www.gses.com.

au

GSES Technical Papers

PV System Design: How to compete

effectively in the wider market place

Commercial scale PV systems present enormous onsite efficiency, the required time for complete
opportunities to our industry. However the installation, the system costs and customer returns.
requirements to source and verify a range of site-
Why use a system design?
specific data over a large site is challenging. To then
ensure this data correctly forms part of all aspects A system design created by an engineering
of the system’s performance and installation consultant provides the installer with complete
requirements can be complicated and unfamiliar to information to deliver an installation efficiently and
some system designers and installers. smoothly. Using a specialist for this design work
provides benefits, including:
Possible scenarios: How to ensure the correct
cable distances and gauges have been calculated; • Increased margins – engineering design will
the site requires zero PV export or additional grid optimise cable, module and racking locations
protection – what products support this and how resulting in quicker installation and reduced
are they programmed; how to avoid confronting the material requirements.
need for unplanned additional work on site; is the • Access to projects beyond current skill level
Bill of Materials for this installation comprehensive – engineering design services can provide
- are there sufficient materials to complete the the the installation methodology for projects
installation? Clients often request financial data for that require advanced control and monitoring
the proposed installation: IRR, LCOE – as system systems using PLCs and zero export relays.
designers, these calculations must be able to be
justified by the system design and performance • Market access to larger project pools – larger
data. The prospect of engaging in quotations for projects often require detailed engineering
larger installations is daunting – do you have the designs that an installer does not have time
skill set to meet the market? to complete. An engineering consultancy
can complete these and complement them

“ A system design created by an

engineering consultant provides
with professional presentations to improve
contract chances.
the installer with complete • Optimised installation processes and time –
information to deliver an installation detailed designs optimise the installation of
efficiently and smoothly modules, cables, inverter and racking to reduce

Having a detailed site-specific system design will ” installation times.

• Maximise customer profits – detailed
provide the Bill of Materials, the system cost range, engineering designs provide the installer with
and the system performance data in a clear and accurate analyses of power generation and
logical fashion. Once successful, this information cost savings.
will ensure a smooth installation process and that
the system is delivered according to specifications. • Reduce return-to-site obligations – The
detailed engineering design will provide a full
In this article GSES outlines design techniques and account of all the materials and equipment
supporting processes – these maximise installer’s

Page | 1

Creating sustainable change through education, communication and leadership

Copyright © 2015 Global Sustainable Energy Solutions Pty Ltd. All Rights Reserved.
 www.gses.com.au

GSES Technical Papers

required, eliminating delays in sourcing of
additional supplies to the installer to ensure adequate information
By using an engineering consultant for this type transfer. The site assessment is essential to
of work, additional services can be offered, such complete the system design.
as DNSP liaison services, site assessments and • Plan view diagrams – Include module layout,
power station registrations – all of which assist the module spacing on roof, row spacing, shading,
installation process and ensure a smooth transition purlin spacing, feet and rail spacing.
of control to the owner.
What comprises a System Design? Array 3 (assumed) purlin
spacing 1200mm

0.7
0m
Preliminary and detailed system designs are a

0.7
0m
Array 3 (assumed) purlin

very obvious way to differentiate your installation

0.7
spacing 1200mm

0m
practices from competitors. These documents
provide the analytical platform underpinning Array 2 purlin

0.7
spacing 1200mm

0m
the optimisation of system installation and Array centered on middle of roof

performance. Important considerations include:

NOTES:

1. THIS DRAWING IS THE COPYRIGHT OF GLOBAL

First purlin of Array 1
SUSTAINABLE ENERGY SOLUTIONS PTY. LTD. AND MUST
and Array 2 203mm

shading, row spacing, module tilt and orientation,

NOT BE RETAINED, COPIED OR USED WITHOUT THE
EXPRESS PERMISSION OF GLOBAL SUSTAINABLE back from ridge line
ENERGY SOLUTIONS PTY. LTD.
2. DO NOT SCALE FROM THE DRAWING

oversizing ratio, wiring runs and cable size.

