Solar
Energy System
A Solar Energy System
is a renewable energy generating system that collects photovoltaic energy from
the sun and converts it into usable electricity. Often found as roof-top PV
arrays, these systems can range in size and are able to power different types
of properties - such as residential, commercial, and utility-scale zones.
Photovoltaic systems
can be used in multiple applications: standard arrays such as roof-top or
ground mount serve to generate energy for a residence or building, while other
non-traditional systems can be utilized to power other objects or function
(such as space satellites, hand-held calculators or vehicles).
For most DC-coupled
off-grid systems it really comes down to four main components – solar panels,
charger controller, inverter and the battery bank. There is a lot more that can
go into a solar system setup, but those are the four main pieces.
Solar
Panels
Starting with the most
obvious part of an off-grid solar system are the solar panels. Currently, the
most cost-effective solar panels are those made up of 60, 72, 120 or 144 cells.
Solar cells are the small squares that makeup the entirety of the panel itself.
These days, monocrystalline panels are the industry standard in most systems. A
typical 60 cell monocrystalline solar panel will be around 66” x 40” in size
and output in the range of 300-330 watts, whereas a 72 or 144 cell panel will
measure 80” x 40” usually and output around 360 watts or above. Knowing how
many solar panels needed for an off-grid solar system varies. Once the number
of panels is known it is time to connect the panels together into a solar
array. The solar panels are connected in series to form a group, then the
various groups of solar panels are connected in parallel and combined into a
combiner box that sends the homerun to the equipment that manages the power.
This method simplifies the solar array output down to a positive and negative
wire.
So why use
monocrystalline instead of polycrystalline panels? It really comes down to
availability and money. Most of the time monocrystalline panels are used in
off-grid solar systems as the industry has shifted to manufacturing those types
of panels instead of polycrystalline. In the early days, affordability gave the
advantage to polycrystalline panels because they were cheaper to manufacture.
Since that time, monocrystalline has become mainstream and affordable, so there
isn’t a real advantage to using polycrystalline any longer.
Now that we’ve
discussed the types of panels you can expect to be using in an off-grid system,
it is time to think about how to mount the solar panels. There are a variety of
ways to mount solar panels to make sure they don’t get damaged or blown away.
There are three main ways of mounting your solar panels and the option chosen
is based on the individual application:
Roof Mount (Mounting
the solar array on a home or other shelter structure)
Pole Mount (Mounting
the solar array on pole secured in the ground by concrete)
Ground Mount (Mounting
the solar array on concrete piers closer to the ground for stability)
Now that the solar
panels are mounted and ready to go, it’s time to figure out what to do with the
positive and negative wires coming from the solar array which leads us to the
next component, solar charge controllers.
Charge
Controller
The charge controller
is the device that manages the flow of energy from the solar panels to the
battery. Charge controllers make sure batteries are charged properly and are
not overcharged which is important for the longevity of the battery bank. There
are two main types of charge controllers, MPPT (Maximum Power Point Tracking)
and PWM (Pulse Width Modulation).
PWM charge controllers
use pulse modulation to turn on and off the rate at which the energy from the
solar panels is being sent to the batteries. When using PWM charge controllers
it’s essential for the nominal voltage of the panels match the nominal voltage
of the batteries. For instance, if the system is using 12 volts panels the
battery bank needs to be 12 volts. There isn’t a lot of control on managing the
power coming from the panels using a PWM, it’s essentially dumping the power
into the batteries. PWMs offer limited input compared to an MPPT controller.
MPPT charge controllers
are different in the fact that the input voltage from the solar panels needs to
be 30% over the voltage of the battery voltage (up to the limit of the charge
controller), so it doesn’t matter as much what voltage solar panel is used with
the system. MPPT charge controllers are more efficient due to their ability to
track the maximum point of power coming from the solar panels and delivering it
to the batteries. It takes a higher voltage / lower current input and
converting it to lower voltage / higher current output for the same amount of
power. Given this fact, MPPTs very accurately control the amount of power that
is sent to the batteries which is important when batteries get full and trying
to satisfy system loads. The main selling point of using an MPPT controller is their
ability to capture the most power from the solar array at any given moment
contrary to limited input of a PWM controller. It is possible for a PWM to
deliver as much power as an MPPT, but it will never deliver more power than an
MPPT. For those reasons, MPPTs are usually the norm when choosing a charge
controller for a solar system design.
