CPD Course on Solar Energy Technologies

( Solar Energy)
RESOURCE PERSON: ENGR. FAIZ M BHUTTA
January 28, 2013
AT IEP AUDITORIUM

TIME TABLE
MODULE

TOPIC

TIME

MODULE - 01

INTRODCUTION TO
SOLAR ENERGY
TECHNOLOGIES

1000-1100

MODULE - 02

CELLS-MODULESARRAYS

1130-1230

MODULE - 03

SOLAR PV SYSTEM
COMPONENTS
1230-1330 & 1430-1515

MODULE - 04

DESIGN OF SOLAR
HOME SYSTEM

1515-1600

MODULE - 05

INSTALLATION
OPERATIONMAINTENANCE

1600-1630
2

MODULE 1
INTRODUCTION TO SOLAR
ENERGY TECHNOLOGIES

Solar Insolation pattern

Pakistan Irradiation data

Average solar irradiation varies from 3.5 to 7 kWh/m per day in Pakistan

Solar energy
potential is high
in all parts of
the country.
Compare Germany:
2.53.2 kWh/m per day
With Pakistan
3.5 to 7 Kwhr/m2/day
STC 1000W/m2/day
At 25 Degree C

Cost trends
Module prices and system cost are decreasing.

SOLAR ENERGY TECHNOLOGIES & APPLICATIONS

1.

2.
3.
4.

SOLAR PHOTOVOLTAIC POWER TECHNOLOGY

SOLAR OFF-GRID POWER SYSTEM
SOLAR ON-GRID POWER SYSTEM
SOLAR HYBRID POWER SYSTEM
SOLAR THERMAL TECHNOLOGY
SOLAR PUMPING TECHNOLOGY
SOLAR LIGHTING TECHNOLOGY

SOLAR PHOTOVOLTAICS (PV)

CONVERSION OF SOLAR
RADIATIONS INTO ELECTRICAL
ENERGY
8

COMPONENTS OF SOLAR PV SYSTEM

Solar panels 45-50% of cost

Controllers ( charge controllers and inverters)
Deep Cycle Battery -20-25%
Mounting ( Ground and Roof)
Cables, thimbles and accessories

Price of system varies as per maximum load in watt, hours of operation

And autonomy
9

OFF-GRID AC SOLAR PV SYSTEM

10

DC AND AC OFF-GRID SOLAR PV SYSTEM

11

ON-GRID PV SYSTEM

The system shuts down when the WAPDA Supply is Out.

12

SOLAR HYBRID PV SYSTEM

AUTOMATIC SYSTEM OF SWITCHING FROM ONE SOURCE TO OTHER

13

COMMERCIAL AND INDUSTRIAL APPLICATIONS

Stand Alone/Off-grid solar System in rural Areas upto 500 W

Solar Power Plants from 10 KW to 200 MW
Solar Parks upto 200 MW
Solar UPS
Solar Traffic Signals Lights
Power for Remote Security and Surveillance Systems
Remote data acquisition and equipment monitoring
Power for Telecommunication Towers and Networks
Building Integrated Photovoltaic System
Military signaling applications
Cathodic Protection of Pipelines
Solar water Pumping
Commercial Solar Lighting for roads, motorways and parks, Bus stops
Solar Lighting for Buildings and Industries
14

SOLAR THERMAL TECHNOLOGY

CONVERSION OF SOLAR
RADIATIONS INTO HEAT OR
TEHRMAL ENERGY
15

SOLAR THERMAL COLLECTORS

Low Temperature Solar Collectors

45 to 90 C
Heat Pipe

Flat Plate

Vacuum Tubes

High Temperature Solar Collectors

Concentrated
Tower

1000 C

Concentrated Parabolic

400 C

Concentrated Dish

400 C

CSP will be able to cover 11% of world electrical demand by 2050

16

Non-Pressurized SWH - 200 Ltrs and 300 Ltrs

17

GRAVITY MUST FOR NON-PRESSURE SWH

18

Non-Pressurized SWH working

19

Pressurized SWH -Heat Pipe System 300 and 500 Ltrs

20

Pressurized heat Pipe SWH working

21

Pressurized heat Pipe SWH working

22

PRESSURIZED SOLAR WATER HEATING

23

TWO COIL PRESSURIZED SWH SYSTEM WORKING

24

Space heating for commercial buildings

25

Swimming Pool Water Heating

26

MYTH AND REALITIES OF SWH

MYTH
Put Solar water heater and get hot water 24
hours a day

REALITY
Hot water supply quantity is limited to Nr of
collectors as per hot water requirement

