PV System Sizing

• Introduction to the Design Process

• To determine total energy requirement
by load and system voltage
• Draw and interpret different diagrams
used in PV system
• Survey of solar resources and
selection of appropriate PV module (s)
5/13/2009 DP 670: Electrical Energy Conversion in Photovoltaic Systems / Sizing /CZMK 1

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 PV System Sizing - Continued
• Sizing and selection of appropriate storage
battery
• Sizing and selection of appropriate inerter
• Sizing and selection of appropriate charge
controller
• Sizing and selection of cables, fuses and
switches
• Selection of other materials, tools and
equipments required
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 Introduction to Design Process
• Major barrier to obtaining PV systems is the
high initial cost.
• Systems large enough to supply enough power
all time are much more expensive than those
that supply power requirements most of times.
• To obtain same amount of energy during cloudy
season as during sunny months, solar array and
battery may have to be sized larger.
• Less-costly alternative to ‘over-sizing’ systems
is to charge batteries by other means and to
limit use of appliances during cloudy weather.
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 Introduction to Design Process - Continued
• When planning, remember that electric energy
demand will probably grow.
• For example, in a school, classrooms may be added,
or in a small home system, a television might be
added.
• Adding more appliances will increase the load and
will often require additional solar modules and/or
batteries.
• Consider and compare costs of alternatives
carefully.
• PV is often cheapest alternative for those who
require power for lighting and small appliances.
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 Introduction to Design Process - Continued
• Before starting, draw a scale diagram of the floor plan where
the system is to be installed.
• It helps to estimate the amount of cables and wiring material
required, and to decide where to locate the battery,
modules, control, sockets and appliances
• Keep your systems as simple as possible.
• More complex the system is, the more likely it is to fail.
• Shop around for different equipment - quality and cost.
• Estimate the load carefully.
• Over estimation of load will increase system cost
significantly.
• Under-estimating size of load may result in continual battery
problems.
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 Total Daily System Energy Requirement
and System Voltage
The steps below explain how to use
Worksheet 1 to calculate the Total Daily
System Energy requirement.

This is the amount of energy the modules

must generate to meet the total daily load
demand plus the extra energy required to
overcome system losses
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 Step 1: Calculate the Daily Load Energy
Demand in watt-hours or amp
hors as in Worksheet 1.
• The Daily Load Energy Demand is the
amount of energy required each day to
power the load (i.e. appliances).
• Measured in watt-hours or amps hours.
• Calculated by totalling the energy that
all appliances uses on an average day.
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 Work Sheet 1
Column A Column B Column C Column D Column E
Lamp or Voltage Power Daily use Daily Energy
appliance (volts) (watts) (hours) Use
(list below) (watt hours)

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 Column A: Individual Load
Description
• List all appliances to be
powered by the system here.
• When listing, consider all
appliances to be powered by
system even those that will
be purchased in future.
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 Column B: Individual
Appliance Voltage

• List the voltage of

each of the
appliances.
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 Column C: Individual Appliance Power

• List the power in watts of each appliance.

• Usually, the manufacturer indicates the
power rating on the appliance itself.
• Radios and cassette player are rated
according to their maximum power, but
they normally operate at much less than
half the indicated power (i.e. if a cassette
player is rated at 30W, write down 15 watts
in column C.
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 Column D: Individual Appliance Daily Use

List the estimated amount of hours per day

that each lamps and appliance will be
used. If the appliance is only to be used a
few times per week (i.e. a sewing machine
might only be used on weekends), estimate
the number of hours it is used per week,
divide by 7 and write the number of hours
per day in column D.
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 Column E: Individual Appliance Daily Energy Use