Inverter
The next component in
an off-grid solar system design would be an inverter. In nearly all off-grid
solar systems, the inverter is a battery-based inverter. The inverter’s purpose
is to take DC power that is stored in the battery bank and converting it to usable
AC power and sending it to your loads so it can be used in the same manner as
plugging into an AC outlet in a home. Inverters come in different sizes which
can accommodate smaller loads or larger loads depending on the off-grid loads
required. Another consideration is making sure the inverter can handle all the
loads running simultaneously in the system. When all the system loads that are
present in the off-grid system are added up, it will determine that maximum
amount the inverter needs to be able to handle.
Another important fact
is that the inverter needs to match “voltage-wise” with the system in which it
is being used. For instance, a 12-volt inverter cannot be used with a 24-volt
battery bank – it must be used with a 12-volt battery bank. Unlike charge
controllers, the voltage on an inverter cannot be changed as it is fixed and
must be matched with the battery voltage of the system. Given that information,
it’s important to choose an inverter wisely when designing a system especially
if expanding the system are in the plans. Choosing an inverter is an important
decision to make correctly in the beginning due to the cost associated with
them.
In most off-grid
systems we choose to use inverter chargers. Notice we said inverter “charger”.
So, we already know what a regular inverter does. What does an inverter charger
do? Basically, the inverter charger acts the same as a regular inverter, but
doubles as a charger. That means that the inverter not only has an output, but
it also has an input. This is important because this allows the system to use
an external power source such as a gas generator to power the system loads and
stops drawing power from the battery bank. Once the system loads are satisfied
the excess power that is being input into the system from the external power
source is then being used to charge the battery bank. Going with an inverter
charger allows redundancy in the system which is needed if there a several
cloudy days and the solar array cannot provide enough power to charge the battery
bank.
Batteries
The last main component
in the solar system is the battery bank, which is one of the most important
considerations and the most expensive. In the solar power industry, there are
two main battery chemistries – lead acid and lithium. With lead acid there are
different battery options, meaning there are multiple ways of constructing the
battery. The two main types of lead acid batteries used in solar are flooded
lead acid batteries and sealed AGM batteries.
A flooded battery is a
standard wet cell lead acid battery which is usually the most cost-effective
battery up front. The batteries themselves are relatively inexpensive, but
there comes necessary maintenance that is required to prolong the life of the
battery. Maintenance such as checking water levels in the battery, checking the
specific gravity are required to prevent the battery from being ultimately
destroyed. Also, regular equalization charges should be done as well to help
loosen build-up that may have become solidified and adhered to the plates
within the battery. Another consideration when thinking about using flooded
lead acid batteries is off gassing. Under certain conditions when lead acid
batteries are being charged, hydrogen gas is a byproduct which requires
ventilation for the battery bank. Lack of ventilation can pose a dangerous
situation when dealing with hydrogen gas fumes, so it must be taken seriously.
Being that these types of batteries are cost effective many people tend to use
them for their solar applications. Many that are new to off-grid solar tend to
burn through their first set of batteries due to battery neglect. If a
maintenance-free battery is desired and a cost-effective lead acid battery
option is needed, AGM batteries may be the perfect fit.
AGM means Absorbed
Glass Mat – which refers to the fiberglass mats between the plates where the
electrolyte is absorbed. These batteries are completely sealed and there’s
little to no maintenance involved. Life expectancy, charge cycles and
size/weight in an AGM battery are consistent with those of a flooded lead acid
battery. Due to the lack of maintenance of AGM batteries, there is an increase
in price compared to flooded batteries which offsets the concern of destroying
the batteries due to lack of maintenance in their flooded counterpart. One of
the drawbacks of an AGM battery is that if it’s abused there isn't much that
can be done to revive the battery once the damage has been done. AGM and
flooded batteries offer a cheaper price point up front than lithium batteries,
but their lifespans are significantly shorter.
Lithium Iron Phosphate
(LiFePO4) is the chemistry makeup of lithium batteries. Lithium batteries are
significantly different than flooded and AGM batteries in several different
ways, not only in size/weight, but also how they can be charged and discharged.
Lithium Iron Phosphate is an extremely safe chemistry which means it does not
off gas and can be stored without the need for ventilation. Lithium batteries
are completely maintenance-free and do not need to be fully charged unlike lead
acid batteries. LiFePO4 chemistry is also designed specifically for a
significant amount of charging cycles. These characteristics make lithium
batteries extremely advantageous for off-grid solar applications. Another
advantage is that lithium batteries have a built-in BMS (battery management
system). The BMS is constantly monitoring the operating state of the battery.
This means if the battery is being over-discharged or if the battery is too hot
or cold, the BMS will force the battery to shut down until those parameter
violations have been resolved. Think of BMS as a level of protection for the
batteries, which makes it difficult to damage them.