Solar water heater can work alone 24 hours on No. It can only work in hybrid with Gas Geyser
solar without any back up
or instant heater. Back up in case of no sun is
necessary
Price told by supplier includes piping and
plumbing work

Price for SWH do not include piping and

plumbing work. Include Rs.2000 to Rs.10,000
in your budget for piping and plumbing work
depending on site

SWH can be placed anywhere at roof

Whole day sun is available without shade and

water tank height should be minimum at 6 ft
to develop gravity in case of non-pressure

One SWH is enough.

No. Number of solar water heaters depends

upon total flow requirement, pressure and
hot water requirement

SYSTEM WILL NEVER GET RUSTED AND

SCALED

Rusting of tank and scaling in tubes depends

upon water quality
27

SOLAR THERMAL APPLICATIONS

Hot water usage for bathing, washing and Laundry

Pre-heat for Boilers
Swimming pool water heating
Space Heating for commercial buildings
Solar Steam Generation for Industrial Process
Degreasing and phosphating in metal finishing industry
Solar Drying in food, wood, Leather

28

SOLAR PUMPING

29

SOLAR PUMP

30

PUMP CURVE

Best Efficiency Point

31

DC SOLAR PUMP

Max Flow = 40,000 Gallons

per day , Max Head = 400 ft
Impellers can be Centrifugal
and Screw Type.
Small land irrigation,
Drinking and Live Stock
Motor up to 4000W

32

AC SOLAR PUMP

Max flow= 200,000 Gallons

per day & Max head = 400
ft.
Impellers are Centrifugal
Suitable for irrigation
purposes
Motor up to 20 KW

33

LED & SOLAR LIGHTING

34

SOLAR STREET LIGHT COMPONENNTS

LED Light Source

MS Pole
Solar Panel with its mounting
Battery
Charge Controller
Cable, connectors and thimbles

35

LED FLOOD LIGHTS & STREET LIGHTS

LED Flood Lights 80W

LED Flood Light 100W
LED Flood Lights 120W
LED Street Lights -30W
LED street Light 60W
LED Street Light 80W
SAVING 75%
36

SOLAR HOME LIGHTING KIT

Sundaya Light Kits

HIHG QUALITY LIGHT

PLUG AND PLAY
THREE LIGHT INTENSITY THROUGH
TOGGLE SWITCH
BATTERY LIFE THREE YEARS BUT
WARRANTY IS ONE YEAR

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

37

SOLAR LIGHTING

Solar Flood Lights 160W

SOLAR STREE LIGHT 60W

38

APPLICATIONS IN INDUSTRY AND BUILDINGS

Solar Street Lights pathways

Solar Street Lights for Boundary walls
Solar Flood Lights for pathways and Boundary
walls and Fields
Solar Parking Lights
Solar Garden Lights

20 ft and 30 ft Pole Length

39

MODULE 2
CELLS MODUELS - ARRAYS

40

Cell-Module- Array

PV systems
PV cell
PV array
Panel Quality

PV modules

A GRADE
B GRADE
C GRADE
Watt = Volt x Current
41

Basic Terms
Conversion efficiency of a PV cell
Proportion of sunlight energy that the cell converts into electricity (in %)

Todays solar cell efficiency: 7 17 % (depending on cell type)

Module peak power

Wp (Watt peak) or kWp (Kilowatt peak)

Measure for the peak output of a PV system under Standard Test Conditions (STC).
Standard Test Conditions (STC):
Solar irradiation of 1000 W/m, module temperature 25C

Maximum output of a PV module (under ideal conditions)

kWp * number of peak sun hours = kWh

Number of peak sun hours (1 kWh/m) per year, for example

Germany
Pakistan

~1,000 1,400
~1,900 2,000
42

Basic Terms

Performance ratio
Real energy yield / theoretical energy yield (in %)

Depends very much on systems design, cabling, location, direction,

inclination, shading and temperature of modules and other on-site
conditions.
Practical experience:
Performance ratio of existing grid-tied systems:
Performance ratios of existing off-grid systems:

75 80 %
60 70 %

Real output of a PV module

kWp * number of peak sun hours * performance ratio = kWh

43

Photovoltaic effect
It starts with sand which is processed into highly purified silicon.

