5/7/19

Determining Cable Sizes and CABLE SIZING

Protection in an Off grid PV System

CURRENT CARRYING CAPACITY - CCC TYPICAL CCC –OLEX CABLE AC

• Current carrying capacity is defined as the amperage or the

current a conductor can carry before deteriorating or before
its insulation is affected.
• Generally, these values could be obtained from cable
manufacturers for a particular cable
• They are subject to derating factors based on the method
of installation, grouping, temperature and other external
factors.

3 4

TYPICAL PV CABLE - CCC

PV CABLE SIZING

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SELECTION OF CURRENT CARRYING SELECTION OF CURRENT CARRYING

CAPACITY OF PV STRING CABLES CAPACITY OF PV STRING CABLES
• If a fault current protection device is located in the string
cable, the string cable must have a rating equal to or • If no fault current protection is provided, the current
greater than the current rating of the fault current protection carrying capacity (CCC) of the string cable will be rated
device. For example, if the fault current protection device is according to:
rated at 8A, the string will need to be rated with a current CCC ≥ 1.25 × ISC MOD × (Number of parallel connected Strings - 1) + In
carrying capacity (CCC) of a minimum of 8A.
where
• In is the current rating of the nearest downstream overcurrent protection
device.

SELECTION OF CURRENT CARRYING CAPACITY

OF PV ARRAY CABLES
• If a fault current protection device is located in the array
cable, the array cable must have a current rating equal to
or greater than the current rating of the fault current
protection device.
PV CABLE PROTECTION

• If no fault current protection device has been included, the

current carrying capacity of the PV array cable will be rated
according to:
CCC ≥ 1.25 × ISC ARRAY

10

SOLAR ARRAY DC CABLE PROTECTION WORKED EXAMPLE

The reverse current rating for a module is 15A while the short
• Each solar module has a maximum reverse current rating circuit current is 8.9A.
provided by the manufacturer. If the array consists of two (2) parallel strings and a fault
• If the array consists of parallel strings such that the reverse occurs in one (1) string then the potential fault current will
current flow into a string with a fault can be greater than the come from the other one (1) string which is only 8.9A and is
maximum reverse current for the modules in that string, less than the reverse current rating so no protection is
then protection shall be provided in each string. required.
• The protection to be used shall be dc rated fuses that meet
the specification shown in 18.2 of the guideline. NO PROTECTION REQUIRED

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WORKED EXAMPLE WORKED EXAMPLE

However, if the array consists of three (3) parallel strings and • A formula for determining the maximum number of strings
a fault occurs in one (1) string then the fault current could allowed before fuses are required is:
come from the other two (2) strings.
This current is 17.8A (2 x 8.9A) and is now greater than the Maximum Number of Strings without string protection
reverse current rating of the module. Protection is now = reverse current rating of a module/Isc of the module
required.

• So in the example; Max Number of strings = 15/8.9 = 1.69

rounded up to 2.

PV FUSES STRING PROTECTION

Fuses used in PV arrays shall — The fuses shall have the following current rating:

(a) be rated for dc use; 1.5 x Isc of module < 𝐼"#$% < 2.4 x Isc of module
(b) have a voltage rating equal to or greater than the PV array and
Fuse Rating < IRC of module
maximum voltage determined in section 5 of the guidelines;
(c) be rated to interrupt fault currents from the PV array; and • Where
• Isc of module= Module short circuit current
(d) be of an overcurrent and short circuit current protective • ITRIP = rated trip current of the fault current protection device.
type suitable for PV complying with IEC 60269-6 (i.e. Type • IRC of module= Module reverse current rating

gPV) or the equivalent through the NEC.

