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GUIDE TO LOW VOLTAGE PV WITH BESS SYSTEM DESIGN

GUIDE TO LOW VOLTAGE PV WITH BESS SYSTEM DESIGN

Rolling blackouts and extreme weather events are becoming more commonplace and owners of solar panels are finding out that when the power goes out for the utility (grid), they also do not have power. With home and business owners looking for a way to keep their lights, refrigerators and other equipment on when the power goes out, PV systems combined with batteries are becoming more mainstream.


Storing energy and managing its consumption requires an understanding of power conversion technologies, their efficiencies and how to size and configure panels for the various battery voltages, batteries and power conversion equipment. DC coupled systems have a higher battery storage conversion efficiency than microinverter AC coupled systems since there are fewer power conversion steps, although AC coupled systems can be easier to design out since they send their power straight to the grid source.

What is a Solar Panel with Battery Storage System?


Solar panels with a battery energy storage system (BESS) is a system that takes the energy harvested from the sun and stores it. Energy stored in the BESS/batteries is used when desired or needed at a later time when there’s not enough sunlight to run your loads or when grid power goes out, Figure 1.


Current PV systems are analogous to operating your cell phone without a battery. Unplug it from its wall charger and it dies. That’s a grid-tie PV system. Seems simple enough? Not quite. Knowing how your BESS/batteries will be used will determine how your system is ultimately designed.

Diagram showing The Vulcan by Sol Donum integrating grid, solar, and generators with BESS for seamless, reliable energy management

Figure 1. PV system with battery energy storage (BESS) - All Sol Donum™ BESS products control grid, generator and PV distributed energy sources for microgrid or hybrid applications

What Size System Do I Need?


For a small business or homeowner, a low voltage system (120V - 600V) with batteries in the 10 - 50kWh (kilowatt hour) range will suit their needs. However, 100 - 200kWh batteries are not out of the question for larger load suites or for longer runtimes. System sizes from 200kWh - 10MWh are usually reserved for industrial and microgrid support. Batteries from 10MWh - 1GWh are utility scale and represent a way to maintain grid stability, quality of service and reduce peak demand pricing.

What Components Do I Need?



A PV system with battery storage requires several components, Figure 1:


  • PV panels with enough harvesting capacity in watts to fully charge the BESS or batteries and simultaneously run the load base during peak irradiation hours.
  • Charge controllers or DC/DC converters to convert the PV energy to a voltage suitable for charging batteries. AC coupled systems will use microinverters that connect directly to grid sources. Regardless, these devices implement an algorithm called maximum power point tracking (MPPT). This algorithm constantly looks at the voltage and current that the panels produce because solar panels are a non-commissionable source of energy which constantly fluctuates voltage and current output. Unlike a gas generator, you cannot turn PV panels on at any time and have them produce a constant and predictable power output.
  • Battery energy storage system (BESS) or batteries with the capacity to run critical loads during panel dark hours.
  • Power conversion equipment/inverters that operate as a grid-forming/voltage source with the power to run critical loads in battery mode. These may be a grid-follow/current source as well.
  • Switchgear components such as automatic transfer and bypass switches, circuit breakers, cabling, conduit and transformers (depending on the isolation requirement).
  • Monitoring and control software or panel controls for knowing the energy flows, storage percentages and demands from the various interconnected sources

What are the Considerations?


Below is a checklist of high-level and detailed information to help ensure that your system design and implementation has a chance to perform as expected for the life span of your installation. Also, batteries have a life span that is affected by temperature, frequency of use, and depth of discharge. Keep them within their operating range and they will perform flawlessly and safely. Below is a general checklist for component configurations and sizing when designing your system.

