trainee handbook - centurion university
TRANSCRIPT
Trainee Handbook
Solar PV Installer
SECTOR: GREEN JOBS
SUB-SECTOR: RENEWABLE ENERGY
OCCUPATION: INSTALLATION OPERATION AND MAINTAINANCE
REF ID: SGJ/Q0101, V1.0 4
ALIGNED TO: NCO-2004/ NIL
NSQF Level: 4
CREDIT: 4
HOURS: 84 (14 Weeks)
This course encompasses 9 National Occupational Standards (NOS) of “Solar PV Installer,"
Qualification Pack issued by “Skill Council for Green Jobs (SCGJ) of India”.
Solar PV Installer is specialized for mechanical, civil, electrical and electronics installations of
Solar Photovoltaic Systems as well as maintaining them properly and has the communication &
soft skills.
This Trainee handbook is designed to enable theoretical and practical training on Solar PV
Installation, O & M as per Solar PV Installer (Suryamitra) Qualification Pack (QP), SGJ/Q0101.
Sl. No. National Occupational Standards (NOS)
1 SGJ/N0101: Site Survey for installation of Solar PV System
2 ELE/N5903: Assess the customer’s Solar PV requirement
3 SGJ/N0102: Procure Solar PV system components
4 SGJ/N0103: Install Civil and Mechanical parts of Solar PV System
5 SGJ/N0104: Install Electrical components of Solar PV System
6 SGJ/N0105: Test and Commission Solar PV System
7 ELE/N6001: Maintain Solar Photovoltaic System
8 SGJ/N0106: Maintain Personal Health & Safety at project site
9 SGJ/N0107: Customer orientation for Solar PV System
Note: The assessment will be done as per performance criteria (PC)
Table of Contents
Sl. No. Topic Page No.
1 Introduction to Solar PV Installer Course (SGJ/N0101)
Unit 1.1 Icebreaker
Unit 1.2 Objective of the program
Unit 1.3 Overview of Solar Industry
Unit 1.4 Roles and Responsibility of Solar PV Installer (Suryamitra)
Unit 1.5 Career Progressions 2 Basics of Electrical and Electronics Concepts (SGJ/N0101) Unit 2.1 Overview and need of Electrical Energy Unit 2.2 Ohm’s Law: Electric Current, Voltage, and Resistance Unit 2.3Work, Power and Energy Unit 2.4 Electrical and Electronics components Unit 2.5 Grounding, Earthing and Lightning Protection Unit 2.6 Measuring Instruments 3 Basics of Solar Energy (SGJ/N0101) Unit 3.1 Energy from the Sun Unit 3.2 Sun-Earth Geometry Unit 3.3 Global Irradiance map Unit 3.4 Solar Energy Technology 4 Basics of Solar Photovoltaic systems (SGJ/N0101, SGJ/N0102) Unit 4.1 Introduction to Solar PV System Unit 4.2 Structure and Specification of different apparatus used in
Solar PV System
Unit 4.3 Operation of Solar Cell/Panel Unit 4.4 Configuration of Solar Panels Unit 4.5 Sizing and Load calculation of a Solar PV System 5 Tools and Equipment Used for Solar PV Installation (SGJ/N0101,
SGJ/N0102, SGJ/Q0104)
Unit 5.1 Identification and Specification of Tools and Equipment for
Solar PV Installation
Unit 5.2 Use of Tools and Equipment for Solar PV Installation 6 Site Survey, Mounting structure and Installation of Solar PV
System (SGJ/N0101, SGJ/N0103, SGJ/N0104, ELE/N5903)
Unit 6.1 The importance of Site Survey and Customer satisfaction Unit 6.2 Steps for safe installation of Solar PV system Unit 6.3 Basic on Mounting Structure and it’s Types Unit 6.4 Install Civil and Mechanical Parts of Solar PV System Unit 6.5 Installation of Electrical components Unit 6.6 Install of Solar Photovoltaic Module Unit 6.7 Install of Battery Bank Stand and Inverter Stand 7 Test, Commission and Maintenance of Solar PV system
(SGJ/N0105, ELE/N6001)
Unit 7.1 Tools and Accessories for SPV System testing and
maintenance
Unit 7.2 Wire and Earthing Continuity Test Unit 7.3 Testing of CCR, Inverter and Battery Unit 7.4 Sample Test and Commission Record Sheet Unit 7.5O & M of PV System 8 Prepare BOM, Maintain Personal Health & Safety at project site
(SGJ/N0102, SGJ/N0106, SGJ/N0107)
Unit 8.1 Prepare Bill of Materials (BOM) Unit 8.2 Establish and Follow Safe Work Procedures Unit 8.3 Use and Maintain Personal Protective Equipment (PPE) Unit 8.4 Work Health and Safety at Heights
1
Introduction
This unit is about an introduction to the industry, job role and responsibility as a Solar
Photovoltaic Installer.
Module Outcomes:
After completing this module, participants will be able to:
1. Know each other 2. List the objective of the program 3. Understand Green Jobs Sector in India 4. Describe and list the roles and responsibility of a Solar PV Installer 5. Identify the skills and attitude required to perform the job
Unit 1.1 Icebreaker/Introduction to each other
The trainer will start the session by introducing himself, and will include the below mentioned
points for smooth interaction.
Trainer Name
Qualification
Native Place
Working Experience
Hobbies
Aim in life
Unit 1.2 Objective of the program
At the end of this unit, you will be able to:
1. Demonstrate general discipline in the class room and during the training program
2. Explain the role of Solar PV Installer and job opportunities
3. Explain the advantages of doing this course
4. Acquire basic skills of communication
5. Monitor and resolve customer issues
6. Work effectively in the team and organization
Unit 1.3 Overview of Solar Industry
Solar Industry
About 5,000 trillion kWh per year energy is incident over India's land area with most parts
receiving 4-7 kWh per sq. m per day. India is the world's third largest producer and third largest
consumer of electricity. The national electric grid in India has an installed capacity of 362.12
GW as of 30 September 2019, given in the below figure. Renewable power plants, which also
include large hydroelectric plants, constitute 34.86% of India's total installed capacity (5th
position in the world). During the 2018-19 fiscal year, the gross electricity generated by utilities
in India was 1,372 TWh and the total electricity generation (utilities and nonutilities) in the
country was 1,547 TWh. The gross electricity consumption in 2018-19 was 1,181 kWh per
capita.Solar power in India is a fast developing industry. The country's solar installed capacity
reached 31.101 GW as of 30 September 2019 (5th position in the world),given in the below
figure. India has the lowest capital cost per MW globally to install the solar power plants.
Figure 1. Top 10 Countries in 2018 based on total PV Installation and added PV capacity
Figure 2.Installed Power Capacity by Sources in India
Pavagada Solar Park is a largest solar park in India, spread over a total area of 13,000 acres
(53 km2) in Pavagada taluk, Tumkur district, Karnataka. 600 MW of power was commissioned
by 31 January 2018. By the end of 2019, the park is planned to have a total capacity of 2,050
MW and will be one of the world's biggest solar farms.
The Top 10 Solar Power Companies in India
1. Tata Power Solar Systems Ltd.
2. Amplus Energy Solutions Private Ltd.
3. Icomm Tele Ltd.
4. Azure Power.
5. Moser Baer Photovoltaic Ltd.
6. Kotak Urja Pvt Ltd.
7. HHV Solar Technologies Pvt Ltd.
8. EMMVEE.
9. Vikram Solar
10. Inter Solar System
Unit 1.4 Roles and Responsibility of Solar PV Installer (Suryamitra)
Solar PV Installer checks, adapts, implements, configures, installs, inspects, tests, and
commissions different components of photovoltaic systems, that meet the performance and
reliability needs of customers by incorporating quality craftsmanship and complying with all
applicable codes, standards, and safety requirements.
1. Plan PV system configurations based on customer needs and site conditions
2. Measure, cut, and assemble the support structure for solar PV panels
3. Install solar modules, panels, and support structures in accordance with building codes
and standards
4. Connect PV panels to the electrical system
5. Apply weather sealant to equipment being installed
6. Activate and test PV systems
7. Perform routine PV system maintenance
Unit 1.5 Career Progressions
Apart from existing reports and analysis carried out, Skill Council for Green Jobs, through
collaboration industry interactions, has conducted an Occupational Mapping and Skill Gap
Analysis to identify the employment patterns in the Solar Industry. As part of this exercise, an
Occupational Map has been prepared to show the career progression for the installers.
Figure 3. Career progression of a Solar PV Installer (Suryamitra)
2
Basics of Electrical and Electronics Concepts
This unit covers the basic knowledge on Electrical and Electronics Engineering.
Module Outcomes:
After completing this module, participants will be able to:
1. Understand Ohm’s Law
2. Understand the basics of electricity, electrical and electronics concepts
3. Perform simple calculations to derive power and energy
4. Knowledge on measuring instruments
Unit 2.1 Overview and need of Electrical Energy
Electrical energy is a form of energy resulting from the flow of electric charge. Energy is the
ability to do work or apply force to move an object. Electrical energy is one of the most
commonly used forms of energy in the world. It can be easily converted into any other energy
form and can be safely and efficiently transported over long distances. As a result, it is used in
our daily lives more than any other energy source.
