Professional Documents
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INTRODUCTION
This book is designed to be used as a manual for training on how to do basic design, install and maintain photovoltaic (SPV) and
Solar Thermal (ST) systems. It is not made to stand alone as a book that a person reads on their own, Rather, this book is more of
a workbook that can be used to help in the training of those who will be installing and using the systems too.
This book is intended to be used as a reference manual along with the certification program for dealer technicians.
Furthermore, the goal of this manual is not to go in depth into all of the intricacies of photovoltaic and thermal systems, but rather
provide the students with the practical information so that he or she will finish the training with knowledge on how to troubleshoot
and maintain solar systems supplied by Tata Power solar.
We hope that this workbook will be a useful resource in the future when the trainees are called upon to maintain, troubleshoot,
design or install a system.
A. Solar Panels
Converts sunlight to electricity.
B. Batteries
They store electricity. Converters Electrical Energy into Chemical
Energy and back when required. Proper use and maintenance
will help batteries work for years.
C. Charge Controller
Manages the flow of electricity between the solar panel, battery
and load. It is the central component of the solar PV system and
very essential part for proper functioning of the overall PV
system.
D. Inverter
Converts DC power from the solar panel and battery to AC
power. Inverters are not always used. When they are used they
can be combined with the same piece of equipment at the
charge controller to combine both and sometimes called a solar
power conditioning unit (PCU).
E. Load
Usage of electricity, e.g. lights, LED light, computer, radio.
F. Wires / Cables
Connects various components together. A proper selection
saves a lot of power. Cables are supplied with TPSSL PV 2.0 HOW A SOLAR PANEL WORKS
systems.
The solar panel only creates electricity when there is sun. The
below picture depicts that when it is sunny the solar panel
captures the energy from the sun and converts it into electricity
Typical battery / inverter based solar PV system and turns on the light. When there is no sun, the panel does not
make electricity and there is no light.
This is the most simplest solar panel system, the load will only
work when there is enough sun for the solar panel to produce
electricity.
The rated output of the panel is determined by the voltage and Voltage at open circuit (no load connected) -19 to 22V depending
current that the solar panel can produce. Generally, solar panels on age, sunlight intensity and cleanliness of the panel surface.
produce electricity at either 12 or 24 volts. Therefore, the Voltage at maximum power Vmp- about 82 to 85% of Voc.
amount of current the solar panel produces determines the Current at short circuit – Isc – depends on power rating. Leads
amount of power the solar panel produces. Using the power short circuited. Current at Maximum power – ~10% less than
equation below, we can calculate the amount of power that Isc.
something will produce or consume.
Power is measured in Watts, Voltage is measured in Volts and Power = Watts Energy = Watt-Hours
the Current is measured in Amps.
A watt is the amount of power that a solar panel can produce or
If a solar panel produces 5 amps of electricity at 12 volts, the that a light bulb consumes.
total power it produces is 60 watts: Watt-Hours = Watt X No. of Hours
5 Amps X 12 Volts = 60 Watts For example, A 11 watt CFL requires power of 11 watts to light
(current) (voltage) (power) up. If a 11 watt CFL works for 3 hours, it consumes energy of 11
watts X 3 hours or 33 watt-hours:
However, if you have 2 panels that produce 5 amps at 12 volts, 11 Watts X 3 Hours = 33 Watt-Hours
the total power that the panels produce is 120 watts:
5 Amps X 12 Volts = 60 Watts x 2 panels = 120 Watts 4.0 The Sun as an energy source
If it is a larger panel and it produces 8 amps at 12 volts, then the Understanding how the Earth receives light from the sun is
total power the panel will produce is watts: extremely important in designing a photovoltaic system. This
section explains some of the basics of how the sun works and
6 Amps X 12 Volts = 96 Watts how we measure the strength of the sun at different locations.
Every solar panel has a maximum amount of current that it can Various ways by which we get solar radiation
produce. The amount of current that a solar panel produces in a
given moment depends on the amount of sunlight present and
several other factors which will be reviewed later.
