Electrical Design Considerations for 800 Vac Solar

PV Projects

Lawrence T. Connor
Senior Application Specialist
Renewable Energy
Eaton

[email protected]
 Current Trends in AC Solar Collection Systems
• String inverters continue to act as a disruptive technology in large utility scale PV projects
• 660 to 800 Vac nominal system outputs with +10% maximum voltage ratings
• kW ratings have grown to 250 kW and will continue to grow higher
• Until now there have been limited commercially available 800 Vac collector solutions
• MCCBs with limited UL interrupting ratings up to 25 kAIC
• Now fused switches are available with interrupting ratings of 65 kAIC, which support:
• Expanded PV system design solutions
• Applications with larger transformer ratings up to 5000 KVA
• Lower project costs with fewer transformers and less infrastructure
• Short circuit calculations are important to confirm adequacy of OCPD (Overcurrent Protective
Device) interruption ratings as transformer KVA increases
Throat-Connected Solar Transformer & 800 Vac Recombiner Switchboard
 800 Vac Switchboard Summary Ratings
• NEMA 1 Indoor & NEMA 3R Outdoor Enclosures

• 800/462 Vac Nominal

• 3 Phase, 4 Wire Grounded Neutral

• Throat or Cable Connection to Pad Mount Transformer

• Up to 4000 Amp Main Bus

• 200 Amp & 600 Amp Fused Switches

• 65 kAIC Interrupting Rating Tested @ 880/509 Vac

• Bussmann NH Series Solar Fuses (Ratings: 32 Amps to 400 Amps)

• Space Heater Power & Thermostat Control Package

• ANSI 61 Light Gray Paint (Standard)

• White Exterior Paint (Optional)

 800 Vac Solar Collector Switchboard 65 kAIC Fused Switches

200 Amp
Fused Switch
with optional
visible
disconnect
viewing
windows
Eaton Bussmann 800 Vac NH Solar Fuses 32 to 400 Amps
Eaton recommends sizing OCPD collection
devices for 50C minimum service in
switchboard enclosures for thermal margin.
Sizing Fused Switches for String Inverters @ 50C In Enclosures
String Inverter 65 kAIC Fusible Switch NH Fuse Margin
Nominal Enclosure 50C Max Rating Enclosure 50C Max Rating OCPD
Max Nominal Max Nominal
Rating Rating Thermal @ 50C in Fuse Rating Thermal @50C in Thermal
Vendor Model Output Voltage Output Rating
@ 40 C Factor Factor Enclosure Size Factor Factor Enclosure Margin at 50C
(kW or KVA) (Vac +/-10%) (Amps) (Amps)
(Amps) (%) (%) (Amps) (%) (%) (Amps) Service

125-TL3 137.5 KVA 600 - 760 132.30 200 80% 90% 144 NH1 200 80% 94% 150.40 8.84%

PVS-175-TL-US 175 kW 800 134.00 200 80% 90% 144 NH1 200 80% 94% 150.40 7.46%

SG250HX-US 250 800 180.50 600 80% 90% 432 NH2 250 80% 94% 188.00 4.16%

255K-EHV-5G-US 255 800 184.00 600 80% 90% 432 NH2 250 80% 94% 188.00 2.17%

275 KVA 800 199.00 600 80% 90% 432 NH3 315 80% 94% 236.88 19.04%
(Planned 2021)

1659 300 KVA 690 279.00 600 80% 90% 432 NH3 400 80% 94% 300.80 7.81%
65 kAIC Interrupting Ratings Support the Use Of Transformers Up to 5000 KVA
800 Vac System Ratings
Transformer Data & Available Fault Current Collector Overcurrent Protective Devices MCCBs rated 25 kAIC limit
1,2,4 1,3,4
Full Load Amps
kA ISC * kA ISC * MCCBs Fused Switches applications to smaller
KVA @ 5.75% @ 5.175% 25 kAIC @ 800 Vac 65kAIC @ 880/509 Vac
@ 800 Vac
Nominal Z Min (-10%) Z UL Listing Certified
transformers approaching 1750
1000 722 12.56 13.95 25 kA 65 kA KVA, requiring more
1500 1,083 18.84 20.93 25 kA 65 kA transformers & infrastructure
1750 1,264 21.98 24.42 Short Circuit Study *5 65 kA
2000 1,444 25.11 27.91 65 kA
costs on PV projects.
2500 1,805 31.39 34.88 65 kA
2750 1,986 34.53 38.37 65 kA
3000 2,166 37.67 41.86 65 kA
3250 2,347 40.81 45.35 65 kA
3500 2,527 43.95 48.83 65 kA Fused switches rated 65 kAIC
4000 2,888 50.23 55.81 65 kA support larger transformer
4250 3,069 53.37 59.30 65 kA
Short Circuit Study *5
applications up to 5000 KVA,
4500 3,249 56.51 62.79
4750 3,430 59.65 66.27 reducing the number of project
5000 3,610 62.79 69.76 transformers & their associated
* Notes :
infrastructure costs.
1. Available utility back fed fault current. Does not include solar inveter fault contributions
2. Available fault at transformer secondary with a typical transformer @ nominal impedance of 5.75%.(Z)
3. Available fault at transformer secondary with a typical transformer @ minimum impedance of 5.175% (-10% Z )
4. Solar inverter fault contribution can be 1.5 to 2PU x Output Amps additional per inverter. (e.g. ~3kA for 16 250 KW Inverters)
5. Short circuit study recommended to determine OCPD adequacy based on transformer & cable impedance & inverter contribution
 Throat-Connected 4080 KVA Transformer & Switchboard
4080 KVA Optimized Transformer 800 Vac NEMA 3R UL891 Low Voltage AC Collection Switchboard
• PV disconnect primary manual load break switch & visible contact viewing • 4000 amp throat-connection to transformer
window • 4000 amp density rated main bus
• Bay-O-Net expulsion & PRCL (Partial Range Current Limiting) fuses • Qty 16 collector switches with 250 amp fuses rated 65 kAIC
• Throat-connection to switchboard • Qty 2 switches with 32 amp fuses for auxiliary power & station service loads
 Cable-Connected 5000 KVA Transformer & Switchboards

