3 DC System Design

This chapter on DC Systems Design

contains the following information:
• String and Array Sizing Rules
• String Connections to Conext CL
Inverter
• DC System Component Design - The
DC Box

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DC System Design
DANGER
ELECTRICAL SHOCK AND FIRE HAZARD

Installation including wiring must be done by qualified personnel to ensure

compliance with all applicable installation and electrical codes including
relevant local, regional, and national regulations. Installation instructions are
not covered in this Solution Guide but are included in the relevant product
manuals for the Conext CL Inverter. Those instructions are provided for use by
qualified installers only.

Failure to follow these instructions will result in death or serious injury.

DC system design comprises of Module and Inverter technology assessment,

string sizing, Arrangement and interconnection of strings, string cable sizing and
length management, DC combiner box sizing if required, string / array cable
sizing and routing up to Inverter’s terminal.

Out of the listed tasks, String sizing is the most important one as many other
decisions depend on it. Like type and size of module mounting tables,
interconnection arrangements and cable routing.

String and Array Sizing Rules

1. Number of modules x Voc (at t° min) < inverter Vmax
The no load voltage of the string (Voc x number of modules in series) at the
minimum temperature of the installation location must be lower than the
inverter’s maximum input voltage.
=> This must be strictly observed. Otherwise the inverter may be destroyed.
Apart from the aforementioned rule for preventing destruction of the inverter
two other limits must be observed.
2. Number of modules x Vmpp (at t° max) > inverter Vmin
The operating voltage (Vm x number of modules in series at all temperatures
at the installation location) should fall within the inverter’s MPPT voltage
range. Otherwise, the inverter will stall and energy supply will cease.
3. Isc strings < inverter Isc max
The total Isc current for strings in parallel must be lower than the maximum
input current for the inverter. Otherwise, the inverter limits the supply of
energy delivered to the network.
We will analyze a use case to understand the string and array sizing in detail.

Number of PV Modules in the Series

For one CL inverter, the maximum number of PV Modules that can be connected
in series will be provided under the most extreme conditions that might occur
during the year. This configuration should consider the effects of temperature,
maximum and minimum radiation in the following order, first, to ensure the

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inverter providing the minimum voltage start-up of the same, and secondly, to
avoid failures in the inverter from surge, with the main objective of maximizing
electricity production.

Minimum Number of PV Modules

We are basically calculating the minimum number of PV Modules in series. The
worst case condition to consider is the maximum radiation incident on the plane
of PV modules. Considering the voltage supplied by each solar cell decreases
with the intensity of incident on the PV Module, the ideal would be that the
number of PV Modules connected in series to provide at least the minimum
voltage of inverter MPPT operation and that will be 350 V DC.

By defining:

Ns min = Number of PV Modules in series at least,

V min = Minimum voltage for maximum power point tracking,

V oc = Open circuit voltage of the panels,

V minr = Voltage at maximum power point

 = Coefficient of variation of voltage with temperature,

Vmp = Voltage at thge point of maximum power

The losses depend on the temperature difference in cell temperature and 25 ºC

of the Standard Test Conditions, the type of cell, encapsulated by the wind.

The Standard Test Conditions (STC) for measurement are the irradiation
conditions and temperature of the solar cell, widely used to characterize the
cells, PV Modules and solar generators and defined as follows:

• Irradiance : 1,000 W/m2

• Spectral distribution : Air Mass 1.5 G
• Cell temperature : 25 º C

To determine the temperature of the cell in any situation using the following
formula:

Tc = T amb + (I inc (w/m2) × (NOCT–20)/800)

Where:

Tc = temperature of the cell, average temperature

Tamb = ambient temperature

I inc = incident radiation (max annual average)

NOCT = nominal operating cell temperature

For this use case, let's calculate the incident radiation when we have a Vmp of
1000 W/m2 and ambient temperature of 35 °C. Assume that NOCT of PV module
correspond to 48 °C (standard value from manufacturer’s data sheet),

We have cell temperature as:

Tc = 35 + ((1000) × (48 – 20) / 800)) = 70 º C

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The temperature difference of the cells relative to Standard Test Conditions will
be:

70 – 25 = 45 º C with a 300 Wp Poly C-Si module

As the manufacturer indicates the variation with temperature of the open circuit
voltage, Vmp to obtain the temperatures of cells shall be indicated by the power
from the PV Module at this temperature divided by the intensity of maximum
power at the same temperature.

This approximation is always the most correct, as the intensity is much more
stable compared to the voltage and it will be possible to assimilate the intensity
variation with temperature of the intensity of a short circuit with the maximum
power.

PV Module  Vmpp/T Vmp Vmp (70ºC)

300Wp Poly C-Si -0.445%/ º C 35.60 28.47
PV module

With this data we can calculate the minimum number of PV Modules to be

connected in series, taking into account that to maintain the minimum voltage
tracking the maximum power is 350 V, we have: 300Wp Poly C-Si module,

Ns min = (Vmin / Vmin r) = (350 / 28.47) = 12.29 modules.

This is the minimum amount of PV Modules to be placed in series with each

brand and ensure the functioning of the inverter 1000 W/m2 and 35°C ambient
temperature.

