TECHNICAL PROPOSAL FOR

SOLAR PV POWER PLANTS of 4kWp to 6kWp

CAPACITIES

Date:

Prepared for:

Document No:

7th May, 2011

Chhattisgarh State Renewable Energy Development Agency

Tender No: 1616/ CREDA/T4/ JNNSM/SPV/Tender/ 2011

EPPPL-110141-CR

Emmvee Photovoltaic Power Pvt Ltd.

#13/1, Bellary Road, Jala Hobli, Sonnappanahalli, Bettahalasur Post
Bangalore-562157, INDIA
Phone: +91-80-43233511/46, 9900545486; Fax: 91-80-28467808;
E-mail: info@emmvee.in ; Website: www.emmveesolar.com

Technical Proposal for Solar PV Power Plants of 4kWp to 6kWp capacities

INDEX
I.

INTRODUCTION ............................................................................................................................. 3

II.

AIM OF THE DOCUMENT................................................................................................................ 5

III. SYSTEM DESCRIPTION SOLAR PV POWER PLANTS ........................................................................ 5

IV. SYSTEM SCHEMATIC DIAGRAM SOLAR POWER PLANT ................................................................. 6
V. SYSTEM CONFIGURATION.............................................................................................................. 9
V.1.

PV MODULES ................................................................................................................................. 9

V.2.

POWER CONDITIONING UNIT ..................................................................................................... 11

V.3.

JUNCTION BOXES ........................................................................................................................ 12

V.4.

MOUNTING STRUCTURE ............................................................................................................. 13

V.5.

PVC Cu. CABLES ........................................................................................................................... 15

V.6.

BATTERY BANK ............................................................................................................................ 15

V.7.

AC DISTRIBUTION BOX ................................................................................................................ 16

V.8.

DC DISTRIBUTION BOX ................................................................................................................ 17

V.9.

LIGHTN ING ARRESTOR ............................................................................................................... 17

VI. SCOPE OF SUPPLY........................................................................................................................ 17

VII. GENERAL ..................................................................................................................................... 19
VII.1.

ASSUMPTION .............................................................................................................................. 19

VII.2.

EXCLUSION .................................................................................................................................. 19

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I.

INTRODUCTION

EMMVEE is one of the leading brands and the largest manufacturers of Solar Photovoltaic Systems, Solar
Photovoltaic Modules, Toughened Glass and Solar Water Heating systems. We have been growing from
strength to strength ever since our inception in 1992. With our Strong fundamentals, commitment
towards quality, World class leadership and state of the art manufacturing facility, we are poised to be
the market leader in the years to come. The strong and versatile quality management system in place
in every stage of the manufacturing process has earned us the prestigious ISO 9001-2008 certification
and our consistent effort towards environmental conservation has earned us ISO 14001 2004
certification.
In order to have a greater market reach, we have diversified into manufacturing of Solar Photovoltaic
(SPV) modules as per international standards. We established a State of the art Export Oriented Unit
(EOU) for manufacturing High quality Mono / Poly Crystalline Solar Photovoltaic Modules of an annual
capacity of 65 MW and will be enhanced to 135MW by the end of the year 2010. We are very well
equipped to produce Solar Modules ranging from 10 Wp to 300 Wp capacity. Our SPV modules are
certified by TV as per IEC 61215 & IEC 61730 (Part 1 and 2) PV module safety qualification amongst
a host of other enviable certifications.
Our Grid connect range of modules are exceptional due to the standard use of SGG Albarino P & G front
glass from Saint Gobain. The optimized surface structure of the glass enables up to 2.5% higher yield
annually. Along with the nationwide dealer network, we assure you get the best products and prompt
service.
Recently, we were awarded the EMERGING INDIA AWARD 2010 for the Best Performing SME in Power
and Telecommunication Space by ICICI Bank Business Banking and CNBC TV18, powered by CRISIL.
This is a testimony for our World Class Leadership, Outstanding Business acumen, best practices and
exemplary vision.

We have a technical tie up with M/s Solar Cap, a leading Denmark based company to produce high
quality Solar Water Heating systems for both domestic and export market. And with a manufacturing
capacity of 5000 collectors per month, we are the undisputed leaders in the manufacturing of solar
water heating systems.
Our company was awarded the Second prize by MNRE for Solar Water Heater Manufacturer (2002 07) presented by Smt. Pratibha Devisingh Patil, Honble President of India and SESI BUSINESS
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Technical Proposal for Solar PV Power Plants of 4kWp to 6kWp capacities

LEADERSHIP AWARD -2008 presented by Mr. S. Raghupathy, Honble Minister for State Environment
and Forest on 16.10.2008 at Chennai.

