Path-Q Solar

How should a long cable run be accounted for when designing a ground-mounted solar array?

Answer

A long cable run should be included in the electrical design, cost, routing, and maintenance plan from the beginning. The designer must account for voltage drop, conductor size, operating voltage, overcurrent protection, trench or conduit requirements, environmental exposure, and access for repair.

Key points

  • Higher operating voltage can reduce current and may reduce voltage-drop losses, subject to equipment limits.
  • Larger conductors may reduce losses but increase material, conduit, pulling, and termination costs.
  • The route should address burial depth, drainage, physical protection, water entry, vegetation, and future access.

What it depends on

  • One-way cable distance and circuit voltage
  • Array current, conductor material, ambient conditions, and installation method
  • Allowable voltage drop and equipment operating ranges
  • Terrain, trench length, conduit, and restoration requirements
  • Local electrical and utility requirements

Risks and trade-offs

  • Undersized conductors can reduce production, cause unacceptable voltage conditions, or create heating concerns.
  • A longer route may be cheaper to install in one location but more expensive to maintain.
  • A higher-voltage design can reduce current but requires compatible equipment and appropriate safety controls.

Information you may need

  • Accurate route length and site plan
  • Array and inverter electrical specifications
  • Conductor, conduit, and burial assumptions
  • Voltage-drop calculation and installation cost
  • Applicable inspection and electrical requirements

Your next step

What to do next

Require the design package to include a voltage-drop calculation, cable schedule, route drawing, and itemized trenching or conduit allowance.

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