Another advantage of
lithium is that you can stack or expand an existing battery bank without
affecting the lifespan of the existing bank. Adding batteries to an existing
lead acid battery bank will ultimately result in failure of the entire battery
bank. Lithium batteries can also be purchased in 12v, 24v and 48v variations so
you can stack them easily in a nominal system voltage. This is important
because if a battery is forced into shut down mode by the BMS, the entire bank
does not shut down. Loads may have to be reduced to accommodate the inoperable
battery, but the remaining batteries will still be online.
In all facets, lithium
batteries are significantly superior to lead acid batteries. Depth of
discharge, the number of charge cycles, safe chemistry and a built-in BMS deal
a knockout blow to lead acid batteries in the long run. Not to mention lithium
batteries also charge faster and deliver a substantial amount of power
continuously without damaging the battery. Also, all reputable manufacturers
are offering warranties on lithium batteries for around 10 years which is
substantially more than warranties given on lead acid batteries. One more
advantage is that space needed for a lithium battery bank is much less than
that of a lead acid battery bank, which also reduces overall weight, which is
roughly a 75% reduction.
FACTORS THAT DETERMINE THE POWER RATING OF A SOLAR POWER SYSTEM AND HOW THE
COMPONENTS OF THE SOLAR SYSTEM ARE CHOSEN TO MEET THE POWER RATING.
Your
personal energy use:
Your utility bills are
a gold mine of information. Each bill shows your total energy used on a
month-by-month basis, with a comparison to the same month from the previous
year. You can even see day-to-day and hour-to-hour consumption. With this data,
we can easily calculate how many solar panels you will need by multiplying your
hourly energy consumption by the sunlight hours that strike your available roof
area, and then dividing that number by a panel’s wattage.
Roof
area and shading:
The amount of roof
space available to solar panels, and the amount of sunlight that strikes that
area are key to determining energy output. Fortunately, here in the Valley of
the Sun, we enjoy more than 300 sunny days every year. So for us, the most important
thing is to avoid shading. Trees, adjacent buildings, chimneys, and other
structures can all reduce panel output.
Panel
efficiency:
Not all solar panels
are created equal. Most commonly used residential panels offer wattages ranging
from 150 to 370 watts per panel, depending on size. Higher-grade panels create
more electricity from less surface area than lower-grade panels. So, if roof
space is limited, or shading structures cannot be removed, a higher-efficiency
panel may cost a bit more, but will produce more electricity from less space.
Buyback
programs through your utility provider:
In the vast majority of
cases, solar works in partnership with the grid, which is essential to ensuring
that your home has electricity even at night. Both electricity purchased from
the utility, and electricity generated by your solar panels is measured by the
same meter. The meter runs forward when being supplied by the grid, and
backward when your solar PV system is generating excess electricity. In utility
districts that support energy buyback programs (net metering), the homeowner
has an opportunity to earn energy credits for their excess power. You can draw
from these credits when you’re using conventional power, such as at night. With
that said, determining how your local power utility provider calculates these
credits is a critical factor in determining how many panels you buy. The more
credits you want, the more panels you will need.
SOLAR PV SYSTEM SIZING
1 Determine power
consumption demands
The first step in designing
a solar PV system is to find out the total power and energy consumption of all
loads that need to be supplied by the solar PV system as follows:
1.1 Calculate total
Watt-hours per day for each appliance used.
Add the Watt-hours
needed for all appliances together to get the total Watt-hours per day which must
be delivered to the appliances.
1.2 Calculate total
Watt-hours per day needed from the PV modules.
Multiply the total
appliances Watt-hours per day times 1.3 (the energy lost in the system) to get the
total Watt-hours per day which must be provided by the panels.
2 Size the PV modules
Different size of PV
modules will produce different amount of power. To find out the sizing of PV
module, the total peak watt produced needs. The peak watt (Wp) produced depends
on size of the PV module and climate of site location. We have to consider
panel generation factor which is different in
each site location. For Thailand, the panel generation factor is 3.43. To
determine the sizing of PV modules, calculate as follows:
2.1 Calculate the total
Watt-peak rating needed for PV modules
Divide the total
Watt-hours per day needed from the PV modules (from item 1.2) by 3.43 to get the
total Watt-peak rating needed for the PV panels needed to operate the
appliances.
2.2 Calculate the
number of PV panels for the system
Divide the answer
obtained in item 2.1 by the rated output Watt-peak of the PV modules available to
you. Increase any fractional part of result to the next highest full number and
that will be the number of PV modules required.