Note : For countries following NEC the requirements are:
o Minimum fuse rating 1.56 x Isc of module(string)
o Maximum fuse rating less than reverse current rating of the
module(string)

ARRAY CABLE PROTECTION ARRAY CABLE PROTECTION

• Array overcurrent protection is designed to protect the • If array overcurrent protection is required for a system, the
entire PV array from external fault currents. nominal rated current for the overcurrent protection device
will be as follows:
• For off grid systems this can only occur in dc bus systems
when the solar controller (switching type solar controller or
1.25× 𝐼,- ./##/0≤ 𝐼"#$% ≤ 2.4 × 𝐼,- /##/0
MPPT) allows fault current from the battery bank to back-
Where:
feed through the controller.
• ISC_ARRAY = short-circuit current of the array.
• ITRIP = rated trip current of the fault current protection device.

Note : For countries following NEC the requirements are:

– Minimum fuse rating 1.56 x Isc of array)

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EXAMPLE 1 EXAMPLE 1
An array consists of 3 parallel strings. These connect to a
controller and then to a battery bank. For this exercise, A table showing current carrying capacities of different cable sizes has been
provided to assist you.
assume the main battery protection is not sized to protect Table 1: Current carry capacities of cables

Conductor Size (mm2) Current Rating (A) Voltage Rating (VDC)

the array cable. Each string has 2 modules in series, with
the following characteristics: 2.5 21 1000

• Vnom = 24V (Voc =44.2 and Vmp = 38.8) 4 27 1000

• Isc = 5.4A 6 34 1000

• Imod reverse=15A 10 48 1000

16 63 1000

What size array cable and array fuse are required?

19 20

SOLUTION

Array Protection
• Must be between 1.25 and 2.4 times the array short circuit
current (from VOLTAGE DROP
• Hence: Minimum fuse size = 1.25 x 3 x 5.4 = 20.25A
Maximum fuse size = 2.4 x 3 x 5.4 = 38.88A
• The fuse chosen is 30A.
Array cable
• The circuit protection can be smaller than the current carrying
capacity of the cable but never larger.
• Thus, the cable chosen from Table 1 is 6mm 2 with a CCC of
34A.

21 22

DETERMINING THE SIZE OF THE DC AND AC VOLTAGE DROP

CABLES
The cables in an installation must be sized correctly so Why do we care?
that: • Power losses in cables
1. there are not excessive voltage drops (also • Voltage rise
corresponding power loss) in the cables;
2. there is not excessive current through the cables
compared with the safe current handling capability Voltage Drop in a wire is a function of three parameters :
of the cables; and • conductor cross sectional area ( mm² ),
3. maximum voltage rating of any cable is never • length of wire; and
exceeded • current flow in the wire.

23 24

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RESISTIVITY VOLTAGE DROP

• The voltage drop between the PV array and the battery
• The resistivity, ρ , varies dependent of the type bank should never exceed 5%
of material. • The voltage drop between the battery bank and any DC
• For copper the resistivity is 0.0183, while for load should never exceed 5%
aluminium it is 0.0294. • The voltage drop between the PV array and Solar
• Note: it can be slightly different for some cables Controller should never exceed 3% (dc bus)
depending on number of strands etc. • The voltage drop between the PV array and PV inverter
should never exceed 3% (ac bus)

25

CALCULATING VOLTAGE DROP (METRIC) FOR

SYSTEMS THAT INCLUDE PWM SOLAR WORKED EXAMPLE
CONTROLLERS A solar array has been installed and the distance between the
• The voltage drop along a cable is given by: output of the array and the solar controller is 10 metres. The
𝟐 × 𝐋𝐂𝐀𝐁𝐋𝐄 ×𝐈 × 𝛒
𝐕𝐝 = short circuit current of the array is 9.6A.
𝐀 𝐂𝐀𝐁𝐋𝐄
>
• Voltage drop (in percentage) = > ? × 100 • The cable has a cross sectional area of 10 mm2
@ABB
• The cable is copper with a resistivity of 0.0183
Where:
• LCABLE = route length of cable in metres (multiplying it by two adjusts for total circuit wire
ohms/metres/mm2
length since a complete circuit requires a wire out and another wire back along the
route). • The battery voltage of the system is 12V .
• I = current in amperes.
• ρ = resistivity of the wire in W/m/mm2
• ACABLE = cross sectional area (CSA) of cable in mm2.
• Vbatt = the nominal voltage of the battery which is the dc system voltage.

