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Monocrystalline
Made up from 1 type of crystal
Polycrystalline
Made up of more than 1 type
Amorphous
Ohms law states that if you have two of the values you can always find the third. In
order to see this we can use the following example.
V I
Power Triangle
The same method can be applied when we
need to calculate the power in a circuit but we
use a slightly different triangle that contains
the values Watts (W), Amps (I) and Volts (V).
As with Ohms law we need to cover up the
value that we wish to find and we will be left
with a formula to apply to find the missing
value, in this example we are going to want
to find the voltage (V) when we have the
wattage (230W) and the current (7.93 A)
The difference between AC and DC current
The difference between AC and DC is that AC is an alternating current
(the amount of electrons) that flows in both directions and DC is direct
current that flows in only one direction; the product that is flowing being
electrons.
AC power is what fuels our homes. The wires outside of our house are
connected to AC generators. DC is found commonly in batteries and
importantly for our purposes, solar photovoltaic cells.
Both AC and DC employ magnets to repel electrons. Electrons are
negatively charged particles that are one of 3 components that make up
an atom. Negative charges will repel negative charges and positive
charges will repel positive charges, so one only needs to introduce a
negatively charged item next to electrons to force them to move in the
opposite direction.
Likewise, you can attract electrons by introducing
something that is positively charged into their
environment drawing the electrons to it. This property of
electrons is what allows for AC power to work; that is, they
switch directions constantly. The picture above is a
demonstration of AC power at work.
DC power was invented by Thomas Edison and first used
to power our homes in the late 1800′s. Its main drawback
being that in order to receive DC power from a generating
station, your home had to be located within a one mile
radius of the station. DC power degrades as it moves away
from its generating source; the further away, the less
power. This is an important fact to remember when
considering the position of inverters in relation to
photovoltaic modules
To produce more power cells can be wired
together.
Temperature Response
Solar cells are also affected by a change in temperature. An increase in
temperature causes a decrease in voltage and power and an insignificant
increase in current. For crystalline cells the voltage is changed by an
average of -0.5% per deg C change from 25°C.
When selecting a Module type for installation it is
important that the modules selected have the relevant type
test approval depending on the type of module to be used:
BS EN 61215:2005 “Crystalline silicon terrestrial
photovoltaic (PV) modules – Design qualification and type
approval” or
BS EN 61646:1997 "Thin film terrestrial photovoltaic (PV)
modules – Design qualification and type approval"
We also have to take into consideration the type and output of the
inverter to be used. Sizing the array and inverter are very important as
having an undersized inverter could cause installation failure and in
the worse case the inverter may break down and cause a fire.
Note the most southerly
part of England in red is
actually 1300
Variations in solar
radiation across the UK
(figures are average
kWh/m2 per year
1300
The array itself should be installed pointing to
true or grid south not magnetic south and angled
at 30˚to 40˚ to horizontal (in UK) to achieve
optimal performance. It can be tilted more or less
to maximize production in summer or winter.
Quite often this angle is controlled by the slope
of the roof and the aesthetics. Most customers
are unhappy with panels standing up off the roof
and this can also cause problems with wind
loading and planning permission.
Example 1:
The power from the array converted by the inverter is then connected via
isolators into the consumer unit via an MCB (miniature circuit breaker).
When we select an inverter we must take account of the size of the array
and the energy level requirements. Over sizing the inverter will increase
installation costs and the inverter will not be used efficiently. Inverter
sizing should always be done alongside manufacturer‟s guidance and
most manufacturers have “online” or downloadable sizing programs that
are very effective. When we don‟t have the manufacturer‟s data we
should size an inverter typically to be 80% of the PEAK POWER (Wp) of
the PV array. We undersize the inverter in the UK due to the relatively
low solar radiation levels and expected losses such as soiling and
voltage drop. As an example a 1kWp grid connected system generating
around 800kWh a year will require an 800W inverter.
The output of the PV system should be estimated using the
Governments standard assessment procedure for energy rating
of buildings (SAP 2009). For PV systems Appendix M is to be
used taking into account orientation, pitch and shading. Various
programs are available using this procedure and others to
simplify your life. SAP is the most commonly used and is
accepted by MCS but this does not mean that it gives the most
accurate results.
