CPD Course on Solar Energy Technologies

( Solar Energy)

RESOURCE PERSON: ENGR. FAIZ M BHUTTA

January 28, 2013
AT IEP AUDITORIUM



1
TIME TABLE
2
MODULE TOPIC TIME
MODULE - 01
INTRODCUTION TO
SOLAR ENERGY
TECHNOLOGIES
1000-1100
MODULE - 02
CELLS-MODULES-
ARRAYS
1130-1230
MODULE - 03
SOLAR PV SYSTEM
COMPONENTS



1230-1330 & 1430-1515
MODULE - 04
DESIGN OF SOLAR
HOME SYSTEM
1515-1600
MODULE - 05
INSTALLATION
OPERATION-
MAINTENANCE
1600-1630
MODULE 1
INTRODUCTION TO SOLAR
ENERGY TECHNOLOGIES
3
Solar Insolation pattern
Pakistan Irradiation data
Average solar irradiation varies from 3.5 to 7 kWh/m per day in Pakistan


Solar energy
potential is high
in all parts of
the country.

Compare Germany:
2.53.2 kWh/m per day


5
With Pakistan
3.5 to 7 Kwhr/m2/day

STC 1000W/m2/day
At 25 Degree C
Cost trends
Module prices and system cost are decreasing.
6
SOLAR ENERGY TECHNOLOGIES & APPLICATIONS
1. SOLAR PHOTOVOLTAIC POWER TECHNOLOGY
SOLAR OFF-GRID POWER SYSTEM
SOLAR ON-GRID POWER SYSTEM
SOLAR HYBRID POWER SYSTEM
2. SOLAR THERMAL TECHNOLOGY
3. SOLAR PUMPING TECHNOLOGY
4. SOLAR LIGHTING TECHNOLOGY



7
8 .
SOLAR PHOTOVOLTAICS (PV)
CONVERSION OF SOLAR
RADIATIONS INTO ELECTRICAL
ENERGY
9 .
COMPONENTS OF SOLAR PV SYSTEM
Solar panels 45-50% of cost
Controllers ( charge controllers and inverters)
Deep Cycle Battery -20-25%
Mounting ( Ground and Roof)
Cables, thimbles and accessories

Price of system varies as per maximum load in watt, hours of operation
And autonomy
10 .
OFF-GRID AC SOLAR PV SYSTEM
11 .
DC AND AC OFF-GRID SOLAR PV SYSTEM
12 .
ON-GRID PV SYSTEM
The system shuts down when the WAPDA Supply is Out.
13 .
SOLAR HYBRID PV SYSTEM
AUTOMATIC SYSTEM OF SWITCHING FROM ONE SOURCE TO OTHER
14 .
COMMERCIAL AND INDUSTRIAL APPLICATIONS
Stand Alone/Off-grid solar System in rural Areas upto 500 W
Solar Power Plants from 10 KW to 200 MW
Solar Parks upto 200 MW
Solar UPS
Solar Traffic Signals Lights
Power for Remote Security and Surveillance Systems
Remote data acquisition and equipment monitoring
Power for Telecommunication Towers and Networks
Building Integrated Photovoltaic System
Military signaling applications
Cathodic Protection of Pipelines
Solar water Pumping
Commercial Solar Lighting for roads, motorways and parks, Bus stops
Solar Lighting for Buildings and Industries

15 .
SOLAR THERMAL TECHNOLOGY
CONVERSION OF SOLAR
RADIATIONS INTO HEAT OR
TEHRMAL ENERGY
16 .
SOLAR THERMAL COLLECTORS
Vacuum Tubes
Concentrated
Tower
Concentrated Parabolic Concentrated Dish
1000 C
400 C 400 C
CSP will be able to cover 11% of world electrical demand by 2050
Flat Plate
High Temperature Solar Collectors
45 to 90 C
Low Temperature Solar Collectors
Heat Pipe
17 .
Non-Pressurized SWH - 200 Ltrs and 300 Ltrs
18 .
GRAVITY MUST FOR NON-PRESSURE SWH
19 .

