I'd go for using that extra module with the damaged frame. What is the frame damage going to do to the system?
Is it bad enough that the module could quit working later (bad edge seal)?
The voltage mismatch isn't the end of the world either, but your over all year round performance will be better with that extra module than not. The thing to remember is that MPP is going to vary all the time with insolation and temperature, so predicting actual performance impact from the mismatch is not just a simple calculation. I have software that can model one way or another, but it can't model the strings together, and what the inverter is going to actually do in various situations. If the module damage is just cosmetic, as they say "if you can't see it from the ground.....", while the loss in performance will be visible. To make the customer feel good, sell him the damaged module at salvage cost or just throw it in, explaining you just want the system to work well, but you don't like selling damaged goods...... We sell used stuff quite a bit, and folks actually like saving a buck when they can. I'd let the customer have the final say, then you're off the hook either way.

R.Ray Walters
CTO, Solarray, Inc
Nabcep Certified PV Installer,
Licensed Master Electrician
Solar Design Engineer
303 505-8760

On 4/28/2013 10:02 AM, Kirk Herander wrote:

Hello everyone,

I am at present adding to a -20- panel array of old Sanyo HIT "lipped" 200 watt panels. They are configured in -4- series strings of -5- panels, with a string MPP voltage of 279 vdc (55.8 v, 3.6 a each). The customer wants to add another nominal 2 kw using the (now) Panasonic 235 watt HIT's which have an MPP of 43.0 vdc, 5.5 a. I am locked in to an existing SMA 6000US inverter. Obviously I cannot get all the strings to the same voltage. But I can get relatively close by rewiring:

String 1: -7- 200 watt @ 55.8 ea. = 390.6 v MPP

String 2: same as string 1

String 3: -6- 200 watt @ 55.8 plus -1- 235 watt @ 43.0 = 377.8 v MPP

String 4: -9- 235 watt @ 43.0 = 387 v MPP

Under this scenario there is a delta of about 12 vdc between high and low MPP. I assume the entire array will operate at the 377.8 V MPP. I know that the 235 watt panel will be current limited also in string 3. Am I missing anything obvious in doing it like this? How will the inverter arrive at an operational MPP voltage?

PS. In a pinch I could install a leftover 200 watt HIT I have in the shop. That way I could have -3- strings of -7- 200's @ 390.6 v MPP, and one string of 235's @ 387v MPP. But I would prefer not to use this panel since the frame is damaged.

Kirk Herander

VT Solar, LLC

dba Vermont Solar Engineering

NABCEP^TM Certified Inaugural Certificant

NYSERDA-eligible Installer

VT RE Incentive Program Partner

802.863.1202



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