
next class).
4. Find out how much you save money per month by
using PV system.
5. Find out the return of investment based on item 4.
6. Submit the assignment in hard form on or before
27.4.18 positively.