DC Balance of System and Protection

Suraj Vernekar
Product Manager

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Solar System Basics

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Basic overview of solar power generation
• Photovoltaic cells utilise the power of sunlight to convert photons to clean DC
(Direct Current) electricity.
• DC electricity fed into a Power Inverter (PV Inverter) that converts and regulates
the DC source into usable AC power.
• AC power can be used for local consumption – (£ saving)
• Domestic
• Commercial
• AC power can be exported to the grid – (£ generation)
• Domestic and commercial excess un-used power
• Larger PV farms

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What is a PV cell?

• One cell – semiconductor device

• 6” square
• Sensitive to fault conditions
• Costly to replace
• On its own very fragile

Low output: 0.646V dc, 7.18A = 4.64W

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What is a PV module/panel?

• Cells connected in
series
• One panel
• Typically made of 54 cells
• 1.5 x 0.6 metre

Symbol

Higher output: 34.9V dc, 7.18A = 250Wpeak

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What is a PV string?

Symbol

34.9V 34.9V + 34.9V + 34.9V = 105V dc

n1 n1+n2+n

• A number of PV modules/panels in series is a string

• Typically made of 20 modules depending on type of
module
• (Domestic systems typically 8 modules = 280V dc)

Higher output: 698V dc, 7.18A = 5kWpeak

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What is a PV array?

• A number of strings in parallel is an array

• Enables the current to be increased
• Help to overcome cable losses
• Increased efficiency
• For example 16 strings in parallel
• 698V dc x (16 strings x 7.18A) = 80kWpeak

Higher output: 698V dc, 115A = 80kWpeak

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Summary

1 Cell 1 Module 1 String 1 Array

(54 cells in series) (20 modules in series) (16 strings in parallel)
0.646V DC x 7.18A 34.9V DC x 7.18A 698V DC x 7.18A 698V DC x 115A
= 4.64W = 250W = 5KW = 80KW

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System topology

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String inverter system design
Typically commercial up to 1MW

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Central inverter system – DC side
Typically large ground mount over 1MW

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Central inverter system – AC side

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Considerations for DC PV protection

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Issues around solar systems

• Why is PV unique?
• AC vs DC power
• Fault conditions (overcurrent)
• Array fault scenario
• Fault conditions (overvoltage)
• Direct lightning strikes
• Indirect lightning strikes
• Impact on Efficiency

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Why is PV unique?
• High DC voltage not AC voltage
• Many points of failure
• Relatively low short-circuit fault current
• Sensitive to overvoltage damage and generally susceptible to
overvoltage conditions
• Installed in challenging environmental conditions:

• High ambient temperatures

• Higher humidity than normal
• Dust and sand
• Animal interference
Remote solar farm Easily accessed power station

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 PV system Vs power station
Power PV Array
Station
Voltage generated 25kV AC 1000V DC
Power measured in: Giga Watts Kilo or Mega Watts
Short-circuit currents: Very High Very Low
Ten of thousands of 1.3 times normal current
times normal current
Circuit protection Traditional circuit Specialist circuit
protection protection
Installation Highly controlled, Remote harsh
locally sited environment
Operational Control Established control Less easy to control
systems

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Fault scenarios
• Many connection
points throughout the
DC system
• Many points of
possible failure
• Damage to panels
• Poor connectors
• Damaged cable
• Failure modes
• +/- ve to ground
• +ve to -ve

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Overcurrent fault conditions
• System is live during daylight
• Cannot simply switch off the DC system
• Difficult to disconnect PV panels from system for maintenance
• Easy to create short-circuit, loose cable, weather, animal
interference
• Short-circuit fault currents relatevely low  very difficult for non-
gPV fuses to clear
• gPV fuse specially designed to clear 1.3 x fuse rating at 1000V
dc
• Typical gG fuse only designed to clear 1.6 x fuse rating at 690V ac
• For example a 10A gPV fuse (eg PV-10A10F) will clear a 13A fault current at
1000Vdc!
A gPV fuse MUST be used

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 Basic array fault scenario
Normal operation VS Short-circuit
current flows normally to system load Current flows is diverted into fault string

Fuse
S/C Current = (Np-1)x 125% x Isc
String current Isc = 7.74A
(16-1) x 125% x 7.74 = 145A

System load
System load

• Cable current /string = 1.56 x Isc = 1.56 x 7.74A = 12A • Short-circuit current > max cable current rating
• Cable current rating = 20A • Therefore individual string fusing is needed
• A Cooper Bussmann PV-12A10F can be used

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Overvoltage fault conditions

