Overcurrent Protection Devices (OCPD) on Solar Arrays

This paper describes when and why PV fuses/breakers are needed and provides high level
information on sizing the PV fuse/breakers. There will be some information about sizing
the PV wires, but a detailed discussion wire sizing is beyond the scope of this paper.
A more detailed description of NEC compliant fuse sizing can be found here:
https://diysolarforum.com/resources/sizing-fuses-for-photovoltaic-systems-per-the-national-electrical-code.133/download

Disclaimer: Unless otherwise noted, I have tried to keep this document in alignment with the National Electric Code (NEC).
However, this document does not address all aspects of the related code.
Rev 0.5
High Level Summary (The short answer):
The following is a summary of the NEC requirements for the Over Current Protection Device (OCPD) and Cabling for a Solar array.
The remainder of this document will examine these requirements in more detail.
Note: For all of the cases below, the Cable sizing and OCPD rating may need to be adjusted for temperature.

Definition: Photovoltaic Source Circuit. Circuits between solar panels and from solar panels to the common connection point(s) of the DC system.
Definition: Photovoltaic Output Circuit. Circuit conductors between the PV Source circuit(s) and the inverter or DC utilization equipment

1 string of 1 or more serial panels

Source

Source
Source

Source
• No fuses or breakers required
• Source circuit cables must be rated for at least 156% of Isc
SCC SCC

1-Ns Series panels

Source
2 Parallel strings of 1 or more series panels

Source
• No fuses or breakers Required
• Source circuit cables must be rated for at least 156% of Isc Source
Source
• Output circuit cables must be rated for at least 2 x 156% of Isc Output Output
SCC Output Output
SCC

3 to Np parallel Strings

1 to Ns Series panels
3 or more Parallel Strings of 1 or more series panels:
• OCPDs (Fuses or breakers) required
• The voltage rating of the OCPDs must be Ns x Vmax or greater. (Ns = number of serial panels)
• Each Source circuit must have OCPD rated for at least 156% of Isc. Source Source
• Source circuit cables must be rated for at least 156% of Isc

OCPD
• Source circuit cables must be rated for more current than the OCPD
• Output circuit cables rated for at least Np x 156% of Isc (Np = number of parallel strings ) Output Output
SCC
 Max Current and Max Voltage calculations for Solar Panels
Max Current from a panel
Solar panels are current limited devices and the maximum current in their specifications will always be the Short-Circuit Current: Isc. However, this is an
amount that is determined at very specific light and temperature conditions. Consequently, in some conditions a panel can produce more than the Isc
current. Consequently, the NEC considers 125% of Isc as the max current (Imax) from a solar panel.
Imax = 1.25 Isc
• Min PV cable sizing: the NEC requires the cable to handle 125% of Imax. When this extra 25% is applied you get:
1.25 x Imax = 1.25 x (Isc x 1.25) = 1.56 x Isc. (For a single panel or set of panels in series)
• Min OCPD Sizing: PV Fuses and breakers should not be run at greater than 80% of their rated value. Consequently, the NEC requires the fuse or
breaker to be a minimum of 125% of Imax. Once again this works out to be:
1.25 x Imax = 1.25 x (Isc x 1.25) = 1.56 x Isc. (For a single panel or set of panels in series)

Max Voltage from a panel

The highest voltage on a solar panel’s specification will always be the Open Circuit Voltage: Voc As with Isc, Voc is determined under very specific
conditions and therefor can be higher than the Voc specification in some situations. If the panel spec provides a temp coefficient for Voc, the NEC
requires you to calculate Vmax (Not covered here). Otherwise the NEC uses the following table for calculating Vmax .

Lowest Ambient Temp Lowest Ambient Temp Example use of table

Factor (Ft) Factor (Ft) If the lowest ambient temperature will be -22oC and your panels
oC oF oC oF

25 or more 77 or more 1 -6 to -10 22 to 14 1.14 have a Voc of 39.9V, the calculation for Vmax is:
24 to 20 76 to 68 1.02 -11 to -15 13 to 5 1.16 Vmax = 1.2 x 39.9V = 47.9V
19 to 15 67 to 59 1.04 -16 to -20 4 to -4 1.18
14 to 10 58 to 50 1.08 -21 to -25 -5 to -13 1.20 For simplicity, this paper will always use a temperature factor of
9 to 5 49 to 41 1.08 -26 to -30 -14 to -22 1.21 1.2 for determining Vmax
4 to 0 40 to 32 1.10 -31 to -35 -23 to -31 1.23 (Some professional installers just use a factor of 1.25 and call it
-1 to -5 31 to 23 1.12 -36 to -40 -32 to -40 1.25 good. This may be overkill in warmer climates)
 Single Panel and Series Panels
One Panel

