FEATURED TOPIC

String Monitoring Unit for Megawatt Solar Power Plants

Tetsuo GOTO*, Yuuki MORISHITA, Masayuki TAKE, Yoshihisa ASAO,

Takefumi SHIMOGUCHI and Tomohisa MATSUSHITA

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While an increasing number of megawatt solar power plants have been constructed, some of them have already been facing
problems with degradation in power output due to initial failures, aging solar panels, or external factors. We have developed a
string monitoring unit that uses the power line communication (PLC) technology. These units monitor individual strings of hundreds
of thousands of solar panels in real time without the need for wiring additional cables. We installed the units at a megawatt solar
power plant, and successfully detected irregularities in power generation by analyzing data collected from the units.
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Keywords: megawatt solar, PLC, string, power conditioning system

1. Introduction
Solar power generation systems have been drawing Network

the attention of the public, as a source of renewable energy. DC cable

Host system

Moreover, in Japan, the systems began to spread rapidly in 600VDC~1KVDC

2012 when the feed-in tariff scheme for renewable energy Solar panels
Combiner box
was replaced by the full amount purchase scheme. Since DC current
sensor
/ AC
output

then, there has been an increase in the construction of

megawatt solar power plants (output: 1 MW or more). Junction box Power conditioning
system (PCS)

These solar power plants consist of a large number of

solar panels. The solar panels are mainly affected by initial
failures, aging solar panels, or external factors. Moreover, Solar panels

this results in a decrease in the power generation amount Combiner box

10 to 20 panels are connected in series per string. Up
String
monitoring Repeater
Data
collection

(hence, a decrease in the amount of electricity sold). It to 20 strings are connected in parallel, and the lines are
concentrated to a combiner box.
terminal unit device

should be noted that it is quite difficult to identify the failed

solar panels based solely on a decrease in the total power Fig. 1. Configuration of the string monitoring system
generation amount. This is because a megawatt solar power
plant consists of thousands of solar panels, and sometimes
hundreds of thousands of them.
We developed a string monitoring unit (SSMAP) that five years after the commencement of their operation.(1) To
can monitor the measurement of the power generation maintain stable power generation for a long period of time,
amount for each string accurately, on a real-time basis, using defects should be identified quickly for replacement or repair.
a power line communication (PLC). Each string consists of Theoretically, a solar panel failure can be detected by
about 1020 solar panels connected in series. Furthermore, monitoring the power generation amount at a PCS,
the string monitoring unit can be retrofitted easily. combiner box, string, or panel. Regarding the monitoring
This paper reports the characteristics and specifica- at a PCS or combiner box, the failure of some solar panels
tions of the string monitoring unit, and the results of the gives little changes in the power generation amount, which
analysis of power generation data obtained by the system. cannot be distinguished from changes due to weather
conditions. Therefore, it is difficult to detect a failure.
Regarding the monitoring at a panel, the larger the scale of
the megawatt solar power plant, the higher the cost
2. Overview and Characteristics of a PLC String
required to introduce the system.
Monitoring Unit
Regarding the monitoring at a string, a decrease in the
2-1 Monitoring by string power generation amount due to a solar panel failure, can
Figure 1 shows the configuration of a megawatt solar be detected quickly. The unit can be introduced inexpen-
power plant, equipped with the string monitoring unit. sively, when compared with the system required for moni-
At megawatt solar power plants, strings are integrated toring at a panel. Consequently, string monitoring is highly
by a combiner box, which is then connected to a power effective in the detection of solar panel failures.
conditioning system (PCS). The electricity generated by 2-2 Characteristics of a PLC string monitoring unit
the panels is converted to AC power by the PCS, for Figure 2 shows the mechanism of PLC-based signal
connection to the power distribution system. transmission.
According to a survey conducted by the National The string data measured at a combiner box is trans-
Institute of Advanced Industrial Science and Technology mitted via a PLC that uses an existing DC cable (600
(AIST), about 2% of solar panels become defective within VDC1kVDC) as a communication line. Thus, a new

