Industrial Ongrid Solar Energy System Designer

Professional solar system design tool for industrial applications

Solar System Designer

Optimized for 18-panel strings at 810 VDC | IEC 61215 & IEC 61730 Compliant

System Overview:

Total System Size: 0 kW
Daily Energy Production: 0 kWh
Monthly Energy Production: 0 kWh

How to Use Industrial Ongrid Solar System Designer

Step 1: Enter Location

  1. Select your country from the dropdown
  2. Enter your zip/postal code, or
  3. Use the "Get My Location" button to automatically detect your location
  4. Location data helps calculate solar irradiance for your area

Step 2: Define System Parameters

  1. Enter your required system load in kilowatts (kW)
  2. Specify the per panel watts (default: 585W)
  3. This represents the peak power demand of your industrial facility
  4. For accurate results, use the average peak demand from utility bills

Step 3: Review Results

  1. Click "Calculate" to generate detailed system specifications
  2. Review all parameters across multiple result cards
  3. Each card shows specific component requirements
  4. Use the specifications for planning your industrial solar installation

Key Design Features

  • Fixed 18 panels per string at 810 VDC maximum
  • 6mm² DC cable for all strings
  • 8% maximum inverter oversizing (e.g., 115kW inverter = 212 panels max for 585W panels)
  • AC cable sizing at 2.5A per 1mm²
  • Aluminum L2 solar stands with 2 panels per structure
  • Optimized row spacing to prevent shadow losses
  • Stand height adjusted based on tilt angle

How to Calculate Industrial Ongrid Solar System

Step-by-Step Calculation

Real-life example for a 500 kW industrial system in Pakistan:

  1. System Load: 500 kW
  2. Location: Pakistan (5.3 peak sun hours/day)
  3. Solar Panel Rating: 585W per panel
  4. Inverter Efficiency: 97%
  5. System Losses: 14% (wiring, dust, temperature)

DC System Size Calculation

  1. DC System Size = System Load ÷ Inverter Efficiency
    = 500 kW ÷ 0.97 = 515.46 kW
  2. Account for Losses = DC Size ÷ (1 - System Losses)
    = 515.46 ÷ (1 - 0.14) = 599.37 kW
  3. Number of Panels = DC Size with Losses ÷ Panel Rating
    = 599,370 W ÷ 585 W = 1,025 panels

Inverter Configuration

  1. Inverter Selection: 4 × 115 kW + 1 × 40 kW = 500 kW
  2. Max Panels per 115kW Inverter = 115 × 1.08 × 1000 ÷ 585 = 212 panels
  3. Panels per String = 18 (fixed at 810 VDC)
  4. Strings per 115kW Inverter = 212 ÷ 18 = 11.78 ≈ 11 strings
  5. Total Strings = 1,025 ÷ 18 = 56.94 ≈ 57 strings

Aluminum L2 Stand & Row Spacing

  1. Tilt Angle for Pakistan = 30°
  2. Panel Length = 2.2m (typical for 585W panel)
  3. Panel Height (h) = Panel Length × sin(Tilt Angle)
    = 2.2m × sin(30°) = 1.1m
  4. Winter Sun Angle = 90° - Latitude - 23.5°
    = 90° - 30° - 23.5° = 36.5°
  5. Row Spacing = h ÷ tan(Sun Angle)
    = 1.1m ÷ tan(36.5°) = 1.5m
  6. Total Distance Between Rows = Row Spacing + Panel Length × cos(Tilt Angle)
    = 1.5m + 2.2m × cos(30°) = 3.4m
  7. L2 Stand Height = 30-40cm for 30° tilt

Key Formulas

DC System Size:
DC Size = System Load ÷ Inverter Efficiency

Number of Panels:
Panels = DC Size with Losses ÷ Panel Rating

String Configuration:
Panels per String = min(18, floor(810V ÷ Panel Voltage))

AC Cable Size:
Cable Size (mm²) = Total Current ÷ 2.5A/mm²

Row Spacing:
d = h ÷ tan(α)

Where: h = panel height at tilt angle, α = sun altitude angle

Total Distance Between Rows:
D = d + L × cos(β)

Where: L = panel length, β = tilt angle

L2 Stand Height & Row Spacing

Aluminum L2 Stand Heights by Tilt Angle:

15° tilt: 15-20 cm stand height

20° tilt: 20-25 cm stand height

25° tilt: 25-35 cm stand height

30° tilt: 30-40 cm stand height

35° tilt: 35-45 cm stand height

40° tilt: 40-50 cm stand height

Row Spacing Example:

For 30° tilt in Pakistan (30° latitude):

Panel height (h) = 2.2m × sin(30°) = 1.1m

Winter sun angle (α) = 36.5°

Minimum spacing (d) = 1.1m ÷ tan(36.5°) = 1.5m

Panel projection = 2.2m × cos(30°) = 1.9m

Total distance between rows = 1.5m + 1.9m = 3.4m

Frequently Asked Questions

Why limit strings to 18 panels at 810 VDC?

This configuration ensures optimal safety margins while maximizing string power. At 810 VDC with 18 panels (45V each), we stay well within inverter MPPT ranges (typically 580-1000V) and provide safety buffer for temperature variations. The 6mm² DC cable is perfectly sized for the resulting current levels, which is approximately 13A for 585W panels.

Why use aluminum L2 stands instead of steel?

Aluminum L2 stands offer several advantages over steel: they're lightweight (60-70% lighter), corrosion-resistant without galvanization, easier to transport and install, and have a longer lifespan (25+ years). While the initial cost is slightly higher, the total lifetime cost is lower due to reduced maintenance and longer service life. The dual-panel configuration provides optimal structural stability while minimizing material usage.

How is the row spacing calculated to prevent shadows?

Row spacing is calculated using the formula d = h ÷ tan(α), where h is the height of the panel (panel length × sin(tilt angle)) and α is the sun's altitude angle at winter solstice (lowest sun position). The total distance between rows is this spacing plus the horizontal projection of the panel (panel length × cos(tilt angle)). This ensures no shadows fall on panels during peak sun hours on the winter solstice, maximizing energy production year-round.

How does the L2 stand height relate to tilt angle?

The L2 stand height directly determines the tilt angle of the solar panels. For a standard 2m panel, a 15° tilt requires a stand height of 15-20cm, while a 30° tilt needs 30-40cm height. Higher tilt angles require taller stands to achieve the proper inclination. The optimal tilt angle is generally equal to the location's latitude for maximum annual energy production, so stand heights are selected accordingly.

Why only 8% oversizing for inverters?

The 8% oversizing rule prevents excessive power clipping while allowing for optimal energy harvest during peak conditions. This conservative approach ensures inverter longevity and maintains warranty compliance while maximizing annual energy production. For example, a 115kW inverter with 8% oversizing can handle up to 124.2kW DC, which equals 212 panels at 585W each.

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