The inverter should be installed on a solid vertical surface with
adequate surrounding space for ventilation as the inverter will
get warm during operation. This may require strong board to be
installed. Some inverters are appropriately rated for outdoor
installation and then AC cabling has to be routed into the
building. For inverters only rated for indoor use the DC cabling
has to be routed into the building. The DC and AC isolators
associated with inverter should be easily accessible from the
inverter position.
Inverter location must be acceptable with
regards to:
◦ Weight bearing capacity of support
◦ IP rating of inverter
◦ Access (maintenance and testing)
◦ Ventilation
◦ Any displays / indicators clearly visible
◦ Live wiring precautions are to be followed if
connecting up the inverter necessitates working
around live DC connections.
AC system to be installed and tested to BS
7671:2008.
Normally all grid connected inverters have a circuit that uses
electronics to change the output of the array so that input of the
inverter is continuously operating at the maximum power point
even when temperature and irradiance are changing. Due to this
the voltage at the input of the inverter will be lower than what
would be normally expected. This voltage is approximately 80%
of Voc.
Efficiency, Longevity and Size.
Most grid controlled inverters are rated at 90% to 98%
efficiency over the majority of the operating range. The efficiency
of the inverter drops drastically below 25% of the maximum
input.
The warranties on inverters range from 1 year to 20 years due
to the different technologies used and production techniques.
The most common is 5-10 years.
Inverters come in many sizes. From a small one of a few watts
for solar lighting to a few megawatts for utility generation.
All systems installed in the UK under 16A per
phase must conform to G83 in respect of the
requirement to disconnect form the grid,
most inverters available are tested to achieve
the requirements set out in G83.
However great care must be taken to ensure
that the inverter selected for the job, has got
the correct certification to G83 as not all
inverters are designed to meet this
requirement.
When you are considering installing a PV installation on a roof,
you will have to understand that the connections and cabling are
not going to be the usual PVC/PVC twin and CPC cable used for
domestic internal wiring. The PV wiring does have to be durable
and protected against voltage constraints, mechanical damage,
movement, wind, rain and solar radiation. (This is not an
exhaustive list). Therefore maximum values need to be assessed.
MC4 connectors
Essential Information
DC Cable Installation- General Guidelines
Cable should always be double insulated and polarized.
DC Connectors should always be used
Cables and connectors will be expected to last for up to 25 years
Cable or fuses should never be disconnected when under load.
Cable from the solar PV modules should follow the shortest route to
the array connection boxes.
All DC cable should be clearly identifiable
Cables should be laid in parallel and loops should be avoided - except
where they enter a building
Cables should never be laid in a hazardous space
Cables should never be in contact with sharp edges
Cables should never be installed near lightning conductors.
Cables should always be tested for polarity in accordance with
specified regulations.
Care must be taken when connecting modules as they will generate if
there is light. (correct PPE is essential)
Voltage drop must be calculated to avoid any
under sizing of the PV cables which would
have a deleterious effect due to overheating
and break down of the insulation. There
follows a table with typical resistances of
different size cables
2.5mm 0.0074
4mm 0.0046
Conductor cross sectional area (mm2) 6mm 0.0031
Resistance in Ohms per metre
10mm 0.0018
16mm 0.0012
25mm 0.00073
35mm 0.00049
Example:-
A 4mm2 cable, 100m long, carrying a current
of 20A.
The voltage drop = 20A x 0.0046 = 0.092V
per metre.
For a cable length of 100m the volt drop =
9.2V.
A <1% voltage drop is recommended from
the inverter to the consumers unit and <3%
voltage drop between the array and the
inverter.
Due to PV arrays being constructed of metal components and the
structure being of metal, there is a possibility of lightning
strikes. The Structure therefore needs to be safe guarded against
these occurrences and earthing needs to be in place to carry any
voltage disturbances that may occur. The two main areas that
need to be considered for lightening and earthing protection
are:-
The PV Array
The Inverter
Location for the Inverter and DC isolator if required, as near to the PV modules as
possible, clear area where it can be easily reached and worked on for maintenance
and where it will have good airflow around it to avoid issues with overheating (see
manufacturer's instructions for guidance)
Cable runs to the inverter from the distribution board
Location of AC isolators
Identification of restrictions that may be placed on the methods of installation,
such as times when the power cannot be switched off
Identification of other hazards (both to the installer and the installation) that may
be present such as asbestos, confined spaces, sharp objects, rodents etc.