• PV Arrays are made of many semiconductor devices

• Susceptible to Lightning strikes due to open air locations
• Huge electromagnetic energy releases cause damaging voltage
spikes onto output of PV arrays. Causing irreparable damage to
PV panels.
Overvoltage = Module unusable = Costly repairs

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 Direct lightning strikes
380 kV 1 Direct / close lightning strike:
1 Lightning strike into the internal
power grid or frame work
110 kV 1a Voltage drop at the
impulse earthing resistance Rst

1b Induced voltages in power

grid or external metal work
1
230 V

20 kV
110 kV

Rst 1b
1a
20 kV

Power supply IT system

Lightning discharges in the external framework

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 Indirect lightning strikes
380 kV
2 Distant lightning strike:
Lightning strike at overhead line
2a system
2b 110 kV
Overvoltage transient waves at the
2b overhead line due to cloud-to-cloud
flashes

2c Fields of the lightning effect spreads

2a
230 V

20 kV

110 kV
2c

Rst
20 kV

IT system
Power supply
Lightning discharges in the power supply system

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 Types of overvoltage protection
Type 1 Protection

Direct lightning strike

Galvanic coupling
Inductive / capacitive coupling

Type 2 Protection

Indirect lightning strike

Conducted partial lightning currents
Inductive / capacitive coupling

SPDs allow damaging overvoltages to pass harmlessly to Earth

System protected from overvoltage damage

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Impact on Efficiency
• Due to the nature of PV systems output power can
easily be affected by:-
• Shading
• Dirt
• Dust
• The actual physical size of large commercial and PV
farms makes identifying faults very difficult
• Often left unattended for periods of time
• How do you know your system is working ok?

Reduced output = Reduced income

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3 Ps of PV Protection

• People: protect people from injury and death

• Property: protect property from fire and

damage

• Payback: protection of investment

Critical to have adequate system protection

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One Combined Solution

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Combiner Box Function
• Combine output of many PV strings into one output

• Provide isolation of supply for maintenance

• Provide overcurrent protection for each string

• Provide overvoltage protection from damaging

• voltage spikes

• Monitor complete system for output and health

• Provide all of the above in robust weatherproof enclosure

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Anatomy of a combiner box

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Enclosure
• Securely houses and protects the internal components
• IP65 rated
• Include breather drains, suitable for tropical and sub-tropical
environments

• Choice of enclosure types

• UV stabilised Glass Reinforced Plastic (GRP)

• Polyester or Polycarbonate

• Polycarbonate window optional

• Painted or stainless steel enclosure

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Number of strings
• Primary function of combiner box is to group together
incoming PV strings to achieve higher output currents.
• Typically from 3 to 24 input strings
• Glands or MC4 connectors
• MC4 connectors save time at point of installation

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DC switch
• Allows safe disconnection of panels
• 1000V DC specific switch disconnect
• Safely disconnect PV array from downstream
equipment
• Critical for safe system maintenance

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Overcurrent protection

• Low level fault protection

• Superior cycling withstand
• Fuse links available from 1A to 630A, 1000V DC
• 10X38mm typically used for string protection

• Housed in Eaton Bussmann gPV fuse holders

• Correct gPV fuse can protect individual strings and
allow system to generate power without interruption in
the event of a single string fault
Eaton Bussmann leading gPV fuse specially designed for PV applications

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Overcurrent protection configuration

• Eaton Bussmann recommends negative and positive

string fusing possible depending on application
• Ensures maximum system protection
• PV panel protection and downstream cable
• Protects against reverse polarity and short-circuits

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 Surge protection
• Surge protection is required to protect the PV strings
and array against overvoltage.
• Protects sensitive semiconductor PV panels from static
discharges, voltage surges and spikes
• Special DC surge devices required for PV applications
• Two ‘Classes’ Type 1 and Type 2
• Type 2 surge protection used in most PV applications
(indirect lightning strikes)
• Important to protect PV DC lines, AC lines and
communication lines

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Monitoring options

• A quick and effective method of remaining constantly updated on

the performance and health of your system

• Individual String current

• Total System Voltage
• Combiner box temperature
• SPD status (PV SPD & 240VAC SPD)
• Main DC Switch status

• Industry standard RS485 Modbus with optional external service

port for ease of integration and deployment

• Power supply options

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Summary
• Ratings
• Fuse Range: 1 - 32A
• Volts 600 – 1000V DC
• Strings 3 to 32
• Sizes: 300x600 / 400x600 / 600x800/ 1050x850mm
• Full overvoltage surge protection options
• Monitoring and Wireless solutions
• IP65 with IP65 breather vents as standard

• Features & Benefits

• Designed for harsh environments & high ambient temperatures
• Fully customisable configurable design
• Global manufacturing capabilities
• Fully IEC compliant
• Designed for long term reliability

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Questions

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