design (/blog/category/design), basics

(/blog/category/basics)

How to Calculate PV String

Size (/blog/pv-string-size)
MR (/blog?author=5a15fb2e5ce350642a67680a)
·
October 10, 2018 (/blog/pv-string-size)

When designing a solar PV system it’s critical to know the

minimum and maximum number of PV modules that can
be connected in series, referred to as a string. PV modules
produce more voltage in low temperatures and less
voltage in high temperatures. If too many modules are on
the same string then the maximum input voltage of the
inverter may be exceeded and the electrical equipment
connected to that string could be damaged, or worse,
start a fire. If too few modules are on the same string,
then the inverter might shutoff when the outside
temperature is high and the system will underperform
during the summer months.
EMAIL CALL

Use the Mayfield Design

Tool
The easiest and fastest way to calculate PV string size and
voltage drop is to use the Mayfield Design Tool. Our web-
based calculator has data for hundreds of PV modules,
inverters, and locations so you don’t have to look up
datasheets nor do manual calculations. You can access
the Mayfield Design Tool for free on our website here.
(/design-tool-request)
 Manual String Size
Calculations
EMAIL CALL

How to Calculate Minimum String

Size
The minimum string size is the minimum number of PV
modules, connected in series, required to keep the
inverter running during hot summer months. The National
Electrical Code (NEC) (https://www.nfpa.org/NEC) doesn’t
address the effects of high temperatures on module
voltages because that is considered a performance issue,
not a safety issue. However, our customers care whether
the system we design is operating during the
summertime when their return on investment is highest.

In order to calculate the minimum string size we first have

to calculate the minimum output voltage, Module
Vmp_min, that each module will produce for the specific
installation site. Then take the inverter minimum voltage
and divide by the calculated module minimum voltage to
get the minimum number of modules.
The module minimum voltage is calculated using the high
temperature for the installation site when the modules
would produce the lowest expected voltage. This is
EMAIL CALL
because as a PV module gets hotter it is less efficient and
produces less voltage.

Where:

Module Vmp_min = minimum module voltage

expected at site high temperature [V].

Vmp = rated module max power voltage [V]. Found

on the module data sheet.

Tmax = the ambient high temperature for the

installation site [°C].

The industry standard for site temperature data is

provided by the American Society of Heating,
Refrigerating and Air-Conditioning Engineers
(ASHRAE (https://www.ashrae.org/technical-
resources/bookstore/ashrae-climate-data-
center)). Find ASHRAE site temperature data for
free on Solar ABCs
(http://www.solarabcs.org/about/publications/r
eports/expedited-permit/map/index.html).
 There are three different options for Tmax, all are
acceptable for design best practices:

• 2% ASHRAE
EMAIL
high temperature
CALL
(most
commonly used)
• 0.4% ASHRAE high temperature (required for
ETO incentives
(https://insider.energytrust.org/programs/
solar/incentives/), slightly more
conservative)
• highest temperature ever recorded (most
conservative)

Tadd = temperature adjustment for installation

method [°C].

The temperature is adjusted to take into account

the installation method. In general, roof mounted
systems get hotter than ground mounted systems
because there is typically less airflow and the roof
surface radiates heat.

• Roof mounted, parallel to roof (<6 in.

standoff): +35°C
• Roof mounted, rack-type mount (>6 in.
standoff): +30°C
• Ground or pole mounted: +25°C

T_STC = temperature at standard test conditions,

25°C
 Tk_Vmp = module temperature coefficient of Vmp
[%/°C], always expressed as a negative value. Found
on the module datasheet.
EMAIL CALL

This is not the same as the temperature

coefficient for Voc. Most often the temperature
coefficient of Vmp isn’t on the module datasheet.
You can use the power temperature coefficient
instead since this will be almost the same.

*rounded up to the nearest whole number

Where:

Module Vmp_min = minimum module voltage

expected at site high temperature [V], from the
previous calculation above.

Inverter Vmin = the inverter minimum MPPT voltage

[V].

