HOW TO There’s, perhaps, never been a better time to

invest in solar energy. The sector is booming,

OPTIMIZE
fueled by tax incentives, advanced technology,
and significantly lower prices. In fact, the cost to
install solar has dropped by more than 70% over
the last decade.

SOLAR BOS According to the Solar Energy Industries

Association (SEIA)*, an average-sized
residential system has decreased from $40,000
for value and efficiency in 2010 to about $20,000 (or less) today, while
utility-scale costs range from $16 to $35/MWh
— making it competitive with all other forms of
power generation.

Despite it being a pandemic year, America hit 10

GW of utility-scale solar commercial operation
in 2020, with little sign of slowing down.

“The technology for solar modules has

improved drastically and the demand in the
marketplace has become much stronger,”
explains Dan Jungels, Business Development –
Alternative Energy Strategy Leader, with Panduit.
Panduit is a top U.S. provider of balance-of-
system (BOS) components for the solar industry.
“In the early days of solar installations, it was
likely only done for environmental reasons.
There were little, if any, cost benefits. But that’s
changed significantly, especially in the last

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few years.”today, solar developers can expect higher capacity factors
with lower capital costs, including reduced maintenance and operating
expenses and increased project lifespans. This has led to improved
financing terms and better returns on investment, thanks to a lower
levelized cost of solar-derived electricity.

“The effectiveness and the efficiency of the solar modules have come a
long way. And by nature, the prices have dropped, as well,” says Jungels.

However, the photovoltaic modules or panels are just part of a complete

solar system. They’re responsible for absorbing sunlight and turning
it into DC power or voltage. For that electricity to be consumable,
additional components are required to convert it to usable AC power.
This is where the BOS components provide an important role.

What does the balance-of-systems include?

Most often, BOS refers to all of the components of a PV system other

than the solar modules and their racking or tracking system.

“The definition of what consists of the balance-of-systems is somewhat

debatable in the industry. It does not include the modules but, for us,
we also exclude major equipment such as the inverters and medium-
voltage transformers.” Jungels says those are expensive, large
equipment purchases that deal with the electricity management of the
panels, which makes them unique.

“The balance-of-systems are all of the other devices that move the
DC energy produced by the panels to the inverter to the power storage
substation, which can then be used by the grid. We typically refer
to these components as the management or cable-management
solutions,” he says.

These products include the cables, wires, clips, switches, connectors,

tubing, and all of the devices that convert the DC to AC power, ensuring
the electricity ultimately gets to the power station and the grid. This
typically also includes enclosures, such as the combiner boxes that
protect electrical connectors, and the software that integrates the
components and monitors the entire solar project.

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What’s interesting is how BOS affects the project costs. They’re
typically the most costly part of a solar system.

“As module prices have come down, a project’s expense has leaned
more heavily toward components that support the panels — which is
the balance-of-systems,” says Jungels.

Whereas once the solar modules and racking system could measure
closely in cost to the BOS, this is no longer the case now that the
module costs are dropping so rapidly.

“Imagine two products are $1 each and, together, they form a system
that costs $2. Then, over time, the first product drops in price and now
only costs half of what it used to. That’s great news,” he says. “The
entire system is now only $1.50. But what makes up that $1.50 has
shifted and weighs far more heavily on the second product…and, in
this case, that’s what happened with the BOS.”

There are valid reasons why the balance-of-system costs have not
followed the lead of solar modules in terms of price decreases. For
one, there’s only so much technological advancement available to
cables and wires.

“These items are commodity-driven and dependent on the materials

used,” he shares. “BOS components rely on plastics or resins, and
copper or steel, which are at the mercy of inflation and the market. It’s
difficult to keep those costs flat and there’s not a lot of technological
improvements that drive those prices down.”

Certainly, good manufacturers will find a way to offer cost-effective

products. But it’s also important to keep in mind that you get what
you pay for. And the components that support electricity and the
conversion of DC to AC power are simply not worth compromising in
terms of quality.

“Supply chain issues can also cause price increases, as we’ve seen in
this last year,” he adds. “Nevertheless, most manufacturers do seek
opportunities for savings that they can pass onto their customers. But
for balance-of-system components, this requires a broader approach
and one that focuses on the functionality of the products.”

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 Where are the opportunities for cost savings?

If it’s not possible to decrease the material or manufacturing costs of a

product, there are sometimes other ways to increase value.

