THE MICRO-GRID ACADEMY

Module no. 2.2: Renewable minigrid components

(PV)

Lesson no. 2.2.4

Title: PV Array Cables

The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of RES4Africa Foundation.
 Contents

• Introduction
• Specifications of DC-side PV array cables
• AC cables from inverter to grid-feed in point
• Solar cable connectors
• SWA steel wire armoured cables
• Installation requirements of DC-side PV array cables
• Rack Cabling
• Minimum voltage drop requirements
• Cable Voltage Drop Calculations
• Voltage drop exercise

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 Glossary

AC Alternating current
CU Copper Wire
DC Direct Current
International Electrical
IEC
Commission
MCB Main circuit breaker
PVC Polyvinyl chloride
SWA Steel Wire Armor
UV ultraviolet
VDC Direct current voltage
XLPE Cross-Linked Polyethylene

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 Introduction​

• Cables found on the AC-side in grid-connected PV systems (connected to the national electric grid or to an AC-
coupled mini-grid) meet the same specifications and are of the same type found in other low-voltage electrical
installations.
• For the DC side, the cables carrying DC current from the PV array(s) to the inverter(s) have special requirements.
• Mostly cables with copper conductors are used. Codes forbid the use of aluminium cables except for special
circumstances.​
• In the case of a large PV array connected to an off-grid system via a solar charge controller to charge batteries
there will be no AC cables directly associated with the PV array.

Source: Grid Tie PV Systems Best Practice Guideline

4
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 Specifications of DC-Side PV Array Cables (1/2)

DC cables need to meet the following requirements:​

• Earth-fault and short-circuit proof (double insulated)​

• Cable temperature ratings. Different wiring methods influence required cable temperature ratings and,
temperature ranges. This vary considerably in different countries

• UV- resistant and moisture-resistant if installed outside​.

• High-voltage range (up to 1,000 VDC)​

• Robust, but flexible​

• Flame retardant, with low toxicity in case of fire.

• Halogen-free

Source: Grid Tie PV Systems Best Practice Guideline

5
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Specifications of DC-Side PV Array Cables (2/2)

• Low cable losses (voltage drop), up to 1% ​

• Conductor material - copper (or aluminium only in special situations​)
• Insulation and sheathing materials – thermoset (most common).​
• Purpose designed ‘PV cables’ or ‘solar cables’ are available.

Source: Grid Tie PV Systems Best Practice Guideline

6
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 AC Cables from Inverter to Grid-Feed in Point

For AC cables;
• Max voltage drop of 2% is acceptable on the AC side, from inverter(s) to the feed-in point.
• AC cabling should meet international standard. For example;
• IEC 60364 standard for low-voltage cabling,
• IEC 60502 standard for cables between 1 - 36 kV,
• IEC 60840 standard for cables between 30 - 150 kV

Requirements for AC cable installation

• AC cable needs to be rated for the inverter AC output current
• Voltage drop should be ≤ 1% (if not specified differently) at maximum current
• The AC cable needs to be protected by a fuse/MCB circuit breaker of the appropriate rating
• AC disconnect/isolator (usually lockable) is installed so that the inverter can be disconnected from the grid for
maintenance and repairs.

Source: Grid Tie PV Systems Best Practice Guideline

7
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Solar Cable Connectors (1/2)

• Most PV modules come with connectors already attached.

• Other types found in the market may not be compatible with each other and require different crimp/termination
tools.
• Connectors should be:
• polarized (reverse polarity protected),
• DC-rated,
• UV resistant if outside,
• and should meet all other requirements such as temperature ratings​

This is used for connecting DC-sting cables, from Multi-contact, type: MC4.​

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Source: Grid Tie PV Systems Best Practice Guideline
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Solar Cable Connectors (2/2)

• Enduring low resistance

• Well connected, not easy to disconnect
• Choose the plugs and sockets according to the
cross section of the cable

Source: Grid Tie PV Systems Best Practice Guideline

9
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 SWA Steel Wire Armored Cables (1/2)

• This is a power and auxiliary control cable, designed for use in mains supply electricity.
• Steel wire armor is only used on multi core cables

Construction of SWA Cables

• Conductor: Stranded Copper (Cu) Conductor, complying with BS EN 60228:2005.
• Insulation: Cross-Linked Polyethylene (XLPE).
• Bedding: Polyvinyl Chloride (PVC) is used as bedding.
• Armoring: Steel Wire Armor (SWA) used for mechanical protection.
• Sheath: Polyvinyl Chloride (PVC) Sheath holds all the components together and provides additional protection
from external damage.