Electricity generation is the process of generating electrical energy from other forms of energy.
For electrical utilities, it is the first step in the delivery of electricity to consumers. The other
processes, electricity transmission, distribution, and electrical power storage and recovery.
Unit 2.2 Ohm’s Law: Electric Current, Voltage, and Resistance
Ohm’s Law, a law stating that electric current is proportional to voltage and inversely
proportional to resistance. Or Ohm's law states that the current through a conductor between two
points is directly proportional to the voltage across the two points.
Mathematical equation:
Where I is the current through the conductor in units of amperes, V is the voltage measured
across the conductor in units of volts, and R is the resistance of the conductor in units of ohms.
Electric current is the flow of electric charge (electrons). In electric circuits this charge is often
carried by moving electrons in a wire.
It is measured in Amperes (Amps), Symbol is I.
DC: Direct Current The electrons flow in one direction only. Current flow is from negative to
positive, although it is often more convenient to think of it as from positive to negative. This is
sometimes referred to as "conventional" current as opposed to electron flow.
AC: Alternating Current The electrons flow in both directions in a cyclic manner - first one way,
then the other. The rate of change of direction determines the frequency, measured in Hertz
(cycles per second).
Voltage, electric potential difference, electric pressure or electric tension is the difference
in electric potential energy between two points per unit electric charge. Voltage is the "pressure"
of electricity, or "electromotive force" (hence the old term E). V=IR
It is measured in is Volts, Symbol is V or U, old symbol was E.
Resistance is a measure of the opposition to current flow in an electrical circuit. It is measured in
ohms, symbolized by the Greek letter omega (Ω).
Signal: an electrical impulse or radio wave transmitted or received. Signal always in electrical
form and contain information/message.
Frequency (f): in physics, the number of waves that pass a fixed point in unit time. Unit- Hz
Unit 2.3 Work, Power and Energy
Work a force causing the movement—or displacement—of an object. Work can be done when a
force produces a motion. Work = Force X Distance = FXS.
Power is defined as the rate of doing work.Electric power is the rate at which electrical energy
is transferred by an electric circuit. The SI unit of power is the watt, one joule per second, P=VI.
Power = Work done/ time taken, P = W/t.
Energy: Capacity of doing work by a body is called energy. The energy required to do 1 joule of
work is called 1 joule energy.
Energy is a conserved quantity; the law of conservation of energy states that energy can
be converted in form, but not created or destroyed.
Example: In the case of an electric bulb, the electrical energy is converted to light and heat. The
amount of electrical energy put into a bulb = the amount of light energy (desirable form) plus
the heat energy that comes out of the bulb (undesirable form).
Figure 4. Basics on Work, Power and Energy
Unit 2.4 Electrical and Electronics components
Electrical and Electronics devices/components are components for controlling the flow of
electrical currents for the purpose of information processing and system control.
Electronic circuit must contain at least one active device.
Passive: Capable of operating without an external power source. Typical passive components are
resistors, capacitors, inductors and diodes (although the latter are a special case).
Active: Requiring a source of power to operate. Includes transistors (all types), integrated
circuits (all types), TRIACs, SCRs, LEDs,Battery, Transformer etc.
Link: https://www.electronics-notes.com/articles/basic_concepts/
https://www.makerspaces.com/basic-electronics/
https://www.watelectronics.com/major-electrical-electronic-components/
Unit 2.5 Grounding, Earthing and Lightning Protection
In electrical engineering, ground or earth is the reference point in an electrical circuit from
which voltages are measured, a common return path for electric current, or a direct physical
connection to the earth.
The key difference between earthing and grounding is that the term “Earthing” means that the
circuit is physically connected to the ground which is Zero Volt Potential to the Ground (Earth).
Whereas in “Grounding” the circuit is not physically connected to ground, but its potential is
zero with respect to other points.
Lightning arrestors and surge protectors are designed to protect electronic equipment by
absorbing electrical surges.
Figure 5. Ground (Electricity), Earth (Electricity) and Lightning protection
Figure 6. Solar module (left) and power plant (right) destroyed due to lightening
Link: https://www.youtube.com/watch?v=SGTUekOsTns
Unit 2.6 Measuring Instruments
Multimeter
A multimeter or a multitester, also known as a VOM (volt-ohm-milliammeter), is
an electronic measuring instrument that combines several measurement functions in one unit. A
typical multimeter can measure voltage, current, and resistance. Analog multimeters use
a microammeter with a moving pointer to display readings. Digital multimeters (DMM,
DVOM) have a numeric display, and may also show a graphical bar representing the measured
value. DMM is more useful than AMM.
Figure 7. Analog Multimeter & Digital Multimeter
Voltmeter
An instrument used for measuring electrical potential difference between two points in an
electric circuit.
Ammeter
A measuring instrument used to measure the current in a circuit.
Figure 8. Voltmeter & Ammeter
Clamp meter
An electrical device with jaws which open to allow clamping around an electrical conductor.
This allows measurement of the current in a conductor without the need to make physical contact
with it, or to disconnect it for insertion through the probe.
Figure 9. Clamp meter
Solar Power meter
A device used to measure power per unit area of incident solar radiation reaching
the meter's sensing area.
Energy meter
An electricity meter, electric meter, electrical meter, or energy meter is a device that measures
the amount of electric energy consumed by a residence, a business, or an electrically powered
device.
Tester
A piece of electronic test equipment used to determine the presence of electricity in a piece of
equipment under test.
Figure 10. Light meter, Energy meter and Tester
3
Basics of Solar Energy
This unit covers the Basic knowledge on Solar Energy and its technology.
Module Outcomes:
After completing this module, participants will be able to:
1. Understand different energy sources
2. Understand the basics of Solar energy and it’s need
3. Perform simple practice on Sun-Earth geometry
4. Knowledge on Solar energy technology
Unit 3.1 Energy from the Sun
Directly or indirectly the Sun is responsible for all of the energy on the earth. Solar
Energy radiation is a Clean, Green and renewable energy produced by the Sun. Solar energy
travels in small particles called “Photons”. Solar energy (photons) converts naturally into three
forms of energy- electricity, chemical fuel, and heat. About half the incoming solar energy
reaches the Earth's surface. The Earth receives 1.9 x 108 Terawatts (TWh) per year of incoming
solar radiation (insolation) onto land and energy used is 1.3 x 105 TWh/year. The amount of
energy humans use annually, about 4.6 x 1020 Joules, is delivered to Earth by Sun is in one hour.
Figure 11.Energy from the Sun
Figure 12. Earth’s Energy budget
Basics of Light to Energy Conversion
Light is a type of energy. It is an electromagnetic radiation within a certain portion of
the electromagnetic spectrum. The Sun is the source of energy for most of life on Earth. Visible
light is usually defined as having wavelengths in the range of 400–700 nanometers (nm) and
speed is 299,792,458 meters per second (2.99792458 x 10 8 m/s). Sunlight can be converted into
electricity by exciting electrons in a solar cell.
Energy Resources
Energy resources may be classified as primary resources, suitable for end use without conversion
to another form, or secondary resources, where the usable form of energy required substantial
conversion from a primary source.
Examples of primary energy resources are wind power, solar power, wood fuel, fossil fuels such
as coal, oil and natural gas, and uranium.
Examples of secondary resources are those such as electricity, hydrogen, or other synthetic fuels.
These primary sources are converted to electricity, a secondary energy source, which flows
through power lines and other transmission infrastructure to your home and business.
Another important classification is based on the time required to regenerate an energy resource.
Renewable and Non-renewable energy resources:
1. Renewable resources
2. Non Renewable resources
Renewable resources
Renewable resources are those resources that can be replenished or renewed or reuse or refill
naturally over time. Renewable resources can be easily renewed by nature.
Examples: Air, water, wind, solar energy (most used), Biomass etc.
Non Renewable resources
Non-renewable resources are those natural resources that are available in limited quantity. These
resources cannot be renewed or replenished in short duration. Therefore they are also known
as exhaustible resources.
Examples- Coal, Natural gas, Fuel, Nuclear etc.
Figure 13. Renewable Energy vs. Non-renewable energy
Unit 3.2 Sun-Earth Geometry
Figure 14.Sun-Earth geometry
Link: https://www.youtube.com/watch?v=rnM1hXJf4WU
Latitude and Longitude are the units that represent the coordinates at geographic coordinate
system. Just like every actual house has its address (which includes the number, the name of the
street, city, etc), every single point on the surface of earth can be specified by the latitude and
longitude coordinates. Therefore, by using latitude and longitude we can specify virtually any
point on earth.
Latitude is distance north or south of the equator (an imaginary circle around the Earth halfway
between the North Pole and the South Pole) and longitude is distance east or west of the prime
meridian (an imaginary line running from north to south), given in figure 15.