SEI TECHNICAL REVIEW NUMBER 84 APRIL 2017 41

 sure, to enable a PLC connection with up to 30 string
monitoring terminal units. The data collected by the
terminal units can be transmitted to a host system via
Modbus (an industry standard). The data can also be trans-
mitted using HTTP or HTTPS, which are typical protocols
for web server communication.
To collect the string data using PLCs, the network IDs
and individual IDs must be set to the terminal units. To
ensure operational convenience, we built mechanism to
simultaneously set the IDs to all the terminal units
(installed in the combiner boxes), via PLCs from the data
collection device. By so doing, the need to set the IDs to
Fig. 2. Mechanism of PLC-based signal transmission
terminal units separately was eliminated.
3-2 String monitoring terminal units
The main specifications of the string monitoring
terminal units are shown in Table 2.
communication line is not required, resulting in a low
initial cost.
A kHz-band PLC technology was adopted for the Table 2. Main specifications of a string monitoring terminal unit
string monitoring unit, because it is used for smart meter Item Specifications
system(2), and is applicable both indoors and outdoors; it is 1ch up to 1,000 V,
also resistant to the noise generated by PCSs, thus ensuring String voltage
accuracy 5% (1,000 V, 25C)
stable communication. Monitoring items 20 ch 15 A, accuracy 5%
String current
A string monitoring terminal unit is installed inside a (15 A, 25C)
combiner box or near a combiner box, in order to measure Digital signal 1 ch (input)
the currents and voltages of the strings. The data measured Measurement cycle Every minute
by a string monitoring terminal unit is transmitted by PLC Current sensor
Clamp type or Through type with hall
to a data collection device (installed near DC input of the element

PCS), and then to a host system via the Internet. The elec- Power consumption 20 W or less
tricity generated by the solar panels is supplied to the Main unit
W 35 D 117 H 223 mm
(excluding protrusions)
terminal unit, eliminating the need for an additional power
line for the terminal unit. The string monitoring unit can be Dimensions Clamp type: W 26 D 27 H 38 mm
Through type:
Sensor
easily retrofit to existing megawatt solar power plants in W 29 D 46 H 24 mm
(excluding protrusions for both types)
operation, by using clamp type DC current sensors.
In the combiner box (IP44 or more),
Installation location
etc.

3. Specifications of the PLC-based String

Monitoring Unit
The string monitoring terminal units are powered by
3-1 Data collection device electricity generated from the solar panels. We made
The main specifications of the data collection device arrangements to achieve operation using a voltage lower
are shown in Table 1. than the PCS start-up voltage, in order to cope with signifi-
The data collection device is installed in a PCS enclo- cant voltage changes and ensure stable system operation.
Given the increasing use of 20 string combiner boxes in
recent years, we made arrangements to measure the
Table 1. Main specifications of the data collection device currents of up to 20 strings. We also reduced the width to
35 mm, and the overall volume by 40% (compared with
Item Specifications
our conventional product). This allowed the terminal units
Communication interface to a host system Ethernet (100BASE-TX) to be easily retrofit to the small combiner boxes at existing
Operates as a Modbus slave to power stations in operation.
Modbus provide data based on a sequence
Communication
protocol to a host from a host system 3-3 How to install a string monitoring system
system Transmits the obtained data to a Figure 3 shows the configuration of the string moni-
HTTP/HTTPs
host system using HTTP or HTTPS toring system in (a) a low-voltage system and (b) a high-
Number of string monitoring terminal units Up to 30 units per data collection voltage system. At the most basic level, a string monitoring
supported device
terminal unit is installed in a combiner box, and a data
Power consumption 3 W or less collection device is installed in a PCS.
Main unit: It should be noted that the low-voltage and high-
W 150 D 150 H 43 mm
Dimensions Coupler: voltage systems require different repeater installation
W 102 D 152 H 82 mm configurations, due to the difference in the line concentra-
(excluding protrusions)
tion configuration from a combiner box to a PCS. In low-
Installation location In the PCS enclosure, etc.
voltage systems, a junction box is installed between a PCS

42 String Monitoring Unit for Megawatt Solar Power Plants

 PCS PCS

DC/AC AC DC/AC AC
Unit output Unit output

Data Breaker Data Breaker A Breaker B

collection collection Repeater
device device
Input terminal Input terminal A Input terminal B

Combiner box Combiner box

Junction box Junction box
String monitoring String monitoring
Repeater Repeater terminal unit terminal unit

Combiner box Combiner box

Combiner box Combiner box String monitoring String monitoring
String monitoring String monitoring terminal unit terminal unit
terminal unit terminal unit

Combiner box Combiner box

Combiner box Combiner box String monitoring String monitoring
String monitoring String monitoring terminal unit terminal unit
terminal unit terminal unit

(a) Low-voltage system (600 V) (b) High-voltage system (1000 V)

Fig. 3. Installation configuration of string monitoring systems (high and low-voltage systems)

