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How to Design Solar PV System

What is solar PV system?

Solar photovoltaic system or Solar power system is one of renewable energy system which uses PV modules to convert sunli

Major system components

Solar PV system includes different components that should be selected according to your system type, site location and appli
• PV module – converts sunlight into DC electricity.
• Solar charge controller – regulates the voltage and current coming from the PV panels going to
battery and prevents battery overcharging and prolongs the battery life.
• Inverter – converts DC output of PV panels or wind turbine into a clean AC current for AC
appliances or fed back into grid line.
• Battery – stores energy for supplying to electrical appliances when there is a demand.
• Load – is electrical appliances that connected to solar PV system such as lights, radio, TV, computer,
refrigerator, etc.
• Auxiliary energy sources - is diesel generator or other renewable energy sources.

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

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 p

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 bette

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 tha
For stand-alone systems, the inverter must be large enough to handle the total amount of Watts you will be using at one time.
For grid tie systems or grid connected systems, the input rating of the inverter should be same as PV array rating to allow for

4. Battery sizing
The battery type recommended for using in solar PV system is deep cycle battery. Deep cycle battery is specifically designed

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 m
For the series charge controller type, the sizing of controller depends on the total PV input current which is delivered to the co
According to standard practice, the sizing of solar charge controller is to take the short circuit current (Isc) of the PV array, and
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 190 W 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.
 ses PV modules to convert sunlight into electricity. The electricity generated can be either stored or used directly, fed back into grid line or c

stem type, site location and applications. The major components for solar PV system are solar charge controller, inverter, battery bank, aux

V, computer,

mption of all loads that need to be supplied by the solar PV system as follows:

PV module, the total peak watt produced needs. The peak watt (Wp) produced depends on size of the PV module and climate of site locati

led, 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 clo

nverter should never be lower than the total watt of appliances. The inverter must have the same nominal voltage as your battery.
atts 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 mo
 e as PV array rating to allow for safe and efficient operation.

e battery is specifically designed for to be discharged to low energy level and rapid recharged or cycle charged and discharged day after da

ct 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
rrent which is delivered to the controller and also depends on PV panel configuration (series or parallel configuration).
current (Isc) of the PV array, and multiply it by 1.3
sed directly, fed back into grid line or combined with one or more other electricity generators or more renewable energy source. Solar PV sy

controller, inverter, battery bank, auxiliary energy sources and loads (appliances).

e PV module and climate of site location. We have to consider “panel generation factor” which is different in each site location. For Thailand

system may not work at all during cloudy periods and battery life will be shortened.

nal voltage as your battery.

nces. In case of appliance type is motor or compressor then inverter size should be minimum 3 times the capacity of those appliances and
e charged and discharged day after day for years. The battery should be large enough to store sufficient energy to operate the appliances a

pe of solar charge controller is right for your application. Make sure that solar charge controller has enough capacity to handle the current fro
el configuration).
enewable energy source. Solar PV system is very reliable and clean source of electricity that can suit a wide range of applications such as

ent in each site location. For Thailand, the panel generation factor is 3.43. To determine the sizing of PV modules, calculate as follows:

the capacity of those appliances and must be added to the inverter capacity to handle surge current during starting.
nt energy to operate the appliances at night and cloudy days. To find out the size of battery, calculate as follows:

ough capacity to handle the current from PV array.

 a wide range of applications such as residence, industry, agriculture, livestock, etc.

PV modules, calculate as follows:

during starting.
 A
DA VG
AP W HR DA Y W
AT S YS AT
P LI Q TS PE T/
AN TY TT TT PE /7 HR
(V R R
CE X DA W S
A) Y K PE
R

42” PLASMA TV 0 390 390 0 4 0 7 0 7 0.0

LAPTOP 0 40 40 0 24 0 7 0 7 0.0
CFL BULB, 60W EQUV 2 18 18 36 4 144 7 1008 7 144.0
8.8 CU/FT FREEZER 0 250 250 0 8 805 7 5635 7 0.0
7.2 CU/FT FREEZER 0 160 150 0 8 773 7 5411 7 0.0
25.1 CU/FT REF 1 0 600 0 8 1310 7 9170 7 1310.0
TABLE FAN 0 70 70 0 12 0 7 0 7 0.0
MODEM 0 6 6 0 24 0 7 0 7 0.0
ROUTER 0 12 12 0 24 0 7 0 7 0.0
DAKOTA ALERT 0 2 2 0 24 0 7 0 7 0.0
HOUSE ALARM 0 5 5 0 24 0 7 0 7 0.0
FIREPLACE BLOWER 1 60 60 60 8 480 2.4 1152 7 164.6
1013 96 3512 22376 1618.6 1.1 TOTAL WATT HRS

