Lightning and

Surge
Protection for
PV Systems

Application Note (AU)

Phillip Tompson
 Introduction

Like all electrical equipment photovoltaic systems can be damaged by both direct and indirect
lightning strikes and other overvoltage disturbances caused by electrical switching operations, load
switching and so on.

Photovoltaic systems are designed to have an operational life of 20 or more years so the chances of
an electrical disturbance causing damage over this time can be quite high. Protection against these
disturbances will help to ensure that a long operational life is achieved.

Statistics on damage due to lightning induced overvoltages have shown that electronic installations
up to about one kilometre from the strike point may be susceptible to induced or line-carried
overvoltages1. In a region with a lightning ground flash density of just one flash per square kilometre
per year this equates to potentially 60 disturbances over a 20 year period.

For comparison a typical domestic dwelling in the same region has about 1 chance in 100 of taking a
direct lightning strike over that 20 year period. Therefore protection against indirect strikes assumes
a greater importance.

Figure 1 shows the ground flash density in Australia, reproduced from AS1768-2007. Ground flash
density varies from 0.5 to over 8 flashes per square kilometre per year throughout Australia.

Figure 1. Australia ground flash density from AS1768-2007

This application note applies specifically to grid connect PV systems but the general principles are
equally applicable to remote area standalone PV systems. Remote area systems are obviously not
prone to line carried overvoltages but comments about induction due to remote lightning strikes
equally apply.

Novaris Pty Ltd Page 2 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
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 Sources of Lightning Damage

Equipment may be damaged by either direct lightning strikes to the structure, direct lightning strikes
to the power line or from indirect strikes caused by cloud to ground or cloud to cloud strikes. These
latter events cause induction and earth potential rises. It should be noted that transient electrical
disturbances similar to lightning may be caused by power switching operations and power line
faults.

Figure 2. Sources of Lightning Damage

Protection Options

This application note follows the recommendations for lightning and surge protection set out in
AS/NZS1768-2007. There are two options to be considered before lightning and surge protection is
applied. Depending upon whether the building has an external lightning protection system (LPS) will
determine the choice and placement of surge protection devices (SPDs).

Novaris Pty Ltd Page 3 72 Browns Rd, Kingston

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 (a) Building without external LPS

This is by far the most common case where a building has no external LPS and so the risk of a direct
lightning strike is not considered. Figure 3 shows a building with roof mounted solar array and
inverter mounted near the main switchboard. Normally the inverter would be mounted close to the
main switchboard and in a location that is readily accessible, in accordance with AS/NZS5033.

Figure 3. Building without LPS

Protection in this case is required only against indirect lightning. The following is necessary to
provide effective protection:

1. The DC cable to the inverter and 4mm2 earth conductor must be run in the same conduit.
2. Install an SPD on the DC input to the inverter (SPD1 in figure 2). This SPD must be specifically
designed for DC PV applications. AC SPDs are unsuitable and could present a hazard under
fault conditions. A rating of Imax = 10kA is suitable.
3. Install an SPD on the AC output of the inverter (SPD2 in figure 2). Whilst a shunt type surge
diverter is suitable more effective protection can be obtained by using a series connected
shunt diverter, like the Novaris SSP, which eliminates the detrimental effects of lead
inductance. A rating of Imax = 10kA is suitable.
4. The protective earths of the SPDs and the frame earth of the inverter must be bonded
together and in turn connected to the main earth bar as in figure 2. 4mm2cable is suitable.
5. Install an SPD on the incoming AC supply in the main switchboard (SPD3 in figure 2). A rating
of Imax = 40kA is suitable.

Novaris Pty Ltd Page 4 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
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 2 2
Note: Many twin and earth AC cables of less than 10mm contain an earth conductor less than 4mm .
An extra earth conductor should be added. Run this in the same conduit as the twin and earth cable.

If the length of cable from the inverter to the switchboard is only one or two meters, SPD2 may be
omitted and SPD3 provides primary protection for the switchboard and inverter.

By far the vast majority of installations can be successfully protected using this approach.

(b) Building with external LPS

Figure 4 shows a building with an external lightning protection system (LPS). In accordance with
AS/NZS1768-2007 the solar array frame must be bonded to the LPS. In this case the solar array
frame and its earthing conductor form part of the LPS. Thus partial lightning current will flow in the
array bonding and earthing conductors. These must be sized accordingly and 35mm2 is
recommended in AS/NZS1768-2007.

Figure 4. Building with LPS.

The following is recommended:

1. Bond the solar array frame to the LPS using 35mm2 cable.
2. Install an SPD at the solar array (SPD4 in figure 3). This SPD must be specifically designed for
DC PV applications. AC SPDs are unsuitable and could present a hazard under fault

Novaris Pty Ltd Page 5 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
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 conditions. A rating of Imax = 40kA is suitable. Connect the protective earth of the SPD to the
solar array frame.
3. The DC cable to the inverter and 4mm2 earth conductor must be run in the same conduit.
4. Install an SPD on the DC input to the inverter (SPD1 in figure 3). This SPD must be specifically
designed for DC PV applications. AC SPDs are unsuitable and could present a hazard under
fault conditions. A rating of Imax = 40kA is suitable.
5. Install an SPD on the AC output of the inverter (SPD2 in figure 3). Whilst a shunt type surge
diverter is suitable more effective protection can be obtained by using a series connected
shunt diverter, which eliminates the detrimental effects of lead inductance. A rating of Imax =
40kA is suitable.
6. The protective earths of the SPDs and the frame earth of the inverter shall be bonded
together and in turn connected to the main earth bar via the main switchboard as in figure
3. 4mm2 cable is suitable.
2 2
Note: Many twin and earth AC cables of less than 10mm contain an earth conductor less than 4mm .
An extra earth conductor should be added. Run this in the same conduit as the twin and earth cable.