Solar panels have a maximum current (Isc: Short Circuit Current) that is low enough
that even a short circuit will not damage the solar panel. Furthermore, the normal
Isc operating current is so close to the short circuit current that it would be very difficult
to select a fuse or breaker that would blow on a short circuit but not blow in normal
operation. Consequently, there is no need to put a fuse or breaker on a single panel.
SCC

Between 1 and N series panels

When adding panels in series, the voltage increases, but the current does not.
Consequently, even a large string of series panels can be treated the same as a single
Isc panel…. And there is no need for a fuse or breaker.
SCC

However, to ensure there is no issue with a short, the cable for the solar panels must be sized to handle 156% or more of the Isc of the
panels. (Temperature adjustments may be needed when sizing the cable)
 2 Parallel or 2 Parallel Strings of 2 or more Series Panels
In the case of parallel panels, the current adds as you add panels. Consequently, in the event of a short circuit in one of the panels, that panel would ‘see’
the combined current of all of the parallel panels.

With two parallel panels or strings of panels, the combined current is low enough that Over-Current Protection(OCP) devices are not needed (See Appendix
B for further explanation). The source circuit cable cabling used must be rated at 156% or more of ISC . The main output circuit cable must also handle 156%
of the expected Isc load from both panels or strings. (Temperature adjustments may be needed when sizing the cable)

EXAMPLES

1-n Series panels

Panel Specs • Minimum Source circuit cable rating:
Watts (STC) 315 W
10.00 x 1.56 = 15.6 A.
The ampacity charts indicate a minimum of 14AWG
Max Power
Voltage 33.1 V wire. (It may need to be larger if it has a long run)
Source

Source
Isc Isc (VMPP)
Source

Isc Isc
Source

Max Power • Minimum Output circuit cable rating:

Current 9.52 A 2x 10.00A x 1.56 = 31.20A
(IMPP)
The ampacity charts indicate a minimum of 10 AWG (It
Open Circuit may need to be larger if it has a long run to the SCC)
39.9 V
Output

Output
Output

Voltage (VOC)
Output

2x Isc 2x Isc Short Circuit

Current (ISC)
10.00 A Notice that additional panels in series does not change the
cable sizing requirements.
SCC SCC Max System
Voltage (UL)
DC 1000 V

2 parallel panels 2 strings of parallel panels

 3 or more Parallel Strings of 1 or more Series Panels
With 3 or more parallel panels, the current due to a short can become a hazard if the current from other strings back-feed into the shorted panel. Consequently,
an OCPD must be placed on each parallel panel or parallel string of series panels. The OCP devices must be rated for 156% or more of the Isc of the panels.
(Many panels have a ‘series fuse rating’. This is the *most* current the panel can handle without damage and therefore the OCPD current rating must be less
than this value. This value is usually quite high compared to Isc and therefor is not usually a factor.) The minimum Voltage rating of the OCPD must be the
Voc x Temp-factor of the of the combined voltage of the number of panels in series. (See page 3 for description of the Temp-factor )

The cable for the Source circuit must be rated to handle at least the current rating of the OCPD selected or 156% of Isc (whichever is larger). The cable for the
Output circuit must be able to handle 156% of the combined Isc of all the parallel panels or strings of panels. (Temperature adjustments may be needed when
sizing the cables)

EXAMPLE
3 parallel strings of series panels
3 parallel panels Panel Specs • OCPD current rating:
10 x 1.56 = 15.6A. This will need to be rounded up to
2 Series panels

Watts (STC) 315 W 20A to find an available device

Max Power (This is well under the 32A String Fuse Rating)
Voltage 33.1 V
•
Source

Source

(VMPP) Minimum OCPD vice voltage rating:

For Figure 1 there is only 1 panel in series, so it is:

Source
Source

Max Power
Isc Current 9.52 A 39.9 x 1.20 x 1 = 47.9V
Isc (IMPP) For Figure 2 there is 2 panels in series, so it is:
OCPD

Combiner Box

Open Circuit 39.9 x 1.20 x 2 = 95.76V

Combiner Box
OCPD

Voltage 39.9 V • Minimum Source circuit cable current rating:

Output

(VOC)
Output

3x Isc
Output
The OCP rating (20A) will be used since it is greater
Output

3x Isc Short Circuit

Current (ISC)
10.00 A than 156% of Isc. This requires a minimum of a 14AWG
cable. (It may need to be larger if it has a long run)
SCC SCC
Max System
DC 1000 V • Minimum Output circuit cable rating:
Voltage (UL)
String Fuse 10 x 3 x 1.56 = 46.8A This requires an 8AWG cable.
32A
Figure 1 Figure 2 Rating (It may need to be larger if it has a long run)
 Sizing cables and adjusting for temperature related issues.
When selecting cable size we often just go to our favorite ampacity chart and select the size based on the expected current. However,
there are several temperature related considerations that could increase the required cable size, particularly for PV cable that may be in
the sun.

Generally speaking, no further adjustments are needed if 1) the ambient temp remains below 105oF (40oC), and 2) the wires are not on
the roof, and 3) there are no more than 3 current carrying wires in the same conduit. (Equipment ground is not considered a current
carrying wire). If these conditions are met, you can use the current discussed earlier in the paper and the Ampacity table for the wire type
you have. See the next page for the NEC Ampacity chart.

However, if any of the following conditions exist, the wire size may need to be larger (sometimes significantly larger):
• Ambient temps above 105oF/40oC.
• More than 3 current carrying conductors in a single conduit or raceway
• Wire on the roof or in the sun (particularly if it is in conduit).

Calculating these adjustments for these conditions is beyond the scope of this paper but will be addressed in a future paper.
Sizing PV cables for length of run
The previous wire sizing calculations in this paper were all for safety (minimizing fire risk). However, The PV array is often a long distance
from the Solar Charge controller. Consequently, there could be a significant voltage drop along the cables if they are not sized
appropriately.

To determine voltage drop I will use an on-line voltage drop calculator. There are many out there. This one works well for me:
https://www.bestboatwire.com/pages/voltage-drop-calculator (Note: Be sure to put in the total round trip length)

When calculating for voltage drop, I use the Array Vmpp and Impp as the inputs to the calculator. (Voc and Isc are not the typical
conditions and the 1.56x factor in the previous calculations is significantly higher than typical conditions).

I like to design for 3% voltage drop or less. Higher voltage drops will still work, but it can be a trade off between cost and system
efficiency.

Notice that because of the 1.56x current multiplier for safety and the possibility of needing larger wires for voltage drop. There can be a
significant advantage to designing the PV array for higher voltage and lower current.

A bit of good news: Because of the 1.56x multiplier for the safety calculations, the safety calculations end up requiring fairly large wires.
Consequently, for short to moderate lengths, it is unusual to need to increase the size of the wire.
PV voltage drop Example 1. Example 1: Calculate the voltage drop for the output circuit

3 parallel strings of series panels

In the previous example, we calculated the output circuit Panel Specs

2 Series panels
needed to be 8AWG for safety reasons. If the array is 100ft Watts (STC) 315 W

from the controller, is 8AWG large enough for a 3% voltage Max Power
Voltage 33.1 V
drop? (Vmp)

Source
Source
Max Power
Current 9.52 A
The ‘normal’ current on the output circuit is 3 x Imp or Imp (Imp)

3 x 9.52 = 28.56A. Open Circuit

OCPD

Combiner Box
Voltage 39.9 V
(VOC)

Output
Output
The Voltage on the output circuit is 2 x Vmp or 3x Imp Short Circuit
10.00 A
50’ Current (ISC)
2 x 33.1V = 66.2V Max System
SCC Voltage (UL)
DC 1000 V

The round trip conductor length is 2 x 50’ = 100ft String Fuse

Rating
32A

Plugging this into the calculator we get 5.4%.

If we bump the wire size up to 6AWG we get 3.4%

To get to less than 3% we would have to go all the way to 4

AWG.