WORKED EXAMPLE SOLUTION CALCULATING VOLTAGE DROP (METRIC) FOR

SYSTEMS THAT INCLUDE A MPPT
The voltage drop along a cable is given by:
𝟐 × 𝐋𝐂𝐀𝐁𝐋𝐄 ×𝐈 × 𝛒
𝐕𝐝 = 𝟐 × 𝐋 𝐂 𝐀 𝐁 𝐋𝐄 × 𝐈 × 𝛒
𝐀 𝐂𝐀𝐁𝐋𝐄 𝐕𝐝 =
𝐀 𝐂 𝐀 𝐁 𝐋𝐄
= (2 x 10 x 9.6 x 0.0183)/10 V
> ?
= 0.35 Voltage drop (in percentage) =
> DEF
× 100

>? Where:
Voltage Drop in percentage = × 100 • LCABLE = route length of cable in metres (multiplying it by two adjusts for total circuit wire
>CABB
length since a complete circuit requires a wire out and another wire back along the route).
• I = current in amperes.
• ρ = resistivity of the wire in W/m/mm2
= 0.351/12 × 100 • ACABLE = cross sectional area (CSA) of cable in mm2.
• VMAX = maximum line voltage in volts
= 2.9%

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WORKED EXAMPLE WORKED EXAMPLE SOLUTION

A solar array has been installed and the distance between the
output of the array and the solar controller is 10 metres. The 𝟐 × 𝐋𝐂𝐀𝐁𝐋𝐄 ×𝐈 × 𝛒
𝐕𝐝 =
short circuit current of the array is 9.6A. 𝐀 𝐂𝐀𝐁𝐋𝐄
• The cables has a cross sectional area of 4 mm2 = 2 x 10 x 9.6 x 0.0183/4 V
• The cable is copper with a resistivity of 0.0183 =0.88V
ohms/metres/mm2
• The array has maximum power point voltage of 154.4V. >?
Voltage Drop in percentage = > × 100
DEF

= 0.88/154.4 x 100
= 0.57%

MAXIMUM DISTANCE IN METRES TO PRODUCE MAXIMUM CABLE LENGTHS IN METRES FOR 12V
5% VOLTAGE DROP (12V SYSTEM) SYSTEM 3% VOLTAGE DROP
Current (A) 1mm2 1.5mm2 2.5mm2 4mm2 6mm2 10mm2 16mm2 Current
(A) 1mm2 1.5mm2 2.5mm2 4mm2 6mm2 10mm2 16mm2
1 16.4 24.6 41 65.6 98.4 163.9 262.3
1 9.8 14.8 24.6 39.3 59.0 98.4 157.4
2 8.2 12.3 20.5 32.8 49.2 82 131.1
2 4.9 7.4 12.3 19.7 29.5 49.2 78.7
3 5.5 8.2 13.7 21.9 32.8 54.6 87.4
3 3.3 4.9 8.2 13.1 19.7 32.8 52.5
4 4.1 6.1 10.2 16.4 24.6 41.0 65.6
4 2.5 3.7 6.1 9.8 14.8 24.6 39.3
5 3.3 4.9 8.2 13.1 19.7 32.8 52.5
5 2.0 3.0 4.9 7.9 11.8 19.7 31.5
6 2.7 4.1 6.8 10.9 16.4 27.3 43.7
6 1.6 2.5 4.1 6.6 9.8 16.4 26.2
7 2.3 3.5 5.9 9.4 14.1 23.4 37.5
7 1.4 2.1 3.5 5.6 8.4 14.1 22.5
8 2.0 3.1 5.1 8.2 12.3 20.5 32.8
8 1.2 1.8 3.1 4.9 7.4 12.3 19.7
9 1.8 2.7 4.6 7.3 10.9 18.2 29.1
9 1.1 1.6 2.7 4.4 6.6 10.9 17.5
10 1.6 2.5 4.1 6.6 9.8 16.4 26.2
10 1.0 1.5 2.5 3.9 5.9 9.8 15.7
11 1.5 2.2 3.7 6.0 8.9 14.9 23.8
11 0.9 1.3 2.2 3.6 5.4 8.9 14.3
12 1.4 2.0 3.4 5.5 8.2 13.7 21.9
12 0.8 1.2 2.0 3.3 4.9 8.2 13.1
13 1.9 3.2 5.0 7.6 12.6 20.2
13 1.1 1.9 3.0 4.5 7.6 12.1
14 1.8 2.9 4.7 7.0 11.7 18.7
14 1.1 1.8 2.8 4.2 7.0 11.2
15 1.6 2.7 4.4 6.6 10.9 17.5
15 1.0 1.6 2.6 3.9 6.6 10.5
16 1.5 2.6 4.1 6.1 10.2 16.4
16 0.9 1.5 2.5 3.7 6.1 9.8
17 2.4 3.9 5.8 9.6 15.4
17 1.4 2.3 3.5 5.8 9.3
18 2.3 3.6 5.5 9.1 14.6
18 1.4 2.2 3.3 5.5 8.7
19 2.2 3.5 5.2 8.6 13.8
19 1.3 2.1 3.1 5.2 8.3
20 2.0 3.3 4.9 8.2 13.1
20 1.2 2.0 3.0 4.9 7.9