• Using the inverter minimum operating voltage

will ensure that the inverter will keep running,
however, the Max Power Point Tracking (MPPT)
function of the inverter may stop working. This
 is the function that ensures the inverter is
producing the maximum possible power output
at any given time.
EMAIL CALL

• Using the inverter minimum MPPT voltage will

ensure that the inverter is running and the MPPT
function is working properly, giving the highest
possible performance.

The calculated minimum number of modules in a

string must always be rounded up to the next
whole number so that the minimum inverter
voltage is being met.

EXAMPLE

Let’s assume we’re designing a PV system in Corvallis, OR

that is roof-mounted, parallel to the roof (<6in. standoff)
using SunPower P17 350W (SPR-P17-350-COM-1000V)
(/s/ds-sunpower-p17-355-commercial-solar-panels.pdf)
modules and CPS 60kW, 1000V string inverters (/s/CPS-
SCA50-60KTL-DO-US-480-Datasheet-August-21-
2018.pdf).

From the module datasheet

Vmp = 43.1 V

Tk_Vmp = -0.37 %/°C

 T_STC = 25°C

From the inverter datasheet

EMAIL CALL

Inverter Vmin (MPPT) = 540 V

From SolarABCs website and based on the site location

Tmax (2% ASHREA) = 33°C

Based on the mounting type, Tadd = 35°C

First, we will calculate Module Vmp_min:

Module Vmp_min = Vmp x [1+ ((Tmax + Tadd - TSTC)

x (Tk_Vmp/100))]

= 43.1V x [1+ ((33°C + 35°C - 25°C) x (-0.37%/°C / 100))]

= 43.1V x [1+ ((43°C) x (-0.0037/°C))]

= 43.1V x [1+ (-0.1591)]

=43.1V x [0.8409]

= 36.24 V

This calculation shows you that the minimum module

voltage expected at this site's high temperature is about
84% of the rated module Vmp.
Next, we will calculate the minimum string size:

Min String Size = Vmin_inverter / Module Vmp_min

EMAIL CALL

= 540V/36.24V

= 14.89

Lastly, we will round up to the nearest whole number:

Min String Size = 15 modules

How to Calculate Maximum String

Size
The maximum string size is the maximum number of PV
modules that can be connected in series and maintain a
maximum PV voltage below the maximum allowed input
voltage of the inverter. This is considered a safety concern
and is addressed by NEC 690.7(A) Photovoltaic Source and
Output Circuits. The 2017 NEC allows the following three
methods for this calculation.

1. Using the module open-circuit voltage temperature

coefficient and the lowest expected ambient
temperature to correct the PV module rated open-
circuit voltage. (The method used in this article).
 2. For crystalline and muticrystalline modules, using the
correction factors in NEC Table 690.7(A) and the
lowest expected ambient temperature. This is the
EMAIL CALL
most conservative method.
3. For PV systems 100kWac or greater, using an
industry-standard method provided by a licensed
professional electrical engineer.

Using the first method allowed by the NEC, the Module

Voc_max is calculated using the site lowest expected
ambient temperature when the modules would produce
the highest expected voltage. 

Where:

Module Voc_max = maximum module voltage

corrected for the site lowest expected ambient
temperature [V].

Voc = module rated open current voltage [V]. Found

on module data sheet.

Tmin = lowest expected ambient temperature for

site [°C].
 The key word here is “expected”. For many
designers, using the data provided by ASHRAE for
the Extreme Annual Mean Minimum Design Dry
EMAIL CALL
Bulb Temperature is the answer in this scenario
and is recommended by the NEC. You can also
consider using the lowest recorded temperature,
this is the more conservative approach. Either
temperature value can be justified and will result
in proper system design. Find site temperature
data on Solar ABCs
(http://www.solarabcs.org/about/publications/r
eports/expedited-permit/map/index.html).

T_STC = temperature at standard test conditions,

25°C.

Tk_Voc = module open current voltage temperature

coefficient [%/°C], always expressed as a negative
value. Found on module data sheet.