Both latitude and longitude are measured in degrees, which are in turn divided into minutes
and seconds.
Figure 15. Latitude and Longitude map
Unit 3.3 Global Irradiance map
Solar radiation, often called the solar resource, is a general term for the electromagnetic
radiation emitted by the sun. Or solar radiation is radiant energy emitted by the sun from a
nuclear fusion reaction that creates electromagnetic energy.
Solar irradiance is the power per unit area, received from the Sun.
A pyranometer is a type of actinometer used for measuring solar irradiance on a planar surface
and it is designed to measure the solar radiation flux density (W/m2) from the hemisphere above
within a wavelength range 0.3 μm to 3 μm.
Most part of India receives high intensity of solar sources with an average of 5 kWh/ m2/day, as
presented in figure 16.
Figure 16. Solar irradiance map
Insolation
Insolation differs from irradiance because of the inclusion of time. Insolation is the amountof
solar energy received on a given area over time measured in kilowatt-hours per square meter
squared (kW-hrs/m2) - this value is equivalent to "peak sun hours".
Peak Sun Hours Peak sun hours is defined as the equivalent number of hours per day, with solar
irradiance equaling 1,000 W/m2 , that gives the same energy received from sunrise to sunset. A
peak sun hour is of significance because PV panel power output is rated with a radiation level of
1,000W/m2. Many tables of solar data are often presented as an average daily value of peak sun
hours (kW-hrs/m2) for each month.
Unit 3.4 Solar Energy Technology
A principle of Solar Energy- It is created by light & heat, which is emitted by the Sun, in the
form of EM radiation. Solar technologies are broadly divided into Active or passive solar
depending on the way they capture, convert & distribute to Energy.
Active Solar Energy- Solar Photovoltaic (PV, 98%) panels, Solar Thermal collectors (CSP, 2%)
and Solar water heating, given in figure 17.
Passive Solar Energy- Orientation of panel to the sun, greenhouses, solariums and sunrooms.
Figure 17. Solar Energy technology
Solar Photovoltaic (PV) is a technology that converts sunlight (solar radiation) into direct
current electricity by using semiconductors. When the sun hits the semiconductor within
the PV cell, electrons are freed and form an electric current. Solar PV technology is generally
employed on a panel (hence solar panels). It is a direct process.
Solar thermal technologies capture the heat energy from the sun and use it for heating and/or
the production of electricity. It is an indirect process.
Advantages of solar energy
As a source of energy, solar has numerous advantages including:
• Sunlight provides 1000 times the energy we need
• Sunlight is free and abundant
• No pollution or waste after use
• Sunlight is quite predictable
• Sunlight is received everywhere on the Earth's surface (daytime!)
• Greater security of energy supply
4
Basics of Solar Photovoltaic systems
This unit covers the basic knowledge on Solar Photovoltaic system.
Module Outcomes:
After completing this module, participants will be able to:
1. Understand different Solar Photovoltaic (SPV) systems
2. Perform the single-line diagram of SPV systems
3. Understand the equipment’s used in SPV systems
Unit 4.1 Introduction to Solar Photovoltaic (PV) System
Solar photovoltaic system consists of following items;
1. Solar Panel/Module
2. Charge Controller/Inverter
3. Battery
4. Electrical Appliances etc.
Introduction to solar PV cell
A solar cell, or photovoltaic cell, is an electrical device that converts the energy of light directly
into electricity by the photovoltaic effect (i.e. EM effect), which is
a physical and chemical phenomenon. Photovoltaic is the process of converting sunlight directly
into electricity using solar cells.A Solar PV cell is the most basic unit of a solar PV system. It is a
form of photoelectric cell, defined as a device whose electrical characteristics, such
as current, voltage, or resistance, vary when exposed to light.It is made up by semiconducting
materials (Ex. Silicon).
Solar cell principle- Photovoltaic cells consist of two or more layers of semiconductors with one
layer containing positive charge and the other negative charge lined adjacent to each other. Light
striking the crystals induces the “photovoltaic effect,” which generates electricity.
Brief History of Solar PV cells
1. The photovoltaic effect was experimentally demonstrated first by French physicist Edmond
Becquerel. In 1839, at age 19, he built the world's first photovoltaic cell in his father's
laboratory.
2. In 1883 Charles Fritts built the first solid state photovoltaic cell by coating
the semiconductor selenium with a thin layer of gold to form the junctions; the device was
only around 1% efficient.
3. In 1985 silicon solar cells achieved the milestone of 20% efficiency.
4. In 1888 Russian physicist Aleksandr Stoletov built the first cell based on the
outer photoelectric effect discovered by Heinrich Hertz in 1887.
5. In 1905 Albert Einstein proposed a new quantum theory of light and explained
the photoelectric effect in a landmark paper, for which he received the Nobel Prize in
Physics in 1921.
6. Vadim Lashkaryov discovered p-n-junctions in Cu O and silver sulphide protocells in 1941.
7. Russell Ohl patented the modern junction semiconductor solar cell in 1946 while working on
the series of advances that would lead to the transistor.
8. The first practical photovoltaic cell was publicly demonstrated on 25 April 1954 at Bell
Laboratories. The inventors were Daryl Chapin, Calvin Souther Fuller and Gerald Pearson.
9. In December 2014, a solar cell achieved a new laboratory record with 46% efficiency in
French-German collaboration.
10. In 2020: Solar cells are predicted to achieve grid parity (solar-generated electricity you make
yourself will be as cheap as power you buy from the grid).
Figure 18. Solar Cell, Symbol, Concentrated solar PV (CSP) & Solar Heating Cooling (SHC)
technology
Advantages of Photovoltaic cells
• Environmental Sustainability: Photovoltaic cells generate clean and green energy as no
harmful gases such as Cox, NOx etc are emitted. Also, they produce no noise pollution
which makes them ideal for application in residential areas.
• Economically Viable: Operation and maintenance cost of cells are very low. The cost of
solar panel incurred is only the initial cost i.e., purchase and installation.
• Accessible: Solar panels are easy to set up and can be made accessible in remote
locations or sparsely inhabited areas at a lesser cost as compared to conventional
transmission lines. They are easy to install without any interference to the residential
lifestyle.
• Renewable: Energy is free and abundant in nature.
• Cost: Solar panels have no mechanically moving parts except in some highly advanced
sunlight tracking mechanical bases. Consequently, the solar panel price for maintenance
and repair is negligible.
Disadvantages of Photovoltaic cells
• The efficiency of solar panels is low compared to other renewable sources of energy.
• Energy from the sun is intermittent and unpredictable and can only be harnessed in the
presence of sunlight. Also, the power generated gets reduced during cloudy weather.
• Long range transmission of solar energy is inefficient and difficult to carry. The current
produced is DC in nature and the conversion of DC current to AC current involves the
use of additional equipments such as inverters.
• Photovoltaic panels are fragile and can be damaged relatively easily. Additional
insurance costs are required to ensure a safeguard to the investments.
Manufacturing process of Solar PV cell
Raw material: Silica (Sand, Sio2) converted to Silicon (Si), N-type and P-type Semiconductor
materials by doping, Sandwiching to make single Solar cell, Mono/Poly crystalline Solar cell,
Wiring and coating, Solar modules/panels.
Figure 19. Solar Cell/Module manufacturing process
Link:http://www.solarworld-usa.com/about-solarworld/value-chain#Silicon
List of solar cell manufacturer in India:
Link:http://www.iitk.ac.in/solarlighting/files/Indian_Solar_Industry.pdf
• Each Solar PV cell (Si type) can produce maximum open-circuit voltage of
approximately 0.5 to 0.6 volts.
• A Solar PV module/panel consists of multiple PV cells connected in series/parallel to
provide a higher voltage/current output.
• PV modules are manufactured in standard sizes such as 36-cells, 60-cells and 72-cells
module.
Figure 20. Structure of Solar cell and module
A PV string is a system consists of multiple PV modules. Array consists of multiple PV string
in parallel.
Figure 21. Solar Cell, Module, String & Array
Link:https://scindeks-clanci.ceon.rs/data/pdf/1451-4117/2016/1451-41171604481R.pdf
https://www.youtube.com/watch?v=ybvP8vjv1UY
Solar PV Cell/Module specification
Figure 22. Specification of Solar cell and panel
Link:https://www.altestore.com/blog/2016/04/how-do-i-read-specifications-of-my-solar-
panel/#.W_00kYczbIU
Technologically Classification of Solar cell
The majority of modules use wafer-based crystalline silicon cells or thin-film cells based
on cadmium telluride or silicon. Most solar modules are currently produced from crystalline
silicon (c-Si) solar cells made of multi-crystalline and mono-crystalline silicon.
Figure 23. Difference between Mono, Poly and Thin film panels
Classification of Solar Photovoltaic (SPV) system
Solar PV system is divided into two types 1) On-Grid and 2) Off-Grid systems
Figure 24. Classification of Solar PV system
On-Grid Solar system
• Solar PV system using On-grid is also termed as a Grid-tied system or Utility interactive
or Grid back feeding or Grid intertie system.