  • What type of Batteries are You Using? - This is very important as it applies to several areas. Lithium-ion batteries are not created equally and lead-acid batteries are not recommended for long-term, continuous backup. The factors that should be considered are:

    Discharge and Charging Current/Rate - This is the rate you can add energy to and draw energy from a battery, measured in Amperes per

    hour (Ah). Batteries are sold based on their maximum one-hour discharge current (105Ah, 20Ah, etc). This means that the battery can

    be discharged at this current for one hour before depletion. The rate is expressed as a factor of the charge “C. For a 105Ah lithium battery

    example, the following applies:

    • 1C means a battery can be discharged at 1 * 105 = 105A
    • 0.5C means a battery can be discharged at 0.5 * 105 = 52.5A
    • 3C means a battery can be discharged at 3 * 105 = 315A
    • (Discharge Current/Rate will affect the amount of energy that can be drawn out of the system on a continuous basis)
    • The discharge current has a different outcome depending on the battery type and chemistry. For example, a lead-acid battery discharged at 1C for 30 minutes will be irreparably damaged and will probably not hold another charge. Lithium batteries are highly tolerant and will survive a total discharge event. They can be repeatedly discharged down to 10% for 500 - 10,000 cycles depending upon their chemistry and the rate of discharge nC.
    • Lithium Ion batteries are not created equally in this area. A battery with a high energy density (the amount of energy it can store per kilogram) cannot necessarily be discharged at its rated capacity. For example lithium-ion NMC batteries (used in cars and cell phones) cannot be discharged above 1C. Lithium-ion Iron Phosphate batteries can be discharged up to 3C and are used for applications that have high power needs.

    Number of Charging and Discharging Cycles - Batteries are rated by the number of times they can be charged and discharged. This detail is very important for the operating capability of your system and is affected by the amount of discharge, time and temperature. For example, a lead acid battery advertised at operating for 10,000 cycles over 20 years means that the battery will stand 10,000 cycles of no more than 10 seconds for each cycle. This works for a UPS or peak shaving application but not for a system that must run a load bank for 18 hours.


    Depth-of-discharge - This is the measure of how deeply a battery can be discharged in percent (%). Lithium-ion batteries can be discharged down to 10%. Lead-acid batteries can be discharged down to 50%. This affects the amount of real energy a battery can deliver (true battery size).

    • For example, a 105Ah lithium-ion battery can deliver 94.5Ah of real energy. A 105Ah lead-acid battery can deliver only 52.5Ah of real energy. This will determine the amount of battery reserve required to run your loads.

    Temperature Stability - Batteries have an optimum operating temperature for charging and discharging. Lithium batteries cannot stand a charging current at freezing temperatures. Whereas, lead-acid batteries are more temperature tolerant.


    Life span - Batteries derate over time and have an active life span and a static life span. Lead-acid batteries can have a static life span of 20 years. Lithium-ion batteries have an active life span of 15 years. For an application such as a telecom site where batteries are subjected to extreme temperatures and are rarely used, lead-acid batteries are the best application. However, when large amounts of energy must be charged and discharged repeatedly in systems such as a backup or off-grid system, lithium-ion batteries are superior.

  • System Type - Off-Grid/Behind-the-meter or Grid-Tied?

    This is a primary consideration and may have already been made for you. If you have a PV system feeding the utility then you’re already grid-tied.

  • How Long Can I Keep the Lights On?

    How long can you run your home or

    business on a battery? This will depend on the loads you need to run and for

    how long. This will probably become a smaller number when you realize the

    amount of energy you really consume added to the equation: Runtime in

    hours = (((true battery size kWh (see "Number of Charging and Discharging Cycles")* [conversion efficiency/100]) /

    24hr consumption in kWh) * 24)

    ○ How will you manage your loads? Now that you are the generator of the

    energy that you consume, you will quickly realize that the lights do not

    need to stay on all day long. Your installer/designer may recommend a

    smart electrical distribution box for your system or you may manually

    turn things off. Make your load list.

    ○ What is the total amount of battery storage required to run those loads

    when solar is not available? = (Minimum panel runtime hours * hourly

    loads (kWh) * power conversion efficiency (0.85 - 0.95))

  • The Inverter/Power Converter - What voltage type and size of inverter (power conversion equipment) is needed to run your loads when the grid power goes down?