800 Vac NEMA 3R UL891 Low Voltage

AC Collection Switchboards:

• Cable connection to transformer

LV secondary air terminal
chamber

• 2000 & 3000 amp switchboards

with density rated main bus

• Qty 20 collector switches with

250 Amp fuses with 65 kAIC
interrupting
5000 KVA Transformer
• Qty 3 switches with 32 amp
• PV disconnect primary manual load break fuses for auxiliary power &
switch & visible contact viewing window. station service loads

• Optional: AR-VFI (Arc Flash Reduction • Short circuit study

Vacuum Fault Interrupter) system recommended to evaluate
transformer and cable
• PRCL (Partial Range Current Limiting) fuses impedance and inverter fault
contribution.
• Low voltage terminal chamber with cable
connection to multiple collection
switchboards
Transformer MV Load breaker Switch as a PV System Disconnect

Visible Break Switch Window

Manual Load Break Switch

Transformer Close-Couple Throat Connection to AC Collector Switchboards
• Quick & simple installation with coordinated drawings

• Reduces total installation labor & material costs

• Bolted bus bar connections made with braided flex connectors

• Eliminates high power cable connections and underground conduit

infrastructure between Transformer LV Secondary Bushings and AC
Collection Switchboard

• Metal barriers isolate transformer secondary bushings to reduce arc

flash risk

• Requires minimal maintenance access after installation

Installation Video:
https://www.eaton.com/Eaton/ProductsServices/Electrical/Markets/AlternativeEnergy/Solar/index.htm#tabs-3
Typical 800 Vac Collection Switchboard Dimensions
 Transformer Secondary Arc Flash Zone
• Transformer low voltage secondaries are very high arc flash
risk zones

LV Air Terminal
• Transformer primary fuses protect the transformer primary Chamber for cable
windings and tank. The fuses react very slowly to secondary terminations to
arcing and ground faults because secondary faults have to downstream
Circuits. Requires
reflect through the transformer. Trip times may be up to 1 periodic access
second or higher. after installation

• The incident energy in arc flash zone from transformer

secondary to the line side of the ac collector switchboard is
often at DANGEROUS levels where no PPE is available to
keep workers safe. LV Throat
For close-couple
connection to AC
Collector Switchboard.
• This applies to LV air terminal chambers with cable Requires almost
connections and close-couple throat connections to ac no access
collector switchboards. after installation
 AR-VFI Option:
(Arc-Reduction Vacuum Fault Interrupter) Transformer

Pad MountororSubstation
Padmount SubstationLiquid-Filled
Liquid-FilledTransformers
Transformers
Integral CTs for Under-oil Integral
Integral VFI Motor
Interlocked Primary PTs Primary PTs Various Various
Integral Integral primary, CTs for Uninterrupt
Control VFI Motor Operator
Load Break 24Vdc Relay 24Vdc for&relay Power for Voltage gauges andgauges and
Vacuum Vacuum secondary,primary able&Power Operator –
Switch with – relay Relay control Battery (optionalalarm monitoring
Fault Fault or both secondary Supplymonitoring
local/remote
external flexibility Control power (relayBackup accessories
accessories
(optional)manual
Interrupter
Interrupter differential 50/51 (UPS) (optional)
viewing dependent) (optional)
reset(optional)
)
protectionProtection System
System
window

Complete total package factory tested & functionally verified

Video: https://www.youtube.com/watch?v=Kq-3DV3sU6o

©2018 Eaton. All Rights

AR-VFI Secondary Overcurrent Protection
Deadfront primary connections

Visible disconnect window

Interlocked manual load break switch

Partial range current limiting fuses

Primary under-oil CTs

Primary under-oil PTs

(voltage monitoring & Control Power)

Motor operator (optional remote reset)

Secondary under-oil CTs

Integral multi-function relay & control package

 Arc Flash clearing time comparison

Typical Lineup Orientation

~52.2 cycles
Traditional primary fusing (Bayonet & PRCLF)
(870 ms)

VFI Primary Protection Only

~31.8 cycles
(490 ms)