CALCULATING VOLTAGE DROP (IMPERIAL) FOR

CABLE RESISTANCE FOR UNCOATED COPPER
SYSTEMS THAT INCLUDE A PWM SOLAR
CABLE AT 75°C (167°F) - NEC
CONTROLLER Wire Size dc Resistance ac Resistance
• This section is for systems that are using switching type (e.g. PWM) solar (AWG) (Ohms per 1000 feet) (Ohms to neutral
per 1000 feet)
controllers.
• To determine the voltage drop the following formula is used. The equation is 14 3.14 3.1

derived from Ohm’s Law i.e. V=IR: 12 1.98 2.0

10 1.24 1.2
8 0.778 0.78
6 0.491 0.49
Where: 4 0.308 0.31
Vd = voltage drop
d = route length of dc cable in feet (2 x adjusts for total circuit wire length) 2 0.194 0.20
I = dc current in amperes (commonly Imp ) 1 0.154 0.16
W/kft = ohms/thousand feet (resistance) 1/0 0.122 0.13
2/0 0.0967 0.10
>?
Voltage drop (in percentage) = > × 100 4/0 0.0608 0.067
@ABB

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WORKED EXAMPLE WORKED EXAMPLE SOLUTION

A solar array has been installed and the distance between the Therefore:

output of the array and the inverter is 33 feet. The short circuit
current of the array is 9.6A.
• The cable is AWG 6 = 9.6 x 2 x 33 x 0.491/1000 V
= 0.311 V
• The battery voltage of the system is 12V . > ?
Voltage Drop (in percentage) = × 100
• From Table 4 (previous slide), the dc Resistance in Ohms > CABB

= 0.311/12 x 100
per 1000 feet =0.491 = 2.6%

CALCULATING VOLTAGE DROP (IMPERIAL) WORKED EXAMPLE

FOR SYSTEMS THAT INCLUDE A MPPT A solar array has been installed and the
• This section is for systems that are using Maximum Power Point Trackers (MPPT)
as the solar controller (dc bus) or a PV inverter that includes an MPPT controller distance between the output of the array and the
•
(ac bus).
To determine the voltage drop the following formula is used. The equation is
inverter is 33 feet. The short circuit current of
derived from Ohm’s Law i.e. V=IR: the array is 9.6A.
• The cable is AWG 10
Where:
Vd = voltage drop
• The array has maximum power point voltage
d
I
= route length of dc cable in feet (2 x adjusts for total circuit wire length)
= dc current in amperes (commonly Imp ) of 154.4V.
W//kft = ohms/thousand feet (resistance)

