MAKING MODERN LIVING POSSIBLE

Concept paper
String inverters for PV power plants

February 2009

SOLAR INVERTERS
Table of Contents

1 Introduction – Executive Summary ................................................................................................................... 2

2 Choosing the optimum layout of a power plant .......................................................................................... 4
2.1 Quadratic PV fields ........................................................................................................................................ 4
2.2 Alternative field layouts............................................................................................................................... 5
2.3 Compact transformer station .................................................................................................................... 6
2.4 Module layout ................................................................................................................................................. 7
2.5 Data connection............................................................................................................................................. 8
3 Service/reliability ...................................................................................................................................................... 9
4 Appendix A – Wiring diagrams............................................................................................................................ 9
4.1 665 kWp Field wiring ................................................................................................................................... 10
4.2 10 MWp Plant wiring ....................................................................................................................................11
4.3 Layout of the low voltage distributor.....................................................................................................12

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Concept paper - String inverters for PV power plants
1 Introduction – Executive Summary
This concept paper will present new ideas of how to utilise string inverters in large PV plants.

It is well known that there is a coupling between inverter size and specific cost in €/kW. Therefore,
when creating state of the art PV plants in the multi MW range the norm has been to utilise as large
inverters as possible in the effort to drive down the investment cost. Today, central inverters are
available up to a power level between 1 and 2 MW. However, this development trend towards
larger and larger inverters is driving external costs higher.

The inherent modular nature of PV modules (largest module is still below 500W) means that a PV
plant of any size is modular. Hence, it makes sense to look at alternative ways to structure a PV
plant.

By using string inverters as a modular element in the plant, the built-in functionalities of the string
inverters make many of the additional functions that are needed when applying a central inverter
station superfluous.

String inverters of today offer the major advantages of central inverters such as high DC system
voltage range and three-phased output while still maintaining the high efficiencies. This leads to
reduced losses in both AC and DC cabling assuring higher yield. A large number of maximum
power point trackers ensure that more power from the panels is utilised. Additionally, string
combiners and external string monitoring are not required thus making simple cabling possible.

Using compact transformer stations to connect the string inverters to the Medium Voltage grid
means that both transformer stations and inverters can be placed amongst the PV module
substructures with little influence. Furthermore compact transformer stations and string inverters
are easy to install and have short lead times as they are commonly used.

Special training is not required to install, maintain or exchange string inverters, whereby service
contracts known from central inverters can be avoided. By omitting junction boxes, service on the
DC side is also avoided.

This paper will highlight why string inverters are an attractive alternative to central inverters in
power plants. This is done by means of an example of a 10 MWp plant in central Europe with 15
identical quadratic PV fields, 15 individual 630 kVA transformer stations and 15x42 TripleLynx
inverters.

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 Transformer station
LV MV

Figure 1 PV field layout based on crystalline modules

This example shows a layout with 14 rows of substructures each with 12 substructures per row (approx. 125 m x 125 m).
Each substructure is fitted with 18 modules placed in landscape orientation in 3 rows.

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2 Choosing the optimum layout of a power plant
The objective when planning a PV plant is to obtain a high return on investment. On one hand this
requires the use of inverters and medium voltage transformers with optimum efficiency, focus on
limitation of cable loss and losses due to shading, as well as detailed plant monitoring.
On the other hand planning, material and installation costs should be reduced as much as possible.

2.1 Quadratic PV fields

The use of cost efficient compact transformer stations that can be placed centrally in quadratic PV
fields, results in minimisation of cable loss on the DC side and on the AC low voltage side as cable
length between modules, inverter and transformer is minimised. See figure 1 PV field layout.

By using inverters that can handle 1000 V input; junction boxes and a number of string combiners
can be omitted. The DC cables are laid directly from the string of modules to the inverter.

A 630 kVA transformer station can have 42 inverters connected directly and the necessary
switchgear including the low voltage distributor fit into the low voltage area of the transformer
station.

Additionally, 665 kWp PV fields of modular design are profitably erected in larger numbers.

See appendix A for an example of suggested wiring.

