In this article, COMTEST presents technical and seminar information from Fluke on commissioning and performance maximisation procedures for PV systems that use the purpose built Fluke instruments from the Fluke Renewable Energy Test Equipment range.
Commissioning a photovoltaic system for maximum performance.
Despite great engineering, no system is failproof. That’s why commissioning needs to establish a baseline of performance for customer acceptance and follow-on maintenance. Commissioning is important not only for photovoltaic (PV) system performance, but also for the longevity of equipment, safety, ROI and warranties. Fluke, locally represented by COMTEST, is experiencing increasing demand for high-precision handheld devices that can measure photovoltaic (PV) systems.
Step 1: Photovoltaic system design and production
The first commissioning tasks for any PV system is to establish the expected production at the site, determine the solar resource and consider any shading that may occur on the panels. The solar resource is measured during peak sun hours, which is the number of hours the installation achieves at or above 1 000 w/m2/day. The solar resource is good if the resource is 6 000 w/m2/day or above. To develop this baseline, the Fluke IRR-1 Solar Irradiance Meter is ideal to determine the actual solar irradiance (w/m2) and shading at the site.
Let’s say it’s a 10 kW PV array. Calculated expected annual production can be determined by multiplying the 10 kW array x 6 peak sun hours x 365 days per year x 0.85 (15% derating due to power losses in wiring and inverter). This array should produce 18 615 kWh of energy for us per year, or an average of 51 kWh per day.
Step 2: Measuring PV performance
Once the system is installed, the commissioning team need to determine if the systems actual operating performance matches the design by measuring the electrical characteristics and the actual power output of the array.
The performance of a PV array is based on its current-voltage (IV) curve. Not only does an inverter convert DC to AC, but it also maximises its power output by capturing the current and voltage — since power is voltage x current — at which the string is producing the most power. The short circuit current (Isc) is the maximum output current from a cell and at this point no power will be produced because there is no voltage difference: the positive and negative wires are touching. The open circuit voltage (Voc) is the maximum voltage from a cell: no power will be produced at this point either, because the circuit is open.
The point at which the module produces the most power is called the maximum power point (MPP).
To know if an array is working as designed, know the values of the Voc and Isc, listed on the module datasheet. Measure the Voc and Isc before and after installation.
Voc is measured by using the Fluke 393 FC CAT III Solar Clamp to determine the voltage between the positive and negative terminals. The 393 FC is CAT III 1500 V/CAT IV 600 V rated, making it safe and reliable for making measurements in CAT III environments such solar installations.
Use the Fluke 64 MAX IR Thermometer to determine the temperature of the module to account for the effect of temperature on Voc (the lower the temperature, the higher the voltage and vice versa). The 393 FC provides audio polarity warning while testing Voc. If it’s reversed, the combiner box or other circuits may be unintentionally connected in series, resulting in voltages over the maximum inverter input voltage.
To test Isc, disconnect all parallel circuits and safely short the circuit. Measure the current between the positive and negative terminals through a multimeter. Set the dial to a current greater than expected. Record the values of Isc and Voc on the Fluke Connect™ app and save them for trending and reporting
Check the insulation resistance of your conductors, the connections between modules and between each module and the racking, as well as the resistance to ground. Use the Fluke 1625-2 FC Earth Ground Tester to measure earth ground resistance to ensure a resistance of less than 25 Ω.
Step 3: Diagnosing variances
Even when installed correctly, a PV system may not meet the expected electrical production. It’s very important for a module to have the electrical characteristics specified, because an inverter has a minimum and maximum input current, below and above which it will have no power output.
Scenario 1: Open circuit voltage or short circuit current is higher or lower than on the datasheet
In this case, the string has one or more modules whose characteristics don’t meet specification. Open circuit voltage out of range means the inverter may not output power. Short circuit current out of range indicates there may be a module mismatch, which can severely degrade the array’s performance because the current of a string is limited by the module with the lowest current. Identify and replace the modules.
Scenario 2: Power output is low
If the power output is lower than expected, there may be a problem. While some fluctuation in output is expected, consistently less than predicted output could be a sign of a faulty string, a ground fault, or shading.
One reason could be hot spots, the accumulation of current and heat on a short-circuited cell, leading to reduced performance and possible fire. Thermal imagers such as the Fluke Ti480 PRO Infrared Camera or the Fluke TiS75+ Thermal Camera can quickly identify hot spots.
Ground Faults are another, but they’re harder to diagnose and require testing the voltage and current of each conductor and the equipment grounding conductor (EGC), which carries stray current to the ground. Voltage and current on the EGC indicate a ground fault. Ground faults can occur due to damaged conductor insulation, improper installation, pinched wires and water, which can create an electrical connection between a conductor and the EGC. Find the source of the problem and replace the damaged wires or improve the conditions.
Other reasons for low power output could be shading and poor tilt and compass direction (azimuth angle) for the location. Use a solar pathfinder to find any new sources of shading and remove them, if possible. While it may not be feasible to change the tilt and compass direction of the array to point the panels more directly toward the sun, you should know the tilt and azimuth angles to establish a baseline for future reference.
In large-scale PV systems, the power from a solar system goes through transformers after being inverted to step up the voltage, then to switchgear and medium voltage cables where decreased insulation resistance is a common issue. For medium and high voltage cables, use the Fluke 1555C FC 10kV Insulation Tester, which can handle voltages of up to 10 000 volts.
For systems with batteries, compare the expected battery voltage and state of charge with the actual using the Fluke 500 Series Battery Analyzer.
Further information on Fluke solutions for PV systems can be accessed from:
- Fluke Solar Solutions: https://bit.ly/3XdeU6F
- COMTEST: +27 10 595 1821: sales@comtest.co.za
- FACEBOOK: ly/3iuk4cg
- YOUTUBE: ly/2V4nc6j
- LINKEDIN: ly/3rpTu86