PSH is found by adding up all the amount of sun received for (Watt hours/m2 /day)/1000watts/m2 = Hours of perfect Sun per day
every hour of the day and then dividing the total by 1000 W/m2. (4000 watt hours/m2 /day)/1000watts/m2 = 4 PHS
In the below Figure, the curve shows the amount of sun received
per hour over the day and the box shows the total number of Unfortunately, every day does not give the same amount of sun.
perfect sun hours in the day. Table 1, on the following page, Therefore before we can know the PSH for a certain area, we
shows one example of calculating PSH. need to do the above calculation for every single day of the year
and calculate the average. For example, in South India the PSH
is 4. Some days there we have a PSH of 5 and other days have
a PSH of 1, but on average the PSH is 3.
Every hour of the day the sun will produce a different amount of
power (watts) per meter squared. To find out how many perfect
hours of sun are present in a day, the amount of watt hours / m2
is added up and then divided by 1000 W / m2.
4.2 Orientation In general, the best average position for mounting the panel is
tilted towards the equator at an angle approxi¬mately equal to
We know that the Sun is the source and it is very important to the latitude of the location. Hence, for locations on the equator,
mount the panel correctly so that we capture as much sun as the optimum angle is horizontal, but we still tilt that panel at an
possible. Solar panels produce the most electricity when they angle to allow the rain and due to help keep it clean.
are perpendicular to the sun light. Since the sun moves all day,
it is not practical to keep moving the panel all day to keep it The following are illustrations for an area about 30o north or
perpendicular to the sun. south of the equator.
The Solar panel functions by collecting the light energy from the
sun, this energy comes in the form of photons. The photons are
captured by the solar cell and the energy from the photon makes Power = Voltage X Current
an electron move in the solar cell, which creates a current and
electricity. 5.2 Changes in IV Curves
Physical
• Material - Mono/Multi Crystalline Si
• Shape - Circular/Pseudo sq./Square The charge controller is the brain of the PV system. The wiring
• Thickness - 200 to 250μ from the solar panels, the batteries, and all of the loads goes
• Colour - Blue/Blueblack through the charge controller. The charge controller manages
the flow of electricity from the panels, into and out of the
Electrical batteries, and to the loads. It has four main functions:
• Current • Protects the battery from overcharging, by controlling how
• Limited to Isc (no damage when shorted) the PV panel charges the battery
• Proportional to area and insolation • Protects the battery from discharge, by disconnecting the
• Very little dependence on temperature loads when the battery voltage gets too low
• Voltage • Gives information on the state of charge of the battery and
• Limited to Voc functional status
• Not dependent on size • Protects the system from reverse connection of battery or
• logarithmically dependent on insolation module
• Dependent on temperature
• Can not store electricity PWM controlled charger
Nominal voltage of 0.55V requires series connection to get • Pulse width modulation (PWM) charge controller; the solar
useful voltage of 17V to charge 12V battery. array is connected to the battery via a switching circuit
Short circuit current is proportional to light intensity. • By varying the pulse width duty cycle the output voltage to the
battery can be controlled
• In such a controller, initially when the battery is low the panel
is directly connected to the battery, however, as the battery
voltage picks up, the switching sequence starts
• The pulse width is randomly modulated to maintain the output
voltage accross the battery
• At the end of the charge the pulse width becomes so narrow
that the battery voltage floats to the set voltage of the charger
Maximum Power Point Tracker solar charger resistance to the flow of electricity. The terminations need to be
made with the proper connection materials.
A Maximum Power Point Tracker (MPPT) solar charger is a high
efficiency DC to DC converter which functions as an optimal Twisted wires can lead to resistance and sometime burning of
electrical load for a solar pane there by extracting maximum the wire, an improper termination and looses connection leads
power from the panel to burning of connector.
