OFF-GRID SOLAR PV SY

- Design an off-grid solar PV system that generates elect

- For a tutorial on how to use this toolkit please watch t

- Developed in partnership between Engineers Without

Instructions

To design an off-grid solar PV system using this toolkit follow these steps:

1 Fill out the first table in “Demand” tab for all the electricity needs you have. You need to enter number of

2 After finalizing all the loads that you want to provide electricity for in the Demand tab, move to the Invert
yellow cells. Rest of the variables are either calculated by the toolkit or your suggested input in case you p

3 In case, you insert a value in blue cells, the table at the bottom performs a validation check to ensure that
4 In the Battery tab you can see the main system variables in the first table. The second table asks for a batt
have access to from local vendors. The Battery Catalog on the left could help you document available batt

5 The third table in Battery tab calculates the number of batteries and the arrangement of them. A validatio
to be within the acceptable range for the arrangement. More information on battery sizing is provided at

6 The fourth step is to design solar PV array in PV Array tab. In the first table you need to enter an estimate
second table you need to enter variables related to the solar panel you want to use for the system. You m

7 The third table in PV Array tab is for designing PV array with calculating the total number of panels requir
required power and current requirements of the charge controller.

8 The Protection tab calculates the cable size and circuit breaker for each section of the system. More on pr

9 Design summary tab provides an overview of all the system variables and components.
10 Costs tab is a basic costs analysis for the capital investment required for the system.

11 If the system is going to be partially installed and operated this tab is to ensure that C-rates are still within

12 Catalogs provides a space for user to gather all the catalogs of equipment that is intended to be used in th

The cells are color coded. It means each cell color has a meaning that makes the design process

Yellow cells are mandatory user inputs. User needs to enter values in yellow cells for the toolki

Light pink cells contain values that are calculated by the software. They can't be changed directly.

Blue cells are optional user inputs referred to as 'user defined' that could be a technically feasible soluti
For example, the toolkit may calculate a certain system voltage or a certain number of parallel battery s

Green cells are design values. These are the values that toolkit uses for further calculations. Design valu

Validity check cells are a simple evaluation if the designed system meets the electricity demand or not.

Gray boxes include information that is important to keep in mind in design and implementation of the

- The spreadsheet has been coded using "worksheet" formulas. This means that all the formulas
have Data Validation checks, to ensure the correct type of data is entered.

- Data validation rules can be seen by clicking the cell and selecting Data\Data Validation in the
- The conditional formatting rules can be seen by clicking the relevant cell and selecting Home\S

- Finally, some cells have been given names to facilitate the writing of formulas; for example, cel
Name Manager

Disclaimer: The toolkit is meant for design purposes. The installation of solar PV system requires technica
consult with an expert for verification of the designed systems and use licensed technicians for system ins

Developed by Miriam Zubizarreta Ostivar, international volunteer of EWB-UK at PRE

Revised and prepared for public release by Dr. Mohammad Pakravan, Green Empowerment
Contact: [email protected]
V SYSTEM DESIGN TOOLK

enerates electricity for a community or special task using this toolkit.

please watch the tutorial video developed by Green Empowerment.

eers Without Borders UK and Penampang Renewable Energy SDN. BHD .

hese steps:

ed to enter number of loads (load means any electricity consuming device), rated power of each load, and estimated times of u

ab, move to the Inverter tab to design the first set of system variables and choose an inverter size that you need to use. The us
ted input in case you prefer to use a different value. More information on inverter sizing is provided in grey boxes at the bottom

n check to ensure that user input is still a design that meets inverter requirements based on demand.
nd table asks for a battery type that you want to use. You can either use typical values and battery types suggested by the syste
ocument available batteries.

ent of them. A validation check enables user to check if user adjusted battery system is in line with overall system architecture.
ry sizing is provided at the bottom of the tab for battery system design.

d to enter an estimated global irradiation value from Global solar atlas from the website with the link provided at the table for
for the system. You may inquire from local vendors for these values that are printed on each panel’s label.

mber of panels required, their arrangement and charge controller size. Two validation check tables at the bottom make sure th

he system. More on protection tab highlights more information that enables user to improve safety and reliability of the system

nts.

t C-rates are still within the appropriate range for the storage unit.

tended to be used in the design in one place.

s the design process easier. Below meaning of each cell color is explained:

low cells for the toolkit to properly design the system.

e changed directly.

echnically feasible solution while not calculated by the system. User could use these cells for evaluating alternative designs or configuratio
mber of parallel battery strings, while the user has flexiblity to choose a different value. If a "userdefined" value is input, this will be used a

calculations. Design values are set to be values calculated by the toolkit, unless user wants to choose user defined values from blue cells.

ectricity demand or not. These cells are important if user decides to evaluate a system using blue cell userdefined values instead of calcula

implementation of the system.

s that all the formulas can be visualised by clicking in the relevant cells and that there is no VBA code or macro runnin

ata Validation in the worksheet top banner. Other cells include conditional formatting, which will make the cells go red
nd selecting Home\Styles\Conditional formatting.

las; for example, cell P22 in "Energy needs" tab has been renamed "SystemV", for system voltage. The list of assign

tem requires technical and comprehensive understanding of system components and safety procedures. This toolkit provides s
hnicians for system installation and/or maintenance.
OOLKIT

oolkit.

DN. BHD .

nd estimated times of usage.

ou need to use. The user input in this tab is shown in three

rey boxes at the bottom in this tab.
suggested by the system or use data related to batteries you

l system architecture. The table below that checks the C-rate

ovided at the table for the intended location of your system. In

el.

e bottom make sure that user suggested design is providing

reliability of the system.

e designs or configurations.
nput, this will be used as Design Value.

values from blue cells.

values instead of calculated values.

code or macro running in the background. Some cells will also

make the cells go red if the design choices are not correct.
ge. The list of assigned names can be seen in Formulas\Defined names\

. This toolkit provides suggestive design information and its advised to

1. ENERGY NEEDS OF THE CLIENT: DEMAND CALCULATIONS

Net Power
Quantity per Number of Nominal Power
Load description AC / DC Location Total Qty in AC
location locations (W)
(Watts)
Households
Internal Lights AC Houses
External Lights AC
Bathroom Lights AC
Charging small devices AC
Charging Large Devices (eg laptops) AC
- Household load 1 TV AC
- Household load 2 AC
fridges

Community spaces
Internal Lights AC
External Lights AC
Bathroom Lights AC
Charging Small Devices AC
Charging Large Devices (eg laptops) AC
- Communial load 1
- Communal load 2
- Communal load 3

Special loads
Septic Pumps AC School
Dryer AC
Commercial refrigeration AC
Water pump AC
- Special load 1 AC
- Special load 2 AC
- Special load 3 AC

Total
Requirement 0W
W_ peak occurs in
Morning (6 am to 11 am)
Usage timeframe
Avg. Duration Of Efficiency Energy Consumption Net Ah Requirement
(part of the Notes Colour Code:
Use (Hours/day) (%) in (Wh/Day) (at 12Vdc)
day)
Mandatory User Input
Mid day (11 am - 4 pm) AC Optional User Input
DC Calculated values
Design values
Validation check: OK
Validation check: not OK

0.0 Wh 0.0 Ah
Wh/day Ah/day (at 12Vdc)
11 am)
Morning (6 am to 11 a 0

Mid day (11 am - 4 pm) 0

Evening (4 pm - 10 pm) 0
Night (10 pm - 6 am) 0
Business hours (8 am - 0
24 hours 0

1
100
2. INVERTER SIZING

Inverter design

Do you want to use an all-in-one Solar Charge Controller & Inverter?

Inverter AC output type:
Inverter efficiency (per unit)
Total energy requirements in (Wh/day)
Gross energy requirements in (Wh/day)
Inverter Requirement: (includes 1.25 safety factor)
Number of inverters: (default = 1)
Nominal size of the inverter (each):
System voltage (VOLT)
Total needs in Ah/day (at 12V)

Validation: Total Inv. capacity > Inverter Requirement?

Inverter requirement: -
Total inverter capacity: 1,000.00

Low frequency or high frequency inverter?

There are two main types of inverters in the market: High and Low frequency inverters. This is related to the intern
will be 50-60Hz in both cases.

- High frequency inverters are the most common for low power applications (a few kW). They are light, compact a
- Low frequency inverters have a much larger iron core transformer that makes them heavier, more expensive, but
current surges (starting of motors, refrigerators etc.).

Selecting one type or another is a matter of cost and intended application.

The difference between high frequency and low frequency inverter

Pure sine or modified wave sine type inverter?