• In this kind of system, the Solar is connected with utility grid (typically the power lines)
along with the loads and batteries if any are present.
• In pure on-grid solar PV system, batteries are not connected.
Working of a Bi-directional meter or net metering
• Difference between the traditional unidirectional meter and the Bi-directional meter is
unidirectional meter only displays the total energy imported from the grid. Whereas Bi-
directional meter reads three readings.
• The total amount of energy exported (in kWh), total amount of energy imported, and net
energy difference of the export and import.
Benefits: These are are simplest systems and the most cost effective to install.
Figure 25. Block diagram of an On-Grid Solar PV system
Off-Grid Solar system
• An off-grid system is not connected to the electricity grid and therefore requires battery
storage.
• An off-grid solar system must be designed appropriately so that it will generate enough
power throughout the year and have enough battery capacity to meet the home’s
requirements, even in the depths of winter when there is less sunlight.
• Charge controller or Hybrid Inverter are used.
Benefits: Provides power for your critical loads when the power grid is down.
Figure 26. Block diagram of an Off-Grid Solar PV system
• Hybrid systems provide power to offset the grid power whenever the sun is shining and
will even send excess power to the grid for credit for later use.
• This means being able to store solar energy that is generated during the day and using it
at night. When the stored energy is depleted, the grid is there as a backup, allowing
consumers to have the best of both worlds.
Figure 27. Block diagram of a Hybrid Solar PV system
Unit 4.2 Structure and Specification of different devices used in Solar PV System
Charge Controller (CCR)
• A charge controller, charge regulator or battery regulator limits the rate at
which electric current is added to or drawn from electric batteries.
• It prevents overcharging and may protect against overvoltageof battery.
• It controls the flow of current in the circuit.
• It is a DC device (DC to DC converter).
• There are different types of solar charge controllers. One is a hybrid controller. Others are
PWM and MPPT solar charge controllers.
• Efficiency of MPPT is more than PWM type charge controller.
• Rating: Volt Ampere Hour (V Ah)
• Example: 12 V 5 Ah, PWM or 12 V 5 Ah, MPPT or 12-24 V 0-15 Ah
Link: https://en.wikipedia.org/wiki/Charge_controller
Figure 28. Solar charge Controller (PWM & MPPT)
Inverter
A power inverter, or inverter, is a power electronic device or circuitry that changes direct
current (DC) to alternating current (AC).
A solar inverter or PV inverter, is a type of electrical converter which converts the
variable direct current (DC) output of a photovoltaic (PV) solar panel into a utility
frequency alternating current (AC) that can be fed into a commercial electrical grid or used by a
local, off-grid electrical network.
• The input voltage, output voltage and frequency, and overall power handling depend on
the design of the specific device or circuitry.
• The inverter does not produce any power; the power is provided by the DC source.
• Rating: Volt-Ampere (VA) or Kilo-Volta-Ampere (kVA)
Solar inverters may be classified into three broad types
1. Stand-alone inverters, used in isolated systems where the inverter draws its DC energy
from batteries charged by photovoltaic arrays. Many stand-alone inverters also
incorporate integral battery chargers to replenish the battery from an AC source, when
available. Normally these do not interface in any way with the utility grid, and as such,
are not required to have anti-islanding protection.
2. Grid-tie inverters, which match phase with a utility-supplied sine wave. Grid-tie
inverters are designed to shut down automatically upon loss of utility supply, for safety
reasons. They do not provide backup power during utility outages.
3. Battery backup inverters, are special inverters which are designed to draw energy from
a battery, manage the battery charge via an onboard charger, and export excess energy to
the utility grid. These inverters are capable of supplying AC energy to selected loads
during a utility outage, and are required to have anti-islanding protection.
4. Intelligent hybrid inverters, manage photovoltaic array, battery storage and utility grid,
which are all coupled directly to the unit. These modern all-in-one systems are usually
highly versatile and can be used for grid-tie, stand-alone or backup applications but their
primary function is self-consumption with the use of storage.
Figure 29. Solar NXG Hybrid Inverter (12/24 V 1500 VA)
Battery
A battery is a device consisting of one or more electrochemical cells with external connections
provided to power electrical devices such as flashlights, mobile phones, and electric cars.
A rechargeable battery, storage battery, or secondary cell, (or archaically accumulator) is a
type of electrical battery which can be charged, discharged into a load, and recharged many
times.
• Battery Charging and discharging Process depends on Chemical Reaction between
Electrode (Anode and Cathode) Material.
• When battery is charging Electrons flow from Cathode to Anode through the Separator
and Current flow from Anode to Cathode.
• When a battery is supplying electric power, its positive terminal is the cathode and its
negative terminal is the anode.
• The terminal marked negative is the source of electrons that will flow through an external
electric circuit to the positive terminal.
• Rating: Volt Ampere-hour (V Ah)
Figure 30. Charging and Discharging process of a Battery
Types of Battery-
1. Lead Acid battery
• It is most widely used rechargeable battery.
• In the fully charged state, the negative plate consists of lead, and the positive plate lead
dioxide. The electrolyte is concentrated sulfuric acid, which stores most of the chemical
energy.
• In the discharged state both the positive and negative plates become lead(II)
sulfate (PbSO4), and the electrolyte loses much of its dissolved sulfuric acid and becomes
primarily water.
• The correct ratio of water to sulfuric acid in battery electrolyte is approximately: 80
percent water to 20 percent sulfuric acid.
• The ratio 3:1 means three parts of acid is mixed to one part of water.
• Efficiency: 80-90 %
2. Maintenance free
• A valve-regulated lead-acid battery (VRLA battery) sometimes called sealed lead-acid
(SLA) or maintenance free battery, is a type of lead-acid battery.
• There are three primary types of VRLA batteries, sealed VR wet cell, absorbent glass mat
(AGM) and gel cell.
• Efficiency: 70-80%
3. Li-ion Battery
• A lithium-ion battery or Li-ion battery is a type of rechargeable battery.
• Lithium-ion batteries are commonly used for portable electronics and electric
vehicles and are growing in popularity for military, aerospace and solar applications.
• Efficiency: 90-95 %
Figure 31. Solar Tubular (Lead-Acid), Maintenance free and Li-ion Battery
C10Solar Battery
Let us just take an example of 150 Ah battery
A 150 AH battery at C20, will last for 20 hours on a load of 7.5 A.
A 150 AH battery at C10 will last for 10 hours on a load of 15 A.
A 150 AH battery at C5 will last for 5 hours at a load of 30 A.
C5,C10,C20 all means the same meaning if it is rated as 150AH. All batteries are able to supply
150 Amps for 1 hour or 1 Ampere for 150 hours. It should follow the simple rule
x(hours)∗y(Ampers)=150 if it is mentioned as 150AH.
Then what is the difference between battery type,such as C5,C10,C20 etc...? The difference is
only in the state of charge.
1. A C5 battery means it should not be discharged within 5 hours otherwise the battery
life decreases
2. A C10 battery means it should not be discharged within 10 hours otherwise the battery
life decreases
3. A C20 battery means it should not be discharged within 20 hours otherwise the battery
life decreases
Simply, it means capacity of battery if any battery is rated 12v,40Ah and C10 it means 4A,
10hours charging and discharging rat, if there is C20 then 2A,20hours charging and
discharging rat.
Configuration of Battery
Two 12V, 100AH batteries are connected in series to get 24V, 100AH and two 24V strings are
connected to get 24V, 200AH.
Figure 32.Series connection of battery
Two 12V, 100AH batteries are connected in parallel to get 12V, 200AH and three 12V batteries
are connected in parallel to get 12V, 300AH.
Figure 33. Parallel connection of battery
Electrical Cable
An electrical cable is an assembly of one or more wires running side by side or bundled, which
is used to carry electric current.
• A solar cable is the interconnection cable used in photovoltaic power generation.
• Solar cables interconnect solar panels and other electrical components of a photovoltaic
system.
• Solar cables are designed to be UV resistant and weather resistant.
• The cable
• Size used for interconnection of SPV module, Charge Controller and battery shall be
minimum 2 X 2.5 sq. mm Cu.
Figure 34. Electrical Cable diagram
Link: https://solarpanelsvenue.com/calculator/wire-sizing-calculator/wire-sizing-calculator.htm
Figure 35. Standard cable size and current carrying capacity
Distribution Board
A distribution board (also known as panel board, breaker panel, or electric panel) is a
component of an electricity supply system that divides an electrical power feed into
subsidiary circuits.
ACDB/ DCDB are an important part of SPV system to provide extra electrical protection to the
system during failures.
Solar DCDB (Direct Current Distribution Box), is used to protect the system if there is any fault
during failure on DC side. Here electricity supply system which divides an electrical power feed
into subsidiary circuits. It contains protective fuse or circuit breaker to switch off system off the
systemduring fault. DCDB controls the DC power from Solar Panels and with having necessary
surge protection device (SPD) and fuses to protect the solar panels strings and solar inverter from
any type of damage.