We have a state of the art Glass Toughening facility. All our glasses for domestic market for both Solar
Thermal & PV products are produced in house. We also cater to sectors like Construction, Architecture,
Furniture and Engineering industry.
Apart from the details which we have furnished, our products have been tested and approved by
ETDC/CPRI/MNRE/State Nodal Agencies to ensure that the customers are given the products of the
highest quality.
We also undertake Design, Supply, Install, Commission, and Provide after sales service for PV and Hybrid
Systems as per site and customized requirements.

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Technical Proposal for Solar PV Power Plants of 4kWp to 6kWp capacities

II.

AIM OF THE DOCUMENT

The purpose of this document is to propose Solar Photovoltaic Power Plants of 4kWp to 6kWp
capacities for Chhattisgarh State Renewable Energy Development Agency at various places in
Chhattisgarh. The document is aimed at giving details of Engineering, Manufacture, Supply,
Installation, Testing and Commissioning of Solar Photovoltaic Power Plants of 4kWp to 6kWp
capacities.
This document is prepared for the main intention to provide vital information on the Solar Photovoltaic
Power Plants. The detailed information regarding the various components that constitute the Solar
Photovoltaic Power Plants is provided in this document.

III.

SYSTEM DESCRIPTION SOLAR PV POWER PLANTS

The whole system comprises of Solar PV Module, SPV Array, Solar Charge Controllers, Battery Bank,
Module Mounting Structures (MMS), Lightning and Over Voltage Protection, Earthing Protection
amongst other vital components. The individual components descriptions are explained later in the next
section.
Solar PV Modules generates DC electricity in proportion to the amount of sunlight available, generating
the most power on a clear day when the sun is at a normal angle to the Solar PV Modules; and these
Solar PV Modules are connected in series and parallel to form a Solar Array, which can collectively
support the intended loads. The cables cross sections are selected in such a way that the voltages drop
and losses is kept at a minimum. The Solar PV Array is mounted on the Module Mounting Structure
(MMS) which are oriented towards the south and tilted at an angle which is determined by the latitude
of the location. The DC power produced from Solar Array through the DC Distribution Box is fed to the
Power Conditioning Unit (PCU). The PCU Installed in a control room converts the DC Energy produced by
the solar array to AC Energy. The AC Power output of the inverter shall be fed to the AC Distribution
Box.
It is essential to protect the system from various concerns and in this regard we have incorporated
Earthing Protection. The MMS material is hot dip galvanized to protect the material from corrosion.

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IV.

SYSTEM SCHEMATIC DIAGRAM SOLAR POWER PLANT

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V.

SYSTEM CONFIGURATION

V.1. PV MODULES
A Photovoltaic module is a packaged interconnected assembly of Photovoltaic cells, which converts
sunlight into Electrical Power. The Solar PV Modules capacity is selected such that they operate within
the system voltage range.
The Solar Modules are mono/ multi crystalline type, employing lamination technology using
established polymer (EVA) and Tedlar laminate. Modules will be made of High Transmissivity front
glass giving high encapsulation gain and silicon rubber edge sealant for module protection, mechanical
support and moisture proofing. This technology will enable the SPV Modules survive in the harshest of
conditions. The SPV modules supplied are IEC 61215 and IEC 61730 (Part I and Part II) certified, copy of
the certificates is enclosed.
The module frame is made of anodized aluminum, which has corrosion resistant properties. Keeping in
mind of the voltage surges in the SPV module, we have provided bypass diodes of suitable rating. The
SPV Modules are equipped with Module Junction Boxes which are IP rated (International Protection
Rating).
Our Solar PV Modules meet the highest technical standards. Inspection of incoming materials and a
comprehensive quality management system in production make sure that each and every solar module
is manufactured according to the same high quality standards. Annual TV inspections of our
production facilities document these high quality demands. Emmvee Toughened Glass and
Photovoltaics Private Limited has been certified ISO 9001:2000 and ISO 14001:2004.
Each PV Modules used in this Solar Power Project will have RF Identification Tag (RFID), which will
contain vital information of the Solar PV Modules. These RFID tags will be outside the module laminate,
and will be able to withstand harsh environmental conditions. The vital information is as follows:

Name of the manufacturer of the PV Module

Name of the manufacturer of Solar Cells

Month and year of the manufacture

Country of origin

IV Curve of the module

Peak wattage, Im, Vm, and FF of the SPV Module

Unique serial number and model no of the module

Date and year of obtaining IEC PV Module qualification certificate

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Name of the test lab issuing IEC Certificates

Other relevant information on traceability of Solar cells and modules as per ISO 9000 series

Features:
Visual, mechanical and electrical testing during and post production.
Automated production level ensures consistently high level of product quality.
Solar safety glass front, Cells embedded in EV, Weather and waterproof foil back.

