Case study

Leveraging PVcase for DC Wiring solutions in solar PV

ENGESOLAR'S story

98%
reduction in quoting time
100k€
material cost savings

Summary

The solar photovoltaic industry continuously seeks ways to enhance efficiency and reduce costs. DC wiring, while fundamental, has traditionally been a significant source of both expense and complexity in ground-mounted solar projects due to manual, on-site methods. ENGESOLAR, a leading cable assembly solutions provider, has addressed this by leveraging PVcase software. Recognizing a market need where pre-assembled wire harnesses are standard, and driven by project developers seeking cost-effective pre-assembly solutions, ENGESOLAR set out to become a 360-degree DC wiring solution provider in the German and European markets.

Challenges

Traditional DC wiring in ground-mounted solar plants, which involves connecting individual PV strings with separate cables, presented several critical challenges for ENGESOLAR and their clients:

1. Time-consuming manual quoting

calculating string lengths from PDF files for project quotes was a manual, hours-long bottleneck.

2. High risk of errors

The manual nature of this process increased the likelihood of mistakes such as incorrect cable lengths, improper connections, and inconsistent quality control.

3. Lack of integrated design capability

As a new entrant into solar design, ENGESOLAR needed a robust and intuitive tool to efficiently plan ground-mounted parks.

Client experience

“If we get the string plan as a PDF, it takes hours to do the quote because we have to calculate each string length manually. And with PVcase it's done in 5 minutes! it's saving a lot of time and it's avoiding human errors.”

Fabian Detemple

Bereichsleiter, ENGESOLAR

Solution

ENGESOLAR adopted PVcase as the cornerstone of their strategy to address these challenges and establish themselves as a comprehensive DC wiring solution provider. PVcase became a crucial tool for automating and optimizing the design process for DC string harnesses.

With PVcase, ENGESOLAR can:

Automate quoting

By receiving PVcase design files (DWG), ENGESOLAR can generate a quote in just 5 minutes, a drastic reduction from the half-day it previously took for a 10 MW park.

Enable in-house design

PVcase's intuitive interface and smooth onboarding process allowed ENGESOLAR a new player in design, to quickly start planning ground-mounted parks. Fabian noted that without PVcase, they "wouldn't have been able to even go this way."

Optimize DC wiring and material costs

PVcase provides precise string lengths and voltage drop calculations, enabling ENGESOLAR to combine different wire gauges effectively. This optimization leads to significant material cost savings. For example, by using 20-25% 4mm² wire instead of 6mm² on a 100 MW project, ENGESOLAR estimates savings of €50,000 to €100,000 in copper costs alone, without compromising voltage drop (remaining under 1%).

Facilitate collaboration

PVcase allows ENGESOLAR to seamlessly exchange design files with customers. For clients already using PVcase, Engesolar can directly upload their DWG files, double-check and optimize the DC wiring.

Results

Massive time savings

Quotes that once took half a day now take 5 minutes with PVcase DWG files.

Enhanced accuracy

Reduced manual errors lead to more precise and reliable DC wiring designs and quotes.

Significant cost reduction

Optimized wire gauging translates to substantial material cost savings for customers, enhancing ENGESOLAR's value proposition.

Expanded service offerings

ENGESOLAR can now offer comprehensive DC wiring planning and pre-assembly services, positioning itself as the "360-degree DC wiring provider."

Stronger customer relationships

By providing valuable design support and cost-saving solutions, ENGESOLAR deepens its partnerships with clients, from small developers to large EPCs.

About ENGESOLAR

ENGESOLAR, a brand of the Engeser Group, is a leading global provider of specialized cable assembly solutions. With a focus on innovation and quality, Engesolar recognized the need to optimize DC wiring processes within the solar photovoltaic industry. Their expertise in cable manufacturing, combined with strategic technology adoption like PVcase, enables them to deliver cutting-edge, pre-assembled DC string harnesses.

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