Solar ACDB (Alternative Current Distribution Box), receives the AC power from the solar
inverter and directs it to AC loads through the distribution board. ACDB includes necessary
surge protection device (SPD), Voltage, Current monitoring and MCCB to protect the solar
inverter from any type of damage or heavy voltage.
Array junction box (AJB), is referred to as solar PV junction box or combiner box. It collects
DC power from PV strings and then transferred either directly or through a main junction box
(MJB) to power inverter. The power inverter converters the DC power to AC which after
metering is used to measure the power consumption in ON-Grid/OFF-Grid/Hybrid system.
Figure 36. Junction Box and Distribution Box
Unit 4.3 Operation of Solar Cell/Panel
Solar PV cell operation
Sunlight consists of little particles of solar energy called photons. The process of converting
light (photons) to electricity (voltage) is called the solar photovoltaic (PV) effect. Photovoltaic
(PV) cell is made up of at least 2 semi-conductor layers. Thin layer (N-Type, negative charge) is
sandwiching with thick layer (P-Type, positive charge) to form solar cell. When sufficient light
energy falls on the solar PV/cell, it passes through the N-Type material to reaches PN-Junction
position by absorption of light/photons. Electron excitation occurs (EM process) in the atom of
the junction and free electrons moves toward N-Type material and at the same time same no of
holes are moves towards P-Type material. Metallic conducting strips helps to flow the charge
particles and current will flow to an external circuit.
The operation of a photovoltaic (PV) cell requires three basic attributes:
• The absorption of light, generating either electron-hole pairs or excitons.
• The separation of charge carriers of opposite types.
• The separate extraction of those carriers to an external circuit.
Figure 37. Operation of Solar PV Cell
Link:https://www.youtube.com/watch?v=XVELb4i1iJUhttps://www.youtube.com/watch?v=UJ8
XW9AgUrw
• If Solar PV cell is made up of Silicon then it will provide 0.58-0.6 Volt in peak hour.
• If Solar PV cell is made up of Germanium then it will provide 0.3-0.4 Volt in peak hour.
For every 10kW PV installation, 11 tons of CO2 are avoided.
Unit 4.4 Configuration of Solar Panels
Series connection of Solar panels
Connect the positive terminal of the first solar panel to the negative terminal of the next one.
Example- If you had 4 solar panels in a series and each was rated at 12 volts and 5 amps, the
entire array would be 48 volts at 5 amps.
Parallel connection of Solar panels
Connect all the positive terminals of all the solar panels together, and all the negative terminals
of all the panels together.
Example- If you had 4 solar panels in parallel and each was rated at 12 volts and 5 amps, the
entire array would be 12 volts at 20 amps.
Figure 38. Series and Parallel connection of Solar panels
Orientation and shading effect
In order to produce the most electricity, the Solar PV array should be orientated between south-
east and south-west.
Shading can have a serious impact on solar thermal and photovoltaic system outputs.The output
of a cell declines when shaded by a tree branch, building or module dust. The output declines
proportionally to the amount of shading. Shading just one cell in the module can reduce the
power output to zero because all cells are connected in series and the output of one cell becomes
the input to the next cell. If just a single cell is shaded than 50% loss in power from a string of
solar cells will occurred.
If one panel is shaded, the current produced by the un-shaded panel can flow through a by-pass
diode to avoid the high resistance of the shaded panel.
There are two distinct forms of shading that we’ve come to describe as “soft” and “hard”
shading.
Soft shading can be described as simply lowering the intensity of the irradiance levels, without
causing any form of visible separation of shaded and un-shaded regions. In partially shaded cell,
the voltage output of the cell will remain unchanged and only the current output will diminish.
Hard shading is created when a physical object, such as a telephone pole, or tree is physically
obstructing the sunlight, creating obvious visible regions of lit and unlit cells on the array.
Figure 39. Different Shadow conditions of Solar cell and panels
Link:https://www.youtube.com/watch?v=rkPBPNSlL74
Unit 4.5 Sizing and Load calculation of a Solar PV System
Design and calculation process: (for all system)
Load 1000 W for 2 hours/day
Standard battery-12V
So, battery ampere required??
For 2 hr/day will be 2x 1000 W=2000 W load,
Ampere of battery=2000 W/12 V=166.67 Ampere
Consider loss in battery is about 20%, we can consider 12 V 200Ampere battery for the load
To charge the battery:
Charge controller should be capable of 200 Ampere
So it will be- 12 V 200 Ampere
Panel size:
To charge 12 V battery at least 15-18 V voltage required.
Panel voltage=15-18 V
Sun hour= 5-7 hour
Current needed 200 Ampere
Panel watt is 17 v x ____ Ampere = _____ Watt
Per hour=200 Ampere/ 6 hr= 33.33 A/hr, it may be 35 A/hr
So, panel watt=17x35 =595 W or 600 W required.
Inverter:
For safety purposes inverter size should be 25-30% extra with taken watt of power.
SPV design and calculation for one household (DC Appliances used):
Example: A house has two 5 Watt LED bulb used for 5 hours per day, one 30 Watt DC fan used
for 12 hours per day and one 60 Watt DC TV used for 8 hours per day.
Solar PV system sizing
1. Determine power consumption demands:
Total power and energy consumption of all loads that need to be supplied by the solar PV system
as follows:
a. Total appliance use = (2x5W x5 hours) + (1x 30W x 12 hours) + (1x60Wx 8 hours) =
890Wh/day.
b. Multiply the total appliances Watt-h/day times 1.3 (the energy lost in the system, for PWM
technology and 1.2 times for MPPT charge controller used) to get the total watt-hours per the
day. Now the total PV panel’s energy required is 890*1.3= 1157 Wh/day.
2. Size the PV modules: Different size of PV modules will produce different amount of power.
To find out the sizing of PV module, the total peak watt produced and average sunny day needs.
In India, average sunny hour will be 5 or 6 hours/day around the year.
So, 1157/6= 192.83 Watt/day which is fraction so we will take as 200 Watt single solar PV panel
or two 100 Watt solar PV panel.
It means that this system requires one 200Wp panel with standard 12 volts battery.
4. Battery Capacity (Ah) = (Total Watt-hours per day used by appliances x Days of autonomy)/
(0.85 x 0.6 x nominal battery voltage) i.e. (890*3)/ (0.85*0.6*12) = 437.27Ah. So the battery
should be rated as 12V, 400/450 Ah, 3 days autonomy.
Solar street light design and calculation
Specification:
Panel: 40 W, 20V, 4 A
CCR: 12V 3A
Battery: 12V 10Ah Tubular
If street light is 10 W than it will emit light up to 12 hours.
If street light is 15 W than it will emit light up to 8 hours.
ON-Grid and Off-Grid solar power plant Design
Technical Data (1 Kw Solar power plant)
Solar Panel: (Pmax: 1080W, Vmp: 33.5V, Imp: 5.38A)
Inverter:
Output Power: 1000W
Output Wave Form: Pure Sine Wave
Output Voltage 110V/220V AC
Output Frequency: 50Hz/60Hz
Output Voltage regulation: 5-10%
Overload: 120%, 30 seconds
THD: < 5%
Efficiency: >85%
Battery Capacity: 48V, 400AH
Solar Charger Controller: 48V, 30A
1kw solar generation system (Off-Grid)
Solar panel: 200 W, 5 Pcs or 250 W, 4 Pcs
Inverter: 1 Kw
Battery: 12 V/100 Ah lead acid, 2 Pcs
Space required 50 ft
Power generation: 4-6 Units
1kw solar generation system (ON-Grid)
Solar panel: 250 W, 4 Pcs
Inverter: 1 kW
Space required 50 ft
AC/DC box: 1 k W
Power generation: 4-6 Units
5Kw OFF grid solar system
Solar panel: 200 W, 20 Pcs
Controller: 96V/ 60 A
Inverter: 96 V/5 kW
Battery: 12 V/150 Ah lead acid, 5-10 Pcs
6Kw OFF grid solar system
Solar panel: 200 W, 24 Pcs
Controller: 96V/ 60 A
Inverter: 96 V/6 kW
Battery: 12 V/150 Ah lead acid, 16 Pcs
10Kw OFF grid solar system
Solar panel: 200 W, 40 Pcs
Controller: 96V/100 A, 1 Pcs
Inverter: 96 V/10 kW
Battery: 12 V/150 Ah lead acid, 32 Pcs
10Kw ON grid solar system
Solar panel: 200 W, 50 Pcs
Controller: 96V/ 100 A (may not require)
Inverter: 96 V/10 kW, 1 Pcs grid tied
AC/DC box: 10 k W
5
Tools and Equipment Used for Solar PV Installation
This unit covers different tools and equipment used for solar PV installation.