Technical Specification of SPV Modules

Parameters

Specification

Make, Country

Emmvee, India
125Wp

Rated Power at STC

300Wp

Tolerance

1%

Number of cells

72

Open Circuit Voltage (Voc)

43.2 V

44.78 V

Short Circuit Current (Isc)

3.73 A

8.57 A

Max. Power Voltage (Vpm)

35.64 V

36.41 V

Max. Power Current (Ipm)

3.55 A

8.14 A

Mono/Multi Crystalline Solar Cells

Type of Cell
Module Dimensions

952 x 988 x 35 mm

2007 x 991 x 50 mm

Module Weight

14.0 Kgs

31.0 Kgs

Temperature coefficient open circuit voltage

-0.36%/ C

Temperature coefficient short circuit current

+0.02%/ C

Temperature coefficient rated power

-0.47%/ C

Certificates

IEC 61215 / IEC 61730 - Part 1 and 2

Operating temperature range

-10 to 90C

SPV Module configurations for Power Packs for 4 -6kWp capacities

Power Pack
Capacity

4kWp

5kWp

6kWp

Each Module rating

125Wp

125Wp

300Wp

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V.2. POWER CONDITIONING UNIT

Solar Power Conditioning unit (PCU) is an integrated system consisting of a solar charge controller,
inverter and a Grid charger. It provides the facility to charge the battery bank either through Solar or
Grid/DG set. The PCU continuously monitors the state of Battery Voltage, Solar Power output and the
loads. Due to sustained usage of power, when the Battery voltage falls below a preset level, the PCU will
automatically transfer the load to the Grid/DG power and also charges the battery.
Once the Batteries are charged to the pre-set level, the PCU cuts off the Grid/DG Power from the system
and will restore to feeding the loads from the battery bank & also restore to charging the battery from
the Available Solar power. The PCU always gives preference to the Solar Power and will use Grid/DG
power only when the Solar Power is insufficient to meet the load requirement.
Main Features of the Solar PCU are as follows, however some of the features are present only in some
Higher Rating Solar PCUs:

Industrial grade bi directional inverter

Integrated PV Charger Controller.

Rated for continuous operation at full load

Programmable battery management parameters

Temperature compensated battery charging

Solar Priority grid Charging

Continuous battery life and State of health monitoring

Integrated data and fault logging

Provision of Communication with external SCADA/ Network/ PC

Remote Diagnostics tools, monitoring and reporting via internet and GSM

The PCU will be equipped with a data logger for collecting & recording the hourly data of grid
status particular voltage & frequency

PCU will have provision for PCU by pass arrangement so as to cater load directly through grid, in
case of PCU failure.

Provision for an emergency switch on the front panel of PCU

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SOLAR PCU (INVERTER + CHARGE CONTROLLER) TECHNICAL SPECIFICATION

Parameters

Specifications

Switching Elements

MOSFET

Type of charger

Two stage PWM (for battery bank 96V), with

settable bulk & float level of battery bank in both
the cases

Nominal Inverter Capacity

4kVA , 5kVA, 6kVA

Inverter Surge Rating

105% > 60 sec, 150% >30 sec, 200% >5 sec

Nominal Array capacity

4kW, 5kW, 6kW

Battery Nominal Voltage

96V

Inverter output voltage

230V 2% for single phase

Grid Frequency

50 0.5%

Inverter THD

<3%

DC Ripple

<3%

Dielectric Strength

1.1kV between input/ output and ground with

EMI protections removed

Inverter Efficiency @ 40C, nominal load

>90%

Operating Ambient Temperature

5 to 50C

Humidity

95% Max. Non Condensing

Enclosure

Free standing, IP 21, Powder coated

Cooling

Temperature controlled fan forced

Protections

Short circuit, overload, over temperature, over

voltage, lightning, phase imbalance (in case of
three phase output), Reverse polarity

Make

Su-Kam / DB / OPS /

V.3. JUNCTION BOXES

The junction box will made up of FRP/PP/ABS with dust. Water and vermin proof. It will be provided
with proper locking arrangements.
Array Junction Box:
All the arrays of the modules shall be connected to MJB/ DCDB through the AJB. AJB shall have terminals
or bus bar arrangement of appropriate size junction boxes shall have suitable cable entry with glanding
arrangements for both input and output cables. Suitable MOV / SPD will be installed in AJB for
protection. Cable connection will be done in such a manner that fault findings, in any, can be identified
easily.
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V.4. MOUNTING STRUCTURE