Another important distinction is the type of output sine wave. Pure Sine Wave are the most recommended ones
suitable to power electric motors or sensitive electronic equipment

The difference between pure sine and modified sine inverter

Calculated/ Userdefined
Design Values
suggested (optional)

n/a NO n/a
n/a Single phase n/a
n/a 0.9 n/a
0.00 n/a n/a
0.00 Userdefined 0.00
0.00 n/a n/a
1 Userdefined 1
1.00 Userdefined 1.00
12 Userdefined 12
0.00 n/a n/a

Validation check margin (±

%)
5

This is related to the internal switching frequency, not the AC output frequency, which

. They are light, compact and cheap.

eavier, more expensive, but inherently more robust. They are more suitable to handling
most recommended ones. The cheaper "Modified Sine Wave" type inverters may not be
Units Colour Code:

n/a Mandatory User Input

n/a Optional User Input

n/a Calculated values

Wh/day Design values

Wh Validation check: OK

Watt Validation check: not OK

units
kW
Volts DC
Ah/day
3. BATTERY SIZING

Total Needs Nd Required Capacity

No.
(Wh/Day)
AUT DOD V Batt
(Ah) BATTERY CATALOG
1 - X / 0.80 / 12 = 0 Type Max. DOD (%) Efficiency (%) Max. C-Rate
Deep Cycle VRLA-AMG (Lead-Acid) 50 85 0.1 C/10
Standard VRLA-AMG (Lead-Acid) 35 85 0.1 C/10
System Voltage (from previous tab): 12V
Deep Cycle Flooded Lead Acid 50 75 0.2 C/5
GEL - Deep Cycle (Lead-Acid) 30 85 0.2 C/5
Lithium-Ion 80 95 0.5 C/2

INPUT DATA: BATTERY SPECIFICATIONS Colour Code:

Battery type (Choose or Enter battery type): Lithium-Ion n/a User Input: mandatory
Battery Parameters: Suggested Userdefined Design Value Units User Input: optional Maximum allowable Depth of Discharge (DOD) to guarantee at least 1500 cycles
% Maximum Depth of Discharge (DOD): 80 Userdefined 80 % Totals & calculated values
Battery efficiency: 95 Userdefined 95 unitary Design values
Individual battery voltage n/a n/a Volts Validation: OK
Individual battery capacity n/a n/a Ah Sanity check: not OK
Battery Charge-Discharge C-Rate 0.5 Userdefined 0.50 C/2

Calculated/
BATTERY DESIGN: suggested
Userdefined Design Values Units

Number of batteries per string: #DIV/0! n/a n/a batteries

Number of parallel strings required: #DIV/0! Userdefined #DIV/0! strings #DIV/0!
Total number of batteries: #DIV/0! n/a n/a batteries
Total capacity: #DIV/0! n/a n/a Ah
Total Stored Energy (nominal 12V): #DIV/0! n/a n/a kWh

Validation: installed capacity > required capacity? Tolerance margin

Required battery capacity (Ah): - (± %)
Installed battery capacity (Ah): #DIV/0! 5

C-RATE check:
Check to be done after "Solar Array Sizing" is Completed
battery bank charge/discharge current for max C-Rate #DIV/0! n/a Amps
C-Rate at max. inverter rating: #DIV/0! n/a #DIV/0! #DIV/0!

Cycle life and Depth of Discharge:

The majority of battery technologies cannot be fully discharged without significantly reducing the battery lifetime. This
means that only a fraction of the stored energy can be effectively utilitised. The level of discharge is referred as Depth of
Discharge (DOD) and is expressed as a %. For example, discharging a 100Ah battery at 70% DOD means extracting 70Ah,
70% of the nominal capacity.

The capacity of the batteries reduces with usage as the batteries age. The cycle life of a battery is measured as the
amount of charge-discharge cycles it can withstand whilst retaining a percentage of the original capacity. This percentage
is typically 60-80%, 80% being the more strict requirement. The cycle life varies drastically with the DOD the batteries are
discharged at and is a very important design requirement. A typicall lead acid battery may last over 1300 cycles at
30%DOD before its capacity drops under 60%, whereas it may only withstand 600 cycles at 50%DOD. 600 cycles is less
than 2 years, if a daily cycle is assumed. It is an economic decision to either oversize the battery bank so that the cells
undergo a shallow cycling of 30%DOD, or to use more of the stored capacity at higher DODs and replace the batteries
more frequently.

Despite the higher initial costs, other battery chemistries such as Li-ion, may prove to be more economical in the future
due to their higher efficiency and longer cycle life at deep DODs.

The cycle life values are usually given for a standard ambient temperature of 25degC. Batteries tend to degrade faster at
higher ambient temperatures.

1
2
3
4
5
6
7
8
Standard Lead-acid battery cycle life
9
Source: GPP122000D (12V-200Ah), GPA Technologies

"Deep Cycle" Lead-acid battery cycle life

Source: VT12250 (12V-250Ah) Greentechy

Types of Lead-Acid batteries:

Batteries used in small off-grid solar installations tend to be Lead-Acid type. These are the oldest and most common type
of batteries. There are various sub-types available:

- Flooded or Wet type batteries: the most simple type, traditionally used in cars. The electrolyte is a free liquid that can
spill out if the battery is moved around or placed horizontally. They generate small amounts of gas during charge that is
vented to the atmosphere and require regular addition of water to ensure they don't dry out. Not recommended for rural
off-grid installations due to maintenance requirements.

- Sealed type batteries. Generic name for batteries that are not flooded type. They can be mounted in any position
without leaking and do not require water addition. Subtypes are:
-VRLA: valve regulated lead acid. They have a safety valve to vent gas buildup in case of overcharge and prevent battery
damage due to pressure buildup.
- AMG: absorbed matt type. Subtype of VRLA but more advanced. Electrolyte is soaked into a sponge type matt.
- GEL: similar to AMG, but the electrolyte is a thick gel. They are very sensitive to overcharge and less common than AMG.

The recommended battery for off-grid solar is AMG sealed type. Peferably "deep cycle" type, which means the cycle can
regularly be discharged to higher DODs with an acceptable cycle life.

Battery types explained (Flooded Batteries, Sealed, VRLA, AGM, Gel)

Gel or AGM battery?

Lead-Acid vs Lithium-ion:
Lead-acid batteries are the oldest and most common type of batteries and the type tradicionally used for off-grid
applications. However, the Lithium-on technology is getting more and more popular due to its far superior performance
and gradually lower cost.

"Lithium-ion" is a generic term to describe a handful of different lithium-based battery chemistries. The type used for off-
grid applications Lithim-Iron-Phosphate batteries, also known as Lithium-Ferro-Phosphate of LFP. These sub-type is safe
and maintenace free and does not suffer from gassing, overheating or thermal runaway.

The main advantages of LFP vs Lead-acid are:

- Deeper cycle life: can be cycled to 80-90%DOD without affecting the battery lifespan --> This means a smaller battery
bank (smaller Ah capacity) is required.
- Higher efficiency: 0.95% roundtrip.
- Higher C-rates: can be charged/discharged faster. Faster discharge means higher power output can be obtained for the
same size battery bank.
- Can be partially charged without affecting the lifespan. Lead-acid batteries should always charged fully before starting a
discharge and kept fully charged, otherwise the lifespan gets reduced.
- The battery bank size (= capacity) can by increaed at any time by adding new batteries. With lead-acid adding new
batteries to an existing bank is NOT recommended, as the internal resistance increases with cycling. This means that for
lead-acid, the new batteries would end up working harder than the existing ones and suffering a premature aging. With
this LFP this isn't an issue because each battery has its own integrated BMS (battery management system) wich controls
the amount of charge going into each battery, and thus ensures a balanced operation.

The main disadvange of LFE is the higher cost. Around x3 or x4 the cost of the same size Lead-acid.

Off-grid solar PV battery buying guide

Note on battery efficiency:

Battery efficiency is accounted for in the PV array sizing. Does not have to be included here again (otherwise is included
twice)

Battery strings in parallel:

Good industry practices do not recommend connecting more than 3 battery strings in parallel as it becomes very difficult
to balance the strings adecuately. A small difference in resistance due to different wire lenghts or connector contact
resistances can make a very large difference in the current that actually flows in and out of each of the strings. Following
Ohm's law, for the same applied voltage, the string with the lowest resitance will have the largest current, working harder
than the rest and thus, aging faster. Some sources go even further and state that parallel strings should be avoided
whenever possible.

https://www.altestore.com/howto/how-to-size-a-deep-cycle-battery-bank-a94/
https://www.sunwize.com/tech-notes/solar-battery-basics/

An alternative to achieve the required the system capacity with less parallel strings is to use battery cells with higher
nominal capacity. For example, 12V sealed lead acid batteries typically have a maximum capacity of 200 to 250Ah. But 2V-
1000Ah are also available in the market. As an example: a 2000Ah - 48V system can be built with:
- 2V-1000Ah batteries: 24 cells in series & 2 strings in parallel
- 12-250Ah batteries: 4 cells in series & 8 strings in parallel.

Using large capacity cells (>1000Ah) allows to meet the required capacity of the system in a single string.
Other advantages of using 2V cells are:
- Individual cell voltage can be monitored and failing cells detected
- System can still work removing the damaged cell
- All cells see the same current --> no need for string fuses

The C-Rate is an important parameter in batteries that determines how fast the battery can be charged and discharged in
relation to its nominal capacity:
C/10 (=0.1C) rate means --> Full Charge or discharge in (1h/0.1) = 10h.
C/5 (=0.2C) rate means --> Full Charge or discharge in (1h/0.2) = 5h
2C rate means --> Full Charge or discharge in (1h/2) = 0.5h.
5C rate means --> Full Charge or idscharge in (1h/5) = 0.2h.