PV PANEL SIZING
1.1 1618.6 WATT HRS
1.3 TIMES SYSTEM LOSS FACTOR
1.2 2104.1 TOTAL WATT HRS
4.1 TIMES AVG SUN HOURS FACTOR
2.1 513 DIVIDE TT WATT HRS BY SUN HRS
160 RATED PV PANEL OUTPUT FACTOR
3.21 NUMBER OF PANELS NEEDED
2.2 4 ROUND UP TO TOTAL PV PANELS NEEDED

INVERTER SIZING
30% SURGE INCREASE (FOR MOTOR/COMPRESSOR START)
3 486 INVERTER SIZE

BATTERY BANK SIZING

4.1 1618.6 TOTAL WATT HRS
0.85 BATTERY LOSS FACTOR
4.2 1904 BATTERY LOSS
60% DEPTH OF DISCHARGE FACTOR
4.3 3174 DEPTH OF DISCHARGE
12 NOMINAL BATTERY VOLTAGE FACTOR
4.4 264 NOMINAL BATTERY VOLTAGE
1 DAYS WITHOUT SUNLIGHT FACTOR
4.5 264 MINIMUM DEEP CYCLE BATTERY AMPERE-HOUR CAPACITY
Typical energy consumption of various appliances.

Air Conditioner - Room - 6000 btu, ½ ton 7.0 seer 857 watts
Air Conditioner - Room - 6000 btu, ½ ton 8.5 seer 706 watts
Air Conditioner - Room - 6000 btu, ½ ton 10.0 seer 600 watts
Air Conditioner - Room - 9000 btu, ¾ ton 7.0 seer 1286 watts
Air Conditioner - Room - 9000 btu, ¾ ton 8.5 seer 1059 watts
Air Conditioner - Room - 9000 btu, ¾ ton 10.0 seer 900 watts
Air Conditioner - Room - 9000 btu, ¾ ton 11.0 seer 818 watts
Air Conditioner - Room - 9000 btu, ¾ ton 12.0 seer 750 watts
Air Conditioner - Room - 12,000 btu, 1 ton 7.0 seer 1714 watts
Air Conditioner - Room - 12,000 btu, 1 ton 8.5 seer 1412 watts
Air Conditioner - Room - 12,000 btu, 1 ton 10.0 seer 1200 watts
Air Conditioner - Room - 18,000 btu, 1½ ton 7.0 seer 2571 watts
Air Conditioner - Room - 18,000 btu, 1½ ton 8.5 seer 2118 watts
Air Conditioner - Room - 18,000 btu, 1½ ton 10.0 seer 1800 watts
Air Conditioner - Room - 24,000 btu, 2 ton 7.0 seer 3429 watts
Air Conditioner - Room - 24,000 btu, 2 ton 8.5 seer 2824 watts
Air Conditioner - Room - 24,000 btu, 2 ton 10.0 seer 2400 watts
Air Filter - Electronic 40 watts
Aquarium Air Pump 5 watts
Bath - Electric 1000 watts
Battery Charger 220 watts
Blanket 150 watts
Blender 330 watts
Bug Killer Lights 15 watts
Bug Killer Lights 25 watts
Bug Killer Lights 40 watts
Can Opener 220 watts
Carving Knife 100 watts
Clock 2 watts
Clock Radio 10 watts
Coffee (Keep warm) 100 watts
Coffee Maker (making coffee) 1500 watts
Coffee Percolator 660 watts
Computer 100 watts
Computer (with accessories) 200 watts
Convection Oven 1500 watts
Cordless Appliance Recharger 6 watts
Crock Pot Cooker (High) 150 watts
Crock Pot Cooker (Low) 70 watts
Curling Iron (hair) 40 watts
Deep Fryer 1400 watts
Dishwasher 1200 watts
Dryer - Clothes 5500 watts
Dryer - Clothes (portable) 1200 watts
Dryer - Hair 1200 watts
Evaporative Cooler 325 watts
Fan - Attic 400 watts
Fan - Blower - Central, ¼hp 250 watts
Fan - Blower - Central, ½hp 500 watts
Fan - Blower - Central, ¾hp 750 watts
Fan - Ceiling 150 watts
Fan - Exhaust 200 watts
Fan - Portable 12" 60 watts
Fan - Portable 20" 180 watts
Floor Polisher 400 watts
Food Processor 400 watts
Food Waste Disposer 800 watts
Freezer 12 cu. Ft. 295 watts
Freezer 16 cu. Ft. 330 watts