MMS will be designed to be sturdy and to assists SPV Modules to render maximum output. The Solar
Module Mounting Structure (MMS) is designed for holding suitable number of modules. MMS are tilted
according to the Site Locations to maximize annual energy output. Support Structure design and
foundation or fixation mounting arrangements shall withstand minimum horizontal wind speed relevant
to site conditions.
All fasteners considered for use are of good quality Stainless Steel (SS-304 Grade). The Solar Array
structure is designed in such a way that it will occupy minimum space without sacrificing the output
from Solar Photo Voltaic (SPV) panels. Structures should be positioned in a shadow free zone/place. The
MMS will be oriented towards south direction and the tilt will be site dependent for the Optimum
energy harnessing capability, which ultimately increases the plant utilization factor, in turn benefits
the customer to a great extent.
Each MMS will have 2 or 4 legs (based on the power plant capacity) grouted on pedestals of minimum
300 x 300 x 300 / 500 x 500 x 500 mm. based on the power plant capacity Foundation bolts of stainless
steel of atleast 300mm long will be used.
Also attached are the general arrangement diagrams of the MMS which will be used to mount the SPV
Modules. Please note that, this is for illustrations only. The final design will be arrived upon at later
stages.

TECHNICAL SPECIFICATION OF PV MODULE MOUNTING STRUCTURE

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Parameters

Specifications

Type

Roof Top / Ground Mounted

Configuration

Designed to suit site requirements

Material

Mild Steel

Tilt angle

Suitable to site

Fasteners

SS 304

Design Wind Speed

150 kmph

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V.5. PVC CU. CABLES

The size of the cables between Solar Array interconnections, Solar Array to junction boxes, Junction
Boxes to Solar PCU and Solar PCU to Battery Bank etc shall be so selected to keep the voltage drop and
losses to minimum. All the cables supplied will be conforming to IS 694 and will be 650 V / 1.1 kV grade.
The bright annealed 99.97% pure bare copper conductors that offer low conductor resistance, thereby
resulting in lower heating and increased life, are considered. These wires are insulated with a special
grade PVC compound formulated and manufactured in-house. The skin coloration offers high insulation
resistance and long life.
CABLES TECHNICAL SPECIFICATION
Parameters

Specifications

Type

PVC cables

Cable Cross section

As per design

Material

Copper

Color

Red, Blue / Black

Standards

IS 694

V.6. BATTERY BANK

The Battery Bank will be of Tubular Low Maintenance Lead Acid type. We shall be using 2V Battery
connected in series to form the appropriate capacity Battery Bank. The Battery Bank will have a low
rate of self discharge of 4% per month. The battery will be staged on a suitable wooden stand duly
painted with acid resistant paint to cover less space. In order to stage the required number of batteries
which form the Battery Bank, we shall be providing Corrosion resistant and acid proof Storage Racks. A
non reactive acid proof mat will be provided to cover the entire floor space covering the batter rack.

BATTERY BANK SPECIFICATION

Parameters

Specifications

Battery type

Tubular Low Maintenance Lead Acid Battery

Battery Bank Capacity

As per the system schematic

Cell Dimensions

As per Design

Self Discharge

4% per month

Electrolyte specific gravity of the filling at 27 C

1.22 0.005

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Electrolyte specific gravity at the end of charge at 27 C 1.24 0.005

Electrolyte specific gravity at the end discharge

1.17 (Approx.)

Material of battery container

PP / HR

Type of Positive Plate

Tubular

Type of Negative Plate

Flat Pasted

Terminals

Lead Alloys

Electrolyte

Sulphuric Acid (H2SO4)

Sealing Method

Heat Sealing

Type of Stands

Wooden (Sal Wood)

Cycle life

1500 cycles at 27 Deg C and DOD of 80%

5000 cycles at 27 Deg C and DOD of 20%

Interconnects

Insulated except at the ends

Make

Southern / HBL / Sakthi

V.7. AC DISTRIBUTION BOX

This consists of box of suitable powder coated metal casing. One feeder per phase will be provided in
ACDB with MCB of suitable capacity installed at each feeder in the ACDB. Two Energy Meters one for
measuring power from Solar power plant and another measuring power from grid, ISI make, Single
Phase/ Three Phase, of good quality will also be installed in ACDB suitable placed to measure the
consumption of power from SPV Power Plant. Proper rating MCB will be installed at every feeder (in
case of single phase output also, there shall be three feeders) to protect feeders from the short circuit
current as per the requirement of the site & instructions of CREDA. A separate dedicated feeder from
conventional line to PCU as well as ACDB should also be installed, as per CREDAs instruction. A separate
change over switch of proper rating will also be suitably installed in the ACDB to isolate the existing
connected load from the Solar System & cater the power to the existing load from convention power
(Mains), in case of emergency. ACDB will be connected between PCU & Load.

