Solis Partners: LPS Industries

LPS Industries, a flexible packaging manufacturer in Moonachie, New Jersey, selected Solis Partners to install what was the largest Solyndra thin-film PV array in the US at the time of commissioning. A new white TPO roof, an integral part of the cylindrical CIGS PV system, was installed just prior to the array to enhance the reflected light available to the panels.

Initially, the roof was capable of accommodating less than 2 additional pounds per square foot of distributed loads. To help overcome this, Solis reinforced the main roofing beams to support up to 4 pounds per square foot. Solyndra panels proved to be the best match for the roof as the total system added approximately 3 pounds per square foot on a distributed basis.

Solyndra provides a racking system specifically designed for its panels that utilizes cable trays to help facilitate proper wire management. In addition, the Solyndra panels include both male and female positive and negative output conductors on each panel. Solis took advantage of the low current output in relation to the maximum series fuse rating and placed as many as three strings in parallel before connecting to a combiner box. This reduced the overall number of source circuits and associated wiring and overcurrent protection devices.

“Because the LPS facility is located in a high-wind zone rated at 110 mph, a flat-panel PV system would have required significant ballast or roof penetrations that would have been unfeasible or cost prohibitive. The Solyndra system required only minimal structural reinforcement and allowed us to move forward with the project without impacting the integrity of the building or day-to-day operations at LPS.”

Rick Surgent, Solis Partners

Overview

DESIGNER: Nickolai Cowell, design lead, Solis Partners, solisllc.com
LEAD INSTALLER: Rick Surgent, senior project manager, Solis Partners
DATE COMMISSIONED: June 2010
INSTALLATION TIME FRAME: 55 days
LOCATION: Moonachie, NJ, 40.8°N
AVERAGE SOLAR RESOURCE: 3.9 kWh/m2/day
RECORD LOW/AVERAGE HIGH TEMPERATURE: -15°F/84°F
ARRAY CAPACITY: 704.3 kW
AVERAGE ANNUAL AC PRODUCTION: 810 MWh

Equipment Specifications

PANELS: 3,870 Solyndra SL-001-182, 182 W STC, +4%/-4%, 2.46 Imp, 73.9 Vmp, 2.76 Isc, 96.7 Voc
INVERTERS: 3-phase, 480 Vac service, two PV Powered PVP260KW-LV, 260 kW each, 600 Vdc maximum input, 265–500 Vdc MPPT range
ARRAY: Five panels per source circuit (910 W, 2.46 Imp, 369.5 Vmp, 2.76 Isc, 483.5 Voc), typical combiner box input circuit consists of three paralleled source circuits (2,730 W, 7.38 Imp, 369.5 Vmp, 8.28 Isc, 483.5 Voc); 387 total source circuits per inverter (352.17 kW, 952 Imp, 369.5 Vmp, 1,068 Isc, 483.5 Voc); PV output circuits are connected to one 225 A and five 300 A fuses in the inverter’s integrated subcombiner
ARRAY COMBINER: 12 custom SolarBOS 24-input disconnecting combiners, 15 A fuses
ARRAY INSTALLATION: Solyndra mounts on a white TPO membrane, 218° azimuth, 0° tilt
SYSTEM MONITORING: Energy Recommerce REC Track 3

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