4. Results of Introducing a String Monitoring

and a combiner box in many cases; and the input terminals
System, a Case Study, and
in the PCS are integrated into a single unit. Moreover, in
Monitoring Data
high-voltage systems, no junction box is installed between
a PCS and a combiner box; and the PCS has multiple input 4-1 Results of introducing a string monitoring system
terminals. The PLC signals from a string monitoring Our string monitoring system has been employed at
terminal unit (which is directly connected to input terminal about 30 power stations with capacities that range from
B) are attenuated when they pass through the DC/AC 1-15 MW (about 150 MW in total).
conversion unit of the PCS. Furthermore, because different A string monitoring terminal unit is installed in the
PCSs generate different levels of noise, the data can be free space inside a combiner box (see Fig. 4). A clamp type
collected stably using a PLC, by installing a repeater in a current sensor is installed on each string in the combiner
junction box or PCS input terminal B. box. Repeaters are installed in the junction boxes or PCS
Table 3 shows the specifications of a PLC-based input terminals, to ensure stable communication.
string monitoring system. A data collection device is installed in the free space
The frequency band that is used for a low-frequency inside the PCS enclosure, etc. (see Photo 1). After the
PLC (applicable both indoors and outdoors) was used in installation, the string data is collected from the terminals
compliance with the Radio law. To improve the robustness every minute.
against noise, a spread spectrum system was adopted.
There are two selectable data transmission speeds,
depending on the noise condition.

Table 3. Specifications of a PLC-based string monitoring unit

Current sensor
Item Details
Frequency range used 120-400 kHz
Communication speed 1.25 kbit/s, 5.0 kbit/s (subject to change depending on
the modulation mode)
Modulation Spread spectrum

String monitoring terminal unit

Fig. 4. String monitoring terminal unit installation status

SEI TECHNICAL REVIEW NUMBER 84 APRIL 2017 43

 3.0

String power generation amount (kW)

2.5
String 1

String 2
2.0
String 3

String 4
PCS enclosure (on the left), installation status in the PCS (on the right) 1.5
String 5

String 6

Photo 1. Data collection device installation status 1.0 String 7

String 8

String 9
0.5
String 10

4-2 A case study and monitoring data 0.0

Table 4 and Photo 2 show a 1 MW solar power station

where our string monitoring system was introduced. (a) April 22, 2015

3.0

Table 4. Configuration of a 1 MW solar power plant

String power generation amount (Kw)

2.5

Item Configuration details String 1

String 2
Generation power 1 MW 2.0
String 3
PCS 500 kW x 2 String 4
1.5
Number of junction box 4 String 5

String 6
Number of combiner box 32
1.0 String 7
Number of strings 314 String 8

0.5 String 9

String 10

0.0

(b) December 18, 2015 (about seven months later)

Fig. 5. Changes in the power generation amount of the strings during the day

found to be lower than that of others, in the morning and

evening (see Fig. 6). An on-site survey of the solar panels
of these strings found that the solar panels were slightly
covered by the shade of trees (see Photo 3). It should be
noted that the string monitoring unit can detect a decrease
in the power generation amount due to solar panels being
slightly covered by the small shade of trees.

Photo 2. Overview of a 1 MW solar power plant

The power generation amount was found to have
3.0 decreased at multiple strings connected to the
same combiner box.
String pwer generation amount (kW)

2.5
We verified the operational status of the monitoring String 1

system and solar power plant, using the string data during 2.0
String 2

the 13-month period from January 2015 to January 2016. String 3

String 4
Figure 5 (a) shows the changes in the power generation 1.5
String 5
amount of 10 strings measured at a combiner box on April String 6

22, 2015. It was confirmed that all 10 strings generated elec- 1.0 String 7

tricity at almost the same level. Figure 5 (b) shows the power String 8

String 9
generation amount of the strings at the same combiner box, 0.5
String 10
measured on December 18, 2015 (about seven months later).
0.0
The power generation amount of one string was found to
have decreased. Based on an on-site survey, no external
factors (e.g. shade of trees and fouling) affecting this string
Fig. 6. Changes in the power generation amount of the strings during the day
were found. It is likely that a problem occurred.
The power generation amounts of several strings were

44 String Monitoring Unit for Megawatt Solar Power Plants

 monitoring of combiner boxes.
Table 5 shows the analysis results of the power gener-
ation amount (with respect to time slots), of strings at
which a decrease in the power generation amount was
detected in January 2015, June 2015, and January 2016.
In the three time slots (8:00-10:00, 10:00-14:00,
14:00-17:00), we compared the mean power generation
amount of 314 strings in total, with the power generation
amounts of the respective strings. We calculated the rate of
strings with power generation amounts that were lower
than the mean power generation amount by 10% or more
(314 strings in total, on the left side of the Table 5).
Moreover, we also calculated the mean decrease rate of the
power generation amounts, of strings that experienced a
decrease in power generation (on the right side of Table 5).