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V.8. DC DISTRIBUTION BOX

This consists of suitable powder coated metal casing. In this box, a separate arrangement which shall
consist of MCBs of suitable specifications and which can withstand respective flow of current, with the
purpose of providing the option for isolating the battery bank & SPV arrays should be made. Proper
rating HRC fuse and MCCB/Isolator should be suitably installed in the DCDB as battery bank isolator. Ah
meter has to be installed to measure the cumulative charging and discharging status of batter banks.

V.9. LIGHTN ING ARRESTOR

The SPV Power Plant should be provided with lightning and over voltage protection. The principle aim in
this protection is to reduce the over voltage to a tolerable value before it reaches the PV or other sub
systems components. The source of over voltage can be lightning or another atmospheric disturbance.
Necessary foundation for holding the Lightning Arrestors (LA) is to be arranged keeping in view the wind
speed of the site and flexibility in maintenance in future. Suitable number of lightning arrestors will be
provided in the array field.

LIGHTNING AND OVER VOLTAGE TECHNICAL SPECIFICATION

Parameters

Specifications

Diameter

1 4 Diameter

GI Spike

12 Feet Long

Earth Pit

As per IS 3043

Protection

Power surges/ Lightning Strikes

VI.

SCOPE OF SUPPLY

The scope of supply by Emmvee covers the Supply, Installation and Commissioning of the Solar
Photovoltaic Power Plants. The system comprises of the following major components:
Each system consists of the following components:

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4kWp (96V Configuration) Solar Power Plant

Sl. No.

Description & Specifications

Quantity

Solar photovoltaic module 125 Wp

32 Nos.

Module Mounting Structure

1 Set

Array Junction Box

2 Sets

AC Distribution Box

1 Set

Power Conditioning Unit (PCU) - 96V, 4 kVA

1 No.

Battery Bank - LMLA Type Low Maintenance

Lead Acid Battery - 96V, 300 Ah

1 Set

PVC Cu. Cables 2.5, 4, 10 and 16 Sq. mm

1 Kit

Earthing Kit

1 Kit

DC Distribution Box

1 Set

10

Lightning Arrestor

1 Set

11

Hardware/ Lugs/ Ferrules/ Miscellaneous

1 Set

5kWp (96V Configuration) Solar Power Plant

Sl. No.

Description & Specifications

Quantity

Solar photovoltaic module 125 Wp

40 Nos.

Module Mounting Structure

1 Set

Array Junction Box

3 Sets

AC Distribution Box

1 Set

Power Conditioning Unit (PCU) - 96V, 5 kVA

1 No.

Battery Bank - LMLA Type Low Maintenance

Lead Acid Battery - 96V, 600 Ah

1 Set

PVC Cu. Cables 2.5, 4, 16 and 25 Sq. mm

1 Kit

Earthing Kit

1 Kit

DC Distribution Box

1 Set

10

Lightning Arrestor

1 Set

11

Hardware/ Lugs/ Ferrules/ Miscellaneous

1 Set

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6kWp (96V Configuration) Solar Power Plant

Sl. No.

Description & Specifications

Quantity

Solar photovoltaic module 300 Wp

20 Nos.

Module Mounting Structure

1 Set

Array Junction Box

2 Sets

AC Distribution Box

1 Set

Power Conditioning Unit (PCU) - 96V, 6 kVA

1 No.

Battery Bank - LMLA Type Low Maintenance

Lead Acid Battery - 96V, 800 Ah

1 Set

PVC Cu. Cables 4, 10, 16 and 25 Sq. mm

1 Kit

Earthing Kit

1 Kit

DC Distribution Box

1 Set

10

Lightning Arrestor

1 Set

11

Hardware/ Lugs/ Ferrules/ Miscellaneous

1 Set

VII.

GENERAL

VII.1. ASSUMPTION
Clear mounting area is available for the PV on the ground without shading/obstruction.
The mounting structures are selected considering significant flat space available.
Scope of supply indicated above.

VII.2. EXCLUSION
Any other items not mentioned in the above scope of supply.
All the civil works other than the foundation for module mounting structure is beyond
EMMVEE scope.
Note: Due to continual improvement and development the data mentioned above may change. Some photos are for indicative purpose and for
Tender purpose only.

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