The wiring is what carries the electricity from the panels to the When current passes through a wire, voltage drops from end to
charge controller and to the batteries and from the batteries end as a result of the resistance in the copper wire. This is an
through the charge controller out to the loads. important consideration in all systems, but more so in low
In a water system, if the pipes are too small, the water will not voltage (12V e.g.) systems. Losing 2 volts on a 240V system is
flow properly through the pipes to where you need it. This is not too bad since it only represents less than 1% of the voltage
because of the small size of the pipe. lost to resistance.
Similarly, in an electric system, if the wiring is not sized and But, losing the same 2 volts on a 12V system represents a
installed correctly, the electricity will not flow properly to the voltage loss of almost 17% which is quite excessive!
loads. In electrical wiring, the two main considerations are the The amount of voltage that is lost for a given wire size and
wire size, and the terminations. current flow is based on how much wire there is, or the length
of the wire and the wire thickness.
If the wiring is too small, or if the terminations are not made
properly, either of these conditions will result in too much We never want to lose more than 5% to voltage drop, so on a
resistance to the flow of electricity, and the system will not work 12V system; we do not want to lose more than 0.6V. Refer a
properly. standard wire table for selecting the correct wire size.
7.1 Terminations
8.0 Batteries
To make terminations properly, all wire connections need to be
clean and tight. Twisting wires together and taping them is not A battery based PV system is really a battery system with PV
good enough. The looseness in these connections adds panels charging the batteries. Batteries store watt hours just
like a fuel tank stores fuel.
In a car when the tank gets low we go to the gas station and fill
it up. A solar panel and battery work similarly. During the day the
solar panel fills up the battery with watt hours and at night we
take the watt hours out of the battery to power our loads.
8.1 Types of batteries Lead Acid Batteries are made for either car/trucks or solar
panels systems. Batteries made for solar panel sys¬tems are
called Deep Cycle Batteries.
(Any measurement done during charging will yield wrong How to use a hydrometer
results)
Battery construction
Handling batteries
Specific gravity measurement
• Do not short battery terminals or else the batteries could
explode
• A fully charge battery can pump a huge current under short
circuit
• Acid is corrosive. Always wear rubber gloves
• Your eyes are too precious. Protect them with safety goggles
• Wear a safety apron to prevent acid spilling on your dress
• Do not wear dangling jewellery. They can cause short circuit
and cause burns
Hazards in batteries
Battery storage
Keep batteries
• In well ventilated rooms
• In coolest part of the room (in warm regions)
• In the warmest part of the room (in very cold regions)
• With no junk lying around
• Away from reach of children
• Away from flames with no stoves anywhere near
• In no smoking areas
Battery topping up to maintain electrolyte levels
Battery care
Battery don’ts
• Don’t put off recharging batteries unless battery is fully 9.1 Pure sine wave inverter
charged
• Don’t discharge a battery any deeper than you possibly have These inverters produce pure sine wave output similar to the
to grid power.
• Don’t mix different size and type of batteries
A microcontroller generates sine modulated PWM sampled at
high frequency.
Battery and electronics
These are fed to a transformer primary thru a set of MOSFETS
• Ensure that the battery is placed in a well ventillated battery arranged as a bridge.
box
• Many a times battery fumes create corrosion in the electronic A series of filter elements with inductor and capacitor filters the
circuits and charge controller PCB and these have to be output to recover the sine wave from the PWM pulses.
inspected frequently Efficiency, waveform quality and no load current needs to be
• A corroded PCB cannot be repaired checked before using these inverters in solar systems.
• Avoid touching metal parts after working on batteries
• Wash your hands immediately after working on batteries
10.0 Designing a PV System
The first step in designing systems is to find out the total • Temperature at 25 degrees Centigrade on the panel surface
consumption that needs to be powered by the PV System. Once • Sun intensity is 1000W/Sq. Mtr. (air mass of 1.5)
the total load on the system is known the PV System can be • Wind Speed of 20mtrs/Sec
designed. The few lines have been filled out as an example.