Maximum Number of PV Modules

The maximum number of PV modules is calculated at the minimum ambient
temperature, considered at the particular geographical installation.

In the second extreme case, the maximum number of PV panels in series that
can be installed to connect the inverter, is given by the ratio between the
maximum input voltage of the inverter and the open circuit voltage of PV Modules
in a situation where the inverter starts with an ambient temperature of 0º C.

Conext CL inverter starts at 130W nominal power value and consider that
approximately we can get to 40 W/m2 radiation accident.

Conservatively considering Tamb min. = -5 ºC.

Operating as in the previous case, we have a cell temperature:

Tc = -5 + ((40 × (48 – 20)/800)) = -3.6 ºC,

The temperature difference of the cells relative to Standard Test Conditions will
be:

-3.6 – 25 = - 28.6 ºC

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PV Module  Voc/T Voc Voc (-3.6 ºC)

300Wp Poly C-Si -0.332%/ º C 45.0 49.7
PV module

Since the maximum voltage is 1,000 V borne by inverters we can know the
maximum number of panels to be placed in series will be: for a 300Wp Poly C-Si
module,

Ns max = (Vmax inv / Voc (0ºC amb)

= (1000 / 49.27) = 20.29

With this we get the maximum number of PV Modules to be placed in series.

Any chosen configuration between 13 to 20 modules will fit, but 20 would be the
most desirable choice.

Number of PV Modules in Parallel

The maximum number of strings installed in parallel connected to Conext
CLConext CL inverters, will be calculated taking into account the worst case for
intensity in the field panels to the inverter.

Whereas the PV Module temperature in 70 °C would have:

2 MPPT / inverter with a maximum input current of 31A DC per MPPT

For 3 strings per MPPT, the maximum current would be:

Impp = 8.30 x 3 = 24.9 Amp at 25 °C Amp modules and 1,000 W

radiation.

If the PV Modules reach 70º C, the increased current would be:

9.16 A × (0.087 / 100) × (70 - 25) × 3 (strings) = 1.07 Amp

Current Total: 24.9 + 1.075 = 25.975 Amp is below the 31 Amp.

The configuration chosen will have 3 strings per MPPT as maximum.

Here we complete our task of string and array sizing.

Schneider Electric offers Conext Designer – A PV string sizing tool to accurately

calculate the size of strings for the selected modules with Conext CL inverters.

The tool is easy to use and available for both Mac and Windows users. The
following link can be used to download the tool.

http://solar.schneider-electric.com/product/conext-designer/

String Connections to Conext CL Inverter

Conext CL inverter’s maximum DC Input current is 31A and Max. Short circuit
current is 40A for independent MPPT operation.

Any string to be connected to each MPPT input has to be within this limit of Short
circuit current for Independent MPPT operation.

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For a Single MPPT operation (MPPT inputs shorted) current limits to follow are
62A for Impp and 77A for Isc.

For the sizing of Strings to connect with Conext CL inverters, one must observe
the short circuit current of PV Module it is going to connect with and number of
parallel string being connected to each MPPT or overall. If there is any multiplier
to be considered based on local standardization or safety authorities, cables and
overcurrent protection devices should be rated for this multiplier (like 25%
overrated).

The DC switch provided with Conext CL inverter is rated 40A DC current and it
breaks both MPPT inputs simultaneously when operated.

Schneider Electric recommends to use One MPPT configuration in case of odd

number of strings being connected to Inverter, if there is no significant difference
within strings (like shadowing or different tilt or a different configuration). In case
of difference in configuration of strings (like tile, shadow, mismatch etc.) dual
MPPT operation is advisable with balanced input.

20kW Conext CL Inverter if connected to four strings, can be used without fuses
but just using Y type string connectors (near PV modules) to combine two strings
into one and terminating one cable on each MPPT terminal. This solution is most
economical option for string connections. Similar approach is not possible for
25kW CL Inverters as more than two strings in parallel requires fuses to avoid
reverse currents in case of fault in one of the parallel connected strings.

DC String Arrangement and Cable Sizing

String cables are sized for three parameters mainly voltage drop, ampacity and
short circuit current. Generally for the PV applications in IEC practice, 4 mm2 Cu,
double insulated, UV protected flexible cables are used to carry string current
which is in order of 8 to 10 Amp.

All DC string cables should be designed for not more than 1% voltage drop.

Following general formula can be used to calculate the % voltage drop in DC

string cables.

2KLI
Vd =  -------------------------------
Cm

Vd
Pct_Vd =  -----------  100
Vop

Where:

Vd, voltage drop (volts)

Vop, the operating voltage at Standard Test Conditions
K, the metal temp coefficient for copper at 25 °C
L, the one way conductor length (m)
I, the operating current at Standard Test Conditions
Cm, the conductor area (circular mm2)
Pct_Vd, the voltage drop at nominal operating conditions (%)

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When a Conext CL inverter is selected with Basic wiring box model, user should
carefully define the DC side protection and disconnect requirement depending
upon the location of inverter with respect to PV module strings.

Length of cable from PV modules to the Inverter / DC Combiner box depends on

the String interconnections and cable routing at the back of PV modules.