The C-Rate is directly related to the charge/discharge currents that the battery can handle and the value depends on the
battery chemistry and type.

The manufaturers specify the nominal capacity for a certain C-Rate value (Lead acid: C/20 to C/100). Discharged at higher
C-rates will give less capacity. Charging at higher than recommended C-rates can reduce the battery lifetime.

Is important to ensure that the total charge current (PV or PV & hydro) is within the recommended C -rate.

Example:
Typical C-Rate for lead acid batteries: C/10
For a 250Ah cell or string:
C/10 rate --> discharge in 10h --> 250Ah/10h = 25Amp charge/discharge current per battery string.

4 parallel battery strings --> 4 x 25A = 100A. An overall charge/discharge current of 100A will charge/discharge the battery
bank at a C/10 rate.

A charge/discharge current lower than 100A will be a lower C/10 rate and a higher current, a higher C-rate. Lower C rates
are NOT a problem.
4. SOLAR ARRAY SIZING

Global tilted
irradiation at ** Hybrid system
Array Peak Power requirement
No. Total Needs Nd (Wh/Day) e_batt e_pv e_SCC optimum angle power input offset
(Wp)
(GTI_opta) [kwh/m2 (1 = full solar)
per year]

1 - / 0.95 / / / 2251 = #DIV/0! x 1.0 =

Annual average DNI

Highest irradiation month #DIV/0!

Follow purple steps A to E
Lowest irradiation month to find these#DIV/0!
values.

System Voltage (from previous tab): 12V

INPUT DATA: PV PANEL SPECIFICATIONS

Peak Power (Pmpp) 245.00 Watt Find these values in the
Rated Voltage (Vmpp - V at max. power) 30.10 Volts catalog of your desired
Open Circuit Voltage (Voc) 37.10 Volts panel or on attached label to
the solar panel like this
Rated Current (Impp - I at max. power) 8.23 Amps example.
Short Circuit current (I_sc): 8.8 Amps
Annual avergae irradiance
Seasonal dependency analysis Lowest irradiance Highest irradiance
month month
(Worst case) (Best case)

Number of panels required #DIV/0! #DIV/0! #DIV/0!

What scenario you want to design the Worst case scenario

system for?

#DIV/0!
Calculated/
PV ARRAY and CHARGE CONTROLLER DESIGN: suggested
Userdefined Design Values

Panel requirement (Wpeak/Wpanel): #DIV/0! n/a n/a

Charge controller type: n/a MPPT n/a
Maximum charge current n/a 500 n/a
Maximum input voltage to SCC (Required for MPPT): n/a 500 n/a
Minimum input voltage to SCC (If its not specified: system Voltage × 1.2): n/a 100 n/a
Panels in series per string: 10 Userdefined 10
Strings in parallel: #DIV/0! Userdefined #DIV/0!
Total number of panels (n_series x n_parallel): #DIV/0! n/a n/a
System peak power capacity (Pmax): #DIV/0! n/a n/a
Max. system operating PV current (I_max_PV): #DIV/0! n/a n/a
Max. system short circuit current (I_sc_PV): #DIV/0! n/a n/a
PWM: Design OUT current (I_sc_PV x 1.25 or 1.56 safety factor): n/a SF = 1.25 - Continous rating n/a

MPPT: Design OUT current (Pmax / System Voltage x Safety Factor(SF)) #DIV/0! SF = 1.25 - Recommended #DIV/0!
Number of Solar Charge Controllers: #DIV/0! Userdefined #DIV/0!
Max. design output current per Controller: (inc. safety factors) #DIV/0! n/a n/a
C-Rate at max. charge controller current: #DIV/0! n/a #DIV/0!
#DIV/0!

Validation: PV Output > PV requirement? Tolerance Margin

PV peak requirement (Watts): #DIV/0! (± %)
PV Peak Output (Watts): #DIV/0! 5

Validation: Imax controllers > Imax design? Tolerance Margin

Imax design (Amp): #DIV/0! (± %)
#DIV/0! #DIV/0! 5

PV SYSTEM DESIGN CONSIDERATIONS:

- Monocrystalline/Polycristalline/Thin film panels: These are the 3 main types of panels in the market. Monocrystalline panels are the most mature technology, and traditionally
offered the highest efficiencies. They are also the most expensive type. Polycrystalline panels are cheaper and used to be less efficient, but currently there is not that much difference.
Thin film is a different technology; cheap but very inefficient, they require much larger surface areas.
https://www.solarreviews.com/blog/pros-and-cons-of-monocrystalline-vs-polycrystalline-solar-panels
- Panel voltage: Once exposed to sunlight, the voltage of the PV panels doesn't vary much with the level solar irradiation but it does vary significantly with temperature. The panel
voltage (and thus power output) decreases as the cell temperature goes up. The panel nameplate will show two voltage values: the open circuit voltage (Voc) and the voltage at the
point of maximum power (Vmpp). The open circuit voltage is always slightly higher that the voltage at maximum power. These values are both measured at standard test conditions of
25degC and 1000W/m2. In normal conditions the actual voltage in the panels will be equal or lower to these values but it can be higher in excepcionally sunny conditions in cold
weather (mountainous areas).
https://www.sunwize.com/tech-notes/temperature-effects-on-pv-modules/
- Solar Charge Controller (SCC): When batteries are applied a charging current the cell voltage rises proportionalely to the current. However, batteries are very sensitive to charging
voltages and thus a charge controller is required between the PV array and the batteries to ensure the charge voltage does not excede manufacturer's specifications. There are 2 main
types of solar charge controllers in the market: PWM and MPPT. In both cases, the PV array voltage must be higher than the battery charging voltage, for the current to be able to flow
from the panels to the batteries.
https://www.victronenergy.com/upload/documents/White-paper-Which-solar-charge-controller-PWM-or-MPPT.pdf (MPPT vs PWM)
PWM (Pulse Width Modulation) controller: The most common type, cheap and simple. The controller drops the PV array voltage to match the charging voltage of the battery. The
voltage difference is dissipated in a resistance within the controller, wasting part of the PV power. For example, if a 100W panel has a nominal (Vmpp) voltage of 18V and a maximum
power current of 5.5A (18V x 5.5A = 100W), when connected to a 12V battery system, the PWM controller will drop the voltage to around 14.5V to charge the batteries. The current
will remain unchanged, and thus, the energy input to the battery will be 14.5V x 5.5 = 80W at maximum. This means at least 20% of the power will be lost in the controller. This is why,
for PWM controllers Vmpp needs to be higher but as close to the charged battery voltag to minimise the losses. In general, PWM controllers are a good, economical solution for small
systems (<1kW).

MPPT (Maximum Power Point Tracking) controller. More modern and traditionally costier controller. Makes PV panels operate at the voltage of maximum power (for the given
sun conditions), and instead of dropping the voltage, it converts it via a DC/DC converter to match the required battery charging voltage. The excess of voltage is converted
into an increased charged current to the batteries, increasing the efficiency of the system. Following on the previous example, with a MPPT controller a 100W panel would
provide a charging current of up to 6.9 A, instead of the 5.5A limit of the PWM. This means that with the same PV panel arrangement, the MPPT controllers can extract 10-40%
more of power from the PV array than a PWM controller. The gain in efficiency is greatest in the following scenarios: batteries are very discharged, low ambient temperatures,
overcast weather, or partial shadowing. At high ambient temperatures (= high panel temp.) and with the batteries close to full charge, PWM and MPPT have a similar
performance. However, the MPPT controller allows for higher input voltage (more panels in series) than PMW, which can boost the performance. Also, higher voltage on the
PV side means lower current (for the same power), and lower current means smaller cables. In large installations the cost of cable can be signficant so being able to use a
smaller cable size can offset the extra cost of the MPPT controller.
"MPPT charge controllers are rated by the output amperage that they can handle, not the input current from the solar module array".
(https://www.civicsolar.com/support/installer/articles/choosing-correct-charge-controller)

- Number of PV panels in series: panels are connected in series to increase the array voltage. As explained above, the array voltage must be higher than the charging voltage
of the battery bank. In PWM controllers, the maximum power Vmpp voltage of the array may be around 30% higher than the nominal voltage of the batteries. In MPPT
controllers, the input voltage can be significantly higher, allowing more panels in series, and less parallel strings for the same PV array power. This means thinner copper wires
will be required. For MPPT controllers, the numer of panels in series will be calculated based on the Open Circuit voltage of the panels, and using a safety factor 1.25 for the
maximum input voltage.
provide a charging current of up to 6.9 A, instead of the 5.5A limit of the PWM. This means that with the same PV panel arrangement, the MPPT controllers can extract 10-40%
more of power from the PV array than a PWM controller. The gain in efficiency is greatest in the following scenarios: batteries are very discharged, low ambient temperatures,
overcast weather, or partial shadowing. At high ambient temperatures (= high panel temp.) and with the batteries close to full charge, PWM and MPPT have a similar
performance. However, the MPPT controller allows for higher input voltage (more panels in series) than PMW, which can boost the performance. Also, higher voltage on the
PV side means lower current (for the same power), and lower current means smaller cables. In large installations the cost of cable can be signficant so being able to use a
smaller cable size can offset the extra cost of the MPPT controller.
"MPPT charge controllers are rated by the output amperage that they can handle, not the input current from the solar module array".
(https://www.civicsolar.com/support/installer/articles/choosing-correct-charge-controller)

- Number of PV panels in series: panels are connected in series to increase the array voltage. As explained above, the array voltage must be higher than the charging voltage
of the battery bank. In PWM controllers, the maximum power Vmpp voltage of the array may be around 30% higher than the nominal voltage of the batteries. In MPPT
controllers, the input voltage can be significantly higher, allowing more panels in series, and less parallel strings for the same PV array power. This means thinner copper wires
will be required. For MPPT controllers, the numer of panels in series will be calculated based on the Open Circuit voltage of the panels, and using a safety factor 1.25 for the
maximum input voltage.