Subsequently, the advantages are addressed in more detail:

2.1.1 Advantages on the DC side

The high max. and low min. DC voltage of the string inverters permits a string power of 5.28 kWp
(when connecting 220 Wp modules that have 60 cells per module). The accordingly reduced
number of strings in relation to power reduces cable and installation expenses significantly.

Inverter
Substructures
1
MPPT

2 ~
3

Figure 2 Module wiring based on crystalline modules

Each module row is connected directly to its own MPPT.

The string voltage at NOCT is well above 600 VDC providing optimum efficiency. Additionally, yield
reductions due to DC cable losses are greatly reduced.

The individual MPP tracking for every string (or string group when using modules with lower MPP
current), which is a major advantage of string inverters, enables maximum energy yield per string.
If additionally the three rows of modules per PV substructure are connected to each their own MPP
tracker the risks of losses due to shading are greatly reduced. This is due to the fact that each string
group then has its own independent MPP tracker to control and optimise output. If a string

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disconnects due to insufficient solar radiation or a failure, the other strings continue generating
power, thus maximising the total energy yield.

2.1.2 Advantages on the AC side:

String inverters with IP54 enclosure are suitable for outdoor installations and need no extra shelter
when mounted in the shade on the back side of the module substructure.
The low weight and small dimensions of string inverters allows for the placement of the unit on the
module construction. If the inverter installation is made close to the transformer, the cost of low
voltage AC wiring is greatly reduced, and yield losses due to AC cable losses on the way to the
transformer are avoided.

Figure 3 Inverter location

Inverters are mounted on the backside of the module substructures close to the transformer station
The low voltage distribution for all connected inverters fit into the low voltage part of the transformer station and can be
pre-assembled in the transformer station prior to delivery. See Appendix A 4.3.

2.2 Alternative field layouts

In the above we have considered a quadratic PV field with centrally placed inverters. The same
consideration and subsequent result could also be made with a rectangular layout with 21 rows of
substructures of 8 substructures per row.
Similarly it is possible to design layouts where the inverters are placed decentrally. Here the
optimum solution depends on the material and installation cost of DC cabling, AC cabling including
junction boxes for bundling and protection of AC wiring weighed up against the losses in the DC
and AC wiring.

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Figure 4 PV field layout with inverters being distributed
This example is identical to figure 1 in terms of module mounting, but inverters are placed close to the modules. Each
inverter is on the AC side wired to a junction box which is then wired to the transformer station.

2.3 Compact transformer station

The 630 kVA transformer station is among the most commonly used transformer stations and
usually has short lead times. The compact dimensions and the low weight of the transformer
station enable the delivery of two units per transport and the use of smaller truck mounted cranes
for mounting. As the height of the transformer station is limited (187 cm above ground), it is
possible to place it behind the modules. The opposite substructure of modules is only slightly more
shaded if distances between substructures remain unchanged.

Figure 5 Transformer station

The use of a low loss transformer reduces the nightly power consumption of the transformer to
below 0.4% of the yearly production. Consequently, short circuit losses in the transformer have little
effect on overall yield. In the medium voltage area of transformers of this size, outgoing feeder
panels with HH-fuses can be inserted instead of the more expensive power-switches. All voltage in
long cabling is converted to the medium voltage level with consequently smaller losses.

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2.4 Module layout
To exemplify the above mentioned advantages an example of a potential module layout is
presented.

To minimise losses due to shading (shed shading) it is advised to mount 3 rows of modules in
landscape orientation per substructure. Wire the modules so that each row forms its own string.
These three strings are then connected individually to the three inputs of the inverter.

Figure 6 Shading on modules

With the sun in a low position only modules in the same string are affected given each row has separate MPPT’s.

Such a configuration will in addition provide a slight advantage on winter days where the lower
modules are often in shadow. A similar advantage can be found on summer days with no wind and
high irradiation where the top module row will experience a slightly higher temperature level and
thereby lower MPP voltage.
The 3 MMP trackers will then optimise the individual rows rather than use a combined average, as
would be the case if the strings were connected in parallel.

The layout with 5.28 kWp per string or 15.9 kWp in total will give a layout factor of Psolar/Pinverter =
1.06 which is within the recommendations given by Dr Bruno Burger1 for a plant placed in central
Europe. The high inverter efficiency and the lower module temperature experienced due to ground
based mounting have been taken into consideration.
The layout can be achieved in different ways but the 1000 V open circuit voltage must of course be
utilised.