• Multiply power of each load (column C) by

number of hours it is used per day (column
D) and write the figure in column E.
• This is the energy use in watt-hours per
day (Wh/day) of each appliance.
• Daily Load Energy Demand: obtained by
adding all the numbers in column E. This is
the Daily Load Energy Demand in watt-
hours per day.
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 Watt Hours and Amp Hours
• For planning purposes, energy consumption is
indicated in watt-hours or amp hours (Watt hours or
kilowatt hours are common measure of electric
energy).
• However, because battery capacity and module
output are generally measured in amp hours, solar
electric system planners often use amp hours to
indicate energy instead of watt-hours (strictly
speaking, amp hours are not a measure of energy,
but a measure of total charge).
• To calculate amp hours, divide the energy in watt-
hours by the system voltage. (12, 24 48 Volts, etc)
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 Example: PV System Sizing
Column A Column B Column Column D Column E
Lamp or Voltage C Daily use Daily Energy
appliance (volts) Power (hours) Use
(list below) (watts) (watt hours)
Sitting Room 12V 13W 3 hours 39Wh
Lamp
Kitchen lamp 12V 13W 2 hours 26Wh

Bedroom 1 12V 8W 2 hours 16Wh

Bedroom 2 12V 8W 1 hours 8Wh
Cassette Player* 12V 10W 3 hours 30Wh
14” Colour TV** 12V 80W 2 hours 160Wh

*REQUIRES DC-DC CONVERTER

Total Daily Load Box F
**REQUIRES 12VDC-240VAC INVERTER Energy Demand 279 Wh

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 Step 2: Estimate System Losses
• Because the system is new, the estimated
losses will be about 15%, or 42 Wh.
• However, an inverter will be used to power
the TV, about half the load, so another
15% of the TV load (i.e. 15% of 160Wh) is
24 Wh.
• Add 42 Wh plus 24 Wh and the Estimated
System Energy Losses is 66 Wh.
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 Step 3: Total Daily Load
Demand
Add the load demand of
279 Wh to the sysyem
losses 66 Wh and to
obtain the total as 345 Wh
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 Step 4: Choosing System
Voltage
Decide to use 12 volts as the
system voltage, although a
TV operating at 240 VAC
through the inverter will be
used.
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 Step 5: Daily System Charge
Requirement
• Divide the total energy requirement
345 Wh, by the system voltage 12V,
to get the Daily System Charge
Requirement, 28.75 amp-hours.
• This is the amount of charge that
must be provided by his modules
each day.
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 Sizing and Choosing the Module (s)

• The size of the module or array is

calculated using the daily total
energy requirement and the solar
resource figures for the site.
• To calculate this, you will also need
information about the solar modules
available in your area.
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 Step 1: Calculate Site Insolation Value
• Before selecting your module, estimate the
solar energy available at your site (i.e.
mean daily insolation in kilowatt hours).
• Records from a nearby meteorological
station should be used if they are available.
• If there is no meteorological station nearby,
estimate the amount of power available
using the insolationmaps in this manual
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 Using Meteorological Records
• If monthly mean daily insolation data is available from a
station nearby, enter the monthly data in the table in
Worksheet 2. (NB Data may be in langleys: to convert
langleys into peak sun hours, multiply by 0.0116).
• Sunshine hours are not the same as insolation or peak
sun hours - they indicate how many hours the sun shines
at the site, but they do not give the intensity of the solar
radiation.
• Check which month has the lowest mean daily insolation.
This is called the design month. Its value is used to size
the array for stand-alone systems. If solar charge is the
source of all your electric power, then you should design
the system so that the modules produce enough power
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 Radiation Data for Dar es Salaam
7

6
Monthly Mean Daily Insolation

5
(kWh/m2)

0
Jan Feb Mar A pr May Jun Jul A ug Sept Oct Nov Dec

1991

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 Choosing the Design Value
• The problem with using the design month to build a system is
high cost. If you do not require power 100% of the time-or if
you can charge the battery by an alternative method when it
is very cloudy – you can use the annual mean daily insolation
value as a planning figure.
• This will reduce size and expense of the array. This value
represents average energy available per day over the whole
year (add all monthly values together and divide by 12).
• Note that a shortage of energy during winter and/or the
cloudy parts of the year is likely if you use this value when
designing, so you will have to reduce use of lights and
appliances (or charge the battery by an alternative method)
during those months.
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 Estimating Insolation without Records