Arc-reduction VFI (primary + secondary 50/51) < 4.6 cycles

(76 ms)

©2018 Eaton. All Rights Reserved

 Designs to Mitigate Arc Flash & Reduce Incident Energy

0 - 4 Cal/cm2 4 - 8 Cal/cm2 8 - 25 Cal/cm2 25 - 40 Cal/cm2 Above 40

Cal/cm2

Level 1 Level 2 Level 3 Level 4 Level

DANGEROUS

• Arc flash energy calculations reveal that some transformer secondaries can present a
problem for access.
• If Incident energy is above 40 cal/cm2, LV & HV compartments are inaccessible until
upstream & downstream disconnect devices are opened.
ArcFlash Incident Energy Comparison
AR-VFI Transformer “Onboard” Relay Assembly

Relay control ships integrally mounted to VFI transformer.

Fully wired & tested at the factory.
Thermal Reliability by Design
e-mail me for a copy of my
presentation “Thermal
Management
Considerations for AC
Recombiner
Switchboards”

Lawrence T Connor
Senior Application Specialist
Renewable Energy
Eaton

[email protected]
 “Thermal Management Considerations for AC Recombiner Switchboards”
• How will your design perform when site conditions approach & exceed record temperatures ? ? ! !
• Design with proper thermal margin to maximize system reliability and prevent equipment overheating &
OCPD nuisance operation
• Site characteristics & peak conditions (especially solar heat gain in enclosures) must be considered
• Applications can exceed UL enclosure design ratings (40C ambient / 65 C rise)
• Switchboard buses are often thermally undersized for the loading & conditions
• OCPDs are all at their highest loading at the same time during the peak of the solar day
• OCPDs (Especially MCCBs) are often densely packed in enclosures
• OCPDs are often thermally undersized without proper thermal rating factors
• OCPDs sized for 50C service in switchboard enclosures is a very good practice.
• OCPD and Switchboard terminal connections are rated for cables applied at 75C ampacities
• Size cables per NEC and apply NEC thermal rating factors
• E-mail [email protected] for a copy
 Useful Application References
• Eaton Solar Website: https://www.eaton.com/Eaton/ProductsServices/Electrical/Markets/AlternativeEnergy/Solar

• Eaton 800 Vac Solar Collector Switchboards: PA083015EN/Z24302 (August 2020) Eaton’s 800 Vac Recombiner
Switchboard

• Transformer Throat Installation Video:

https://www.eaton.com/Eaton/ProductsServices/Electrical/Markets/AlternativeEnergy/Solar/index.htm#tabs-3

• Transformer AR-VFI (Arc Reduction Vacuum Fault Interrupter) Video: https://www.youtube.com/watch?v=Kq-3DV3sU6o

• Site Temperature Data for PV System Design:

http://www.solarabcs.org/about/publications/reports/expedited-permit/map/index.html
https://weather.com/weather/monthly/l/c16d76b0cbed72feae78bce2f5a7a7bbb2abb18ccf7478dda801a791cae32da8
 Useful Application References
• Eaton Consulting Application Guide
https://www.eaton.com/EatonCA/ProductsSolutions/Electrical/YourBusiness/ConsultantsandEngineers/index.htm
• PV and The NEC, Bill Brooks & Sean White
• Understanding NEC Requirements for Solar Photovoltaic Systems, Mike Holt’s Illustrated Guide,
Based on the 2017 NEC
• NFPA 70 National Electric Code Handbook, 2020
• NFPA 70E Standard for Electrical Safety in the Workplace 2020
• IEEE-1584 IEEE Guide for Performing Arc-Flash Hazard Calculations 2018
• IEEE C37.24 IEEE Guide for Evaluating the Effect of Solar Radiation on Outdoor Metal Enclosed
Switchgear
 Abstract
• The innovation of 800 Vac string inverters for use in large scale solar projects has disrupted traditional
PV system design architecture. UL1741 allows for the maximum inverter output voltage to be 10%
higher than nominal, therefore the ac combiner system voltage requirement can reach 880 Vac. The
size of the dc collection system has been reduced, while the ac collection system has been
significantly expanded. System voltages and the available fault currents have been pushed well
beyond commonly available UL Listed equipment ratings, which until recently were rated 600 Vac
maximum.

• 800 Vac combiner equipment solutions are now available with testing to UL891 and third-party
certification. These UL891 switchboards employ switch and fuse component overcurrent protective
devices that provide demonstrated interruption ratings of 65 Ka at the maximum rated voltage of 880
Vac. The 65kA interruption performance is superior to molded case circuit breakers that are typically
limited to 25kA. The higher fuse interruption ratings of 65kA allow for the application of larger power
transformers from 1500 to 3000 KVA that are throat connected to the switchboard bus. This greatly
allows system design flexibility to reduce the number of power transformers and ac collection system
infrastructure, which drives down the total installed cost and increases system reliability.

• Typical single line diagrams of 800 Vac combiners will be presented from various solar projects to
show optimal UL891 switchboard and transformer combinations. The objective is to provide system
design standards for those who develop, design, specify, purchase, construct, and operate solar PV
systems.