Steel Wire Armored cable

Source: steel wire armored cable: all you need to know

10
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 SWA Steel Wire Armored Cables (2/2)

SWA Cable cores

• Two (2) Core is live and neutral for Class II and Double Insulated appliances which do not need earth connection.
• Three (3) Core are live, neutral and earth, unlike 2-Core. Three core cable is for Class I or Single Insulated.
• Four (4) Core cable are perfect for low voltage or low current signal applications. Made of 4 copper individual
color coordinated cables hence the name four core cable.
• Five (5) Core cable is most commonly used in low-voltage transmissions and uses a three-phase line with one
zero line for the power supply.
• Seven (7) Core cable’s main purpose is for low-voltage connections with a max of normal 50Vdc. Each core is
made from copper

Source: steel wire armored cable: all you need to know

11
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Installation Requirements of DC-Side PV Array Cables (1/3)

• DC cable installation include:

• Inter-module connections,
• the cables from the PV array to PV junction/combiner boxes,
• the cables from PV junction/combiner box to the inverter.​
• Cables should be:
• double-insulated,
• UV resistant if outside or installed in conduit or trunking,
• and should meet all other requirements such as temperature ratings​
• They should be sized so as to meet voltage drop requirements, and follow shortest possible routes to prevent
losses​
• be tied-up/ fastened with UV-resistant cable ties, or enclosed in conduit (solid or flexible)
• should be installed as far as possible from lightning protection equipment, not cross over lightning conductors
and associated cables​
• Cables on roofs should not interfere with the rainwater flow from the roof
• Cables should not be laid in large loops, but laid parallel to each other and close together

Source: Grid Tie PV Systems Best Practice Guideline

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The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Installation Requirements of DC-Side PV Array Cables (2/3)

• Cables should not be run through spaces in which there might be particular fire danger from flammable materials
or combustible atmosphere (e.g. workshops)​
• Labels/marking – DC cables should be clearly identifiable as such, particularly when they are installed near to or
together with AC cables, all cables should be given numbers (to help with any later fault finding)​
• All continuity, insulation and other tests specified in national electrical codes should be performed before cables
are energized​
• Avoid disconnections of any kind (including removal of string fuses) when the array is ‘under load’ because of arcing
danger

Source: Grid Tie PV Systems Best Practice Guideline

13
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Installation Requirements of DC-Side PV Array Cables (3/3)

• DC cables not secured properly, can cause damage to module junction boxes/modules.​

string DC cables, neatly fixed cables under strain

Source: Grid Tie PV Systems Best Practice Guideline

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The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Rack Cabling (Large Ground-Mounted Systems) (1/2)

• Cabling represents a significant portion of overall electrical balance of system (BOS) costs.
• Layout and inverter positioning should be optimized to reduce the amount of cable required by reducing the
distance to junction boxes and to the inverters. Butterfly wiring is fairly standard.

Rack/table butterfly cabling layout.​

Source: Hybrid Systems Comprising Solar PV and Fuel Fired Generators Best Practice Guideline
15
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Rack Cabling (Large Ground-Mounted Systems) (2/2)

• it is advantageous to have symmetric cabling as this leads to balance of systems.

• In this way, the PV system is built up symmetrically, contributing to ease of planning, purchasing, installation,
monitoring and maintenance.​
• This can also allow for better electrical performance of the system, and performance data can easily be compared
between several parts of the PV plant.
• Positive and negative cabling should ideally be installed with the least possible distance between them. So-called
cable loops which can induce voltages during thunderstorms and should be avoided.​

Source: Hybrid Systems Comprising Solar PV and Fuel Fired Generators Best Practice Guideline

16
The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Minimum Voltage Drop Requirements

• IEC 60364-7-712 specifies that the total wiring losses of the DC side should not exceed 1%.
• A max voltage drop of 2% is acceptable on the AC side
• Cables should be sized such that the overall voltage drop, at STC, between the array and the inverter is <3%, a
voltage drop of <1% is recommended

Source: Grid Tie PV Systems Best Practice Guideline

17
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 Cable Voltage Drop Calculations (1/2)

