There's a pic down below- does it somewhat represent what we are talking about?
125% of the inverter's max current is the PV contribution to the 120% rule in every panel between the PV and the service. Only the panel main breaker is part of the calculation, and it only counts toward the 120% rule in the panel it is the main breaker for.
Well yes ok, you are right, so 62.5 * 125% = 78.125A.
And with the 100A main breaker in the barn, that's 178A for the 120% rule.
A 150A rated bus (with 100A main breaker) would even be ok (150 *120% = 180A).
A 200A main barn breaker would not be ok for either a 200A *or* 225A rated bus, because you only get 225 * 120% = 270A with a 225A bus.
A 150A breaker would be ok with 200A bus (240A allowed) because 150 + 78 = 228A.
A 175A breaker? Plus 78A of PV = 253A, you'd need a 225A bus for that.
However, none of that affects the size of the conductors between the 100/150/175 or 200A breaker and the 200A main service breaker, as far as I can tell.
I still think if you have 2 100A breakers, 1 in the barn and one in the house, and they are connected to the same 200A breaker lugs, and one of them is over 25 feet, you're looking at 3/0 (or larger) wire.
Look at it this way- forget the PV, all it will actually do is reduce the current going to the barn during the day.
So there is a 100A breaker for the barn and a 100A breaker for the house. If each was fed by a separate 100A breaker, #2 would be fine.
However. there is a 200A main breaker feeding them both. If you were to tap the barn conductors into the house conductors, or the other way 'round, you would NOT use #2, because there would be a section (between 200A breaker and tap) that could potentially have to carry 200A (100 for barn, 100 for house).
When the barn and house conductors are connected to the same lugs of a 200A breaker, that section might only be a few millimeters, but it still exists.
If eds' meter had 2 100A breakers instead of 1 200A, he'd be all set.
However, a 100A fused switch at under $300 (not a $3000 stainless...) is a lot less than the difference between 200 feet of 2 AWG vs. 200' of 3/0.
Whoa! I just looked real quick- for 1000', the 3/0 is 10x as much as the 100A switch+2 AWG! (copper)
Actually, IIRC, the OP may be operating under the 2011 code...
Just to confuse things.
Hee hee. Well... can't the AHJ say "well yes the 2014/2017 makes a lot more sense for this part, so that bit of the set up is fine"...?
It's possible the OP would be under 2014 by July 1 2017? (or Dec. 31)
http://www.electricalcodecoalition.org/state-adoptions.aspx