> ?
• From Table 4, the dc Resistance in Ohms per
Voltage drop (in percentage) =
> DEF
× 100
1000 feet =1.24

WORKED EXAMPLE SOLUTION MAXIMUM DISTANCE IN FEET TO PRODUCE 5%

Therefore: VOLTAGE DROP (12V SYSTEM)
Wire Size- 14 12 10 8 6 4 2 1
AWG (mm²) (2.08) (3.31) (5.26) (8.36) (13.29) (21.14) (33.61) (42.39)
Current (A)
1 34.10 54.26 86.23 137.05 217.87 346.56 550.98 694.92
2 17.05 27.13 43.11 68.52 108.93 173.28 275.49 347.46
= 9.6 x 2 x 33 x 1.24/1000 V 3
4
11.37
8.52
18.09
13.57
28.74
21.56
45.68
34.26
72.62
54.47
115.52
86.64
183.66
137.75
231.64
173.73
= 0.786V 5 6.82 10.85 17.25 27.41 43.57 69.31 110.20 138.98
6 5.68 9.04 14.37 22.84 36.31 57.76 91.83 115.82
7 4.87 7.75 12.32 19.58 31.12 49.51 78.71 99.27
> ? 8 4.26 6.78 10.78 17.13 27.23 43.32 68.87 86.86
Voltage Drop (in percentage) = × 100 9 3.79 6.03 9.58 15.23 24.21 38.51 61.22 77.21
> DEF
10 3.41 5.43 8.62 13.70 21.79 34.66 55.10 69.49
= 0.786/154.4 x 100 11 3.10 4.93 7.84 12.46 19.81 31.51 50.09 63.17
= 0.51% 12 2.84 4.52 7.19 11.42 18.16 28.88 45.92 57.91
13 2.62 4.17 6.63 10.54 16.76 26.66 42.38 53.46
14 2.44 3.88 6.16 9.79 15.56 24.75 39.36 49.64
15 2.27 3.62 5.75 9.14 14.52 23.10 36.73 46.33
16 2.13 3.39 5.39 8.57 13.62 21.66 34.44 43.43
17 2.01 3.19 5.07 8.06 12.82 20.39 32.41 40.88
18 1.89 3.01 4.79 7.61 12.10 19.25 30.61 38.61
19 1.79 2.86 4.54 7.21 11.47 18.24 29.00 36.57
20 1.70 2.71 4.31 6.85 10.89 17.33 27.55 34.75

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EXAMPLE – VOLTAGE DROP METHOD WHEN

MAXIMUM DISTANCE IN FEET TO PRODUCE 3%
SELECTING CABLE (PWM Controller)
VOLTAGE DROP (12V SYSTEM)
Wire Size- 14 12 10 8 6 4 2 1
AWG (mm²) (2.08) (3.31) (5.26) (8.36) (13.29) (21.14) (33.61) (42.39)
Current (A)
1
2
20.46
10.23
32.56
16.28
51.74
25.87
82.23
41.11
130.72
65.36
207.93
103.97
330.59
165.30
416.95
208.48 Cable length = 12m between solar array
3 6.82 10.85 17.25 27.41 43.57 69.31 110.20 138.98
4
5
5.11
4.09
8.14
6.51
12.93
10.35
20.56
16.45
32.68
26.14
51.98
41.59
82.65
66.12
104.24
83.39 and standard controller
6 3.41 5.43 8.62 13.70 21.79 34.66 55.10 69.49
7
8
9
2.92
2.56
2.27
4.65
4.07
3.62
7.39
6.47
5.75
11.75
10.28
9.14
18.67
16.34
14.52
29.70
25.99
23.10
47.23
41.32
36.73
59.56
52.12
46.33
Array current = 30A
10 2.05 3.26 5.17 8.22 13.07 20.79 33.06 41.70
11
12
1.86
1.70
2.96
2.71
4.70
4.31
7.48
6.85
11.88
10.89
18.90
17.33
30.05
27.55
37.90
34.75
System voltage = 24V
13 1.57 2.50 3.98 6.33 10.06 15.99 25.43 32.07
14
15
1.46
1.36
2.33
2.17
3.70
3.45
5.87
5.48
9.34
8.71
14.85
13.86
23.61
22.04
29.78
27.80 Using copper wire – resistivity = 0.0183
16 1.28 2.03 3.23 5.14 8.17 13.00 20.66 26.06
17 1.20 1.92 3.04 4.84 7.69 12.23 19.45 24.53
18
19
1.14
1.08
1.81
1.71
2.87
2.72
4.57
4.33
7.26
6.88
11.55
10.94
18.37
17.40
23.16
21.94
Maximum allowable voltage loss = 3%
(0.03)
20 1.02 1.63 2.59 4.11 6.54 10.40 16.53 20.85