3. ALL DIMENSIONS ARE IN MILLIMETRES AND LEVELS
IN MILLIMETRES UNLESS NOTED OTHERWISE. ALL
DIMENSIONS TO BE VERIFIED ON SITE Safety rail Safety rail
4. EXACT LOCATION OF ALL PARTS OF THE
INSTALLATION TO BE DETERMINED BY CONTRACTOR ON
SITE

A preliminary design offers information vital for

5. CONTRACTOR WORKS ARE RESTRICTED TO THE
GRID CONNECTED PHOTOVOLTAIC SYSTEM AND
ASSOCIATED STRUCTURAL AND ELECTRICAL
COMPONENTS

winning a contract, including elements such as

6. PHOTOVOLTAIC ARRAY MOUNTING SYSTEM TO BE
INSTALLED IN ACCORDANCE WITH AS1170.2 AND THE
MANUFACTURER SPECIFICATIONS
Array 1 purlin
spacing 1200mm 0.7
0m
0.7
0m

0m

plan view diagrams, fly over video presentations,

0.7
6m
25.2

monthly power generation analyses, required

design calculations and material costings.
Site Plan - THE CONCOURSE : WILLOUGHBY CITY Scale: NTS
REMARKS

Figure 1. 3D view of object or structure (i.e. the PV

...

COUNCIL
A detailed design is the installation road map: it
Print: A3
Project & drawing name/number: SP-294-004 REVISIONS

Array and related structures) as seen from above.

DATE DETAILS DRAWN REVIEWED APPROVED
Drawn by: Reviewed by: Approved by:

provides site layout plan drawings, string layout

1 Date Revision for flush mounted modules 10/11/15 ... ...
J.PYE C.MARTELL S.NEILL 2 Date ... ... ... ...

12/11/15 13/11/15 13/11/15

Global Sustainable Energy Solutions 3
4
Date ... ... ... ...
Date ... ... ... ...

drawings, elevations, inverter station drawings, PRIVATE & CONFIDENTIAL. Copyright © 2015 Global Sustainable Energy Solutions Pty Ltd . All Rights Reserved. Pg 1

electrical drawings, protection and zero export • System design calculations –The number of
schematics and a bill of materials. In addition the modules in series and parallel, cable, isolator,
accompanying detailed report explains the design circuit breaker sizes, MPPT configurations,
choices and installation methodology. An installer inverter inputs and system protection
can safely follow these drawings knowing the requirements.
system will meet the CEC, Australian Standards and
DUAL MPPT STRING CALCULATIONS
best practice guidelines. GSES’ design report also Arrays 1-7
Array Overview Calculations String Ca
complies with the DNSP document requirements MPPT1 MPPT2

and can be submitted alongside the application Panel Type

Number of Panels in Series (N)
Jinko JKMS255P
20
Jinko JKMS255P
19
Distance t
DC Cable R

to connect. Number of Parallel Strings

Total Number of Panels
3
98
2 Min cable
Cable Size
Inverter Type SMA STP25000TL-30 Voltage dr
High quality system designs should contain Number of Individual MPPT's
Rated Power (W) 15302
2
9691
Cable Min
Cable Cho
the following: Total Rated Power (W)
Panel Voc (V) 33.60
24993
33.60
String Pro
String Pro
Panel Isc (A) 8.92 8.92 String Pro
• Site Assessment – A complete site assessment Fill Factor (%) 0.851 0.851 String Pro
Input Voc (V) 672 638.4
will include: the roof structure, roof obstacles, Input Isc (A) 26.76 17.84
MPPT Input Current Ok? Checked Checked
building height, shading, roof type, access, PV Array Max Voltage 718.37 682.45

and existing electrics. This assessment can be Inverter and AC Protection Calculations Array Cab

conducted by the engineering consultant or Figure 2. Extract of a System design calculation

Phases output 3 Distance t

by the installer. When the latter is used the AC Breaker min Current (A)
36.20
Max AC current [per phase; line to neutral] (A)
36.20
DC Cable R
Min cable

consultant provides questionnaires and forms AC Breaker max Current (A)

• Electrical schematics – Include electrical
AC Breaker Chosen (A)
72.40
40
Cable Size
Voltage dr
Distance to POC (m) 20.00 Cable Min
information about cable sizes, isolator rating,
Cable Impedance (Ohm*mm /m)
2
0.018 Cable Cho
Min cable size (mm2) 10.86 DC Isolatio
AC Cable size (mm2) 10.00 DC Isolatio
AC Cable Current Carrying Capacity Ok? Checked

