Quantifying the Impact of Minor Design Changes on the Direct Current Cable Network in Large‐Scale Solar Photovoltaic Plants

Solar photovoltaic (PV) systems are among the most widely used renewable energy sources, with the global capacity expected to grow by 4000 GW by 2030 – mostly from utility‐scale projects. While many strategies to improve PV plant performance and efficiency exist, enhancements through optimal cable design and plant layout are often overlooked. Focusing on central inverter architectures, this study aims to investigate the impact of minor design changes on direct current (DC) string and sub‐array cables in PV systems, and the resulting impact on yield, power loss, and capital expenditure. A base case scenario PV plant is defined, and nine design variations are assessed, incorporating modifications to equipment selection and placement, inter‐tracker corridor widths, and cable sizes. For each scenario, DC cable layouts are developed, and the associated cable costs, losses, and yield impacts are calculated. Results show that equipment selection and placement have the most significant influence on cable cost and electrical performance. While increasing cable size reduces power losses, the associated capital cost potentially outweighs the energy yield benefits. This study highlights the importance of an iterative design during early project stages to balance financial return and technical performance, providing a practical framework for evaluating trade‐offs in PV plant design.