The charge controller's nameplate will indicate what system voltage is required and what are the minimum and maximum allowable PV input voltages. These are referring to
the Open Circuit voltage, which is the highest voltage the panels can produce.

- System design current: Unlike panel voltage, which is fairly constant, the current varies greatlly depending on the sun irradiation levels. Panel nameplates indicate two
current values, the current at the point of maximum power (Impp) and the short circuit current (Isc). The short circuit current is typically 5-10% higher than the current at the
point of maximum power and is the value used to calculate the system design current. Adding PV panels in series increases the total string voltage but does not increase the
string current. Connecting strings in parallel adds up the current of each string. The maximum system current is calculated by multipliying the panel short circuit current by the
amount of strings in parallel.
For PMW controllers, the system design current is calculated as: I design PWM = Isc x number of strings in parallel x 1.56
The design factor of 1.56 is the result of allowing 125% factor for stronger sun irradiation than test conditions and a further 125% for "continuos use". Continuous use design
factor must be considered when an electrical installation can run at the rated current for more than 3 hours. 1.25 x 1.25 = 1.56 design factor. This design approach is the one
recommended in the industry. If the controller specifically states that is rated for continuous use, 1.25 safety factor, instead of 1.56, will be enough. Unlike MPPT controllers,
PMW controllers are UNABLE to limit the current, so it is importat to size them adecuately to avoid damaging them.
https://www.altestore.com/howto/sizing-pwm-solar-charge-controllers-a91/
For MPPT controllers, the calculation is different, because the Input current and output current are no longer equal. MPPT are rated on thed DC output current and
aproximately: Idesign MPPT = PV Array Power/ System Voltage x 1.25
Currently some MPPT controllers are able to limit the current, so technically the solar PV array can be as large as desired (regarding current) and the 1.25 safety factor above
can be ignored. However, any excess of current above the controller's capability will be simply lost.
https://www.sunwize.com/how-size-solar-charge-controller/
- Controller size: The charge controller current rating must be equal or higher than the system design current. If the design current exceeds the maximum charge controller current,
multiple charge controllers can be connected in parallel, with the PV strings equally distributed among them. Is important that the controllers have voltage calibration or paralelling
capability to ensure all controllers are measuring the same voltage and charging the batteries adequately.
Paralleing charge controllers: https://www.morningstarcorp.com/parallel-charging-using-multiple-controllers-separate-pv-arrays/

- Mean Solar Insolation: Also known as (PeakSunHours/day). Peak solar irradiance on the Earth crust is standarised at 1kW/m2. Actual irradiation varies with the hour of the day,
season and weather conditions. Mean solar insolation is the average value of the solar irradiance during the day, the average being taken on a montly or yearly basis. Because the
standard irradiance value is 1kW/m2, numerically, "it is the same" to express it as 4.5kWh/day or 4.5h/day. It is often referred as "Sun-hours/day".
(Radiance = units of Power [W], Irradiance = power/area [W/m2], Insolation = Power x time/area [Wh/m])
https://www.pveducation.org/pvcdrom/properties-of-sunlight/average-solar-radiation
http://ecgllp.com/files/3514/0200/1304/2-Solar-Radiation.pdf
- Why you should oversize your PV array?

https://www.sma-sunny.com/en/7-reasons-why-you-should-oversize-your-pv-array-2/
Required Installed watt
peak
(Wp)

#DIV/0!

#DIV/0! A click on the link below to open the B In the Global Solar Atlas website simply point the cursor to the
global solar atlas in your web browser. approximate intended location of your system.
#DIV/0!
To find out GTI_opta, in the right panel (1) read GTI_opta value and
Global Solar Atlas enter it in the table.

Caution: Your panels should be installed at the optimum tilt angle for
best energy generation capacity. (2) is the optimum tilt angel and
horizontal direction of the PV panel that you need for system
installation to achive the calculated output.
Units

panels
n/a
Amps
Volts
Volts
panels
strings
panels
Watts
Amps
Amps
Amps C From the Global Solar Atlas page that GTI-opta was copied follow these steps:
3- click on "Open Detail"
Amps

Amps
D
4- Scroll down to find "PV ELECTRICITY AND SOLAR RADIATION" section
D
4- Scroll down to find "PV ELECTRICITY AND SOLAR RADIATION" section

4
E
5- In this section click on "DNI Data"
6- Read "Annual Average DNI" value and enter it in the table.
7- Read the highest value of direct average normal and lowest value in the monthly chart and enter t

7
7
Annual average scenario

Best case scenario

Worst case scenario

Annual average scenario

3
art and enter them in the table.
1

8
9

10
11
12
13
14
15
16

17

18

19

20

21

22
23

24

25

26

27

28

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30

31

32
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35
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37
38
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40
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43

44

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47
48

49
50
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56
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60

61

62
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65
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75
76
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79
80
81
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125
126
127
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131
132
133
134
135
136
137
138
139
140
141
142
143
144
5. PROTECTION AND CABLE REQUIREMENTS

Calculated/
PV PANELS to (Each) CHARGE CONTROLLER: Suggested
Userdefined

Short circuit current per string (I_sc): 30.1 n/a

Design current per string (I_design = I_sc x 1.56) 47.0 n/a
Number of parallel PV strings: #DIV/0! n/a
String fuse rating: 40
Copper cable installation method: n/a Clipped direct

PV panel integral cable size: 6 4

Cable amperage: 37

Combined design current: #DIV/0! n/a

Number of PV sub-arrays: #DIV/0! n/a
Design current per sub-system (Idesign-subsystem): #DIV/0! n/a
Controller(s) rating: 500 n/a
DC combiner(s) busbar rating: 125
Combiner to SCC: MCB minimum current rating: #DIV/0! Userdefined
Copper cable installation method: n/a Clipped direct

Combiner to SCC cable size (suitable for MCB): #DIV/0! Userdefined

Cable amperage #DIV/0! Userdefined

Combiner to SCC MCB minimum DC Voltage rating: 470 n/a

Calculated/
(Each) CHARGE CONTROLLER to BATTERIES: Suggested
Userdefined

Charge controller type: MPPT n/a

Charge controller size: 500.00 n/a
Output design current (per controller): 500.00 n/a
Each SCC to Battery bank: MCB minimum Current rating: 0 userdefined
Copper cable installation method: n/a Clipped direct
Each SCC to Battery bank: cable size (suitable for MCB): 1 userdefined
Cable amperage (value shown for sanity check): 15.5 userdefined

SCC to Battery bank: MCB minimum Voltage rating: 125 n/a

Optional: best practice if >1 parallel battery strings
Design current per battery string: #DIV/0! n/a
Series connection protection fuse: #DIV/0! userdefined
Copper cable installation method: n/a Clipped direct
Reduced series connection cable size: #DIV/0! userdefined

Cable amperage (value shown for sanity check): #DIV/0! userdefined

Calculated/
BATTERIES TO (Each) INVERTER: Suggested
Userdefined

Inverter rating: 1.00 n/a

DC Current at max. inverter rating: 92.59 n/a
Number of DC-MCBs in parallel: 1 userdefined
Battery to Inverter DC MCB size: 125 userdefined
Copper cable installation method: n/a Clipped direct

Battery to Inverter cable size (suitable for MCB): 35 userdefined

Cable amperage (value shown for sanity check): 141 userdefined

Calculated/
(Each) INVERTER OUTPUT: Suggested
Userdefined

AC Current at max. inverter rating: 4.83 n/a

(Each) Inverter to AC Load MCB size: 10 50
Copper cable installation method: n/a Clipped direct

(Each) Inverter to AC Load cable size (suitable for MCB): 10 userdefined

Cable amperage (value shown for sanity check): 65 userdefined

If more than one inverter or All-in-one Controller:

Number of paralleled inverters: 1 n/a
Combined kW capacity: n/a n/a
Combined AC current:
Combined AC Load MCB size: n/a userdefined
Copper cable installation method: n/a Clipped direct
Combined AC Load cable size (suitable for MCB): n/a userdefined

Cable amperage (value shown for sanity check): n/a userdefined

Key rule: Design Current [A] ≤ MCB Size [A] ≤ Cable capacity [A

Design Values Unit

n/a A
n/a A
n/a strings
40 A
n/a

4 sqmm

37 A

n/a A
n/a systems
n/a A
n/a A
n/a A
#DIV/0! A
n/a

#DIV/0! sqmm

#DIV/0! A

n/a Vdc

Design Values Unit

n/a n/a
n/a A
n/a A
0 A
n/a
1 sqmm
15.5 A

n/a V

n/a A
#DIV/0! A
n/a
#DIV/0! sqmm

#DIV/0! A

Design Values Unit

n/a kW
n/a A
1
125 A
n/a

35 sqmm

141 A

Design Values Unit

n/a A
50 A
n/a

10 sqmm

65 A

n/a n/a
n/a kW
A
n/a A
n/a
n/a sqmm

n/a A
ey rule: Design Current [A] ≤ MCB Size [A] ≤ Cable capacity [A]

Comments

PV panel short circuit current - from panel nameplate.