Where:

Module Voc_max = maximum module voltage

corrected for the site lowest expected ambient
temperature [V] from previous calculation above.
 Inverter Vmax = the inverter maximum allowable
voltage [V]. Found on inverter data sheet.

EMAIL CALL

The calculated maximum number of modules in a

string must always be rounded down to the next
whole number so that the maximum inverter
voltage is not exceeded.

EXAMPLE

Let’s assume we’re designing a PV system in Corvallis, OR

that is roof mounted, parallel to the roof (<6in. standoff)
using SunPower P17 350W (SPR-P17-350-COM-1000V)
(/s/ds-sunpower-p17-355-commercial-solar-panels.pdf)
modules and CPS 60kW, 1000V string inverters (/s/CPS-
SCA50-60KTL-DO-US-480-Datasheet-August-21-
2018.pdf).

From the module datasheet

Voc = 51.7 V

Tk_Voc = -0.34 %/°C

Note: The datasheet shows Tk_Voc = -175.8 mV/°C.

You can convert this to a percentage -0.1758 V / 51.7 V
= -0.0034 = -0.34%
 T_STC = 25 °C

From the inverter datasheet

EMAIL CALL

Inverter Vmax = 1000 V

From SolarABCs website and based on the site location

Tmin = -8 °C

First, we will calculate the Module Voc_max:

Module Voc_max = Voc x [1 + (Tmin - TSTC) x

(Tk_Voc/100)

= 51.7V x [1 + (-8°C - 25°C) x (-0.34 %/°C /100)]

= 51.7V x [1 + (-33°C) x (-0.0034/°C)]

= 51.7V x [1 + (0.1122)]

= 51.7V x [1.1122]

= 57.50 V

This calculation shows you that the maximum module

voltage expected at this site low temperature is about 11%
higher than the rated module Voc.

Next, we will calculate the maximum string size:

Max String Size = Inverter Vmax / Module Voc_max

 = 1000 V / 57.50 V

= 17.39
EMAIL CALL

Lastly, we will round down to the nearest whole number:

Max String Size = 17 modules

M A X VO LTAG E FO R P V SYST E M S 1 0 0 K W ( AC ) O R
G R E AT E R

The 2017 NEC added a third method for calculating

maximum voltage and allows using an “industry-standard
method” provided by a licensed professional electrical
engineer. This method requires a more in-depth analysis
of the site-specific weather data such as irradiance and
the temperatures during sunlight hours when the PV
system is actually operating. The amount of work required
to do this analysis may not be worth the additional cost
for smaller systems but may be very valuable for large PV
systems.

See Resources & References below for the links to the

Sandia report referenced in the NEC as an industry-
standard method and the article Simulating NEC Voltage
and Current Values which explains this method and gives a
detailed example.
 EMAIL CALL

Multiple Allowable String Sizes

For the example above, the allowable string size is
between 15 to 17 modules. That means that we have the
flexibility of choosing 15, 16 or 17 modules connected in
series on one string. Depending on the available
installation space and system layout we might need to use
a mix of string sizes. When using multiple string sizes we
want to make sure that all the strings going into one MPPT
have the same number of modules. Having multiple string
sizes connected to the same MPPT is one cause of
mismatch, the variation of input power from one string to
another. Mismatch affects the MPPT’s ability to function
properly and will result in decreased inverter
performance.

For example, the CPS 60kW string inverter has 15 inputs

and 3 MPPTs allowing for 5 strings to be connected to
each MPPT. Let’s assume we’re using 5 strings of 15
modules, 5 strings of 16 modules, and 5 strings of 17
modules all connected to the same inverter. All the strings
with 15 modules should be connected to MPPT 1, all the
strings with 16 modules should be connected to MPPT 2,
and all the strings with 17 modules should be connected
to MPPT 3.
Every inverter manufacturer has a team of applications
engineers who can help you determine proper system
design with their products. If you’re ever unsure of what
EMAIL CALL
string sizes to use with a particular inverter you can
contact the technical support team for the inverter
manufacturer.

