How to Select Circuit Breakers for
Solar Systems
Done by : Asaad ALBadowi
5kW Solar System
• - 10 Solar Panels (500W each, total 5kW)
• - MPPT Charge Controller (100A / 48V)
• - Battery Bank (48V - 4 batteries at 12V each)
• - 5kW Inverter to Convert DC to AC
Breaker Distribution in the System
• 1. Between Solar Panels and Charge Controller
(MCCB)
• 2. Between Charge Controller and Batteries
(MPCB)
• 3. Between Batteries and Inverter (ACB)
• 4. After Inverter to Household Loads (MCB)
• 5. Earth Leakage Protection (RCCB)
1️⃣ MCCB Calculation (Panels to
Charge Controller)
• Formula:
• I = P / Vmp
• 5000W ÷ 50V = 100A
• Safety Margin:
• 100A × 1.25 = 125A
• Recommended Breaker: MCCB 125A –
600V DC
2️⃣ MPCB Calculation (Charge
Controller to Batteries)
• Formula:
• I=P/V
• 5000W ÷ 48V = 104A
• Safety Margin:
• 104A × 1.25 = 130A
• Recommended Breaker: MPCB 130A –
48V DC
3️⃣ ACB Calculation (Batteries to
Inverter)
• Formula:
• I=P/V
• 5000W ÷ 48V = 104A
• Safety Margin:
• 104A × 1.25 = 130A
• Recommended Breaker: ACB 160A – 48V
DC
4️⃣ MCB Calculation (After Inverter to
Loads)
• Formula:
• I=P/V
• 5000W ÷ 230V = 21.7A
• Safety Margin:
• 21.7A × 1.25 = 27.1A
• Recommended Breaker: MCB 32A – 230V
AC
5️⃣ RCCB Calculation (Earth Leakage
Protection)
• Load Current:
• 63A
• Sensitivity:
• 30mA for Personal Protection
• 100mA – 300mA for Equipment Protection
• Recommended Breaker: RCCB 63A / 30mA
Breaker Distribution Summary:
• Solar Panels (DC) → MCCB → MPPT Charge
Controller → MPCB
• → Battery Bank (48V) → ACB → Inverter (AC)
→ RCCB → MCB → Loads