EXAMPLE – VOLTAGE DROP METHOD WHEN EXAMPLE - VOLTAGE DROP METHOD WITH
SELECTING CABLE (PWM Controller) SOLUTION MPPT (MPPT Controller)
Minimum cross-sectional area = Cable length = 10m between solar
2 x 12 x 30 x 0.0183 array and MPPT controller
0.03 x 24 Array current = 27.3A
= 18.3 mm2
Vmpp of array= 92.1V
Choose the next size of cable ABOVE this – 25mm
squared. Using copper wire – resistivity = 0.0183
Next, we have to check that the 25mm sq. cable can Maximum allowable voltage loss = 3%
carry 30A. (0.03)
Upon checking CCC tables, it can carry more than
30A, therefore 25 sq. should be ok.

EXAMPLE - VOLTAGE DROP METHOD WITH

CABLE SIZING BETWEEN STANDARD SOLAR
MPPT (MPPT Controller)
CONTROLLER AND BATTERY
Minimum cross-sectional area = • The cables between the standard solar controller and the
battery shall have a voltage rating greater than the
2 x 10 x 27.3 x 0.0183
maximum voltage rating of the battery when being charged.
0.03 x 92.1 .
= 3.61 mm2 • The current carrying capacity of the cable between the
Choose the next size of cable ABOVE this – controller and battery shall be capable of carrying the
4mm squared. maximum charge current from the array.
Check CCC. Upon checking CCC of 4mm
sq. cable, it was found that 4mm sq cable • The dc current rating of the associated over-current
can carry around 32A, therefore ok. protection shall not be greater than that of the cable.
48

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EXAMPLE EXAMPLE SOLUTION

• The distance between standard controller and battery is

2m. The maximum charge current is 30A. What size cable • Cable must meet both CCC and voltage drop .
is appropriate?
• A cable that can carry the maximum charge current of 30A,
from CCC tables, a 4mm sq. cable is appropriate,
Alternatively, we can also use the voltage drop method
here.
• We then determine the voltage drop present in the cable, if
it exceeds say 3%, we can increase the cable size to
reduce the voltage drop.

49 50

CABLE SIZING BETWEEN MPPT CONTROLLER CABLE SIZING BETWEEN BATTERY AND BATERY
AND BATTERY INVERTER (IF APPLICABLE)
• The current carrying capacity of the cable between the • The current carrying capacity of the cable between the
controller and battery shall be capable of carrying the battery bank and the battery inverter shall be capable
maximum charge current from the MPPT. of carrying the maximum current based on either the 30
• The dc current rating of the associated over-current minute power rating of the inverter (if provided) or the
protection shall not be greater than that of the cable. continuous power rating of the inverter.
• If it is an non-seperated MPPT (all are at moment) the • The dc current rating of the associated over-current
cable needs voltage rating greater than the Voc of the protection shall not be greater than that of the cable
array.

51 52

EXAMPLE EXAMPLE SOLUTION

• The continuous rating of inverter of an inverter is 2000W.