• If no meteorological station is nearby, it will be

necessary to make an estimate (or educated
guess) of the insolation received at your site.
• Consult the solar resource maps to get a rough
estimate of your site’s annual mean daily
insolation. For example, Dar es Salaam is located
between the 5.1 and 5.3 peak sun hour contours
on the map. Therefore Dar has an estimated
annual mean daily insolation value of about 5.2
peak sun hours. Write the value for the site
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 Insolation Contour Map for East Africa

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 Step 2: Decision on Fixed vs Tracking System
• Modules attached to properly operated tracking
mounts will collect up to 25% extra energy.
• For those people who have a tight budget, we
recommend that they mount modules on
manually power tracking mounts.
• However, we also warn you that if you do not
operate the mounts properly, your module (s) will
collect less energy.
• If you decide to mount your array on a tracker,
calculate 20% of the design month value.
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 Step 3: Calculate the Design Solar
Insolation Value
Obtain the total energy together, and
write the sum in the worksheet. This is
the number of peak sun hours (or the
total energy in kilowatt-hours per
square metre) expected per design
day, from which the size of the array
and battery will be determined.
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 Step 4: Calculate System Design Charging Current
• The module (s) in a system must be chosen so
that their energy output matches the Total Daily
System Energy Requirement.
• For your solar electric system to succeed over
the long term, the average daily energy output of
the modules must equal the average daily energy
requirements:
• Charge Produced by Array per day (in amp
hours) = Daily System Charge Requirement (in
amp hours)
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 System Design Charging Current - Continued
In Worksheet 1, Daily Total System Charge Requirement
(in amp hours) for the system was determined .
28.75 amp-hours
We also determined site Design Solar Insolation Value.
4.5 peak sun hours
Divide: 28.75 amp-hours/4.5 hours = 6.4 amps
This is the System Design Charging Current ( in amps)
which is needed to meet your energy requirements.
Enough modules are needed to produce this current at the
system voltage.)
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 Step 5: Select of PV Modules
• Now, select enough modules (or a large enough array)
to produce the system Design Charging Current at the
operating voltage and conditions at your site.
• To do this, divide the System Design Charging Current
by operating current output of the modules e available.
• First, find out what modules are available. If possible,
see manufacturers tables or I-V curves to calculate a
module’s current output.
• Remember, the higher the temperature, the lower the
module output, and modules are typically 20 degrees
warmer than the ambient temperature.
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 Approximate Daily Charge Outputs of Various Modules
at a Load of 14 volts at 50 degrees C (in Amp hours)
Module type Module Actual Amp hours Amp hours
Rating Current Peak day at Peak day at 5
Wp Output 4 Peak Peak hours*
(Amps) hours* (Ah) (Ah)
Fixed Fixed
NAPS A 13P 12 Wp 0.8 3.2 4.0
Uni-Solar 22 Wp 1.5 6.0 7.5
(Canon)
Siemens M-65 43 Wp 2.4 9.4 12
Siemens M-55 53 Wp 3.2 12.8 16
Solarex MSX-60 60 Wp 3.75 15.0 18.7
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 Choice of Battery
• Choice of battery will be limited by what is
on the market and how much money is
available.
• Consult for more information on battery
selection. Remember, to buy a good battery
if can afford it - it will pay off over the years.
• Avoid choosing second-hand automotive
batteries, as their capacity will be greatly
reduced by age and previous cycling.
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 Choice of Battery - Continued
• Battery voltage determines the
system voltage.
• Small systems mostly use 12 volts
batteries, or, for smaller systems, six
volt (or smaller) batteries.
• Larger systems use 12-volt batteries,
or strings of 2-6-volt cells, arrange in
series.
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 Calculation of Required System Battery Capacity
(i) Record Daily System Charge Requirement
(This number was calculated earlier)
(ii) Enter the number of storage days required.
This is the maximum expected consecutive
days of cloudy weather when the battery will
supply most system power. In sunny areas, this
number may be as low as two or three days
only. In places with long cloudy seasons, this
number may be much larger (i.e. 7 days or
more). Write your estimate in a data sheet.
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 Calculation of Battery Capacity - Continued
(iii) Enter the maximum depth of discharge. This value is
that portion of the battery storage that will be
regularly used. Shallow cycle automotive batteries,
for example, should not be cycled below 80% state of
charge, so only 20 % of their capacity should be
available for system energy requirements. Deep
discharge batteries can regularly handle 50 %
discharges. Write this number as decimal (i.e. 20 %
as a decimal).
(iv) The required system battery capacity can now be
calculated by relating the three variables as shown in
the next slide.
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 Calculation of Battery Capacity - Continued