Array short circuit current, including the relevant design factor
As calculated or specified in "Solar array sizing" tab
Selected from catalog. Fuse rating must be higher than the design current. Not required if two or less parallel PV strings
Cable installation methods affects current carrying capacity of cables

Typically PV panel cables are copper, 4mm2 size. 6mm2 also available.

Amp rating for the cable type selected as per: 'BS7671 - PVC copper cable, Clipped direct ' based on cable size (see Catalogue t
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to string fuse rating.
I_design x number of parallel PV strings.
From PV array sizing. Based on the number of charge controllers.
I_design_system/number of subsystems. Assumes equal distribution of PV arrays per controller
"Solar array sizing" tab. One controller per sub-array
One combiner per sub-array (or combined in a single multi-output combiner)
One MCB per each sub-system. Rating must be higher than "I_design_subsystem". MCB rating will detemine required cable siz
Cable installation methods affects current carrying capacity of cables

Cable size automatically selected from: 'BS7671 - PVC copper cable, Clipped direct ' (see 'Catalog' tab) based on the selected M

Amp rating for the selected cable size as per: 'BS7671 - PVC copper cable, Clipped direct ' based on cable size (see 'Catalogue'
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to the MCB rating.

Minimum DC voltage rating required. Must be higher than the string open circuit voltage x 1.25. Many DC rated fuses and MC
handle up to 1000Vdc, but rating must be double-checked.

Comments

As specified in "Solar Array Sizing" tab.

As specified in "Solar Array Sizing" tab.
If charge controller is PWM type, same as "I_design_subsystem". If it is MPPT type, same as controller rating.
If MPPT, includes 1.25 factor for continous use (in PWM implicit in design current)
Cable installation methods affects current carrying capacity of cables
Amp rating for the selected cable size as per: 'BS7671 - PVC copper cable, Clipped direct ' based on cable size (see 'Catalogue'
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to the MCB rating.
Must be higher than battery bank voltage. 125V DC is the standard lowest DC rating for MCBs.

I_design_subsystem*number of subsystems/number of parallel battery strings

Selected from catalog. Fuse rating must be higher than the design current.
Cable installation methods affects current carrying capacity of cables
Series connection cable in each battery string can be a smaller size than the overall controller to battery bank cable.
Amp rating for the selected cable size as per: 'BS7671 - PVC copper cable, Clipped direct ' based on cable size (see 'Catalogue'
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to the MCB rating.

Comments

From "Client energy needs" tabs

Includes 0.9 inverter efficiency
Default is one. DC-MCBs larger than 125A are difficult to find. In that case, proposed solution is various smaller ones in paralle
Includes 1.25 design factor
Cable installation methods affects current carrying capacity of cables

Cable size automatically selected from: 'BS7671 - PVC copper cable, Clipped direct ' (see 'Catalog' tab) based on the selected M

Amp rating for the selected cable size as per: 'BS7671 - PVC copper cable, Clipped direct ' based on cable size (see 'Catalogue'
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to the MCB rating.

Comments

Includes 0.9 inverter efficiency

MCB size includes a 1.25 overload factor
Cable installation methods affects current carrying capacity of cables
Cable size automatically selected from: 'BS7671 - PVC copper cable, Clipped direct ' (see 'Catalog' tab) based on the selected M
cable size considered is 2.5sqmm
Amp rating for the selected cable size as per: 'BS7671 - PVC copper cable, Clipped direct ' based on cable size (see 'Catalogue'
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to the MCB rating.

MCB size includes a 1.25 overload factor

Cable installation methods affects current carrying capacity of cables
Cable size automatically selected from: "BS7671 - PVC copper cable, clipped direct" (see "Catalog" tab) based on the selected
cable size considered is 2.5mm2

Amp rating for the selected cable size as per: "BS7671 - PVC copper cable, clipped direct" based on cable size (see "Catalogue"
size is not in the catalogue, rating must be specified manually.
Cable Amp rating must be higher or equal to the MCB rating.
BALANCE OF PLANT - PROTECTION AN
Please update here based on available/preferred cables. Once you adjust these values the protection des
Cable catalogue: (BS7671-18th) Method sqmm 1 1.5 2.5 4
4D1_Copper, Single Core, PVC 70degC, Clipped Amp 15.5 20 27 37
non-armoured
Conduit Amp 12 15.5 21 28

DC MCB catalogue: FEEO, dual pole

MCB
n/a Amp: 3 6 10 16
n/a ###
DC Fuse for array protection: FEEO Amp: ### 8 10 12

AWG - sqmm conversion table

AWG 30 28 26 24 22
sqmm 0.05 0.08 0.14 0.25 0.34
ANT - PROTECTION AND CABLE CATALOGUE
ese values the protection design automatically updates
5 6 10 16 25 35 50 70 95 120
42 47 65 87 114 141 181 234 284 330
28 36 50 68 89 110 134 171 207 239

20 25 32 40 50 63 80 100 125

15 20 25 32 40 50 63 100 125

on table
21 20 18 17 16 14 12 10 8 6 4
0.38 0.5 0.75 1 1.5 2.5 4 6 10 16 25
2 1 1/0 2/0 3/0 4/0 300MCM 350MCM 500MCM 600MCM
35 50 55 70 95 120 150 185 240 300
750MCM 1000MCM
400 500
6. Design summary

DESIGN INPUT SUMMARY

Tab Description
Energy needs Inverter efficiency
Energy needs Number of inverters
Energy needs Nominal size of the inverter
Energy needs System voltage
Solar array sizing e_batt
Solar array sizing e_pv
Solar array sizing e_SCC
Solar array sizing GTI_opta
Solar array sizing Hybrid offset
Solar array sizing Panel peak power
Solar array sizing Panel Vmpp
Solar array sizing Panel Voc
Solar array sizing Panel Impp
Solar array sizing Panel Isc
Solar array sizing Controller type
Solar array sizing Vmax (for MPPT)
Solar array sizing Number of parallel strings
Solar array sizing Safety factor (for PWM)
Solar array sizing Safety factor (for MPPT)
Solar array sizing Controller size
Solar array sizing Number of controllers
Solar array sizing All-in-one controller?
Battery sizing Days of autonomy
Battery sizing Depth of discharge (DOD)
Battery sizing Individual battery voltage
Battery sizing Individual battery capacity
Battery sizing Number of batteries per string
Battery sizing Number of parallel strings of batteries
Battery sizing Max. C-rate
Protection String fuse rating
Protection PV panel integral cable size
Protection Cable amperage
Protection MCB minimum current rating
Protection Combiner to SCC cable size
Protection Cable amperage
Protection MCB minimum current rating
Protection SCC to battery cable size
Protection Cable amperage
Protection Series connection protection fuse
Protection Reduced series connection cable size
Protection Cable amperage
Protection Battery to Inverter DC MCB size
Protection Battery to Inverter cable size
Protection Cable amperage
Protection Inverter to AC Load MCB size
Protection Inverter to AC Load cable size
Protection Cable amperage
SUMMARY
Input Value Unit #
0.9 1
1 2
1 Kw 3
12 V 4
0.95 5
0 6
0
2251 kwh/m2 per day

1
245 W

30.1 V

37.1 V

8.23 Amps

8.8 Amps

MPPT
500 V

#DIV/0!
SF = 1.25 - Continous rating
SF = 1.25 - Recommended
500 Amps

#DIV/0!
NO
0 Days

0.8 %
0 V

0 Ah

#DIV/0!
#DIV/0!
0.50
40 Amps

4 sqmm

37 Amps

#DIV/0! Amps

#DIV/0! sqmm

#DIV/0! Amps

0 Amps

1 sqmm

15.5 Amps

#DIV/0! Amps

#DIV/0! sqmm

#DIV/0! Amps

125 Amps

35 sqmm

141 Amps

50 Amps

10 sqmm

65 Amps
DESIGN OUTPUT SUMMARY
Description Size Quantity
Inverter 1 kW 1
Battery: Lithium-Ion Ah , V #DIV/0!
Solar panel 245 Watt #DIV/0!
Charge controller MPPT , 500 A , 500 V #DIV/0!
MCB #DIV/0!
Cable size #DIV/0!
Tab
Inverter
BATTERY
PV ARRAY
PV ARRAY
PROTECTION
PROTECTION
7. Schematic Design
[Project Title] [Project title]
STANDALONE OFF-GRID SOLAR PV INSTALLATION
- All-in-one Controller & Inverter -
STANDALONE OFF-GRID SOLAR PV INSTALLATION
NOTE: numbers in drawing will
update automatically with data
PRINT DRAWING:
Drag and select from Cell K1 to AJ103 - Separate Solar Charge Controller & Inverter -
from other tabs. File - Print - Slect printer or PDF printer #DIV/0!
To copy-paste as figure, select the Choose ''Print Selection"
whole drawing area and "paste Choolse scaling "Fit sheet in one page"
special" as a figure #DIV/0!