Module Outcomes:
After completing this module, participants will be able to:
1. Understand different tools and its use in SPV installation
2. Understand different equipment’s and its use in SPV installation
3. Demonstrate both tools and equipment’s
4. Specify each tools and equipment’s
Unit 5.1 Identification and Specification of Tools and Equipment for Solar PV Installation
Basic Tools Needed for Installation
• Angle finder
• Torpedo level
• Fish tape
• Chalk line
• Cordless drill (14.4V or greater), multiple batteries
• Unibit and multiple drill bits (wood, metal, masonry)
• Hole saw
• Hole punch
• Torque wrench with deep sockets
• Nut drivers (most common PV sizes are 7/16”, ½”, 9/16”)
• Wire strippers
• Crimpers
• Needle-nose pliers
• Lineman's pliers
• Slip-joint pliers
• Small cable cutters
• Large cable cutters
• AC/DC multimeter
• Hacksaw
• Tape measure
• Blanket, cardboard or black plastic to keep modules from going “live” during installation
• Heavy duty extension cords
• Caulking gun
• Fuse Pullers
Additional Tools to Consider (especially for multiple installations)
• DC clamp-on ammeter
• Reciprocating saw / Jig saw
• Right angle drill
• Conduit bender
• Large crimpers
• Magnetic wristband for holding bits and parts
• C-clamps
• Stud finder
• Pry bar
Tools for Battery Systems
• Hydrometer or Refractometer
• Small flashlight (to view electrolyte level)
• Rubber apron
• Rubber gloves
• Safety goggles
• Baking Soda (to neutralizer any acid spills)
• Turkey Baster
• Funnel
• Distilled Water
• Voltmeter
Link:https://www.altestore.com/multimedia/Images/Tools.html
Figure 40. Essential tools and equipment for SPV installation
Unit 5.2 Use of Tools and Equipment in a Solar PV Installation
Figure 41. Use oftools and equipment in a Solar PV installation
6
Site Survey, Mounting structure and Installation of Solar PV
System
This unit covers the basic knowledge on Site Survey, Mounting structure and Installation of
Solar Photovoltaic system.
Module Outcomes:
After completing this module, participants will be able to:
1. Understand the process of customer satisfaction and site survey
2. Understand the Civil and Mechanical structure for Solar PV installation
3. Perform the single-line diagram of SPV systems
4. Understand the equipment’s used in Site survey and Structure design
Unit 6.1 The importance of Site Survey and Customer satisfaction
It’s customary for a PV system integrator to do a Site survey and collect information about local
conditions and issues before any proposal is made. The information collected is then combined
with the load patterns and the customer preferences to make a final proposal.
Why is site survey so important?
1. Each Rooftop or ground location is unique
2. Shadow analysis is crucial
3. Electricity Bill & sanctioned Load is required
4. It helps us ensure our rooftop or ground is usable
5. Any special requirements can be addressed
We need to the following in a site assessment.
1. A suitable location for Solar Panels.
2. What and where are the shaded areas that might fall on proposed Solar arrays during day
time with maximum Sun, typically 9.00am to 4.00pm
3. What type of Mounting is required for the Solar Array
4. Where do we locate the Balance of System components? Ex: Inverter, DC Combiner box,
AC Distribution Box, Batteries, if required.
5. What are the Energy Needs of the Building? A detailed Loading Sheet is present here .
6. How is the PV system going to be connected to the existing electrical systems.
Array Location:
In order to maximize the output from Solar PV system, one must orient the panels towards
South direction at optimal angle. One must consider the following for an array location.
1. What is the type of Roof? Is it Flat concrete Roof, slanted terra cota tiled roof, Tin roof,
corrugated roof?
2. What is the condition of the rooftop? Is it good, bad or Ugly? Can it take extra load?
3. If it’s Flat roof, are there any obstructions across south, east and west that could cause the
shadow on the panels facing towards south.
4. If so, at point of day do they create shadow on a proposed solar System?
5. Draw a drawing of the roof with the obstructions and the height of the obstruction above
the Roof. One can look up the shadow of the building during different times of a day
throughout the year.
6. If it’s a Slanted roof, then in what direction is the roof angled?
7. What is the angle of the Slanted roof?
8. If it’s a slanted roof, then what is the distance between two tuffs?
9. Can we include the panel arrays to achieve the optimal efficiency?
10. What is the size of shade free rooftop Area? Specify the Length and breadth and the
direction of the roof.
11. How far will the array be from other system equipment like charge controller, battery,
inverter?
12. How is the access to reach to the rooftop? is there staircase, ladder? Or external ladder
needs to be arranged
13. In case of maintenance, how easy is it to access the solar array?
14. If it’s a flat roof, is there any parapet wall next to it the panels?
15. Are there any safety, installation or any maintenance concerns?
16. Can the rooftop structure handle the additional load?
Solar PV Array Area:
A typical 250W poly crystalline solar panel is of size 1.7×1 sq m or its equivalent to 1.7sqm or
18.2sqft. So 1kWp Solar Panel array would take around 72sft or 7sqm.
Considering that you need to give spaces between each panel array, as a thumb rule you can
consider 80 to 100sqft or 7.4 to 9.3 sqm of shade free south facing area per kW of solar PV
panels.
Once the Site survey is done and the energy needs of the building is assessed we are ready to do
the system sizing.
Figure 42. Site Survey & Assessment for Solar PV Installations
Figure 43. Sample site survey report
Unit 6.2 Steps for safe installation of Solar PV system
Installation process of Solar PV power plant
This section describes the most common type of home Solar PV installation and is divided into
following tasks;
Step 1: Identification, Designing and Marking the location
The process of installing a solar plant begins with designing and marking on the rooftop.
Step 2: Civil Work and Curing
Next, engineers begin the civil work which includes building columns to hold module mounting
structures. As you can see in the video, there is no drilling, anchoring or puncturing on the
rooftop. The civil work took around 5-6 days to be completed.
Step 3: Module Mounting Structure Installation
In the third step, the execution team mounts the module mounting structures on the civil
foundations.
Step 4: Module Installation
Once the module mounting structures are in place, solar modules (panels) are bolted onto the
structures. The entire process is completed within a few days, depending on the size of
installation. For this project, it got completed in 4 days.
Step 5: Cabling
Next, the solar modules are connected in series with DC cables to the inverter, and with AC
cables from the inverter to the evacuation point (customer’s LT panel).
Step 6: Inverter Connection and Grid Synchronization
Once the installation is ready, the inverter is charged, and begins synchronizing the solar power
with the customer’s existing electrical grid.
Step 7: Seamless Power Distribution
Lastly, seamless power distribution begins as soon as the electrical connections are in place.
Indeed, installing solar is not only a hassle-free solution to go green but also a wise business
move to cut operational cost.
Step 8: Connect your systems monitoring gear (if any)
Unit 6.3 Basic on Mounting Structure and its Types
Photovoltaic mounting systems (also called solar module racking) are used to fix solar panels on
surfaces like roofs, building facades, or the ground. These mounting systems generally enable
retrofitting of solar panels on roofs or as part of the structure of the building.
Roof Mounting
The solar array of a PV system can be mounted on rooftops, generally with a few inches gap and
parallel to the surface of the roof. If the rooftop is horizontal, the array is mounted with each
panel aligned at an angle. If the panels are planned to be mounted before the construction of the
roof, the roof can be designed accordingly by installing support brackets for the panels before the
materials for the roof are installed.
Ground Mounting
Ground-mounted PV systems are usually large, utility-scale photovoltaic power stations. The PV
array consists of solar modules held in place by racks or frames that are attached to ground-based
mounting supports.
Ground-based mounting supports include:
• Pole mounts, which are driven directly into the ground or embedded in concrete.
• Foundation mounts, such as concrete slabs or poured footings
• Ballasted footing mounts, such as concrete or steel bases that use weight to secure the solar
module system in position and do not require ground penetration. This type of mounting
system is well suited for sites where excavation is not possible such as capped landfills and
simplifies decommissioning or relocation of solar module systems.
Figure 44. Different Solar Mounting structure
Link: https://www.powerfromsunlight.com/main-solar-panel-mounting-systems-grid-tied-
photovoltaic-plants/
Unit 6.4 Install Civil and Mechanical Parts of Solar PV System
Figure 45. Install Civil and Mechanical Parts (Ground and Roof-top type)
Link:http://www.thesolarplanner.com/steps_page12.html
Unit 6.5 Installation of Electrical components
Figure 46. Installation of Electrical components in a Solar PV system
Unit 6.6 Install of Solar Photovoltaic Module
Figure 47. Sketch showing (a) Panel Orientation, (b) Height, spacing between adjacent rows and
angle of tilt
Figure 48. Installation of Solar PV Module or Panel
Unit 6.7 Install Battery Bank Stand and Inverter Stand
Figure 49. Install Battery Bank Stand and Inverter Stand
7
Test, Commission and Maintenance of Solar PV system
This unit covers the basic knowledge on Test, Commission and Operation & Maintenance of
Solar Photovoltaic system.
Module Outcomes:
After completing this module, participants will be able to:
1. Understand the basicTesting and Commissioning process
2. Knowledge on Continuity test
3. Understand the Operation & Maintenance of Solar Photovoltaic system
4. Knowledge on Preventive Maintenance (PM)of Solar Photovoltaic system
Unit 7.1 Tools and Accessories for SPV System testing and maintenance
The following major Tools and Accessories are required for overall SPV System testing and
maintenance.