Non-Pressurized SWH working
20 .
Pressurized SWH -Heat Pipe System 300 and 500 Ltrs
21 .
Pressurized heat Pipe SWH working
22 .
Pressurized heat Pipe SWH working
23 .
PRESSURIZED SOLAR WATER HEATING


24 .
TWO COIL PRESSURIZED SWH SYSTEM WORKING

25 .
Space heating for commercial buildings
26 .
Swimming Pool Water Heating
27 .
MYTH AND REALITIES OF SWH
MYTH REALITY
Put Solar water heater and get hot water 24
hours a day
Hot water supply quantity is limited to Nr of
collectors as per hot water requirement
Solar water heater can work alone 24 hours on
solar without any back up
No. It can only work in hybrid with Gas Geyser
or instant heater. Back up in case of no sun is
necessary
Price told by supplier includes piping and
plumbing work
Price for SWH do not include piping and
plumbing work. Include Rs.2000 to Rs.10,000
in your budget for piping and plumbing work
depending on site
SWH can be placed anywhere at roof Whole day sun is available without shade and
water tank height should be minimum at 6 ft
to develop gravity in case of non-pressure
One SWH is enough. No. Number of solar water heaters depends
upon total flow requirement, pressure and
hot water requirement
SYSTEM WILL NEVER GET RUSTED AND
SCALED
Rusting of tank and scaling in tubes depends
upon water quality
28 .
SOLAR THERMAL APPLICATIONS
Hot water usage for bathing, washing and Laundry
Pre-heat for Boilers
Swimming pool water heating
Space Heating for commercial buildings
Solar Steam Generation for Industrial Process
Degreasing and phosphating in metal finishing industry
Solar Drying in food, wood, Leather


29 .
SOLAR PUMPING
30 .
SOLAR PUMP
31 .
PUMP CURVE
Best Efficiency Point
32 .
DC SOLAR PUMP
Max Flow = 40,000 Gallons
per day , Max Head = 400 ft
Impellers can be Centrifugal
and Screw Type.
Small land irrigation,
Drinking and Live Stock
Motor up to 4000W




33 .
AC SOLAR PUMP
Max flow= 200,000 Gallons
per day & Max head = 400
ft.
Impellers are Centrifugal
Suitable for irrigation
purposes
Motor up to 20 KW




34 .
LED & SOLAR LIGHTING
35 .
SOLAR STREET LIGHT COMPONENNTS
LED Light Source
MS Pole
Solar Panel with its mounting
Battery
Charge Controller
Cable, connectors and thimbles



36 .
LED FLOOD LIGHTS & STREET LIGHTS
LED Flood Lights 80W
LED Flood Light 100W
LED Flood Lights 120W

LED Street Lights -30W
LED street Light 60W
LED Street Light 80W

SAVING 75%

37 .
SOLAR HOME LIGHTING KIT
Sundaya Light Kits
HIHG QUALITY LIGHT
PLUG AND PLAY
THREE LIGHT INTENSITY THROUGH
TOGGLE SWITCH
BATTERY LIFE THREE YEARS BUT
WARRANTY IS ONE YEAR

BACK UP

6 HOURS AT FULL LIGHT
12 HOURS AT MIDDLE LIGHT
56 HOURS AT LOW LIGHT

38 .
SOLAR LIGHTING
Solar Flood Lights 160W
SOLAR STREE LIGHT 60W
39 .
APPLICATIONS IN INDUSTRY AND BUILDINGS
Solar Street Lights pathways
Solar Street Lights for Boundary walls
Solar Flood Lights for pathways and Boundary
walls and Fields
Solar Parking Lights
Solar Garden Lights

20 ft and 30 ft Pole Length
MODULE 2
CELLS MODUELS - ARRAYS
40
Cell-Module- Array
PV cell
PV modules
PV array
PV systems
41
Watt = Volt x Current
A GRADE
B GRADE
C GRADE
Panel Quality
Basic Terms
Module peak power
Wp (Watt peak) or kWp (Kilowatt peak)
42
Measure for the peak output of a PV system under Standard Test Conditions (STC).
Standard Test Conditions (STC):
Solar irradiation of 1000 W/m, module temperature 25C
Maximum output of a PV module (under ideal conditions)
kWp * number of peak sun hours = kWh
Number of peak sun hours (1 kWh/m) per year, for example
Germany ~1,000 1,400
Pakistan ~1,900 2,000
Conversion efficiency of a PV cell
Proportion of sunlight energy that the cell converts into electricity (in %)
Todays solar cell efficiency: 7 17 % (depending on cell type)
Basic Terms
Performance ratio
Real energy yield / theoretical energy yield (in %)
43
Depends very much on systems design, cabling, location, direction,
inclination, shading and temperature of modules and other on-site
conditions.
Practical experience:
Performance ratio of existing grid-tied systems: 75 80 %
Performance ratios of existing off-grid systems: 60 70 %
Real output of a PV module
kWp * number of peak sun hours * performance ratio = kWh
Photovoltaic effect
It starts with sand which is processed into highly purified silicon.
Silica sand
Silicon blocks
Monocrystalline wafers
44
Photovoltaic effect
In a process called doping, trace amounts
of special impurities are added to this
purified silicon.
For example:
When silicon is doped with Boron, the
resulting material is called P-type.
When silicon is doped with Phosphorus,
the resulting material is called N-type.