7. Install an SPD on the incoming AC supply in the main switchboard (SPD3 in figure 3). A rating
of Imax = 100kA is suitable.

If the length of cable from the inverter to the switchboard is only one or two meters, SPD2 may be
omitted and SPD3 provides primary protection for the switchboard and inverter.

If the length of cable from the solar panel array to the inverter or from the inverter to the
switchboard containing SPD3 is greater than 40m higher surge ratings for SPD1, SPD2 and SPD4
should be considered. 80kA is suitable.

(c) Other Considerations

The above examples serve as a basis for most installations. Where a multi string array is installed,
multiple DC SPDs will be required depending upon the configuration. Where the solar array is
located remote from the building housing the inverter, SPDs will be required at each string and at
the inverter.

If the array and inverter system contain monitoring instruments such a temperature, insolation,
wind etc. surge protection will be required for these as well. The Novaris application note on PLC
and SCADA (Document no. 0015-D17V3) provides detail on this protection.

SPD Selection

(a) SPD for DC PV

The SPD for the DC input to the inverter and solar array must be designed specifically for DC
application. AC SPDs are not suitable because upon failure their disconnect circuitry may not quench
the arc. AC SPDs rely upon a voltage zero crossing to quench the arc. This does not occur with DC. So
the arc may persist, with the attendant hazard of fire.

Novaris Pty Ltd Page 6 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
sales@novaris.com.au Document No: 0015-D29V2 (AU) Fax +613 6229 9245
 At the time of writing this document (early 2013) there exists only one standard relevant to the
testing and performance of DC SPDs for PV application. This is prEN50539-11. All Novaris DC PV SPDs
comply with this standard. The configuration is shown in figure 5, comprising all mode protection
and equal let through voltage, Up, from each line to earth and line to line.

Figure 5. DC PV Configuration

The voltage clamping components are ZnO varistors. These are fitted with thermal disconnects and
an arc quenching DC fuse.

Due to the characteristics of PV panels, over current fusing of DC PV SPDs is ineffective. The short
circuit current from a typical PV string is limited and so an SPD fault even to a short circuit may not
cause the fuse to trip. Figure 6 shows the typical characteristic of a solar panel. The short circuit
current is very close to the maximum power point current. It is important to choose a DC PV SPD
with a short circuit withstand current, ISCWPV, greater than the short circuit current of the solar array
string, ISCPV, to which the SPD is connected.

Figure 6. Typical solar panel characteristic (Sunpower E19/425)

Figure 7 provides a specification summary for the Novaris DC PV SPDs.

Novaris Pty Ltd Page 7 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
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 Model UCPV Imax In Iscwpv Up
SDPV-40-600 600V 40kA 20kA 63A <2000V
SDPV-40-1000 1000V 40kA 20kA 63A <3000V

Figure 7. Novaris DC PV SPDs

UCPV Maximum continuous operating voltage

Imax Maximum discharge current (8/20us)
In Nominal discharge current (8/20us)
ISCWPV Short-circuit withstand
Up Voltage protection level (in accordance with AS/NZS1768-2007)

Figure 8. Novaris DC PV SPD, model SDPV-40-600

(b) SPD for AC

SPDs for AC protection may be either SDD, surge diverters or SSP, series surge protectors. Figure 8
summarises some of the options.

Model Uc IL Imax In ISCCR Up

SDD1-50-275 275V 50kA 20kA 25kA <800V
SDD3-50-275 275V 50kA 20kA 25kA <800V
SDD1-100-275 275V 100kA 40kA 50kA <800V
SDD3-100-275 275V 100kA 40kA 50kA <800V
SSP1-20-50-275 275V 20A 50kA 20kA 25kA <800V
SSP1-32-50-275 275V 32A 50kA 20kA 25kA <800V
SSP1-63-50-275 275V 63A 50kA 20kA 25kA <800V

Figure 9. Novaris AC SPDs

UC Maximum continuous operating voltage

IL Maximum load current
Imax Maximum discharge current (8/20us)
In Nominal discharge current (8/20us)
ISCCR Short-circuit current rating
Up Voltage protection level (in accordance with AS/NZS1768-2007)

Novaris Pty Ltd Page 8 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
sales@novaris.com.au Document No: 0015-D29V2 (AU) Fax +613 6229 9245
 Figure 10. Novaris AC SPDs SDD1-50-275 & SDD3-100-275

References

1. Overvoltage Protection of Low Voltage Systems. P. Hasse IEE Power Series 12

2. IEC62305-3. Protection against lightning – Part 3: Physical damage to structures and life hazard
3. IEC62305-4. Protection against lightning – Part 4: Electrical and electronic systems within structures
4. IEC61643-11. Low voltage surge protective devices – Part 11: Requirements and test methods
5. IEC61643-12. Low voltage surge protective devices – Part 12: Selection and application principles
6. prEN50539-11. Low voltage surge protective devices – Part 11: Requirements and tests for SPDs in photovoltaic
applications
7. AS/NZS1768-2007. Lightning Protection.
8. AS/NZS5033-2012. Installation and safety requirements for photovoltaic (PV) arrays.

Novaris Pty Ltd Page 9 72 Browns Rd, Kingston

33 061 301 88 TAS, AUSTRALIA 7050
novaris.com.au Tel +613 6229 7233
sales@novaris.com.au Document No: 0015-D29V2 (AU) Fax +613 6229 9245