10.4 Accounting for non-perfect Sun
Loads Qauntity Watts Hrs/Day Whrs/Day
Fluorescent Lamp 2 20 4 160
We take care of the issue with the amount of perfect sun shining
LED Light 1 1 6 6
on the panel by using the Peak sun shine hours for the hours of
DC Outlet (computer 1 70 1 70
or charger) sun, instead of counting the hours when the sun is shining. Even
Total 236
though it might look like the sun is shining brightly for 6 or even
8 hours in a day, we use the PSH value talked about earlier to
estimate how many watt hours the panel will produce.
10.2 Efficiency of the PV System
For example, one might think that a 100 watt panel would
Now that we know the loads that we need to provide power for, produce 600 or 800 watt-hours in a given day because the sun
the next step is in sizing the main components – the solar is shining for 6 or 8 hours. However, if the PSH value for the area
panels, the battery, the charge controller, and the wiring. is 3, then we can only count on the panel producing 3hrs * 100
watts, or 300 watt hours in a given day.
We need to keep in mind that we need the energy we calculated
above available at the loads. But, when ever energy is produced
or moved, there are losses involved, since nothing is perfect. So, 10.5 Accounting for non-standard temperature
we need to size the panels and the batteries large enough to
account for the losses, and still have enough power left over for As stated above, the panel produces its rated watts when the
the loads. temperature of the panel surface is 25 degrees C. So, we have
to adjust for the times when the panel surface is NOT at 25
System Efficiency depends on the efficiency of all the associated degrees C.
parts like Module / Panel + Charge Controller +Battery + Wire
and cables + Loads + Inverter. Although Solar Panels need sun to produce energy, when it is
very hot out the solar panels will not work as well as on sunny
days when it is cold. Solar panels functions the best at 25o C.
10.3 PV Panel Output Therefore, whenever the solar panel is warmer than 25o C, it will
not produce is rated wattage.
In an ideal condition, a 100 watt solar panel will produce 100
watts of power when the sun is shining on it. But, this is rarely Air Temperature C + 15 C = Temperature of the Solar Panel
the case. A solar panel only produces its rated watts under a
specific set of conditions: For every degree that the solar panel temperature is above 25oC
the solar panel output 0.5% less. Below is an example.
• Perfect sun shining on the panel, perpendicular to the surface If the Air Temperature = 30o C,
Temperature at which the solar panel produces its rated watts = 10.7 Wiring Efficiency
25 C
o
45oC-25oC=20oC (this is the amount that the solar panel is Earlier, we talked about the need to use larger wire so we don’t
above the optimal temperature) have a large voltage drop. We wanted to keep the voltage drop
20oC * 0.5% per degree = 10% loss, so the panel output is 90% to 5% or less. When we lose volts because of wire that is too
at 30 Co
small, this also means we lose energy because volts multiplied
by amps = watts.
IN THIS EXAMPLE THE SOLAR PANEL LOSES 10% OF ITS
POWER TO TEMPERATURE LOSSES Properly designed wiring may have a combined efficiency of
97% or 0.97. So, we need to include a loss factor for what we
lose in the wire. If we size the wire correctly, this loss factor
could be as little as 3%. If we use too small, or too long a wire
then this factor could be over 10% which is very large.
In taking all loses into account, the PV array size can be found
100W Panel X 90% (because of loss due to temperature) X 3PSH by dividing the total number of watt hours re¬quired in a day by
per day = 270 watt-hrs per day of energy output the multiplication of the PV panel output, battery efficiency and
wiring efficiency. If we have a condition where the air
To summarize, if we install a 100 watt solar panel in an area temperature is 30oC on average, we have a battery, and the
with a PSH of 3.0 and where the average air temperature is 30 wiring is sized correctly, then the power delivered to the load
degrees C, we can expect to produce from this panel. from a 100 watt panel would be:
But, this output is still at the panel, and not at the load. We still 100W X 90% for temp. loss X 85% for battery losses X 97% for
have to get the energy through the wiring and through the wiring losses = 74W
battery. We will lose some energy at each place.