When purified silicon is doped with Boron
and Phosphorus in just the right way,
a P-N Junction is formed.
This process establishes a permanent
electrical field in the crystal.
P-N Junction is establishing a permanent electrical field in the crystal.
45
Photovoltaic effect
When a P-N Junction is made so that light can strike its top surface and metal
conductors are attached to the P- and N-type sides, a solar cell is formed.
When sunlight strikes the solar cell, electrons are ejected from the atoms
and the permanent electrical field in the junction steers them to the N-type side.
If a wire is connecting
both sides of the
solar cell, electric
current can flow,
whenever sunlight
is striking the
solar cell.
Solar cells are based on the electrical field in the P-N Junction
46
Cell types
The most significant is crystalline silicon.
Two main types of commercially available cells are:

Silicon wafers
Monocrystalline silicon cells
Polycrystalline silicon cells

Thin film:
Amorphous silicon (-Si) ~ 4,2 % of the market
Copper-indium-diselenide (CIS) ~ 0.7 % of the market
Cadmium-telluride (CdTe) ~ 1.0 % of the market
Cells can be manufactured from different types of materials.

}
~ 93% of the market
47
Cell types
A crystal of silicon is grown from highly
pure molten silicon.
The single crystal cylindrical ingot is
cut into thin slices (200 300 m).
The edges are cut off to give a
hexagonal shape in order to make
optimum use of available module
surface.

Most efficient type of cell
(11-16 % efficiency).
Energy- and time-consuming
production
Monocrystalline silicon cells
48
Cell types
Silicon is heated to high temperature
and cooled under controlled
conditions in a mould (casting
process).
As the molten silicon sets, an irregular
poly- or multi-crystal is formed.
This is visible in the shimmering fish-
scale like appearance of the wafers.
The square silicon block is then cut
into thin slices (~300 m).
The blue colour is due to the
application of an anti-reflection layer.

Less efficient than mono-crystalline
cells (efficiency 10-14%).
Polycrystalline silicon cells
49
Cell types
Silicon, CIS or CdTe is deposited as gas on a
glass, aluminium or plastic surface.
Layer (thin film) of semiconductor material is
only 0.5-2.0 m thick.
Less semiconductor raw material is used.

Less sensitive to the effects of shade and high
temperatures.
Better suitable for locations with large share of
diffuse irradiation (e.g. in areas with high air
pollution).
Production cost today similar to silicon wafers.
Lower efficiency than silicon wafers
(e.g. CIS efficiency 6 - 8%).

Thin film
50
Cell types
Comparison of different cell types
Cell
material
Module
efficiency
Module surface area
for 1 kWp
Module surface area
for 1 MWp
Mono-crystalline
silicon
11 16 % 7 9 m 7,000 9,000 m
Poly-crystalline
silicon
10 14 % 8 9 m 8,000 9,000 m
Thin film
(CIS)
6 8 % 11 13 m 11,000 13,000 m
Amorphous silicon 4 7% 16 20 m 16,000 20,000 m
51
Electrical characteristics of PV cells
Current:
Current produced by a cell is
depending on:
Quantity of light falling on the cell
Size of cell surface area
Operating voltage
Maximum current:
Short circuit current (Isc)
Impedance R = 0
Current ISC = max.
Voltage V = 0
Power P = 0
Voltage:
Output voltage is depending
on the cell material (largely
independent of the level of solar
radiation falling on the cell).
Silicon cells: 0.5-0.6 VDC
Maximum voltage:
Open circuit voltage (Voc)
Impedance R =
Current I = 0
Voltage VOC = max.
Power P = 0


Principal electrical properties of a PV cell are its current and voltage.
Power (P) = Current (I) * Voltage (V)
52
Electrical characteristics of PV cells
The Maximum Power Point (MPP) is defined by the I-V curve of a PV cell
Maximum Power (PMAX) = Current at MPP (IMP) * Voltage at MPP (VMP)
53
In crystalline silicon PV cells:
VOC = ~ 0.5 V
VMP = ~ 80% of VOC
IMP = ~ 95% of ISC
ISC is depending on the cell surface.

