BoS Cost Reductions

 Structural system – optimized for streamlined installation

 Reduce install labor - pre-assembly, on-site assembly line, etc.
 Reduce O&M Costs – Reliability, increased uptime
 Wiring reduction methods (CPT, RPT)
 MV Applications: Multiple inverters  1 Step up transformer

Increase Energy Harvest

 Increase panel performance
 Inverters lifetime = module lifetime
 Increased inverter reliability & uptime
 Increased inverter efficiency
 Trackers
 MPPT – Wider range, improved algorithms
 Use of modeling for design optimization
ROI-Enhancing Benefits:
 Optimal match of power conversion capacity to array
capacity – using smaller 15-24kW inverter blocks
 Eliminate DC Combiner Boxes (note: AC combiners still
required)
 Reduced cost of (commodity) AC aggregation equipment
versus low volume/high cost DC equipment
 Less mounting space. Compact size allows close-
proximity mounting to array. No pad or rigging.
 Multiple MPPT Trackers on each roof offset shading &
less-than-optimal array orientations
 Rapid field replacement serviceability
 Build-in monitoring capability for each inverter
ROI-Enhancing
Benefits:
 Low (and lowering) cost of
panels permit higher panel
densities at small overall cost
impact
 Utilize higher DC:AC Ratios to
increase time at full power and
increase Capacity Factor
(Actual Energy / Max. Potential
Energy)
 Achieve increased energy
harvest in high temperature
climates and less-than-
optimal array mounting
configurations
 CEC efficiency & MPPT less
relevant in high DC:AC ration
systems.
 DC:AC ratios 1.75-2:1 are
available.
UL-Listed installations are happening
• Utility, commercial ground mount and rooftop
Many developers & EPC’s going to 1kV DC
• Both central and string
• Projected to become mainstream solution for large commercial applications
No NEC barriers, roadblocks clearing
• 1000 VDC on commercial rooftop and ground mount today with minimal challenges
• Ambiguity in code slowly being cleared up, acceptance accelerating
1000 VDC equipment selection growing
• Driven by growth of Utility segment
• Including modules, inverters, combiners, BOS
ROI-Enhancing Benefits:
 20 modules per 1000 Vdc string vs. 12 per string at 600 Vdc in same location =
 ~40% less strings for same power, ~40% less combiner boxes, ~40% less home
runs
 Conductor savings
 “Amps cost $, volts are free” : This is almost true, 1000 Vdc PV wire costs more
that same gauge 600 Vdc wire, but it carries far more energy
 ~40% less conductor costs.
 Lower voltage drop losses
 Less losses from strings to combiners

Downsides:
 Requirement to meet >600V (multiple) sections code can complicate AHJ approval
 1000V equipment availability still biased towards large scale utility applications (but changing…)
 Additional permitting and inspection “hoops” may offset benefits
 Short cable length & restrictive wiring applications may limit benefits
 Additional safety & training considerations for higher/1000V
Concept:
Solar
 Battery storage + PV
PV array become Hybrid
”dispatchable” PV/Battery
power supply System Standby
asset Battery -
-
+
+
Inverter
Generators
Storage
Enterprise
- +
 Start/Stop
Controls Charge/ Load Level Load Level
intelligent Discharge pF Level
dispatch Load Level
generation
sources + load Facility Grid
controls to Utility Supply
optimally-reduce
energy costs Enterprise
…
 Reduce size and Level Control
usage of diesel Load
Shed/Add
Facility
gens for standby Loads
power. Reduce
UPS. PCC
 Participate in
Energy Markets Utility Rev. meter,
and sell excess Master Grid/Island
electricity when Control
prices high
Continued Product Development
• 1000V Solutions
• Distributed/String solutions

Forward-thinking R&D and Technology Partnerships

• SEGIS-AC and SEGIS: 4 years and counting
 Partnering with industry leaders to develop collaborative solutions: PGE, PEPCO,
SAFT, NPPT, Sandia, NREL, etc
• 3+ year relationship with Schweitzer Engineering Lab (SEL) to advance technologies
and products related to utility, facility, and PV system integration
 Closed-loop controls, advanced anti-islanding, reliability and stability, cyber-
security

Thinking beyond the Inverter

• PowerStation packaging, hybrid power system, energy storage, advanced inverter
master controllers, etc.
 There are dozens of design decisions
 Cost/Benefit Analysis
 Financial Model
 Keep in mind that there are many design decisions that are
difficult to quantify
 There are very few “Rules of Thumb”
 Project Goals and Challenges Vary
 Financial Models Vary
Use Max Allowable String Size to:
 Reduced BOS Costs (Fewer strings means fewer
combiner boxes and fewer source and output circuits)
 Reduce System Losses (fewer circuits and higher
voltage/lower total current)
 Maximize Production for System Life Ensures that
max power voltage of the array will stay within the
Max Power Point Tracking range of inverter as
modules degrade during the lifetime of the system
Of course, using max. number of modules is not always
possible or preferred for other reasons (complex layout,
odd string size, carport…)
Next Stage in Design Evolution: 1000V Systems
 Consider using…
 ASHRAE Temperature (Extreme Annual Mean
Minimum Design Dry Bulb Temperature) for
larger max string size
 NEC 2011 690.7(A) Informational Note
 Read: “Array Voltage Considerations”, B. Brooks,
SolarPro Oct/Nov 2010
 CHECK WITH INSPECTOR!!
 SolarABC’s Map Tool
 Use Solectria PV System
Builder
• Array Size: 600kW DC
• Module: Sharp NU-U235F1
• Inverter: PVI 500
 Record Low/Average
High
 -23°C/29°C
 13 Modules Per String
 196 Strings
 ASHRAE
 -16°C/33°C
 14 Modules Per String
 182 Strings
 Historically, designers oversize by
10% to 25% optimize kWh/kW
(Specific Yield) -> High Module Prices
 Times have change:
 Cheaper Module Prices (More
production for less incremental cost,
same fixed cost)
 Time-of-Use Utility Rate structures
 Limiting factor is short circuit current
 Designers can vary tilt angle, power
density, and encroach into shaded
regions
 Definition of “Best” Ratio => Optimizes
financial model (IRR, NPV, LCOE)
 Perform Oversizing Analysis using
simulation program (PVsyst, PV*SOL,
SAM) which feeds financial model
 Inverter Location (longest run DC or AC?)
 Inverter Efficiency
 Module Specs: Efficiency, IP rating, Loading specs
 Module Tilt Angle/Orientation/Inter-row separation/Power
Density
 Small vs. Large Combiner Boxes
 Copper vs. Aluminum Wiring
  Save field labor, equipment
costs, and
engineering/procurement
overhead by having inverter
options factory integrated.
 Examples:
 Subcombiners (Fuses, Breakers)
 Revenue Grade Meter
 Monitoring
 Gateway Card
 Zone Level Monitoring
 (troubleshooting value)
 Same company for
inverter/monitoring
(troubleshooting value)
  Means to Ensure UPTIME and Minimize
DOWNTIME
 Perform Preventative Maintenance
 Inverter Provider Preventative Maintenance Plans
 Inverter Provider Uptime Guarantee
 Monitoring with Fault Notification Alerts
 Fault Action Plan (Installer, O&M Provider, Inverter
Company)
 Spare Parts?? (Ground Fault Fuse, Subcombiner
Fuses)
 Service and Maintenance Friendly Design (Site
Plan Placards, Shade structure, Service
receptacles)
 Thank You!

Chemtrols Solar Private Limited

Amar Hill Saki Vihar Road
Mumbai
Jay Ranvir
Jay.ranvir@chemtrolssolar.com
+919594998390