#DIV/0!
#DIV/0!

n/a
The following table summarised the User Input data (except the individual loads in the energy needs table). #DIV/0!
Copy/paste this table together with the schematic above to be able to replicate and have a record of the
results shown in the schematic above.
#DIV/0! Each Panel:
Vpmax = 30.1V
#DIV/0!
Ipmax = 245A
Pmax = 245W

#DIV/0!

Graphic Text:
PV panel to Charge Controller: Each Panel:
Vpmax = 30.1V
#DIV/0! Ipmax = 245A
#DIV/0!
Ipmax = 245A Pmax = 245W String 1
Pmax = 245W #DIV/0!
#DIV/0!
#DIV/0! #DIV/0!
#DIV/0! #DIV/0! #DIV/0! String 1
#DIV/0! #DIV/0!
#DIV/0!
40A string fuses #DIV/0! #DIV/0!
(one per string) STRING FUSES NOT NEEDED IF 2
DC Combiner box OR LESS PARALLEL PV STRINGS
4 mm2 solar cable
with integral MC4 connectors
#DIV/0! #DIV/0!
#DIV/0!
4 sqmm #DIV/0!
#DIV/0!
500A MPPT Battery 1 V - Ah #DIV/0!
#DIV/0! String 1
#DIV/0! #DIV/0! 4 mm2 solar cable
Optional Fuses with integral MC4
connectors
Battery section: 4 sqmm
0A - 2pole
DC MCB Battery 1 V - Ah #DIV/0! #DIV/0!
1 sqmm String 1 #DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0! 4 mm2 solar cable
with integral MC4 4 sqmm
#DIV/0! connectors #DIV/0!
#DIV/0! #DIV/0! #DIV/0!
#DIV/0! #DIV/0!
V - Ah #DIV/0! #DIV/0!
#DIV/0!
#DIV/0! 40A string fuses
(one per string)
#DIV/0!

#DIV/0! #DIV/0!
Inverter input/output: 40A string fuses
Single Inverter (one per string)
1kW
125 A- Single
- 2polephase
DC MCB
35
50Asqmm
- 2 pole 1 sqmm
AC MCB
0A - 2pole 32 A - 2pole 4 sqmm
10 sqmm
n/aA - 2 pole DC MCB DC MCB
AC MCB 4 sqmm
n/a sqmm
Display "n/a" over Separate 1 sqmm
n/a Display "n/a" over All-in-one 0A - 2pole 0A - 2pole 1 sqmm
#DIV/0! DC MCB DC MCB
1 sqmm
Single Inverter
#DIV/0!
32 A - 2pole
DC MCB
For
125all
A -in2pole
one inverter, show highest breaker-cable
DC MCB 1 sqmm 1 sqmm
35 sqmm
4 sqmm

50A - 2 pole
AC MCB
50A - 2 pole 500A MPPT
AC MCB
500A MPPT 1kW - Single phase
n/aA - 2 pole
n/aA - 2 pole AC MCB
AC MCB
10 sqmm
10 sqmm 10 sqmm
1kW - Single phase

n/a sqmm n/a sqmm

n/a sqmm n/a sqmm
Comments:

The main change is to use an All-In-One controller and select the functionality where the hydro source is used to
COMMENTS TO EXISTING INSTALLATION:
charge the batteries, and the solar & batteries power the load. Limit the charging current from the hydro to
- No string protection fuses or combiner installed.
match actual output in the field. 60A MPPT would meet actual requirement, but 80A is recommended to allow
- Solar cable size is 4mm2 all the way. Connected in two strings to the controller. Cabling
for future upgrade. 4kW or 5kW options available, 4kW recommended with current battery size.
distributed in 2 sub-arrays ( 3 parallel branches each).
- Battery cabling size - unknown. Inverter output cable size: unknown.
SAKO SUNSEE 80A-MPPT & 4kW (around 400USD) or equivalent recommended.
- Batteries to inverter breaker installed on site is 63A. Would trip before the inverter. But a
5kW inverter is large for the installed battery size: C/5 discharge rate
Installation of combiner is recommended. Assesment of installed cable sizes is required.
- Installed bi-directional inverter hasn't got the necessary functionality to adequately
integrate the small (design: 3kW, actual : 1kW hydro). Will lead to unstable operation when
the demand exceeds the hydro generation. NOTE:
NOTE: Earthing and lightning protection requirements vary between countries and also depending on the type of inverter used.
Earthing and lighting protection requirements vary between countries and also depending on the type of inverter used. Follow Follow inverter manufacturer's guidance for battery and inverter earthing connections.

n/a
inverter manufacturer's guidance for battery and inverter earthing connections.

unit price unit price

[Local number of [Local number of
No. Item unit size [unit] currency] units total price No. Item unit size [unit] currency] units total price
1 Main Equipment cost (based on design input): 1 Main Equipment cost (based on design input):
1.1 Solar Panel 245.00 watts - #DIV/0! #DIV/0! 1.1 Solar Panel 245.00 watts - #DIV/0! #DIV/0!
1.2 Battery 0.00 Ah - #DIV/0! #DIV/0! 1.2 Battery 0.00 Ah - #DIV/0! #DIV/0!
1.3 MPPT Solar charge controller 500.00 A - #DIV/0! #DIV/0! 1.3 MPPT Solar charge controller 500.00 A - #DIV/0! #DIV/0!
1.4 Pure sine inverter 1.00 kw - 1 0 1.4 Pure sine inverter 1.00 kw - 1 0
Total equipment cost: #DIV/0! Total equipment cost: #DIV/0!
#DIV/0! #DIV/0!

Force to match calculated value

9. Costs Table

Capital costs
unit price [Local number of
No. Item unit size [unit] total price
currency] units
1 Main Equipment cost (based on design input):
1.1 Solar Panel 245.00 watts #DIV/0! #DIV/0!
1.2 Battery 0.00 Ah #DIV/0! #DIV/0!
1.3 MPPT Solar charge controller 500.00 A #DIV/0! #DIV/0!
1.4 Pure sine inverter 1.00 kw 1 0
1.5 Cables (combined) -
1.6 MCBs (combined) -
1.7 Public loads

#DIV/0!
Total equipment cost:
#DIV/0!
2 Balance of plant hardware costs:
2.1 PV connector 0
2.3 DC string fuse holder 0
2.5 PV Panel mounting rack 0
2.6 DC combiner box
2.7 Battery Rack 0
2.8 Monitoring Panel and DB box 0
2.11 AC distribution box

0
Total balance of plant cost:
Total balance of plant cost:
#DIV/0!
3 Non-material costs:
3.1 technical consultations 0
3.2 Logistics & installation works 0
3.3 Monitoring Panel and DB box 0
3.4 Operations and maintenance training 0
3.5 community workshops and discussions 0
0
Total non-material cost:
#DIV/0!
#DIV/0!
Total cost:
#DIV/0!

Local
USD
currency
1 (May 2019)
Operation costs
(Based on present value of money and equipment costs)

Expected life
Note Share of project total lifetime cost
No. Item cycle (Years)
Worst Best Worst Best
1 Solar panels #DIV/0! ### #DIV/0! ###
2 Charge controller #DIV/0! ### #DIV/0! ###
3 Inverter #DIV/0! ### #DIV/0! ###
4 Battery #DIV/0! ### #DIV/0! ###
5 Public loads #DIV/0! ### #DIV/0! ###
6 Accidental costs Annual $ - ### $ - ###
Project life time

Total #DIV/0! ### #DIV/0! ###

ent costs)

Annualized Operation & Maintenance cost

Worst Best
#DIV/0! ### #DIV/0! ###
#DIV/0! ### #DIV/0! ###
#DIV/0! ### #DIV/0! ###
#DIV/0! ### #DIV/0! ###
#DIV/0! ### #DIV/0! ###
### ###

#DIV/0! ### #DIV/0! ###

8. Installation C-Rate

During installation or maintenance, sometimes not all the panel and battery arrays are
connected. It is important to check that in this temporary conditions, the C-rate is still
within the acceptable range:
Userdefin
C-RATE check during installation & maintenance: Calculated Units
ed
Number of PV strings currently connected: n/a strings
Number of battery strings currently connected: n/a strings
Max. charge current with connected panels: TBC n/a A
Max. Battery discharge current to inverter: 83.33 n/a A
Connected battery capacity: TBC n/a Ah
C-Rate check:
Maximum C-Rate allowable: 0.50 n/a C/2
Current at max C-rate for connected batteries: #VALUE! n/a Amps
Charge C-Rate with connected PV & batteries: #VALUE! n/a #VALUE! #VALUE!
Discharge C-Rate with connected batteries: #VALUE! n/a #VALUE! #VALUE!