Freezer 16 cu. Ft. (auto defrost) 500 watts
Freezer 18 cu. Ft. 350 watts
Freezer 18 cu. Ft. (auto defrost) 520 watts
Freezer 20 cu. Ft. 475 watts
Freezer 8 cu. Ft. 245 watts
Garage Door Opener ¼ hp (w/ light) 250 watts
Garage Door Opener ½ hp (w/ light) 500 watts
Grill - Outdoor 1600 watts
Heat Lamp 250 watts
Heater - Large Portable 1500 watts
Heater - Small Portable 750 watts
Heating Pad 60 watts
Hedge Clipper 300 watts
Hot Tub Heater 6000 watts
Hot Tub Pump (Low Speed) 300 watts
Hot Tub Pump, 1½ HP 1800 watts
Humidifier 90 watts
Ice Cream Freezer 140 watts
Ice Maker (self-contained) 350 watts
Iron 1100 watts
Lawn Edger 595 watts
Lawn Mower 750 watts
Lawn Trimmer 460 watts
Light Bulb - Fluorescent w/ ballast 40 watts
Light Bulb - Incandescent 100 watts
Light Bulb - Incandescent 60 watts
Light Bulb - Incandescent 40 watts
Light Bulb - Spot Light 150 watts
Light Bulb - Spot Light 250 watts
Light Bulb - Spot Light 300 watts
Lighting - Mercury Vapor w/ ballast 175 watts
Lighting - Mercury Vapor w/ ballast 50 watts
Microwave Oven 1500 watts
Mixer 225 watts
Oven - Double 17000 watts
Oven - Self Cleaning Feature 3500 watts
Oven - Single 12000 watts
Paint Sprayer 110 watts
Power Tools - Bench Grinder 370 watts
Power Tools - Chain Saw 1200 watts
Power Tools - Circular Saw 1320 watts
Power Tools - Drill 360 watts
Power Tools - Portable Tool Charger 5 watts
Power Tools - Sander, Belt 900 watts
Power Tools - Sander, Pad 360 watts
Power Tools - Scroll Saw 420 watts
Power Tools - Soldering Gun 600 watts
Power Tools - Soldering Iron 20 watts
Radio 15 watts
Refrigerator & Freezer 10-12 cu. Ft. auto defrost 400 watts
Refrigerator & Freezer 12-14 cu. Ft. auto defrost 475 watts
Refrigerator & Freezer 14-16 cu. Ft. auto defrost 500 watts
Refrigerator & Freezer 18-20 cu. Ft. auto defrost 550 watts
Refrigerator & Freezer 20-24 cu. Ft. auto defrost 600 watts
Refrigerator & Freezer 24-26 cu. Ft. auto defrost 625 watts
Refrigerator 12 cu. Ft. Single Door 225 watts
Roaster 1425 watts
Sewing Machine 120 watts
Shaver 15 watts
Shoe Buffer 175 watts
Skillet 1250 watts
Smoke Detector 2 watts
Sound Equip - Component System 500 watts
Sound Equip - Record Player 50 watts
Sound Equip - Stereo Unit 100 watts
Sun Lamp 800 watts
Sun Lamp (small) 60 watts
Swimming Pool Filter Pump 1 HP 1200 watts
Swimming Pool Filter Pump 1½ HP 1800 watts
Swimming Pool Filter Pump 2 HP 2400 watts
Swimming Pool Sweep Pump ¾ HP 900 watts
Telephone Answering Machine 9 watts
Telephone Cordless 6 watts
Television - Large Projection 195 watts
Television - Large Solid State 150 watts
Television - Small Solid State 100 watts
Toaster 1100 watts
Toaster-Broiler Oven 1500 watts
Vacuum Cleaner 740 watts
Vaporizer - Large 660 watts
Vaporizer - Small 30 watts
Video Games 9 watts
Waffle Iron 1400 watts
Washer 840 watts
Water Heater 4500 watts
Whirlpool Bath ¼ HP 250 watts
Whirlpool Bath ¾ HP 750 watts
Wok 1000 watts