Result of the
calculation is the minimum number of PV panels. If more PV modules are
installed, the system will perform better and battery life will be improved. If
fewer PV modules are used, the system may not work at all during cloudy periods
and battery life will be shortened.
3 Inverter sizing
An inverter is used in
the system where AC power output is needed. The input rating of the inverter
should never be lower than the total watt of appliances. The inverter must have
the same nominal voltage as your battery.
For stand-alone
systems, the inverter must be large enough to handle the total amount of Watts
you will be using at one time. The inverter size should be 25-30% bigger than
total Watts of appliances. In case of appliance type is motor or compressor
then inverter size should be minimum 3 times the capacity of those appliances
and must be added to the inverter capacity to handle surge current during
starting.
For grid tie systems or
grid connected systems, the input rating of the inverter should be same as PV
array rating to allow for safe and efficient operation.
4. Battery sizing
The battery type
recommended for using in solar PV system is deep cycle battery. Deep cycle
battery is specifically designed for to be discharged to low energy level and
rapid recharged or cycle charged and discharged day after day for years. The
battery should be large enough to store sufficient energy to operate the
appliances at night and cloudy days. To find out the size of battery, calculate
as follows:
4.1 Calculate total
Watt-hours per day used by appliances.
4.2 Divide the total
Watt-hours per day used by 0.85 for battery loss.
4.3 Divide the answer
obtained in item 4.2 by 0.6 for depth of discharge.
4.4 Divide the answer
obtained in item 4.3 by the nominal battery voltage.
4.5 Multiply the answer
obtained in item 4.4 with days of autonomy (the number of days that you need
the system to operate when there is no power produced by PV panels) to get the
required Ampere-hour capacity of deep-cycle battery.
Battery Capacity (Ah) =
Total Watt-hours per day used by appliances x Days of autonomy
(0.85 x
0.6 x nominal battery voltage)
5. Solar charge controller sizing
The solar charge
controller is typically rated against Amperage and Voltage capacities. Select
the solar charge controller to match the voltage of PV array and batteries and
then identify which type of solar charge controller is right for your
application. Make sure that solar charge controller has enough capacity to
handle the current from PV array.
For the series charge
controller type, the sizing of controller depends on the total PV input current
which is delivered to the controller and also depends on PV panel configuration
(series or parallel configuration).
According to standard
practice, the sizing of solar charge controller is to take the short circuit
current (Isc) of the PV array, and multiply it by 1.3
Solar charge controller
rating = Total short circuit current of PV array x 1.3
Remark: For MPPT charge
controller sizing will be different. (See Basics of MPPT Charge Controller)
Example:
A
house has the following electrical appliance usage:
One
18 Watt fluorescent lamp with electronic ballast used 4 hours per day.
One
60 Watt fan used for 2 hours per day.
One
75 Watt refrigerator that runs 24 hours per day with compressor run 12 hours
and off 12 hours.
The
system will be powered by 12 Vdc, 110 Wp PV module.
1.
Determine power consumption demands
Total
appliance use = (18 W x 4 hours) + (60 W x 2 hours) + (75 W x 24 x 0.5 hours)
=
1,092 Wh/day
Total
PV panels energy needed = 1,092 x
1.3
=
1,419.6 Wh/day.
2.
Size the PV panel
2.1
Total Wp of PV panel capacity
needed = 1,419.6 / 3.4
=
413.9 Wp
2.2 Number of PV panels needed = 413.9 / 110
=
3.76 modules
Actual
requirement = 4 modules
So
this system should be powered by at least 4 modules of 110 Wp PV module.
3.
Inverter sizing
Total Watt of all
appliances = 18 + 60 + 75 = 153 W
For safety, the
inverter should be considered 25-30% bigger size.
The inverter size
should be about 190W or greater.
4.
Battery sizing
Total
appliances use = (18 W x 4 hours) + (60 W x 2 hours) + (75 W x 12 hours)
Nominal
battery voltage = 12 V
Days
of autonomy = 3 days
Battery
capacity = [(18 W x 4 hours) + (60 W x 2 hours) + (75 W x 12 hours)] x 3
(0.85
x 0.6 x 12)
Total
Ampere-hours required 535.29 Ah
So
the battery should be rated 12 V 600 Ah for 3 day autonomy.
5.
Solar charge controller sizing
PV
module specification
Pm
= 110 Wp
Vm
= 16.7 Vdc
Im
= 6.6 A
Voc
= 20.7 A
Isc
= 7.5 A
Solar
charge controller rating = (4 strings x 7.5 A) x 1.3 = 39 A
So the solar charge controller should be rated 40 A at 12 V or greater.
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