For monocrystalline or polycrystalline modules based on 156 x 156 mm cells there are two options
depending on the number of cells per module:
• 1 string of 24 modules (220 W with 60 cells) on each of the 3 input
• 1 string of 30 modules (175 W with 48 cells) on each of the 3 input

1
Inverter sizing for grid connected PV plants, Dr.-Ing. Bruno Burger, Fraunhofer-Institut für Solare
Energiesysteme ISE, Heidenhofstraße 2, D-79110 Freiburg.
http://www.ise.fraunhofer.de/veroeffentlichungen/nach-jahrgaengen/2005/auslegung-und-dimensionierung-
von-wechselrichtern-fur-netzgekoppelte-pv-anlagen/at_download/file

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Alternative use of 116 CdTe cell thin film modules is also possible with similar layout factors. They
are collected in groups per input:
• 1 group with 7 strings of 10 modules (75 W with 116 cells) on each of the 3 inputs
• 1 group with 8 strings of 10 modules (72 W with 116 cells) on 1 input and
1 group with 7 strings of 10 modules (72 W with 116 cells) on 2 inputs

For installations in southern Europe where a lower layout factor is recommended the power can
easily be lowered by:
- Connecting fewer modules on a single string when using polycrystalline modules
- Reducing the number of strings on a single input when using thin film modules.

2.5 Data connection

Data for plant supervision can be transmitted to a data warehouse service through webloggers
placed at each transformer station. Power to the weblogger and associated modem can be taken
from the low voltage side of the transformer, as only a small amount of power (<20 W) is required.
If direct online data access is required it is suggested to connect each weblogger directly to an
ethernet connection instead of using a modem.
In case the transformer station is disconnected and the weblogger is powered off, inverter data will
be taken from the integrated datalogger in the inverter when power is restored. The integrated
datalogger keeps inverter records of the past 3 days in a ring memory.

With the inverters placed centrally in close proximity to the transformer station it is easy to carry
out the wiring for data transmission. Inverters can be connected in series using a standard Cat 5
cable. The cable can be connected directly to the inverter by either using screw terminals or pre-
fabricated cables with RJ45 connectors.

For all inverter inputs it is possible to monitor current and MPP voltage individually. This means
that even with 7 strings of CdTe modules detection of error in an individual string (720 Wp) is
possible down to the affected inverter input (5 kWp) without additional equipment. See figure 2.
Data is recorded in 10 minute intervals and is normally transmitted to a data warehouse service
daily.

Data wiring is shown in Appendix A 4.1.

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3 Service/reliability
String inverters have the benefit of being a standard commercially available component. This
means it is possible to let a local installer or plant supervisor with no special training carry out
exchange of the inverter if necessary. Therefore, service contracts known from central inverters are
not necessary for string inverters. Extra inverters can also be kept in stock locally for fast exchange.

Furthermore, in case of failure only a smaller part of the system will be affected. With the 10 MW
plant it means more than 6 inverters must completely fail before the loss reaches 1% of production.

With the proposed compact transformer stations yearly service on the medium voltage grid will
require slightly more effort, due to the number of transformer stations. However, no service is
required on the DC side as junction boxes are omitted. E.g. no problems due to broken DC fuses.

The 5-year warranty remains unchanged for inverters used in large plant applications and warranty
prolongation to 10 years is possible.

To aid the installer or plant supervisor during fault finding each inverter comes with a display.

4 Appendix A – Wiring diagrams

4.1 665 kWp Field wiring

Drawing from Gräper

4.2 10 MWp Plant wiring

Drawing from Gräper

4.3 Layout of the low voltage switchgear

Drawing from Gräper

Page 9 Danfoss Solar Inverters A/S

GRÄPER GRÄPER

GRÄPER

GRÄPER GRÄPER
GRÄPER GRÄPER

GRÄPER

GRÄPER GRÄPER
GRÄPER GRÄPER

GRÄPER

GRÄPER GRÄPER
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Rev. date 2009-02-19