The surge rating is 4000W. The system voltage is 24V and • If we size using surge current, it will lead to a bigger cable
the inverter efficiency is 90%. What size cable is required size. Assuming that cables have the capacity to take surge
between battery and inverter if the distance is 3m? currents for few seconds, we can just use the continuous
• I cont = (2000/(24 x 0.9)) = 92.59 A rating.
• I surge = (4000/(24 x 0.9)) = 185.19A • We can thus use a 25mm sq. cable that meets this current
requirement.
• We need to check for the percentage voltage drop as a
matter of check.

53 54

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PROTECTION REQUIREMENTS IN SYSTEM

• All cables shall be electrically protected from fault currents that could occur.
• dc bus-Simple dc only system

SYSTEM CABLE PROTECTION and

ISOLATION

Notes:
1. A PV array dc switch disconnector is recommended because it helps with maintenance and
troubleshooting. However many standards allow the battery bank switch fuse to meet the isolation
requirement. A switch disconnector will be required to be a protection device (e.g. a non polarised
dc circuit breaker) if the battery bank fuse ratings are greater than the current carrying capability of
the PV array cables and the solar controller allows back feed from the battery bank.

dc BUS - LARGER dc ONLY SYSTEM

dc BUS-LARGER dc ONLY SYSTEM
Notes
1. String fusing is required if the potential fault current is
greater than the reverse current rating of the PV module.
2. The PV array dc switch disconnector is recommended
because it helps with maintenance and troubleshooting
although many standards allow the battery bank switch
fuse to meet the isolation requirement. The switch
disconnector will be required to be a protection device
(e.g. a non polarised dc circuit breaker) if the battery bank
fuse ratings are greater than the current carrying
capability of the PV array cables and the solar controller
allows back feed from the battery bank.

dc BUS-LARGER dc ONLY SYSTEM dc BUS WITH dc AND ac LOADS

Notes

3. Batteries in parallel each require their own isolation and protection devices.
Over-current protection is required for the battery bank cable when the current-
carrying capacity of the battery bank cable is less than the sum of all individual
battery over-current protection devices. A battery bank switch disconnecting
device is recommended because it allows the disconnection of the complete
battery bank via the one switch disconnector.

4. The loads dc switch disconnector is recommended because it helps with

maintenance and troubleshooting although many standards allow the battery
bank switch-fuse to meet the isolation requirement. The switch disconnector
will be required to be a protection device (e.g. a non polarised dc circuit
breaker) if the battery bank fuse ratings are greater than the current carrying
capability of the load cables.

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dc BUS WITH dc AND ac LOADS dc BUS WITH dc AND ac LOADS

Notes: • Notes:
1. String fusing is required if the potential fault current is greater
than the reverse current rating of the PV module. 3. Batteries in parallel each require their own isolation and
protection devices. Over-current protection is required for the
2. The PV array dc switch disconnector is recommended battery bank cable when the current-carrying capacity of the
because it helps with maintenance and troubleshooting although battery bank cable is less than the sum of all individual battery
many standards allow the battery bank switch fuse to meet the over-current protection devices. A battery bank switch
disconnecting device is recommended because it allows the
isolation requirement. The switch disconnector will be required disconnection of the complete battery bank via the one switch
as a protection device (e.g. a non polarised dc circuit breaker) if disconnector. Sometimes this might be a four (4) pole device to
the battery bank fuse ratings are greater than the current allow different size fuses to protect the inverter cable and the solar
controller cable which will be generally be different cross sectional
carrying capability of the PV array cables and the solar areas (or gauges)
controller allows backfeed from the battery bank.

dc BUS WITH dc AND ac LOADS ac BUS WITH ac LOADS

Notes:

4. The loads dc switch disconnector is recommended because it

helps with maintenance and trouble shooting although many
standards allow the battery bank switch-fuse to meet the isolation
requirement. The switch disconnector will be required to be a
protection device (e.g. a non polarised dc circuit breaker) if the
battery bank fuse ratings are greater than the current carrying
capability of the load cables.
5. A separate ac load disconnector is required if the battery
inverter does not have a switch disconnector on the ac output. This
will be required as a protection device (e.g. an ac circuit breaker)
for protecting the ac load cable.