Internal check of roof construction for structural capability to accept PV array and
internal roof assessment to ensure that the work can be carried out within the roof
void safely
Any additional cabling or positioning of data processing units and digital displays
that may be attached to the system
External Survey
When considering the external survey we need to look at the availability
of roof space or area for mounting (if at ground level) and its suitability
for a PV system to be mounted. We also need to consider access issues
for the installation to be completed. As with the internal survey we have
listed below the key points that we think need to be addressed, again
these may need to be added to dependant on any particular site specific
issues.
If the above sequence is followed then it will ensure that there will not be any live cables, un-
terminated, in the building. It will also ensure that connections are not made under load during
the assembly of the array.
Roofing is an extremely important factor to consider
when installing a PV system as an old building having
thin rafters and purlins may not have the desired
strength to facilitate a full PV array through weight
and the natural forces of wind in which the roof
structure will be under. An assessment of the roofing
structure, the age of the building and the capacity for
the building to take the new system is essential.
Battens
Strut Near vertical supports for rafters
Strut
Tie-Beam Horizontal beam across the roof at
the eaves
Tie beam
Wall Plate Horizontal beam along eaves
Ridge board Horizontal beam along ridge
Purlin Horizontal roof beam supporting the
rafters
Purlin
These components can be seen on the next page and the
condition of all of these must be assessed to ensure the
roof integrity and structure can be maintained during and
after the installation, and also that the safety of the
installers and the householders can be ensured whilst the
work is being carried out. If it can be seen that the roof
components are in poor repair then advice and guidance
should be sought from a roofing professional via the
National Federation of Roofing Contractors (NFRC).
Where the cabling systems enter the building it must be ensured that the
penetrations are watertight and do not adversely affect the structure of the
building. When using roof mounted systems the most common way of entering
the building is through the tile or slate that the system is installed on, where this
is the case there are a number of proprietary slate adaptors and entry systems to
suit most types of roof structure.
Alternatively you could choose to form your own slate adaptor using one or more
sections of lead, however the proprietary slate adaptors are more reliable and
should be used in preference where available. Where the cable entry point is
through a wall then in addition to the water tightness of the building we also need
to consider the structural integrity of the wall and that, after the hole has been
drilled, it won't compress, cut or damage the cabling in any way; for this reason
the same methods of protecting the cabling system that apply to AC cables should
be applied to DC cables, dependant on the wall construction.
PV tracking systems also work best when you
have a high proportion of direct irradiation which
allows for accurate tracking and the best
possibility to gain from the tracking system,
where diffuse irradiation is most dominant it may
well not be so viable to utilise a tracker.
For the size of systems that we cover within this
manual it is unlikely to be financially beneficial to
install a tracking system due to the cost and
complexity that can be involved, it may well be
the case that where the customer is considering a
tracking system there is a case to spend the
additional money on more static modules so long
as there is the available space to do so.
The best angle to fit solar panels is South
East facing & at 30° inclination
Testing array
Temperature
Calculation of Voc
Adjusting figure(s) for temperature
Measure Voc and compare results
Measure irradiance
Calculate Isc
Measure Isc and compare results
The inspection process precedes the testing and can be broken down as
follows.
A visual inspection of the system and components is required and the
following items should be inspected:-
AC wiring and connections
AC isolators and junction boxes
Full labelling of the AC and DC supplies
Earthing and lightening protection
Inverter/s
DC wiring and connections including PV cabling
DC isolators and junction boxes
PV modules
Overcurrent protective devices
Array mounting system (secure and properly weather sealed)
Confirm that the modules comply with the international standards IEC
61215 (crystalline modules) or IEC 61646 (thin film modules)
Confirm that the inverter has a type test certificate to the requirements
of ER G83/1
There are a number of tests that need to be
taken before the installation can be safely put
into service and these can be broken down
into groups of tests.