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 Cable Voltage Drop Calculations (2/2)

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 Voltage Drop Exercise (1/4)

1. The distance between the array junction box and inverter is 30 metres metres in length. The Array MPP current is
15 amps and the MPP voltage is 240 V. What is the minimum size cable you could select to have a voltage drop
of 2%? You have a choice of the following cables: 2.5sq mm, 4 sq mm, and 6sq mm, which is the smallest size
cable you can select to meet the 2% voltage drop?
Answer:
The voltage drop is

= (2 x 30 x 15 x 0.0183)/ (0.02 x 240) = 3.43 sq mm

So choose 4 sq mm cable.

Source: Grid Tie PV Systems Best Practice Guideline

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The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of MICRO-GRID ACADEMY
 Voltage Drop Exercise (2/4)

2. For the PV array shown. each module is 0.8m wide and 1.2m in length. The distance from the top right module to
the array junction box is 5m. The current from each module is 5.5A while the MPP voltage of each modules is 34
V.
What is the minimum size cable I can have if I want a voltage drop of 1% between the array and the junction box?

Answer:
Positive wire is approximately 5 +.400= 5.4
Negative wire is approximately 5 + 0.8 + 0.8 + 0.8+ 1.2 + 0.8+ 0.8 + 0.4 = 10.6

Voltage at Vmp = 6 x 34 = 204

Adc cable = ( 2 x Ldc cable x Idc x ρ ) / ( LOSS x V )
= ( (10.6 + 5.4) x 5.5 x 0.0183 ) / (0.01 x 204)
= 0.7894

Source: Grid Tie PV Systems Best Practice Guideline

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 Voltage Drop Exercise (3/4)

3. You have a solar array that comprises three (3) parallel strings. Each string contains 10 modules and each
module has a Maximum Power Point current of 5 A and Maximum Power Voltage of 35 V. The string cabling has
been installed such that the distance from the negative terminal of each string to the array junction box is 8 metres
while the distance from the positive terminal of each string is 12 metres. The string cabling diameter is 2.5 mm2 .
The distance from the array junction box to the inverter is 8 metres and the array cabling is 6 mm2 .
• What is the voltage drop between the array and the inverter - expressed as volts and %?
• What is the power loss?
Answer:
Each String voltage has the following voltage drop:
= ((8 + 12) x 5 x 0.0183)/ 2.5 = 0.732 V
While the array would be:
= (2 x8 x 3 x 5 x 0.0183)/6 = 0.732 V

Total voltage drop = 0.732 + 0.732 = 1.464 V

Expressed as % Total Vmp of array = 350V Therefore % VD = 1.464/350 x 100% = 0.418%

Source: Grid Tie PV Systems Best Practice Guideline

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 Voltage Drop Exercise (4/4)

Power Loss
Each string would be Pdc = 2 x L dc-cable x I2dc x p / A dc cable
= ((8 + 12) x 5 2 x 0.0183)/ 2.5 = 3.66 W

Array
= (2 x 8 x 152 x 0.0183)/6 = 10.98 W
Total Power Loss = 3 x 3.66 + 10.98 = 21.96 W

Now Check: Array = 3 x 10 x 5. x 35 = 5,250 W

Power Loss= 21.96/5250= 0.418%

Another way is just P=Vd x I

Power Loss = 0.732x 5. x 3 + 0.732 x 15 = 10.98 + 10.98 = 21.96 W

Source: Grid Tie PV Systems Best Practice Guideline

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 Recommended Reading / Sources of Information​

• Grid Tie PV Systems Best Practice Guideline (Kenya):​

• Hybrid Systems Comprising Solar PV and Fuel Fired Generators Best Practice Guideline (Kenya)
• Wiring from Arrays with Voltages Above DVC-A to PV Array Switch-Disconnector Near Controller.
• Grid-connected Solar Electric Systems by Geoff Stapleton & Susan Neil, Chapter 10: Installing Grid-connected PV
Systems, Earthscan Expert Series.

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 Thank You for Your Kind Attention.

Contacts RES4Africa Foundation

Renewable Energy Solutions
Micro-Grid Academy for Africa Foundation
Email: info@microgridacademy.org Rome, via Ticino 14
Website: www.microgridacademy.org www.res4med.org
25 www.resafrica.org