PV System Design: How to compete effectively in the widerMatching

market Array to Inverter Calculations
place MPPT1 PageMPPT2
|2
Min Cell Temp 2
Max Cell Temp 70

Creating sustainable change through education, communication and leadership Max Modules Safety Factor
Min Modules Safety Factor
5.0%
10.0%
Absolute Min Number of Panels 9 9
Min Number of Panels 16 16
Max Number of Panels 23 23
Absolute Max Number of Panels 26 26
Copyright © 2015 Global Sustainable EnergyOptimal
Solutions
NumberPty Ltd. All
of Panels Rights Reserved. 20 20
 www.gses.com.au

GSES Technical Papers

DESCRIPTION QTY RATE TOTAL $/w

fusing and MPPT configuration requirements MODULES

YINGLI PANDA 280W with SOLAR EDGE (P300) Capacity 520 $ 288.40
$ 149,968.00
$ 149,968.00
$ 1.03

as well as additional safety and protection INVERTER

(Watts):
280
$ 23,992.00 $ 0.16
integration information. Solar Edge SE16K-AUS 8 $
2,999.00
$
23,992.00
Solar Edge-P300-MC4 520 $ $
76.30 39,676.00
PV Array 1 PV Array 2
MOUNTING
PV Array 3
PV Array 4 $ 18,506.94 $ 0.13
String 1 String 2 String 3 String 4 String 1 String 2 String 3 String 4 String 1 ER-R-ST2560
String 2 EZYRACK
String 3 ST RAIL
String 4 PAIR 2560MM
String 1 String 2 88 String 3 $4
String $
LENGTH 30.58 2,691.04
ER-R-ST3405 EZYRACK ST RAIL PAIR 3405MM 52 $ $ Key
1 1 1 1 1 1 1 1 1 LENGTH
1 1 1 40.67 2,114.84
ER-R-ST4200 EXRACK ST RAIL PAIR 4200MM 1 1
22 1 1
$ $
LENGTH 50.16 1,103.52 Circuit breaker
ER-SP-ST EZYRACK ST SPLICE KIT 1 PAIR 58 $ $
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 3.26
2 189.08
ER-IC40 EZYRACK MID CLAMP SUITS 32.5MM 678 $ $ Switch disconnector (on-load isolator)
4mm2 4mm2
PV-1F PV-1F to 42MM FRAME PV-1F4mm2 4mm2
PV-1F 0.78 528.84
Solar Cable Solar Cable ER-EC40 EZYRACK SolarEND
Cable CLAMP SUITS 40MM Solar Cable 648 $ $
FRAME 0.78 505.44
19 19 19 20
17 19 19 19 20
17 19 ER-IB-SR240/100
19 19 EZYRACK 20 ISOLATOR
19 19 19 16 19 19$ $ Moulded case circuit breaker
MOUNTING BRACKET 5.44 87.04
EZ-GC-ST EZYRACK GROUND WASHER SUITS 408 $ $ Fuse
20 20 20 21
18 20 20 20 21
18 20 R,ST20and T 20
RAIL 21
20 0.17 69.36
- + - + - + - + - + - + - + - + - +
EZ-GL-ST
- +
EZYRACK
- +
GROUND - +
LUG SUITS 20
R,- +
20
- +
162 20
- +
20
$
- +
$ ELV disconnect
ST, and T RAIL 2.39 387.18
20 A Sting Comb
20 A Sting Comb 20 A ER-IK-05CA CLENERGY L-FEET X 10
Sting Comb
100 $ $
1,000 V Box 1.2
1,000 V
gPV fuses
Box 2.2 1,000 V
gPV fuses
Box 3.2 14.14 1,414.00
gPV fuses
ER-CC-PV/4 MODULE CABLE CLIP 520 $ $ PV module
50 A
1,000 0.30 156.00
50 A 50 A 50 A 50 A 50 A 50 A Sting Comb 50 A Sting Comb
Sting Comb Sting Comb Sting Comb V
1,000 V 1,000 V 1,000 V
Box 1.1 1,000 V Box 2.1 1,000 V
EZ-CC-R/ST/6
Box 3.1 RAIL 1,000
CABLE V
CLIP Box 4.1 1,000 V
1040
Box 4.2
$ $
0.17 176.80
50 A 50 A
6mm2
PV-1F Solar Cable 50 A 50 A
6mm2
PV-1F Solar Cable
ER-Z-STBW
50 A EZYRACK 50ZA MODULE WITH
6mm2 BOLT 50 A
200
50 A
$
6mm2 $ Inverter
1,000 V 1,000 V 1,000 V 1,000 V
AND WASHER
1,000 V
(SPARE)
1,000 V PV-1F Solar Cable
1,000 V 1,000 V 0.57
PV-1F Solar Cable 114.00
CLAMPING SYSTEMS
MPPT A - + - +
MPPT B MPPT A
- + - +
MPPT B
ER-IK-09
MPPT A
KLIP- LOK
+ - +INTERFACE KIT 10 X
MPPT B
MPPT A
- + - 100
+
MPPT B $ $ DC cable
BRACKETS AND FITTINGS 60.03 6,003.00
MPPT CONNECTIONS SHOWN INVERTER 2 MPPT CONNECTIONS SHOWN ER-IK-05CA CLENERGY MPPTL-FEET
CONNECTIONSXSHOWN
10 40MPPT CONNECTIONS SHOWN
$ $
INVERTER 1 INVERTER 3 SMA INVERTER 3 SMA AC cable
SMA STP 25000TL ARE INTERNAL TO THE SMA STP 25000TL ARE INTERNAL TO THE STP 25000TL ARE INTERNAL TO THE
INVERTER
STP 25000TL 14.14
ARE INTERNAL TO THE
565.60
INVERTER INVERTER
ER-IK-09 KLIP LOK INTERFACE KIT 10 X 40 INVERTER
$ $
40 A 40 A
BRACKETS40 A
AND FITTINGS (Cable Tray Support) 60.03 2,401.20
40 A
230 V 230 V 230 V 230 V
Inverter station
Modules: 316 x LG 315N1C-G4 Module