Daily Required System Battery Capacity =

System Charge Requirement x
Number of Storage Days required /
Maximum Depth of Discharge

[28.75 amp hour x 5 days]/ 0.5 = 287.2 amp

hour
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 Choice of Battery - Continued

Batteries come in various sizes and any

parallel combination can give you a
bank that will suit your requirement with
the range of 287.2 amp hour
E.g.3 batteries of 100 amp hour each or
2 batteries of 150 amp hour each or
1 battery of 300 amp each
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 Choosing the Charge Controller
• Before choosing a charge controller, the
planner must decide:
9If charge controller is necessary;
9What controller size is needed; and
9What controller features are required.
• This section provides space to answer
these questions.
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 Choosing the Charge Controller - Continued

• First of all, is a control needed?

• The answer to the above question is that
some type of control system is always
necessary for solar systems.
• If the system is below 40 Wp, there may be
a case for user management instead of use
of a charge controller - but end-users should
be encouraged to invest in controllers when
possible.
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 Choosing the Charge Controller - Continued
• Controller must be sized to handle incoming current from
module and demand of the load.
• They are ordinarily rated at current of the module.
• Common controller sizes are 5, 10, 20 and 30 A inputs.
• Small home lighting systems (with less than 50 Wp of
modules) can ordinarily use a 5 A unit, while a clinic or
secondary school might use a 20 A or higher unit.
• Controllers also need to be sized to system voltage
9If the system is 12V, a 12 V controller is needed and
9If the system is 24 V, a 24 V controller is needed
• Advanced controllers that can automatically switched
from 12 V to 24 V exist.
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 Functions of Charge Controller

• Depending on the size of the system, the

appliances used, and the solar insolation at the
site, a controller will be required to perform
different functions.
• Important features to consider include:
Overcharge protection,
9Low voltage disconnect,
9Solar charge and low voltage warning lamps,
9Voltage and current meters, and
9Load timers.
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 Choosing an Inverter
Important tips to consider:
• Why do you need to use an
inverter in your system?
• Is your application going to run
a pump/refrigerator, TV etc?
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 Choosing Cable and Cable Sizes

Topics covered in the sections

include:

•Choosing cable size and type,

•Choosing fittings (switches, fuses,
connector strips, etc.) and
•The method of earthing the system.
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 Guidelines for Planning and Sizing PV System
1. Draw a floor plan of the house or institution on a
larger piece of paper and mark where the
appliances, batteries, modules and will be located.
2. Determine proper size of cables for each run to
avoid voltage drop.
3. Determine the total length of each type of cable
required.
4. Size fuses for each major circuit.
5. Determine the type and quantity of wiring material
(i.e. sockets, fuses, switches, connector strips and
clips, tacks, etc.).
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 Floor Plan Drawing
• This drawing should be to scale if
possible, so that you can estimate cable
lengths.
• Indicate clearly where each appliance
including sockets and switch will be, and
the position of the battery, charge
controller and module (refer to the
appropriate chapters to decide on
placement of these items)
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 Wiring Plan for a House

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 Determine the Proper Size of Cables