1. First & Kit
2. Multimeter
3. Clamp-meter
4. Electrical Power Testers
5. Energy meter
6. Insulation Resistance Testers
7. Disconnection Detector for DC Current Circuit (NSEI-100D)
8. PV Characterization Testers
9. Commissioning and Safety Testers
10. Solar Power and Thermal Testers
11. Irradiance Meters
12. Light meter
13. Distance meter
14. Hydrometer
15. Hygrometer
16. Portable Test Equipment
17. Wire strippers
18. Crimping tool
19. Soldering Iron
20. Battery terminal cleaner
21. Compass
22. Hammer
23. Flashlight
24. Paper/pencil
25. Safety goggles
26. Rubber gloves
27. Shoes
28. Cleaning brush etc.
Figure 50. Major Tools and Accessories for overall SPV System testing and maintenance
Photovoltaic cells testing
Standard Test Conditions (STC) against Nominal Operating Cell Temperature (NOCT) Standard
Test Conditions is the laboratory conditions under which all PV modules are tested. It can be
said that STC is a benchmark for comparing different types of PV modules, even if they are not
from the same provide.
STC means:
• An irradiance of 1000 watts per square meter, which simulates peak sunshine on a surface
directly facing the sun in a day without clouds.
• A surface temperature of 25°C.
The conditions at Nominal Operating Cell Temperature aim to simulate reality more closely:
• The irradiance is 800 watts per square meter, which takes into account the fact that PV
modules don't always face the sun. It also considers atmospheric or geographic conditions
what might diminish sunshine.
• Solar panels heat up considerably during operation, so the temp considered is 45 (+/- 3) °C.
• The light spectrum is the same as for STC.
• A wind speed of 1 m/s is considered, with air at 20°C
This means that solar panels will always have higher ratings at STC compared with NOTC.
I.e. STC: Irradiance 1000 watts per square meter, Module Temp= 25oC, Air Mass=1.5.
NOTC: Irradiance 800watts per square meter, Module Temp= 20oC, Wind speed= 1m/s.
Testing before installation of Solar Panel
Before installation the solar panels are tested at the manufacturing unit to check for the following
parameters:
• Voc-Open circuit voltage
• Isc-Short circuit current
• Vmax- Maximum Voltage
• Imax- Maximum Current
• Pmax- Maximum power at Standard Test Conditions or Peak Power Output.
Figure 51. Measurement of (a) Voc (b) Isc
Figure 51. IV Curve of Solar Cell or Module
Unit 7.2 Wire and Earthing Continuity Test
Figure 52.Electrical wire and Earthing continuity test process
Unit 7.3 Testing of CCR, Inverter and Battery
Figure 53. Testing of (a) CCR, Battery and (b) Inverter
Unit 7.4 Sample Test and Commission Record Sheet
Table 1. Sample Test and Commission Record Sheet
Unit 7.5Operations and Maintenance of solar PV System
This section describes the most common type of Solar PV O&M process and its contract
typically 10-30 years.
Power plant operation
An operation is about remote monitoring, supervision and control of the PV power plant. it also
involves liaising with or coordination of maintenance activities. a proper PV plant
documentation management system is crucial for Operations. a list of documents that should be
included in the as-built documentation set accompanying the solar PV plant (such as PV
modules’ datasheets), as well as a list of examples of input records that should be included in the
record control (such as alarms descriptions) can be found in the annex of these Guidelines. Based
on the data and analyses gained through monitoring and supervision, the O&M Contractor
should always strive to improve PV power plant performance. as in most countries there are
strict legal requirements for security services, PV power plant security should be ensured by
specialized security service providers.
Power plant maintenance
Maintenance is usually carried out on-site by specialized technicians or subcontractors,
according to the Operations team’s analyses. A core element of maintenance services, Preventive
Maintenance involves regular visual and physical inspections, as well as verification activities
necessary to comply with the operating manuals. The annual Maintenance Plan (see an example
in the Annex) includes a list of inspections that should be performed regularly. Corrective
Maintenance covers activities aimed at restoring a faulty PV plant, equipment or component to a
status where it can perform the required function. Extraordinary Maintenance actions, usually not
covered by the O&M fixed fee, can be necessary after major unpredictable events in the plant
site that require substantial repair works. Additional maintenance services include tasks such as
module cleaning and vegetation control.
Purpose: Conduct or ensure ongoing operations and maintenance (O&M), including repair and
replacement (R&R)
Task:
• O&M agreements
• Warranties
• Monitoring system
• System performance
• Production guarantees
• Buyout Options
Outputs:
• Ensure responsible party carries out O&M/R&R
• Measuring and tracking success
• Correlate with business plan and strategic energy plan
• Contract compliance
• Reporting of generation
• Met or exceeded energy and financial performance
Figure 54. O&M of Solar PV system
Preventive Maintenance (PM) of PV System
Preventive maintenance (or preventive maintenance) is maintenance that is regularly performed
on a piece of equipment to lessen the likelihood of it failing. It is performed while the equipment
is still working so that it does not break down unexpectedly.
Recommended materials and supplies list for repair or maintenance
• Distilled water
• Baking soda
• Wire nuts
• Crimp connectors
• Ring, spade, and lug terminals
• Load, inverter, and charge controller fuses
• Rosin core electrical solder
• Conduit connectors
• Cable ties
• Rags or paper towels
• Dish soap or pulling grease
• Red and black electrical tape
• Assorted screws and nails
• Cable, wire and/or conduit, as needed
• Silicone sealant
A sample maintenance schedule is presented below to indicate typical frequencies of
maintenance actions.
Weekly Maintenance
• Clean PV panel or array from dust, birds drop. Use clean water and avoid hard water.
• Observe battery state of charge (SOC) using hydrometer.
• In case of VRLA battery use voltmeter to measure voltage to check corresponding SOC.
Annual Maintenance
• Check array wiring for physical damage and wind chafing
• Check array mounting hardware for tightness
• Inspect inverter - remove dust or dirt, inspect system wiring for poor connections. Look
for signs of excessive heating, inspect controller for proper operation
• Verify output from the array (Isc and Voc and if possible Imp and Vmp) • Inspection and maintenance of System Wiring
Troubleshooting and Repair
As with any troubleshooting call, try to get as much information from the customer as possible.
Try to find out when the problem occurred and when the last time the PV system operated
normally. Get as much information, such as prints, outputs and wiring diagrams, as possible.
There are two failure modes which the solar system may be experience. These two conditions
which may require troubleshooting are:
1. Zero Power Output (No Power)
2. Low Voltage Issue
Troubleshooting: Zero power output
Zero output is a common problem and in nine out of ten cases, it is due to a faulty inverter or
charge controller.
It’s also possible that one solar panel in your pv array failed. As the pv modules are connected in
series, one failing pv module will shut down the entire system.
Troubleshooting: low power situation
If your solar system is not delivering sufficient power for which it is rated for, the resulting
situation is called a low power situation.
This is the most common type of problem and a few, quick, troubleshooting steps will help you
find the source of the problem. The factors that could contribute to a low power problem are:
Shading
• This is possibly the most common cause of low voltage.
• Ensure that there are no trees around and that the solar panels are not blocked by shadow
at any time during the day.
Temperature
• If shading is not an issue, most likely it will be the higher than normal operating
temperature of the solar panels.
• It has been scientifically proven that the voltage drop rises with the rise in temperature.
The higher the temperature, the lower will be the power output.
Bad Connections
• If the modules are not overheated, the best bet for you will be to check for a bad
connection.
• You can use a multi-meter to check the voltage levels at various points to find out the
point beyond which the problem of low voltage begins.
Solar panel defects
It’s uncommon for a solar panel to fail as they’re meant to last 25 years in the field.There are a
dozen of problems that may occur, let me mentioned the most common ones:
Hotspots, Junction box, Connectors, Delamination and Glass break etc.
Table 2. Solar PV O&M Maintenance Plan Sheet
Link:https://isolaralliance.org/docs/Microgrid-Trainers-Handbook.pdf
Table 3. System inspection and troubleshooting worksheet
8
Prepare BOM, Maintain Personal Health & Safety at Project Site
Unit 8.1 Prepare Bill of Materials (BOM)
A bill of materials (also known as a BOM or bill of material) is a comprehensive list of parts,
items, assemblies and other materials required to create a product, as well as instructions
required for gathering and using the required materials.
• The bill of materials can be understood as the recipe and shopping list for creating a final
product.
• It explains what, how, and where to buy required materials, and includes instructions for
how to assemble the product from the various parts ordered.
• All manufacturers building products, regardless of their industry, get started by creating a
bill of materials (BOM).