“Product availability and quality are two key differentiators to project

managers and EPC contractors in the industry,” says Jungels. And
this is particularly true when supply chains are delayed. “However,
improvements and cost-savings can also be met through product
efficiencies.”

Imagine a 2,000+acre or more utility-scale solar

site. The sheer number of BOS components requiring
installation is typically anything but efficient. Such
projects rely on thousands of cable ties and clips
alone, which require manpower and time. Panduit offers a
complete selection
of cable-tie
“Products that offer installations efficiencies, and
styles, sizes, and
fewer or more proficient tools, can save tremendous materials to meet
customer needs.
labor costs — and ergonomics. Repeatedly installing
ties by hand on one site, let alone on several solar
sites, can lead to overuse issues,” he says. “So, simplifying BOS-related
installation can save on the overall project costs.”
Panduit BlackFin™ Installation
Tools lead the industry in As most utility-scale solar sites are located in remote areas, finding
safety and reliability. and maintaining labor are critical to project timelines and budgets.
Depending on the project, dozens to hundreds of workers are required
for these manual-labor jobs, which vary in length and location.
Reliability is also important. Wires and cable ties must be installed
correctly to maximize operation and minimize maintenance calls.

“Tools that can simplify and speed these

manual installation tasks are critical,” says
Jungels. “So, for example, we offer a cable-
tie tool that works in one motion. Where with
conventional cable ties, one would have to
Panduit provides the most preferred
hand-operated tools in the industry, run, sink, pull, and tighten the tie down and
which can be used for production,
then clip the end, Panduit’s installation tool can go down a line of wire,
maintenance, or construction
applications. installing these ties with little motion. Plus, users need not carry around
cutters or anything like that.”

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 Edge clips are another example of a
product that’s speeding and simplifying wire
installations at solar sites. “They’re ideal for
securing PV cable bundles and keeping them
New edge-clip, cable-tie mounts from organized and cleanly mounted — without additional tools,” he explains.
Panduit help secure wire and cable
bundles with versatile mounting edges.
“Every solar module requires a few of them, so to be able to do those
without extra tools or equipment saves time and improves efficiencies.”

Another way developers are optimizing projects is by first testing the

components through a mock-up scenario. It’s called a “golden row,”
which is a test scenario where each part of a solar system — including
the modules and the BOS components, from the cable and wire to
the combiner boxes — is set up in a minor experiment to see how it
operates together.

“It’s a great way to pilot the components during the design stage,”
says Jungels. “I mean, you likely wouldn’t buy a car without a test-
drive or to see how it handles, to learn where the different knobs,
controls, and cup holders are at, and so on….and this is similar. It’s even
possible to test for the ergonomics and installation rates of different
BOS components before assembling the entire project.”

As each solar system is customized differently, the golden row test

helps ensure the functionality of the project as a whole before it’s fully
installed. It can also be inspected to ensure industry best practices
and standards are supported throughout the site.

“The golden row provides an overview, allowing for last-minute changes.

And, most importantly, it helps avoid potentially costly mistakes being
repeated thousands of times during installation,” he says.

How to ensure product reliability?

When choosing balance-of-system components, it’s important to

consider wire and cable-management solutions that are versatile,
reliable, universal, and efficient.

“Consider products that are lightweight and easy to install, requiring few
Stainless Steel Trefoil Cable Cleats offer tools to save on labor and installation costs,” says Jungels. “But it’s also
protection against extreme environments
and short-circuit current faults. important to pick what’s going to last to save on maintenance costs.”

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This means assessing the environment that a project must operate
in successfully and for as long as possible without unscheduled O&M
issues. This is where product quality comes in.

“Cheaper nylon or plastic components are typically susceptible to UV

damage. A lot of sunlight can make these materials brittle,” Jungels
says. “It’s also important to use protective casing for wiring and cable
ties that hold up in harsh conditions and aren’t easily subjected to
wear and tear, or rodents chewing through it.”

Taking the time to choose wisely during the design stage of a project
can equate to greater savings in the long term. BOS components
should be UV- or harsh-environment-rated and insulated against
weather and animals.

“Ultimately, you’re dealing with electricity for these projects, which is

not something you want to mess with. So, if you’re buying lower-grade
materials or metals that are mixed or not up to UL standards, that’s
an operational risk. It could result in a minor maintenance issue or
something larger and catastrophic…and is it worth it?”