• Choose the proper size of cables for each run

to avoid voltage drop.
• Do this using the voltage drop table described
later.
• Usually, the run from module(s) to charge
controller, and from the control to the battery
requires a larger wire size (4mm2 or 6mm2).
• System will get the most energy if battery and
module cables are sized for a voltage drop of
less than 2 %.
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 Determination of Cable Length
• Determine the total length of each type of
cable required.
• Measure the distance of each run between
the loads and battery, and between the
battery and the module, remembering that the
cable goes up and down, as well as across.
• It is good to over-estimate the amount of
cable required unless you will be near to a
shop that sells it.
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 Sizing Fuses
• Size fuses for each major circuit
following the instructions on the
worksheet.
• Remember, it is crucial for the
system’s safety that a fuse is put
between the battery and the control,
and between each major load and the
control.
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 Type and Quantity of Wiring Materials

• Determine the type and quantity of

wiring material (i.e. sockets, fuses,
switches, connector strips and clips,
tacks, etc.).

• Make a list of the materials required

before going to purchase them.
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 Voltage Drop and Cable Sizes
• Cables with a large cross sectional area allow more current
to flow than those with small cross sections.
• Size of a wire thus determines the amount of current that
can pass through it.
• Low voltage systems require a higher current to carry the
same power as high voltage systems.
• In long cable runs, energy is lost as heat through the
resistance of the wire to the flow of electricity.
• If wire cross section is not large enough to support the
current, voltage drop will occur over the length of the cable.
• This may damage or cause poor performance in
appliances.
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 Voltage Drop and Cable Sizes - Continued
• A 24W appliance consumes 24W of power
regardless of whether is designed to work with a 240
V AC on 12V DC power supply.
• The power law is used to determine the current
flowing in each wire:
Power (Watts) = Voltage (Volts) x Current (Amps)
• To produce the same power as high voltage AC,
more current must flow in the low voltage appliance.
• Note that the current drawn between the high
voltage appliance, 0.1 A, is 20 times less than the
low voltage appliance current of 2.0 A.
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 Voltage Drop and Cable Sizes - Continued

• The above discussion makes it clear that

low voltage systems use a much higher
current than high voltage systems.

• Cables for low voltage system must have a

large enough diameter carry this high
current, especially the cables between the
module, control and battery.
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 Voltage Drop

• Voltage drop is loss of voltage (and

hence power) due to resistance in
long runs of cable.

• It occurs in all wire runs, but is more

serious problem in low voltage
systems with long cable runs.
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 Example - Voltage Drop
Suppose that the 24 W appliance
operated from a battery in the above
example is located in the kitchen 50
metres from the battery. How much
voltage drop will there be if a 1.5 mm2
cable carries the power to the appliance?
Will the voltage drop affect the
performance of the lamp? If so, what wire
size should be used?
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 Voltage Drop - Continued
• Questions in the example need to be answered
before installing the appliance.
• Whether voltage drop will affect an appliance
depends on the appliance (fluorescent lamps
may be ruined when run at a voltage below the
recommended level).
• It is good practice not to allow voltage drops of
more than 5% on a cable, but in most cases
equipment in small systems can tolerate up to
10% voltage drops.
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 Voltage Drop - Continued

• Proper wire size for a cable run

can be determined in either of
two ways: By using

9 Maximum Wire Run Tables or

9 Calculating the voltage drop.

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 12 Volt System Maximum Wire Length in
Metres (0.6V max voltage drop, or 5%)
Wire Load Current (Amps)
Size
(mm2) 1 2 3 4 5 6 8 10 14

1.5 22 11 7 6 4 4 3 2 2

2.5 38 19 13 9 8 6 5 4 3

4.0 60 30 20 15 12 10 8 6 4

6.0 88 44 29 22 18 15 11 9 6

10.0 15 75 50 38 30 25 19 15 11
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 24 Volt System Maximum Wire Length in
Metres (1.2 V max voltage drop, or 5%)
Wire Load Current (Amps)
Size
(mm2) 1 2 3 4 5 6 8 10 14

1.5 44 22 15 11 9 7 6 4 3

2.5 75 38 25 19 15 13 9 8 5

4.0 120 60 40 30 24 20 15 12 9

6.0 176 88 59 44 35 29 22 18 13

10.0 300 150 100 75 60 50 38 30 21

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