Sample
specification:
Source: www.made-in-china.com
(MPP)
Ambient influences on cells and modules
Electrical output and the current produced
are directly proportional to the level of solar irradiation.
54
Ambient influences on cells and modules
Increasing module temperature leads to decreasing power output.
55
Example:
Silicon cell
Ambient influences on cells and modules
In regions with little rainfall or with long
dry seasons, dust may accumulate on the
modules and reduce efficiency by 10-25%.


Module efficiency may drop
by more than 50% if 3% of
module surface are covered
with dirt.
56
Example:
PV modules after 2 months without rain in the area of Los Angeles.
Efficiency dropped at approx. 10% (estimated by the owner).
Production failures and damages
of the module structure spoil
efficiency and reduce lifetime
of the module.
57
Defect:
Delamination PV cell encapsulation
(EVA foil)
PV cell interconnection and module design
Shading from distant trees, roofs, chimneys
etc. creates soft or diffuse shadow
which reduces irradiation and reduces
power output of the whole module.

When cells are connected in series,
overall output is adjusted to the output
of the weakest cell.

Hard shadow from blankets, bird drops
etc., which prevents light from reaching
individual cells or groups
of cells may bring power output
down to zero.

Shading must be avoided !!!
58
Examples of partial cell shading that can reduce
PV module power reduced by half
Ambient influences on cells and modules
Azimuth =
Orientation to the sun
Optimum is South.

Tilt angle =
Inclination of the
PV module/array.




Azimuth and tilt angle are influencing module efficiency
59
Ambient influences on cells and modules
Modules & arrays
1. Electrical characteristics of PV cells
2. Ambient influences on cells and modules
a) Irradiation
b) Temperature
c) Dust and dirt
d) Shading
e) Direction to the sun (azimuth)
f) Tilt angle
3. PV cell interconnection and module design
4. Module interconnection and array design

60
Serial interconnection of cells of
the same type leads to a
multiplication of voltage.
PV cell interconnection and module design
PV cells may be interconnected in parallel or in series.

61
Parallel interconnection of cells of the same type leads to a multiplication of current.
PV cell interconnection and module design
PV cells may be interconnected in parallel or in series.

62
PV cell interconnection and module design
Example: Charging 12V solar batteries
Charge controller specification:
Max. charging current: 8 A
Charging voltage: 14 V
Required module voltage: 18 VOC


Sample module specification
36 cells in series = 36 * 0.5VOC = 18 VOC
2 series in parallel = 2 * 4 A = 8 A

Selection of cells and module design are depending on the specific
application and demand.

63
Example: Module specification
PV cell interconnection and module design
Module structure
has to protect the cells
and to ensure functionality
over 25 years lifetime of the module.
64
Quality standards:
International Electronical Commission (IEC):
IEC 61215 Crystalline silicon PV modules
design qualification and type approval
IEC 61646 Thin-film PV modules
design qualification and type approval
IEC 61215 and IEC 61646 are covering external conditions to
which modules are exposed, for example mechanical stress,
climatic conditions, aging.

IEC 61730 PV modules safety qualification
Part 1: Requirements for production
Part 2: Requirements for testing

Quality standards and certificates for PV modules.
65
PV cell interconnection and module design
Quality standards and certificates
66
PV cell interconnection and module design
Visual inspection and performance
tests are recommended before
delivery.
Production failures and damages
of the module structure are spoiling
efficiency and reducing lifetime
of the module.
67
Defect:
Gap due to
poor sealing
Defect:
Excessive
glue mark
Defect:
Scratch on glass
PV cell interconnection and module design
Module interconnection and array design
Modules can be connected in series or in parallel


Modules behave in principle
like the cells they are
composed of.




