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CONTRACTOR REPORT SAND80-7171 Unlimited Release UC-63a

The Design of a Photovoltaic System for a Passive Design Northeast All-Electric Residence

E. M. Mehalick, G. F. Tully, J. Johnson, J. Parker, R. Felice Philadelphia, PA 19101 Prepared by Sandia National Laboratories Albuquerque, New Mexico 87185 and Livermore, California 94550 for the Uhited States Department of Energy under Contract DE-AC04-76DP00789

Printed January 1982

Issued by Sandia National Laboratories, operated for the United States Department of Energy by Sandia Corporation. NOTICE: This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Govern· ment nor any agency thereof, nor any of their employees, nor any of their contractors, subcontractors, or their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government, any agency thereof or any of their contractors or subcontractors. The views and opinions expressed herein do not necessarily state or reflect those of the United States Government, any agency thereof or any of their contractors or subcontractors.

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Distribution Category UC-63a SAND80-7171 Unlimited Distribution Printed January 1982

THE DESIGN OF A PHOTOVOLTAIC SYSTEM FOR A PASSIVE DESIGN NORTHEAST ALL-ELECTRIC RESIDENCE

E. M. Mehalick, G. F. Tully, J. Johnson, J. Parker, R. Felice General Electric Energy Systems and Technology Division General Electric Advanced Energy Programs Department P. O. Box 8555 Philadelphia, Penn. 19101

ABSTRACT A photovoltaic system has been developed and integrated into a passively designed, low energy consuming home suitable for the Northeast region of the country. The selected array size is 4.1 kW at NOCT conditions, and covers 51 sq.m. of roof area. The design addresses the residential market segment of low energy consuming houses with limited roof area availability for photovoltaic arrays. A direct mount, next generation, larger sized, PV shingle module is used to reduce installation costs over earlier generation shingle modules. A 4 kW line-commutated inverter is used in the power conversion subsystem, since it is representative of currently available equipment. This report describes the complete system and house design, including all the pertinent installation and construction drawings. Specific performance results are presented for the Boston and Madison region. The system design presented in the report, coupled with previously completed designs, provide a set of design options expected to be available to residential homeowners in the mid 1980's. Prepared for Sandia National Laboratories under Contract No. 13-8779. iii-iv

FOREWARD

This

report

presents

developed on the Detailed

the fourth of six detailed residential designs

Residential

Photovoltaic

System

Preferred

Designs

Study.

The Advanced Energy Programs Department of the General Electric Company,

Energy

Systems

and

Technology

Division,

National Laboratories, Contract 13-8779.

performed the contract under Sandia

Mr. E. M. Mehalick served

as

the

GE

Program Manager and Dr. G. Jones served as the Sandia Technical Monitor. The

choice

of

hardware

for

this design is made primarily based on

available

p-.""v

"

1&$1,'

r • ~

t

GENERAL. ELECTRIC ...ao.

IIIYI.ION

Detailed Residential P.V. System

PrefernMI ~8 SaIdIa Lab. COntract Doc.#13-8179

Johnson &Stover, Inc. Electrical Engineers

127 Taooton st. MlddIIIborough. Maaa. 02346 617-947-8464

tf

~,

massciesigh " i i

c-_. . .

~","""'I~

,38 Mt. JWbILJ> 80- 3Z27S COH~ ""-' ,YPe" .,..,.,/> '-'S

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GENERAL. ELECTRIC ... AO. IIIYI.IO"

Detded Realdentlal P.V. System

==~~ract Doc.#13-8779

Johnson & Stover, Inc. 8ectrical Engineers

127 Taunton st. Middleborough. Mass. 02346

massdesian ............2: ... '.MI.AuDumSt./~'''''',021.!lIn.'''1

Northeast Passive House P.V. Only

617-947-846'4

Figure 5-9. Array Installation Details

5-17/18

The negative leads from the first active row of shingles are connected to a single run of the triple layered negative FCC bus cable as indicated in the second step shown on Figure 5-8. are

connected

to

FCC

cable

The positive leads from the first shingle

row

row B as shown in step three of Figure 5-8.

The

positive and negative shingle leads are connected to the rows

after

nailing

the shingles in place.

horizontal

5-9.

The

cable

All electrical connections and FCC

cable terminations are covered with a two-piece insulating Figure

FCC

patch,

detailed

1n

glass portions of the shingles are secured by an adhesive on

the back surface of the module to prevent module lifting during wind conditions. Subsequent rows of shingles are attached in a similar manner.

5-10

shows

typical

array

connections

on the roof. The positive leads of the

eighth active course of shingles terminate layered

positive

busbar

identical

to

in the

a

block

shown in Figure 5-9.

FCC cable to the conventional cable. the

eighth

course

shingle

negative

positive and negative buses are dressed through the transition

Figure

run

of

the

triple

busbar connections. The

roof

to

an

AMP

supplied

This block provides the transition from

The remaining portion of

the

roof

is then covered with two courses of dummy shingles.

above Figure

5-11 shows additional details at the edges of the installation. At the completion of applied system

to has

provide been

a

shingle

installation,

weather-tight seal.

successfully

installed

gable

edge

strips

The FCC electrical interconnection at

the

Northeast

and

Residential Experiment Stations with the GE Block IV-A shingle module.

5-19

are

Southwest

Power Conversion Subsystem (PSC)

The

power

conversion

subsystem,

switchgear, provides the interface between array

and

the

with the

the

associated

residential

normal residential utility service and loads.

roof

cabling ana photovoltaic

Functionally, it

must convert the available array dc power to a usable and acceptable ac form. line commutated inverter manufactured by the Gemini Corporation and marketed Windworks,

Inc.,

of

pes with

to

the

included as Appendix A to meet the preferred control options.

The

is packaged in three units: the

control

transformer

by

Mukwonago, Wisconsin, is available in the 4 kVA range and

therefore selected for this application. sp~cification

A

circuitry.

options

are

It can be supplied

according

the inverter, dc filter and transformer, along Standard

provided

by

controls,

Gemini

to

filters encompass

and

isolation

the requirements

specified for the residential design. Procurement of the basic inverter

bridge,

desired controls, filter, and transformer from a single source is recommended to assure compatible matching of PCS components. Subsystem Requirements The

dc

to

ac conversion must be accomplished in a manner consistent

with residential electric practice. The conversion techniques should accommodate the large range of solar array electrical parameter variations load

and

utility

line

interconnections under all feedback

of

any

voltage

variations.

operational

and

and

residential

The interface must provide safe failure

modes

and

must

provide

excess array power to the utility. Equipment selection should

use proven technology to the extent available. The requirements for converting the variable dc power and voltage of a

5-20

+

--- +

Ihmnm::::::::::=~

I

!---- +

---------:== +

GENERAL. ELECTRIC .PADS DIYI.IDH

Detailed Residential P.V. System Pre_AId Designs

&ntIa lab. Contract Doc,#1:}-8779

'Johnson & Stover, Inc. Electrical Engineers

127 Taunton St.

Middleborough, Mass, 02346

617-947-8464

mas.sdesian

........... ~ ...c..

138Mt.AubllmSt.I~,""'"'-IJ2'9I/.'7"'".cJ8&1

Sheet

Northeast Passive House

P.V. Only Jobl