ac BUS WITH ac LOADS ac BUS WITH ac LOADS

Notes: Notes:
1. String fusing is required if the potential fault current is greater
than the reverse current rating of the PV module. 4. A separate ac bus interactive inverter disconnector device
2. A PV array dc switch disconnector is required but it can be part is required if the battery inverter does not have a switch
of the inverter disconnector on the ac output. This will be required to be a
3. Batteries in parallel each require their own isolation and protection device (e.g. ac circuit breaker) for protecting the ac
protection devices. Over-current protection is required for the
battery bank cable when the current-carrying capacity of the load cable.
battery bank cable is less than the sum of all individual battery
over-current protection devices. A battery bank switch
disconnecting device is recommended because it allows the
disconnection of the complete battery bank using only one
switch disconnector.

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BATTERY CABLE PROTECTION- dc BUS – dc BATTERY CABLE PROTECTION- dc BUS – ac

LOADS ONLY AND dc LOADS
• For dc bus systems with dc loads only, as shown in • dc bus systems with ac and dc loads as shown in previous
previous Figures , the only battery cables are those Figure can potentially have two different sized battery
between the battery bank and the controller. The protection cables:
devices will be rated to allow the maximum charge • the battery cable between the battery bank and the solar
current provided by the solar controller and the controller.
maximum dc load current that is to be provided by the
• The battery cable between the battery bank and the battery
solar controller. inverter.

BATTERY CABLE PROTECTION- dc BUS – ac BATTERY CABLE PROTECTION - ac BUS

AND dc LOADS
• The protection devices for the cable connected to the solar • Systems with an ac bus as shown in previous Figure only
controller from the battery will be rated to allow the have one set of cables from the battery bank and that is to
maximum charge current provided by the solar controller the battery inverter.
to the battery and the maximum dc load current that is to be
provided at the output of the solar controller, whichever is
larger. This protection device will need to be suited for • The protection device for the battery inverter will be
motors of there are any dc motors connected to the system. determined via the process defined in section 18.13
These fuses are a specific type to allow for the motor surge
capability.
• The protection device for the battery cable to an inverter
will be determined via the process defined in section 18.13

BATTERY CABLE PROTECTION- BATTERY BATTERY CABLE PROTECTION- BATTERY

INVERTER INVERTER
To select the appropriate battery protection for the cable to the • For each inverter power rating determine the current drawn
battery inverter: from the battery bank using:
• Obtain the battery inverter manufacturer’s data of:
o Continuous power rating (Watts )
o 3 to 10 second surge rating (Watts ) I = Inverter Power Rating ( W )
o Average inverter efficiency (%) ( inverter efficiency x nominal battery voltage )

• Obtain Time-Current characteristics for the overload protection • Consult the Time-Current characteristic of available
to be used. overload protection devices to determine the device with an
[All manufacturers publish time-current information for their circuit appropriate rating that matches the maximum load and
breaker and HRC fuse ranges]
maximum load surge characteristics.

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EXAMPLE

• The inverter has continuous rating of 800W and surge

rating of 1600W. Assume system voltage is 24V and
inverter efficiency is 93%.

74

EXAMPLE SOLUTION EXAMPLE SOLUTION

• Referring to NHG General purpose fuse time-current

• The continuous current will be 800/(24 x 0.93) = 35.84 A graph, a 40A fuse is chosen.
and surge current will be 1600/(24 x 0.93) = 71.68A. • This rating should also be checked against the cable
• We need a fuse that is able to carry these currents and current carrying capacity as it should be less.
rupture beyond this current. • Generally, a 35mm2 cable can carry around 110A,
• Some inverter manufacturers also provide the 12s surge therefore 80A fuse will ensure protection of the cable.
rating. The fuse firstly should be able to carry continuous
current and also should be able to carry the 12s surge
current for 12 seconds.

75 76

The End

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