It is urgently requested
to use always the same type
of modules in an array !
68
Module interconnection and array design
Selection of modules and array design are first of all determined by the
specific application and power demand.
69
(1) Power demand: 600 W
Voltage required: 12 V
PV Modules (12 V):
Option a: 12x50 W
Option b: 6x100 W
Option c: 3x200 W
Array design:
All modules in parallel (option b)
(2) Power demand: 600 W
Voltage required: 24 V
Array design:
2 x (3 x 100 W) in serial (option b)
Module interconnection and array design
Parallel arrays
which are connected
in serial must be
equal.


For example:
10 modules with
12 V / 50 Wp each
70
MODULE 3
SOLAR PV SYSTEM
COMPONENTS
71
Components



1. PV Modules
2. Batteries
3. Charge controllers
4. Inverters
5. Cables and wiring
6. Connectors
7. Mounting systems
72
Batteries
Rechargeable lead-acid batteries
are the most common type of
batteries used for PV systems.
Storage capacities in the range of
0.1 kWh to 100 kWh.
Batteries are built from 2 V cells
(e.g. 6 cells for a 12 V block).
Charging voltage is higher
than battery voltage
( e.g. up to 14.5 V charging power for a 12V battery).
Battery types:
Grid-plate battery (solar batteries).
Gel batteries.
Tubular plate batteries.
Battery design
Bloc batteries.
Individual cells (tubular plate).
Energy storage is required in most off-grid PV applicatons
(except solar pumping)
73
Grid-plate battery
Tubular plate
solar batteries
(cell design)
Solar gel battery
Solar battery
Grid-plate batteries
with thicker plates,
hardened grids and
low acid content:
Increased cycle resilience.
Reduced corrosion.
longer service life.
Lifetime (in cycles) depends on the discharge per cycle.
For example:
100 % discharge = reducing battery lifetime.
70 % discharge ~ 200 cycles.
50 % discharge ~ 400 cycles
20 % discharge ~ 1000 cycles
Cycle resilience and deep discharge protection are
improved in so-called deep cycle batteries.


Proper charge control saves battery lifetime and cost!
Vehicle starter battery





Grid-plate batteries with a
large number of
thin plates:
Large active surface area.
High starting current to be
provided over a few seconds.
Only very small discharge per
cycle in normal operation.
Very low cycle resilience.
Extremely short life time of
car batteries when used for
solar systems!
Batteries
ATTENTION: Vehicle starter batteries must not be used in PV systems !
74
Exide battery
Parallel connection of batteries
The terminal is connected with the terminal of the next battery.
The terminal is connected with the terminal of the next battery.

The battery bank has the same voltage as a single battery.
Capacity of the battery bank is rating equal to the sum of the individual batteries
capacities.
Batteries
From single batteries to battery banks
75
Series connection of batteries
The terminal is connected with the terminal of the next battery.
In serial connection, a battery bank has the same capacity as a single battery.
Overall voltage is rating equal to the sum of the individual batteries voltages.
Batteries
From single batteries to battery banks
76
Series-Parallel connection of batteries
Series and parallel connection are use in combination.
Capacity (Ah) and voltage are increasing.
This is done to make a battery bank with large capacity
and larger voltage out of several smaller, lower voltage batteries.
Batteries
From single batteries to battery banks
77
24 V battery bank
Components
1. Batteries
2. Charge controllers
3. Inverters
4. Cables and wiring
5. Mounting systems
79
charge controllers
Charge voltage must be higher than
battery voltage:
Standard example:
Battery nominal voltage: 12V
Charge voltage: up to 14.5 V
PV nominal voltage: 15-18 V
(e.g. NOCT = 45C)





Discharge voltage is decreasing while
the battery is discharging (discharge
current stays almost constant).

During times of high irradiance & low
temperature (e.g. 0C), MPP of the PV array
may increase up to ~21 V, MOC up to ~25V.
Therefore, the battery must be protected
against overcharging.

During times of low / no irradiance, PV voltage
breaks down and the battery starts to discharge
via the PV array.
Protection against self-discharging via the PV
array, increases overall efficiency of the system.


Deep discharge is reducing battery lifetime
dramatically.
Therefore a specific discharge cut-off voltage is
to be respected in order to save battery life.