The C-Rate is an important parameter in batteries that determines how fast the battery can be charged and
discharged in relation to its nominal capacity:
C/10 (=0.1C) rate means --> Full Charge or discharge in (1h/0.1) = 10h.
C/5 (=0.2C) rate means --> Full Charge or discharge in (1h/0.2) = 5h
2C rate means --> Full Charge or discharge in (1h/2) = 0.5h.
5C rate means --> Full Charge or idscharge in (1h/5) = 0.2h.

The C-Rate is directly related to the charge/discharge currents that the battery can handle and the value
depends on the battery chemistry and type.

The manufaturers specify the nominal capacity for a certain C-Rate value (Lead acid: C/20 to C/100). Discharged
at higher C-rates will give less capacity. Charging at higher than recommended C-rates can reduce the battery
lifetime.

Is important to ensure that the total charge current (PV or PV & hydro) is within the recommended C -rate.

Example:
Typical C-Rate for lead acid batteries: C/10
For a 250Ah cell or string:
C/10 rate --> discharge in 10h --> 250Ah/10h = 25Amp charge/discharge current per battery string.

4 parallel battery strings --> 4 x 25A = 100A. An overall charge/discharge current of 100A will charge/discharge
the battery bank at a C/10 rate.

A charge/discharge current lower than 100A will be a lower C/10 rate and a higher current, a higher C-rate.
Lower C rates are NOT a problem.
#VALUE!
#VALUE!

be charged and

and the value

o C/100). Discharged
educe the battery

mended C -rate.

y string.

ll charge/discharge

a higher C-rate.
1
2
8
9
10
11

12
13
14
15
16
17
18
19
20
10. Catalogs

NOTE: The prices below are indicative for the typical sized components and have been sourced in Malaysian websites or
section based on products that are available in local market or desired products that you intend to purchase for your pro

Item - description UNIT PRICE COMMENTS

PV panels:
200W to 280W, poly or mono 500 RM Average price for these size panels.
200W to 280W, poly or mono 500 RM Average price for these size panels.

Batteries: Lead Acid

12V-200Ah AGM 2000 RM "Premium" type
12V-100Ah AGM 800 RM "Premium" type
12V-200Ah AGM - deep cycle 1600 RM Discounted price (%40 off)
12V-260Ah AGM - deep cycle 2175 RM Discounted price (%30 off)
12V-200Ah AGM - deep cycle 200 USD (about 800 MYR)
12V-200Ah AGM (230Ah?) 1200 RM Powerbatt brand (China), from Malaysian distributor "Pollux"
12V-250Ah AGM 1400 RM Powerbatt brand (China), from Malaysian distributor "Pollux"
12V-200A AGM - deep cycle 2400 RM Lelong. Shipment to West Malaysia only

2V-1000Ah AGM - deep cycle 200 USD Average price in Alibaba(about 800 MYR)
2V-1000Ah AGM - deep cycle 200 USD Average price in Alibaba(about 800 MYR)
2V-1000Ah AGM - deep cycle 200 USD Average price in Alibaba(about 800 MYR)

Batteries: LFP (Lithium-Iron-Phosphate)

48V-130Ah LFP battery 6900 USD Expensive. Needs several units in parallel to reach capacity

Charge Controllers most 48V - large current (>60A) controllers are MPPT nowadays.
48V - 60 A PWM 172 RM 50% discount.
12V-24-36V-48V - 60A PWM 400RM
12V-24-36V-48V - 30A MPPT 600 RM Discounted price. Auto detect voltage
12V-24-36V-48V - 80A MPPT 1500 RM
12V-24-36V-48V - 60A MPPT 1200 RM
12V-24-36V-48V - 40A MPPT 360 RM Cheap option. Max voltage 120V
12V-24-36V-48V - 60A MPPT 270 RM 65% discount. Max voltage 190V
12V-24-36V-48V - 45A MPPT 2464 RM Victron - Top quality brand
12V-24-36V-48V - 60A MPPT 2418 RM Victron - Top quality brand
12V-24-36V-48V - 100A MPPT 8716 RM Victron - Top quality brand

Inverter
48V - 3000W - 220Vac (DC to AC only) 160 RM Modifiied Sine. Cheap. For basic loads: lights, cooker etc. Not sui
48V - 3000W - 220Vac (DC to AC only) 1150 RM Pure sine inverter. DC to AC only (no AC input)
48V - 3000W - 220Vac (DC to AC only) 1000 RM Pure sine inverter. DC to AC only (no AC input)
48V - 5000W - 220Vac (DC to AC only) 2200 RM Pure sine inverter. DC to AC only (no AC input)

- in one controllerAll-in-one
Architecture
controller (MPPT charger, bi-directional inverter charger, AC input & AC output)
48V - 60MPPT - 230Vac - 5kVA 2360 RM Pure Sine. CANNOT be paralleled
48V - 50PWM - 230Vac - 5kVA 1850 RM Pure Sine. CANNOT be paralleled
48V - 50PWM - 230Vac - 5kVA 3400RM Pure Sine. Can parallel 4 units
48V - 80 MPPT - 230 V - 5kVA 400 USD SAKO SUNSEE. Can parallel 4 units

AC-boost inveters for hybrid solar - hydro with small hydro outputs (hydro output < inverter rating)
48v - 30 Charge from AC- 230v - 3Kva 6500 RM Victron - Top quality brand. Generator power assist functionality
(needs a separate MPPT charger) (ideal solution for small hydro where hydro power < inverter
rating). Model: Victron Multiplus 48/3000/35

48v - 70 Charge from AC- 230v - 5Kva 11,000 RM Victron - Top quality brand. Generator power assist functionality
(ideal solution for small hydro where hydro power < inverter
rating). Model: Victron Multiplus 48/5000/70

Others:
Solar combiner box - single DC output 1300 RM 6 strings, includes strings fuses & 125 output breaker
Solar combiner box - single DC output 1000 RM 3 strings, includes strings fuses & 125A output breaker
Solar combiner box - single DC output 157 USD 6 strings, includes strings fuses & 63A output breaker
Solar combiner box - single DC output 120 USD 4 strings, includes strings fuses & 40A output breaker
157 USD Discounted price. 12 strings, includes string fuses and 2 x 40A
Solar combiner box - double DC output output breakers
urced in Malaysian websites or websites that deliver to Sabah as an example. You can populate this
intend to purchase for your project.

MENTS SOURCE

s. Lazada Malaysia - discounted prices

s. https://www.lelong.com.my/catalog/all/list?TheKeyword=PV+PANEL

https://www.lazada.com.my/products/gp-12v-200ah-premium-rechargeable-sealed-lead-acid-battery-
https://www.lazada.com.my/products/gp-12v-100ah-premium-rechargeable-sealed-lead-acid-battery-
https://www.lazada.com.my/products/msb-ultra-12v-200ah-2400watt-solar-deep-cycle-rechargeable-b
https://www.lazada.com.my/products/msb-ultra-12v-260ah-3120watt-solar-deep-cycle-rechargeable-b
https://www.alibaba.com/product-detail/12V200AH-Deep-Cycle-Battery-for-solar_1710876161.html?s
alaysian distributor "Pollux" Quote
alaysian distributor "Pollux" Quote
ia only https://www.lelong.com.my/gp-12v-200ah-deep-cycle-sealed-lead-acid-battery-solar-backup-ittechss-1