Next, multiplying 74W by the Peak Sun Hours (PSH), in one day
in an area with a PSH of 3.0, the energy, in watt-hours, available
10.6 Battery Efficiency at the loads from a 100 watt panel would be:
74 watts * 3 hours of perfect sun = 223 watt-hrs
Most batteries have an efficiency rating of about 85%. This
means when energy passes through the battery, about 15% of This is quite different than if we had assumed no losses and
the energy is lost. hoped to get 100 watts of power for 3 hours or 300 watt-hours.
It is even more different than if we had hoped to get the 100
Battery efficiency is 85% or 0.85. watts of power for all 6 hours when the sun appears to be
shining, or 600 watt hours.
307 watt-hrs / 3 hours = 102 watts But, if we sized the battery at 271 watt hours, this would mean
that:
We would purchase a solar panel rated at least 100 Watts. But • We would not have any energy left in the battery on days when
for battery charging considerations, a larger panel would be the sun does not shine to charge the battery backup.
better to be able to fill up the battery more quickly following time • We would also be completely discharging the battery every
with low sun. day, which we said earlier is very bad for the battery.
This example was for a DC system, with no inverter. A charge So, we have to size the battery with these two considerations in
controller is quite efficient in passing through electricity, but the mind:
inverter does incur losses. If an inverter is in the system, we will
have to add another loss factor. Inverters are typically 85% to Days with no sunshine
90% efficient. So, with an inverter in the system, the panel and
the battery would need to be even larger. We have to make some kind of guess as to how many days we
want to keep the system working with no sun. One day is
obviously not enough. But, if we try to make it too long, the
battery gets too big and expensive. Changing the days without sun, and the allowable depth of
discharge can make a big difference in the size of the battery.
Often, we use three days as a good design range for providing
for power with no sun. So, to provide for three days of no sun, For example, if we said we only needed to provide for two days
we would need the battery to store: with no sun, and we could discharge the battery to 55%, then
the battery size would be:
271 watt-hrs needed per day x 3 days with no sun = 813 watt-
hrs 230 watt-hours / 0.85 for battery loss = 271 watt-hrs
271 watt-hours x 2 days with no sun = 542 watt-hrs
Prevent the battery from discharging more than 542 watt-hours / .55 for depth of discharge = 985 watt-hrs
50% 985 watt-hours / 12V = 82 Amp hours
The above sized battery would still have us completely So, we need to understand what size of battery we are providing
discharging the battery during those times when there is no sun when we size, and purchase a battery. It might be necessary for
for three days. We said earlier that we did not want to discharge cost or portability, in this case to purchase the smaller battery.
the battery any further than half. So, we would need to have a But, we need to know that we are giving up the one day of
battery that would hold twice as many watt hours as we need. energy without sun when we make that decision.
Aiming or Orientation
The earlier sections on design showed that to get the maximum
output from the panel, it needs to be oriented to the sun properly.
The panel should mount on an angle approximately equal to the
latitude of the area, and pointing to the equator. There are also
mentions of the correct tilt angle in the system user manual.
(If you are in the southern hemisphere, aim the panel to the
24V 3.5A-VOLTAGE HAS ADDED UP IN SERIES CONNECTION
north, and if you are in the northern hemisphere, aim the panel
to the south.)
12.3 Shading
If any portion of the panel is shaded at any time during the day,
its power output will be significantly reduced. Quite often,
panels are installed where there is no shading, but since trees
and bushes grow quickly in some areas, they become shaded,
so this needs to be considered during installation, maintenance
and proper customer education.