    • If you're planning to run non-resistance loads with a high inrush current and a large power needs (air conditioning, motors, pumps) then your inverter must be capable of 2 times the maximum continuous loads for several seconds. Continuous power overhead should be 20%. 10kW loads + 20% = 12kW inverter (24kW surge)
    • If you want to power a residential electrical distribution sub-panel, you must provide a 120V/240V split phase output. This is a 1-phase circuit with a center tap 120V|120V for a total of 240V.
    • If you only want to run a few critical 120V circuits then you will only need an inverter suitable for 120V 1-phase.
    • If you are planning to support a refrigeration system or other 3-phase motor loads, then you will need a 3-phase, 120V/208V Wye setup.
  • How many Panels? - What are the number of and performance rating of the panels needed to harvest the appropriate amount of power required in watts - (short circuit voltage * short circuit current = real power output)?

    This is important because of the way the devices that convert PV power to battery (DC coupled) or directly to AC voltage (AC coupled - must manage clipping) work. Once the power need is known, an installer will use a device such as Pathfinder to determine the amount of sun irradiation at your site. This will inform your panel layout and design. Remember, your panels will need to harvest enough energy to simultaneously run loads and top off your batteries to a full charge.

  • Configuring the PV Panels - How will you configure the panel strings to properly work with a DC coupled system power conversion devices, MPPT charge controllers or MPPT inverter/chargers, to charge your batteries properly (parallel/series configuration)?

    Use the following rules-of-thumb when

    designing out your DC coupled system:


    • Know your system battery voltage. This is important for configuring the panel strings, primarily for the input voltage to the charge controller or DC/DC converter. How many panels will you need to tie in series and or parallel to achieve the effective input voltage
    • The charge controller input voltage is the maximum voltage that the charge controller can manage. Your panel string output voltage must be at least 5V or more than the top voltage of the battery bank for an MPPT charge controller. A 48V battery pack has an operating voltage of 51.2V and requires a minimum input voltage of 60V when DC coupled.
    • The charge controller current is the maximum constant current the charge controller can send to the battery pack during charging. Ultimately, this will determine the power (watts) available to charge the battery pack.

A Few Reminders


A battery energy storage system is more complex than a standard grid-tie PV system to design and build out. If not properly sized or matched to the correctly sized and type of power conversion equipment, a battery system will end up operating poorly or not at all and costing you more in utility bills. Proper knowledge of the role of the batteries and proper system engineering is required.


Secondly, battery energy storage systems need to be smarter since they store and control the flow of energy, unlike a grid-tie system. When done correctly, they can run loads indefinitely using batteries with solar panels or other distributed energy resources and use the grid only as a backup. They provide energy resiliency and security that a PV grid-tie system cannot achieve. Lastly, a modular system can ease the job of design and implementation and lower your overall installation and operating costs.


About Sol Donum™


Sol Donum™ (www.soldonum.com) is a U.S. domiciled power technology developer and integrator founded in 2019. Our products are built for operation in the toughest environments and our professional services arm provides engineering and technical support for battery storage and power solutions around our technology. Using our unique IT and energy systems experience, our contribution to a decentralized and decarbonized energy future is through our energy storage products that augment existing electrical power, operate independently for cost savings or provide direct backup power for continuity of operations. Our products fit use cases in the 1.5kWh - 10MWh range. We welcome your call or email to discuss how we may provide battery storage for your organization info@soldonum.com.


DUNS: 122232337 | CAGE: 93ML5 | NAICS: 335911, 335999, 541330 | PSC: 6117, 6130, 6140

Acronyms

A - Amperes

AC - Alternating Current

BESS - Battery Energy Storage System

COOP - Continuity of Operations

DC - Direct Current

EV - Electric Vehicle

GW - Gigawatts

GWh - Gigawatt Hour

Hz - Hertz KW - Kilowatts

kWh - Kilowatt Hours

LFP - Lithium Ferro Phosphate

LiFePo4 - Lithium Iron Phosphate

MW - Megawatts MWh - Megawatt Hour

ROI - Return on Investment

SWAP - Size, Weight and Power

UPS - Uninterruptible Power Supply

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