Matching voltage of the PV array and the systems to that of the battery.
80
charge controllers
Series controller
81
When the charge cut-off voltage is reached, a series controller interrupts the
module power using S1 and switches it back on after a defined voltage drop.
This creates an oscillating state of constant switching operations around the charge
cut-off voltage, as well as permanent forward losses.
S2 is used to interrupt battery power when the battery voltage drops below a
defined discharge cut-off limit.
Series solar charge controller
charge controllers
MPP charge controllers
82
An MPP tracker essentially consists of a regulated DC/DC converter.
MPP power is determined every few minutes.
The DC/DC converter is the set so that it takes the optimum power from the PV
array and adjusts it to the charge voltage of the battery.
In this way, optimum use is made of the available solar energy.
MPP charge controllers are useful in combination with larger PV arrays or when
using high voltage modules/arrays
MPP Tracking Solar Charge Controller 10 Amp 12/24V
charge controllers
Sample
Specifications










83
Components
1. Batteries
2. Charge controllers
3. Inverters
4. Cables and wiring
5. Mounting systems
84
Inverters
Optimum requirements :
Sinusoidal AC with stable voltage and
frequency.
Good conversion efficiency, even in partial
load range.
High overload capacity for switch-on and
starting sequences.
Tolerance against battery voltage fluctuations.
Economic standby mode with automatic load
detection.
High electromagnetic compatibility (EMI
suppression)
Surge voltage protection.
Bidirectional operation (AC/DC conversion +
DC battery charging from AC generators).
Inverters are needed to use conventional 230V AC loads in off-grid solar
applications (e.g. UPS in urban solar home system.
85
Inverters
Best fulfilling the
above mentioned
requirements:
Working on the
principle of pulse
width modulation.
Suitable even for
operation sensitive
electronic
equipment.
Complex circuitry.
Higher in price than
square wave
inverters.
Sine-wave inverters
86
Inverters
Cheaper than
sine-wave inverters
DC is chopped into a 50Hz alternating current with square characteristic.
DC voltage is stepped up using a transformer to a voltage of 230V.
Square-wave inverters
87
Components
1. Batteries
2. Charge controllers
3. Inverters
4. Cables and wiring
5. Mounting systems
88
The bigger the load (W)
and the longer the distance (m),
the bigger is the required
cable diameter (mm).

Losses in Voltage are increasing:
if the cable is too long or
if the diameter is too small.
Losses must be limited in order
to ensure proper functionality of
the system.

Cables and wiring
General rule:
DC requires bigger cable diameters than AC.
12 VDC requires bigger cable diameters
than 24, 36 or 48 VDC.
(for the transmission of the same power over the same distance)

Formula for the calculation of the required cable
diameter A in mm:




If the calculated diameter is not exactly fitting to
available standard cables,
choose the next bigger standard cable.
For DC systems, cable diameters are very important
89
| |
| | | |
| |
(

O -
- -
-
=

2
mm
m
losses V voltage
W power m length
mm A
Cu
_
Standard cables: 0.5 0.75 1.0 1.5 2.5 4.0 6.0 10 16 25 35 50 -70 95 ... mm.

insert here
56
for copper cables
(38 for aluminium)
Module interconnection and array design
Specific solar cables increase safety and efficiency
90
In order to ensure earth fault and short-circuit
proof cable laying,
+ and poles must not be laid together in the
same cable.
Standard cables are normally approved up to
60C temperature. Outdoor module cables may
reach higher temperatures.

Solar cables are double-insulated and approved
for up to 125C.
Connectors must be touch-proof and sealed.


Proper connections are necessary to avoid
excessive losses.
Poor contacts can lead to the occurrence of
arcing and increase fire risk.
Connectors
Sealing caps
Fasteners
III. Components
1. Batteries
2. Charge controllers
3. Inverters
4. Cables and wiring
5. Mounting systems
91
Mounting Systems
92
Roof integrity must be maintained.
Panel must be stable,
even in strong wind.
MODULE 4
DESIGN OF SOLAR SYSTEM
93
Planning and design guidelines
Recommended
planning procedure
94
Planning and design guidelines
Checklist:
Type and location of consumers.

Existing power supply on site: public grid diesel generator none.
Existing electrical installation; okay needs improvement none

Location and available space for the PV array (checked with meter - drawing)
Possibility to orientate the PV array to the south (checked with compass).
Buildings, trees, bushes south of the PV array (distance and height - drawing).
Overhead cables ( electricity, telephone) which could shadow the PV array (distance and
height).
Distance between PV array and consumers (checked with meter - drawing).