I would be tempted to call it good with 6AWG and 3.4%

 PV voltage drop Example 2 Example 2: Calculate the voltage drop for the output circuit

2 parallel strings of series panels

For safety purposes, the source cable for example 2 needs to Panel Specs

be at least 10AWG. (See previous slides for how that is Watts (STC) 315 W

3 Series panels
calculated) Max Power
Voltage 33.1 V
(Vmp)

Source
The ‘normal’ current on the output circuit is 2 x Imp or Max Power
Current 9.52 A
2 x 9.52 = 19.04 A. (Imp)
Open Circuit

Source
Voltage 39.9 V
The Voltage on the output circuit is 3 x Vmp or (VOC)

2 x 33.1V = 99.3V Short Circuit

10.00 A
Current (ISC)
Max System

Combiner Box
OCPD
DC 1000 V
The round trip conductor length is 2 x 50’ = 100ft Voltage (UL)
String Fuse

Output
Output
32A
Rating
Plugging this into the calculator we get 3.82%. A bit high 50’

SCC
If we bump the wire size up to 8AWG we get 2.4%. Good!

Notice how a simple rearrangement of the array layout allowed us to significantly reduce the wire size for the PV cables.
In this case, it also allowed us to remove the Source Circuit OCPD devices!
2017 NEC 310.15(B)16
Ampacity Chart
 Fuses vs Breakers
• Either a fuse or a breaker can be safely used to protect parallel strings of panels.
• Breakers and fuses must be DC rated for the voltage of the circuit.
• Fuses are usually significantly less expensive
• There are manufacturer defined temperature deratings for fuses when operated above 104oF/40oC ambient.
• Breakers are resettable, but a well-designed system should not be blowing a breaker or fuse in normal operation.
• Breakers are not generally designed as a switch that can be used regularly. However, a breaker can be use for a
disconnect that is rarely used.

Directional or Polarized DC Breakers

1-n Series panels

Many DC breakers are designed to trip on excessive current in only one direction.
With these breakers, the positive should be on the ‘source’ side of the circuit the
breaker is protecting).
Polarized
Breakers
The String breakers in Figure 1 are there to protect from too much current back-
Brkr
Brkr
Brkr
String

Combiner Box

+ + + feeding into the panel(s). (The ‘source’ is the other panels in the array) Consequently,
Figure 1 the positive side of the breaker should be toward the SCC (Away from the string being
protected)
SCC
 Disconnects Vs OCP on the Output circuit.
All solar installations should have a disconnect on the output circuit, between the solar array and the solar charge
controller. This disconnect should disconnect both the positive and the negative line from the array. (This is one of
many disconnect requirements that the NEC places on solar installations).

Quite often, the disconnect is implemented using a dual circuit breaker because using a breaker can be a cost-effective
way to implement a disconnect. Even some controller manufacturers say to use a breaker. This has created confusion
that leads some people to believe breakers are required. However, if the system is installed with proper string OCP (if
needed) and properly sized wires, there is not a need for the disconnect on the PV Output circuit to be a breaker. A
properly rated dual pole switch is adequate.

If a breaker is used as the disconnect, there are a few things to keep in mind.
• Breakers are not typically designed for frequent use as a switch. Using a breaker as a switch can weaken them over
time, and this could result in nuisance trips.
• When used in place of a switch, a breaker’s trip rating should be higher than the calculated PV output circuit current
(PV output current = Isc x number of parallel stings x 1.56 =)
Appendix A: Additional considerations for NEC compliance
The NEC has additional requirements on PV OCP and PV Disconnect that are not addressed in this paper. Some of the
other requirements that are not addressed in this paper include
• Must use Listed components to be NEC compliant.
• Location and Labeling of the OCP devices.
• Derating OCP devices in high temperature climates to avoid nuisance trips.
• Wire and Cabling types.
• Adjusting wire size for temperature, conduit fill and conduit placement.

Important related items to consider are

• PV Ground Fault Protection and Arc Fault Protection.
• PV Rapid Disconnect requirements.
• OCPD on the battery side of the SCC
Appendix B: Why 2 parallel panels don’t need OCPDs
As stated above, two parallel panels do not need OCP devices on the two strings. However, if both of the panels can produce the Isc
current, then we are dealing with twice the current of a single panel…. Why don’t you need to put a fuse or breaker on it?

The diagrams below show two parallel panels with shorts in a couple places

Imax Imax Imax Imax

Imax

Imax
Short Imax
Imax Imax Imax = 1.25 x Isc

Short
Main Main
Notice that the only place that sees the 2xImax is the short itself. Everyplace else in the circuit only sees Imax. Therefor, there is no place
you could put an OCP device on the parallel circuits that would see the double current. Furthermore, the main circuit wires must be sized
to handle the 2x 1.25 X Imax ( 2 x 1.25 x 1.25 x Isc) and a short would not be harmful on them.