The following component types are included in the BOM:
• Solar Panels
• Charge Controller
• String Inverters
• Inverters
• DC Optimizers
• Combiner Boxes
• Load Centers
• Disconnects
• Service Panels (unless marked as Exists)
• Meters (unless marked as Exists)
For each component type, it generates the following data:
• Type: The type of the component (e.g. "Load Center")
• Manufacturer: The manufacturer of the component as specified in the database
• Item: The name of the component, as specified in the database
• Quantity: The quantity of the component in the design
Unit 8.2 Establish and Follow Safe Work Procedures
Installing solar systems is a risky business. Lifting and arranging unwieldy solar panels, the
potential for falls off many-storied rooftops, panels that heat up as soon as they’re uncovered –
these are some of the serious hazards that solar workers face. They’re also subject to the risks of
traditional roofing, carpentry and electrical trades – some of the most injury-prone occupations
around.
• The Occupational Safety and Health Administration (OSHA) require employers to
implement safety training and protection for their employees.
• Safety issues are common for solar installations, but proactively putting preventive
measures in place can help mitigate on-the-job injuries.
Every Worksite Presents Different Risks
No two worksites are the same. Before a solar installation begins, it’s essential for the installer to
visit the site, identify the safety risks and develop specific plans for addressing them. Plans
should include:
• Equipment to be used for safe lifting and handling of solar panels
• Type and size of ladders and scaffolding if needed
• Fall protection for rooftop work
• Personal protective equipment for each installer
All equipment needed for the job should be inspected and verified to be in good working order
before being brought to the worksite.
Lifting and Handling Solar Panels
Solar panels are heavy and awkward to lift and carry. Loading and unloading panels from trucks
and onto roofs can cause strains, sprains, muscle pulls and back injuries as well as cumulative
trauma that stress the spine. The panels can also heat up quickly when exposed to sunlight,
causing burns if not handled safely.
Safety measures for solar workers:
• Lift each solar panel with at least two people while applying safe lifting techniques.
• Transport solar panels onto and around the work site using mobile carts or forklifts.
• Never climb ladders while carrying solar panels. To get solar panels onto rooftops, use
properly inspected cranes, hoists or ladder-based winch systems.
• Once unpackaged, cover panels with an opaque sheet to prevent heat buildup.
• Always wear gloves when handling panels.
Ladder Safety
Solar construction often involves working on roofs and from ladders. Choosing the right ladder
and using it properly are essential.
Safety measures for solar workers:
• Select the ladder that best suits the need for access – whether a stepladder, straight ladder
or extension ladder. Straight or extension ladders should extend a minimum of three feet
above the rung that the worker will stand upon.
• Select the right ladder material. Aluminum and metal ladders are the most commonly
used today and may have their place on the job, but they’re a serious hazard near power
lines or electrical work. Use a fiberglass ladder with non-conductive side rails near power
sources.
• Place the ladder on dry, level ground removed from walkways and doorways, and at least
10 feet from power lines and secure it to the ground or rooftop.
Trips and Falls
Trips and falls are a common hazard of all construction jobs, including solar. They can happen
anywhere on the jobsite, especially off roofs or ladders. Rooftop solar installations are especially
hazardous because the work space diminishes as more panels are installed..
Safety measures for solar workers:
• Keep all work areas dry and clear of obstructions.
• For fall distances of six feet or more, take one of three protective measures: install
guardrails around ledges, sunroofs or skylights; use safety nets; or provide each employee
with a body harness that is anchored to the rooftop to arrest a potential fall.
• Cover holes on rooftops, including skylights, and on ground-level work surfaces.
Solar Electrical Safety
Solar electric (photovoltaic or PV) systems include several components that conduct electricity:
the PV solar array, an inverter that converts the panel’s direct current to alternating current, and
other essential system parts. When any of these components are “live” with electricity generated
by the sun’s energy, they can cause injuries associated with electric shock and arc-flash. Even
low-light conditions can create sufficient voltage to cause injury.
It’s also important to recognize that with PV systems, electricity comes from two sources: the
utility company and the solar array that is absorbing the sun’s light. Even when a building’s main
breaker is shut off, the PV system will continue to produce power. This makes isolating the
power source more difficult, and requires extra caution on the part of the solar worker.
Safety measures for solar workers:
• Cover the solar array with an opaque sheet to “turn off” the sun’s light.
• Treat the wiring coming from a solar PV array with the same caution as a utility power
line. Use a meter or circuit test device to ensure that all circuits are de-energized before
working on them.
• Lock out the power on systems that can be locked out. Tag all circuits you’re working on
at points where that equipment or circuit can be energized.
• Never disconnect PV module connectors or other associated PV wiring when it is under
load.
Unit 8.3 Use and Maintain Personal Protective Equipment (PPE)
Personal protective equipment (PPE) is clothing or equipment designed to be worn by someone
to protect them from the risk of injury or illness. PPE can include:
• Hearing protective devices, such as ear muffs and ear plugs
• Respiratory protective equipment
• Eye and face protection, such as safety glasses and face shields
• Safety helmets
• Fall arrest harnesses for working at heights
• Skin protection, such as gloves, gauntlets and sunscreen
• Clothing, such as high visibility vests, life jackets and coveralls
• Footwear, such as safety boots and rubber boots.
• Knowledge on Fire Extinguisher classification
Figure 55. Fire Extinguisher classification
Selection and use
You should ask yourself the following questions:
Who is exposed and to what?
How long are they exposed for?
How much are they exposed to?
Unit 8.4 Work Health and Safety at Heights
Occupational Health & Safety Assessment
Prior to starting any on-site work it is recommended that the installer undertake an on-site risk
assessment. This requires:
• The identification of all possible risks;
• Determination of the work practices that will be undertaken to remove the risk, or to
minimize the risk if it cannot be removed altogether; and
• Communicating with all the staff working on-site about these risks and how they will be
removed or minimized.
• Working at Height – Working at height includes safe access and planned prevention of
falls from edges. Whether you are using ladders or scaffolding it is important to follow
the correct procedures for use, erection, positioning etc. The HSE (Health and Safety
Executive) states that best practice when installing solar panels requires trained,
dedicated working at height maintenance teams to access risks and select appropriate
equipment before any work is carried out.
• Use hazard assessment checklist to describe the possible hazards and sources.
• Training – Installation of the panels and operation of equipment should only be
undertaken by fully trained operatives.
• Any installation must comply with health and safety regulations.
• Ensure only fully licensed electricians who have been inducted into an installer’s safety
program will be undertaking licensed work.
Figure 56. Work Health and Safety at Heights photographs
Environment (E), Health (H) and Safety (S)
Environment (E), health (H) and safety (S) (together EHS) is a discipline and specialty that
studies and implements practical aspects of environmental protection and safety at work. In
simple terms it is what organizations must do to make sure that their activities do not cause harm
to anyone.
From an environmental standpoint, it involves creating a systematic approach, design and
maintenance to complying with environmental regulations, such as managing waste or air
emissions all the way to helping sites reduce the company's carbon footprint.
Better health at its heart, should have the development of safe, high quality, and environmentally
friendly processes, working practices and systemic activities that prevent or reduce the risk of
harm to people in general, operators, or patients.
From a safety standpoint, it involves creating organized efforts and procedures for identifying
workplace hazards and reducing accidents and exposure to harmful situations and substances. It
also includes training of personnel in accident prevention, accident response, emergency
preparedness, and use of protective clothing and equipment.
Environmental problems are normally avoidable through proper plant design and maintenance,
but where issues do occur the O&M Contractor must detect them and respond promptly. In many
situations, solar plants offer an opportunity to provide opportunities for agriculture and a
valuable natural habitat for plants and animals alongside the primary purpose of generation of
electricity. Solar plants are electricity generating power stations and have significant hazards
present which can result in injury or death risks should be reduced through proper hazard
identification, careful planning of works, briefing of procedures to be followed, documented and
regular inspection and maintenance.
EHS guidelines cover categories specific to each industry as wells as those that are general to
most industry sectors. Examples of general categories and subcategories are:
1. Environmental
1.1 Air emissions and ambient air quality
1.2 Energy conservation
1.3 Wastewater and ambient water quality
1.4 Water conservation
1.5 Hazardous materials management
1.6 Waste management
1.7 Noise
1.8 Contaminated land
2. Occupational health and safety
2.1 General facility design and operation
2.2 Communication and training
2.3 Physical hazards
2.4 Chemical hazards
2.5 Biological hazards
2.6 Radiological hazards BG
2.7 Personal protective equipment (PPE)
2.8 Special hazard environments
2.9 Monitoring
3. Community health and safety
3.1 Water quality and availability
3.2 Structural safety of project infrastructure
3.3 Life and fire safety (L&FS)
3.4 Traffic safety
3.5 Transport of hazardous materials
3.6 Disease prevention
3.7 Emergency preparedness and response
4. Construction and decommissioning
4.1 Environment
4.2 Occupational health and safety
4.3 Community health and safety
Using solar power to run your home will reduce your carbon footprint by around 20% per year,
as solar power is renewable and therefore ‘cleaner’ than regular electricity, which is created
through the combustion of fossil fuels and produces carbon dioxide as a result.