12.5 Cabling from the Panel to the Controller should be neat, and fastened securely in all locations. This
makes checking and fault finding much easier, and avoids
The cabling from the Panel to the Controller should be sized problems of connections being hung on the wiring.
large enough, and kept as short as possible, and located where The wiring needs to be large enough to avoid voltage drops.
it will not be a hazard or be pulled down. At the panel location Strain relief should be provided at all points where the wiring is
and at the building location, secure the cable tightly so that terminated to avoid tension on the connection.
there is no tension being placed on the junction box of the panel. All terminations should be made with proper connection
There are no sharp edges where the cable enters the building. equipment (wire nuts or terminal strips). Try to avoid just
stripping, twisting, and taping for connections, as this leads to
12.6 Controller Installation early failures and energy loss.
4. Battery initial charging not done properly implements as well as proper measuring equipments. Below are
5. Battery cable too thin to handle current. the lists of tools that are required.
8. Acid spillage on battery box and floor or worn out during normal use.
3. Age of a battery also can lead to this problem, in which case 24V battery powered unit- working window - 21V to 30V
a battery needs to be replaced and defective battery to be
recycled properly Array ON indication is glowing, but no charging current:
One or two cells show low specific gravity: 1. Check array voltage at A+ and A- Terminal of the controller.
Remedy:
1. This problem is more likely due to improper initial charging. 2. If it is between 17 to 20V for a 12V system, the charging
While the battery has been initially filled the acid concentration section is not probably working, Check the connections to the
could have varied from cell to cell due to stratification. This power device or relay in the controller.
normally happens in very large batteries.
3. If it is correct, Check continuity in the wires of both A+ and
2. Improper usage and battery kept on excessive usage with A- to ascertain that power flow is possible to the power card or
improper charging for long time. Due to sulphation the cells are relay card.
unable to produce power and also react back to produce acid.
4. If the array voltage is 1V above the battery voltage, then
3. Internal short circuit of cell due to entry of foreign materials probably the indicator has failed or LED is defective.
and impurities can also be the reason.
5. Check charging current is available by measuring using an
4. Most likely the battery can be revived by slow charging using ammeter.
a battery charger; however cell short circuits can be rectified by
manufacturer only. No load voltage:
14.3 Solar charge controller Likely reason for this symptom can be many.
Solar charge controllers are the central part of the solar PV 1. Low battery voltage – Battery voltage is lower than the
system and hence handle all the power flow in the system. The reconnect voltage of the regulator.
battery charging and discharge is controlled by this unit.
2. Power device failure in load side. (this can be a failure in
Before checking it is very important to ensure that all connections MOSFET or relay)
to and from the unit are in place with the correct polarity.
Protections circuits like fuse and circuit breakers are in proper 3. Defective output fuse.
condition and are ON. Reversal of polarity in DC supply can be
fatal and catastrophic. 4. Wrong settings in the control card.
Before checking charger one should have a fair idea of what the 5. Loose contact in the load output terminal.
working voltage of the charge controller is. This can be
ascertained by the following: 6. Defective PCB and control parts.
12V battery powered unit - working window - 10.5V to 15V
Unlike the solar PV panels, the solar Thermal systems use the
heat energy of the sun. Sun radiates heat and light continuously.
We can trap the sunlight to either generate heat or use it to
generate electricity.
Principle of operation
System components:
Absorption and Emission
1. Solar collector or Evacuated tube
2. Solar Hot water tank (Insulated)
When a material absorbs all the incident sunlight it looks black.
3. Piping and accessories
There are two types of solar collectors, one called a flat plate
collector and the other an evacuated tube collector. The collector
serves to collect the solar thermal radiation or heat. The collector
is filled with water from the solar tank which heat as the collector
heats.
Various insulating materials used in PUF-Polyurethane foam is used in all our solar tanks.
solar thermal system
7. Ideal for warm climates & Industrial application Evacuated tube collectors
Key components of a
solar water heating system
o
Solar water can heat the water from ambiet temprature of 25 C
o
to 60 C
Storage tank is used to store the hot water and to retain the heat
overnight
Absorbers
tube that carry the hot water. There are 9 such fins in a standard to the header. From the header the water rises to the storage
collector. tank.