Figure 5. Extract of a BOM used to

Inverter: 4 X SMA STP 25000TL
40 A 40 A 40 A 40 A
230 V 230 V 230 V 230 V Total: 99.54 kWp / 100 kVA
10mm2 4C+E 10mm2 4C+E 10mm2 4C+E 10mm2 4C+E
NOTES:
L1
L2
L3
specify equipment for a project. 1. PV MODULES: TO USE TEMPERED GLASS, BE SELF CLEANING & A
REFLECTIVE.
N
E
2. PV SERIES CONNECTIONS SHALL BE SECTIONALIZED AT EACH PA
OPEN CIRCUIT VOLTAGE AT STC IS WITHIN ELV RANGE. IP67 SEGME
160 A
CONNECTORS TO BE USED.

• String layout and electrical wiring drawing

230 V
4 X 95mm2 SDI Double
Solar Distribution Board Main switch
Insulated Single Core and
3. DOUBLE INSULATED PV1-F CABLES INSTALLED IN UV R ESISTAN
25mm2 Earth Cable TRAY/CONDUIT SHALL BE USED ON ROOF SPACE.
4. THE FOLLOWING AUSTRALIAN STANDARDS ARE APPLICABLE:
160 A
230 V (p-n)
– Highlights the module strings, method of - AS 5033:2014 INSTALLATION OF PHOTOVOLTAIC ARRAYS
- AS 4777.1,2,3:2005 GRID CONNECTION OF ENERGY SYSTEMS VIA

Figure 3. Single Line Diagram (SLD)

MCCB
INVERTERS
L1
L2
connection and cable run locations within roof - AS 3000:2007 ELECTRICAL WIRING RULES
- AS 3008:2009 ELECTRICAL INSTALLATION -SELECTION OF CAB

depicts the electrical connections

L3
5. INSTALL TO BE LABELED IN ACCORDANCE WITH RELEVANT SER

space, conduit and cable tray.

N
E INSTALLATION RULES AND AS 5033:2014
6. PV ARRAY V/oc AND I/SC IS CALCULATED USING STANDARD TES

between the PV array, inverter, electrical CONDITIONS (STC). STC SPECIFIES THE MODULE TEST CONDITION A
TEMPERATURE OF 25 CELSIUS DEGREE AND AN IRRADIANCE OF 100
WITH AN AIR MASS 1.5 SPECTRUM.

