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⚡Designing Solar Systems That Endure

• Solar energy is evolving rapidly, and staying relevant requires ongoing learning and technical insight.

• 50V battery systems with basic inverters remain viable and cost-effective—if designed with thermal and fault-level expertise.

• Temperature is a critical factor: Excess current on hot days can dangerously raise temperatures in electronics, cables, and switchgear.

• Key design considerations:

  • Ambient vs design temperature

  • Copper cable thermal characteristics

  • Fast-acting protection devices matched to fault levels

  • Seasonal derating and I²t fault current analysis

• Real-world example: A 6kW inverter limited to 20A performs reliably in Johannesburg, but hotter regions require stricter limits.

• High-voltage systems face similar risks, especially from inrush currents and inadequate resistance in supply lines.

• Conclusion: Reliable solar systems demand deep understanding of electrical physics—not just component selection.

For smarter, safer solar solutions, visit AlwaysON Energy.

Let me know if you'd like this adapted into a flyer, blog post, or client pitch.

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Comparison to determine whether oversizing PV or up sizing the Inverter is the

better choice.

Scenario Overview

The following analysis is based on full sunlight assumption and economy comparison:

• a system with 16 × 600 W panels (totalling 9.6 kW), with optimal sunlight conditions and all generated energy fully utilized for

•  battery charging and self-consumption.

1. The goal is to evaluate whether oversizing the PV array and or rather upgrading the inverter, makes economic sense.

• PV Array Size 9.6 kW (16 × 600 W panels)

• Inverter Capacity 6 kW & 10 kW

• Average Peak Sun Hours ~5.5 hours (SA average)

• Maximum Daily PV Output - 9.6 kW × 5.5 h = 52.8 kWh

• 6kW Inverter Limitation -limits output to 6 kWh per hour in peak hours

• 10kW Inverter output cap is the PV kWh - up to 9.6 kWh per hour in peak hours

Energy Yields Over 30 Days

Actual Daily Output

• 6kW Inverter Limited to ~45–48 kWh*

• 10kW Inverter Full ~52.8 kWh

• Monthly Output (30 days) 6kW Inverter ~1,350–1,440 kWh

• Monthly Output (30 days) 10kW Inverter~1,584 kWh

• Energy Loss from Clipping on 6kW system-~7 kWh/day - 210kWh per 30 days.

• Energy Loss from Clipping on 10kW system-~None

*The actual output is lower due to "clipping" at peak hours; the extent depends on load and sunlight patterns.

Key Insights

• Since both systems use the same PV array, their generation potential is identical.

• The 6kW inverter restricts output during peak sunlight, leading to about 10–15% energy loss over a month.

• The 10kW inverter can harvest the full output from the array, maximizing energy yield.

• If the demand matches the full daily production, the larger inverter is the better fit.

Design Recommendations

• A 6kW inverter is more economical but sacrifices some energy during peak generation.

• A 10kW inverter enables full energy utilization, making it ideal for high-consumption needs or battery-heavy setups.