Optimal String Sizing

Yun Lee - 5/14/14

Intro

P. 2 | SunEdison Confidential
Design Considerations
 What do you consider when selecting a string
size?
• Maximum system voltage
• Inverter MPPT Window
• Site Conditions
• Site Layout
• AHJ / Fire Dept requirements
• Maximize capacity of racking equipment
• Voltage drop
• Module degradation
• AC line voltage tolerance
• Reactive power requirements

P. 3 | SunEdison Confidential
Minimum String Size
• Inverter MPPT Window

P. 4 | SunEdison Confidential
Calculating Vmin
 VMIN = n x (VMP + ((THI + TRISE − TREF) × βVMP))
̶ n = # of modules per string
̶ VMP = module voltage at max power
̶ THI = ASHRAE 2% Annual Design Dry Bulb Temperature
̶ TRISE = rise in cell temperature expected (~ 20 - 30°C)
̶ TREF = cell temperature at STC (25°C)
̶ β = temperature coefficient of Vmp (use Pmp coefficient)

 TRISE Calculation
• TRISE = (TNOCT - 20) x S / 800, where
• TNOCT = Nominal Operating Cell Temperature (NOCT)
• S = Insolation in plane of array at site (W/m^2)

P. 5 | SunEdison Confidential
Additional Considerations
 What other factors affect Vmin?
• High AC grid voltage (~2%-3%)
• Module Voltage Tolerance (~5%)
• Voltage drop (~1.5%)
• Mismatch (~0.5%)
• Light Induced Degradation (~2%)
• Array Degradation (~2%)
• Total (~14%!!!)

 Increase string size as much as possible!

P. 6 | SunEdison Confidential
Maximum String Size
 Max system voltage (600V, 1000V, 1500V)
 How do you calculate max Voc?
• NEC Table 690.7 (Conservative)
• Adjusted for temperature (Less Conservative)
• Proposed Method (Optimal)

P. 7 | SunEdison Confidential
Calculating Vmax
 NEC Table 690.7

P. 8 | SunEdison Confidential
Calculating Vmax
 Adjusted for Temperature – Allowed in NEC 2005

P. 9 | SunEdison Confidential
Calculating Vmax
 VMAX = n x (VOC + ((TLOW − TREF) × αVOC))
• n = # of modules per string
• VOC = module open circuit voltage
• TLOW = ASHRAE Extreme Annual Min Temp
• TREF = cell temperature at STC (25°C)
• α = temperature coefficient of Voc

P. 10 | SunEdison Confidential
Proposed Method for Calculating Vmax
 Adjusted for temperature and irradiance

P. 11 | SunEdison Confidential
Proposed Method for Calculating Vmax
 Step 1 – Obtain module data
Voc Irradiance (W/m^2)

Cell Type 200 400 600 800 1000

Gintech Mono AFS 3BB 43.77 44.82 45.47 45.97 46.42

JA Solar Mono AFS 3BB 43.54 44.60 45.32 45.87 46.23

NSP Mono AFS 3BB 43.69 44.70 45.42 45.92 46.32

NSP Mono PS 3BB 43.64 44.65 45.37 45.87 46.27

Suniva Mono AFS 3BB 43.88 44.89 45.62 46.16 46.52

Sunrise Mono PS 3BB 44.57 45.58 46.25 46.75 47.10

Tainergy Mono AFS 3BB 43.19 44.24 44.89 45.39 45.84

P. 12 | SunEdison Confidential
Proposed Method for Calculating Vmax
 Step 2 - Download all weather data (not TMY)

P. 13 | SunEdison Confidential
Proposed Method for Calculating Vmax
 Step 3 – Create and run PVSyst model to output:
• Plane of Array Irradiance
• Cell Temperature

P. 14 | SunEdison Confidential
Proposed Method for Calculating Vmax
 Step 4 – Calculate Vmax
• VMAX = n x (VIRR + ((TCELL − TREF) × αVIRR))
̶ n = # of modules per string
̶ VIRR = irradiance adjusted Voc
̶ TCELL = modeled cell temperature
̶ TREF = cell temperature at STC (25°C)
̶ α = temperature coefficient of Voc

P. 15 | SunEdison Confidential
Method Comparison

Vmax Calculation Method Comparison for 1 Year

1,025.0

1,000.0
Maximum Open Circuit Voltage (Voc)

975.0

950.0

925.0

900.0

875.0

850.0
1/1/1990 31/01/90 2/3/1990 1/4/1990 1/5/1990 31/05/90 30/06/90 30/07/90 29/08/90 28/09/90 28/10/90 27/11/90 27/12/90
0:00 00:00 0:00 0:00 0:00 00:00 00:00 00:00 00:00 00:00 00:00 00:00 00:00

Temp Adj Only Irr & Temp Adj

P. 16 | SunEdison Confidential
Method Comparison

Vmax Calculation Method Comparison for All Years

1020.00

1000.00
Maximum Open Circuit Voltage Voc

Max Voc based on Irr & Temp Adj

Max Voc based on Temp Adj Only
980.00

960.00

940.00

920.00

900.00
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

P. 17 | SunEdison Confidential
Benefits
 For 20MWac / 26MWdc system:
• Increase strings size from 19 to 20 modules
• Reduce DC electrical installation by 5% (~$200k)
• Maximize capacity of tracker (~$200k)
• Decrease DC voltage drop (~0.1%)
• Approximately $0.015/Wdc ($0.020/Wac) in savings

P. 18 | SunEdison Confidential
Challenges
 AHJ / inspector
 Inverter manufacturer / warranty
 Independent Engineer
 Engineer of Record
 Lengthy calculation process
 What else?

P. 19 | SunEdison Confidential
Questions/Discussion?
 Next steps
• Analyze benefits in further detail
• White paper independently reviewed and certified by a 3rd party
engineer to address challenges
• Automate calculation using SunDat or other…

P. 20 | SunEdison Confidential