Cold water from the storage enters from the bottom header and
gets heated and rises again and the process continues.
Collector components
Collectors are flat plates which collect the sunlight and convert
them into heat and consists of:
1. copper tubes called risers
2. copper fins
3. headers
Requirements for installation
4. frame
5. black insulation
1. Water hardness is <300 ppm
2. Shadow free area between 9 AM and 5 PM for fixing collectors
facing south.
3. Overhead tank that is 100mm over the
4. Storage tank level but not greater than 10feet
5. Overhead tank whose capacity is more than twice the
capacity of the storage tank
6. Usage point as close to the system as possible
7. Well insulated piping
Principle of operation
Important installation points
Copper collector fins absorb the sunlight and get heated up.
Copper riser tubes in turn get heated up and the water inside it. 1. Collector should be inclined at the angle specific to the place.
As the water in the riser gets heated, becomes lighter and rises 2. Storage tank should be kept close and just behind the
Sacrificial Anode
to the latitude of your site or as specified by the system stand WATER HARDNESS SCALE
inclination Grains/Gal mg/L & ppm Classification
Less than 1 Less than 17.1 Soft
1-3.5 17.1-60 Slightly hard
3.5-7 60-120 Moderately hard
7-10 120-180 Hard
Over 10 Over 180 Very hard
Recommended water conditions at usage point for our range of has to be minimum, to ensure adequate hot water to customer.
systems A large user line can significantly reduce hot water output and
loss of temperature.
1. Always ensure that the cold water line is tapped from the over
Installation tips for
head tank separately and not from the existing utility line. This
solar thermal Systems
will ensure reverse flow is prevented during high demand in
utility line.
Over head tank height:
2. Always bring the system cold water line to the terrace level
The over head tank bottom level should be at least 1feet above
before taking it to the system tank.
the top height of the system tank and this is a must for proper
3. Always install an air vent as close to the system outlet as
working of the system. The overhead tank height should not
possible.
exceed 12feet for a non pressurized system.
4. Ensure that the cold water tank is well within 10feet height
and also support the air vent when the height is more.
5. Ensure that the hose pipes connecting the tank to collector
have a smooth bend and is not sagging
6. Ensure that the customer is aware of mixer taps and its
functions always check if cold water is getting mixed with hot
water in the mixer taps.
7. Use only recommended pipe size for hot water external piping.
8. Ensure proper insulation of complete hot water piping.
9. External piping should not exceed 10 mtr. / 30 feet. If this
exceeds, the system output will be reduced on account of
Tank location:
increased heat losses in the pipe line.
The solar hot water tank has to be placed behind the collectors
10. Grouting of the system is mandatory.
and not in any other side; this ensures that the shadow of the
11. Immediately after installation, system must be filled with
tank does not fall on the collectors during any part of the day
water. Otherwise, in case of heavy wind, system may topple.
and year.
12. Do not let water into the system when it is very hot. Tank and
ETC tubes can get damaged due to sudden entry of cold water. Importance of air vent
Solar water heater sizing 1. Height of air vent - need to tie using guy wire
2. When the air vent is very tall [more than 5 feet] the air vent
Some useful thumb rules must be securely tied in all direction to prevent oscillation during
heavy wind and when birds sit on it
Capacity Number Number of Number of 3. This will ensure that the tank hot water outlet collar is safe
(in litres) of people bathrooms kitchens
from breakage
100 2-3 1 1
4. System without air vent would result in shrinking of the tank
200 4-8 2 1
300 8-10 3 2
500 10-12 4 3
Too big a system can lead to very high temperature hot water
and can reduce the system life. Scaling of hot water pipes and
the collector would also render the system useless after
prolonged non-usage.