MAIN SWITCHBOARD #1 protection equipment and MPPTs. 7. ALL EXPOSED CONDUCTIVE METAL COMPONENTS MUST BE
EQUIPOTENTIALLY BONDED AND CONNECTED TO MAIN EARTH
8. AC CABLES SIZE BASED ON INSTALLATION ON CABLE TRAY, SPACE
SURFACE CABLES TOUCHING ON TRAY 4C+E O/C V75
Key
9. MAIN AC SUPPLY CABLE TO PV DB BOARD SIZED TO 1% VOLTAGE
Main Switchboard To Meter To site loads ASSUMING MAXIMUM CABLE RUN OF 60m. EXACT CABLE LENGTH TO
L1
250/5A
Board Circuit breaker VERIFIED BY INSTALLER.
L2
L3
N Switch disconnector (on-load isolator)
E

2A HRC
Moulded case circuit breaker

Fuse
CT termination

ELECTRICAL SCHEMATIC - THE CONCOURSE :

block with
shorting links
ELV disconnect Scale:
REMARKS ...

WILLOUGHBY CITY COUNCIL

To
Meter To Sub Board 3
PV module
To site loads
Board
Power
Meter Print:
Inverter

Project & drawing name/number: EL-294-001 RS485 MODBUS RTU DC cable

REVISIONS

DATE DETAILS DRAWN REVIEWED APP

Drawn by: Reviewed by: Approved by: AC cable
1
22/10/2015 Updated Electrical schematic based on new module configuration A.GANDHI A.BONANNO T.FR
PLC Controller Transformer
2
A. GANDHI COMS PORT
A. BONANNO HMI T. FRANCIS Date ... ... ...

Global Sustainable Energy Solutions

Digital Outputs
(Optional)
Current Transformer 3
Date ... ... ...
15/09/15 Out 3 Out 2 Out 1 Out 0 C 15/09/15 15/09/15 Switch Fuse
4
Date ... ... ...

Inverter 1 Power Control Module Inverter 2 Power Control Module Inverter 3 Power Control ModulePRIVATE
Inverter& CONFIDENTIAL.
4 Power Control Module Copyright © 2015 Global Sustainable Energy Solutions Pty Ltd . All Rights Reserved.

NOTES:

1. PV MODULES: TO USE TEMPERED GLASS, BE SELF CLEANING & ANTI-

REFLECTIVE.
2. PV SERIES CONNECTIONS SHALL BE SECTIONALIZED AT EACH PANEL
SO OPEN CIRCUIT VOLTAGE AT STC IS WITHIN ELV RANGE. IP67 SEGMENT NOTES:
CONNECTORS TO BE USED.
3. DOUBLE INSULATED PV1-F CABLES INSTALLED IN UV R ESISTANT
CABLE TRAY/CONDUIT SHALL BE USED ON ROOF SPACE. 1. STRING NOM
4. THE FOLLOWING AUSTRALIAN STANDARDS ARE APPLICABLE:
WHERE X
5 14 5 14 5 14 5 14 - AS 5033:2014 INSTALLATION OF PHOTOVOLTAIC ARRAYS
- AS 4777.1,2,3:2005 GRID CONNECTION OF ENERGY SYSTEMS VIA Y
INVERTERS 2. STRINGS TO
- AS 3000:2005 ELECTRICAL WIRING RULES
4 15 4 15 4 15 4 15 - AS 3008:2005 ELECTRICAL INSTALLATION -SELECTION OF CABLES ISOLATION AT TH
5. INSTALL TO BE LABELED IN ACCORDANCE WITH RELEVANT SERVICE OF CONNECTION
AND INSTALLATION RULES AND AS 5033:2014
3 16 3 16 3 16 3 16 6. PV ARRAY V/oc AND I/SC IS CALCULATED USING STANDARD TEST
CONDITIONS (STC). STC SPECIFIES THE MODULE TEST CONDITION AT A
TEMPERATURE OF 25 CELSIUS DEGREE AND AN IRRADIANCE OF 1000W/m2
2 17 2 17 2 17 2 17 WITH AN AIR MASS 1.5 SPECTRUM.
7. ALL EXPOSED CONDUCTIVE METAL COMPONENTS MUST BE
EQUIPOTENTIALLY BONDED AND CONNECTED TO MAIN EARTH
1 18 1 18 1 18 1 18

Scale:

Figure 4. SLD of the electrical schematic

REMARKS ...
WENDOUREE ZERO EXPORT DEVICE CONFIGURATION Print:

REVISION HISTORY

of a custom zero export device.