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Jungels says it’s important to balance the risk and reward when
making these choices. Similar factors must be considered when
choosing the suppliers for a project.

“There’s always going to be several sources supporting a solar

project,” he says. “You just can’t get everything, from the panels to
the enclosures, in one place. But bear in mind, a greater number
of suppliers equates to more complexity. There’s a greater chance
of timeline, pricing, and transport issues. At Panduit, we think it’s
extremely important to eliminate such complexities for balance-of-
system components.”

Panduit’s portfolio currently offers about 75% of the build material

required for the balance-of-system products. This includes expert
consultations to maximize solar project efficiencies and decrease the
total cost of ownership.

“We typically group this into four main categories that ensure safe and
reliable balance-of-systems. This includes to bundle, connect, protect,
and identify.”

The Panduit solutions that cover more ground:

• BUNDLE: Cable-management solutions that reduce installation

time and improve the operating life of wire and cables in harsh
environments — while keeping them secure yet easy to access for
maintenance calls.

• CONNECT: Designed to meet all applicable standards, such as

UL and IEEE standards, and are tested to perform for 20 years in
outdoor environments. Grounding connectors must ensure the
system remains safe and is not susceptible to short circuits or fires.

• PROTECT: Technology that reduces risk and increases safety

at solar sites.

• IDENTIFY: Labels and ID solutions that hold up

in harsh environments.

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 “When we consider a connection from point A to point B, we’re
thinking about safety and reliability,” share Jungels. “This includes
the grounding connectors and power connectors. We’re also thinking
about the cable management and secure bundling options, which are
easy to access yet not susceptible to damage.”
Panduit compression connectors
provide permanent terminations He adds that identification is
for a variety of industrial cabling also extremely important. “We
applications, with best-in-class
installation tools. offer UV-rated labels for the
different applications, as well as
mobile printers and programs
to help with their identification
A comprehensive offering of innovative
process.” These include pre-
printing systems, labels, and labeling
printed and print-on-demand software are available to properly identify
electrical and network infrastructure.
labeling options that allow NEC
compliance solutions.

Protection is a must for safe and reliable project operation. “One of

our safety-related products is the VeriSafe Absence of Voltage Tester,
which is a product put into converters, such as substation power
boxes. It determines the absence of voltage with just a push of a
button,” he explains.
The VeriSafe™ Absence of Voltage
Tester minimizes risks by verifying the In summary, when choosing quality balance-of-system
absence of voltage before equipment components, look for products that are:
is accessed, making it easier for
qualified electrical workers to ensure • Tested to perform in harsh environments, ensuring UV protection
an electrically safe environment in
a fraction of the time compared to • Meet all applicable standards, such as UL and IEEE
hand-held portable test instruments.
• Install simply and reliably, with little complexity and few tools
• Modular, offering versatility and scalability
• Designed for longevity and reduced maintenance
• Compatible — that ground, bundle, connect, and protect efficiently
and effectively together
• Labeled correctly — an important safety feature

“There’s a lot going on in a solar system, so it’s extremely important to

source supplies that can offer peace of mind, experience, and proven
products,” says Jungels. “It’s also worth partnering with a company
that is interested in truly learning about your project and how to best
optimize it right from the start.”

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To learn more about what the industry’s current thoughts and ideas
are on BOS, Panduit launched a recent survey, “Recommendations
and challenges regarding balance-of-system components.”

* seia.org/solar-industry-research-data

ABOUT PANDUIT…

Over the last decade, Panduit has partnered with EPCs and solar
installers on PV installations totaling more than 5 GW of capacity.
The company offers solar-specific, end-to-end solutions designed to
reduce complexity and labor, thereby lowering total installed costs.

The company offers a combination of engineering and manufacturing

expertise with a full portfolio of products, covering up to 75% of a
typical PV installation electrical BOS.

Heilind Electronics is currently Panduit’s largest electronics distributor,

and one of its oldest, maintaining the world’s largest inventory of
Panduit products.

ABOUT HEILIND ELECTRONICS…

Heilind Electronics is a global distributor for interconnect,

electromechanical, and sensor products. As the industry’s preeminent
distributor, the company stocks the largest inventory of connector
products in North America.

Heilind offers products in over 25 component categories including wire

and cable, connectors, switches, circuit protection products, terminal
blocks, insulation and identification products, and much more.

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