Module testing
Array Testing
Inverter testing, AC and DC
AC testing
DC testing
The testing of a PV system should begin during the Installation phase. As each module is
installed it should be tested as this saves time in troubleshooting and the need to dismantle
the array to find a faulty module. Below is a sequence for module testing:-
1. Place the module in constant sunlight and then measure the open circuit voltage on the
output of the module
2. Remove the module from the sunlight (preferably by covering it). Then short the output of
the module and then once again place it in sunlight. Use a clamp on dc amp meter to then
measure the short circuit current. (Not all clamp on meters will measure DC amps)
4. The Isc is then multiplied to (irradiance @ standard test conditions / irradiance measured).
The Voc is then corrected for the temperature change (-0.5% change for each degree of
increase from 25oC).
These numbers can then be compared to the electrical ratings on the module nameplate to find
if the module is operating to its design parameters or is faulty or out of spec.
The open circuit voltage and short circuit current of the array need to be measured prior to
connection to the AC supply. Below is a sequence for array testing.
1. Isolate all of the strings by ensuring that all of the string DC isolators and the main DC array
isolators are set to the OFF position.
a. Connect a voltmeter across the positive and negative input terminals of the DC isolator and
record the voltage displayed. Then correct this value for temperature changes from the
standard test conditions. This is the open circuit Voltage (Voc).
b. Verify that the open circuit voltage value is around n times Voc for a module, from
manufacturer's data, where n is the number of modules connected in series in the string.
c. With the DC isolator set in the OFF position, connect a shorting link across the positive and
negative output of the DC isolator, i.e. not on the PV side of the DC isolator.
d. Clamp a current adapter (for non-intrusive current measurement, i.e. an „amp clamp‟)
around the shorting link.
e. Switch the DC isolator to the ON position and record the current displayed. This is the short
circuit current (Isc).
A simultaneous reading of the in-plane irradiance, GI, should be
taken.
Verify that the normalised short circuit current value agrees with
manufacturer's data for the module.
2. Insulation resistance
Under G83/1 the inverter should be in standby mode for the first
3 minutes.
The inverter should have a DC voltage input of approximately
80% of the measured PV open circuit voltage indicating the
inverter is tracking the maximum power point (MPP)
AC Testing
The testing of the AC side of the system must
conform to BS 7671 so each of the following
must be satisfied as a minimum; the specifics of
each test are not covered by this course.
1. Continuity of protective conductors
2. Insulation resistance
3. Polarity (live and dead)
4. Earth fault loop impedance (TN systems) or
earth electrode resistance (TT system)
5. Prospective fault current.
6. Functionality of RCDs and switchgear.
Module voltage and current (individual module output). Depending on
the type, composite and size of the PV module being used, this will
determine the output voltage and current. A typical 36 cell module
measuring 1mtr x 0.5mtr will have a Voc (voltage open circuit) of
21.4volts (approx.) and an Isc (short circuit current) of 4.45Amps
(approx.)
Date and time. We will be required to input the time and date of the
tests as every day can have different characteristics so comparing the
tests results can give us an indication of the overall efficiency of the
generator over a long period of time.
Temperature. The temperature of the modules at time of test is
required as there will be a difference between temperature of the
module on a specific day and the STC (standard test conditions)
temperature we use for the calculations. STC temperature is set at 25˚C.
Solar irradiance levels. STC irradiance levels are set at 1000W/m2
(1000 watts per metre square) in the UK. It is very unlikely that these
levels will be achieved or constant in the UK. We measure the irradiance
levels by the use of an IRRADIANCE METER
Example
We have installed 12 BP 75 Wp crystalline modules (Voc = 21.4v and an Isc = 4.45amps) on to
a roof as one string, the time of day is 10.25am and the date 05/07/08. The weather
conditions are overcast and we have an irradiance level of 350W/m2. The module temperature
is 35˚C.