Sufficient space for batteries/charge controllers/inverters. open space in a building
Cabling requirements and barriers (cable lengths checked with meter drawing).

Required site protection (e.g. against vandalism or theft - description).

On-site visit and site survey
95
Planning and design guidelines
Select the key elements of the required systems design
Required solar/electrical system components:
PV module/array
Charge controller
Battery/battery bank
Inverter
Backup power supply (diesel)
____________________
____________________
Consumers devices to be supplied with power:
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
(3) Basic systems design

96
97 .
SOLAR SYSTEM DESIGN
STEP-1 ( Power Consumption)
APPLIANCE WATTS QTY TOTAL
WATTS
HRS/DAY TOTAL
WATT-HRS
Ceiling fan 115 02 230 20 4600
Energy
Saver
24 02 48 06 308
TOTAL 139 04 278 26 4908
Total Watts = 300W
TOTAL WATT-HRS= 5 KWHRS PER DAY = 5 units per day

98 .
SOLAR SYSTEM DESIGN
STEP-2 ( Watts to be generated)
TOTAL WATT-HRS= 5 KWHRS PER DAY = 5 units per day

Multiply loss factor = 5000 x 1.3 = 6500 Watt-Hours per day

Total peak hours = 5

Total watts generated = 6500/5 = 1300 W

99 .
SOLAR SYSTEM DESIGN
STEP-3 ( Watts Peak Required to be generated)
TOTAL WATT-HRS= 5 KWHRS PER DAY = 5 units per day

Multiply loss factor = 5000 x 1.3 = 6500 Watt-Hours per day

Total peak hours = 5

Total watts generated = 6500/5 = 1300 W

Let we use 100W solar panels = 1300/100 = 13 Panels

100 .
SOLAR SYSTEM DESIGN
STEP-4 ( Inverter sizing)
TOTAL WATT- of all appliances = 300 W

Safety = 30%

Total Load watts = 300 x1.3 = 390 Watts

Inverter Size = 400W




101 .
SOLAR SYSTEM DESIGN
STEP-5 ( Battery sizing)
Battery Voltage = 12 V

Autonomy = 2 days

Battery capacity = Total watt-hours x 2
-------------------------------
0.85 x 0.5 x 12

Battery = 5000 x 2
------------------ = 1960 Ahrs
0.85 x 0.5 x 12

Let we use 200AHR battery
Total number of batteries of 200AHr each = 10

102 .
SOLAR SYSTEM DESIGN
STEP-6 ( Charge Controller)
One string = 06 panels
Each String has short circuit current = 07 Amp
Charge controller size = 7x2 = 14 Amp /12V

Solar Charge Controller = 15 or 20 Amp

300 W Solar Off-Grid System
Energy Generated = 5 Kwhr per day average
Operational Hours = 16.66 Hours per day
Solar PV Module = 100W QTY 12
Charge Controller = 20 Amp/12V
Inverter = 400W /12V QTY 01
Battery = 200AHR/12V QTY 10

103 .
COMPLETE INFROMATION FOR OFF-GRID SYSTEM DESIGN
TOTAL WATTS LOAD AND LOAD PROFILE
TYPES OF APPLIANCES
TOTAL OPERATIONAL HOURS PER DAY
AUTONOMY - OPERATION TIME WOTHOUT SUN
SPACE AVAILIBILITY FOR SOLAR PANELS AND
SHADING
DC CABLE LENGTH AND ROUTING
Price of system varies as per maximum load in watt, hours of operation
And autonomy
MODULE 5
INSTALLATION-
COMMISSIONING- OPERATION
104
Installation and commissioning
105
General safety guidelines
When installing off-grid PV systems, all the precautions taken when working on any
electrical system need to be observed.
Batteries in these systems present additional dangers.

Before carrying out any task, the relevant section of the manufacturers manual
should be read.
Components should be checked to make sure they are not damaged.
Components should be connected/disconnected in the correct sequence.
Work should only be done in dry conditions.
No work should be done on PV arrays, if there is any lightning in the area.
Systems should be inspected and tested before commissioning.
National codes and working practices should always be complied with.