Resources & References

F R E E ST R I N G S I Z I N G TO O L S

1. The Mayfield Design Tool (/design-tool-request) for

string size and voltage drop calculations.
2. PVselect.com (http://www.pvselect.com/index.php) a
free solar design tool provided by Blue Oak Energy
and SolarPro magazine.
3. Most inverter manufacturers have their own string
sizing tool for their products that can be found on
their website.

U S E F U L R ESO U RC ES
 1. Solar ABCs
(http://www.solarabcs.org/about/publications/report
s/expedited-permit/map/index.html) has ASHREA
EMAIL CALL
site temperatures by zip code in United States.
2. Solar Design Temps
(http://www.solardesigntemps.com) has site
temperatures worldwide.
3. National Electrical Code (NEC), NFPA 70
(https://www.nfpa.org/codes-and-standards/all-
codes-and-standards/list-of-codes-and-
standards/detail?code=70), National Fire Protection
Association
4. Climatic Design Information, Chapter 14 from the
2017 ASHRAE Handbook—Fundamentals
(https://www.ashrae.org/technical-
resources/bookstore/ashrae-climate-data-center).
5. PV Performance Modeling Collaborative (PVPMC)
(https://pvpmc.sandia.gov) provides detailed
information and resources on PV system modeling
that meets NEC 690.7(A)(3).
6. System Advisor Model (SAM) (https://sam.nrel.gov) is
a free performance modeling tool provided by
National Renewable Energy Laboratory (NREL)

ADDITIONAL READING
1. “String Theory: PV Array Voltage Calculations”
(https://www.homepower.com/articles/solar-
electricity/design-installation/string-theory) by Ryan
EMAIL CALL
Mayfield, Home Power Magazine Issue #125, June /
July 2008.
2. “METHODS: Selecting Appropriate PV Array String
Sizes” (/s/Home_Power_173-compressed.pdf) by
Kent Osterberg, Home Power Magazine Issue #173,
May / June 2016.
3. “Install tip: Know How Inverter MPPT Functionality
Affects Performance”
(https://www.solarpowerworldonline.com/2018/03/i
nstall-tip-inverter-mppt-functionality-affects-
performance/) by David Bromberg, Aurora Solar via
Solar Power World.
4. “Understanding PV System Losses, Part 1:
Nameplate, Mismatch, and LID Losses”
(https://blog.aurorasolar.com/understanding-pv-
system-losses-part-1) by Andrew Gong, Aurora
Solar blog.
5. “Array Voltage Considerations”
(/s/SolarPro_36_compressed.pdf) by Bill Brooks,
SolarPro Magazine Issue 3.6, Oct/Nov ‘10
6. “Simulating NEC Voltage and Current Values”
(/s/SolarPro_114.pdf) by Charles Ladd, SolarPro
Magazine Issue 11.4, July/August 2018.
 7. Photovoltaic Array Performance Model, SAND 2004-
3535 (https://prod.sandia.gov/techlib-
noauth/access-control.cgi/2004/043535.pdf),
EMAIL CALL
Sandia National Labratories. Referenced in 2017
NEC, industry standard method for calculating
maximum voltage of a PV system.

H AV E Q U EST I O N S O R CO M M E N TS?

Comment below or email design@mayfield.energy

(mailto:design@mayfield.energy?
subject=How%20to%20Calculate%20String%20Size) and
we would be happy to answer. Feedback welcome!

Tagged: PV system design

(/blog/tag/PV+system+design), string size
(/blog/tag/string+size)

 Share
Newer Post
ETO Solar Incentives for
New Buildings
EMAIL CALL
(/blog/2018/8/23/eto-
solar-incentives-new-
building)

(http(http(http

2210 NW Hayes Ave., Corvalli s,

OR (541) 754-2001 hello@Mayf i eld.Energy (Ma

© Mayfield Renewables, LLC 2021. All rights reserved. Give

credit to our work if you use it.
EMAIL CALL