Voc Measurement
1. Voc = 12 (amount of modules) x 21.4 (voltage per module) = 256.8v
2. Temperature correction facto r= (35˚C(measured)-25˚C(stc)) x0.5%=5% change or
0.05x256.8v=12.84v
3. Voc = 256.8v (calculated from step 1) – 12.84v (calculated from step 2) = 244volts
4. Measure the Voc actual of the array using a multimeter. Example measured Voc = 239v
5. Expected Voc = 244v. Actual measured Voc = 239v. A difference of 5v or 2%
Isc Measurement
1. Isc at STC for an individual module is 4.45 Amps
2. Isc = 4.45 x 350W/m2 (irradiance level) / 1000 W/m2 (stc) = 1.55A
3. Measure the actual Isc of the array = 1.67A (example)
4. Therefore Isc measured 1.67A – Isc calculated 1.55A making a difference of 0.12A or 7%
The differences in actual measurements and calculated measurements could be due to weather
conditions, temperature, light levels, shading etc. The difference in the levels of the above
calculation is considered reasonable. A large difference could be caused by many possible
problems such as shading, module malfunction or damage to the cables and components.
Maintenance & fault finding with PV systems is a relatively straight forward
process that can often pivot around any message that may appear in the inverter,
however before we detail these we must first consider the risks involved whilst
working on these systems. Often the module will be generating an amount of
power whilst we are working on them as it is very difficult and it can often be
more dangerous to attempt to isolate the modules before working on them.
The risks that we may encounter are as follows:
DC voltages present
Working at heights
AC voltage present
Generation when not expected (if for example the modules were not showing a
voltage then the sun came out whilst you are working on them)
Confined spaces (roof spaces)
Asbestos
High ambient temperatures (roof spaces)
Working platforms (either external scaffold or within the roof space)
It is vital that you assess any of the above that may apply, or indeed any others
that may apply that are specific to the site that you are working on, prior to
undertaking any work on the system.
Maintenance & fault finding with PV systems is a relatively straight forward
process that can often pivot around any message that may appear in the inverter,
however before we detail these we must first consider the risks involved whilst
working on these systems. Often the module will be generating an amount of
power whilst we are working on them as it is very difficult and it can often be
more dangerous to attempt to isolate the modules before working on them.
The risks that we may encounter are as follows:
DC voltages present
Working at heights
AC voltage present
Generation when not expected (if for example the modules were not showing a
voltage then the sun came out whilst you are working on them)
Confined spaces (roof spaces)
Asbestos
High ambient temperatures (roof spaces)
Working platforms (either external scaffold or within the roof space)
It is vital that you assess any of the above that may apply, or indeed any others
that may apply that are specific to the site that you are working on, prior to
undertaking any work on the system.
When undertaking maintenance it is important to ensure that the system is
performing, and has the output, that was originally specified (dependant on
annual irradiance levels). To enable this, personnel that undertake maintenance
must have access to the PV array test report and the declaration of expected
annual output from the original quotation or documentation.
A basic maintenance check list can be drawn up and used to check the system and
should include as a minimum the following:
Check to see if the customer is aware of any issues
Electrical installation periodic inspection report on the AC side as per BS 7671
Verification that the array fixings are still in a suitable condition
Verification that any roof penetrations are still watertight
Verification of the condition of the DC supply cables
Check the inverter data log (where possible) to verify actual output against what
might be expected
Module inspection. An inspection should be made for physical damage, the
entrance of water into the module, delamination or any form of degradation of cell
connections.
Array mounting. The mounting system should be inspected for corrosion or
weakness. The weather sealing of the roof penetrations must also be checked.
Cleaning of the array. The array depending on the location and inclination may
suffer from dust, dirt, salt water if near the coast etc. so cleaning the modules on
a regular basis depending on the amount of soiling will be required. Soiling can
cause a decrease of 10-15% in the output. The obvious danger is working at
heights. Refer to working at heights documents. Care should be taken when
cleaning the module so as not to remove the anti-reflection coating as this will
affect the output of the modules
Check that shading is still not affecting the array, for example:
New buildings causing shading
Dirt or debris covering the modules
Growth of trees or hedges locally that may affect the arrays collection
Monitoring. Monitoring can be as simple as noting down the output of the PV
system once a month and comparing it against the expected output. A significant
difference must be investigated as a possible problem. Some monitoring systems
are run in real time by a computer which in some systems can even monitor
individual modules. This allows the operator to locate faulty or
problematic modules before significant power generation is lost. The cost and the
complexity of such systems must be balanced against possible losses. Many
market incentives require some form of monitoring to be part of their program.
Completion of the relevant paperwork for the maintenance procedure