DATE DESCRIPTION DRAWN REVIEWED APPROVED
Drawing type: SLD Project №: 291 Drawing №: 007 Revision №: 000
1 DD/MM/YY ... ... ... ...
Drawn by: Reviewed by: Approved by: 2 DD/MM/YY ... ... ... ...
100kW SOLAR POWER SYSTEM WENDOUREE 3 DD/MM/YY ... ... ... ...
A.BONANNO C.MARTELL C.MARTELL
4 DD/MM/YY ... ... ... ...
06/08/15 06/08/15 06/08/15 NEXT GENERATION ELECTRICAL 5 DD/MM/YY ... ... ... ...

PRIVATE & CONFIDENTIAL. Copyright © 2014 Global Sustainable Energy Solutions Pty Ltd. All Rights Reserved. Pg 1

• Bill of materials – The bill of materials (BOM) is Figure 6. String layout, designating
PLAN VIEW DIAGRAM - CLENERGY MOUNTING SYSTEM REMARKS ...

based on the design drawings and schematics. Project & drawing name/number:
modules to selected inverter and string.
GE-281-004

This allows for the quantities of all major and

DATE
Drawn by: Reviewed by: Approved by: 1
Date
2
C. MARTELL A. BONANNO S.NEILL Date
3

minor components to be defined.

Date
02/02/15 02/02/15 02/02/15 Centsible Energy 4
Date

PRIVATE & CONFIDENTIAL. Copyright © 2014 Centsible Energy. All Rights Reserved.

PV System Design: How to compete effectively in the wider market place Page | 3

Creating sustainable change through education, communication and leadership

Copyright © 2015 Global Sustainable Energy Solutions Pty Ltd. All Rights Reserved.
 www.gses.com.au

GSES Technical Papers

the competition.
GSES offers engineering consulting services,
including feasibility studies, system design, tender
preparation and evaluation, commissioning,
inspection and performance review services.
CABLE ENTRY POINT USING DEKTITE FLASHING

GSES welcomes feedback on technical papers and other

resources available on www.gses.com.au, please contact
GSES by email at info@gses.com.au or by telephone
on 1300 265 525.

Figure 7. Module and wiring layout with

STRING LAYOUT DIAGRAM REMARKS ...
Scale: NTS

Project & drawing name/number: directions for roof entry point.

GE-289-008
DATE DETAILS
REVISIONS

DRAWN REVIEWED
Print:

APPROVED
A3

Drawn by: Reviewed by: Approved by: 1

Date ... ... ... ...
2
C. MARTELL A. BONANNO S.NEILL Date ... ... ... ...
3
Date ... ... ... ...
05/08/15 05/08/15 05/08/15 Centsible Energy 4
Date ... ... ... ...

• Financial Analyses – An analysis of consumption

PRIVATE & CONFIDENTIAL. Copyright © 2014 Centsible Energy. All Rights Reserved. Pg 1

data and predicted system yield information

will allow for an accurate calculation of system
return and savings.

Consumption v Generation Dec 1st - Dec 7th

120

100

80
Energy kWh

60

40

20

0
1
7
13
19
25
31
37
43
49
55
61
67
73
79
85
91
97
103
109
115
121
127
133
139
145
151
157
163
169
175
181
187
193
199
205
211
217
223
229
235
241
247
253
259
265
271
277
283
289
295
301
307
313
319
325
331

Consumption Generation Cons-Gen

Figure 8. Data from an interval analysis of the

comparison of consumption and generation data
collected using a power analyser or interval meter.

Conclusion
The system design process and the
documentation provided allows the installer to
visualise the installation, predict and mitigate
installation issues and provide accurate data on
performance and performance and financial returns
to the customer. At the same time, this information
provides a potential for installation cost savings by
reducing the material requirements and the time to
completion – this improves the installer’s margins.
System designs can be used as promotional material
to win contracts and differentiate your service from

PV System Design: How to compete effectively in the wider market place Page | 4

Creating sustainable change through education, communication and leadership

Copyright © 2015 Global Sustainable Energy Solutions Pty Ltd. All Rights Reserved.