0 MYR) https://www.alibaba.com/product-detail/2V-1000ah-Rechargeable-Gel-VRLA-Mf_60625434620.html?s
0 MYR) https://www.alibaba.com/product-detail/Deep-cycle-2v-1000ah-solar-battery_60736072327.html?spm
0 MYR) https://www.alibaba.com/product-detail/Yangtze-solar-energy-storage-vrla-gel_60825086552.html?sp

parallel to reach capacity https://www.wholesalesolar.com/9979980/discover-battery/batteries/discover-battery-aes-6.6kwhr-48

ontrollers are MPPT nowadays. PWM is mostly used for low cost, small systems
https://www.lazada.com.my/products/60a-solar-charge-controller-48v-ldc-display-pwm-battery-charge
https://www.lelong.com.my/epsolar-epever-60a-solar-controller-12v-24v-36v-48v-vs6048au-pwm-cha
tage https://www.lelong.com.my/solar-hybrid-12v-24v-36v-48v-mppt-solar-charge-controller-30a-emarketl
https://www.lelong.com.my/60a-80a-solar-charge-controller-12v-24v-48v-auto-detect-perfectlink-211
https://www.lelong.com.my/12v-48v-auto-detection-45a-60a-lifepo4-mppt-solar-charge-controller-per
https://www.lazada.com.my/products/yh-40a-mppt-solar-regulator-charge-controller-48v36v24v12v-s
https://www.lazada.com.my/products/powmr-mppt-60a-solar-charge-and-discharge-controller-12v-24
https://www.ubuy.com.my/en/search/index/view/product/B01EUBOL7W/s/victron-bluesolar-mppt-15
https://www.ubuy.com.my/en/search/index/view/product/B01EW2ASIK/s/victron-bluesolar-mppt-150
https://www.ubuy.com.my/en/search/index/view/productebay/323659743906/s/regulator-charge-sol

oads: lights, cooker etc. Not suitab https://www.lazada.com.my/products/car-inverter-3000w-p-eak-dc-48v-to-ac-220v-led-modified-sine-

no AC input) https://www.lazada.com.my/products/jnge-3000w-pure-sine-wave-solar-power-inverter-12v-24v-48v-
no AC input) https://www.lelong.com.my/3000w-12v-24v-48v-to-220v-pure-sine-wave-power-inverter-home-conve
no AC input) https://www.lazada.com.my/products/jnge-5000w-pure-sine-wave-solar-power-inverter-12v-24v-48v-

https://www.lazada.com.my/products/y-solar-5kva-48v-input-and-220v-out-putpure-sine-wave-hybrid
https://www.lazada.com.my/products/5kva-48v-input-and-220v-output-pure-sine-wave-hybrid-solar-in
https://www.lazada.com.my/products/5kva-pure-sine-wave-hybrid-inverter-built-in-mppt-solar-charge
s Quote from supplier. Quote and datasheet in google drive folder

erter rating)
rator power assist functionality Quote from supplier. Quote and datasheet in google drive folder
ere hydro power < inverter
48/3000/35

rator power assist functionality Quote from supplier. Quote and datasheet in google drive folder
ere hydro power < inverter
48/5000/70

125 output breaker https://www.ubuy.com.my/en/search/index/view/product/B07MH6BSWS/s/aims-power-6-string-solar

125A output breaker https://www.ubuy.com.my/en/search/index/view/product/B07M687L4Z/s/aims-power-3-string-solar-a
63A output breaker https://www.aliexpress.com/item/6-String-Solar-PV-Combiner-
40A output breaker https://www.aliexpress.com/item/4-String-PV-Solar-Combiner-
des string fuses and 2 x 40A https://www.aliexpress.com/item/8-String-PV-solar-input-arr
uilt-in-mppt-solar-charge-controller-mps-5k-i350026473-s492755778.html?spm=a2o4k.searchlist.list.16.11b588felTfgWU&search=1
lTfgWU&search=1
** PV PANELS TO SOLAR CHARGE CONTROLLER (SCC)**

There are 3 types of protection devices that can be installed between the PV panels and the SCC:

Device Description
Bypass diode When various PV panels are connected in series, if one panel gets shadowed
or dirty compared to the others, it reduces overall efficiency. Bypass diodes
can be installed in PARALLEL to each PV panel, provides a low resistance path
to avoid energy losses.

Blocking diode When batteries are fully charged and sunlight goes down (night, cloudy),
battery voltage can be higher than PV voltage. Blocking diodes avoid
unwanted current flowfrom the batteries to the panels.

Array fuses or MCBs When PV cells or arrays are connected in parallel, the current of each parallel
MUST BE DC-RATED array gets added. In an event of a short circuit, the entire array current would
flow into the shorted cell, and the likehood is that the cell cables are not able
to handle it, getting hot and potentially catching fire. Fuses and MCBs are
required in each array to protect them from these high currents.

Main DC MCB or DC disconnect To connect/disconnect the PV panels from the SCC and provide overcurrent
MUST BE DC-RATED protection.
FEEO products at Aliexpress: marginally higher unit cost but cheapear shipping (15-20 USD - 30 days), shorter delivery times at

https://www.aliexpress.com/store/912868?spm=2114.10010108.0.0.7732e94edQSUG5

FEEO products have a good selection of small (<63A) MCBs but then jump from 63A to 125A.
This manufacturer has 63A, 80A, 100A, 125A MCBs available:
https://www.aliexpress.com/item/free-shipping-2p-DC120V-63A-80A-100A-125A-DC-circuit-breaker-mcb-breaker-for-global-e
Higher cost but free delivery.

Preferred solutions: FEEO fuses and MCBs:

Prices below are buying directly from supplier (FEEO), however shipping costs are high (around 40-50USD)
5.5USD/unit

DC Fuses for array protection:

2.5USD/unit
(fuse and holder)
https://www.lazada.com.my/products/30a-mc4-in-line-fuse-connector-1000-vdc-male-to-fem-pv-solar-fuse-holder-i12292344
Alternative to cartridge fuses: In-line MC4 compatible fuses. Cheap and simple to install. More difficult to test/inspect.

https://www.lazada.com.my/products/loviver-10-units-of-1000vdc-fusible-safety-solar-pv-explosion-proof-fuse-15a-silver-i45
https://my.element14.com/mersen-ferraz-shawmut/cms101/fuse-holder-10x38mm-din/dp/248757
Other options:

https://my.element14.com/bulgin/fx0385/fuse-holder-in-line-20x5mm/dp/272176

https://www.aliexpress.com/item/ECO-800W-8x100W-Solar-Panel-with-60A-Controller-6-String-PV-Combiner-Box-Home-sola

Bluesun PV: https://www.bluesunpv.com/

Exceltest http://www.exceltest.com.my/index.php?ws=showproducts&products_id=520288#botfo
E CONTROLLER (SCC)** ** CHARGE CON

els and the SCC:

Necessary? Device
ies, if one panel gets shadowed Nice to have. Does not affect SCC to Battery MCB
verall efficiency. Bypass diodes safety or equipment integrity. MUST BE DC-RATED
l, provides a low resistance path Some panels have inbuilt bypass
diodes.

t goes down (night, cloudy), Not required; modern charge Battery to Inverter MCB
e. Blocking diodes avoid controllers have this protection MUST BE DC-RATED
the panels. inbuilt in the design. Panels
themselves can have it too.

allel, the current of each parallel Yes. Ideally in each branch. Inverter output MCB (AC)
t, the entire array current would Branches may be combined if all
that the cell cables are not able the cables within that can handle
ing fire. Fuses and MCBs are the combined PV short circuit
these high currents. current.

e SCC and provide overcurrent Yes. Rated for 156% combined Isc
and not exceeding the Charge
Controller maximum current.
5-20 USD - 30 days), shorter delivery times at higher cost

3A to 125A.

-DC-circuit-breaker-mcb-breaker-for-global-electrically/32870194881.html?spm=2114.search0104.3.85.1b2f5e83VCTC6c&ws_ab_test=se

high (around 40-50USD)

-male-to-fem-pv-solar-fuse-holder-i122923445-s134940286.html
install. More difficult to test/inspect.

-solar-pv-explosion-proof-fuse-15a-silver-i453246001-s691817001.html?spm=a2o4k.searchlist.list.68.6f9e680aI2H5mA&search=1
mm-din/dp/248757
troller-6-String-PV-Combiner-Box-Home-solar-energy/32956658782.html?spm=2114.search0104.3.47.12f94081FShwBM&ws_ab_test=se

=showproducts&products_id=520288#botform
** CHARGE CONTROLLER TO BATTERIES AND BATTERIES TO INVERTER **

Description
Necessary to connect/disconnect the batteries from the charge controller. Dual pole and DC-rated.
If the SCC is PWB type, input and output MCB and cables can be the same size, both smaller or
equal to the controller rating. If SCC is MPPT type, the output MCB and cables must match the
MPPT controller rating. If the MCBs are not specifically rated for "continous use", a 1.25 factor
needs to be applied: 80A controller x 1.25 = 100A MCB.

Necessary to connect/disconnect the batteries from the inverter. Dual pole and DC-rated. Must be
sized for the inverter rating, accounting for inverter efficiency and 1.25 desing factor.

Overcurrent protection at the inverter output. Must match the inverter rating. Installing a smaller
breaker to limit the power output may be a solution in certain cases if the MCB size is adequately
selected but in general is not recommeded. It's a better solution to limit the output current within
the inverter settings, if that option is available.
3VCTC6c&ws_ab_test=searchweb0_0,searchweb201602_4_10065_10068_319_10059_10884_317_10887_10696_321_322_10084_453_
7.5USD/unit
2H5mA&search=1
FShwBM&ws_ab_test=searchweb0_0,searchweb201602_4_10065_10068_319_10059_10884_317_10887_10696_321_322_10084_453_
RTER **

Necessary?
Yes. For safe
disconnection and
overcurrent
protection.

Yes. For safe

disconnection and
overcurrent
protection.

Yes. For overcurrent

protection. Most
inverter have inbuilt
protection but stil
desirable.
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2,ppcSwitch_0&algo_expid=de64d224-3663-4929-b6b3-21fef6e71fac-7&algo_pvid=de64d224-3663-4929-b6b3-21fef6e71fac&transAbTe
7-5c1c300ae930&transAbTest=ae803_4
1fef6e71fac&transAbTest=ae803_4