Photo 3. Shade of trees on panels

Table 5. Decrease in the string power generation amount

Mean decrease rate of the power

Rate of strings whose power
generation amount of strings
generation amount decreased 10%
Period whose power generation decreased
Next, we used the string data to compare the power or more (314 strings in total)
(indicated on the left)
generation amount monitored at a combiner box (the total 8:0010:00 10:0014:00 14:0017:00 8:0017:00 8:0010:00 10:0014:00 14:0017:00 8:0017:00
January
string data in a combiner box), with the power generation 2015
11.8% 2.2% 6.1% 2.9% 22.0% 26.0% 19.0% 22.0%
amount monitored at a string. June
4.5% 1.3% 3.2% 2.2% 16.0% 22.0% 33.0% 25.0%
The bar chart in Fig. 7 shows the total power genera- 2015
January
tion amount at a combiner box, normalized with respect to 2016
15.0% 2.5% 9.6% 4.5% 26.0% 28.0% 22.0% 22.0%
the mean value of the power generation amount at all the
combiner boxes connected to the same PCS, in the time
series.
The line chart in Fig. 7 shows the power generation The data enabled the analysis discussed below. The
amount at each string connected to a combiner box, maintainability can be improved by the implementation of
normalized with respect to the mean value of the power the string monitoring unit.
generation amount at all the strings connected to the same (1) The power generation amount in many strings
PCS, in the time series. The monthly value was calculated decreased by 10% or more from the mean power
based on the value on the day in the month when the daily generation amount of the 314 strings in total. This
power generation amount was highest. occurred more readily in the time slots of 8:00-
In the bar chart that shows the comparison by 10:00 and 14:00-17:00, than in the time slot of
combiner boxes, the power generation amount ratio is 10:00-14:00. Moreover, it is attributed to the influ-
almost equivalent to the mean value (power generation ence of the shade of trees, etc. in the morning and
amount ratio 1.0). In the line chart that shows the evening.
comparison by strings, the power generation amount ratio (2) We calculated the decrease rate of strings whose
of a single string is far below the mean value. That is, power generation amount decreased by 10% or
string monitoring can detect a slight decrease in the power more and the mean power generation decrease
generation amount, which cannot be detected with the rate. We compared the results in January 2015
with those in January 2016. The table shows that
both rates increased. Although the influence of
1.10 Combiner box shade remains relatively the same, both rates
String 1
increased in the same month in the following year.
1.05
String 2
The power generation amount is considered to
Power generation amount ratio

String 3
have decreased for some reason.
1.00

String 4

0.95
String 5

0.90
String 6 4. Conclusion
String 7
A string monitoring unit can detect a slight decrease
0.85
String 8
in the power generation amount, prior to the occurrence of a
0.80
String 9 significant decrease. This makes it possible to detect a failure
String 10 quickly. In Japan, the amount of solar power plants equipped
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Fig. 7. Mean power generation amount ratio for strings and combiner boxes to be overlooked, resulting in a loss of electricity sales.

SEI TECHNICAL REVIEW NUMBER 84 APRIL 2017 45

 A PLC-based string monitoring unit does not require a
new communication line or power line, and can be easily Contributors The lead author is indicated by an asterisk (*).
retrofit to existing power plants in operation. It is therefore
considered an effective means to check and maintain the T. GOTO*
soundness of power plants, and to reduce the loss of elec- Assistant Manager, Power Systems R&D Center
tricity sales. Moreover, it is expected to be sold in markets
outside Japan, where string monitoring units have been
widely introduced.

Y. MORISHITA
SSMAP is a trademark or registered trademark of Sumitomo Electric Indus- Power Systems R&D Center
tries, Ltd.
Modbus is a trademark or registered trademark of Schneider Electric USA Inc.

M. TAKE
References Assistant Manager, Power Systems R&D Center
(1) K. Kato, Deficient example file of the PV system, Nikkan Kogyo
Shinbun, Ltd., pp. 134-136 (2010)
(2) O. Ogawa, K. Takeshita, Trends of kHz-band power line communications
and technical issues for demand-area communication networks, Central
Research Institute of Electric Power Industry, pp. 1 (2011)
Y. ASAO
Group Manager, Power Systems R&D Center

T. SHIMOGUCHI
Department Manager, Power Systems R&D Center

T. MATSUSHITA
Group Manager, Energy System Division

46 String Monitoring Unit for Megawatt Solar Power Plants