There are several ways modules can be installed using some standard racking
options. We suggest our customers to analyze following parameter before
deciding the type of arrangement to interconnect.

Example:

If 300Wp modules to be connected to a 25kW Conext Inverter for any assumed

location where string sizing ends up in 18 modules/ string and considering 20%
oversizing we have following system to connect.

1. DC size – 25kw X 1.2 = 30kWp

2. AC size – 25kW
3. Module size – 300Wp Multi C-Si
4. String size – 18 module/string
5. Number of Strings – (30X1000)/(300X18) = 5.556

Since this set up does not end up in a complete number, we have following
choices:

• Connect 5 string to each inverter with oversizing of 8%

• Connect 6 strings to each inverter with oversizing of 29.6%
• Reduce the rating of Modules from 300Wp to 280Wp and connect 6 strings
with 20% oversizing
• Increase the rating of Modules form 300Wp to 330Wp and connect 5 strings
with 19% oversizing
• Reduce the number of modules in string to 16 and connect 6 strings with
15% O/S
• Increase the number of modules in string to 20 and connect 5 strings with
20% O/S

Recommended basic rules for string formation

1. Select EVEN number for modules in a string.

2. Select EVEN number of strings in a inverter, if possible.
3. Try to maximize modules per string within Voc and Vmpp limits of Inverter.
4. Formation of strings should be designed in a way that cable management at
the back of modules could be followed as per electrical installation rules and
with shortest string cable length as well as minimum bends.
5. Support the Connectors and avoid sharp bend from PV Module cable box.
6. If possible, keep the PV module strings connected and formed in horizontal
lines to avoid row shadow impact on all strings in each wing of racks or
trackers.
7. Follow the instructions of PV module manufacture to select Portrait or
Landscape position of Modules.

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8. Connect shadowed strings to same MPPT and others to the different MPPT to
achieve maximum harvest.
9. Do not combine separate ratings of PV modules in one string

Now considering above basic rules and given situation, we decide to connect 20
PV modules of 300Wp in one string and 5 strings to each inverter.

String cable lengths should be managed by deciding proper interconnection

method and racking block design. An example for 5 string connection with
landscape modules is as below.

Figure 3-1 String arrangement and interconnection example with Landscape

The other way to connect the string when portrait arrangement is chosen can be:

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Figure 3-2 String arrangement and interconnection example with Portrait oriented modules

It is essential to understand and select the right circuit components when any PV
system is designed. After the cables, racking and strings, we will move on to the
next circuit component identified as DC Box.

DC Box consists of Disconnect switches, Surge protection devices and Thermal

release (optional) for emergency operation.

Schneider Electric offers DC Box solution for such installation.

DC System Component Design - The DC Box

Function
1. SW60DC switch – Disconnects each MPPT input of the inverter from the DC
line disconnect.
2. PRD-DC – Protects the inverter against voltage surges coming from DC lines
(Applicable for the Base model only and if circuit required additional SPD).
3. MX+OF releases / MN releases Controls the release of the switches remotely
for emergency purpose – For Rapid shutdown purpose of for fireman safety
requirement.

Typical use
1. The DC box is an optional offer, but is necessary when:
• Local regulations require the use of external DC switch disconnects
• Local regulations require the disconnection of DC lines remotely
(generally as close as possible to the PV modules) in case of emergency
• The lightning risk assessment concludes that protection by SPD is
required
• However, DC Box is required when the base model is chosen
2. The PV array of each MPPT input is preferably disconnected separately
• One switch disconnect per DC input
3. DC box is installed close the PV modules when:

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• Protection by SPD is required and the distance between PV modules and

the inverter is higher than 10 m
• Emergency control of the DC lines is required and the inverter is located
far from the PV modules or inside the building
• Wiring between DC box and inverter must use 6mm² cross-section PV
conductors

Advantages of the offer

1. Two models of DC box:
• with surge protection
• without surge protection
2. Each model is suitable for both CL 20000 E and CL 25000 E inverters.
3. One DC box per inverter, for both MPPT inputs. This allows for separate
disconnection of the PV arrays.
4. Easiness of the DC connections by using PV connectors mounted on the DC
box or close to the DC box.

Figure 3-3 DC Box Schematic Diagram

5. Range for CL 20000 E and CL 25000 E

6. Two models – DC01(R), DC02(R)
• DC01 with switch-disconnects only – DC01R includes release for
emergency control
• DC02 with switch-disconnects and surge voltage protection – DC02R
includes release for emergency control
7. Schneider Component References
Table 3-1 DC Box Component Reference
Components Model Reference Number
Switch SW60 DC – 1000DC, A9N61699 and A9N61701
Disconnect For combined MPPT use
C20NADC
Optional Release MX+OF 26947
48-130 VDC A9N26948
12-24 VDC

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Table 3-1 DC Box Component Reference

Components Model Reference Number
Surge Protection iPRD40r -1000DC A9L16436
device
Enclosure Thalassa PLS modular 24 NSYPLS2727DLS24

Note: For combined MPPT operation, C120NADC type DC MCB should be

used instead of SW60DC.

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