Installation and commissioning
106
Electrical work on stand-alone PV systems and particular hazards
Never disconnect the batteries from the charge controller while the PV modules
are still connected to the charge controller.
The charge controller can be damaged by the high open circuit voltage of the modules.
Always disconnect the modules from the charge controller, before disconnecting the
batteries.
Always connect the batteries to the charge controller before connecting the modules to it.
Inverters are normally not reverse polarity protected.
If an inverter is connected incorrectly to a battery, it can be seriously damaged.
This will not be covered by the inverter warranty.
Fuses should not be removed when a circuit is under load to do so can cause arcing.
Correct DC polarity is to be observed when making all electrical connections.
Incorrect polarity can damage appliances and system components.
All wiring should be inspected and tested before commissioning. This includes:
Testing module/array open circuit voltage VOC and short circuit current ISC.
Verifying polarity.

Installation and commissioning
107
Lightning protection
National codes need to be consulted.
Modules on roofs or on poles attached to buildings should not be higher than the
highest point of the building.
In regions with frequent thunderstorms, a double pole disconnect / isolator should be
installed (even on small systems), so that the PV array can be isolated from the rest of
the system, when there is a risk of lightning strike.
No work should be carried out on PV arrays if there is thunder or lightning in the area.
Grounding/earthing
It is in many countries not usual to ground/earth off-grid PV systems with only one or
two modules (<100 Wp) and with system voltages below 24VDC.
National codes need to be referred to.
If grounding/earthing is required, the inverter ground/earth terminal, the PV array
and the battery are connected to a single ground/earth electrode.
For inverter grounding/earthing requirements to refer to the inverter manual.
Installation and commissioning
108
Battery safety
Battery manuals and instruction sheets should always be read.
Batteries are hazardous. The utmost care is called for when working on batteries.
(Sulphuric acid is corrosive in both liquid and vapour form.)
Hydrogen gas produced by vented batteries becomes explosive when mixed with
oxygen in the air. Battery rooms and enclosures must be vented at their highest point.
Pay attention to correct polarity when connecting cells/batteries to each other or the
inverters and other system components.
While working on batteries, remove metal jewelry such as rings, watches, chains.
Batteries should never be charged without a charge controller.
Tools should be insulated and placed on the floor, when not in use.
Battery temperatures should not exceed 50 C and batteries should not be exposed
to direct sunlight.
Used batteries are toxic waste and need to be recycled or disposed of correctly.

If the positive and negative terminal of a battery are connected (e.g. by a wrench or a
screw driver, the battery will short circuit. This can lead to explosion and fire.
Operation & Maintenance
1. Wise operation: Means the operation within designed limits.
2. Power management for maximum energy gain
3. Weekly or fortnightly cleaning of panels with wiper or with warm
water if the animal waste or some hard stints are there.
4. Continuous check of batteries charging and discharging through
solar controller.

109
Operation & Maintenance
a. What system owners can do to maintain proper function of the PV system
Visual inspection
Array shading or dirt on the array dust, dirt, pollen, leaves, tree growth, bird
droppings.
Dirt gathering near the edges of the modules.
Storm damage to modules or supporting structures.
Loose cables, cable damaged by rodents, chaffing or abrasion.
System owners must be informed of the danger of electric shock that occurs if cables or
components are damage and that these should never be touched.

Cleaning the array
Necessary in dry and dusty areas or during longer dry periods.
Water with a small amount of soap is sufficient. Never use solvents !
1. Maintenance of the PV systems

110
Operation & Maintenance
b. What the specialist can do
Yearly maintenance visits
Checking the operation of the charge controller and the inverter (if there is any
inverter).
Visual inspection of the array and visible cables.
Inspection of module mounting frame.
Checking the output of the PV system (voltage, current),
e.g. with multi-meter or special PV Analyzer.

Additional services
Measuring system performance.
Cleaning the array.
Cutting back vegetation causing shade.

When any maintenance or servicing is being done on the PV module/array, the
module/array should be disconnected from the charge controller and the battery.
1. Maintenance of the PV systems

111
Operation & Maintenance
Check in 6-monthly intervals:
Connections are sound and not corroded. Use terminal grease to avoid corrosion
Electrolyte level is sufficient top-up with de-ionized/distilled water if required.
Clean top of batteries to remove dirt, dust and moisture.
Check cell/battery voltage
In fully charged condition, disconnect from loads and power sources for at least half an
hour before checking voltage.
Check specific
gravity of
electrolyte
with hydrometer
in the event
of flooded cells.
2. Maintenance of the battery

112
113
THANKS


Faiz M BHUTTA faiz@izhar-energy.com