Monocrystalline wafers

Silicon blocks

Silica sand

44

Photovoltaic effect
P-N Junction is establishing a permanent electrical field in the crystal.
In a process called doping, trace amounts
of special impurities are added to this
purified silicon.
For example:
When silicon is doped with Boron, the
resulting material is called P-type.
When silicon is doped with Phosphorus,
the resulting material is called N-type.

When purified silicon is doped with Boron

and Phosphorus in just the right way,
a P-N Junction is formed.
This process establishes a permanent
electrical field in the crystal.

45

Photovoltaic effect
Solar cells are based on the electrical field in the P-N Junction
When a P-N Junction is made so that light can strike its top surface and metal
conductors are attached to the P- and N-type sides, a solar cell is formed.
When sunlight strikes the solar cell, electrons are ejected from the atoms
and the permanent electrical field in the junction steers them to the N-type side.
If a wire is connecting
both sides of the
solar cell, electric
current can flow,
whenever sunlight
is striking the
solar cell.

46

Cell types
Cells can be manufactured from different types of materials.
The most significant is crystalline silicon.
Two main types of commercially available cells are:
Silicon wafers
Monocrystalline silicon cells
Polycrystalline silicon cells

~ 93% of the market

Thin film:
Amorphous silicon (-Si)
Copper-indium-diselenide (CIS)
Cadmium-telluride (CdTe)

~ 4,2 % of the market

~ 0.7 % of the market
~ 1.0 % of the market

47

Cell types
Monocrystalline silicon cells
A crystal of silicon is grown from highly
pure molten silicon.
The single crystal cylindrical ingot is
cut into thin slices (200 300 m).
The edges are cut off to give a
hexagonal shape in order to make
optimum use of available module
surface.
Most efficient type of cell
(11-16 % efficiency).
Energy- and time-consuming
production

48

Cell types
Polycrystalline silicon cells
Silicon is heated to high temperature
and cooled under controlled
conditions in a mould (casting
process).
As the molten silicon sets, an irregular
poly- or multi-crystal is formed.
This is visible in the shimmering fishscale like appearance of the wafers.
The square silicon block is then cut
into thin slices (~300 m).
The blue colour is due to the
application of an anti-reflection layer.
Less efficient than mono-crystalline
cells (efficiency 10-14%).
49

Cell types
Thin film
Silicon, CIS or CdTe is deposited as gas on a
glass, aluminium or plastic surface.
Layer (thin film) of semiconductor material is
only 0.5-2.0 m thick.
Less semiconductor raw material is used.
Less sensitive to the effects of shade and high
temperatures.
Better suitable for locations with large share of
diffuse irradiation (e.g. in areas with high air
pollution).
Production cost today similar to silicon wafers.
Lower efficiency than silicon wafers
(e.g. CIS efficiency 6 - 8%).

50

Cell types
Comparison of different cell types

Cell
material

Module
efficiency

Module surface area Module surface area

for 1 kWp
for 1 MWp

Mono-crystalline
silicon

11 16 %

7 9 m

7,000 9,000 m

Poly-crystalline
silicon

10 14 %

8 9 m

8,000 9,000 m

Thin film
(CIS)

68%

11 13 m

11,000 13,000 m

Amorphous silicon

4 7%

16 20 m

16,000 20,000 m
51

Electrical characteristics of PV cells

Principal electrical properties of a PV cell are its current and voltage.
Power (P) = Current (I) * Voltage (V)

Current:

Voltage:

Current produced by a cell is

depending on:
Quantity of light falling on the cell
Size of cell surface area
Operating voltage

Maximum current:
Short circuit current (Isc)

Impedance
Current
Voltage
Power

R=0
ISC = max.
V=0
P=0

Output voltage is depending

on the cell material (largely
independent of the level of solar
radiation falling on the cell).
Silicon cells: 0.5-0.6 VDC

Maximum voltage:
Open circuit voltage (Voc)

Impedance
Current
Voltage
Power

R=
I =0
VOC = max.
P=0

52

Electrical characteristics of PV cells

The Maximum Power Point (MPP) is defined by the I-V curve of a PV cell
Maximum Power (PMAX) = Current at MPP (IMP) * Voltage at MPP (VMP)

In crystalline silicon PV cells:

VOC = ~ 0.5 V
VMP = ~ 80% of VOC
IMP = ~ 95% of ISC
ISC is depending on the cell surface.

(MPP)

Sample
specification:

Source: www.made-in-china.com

53

Ambient influences on cells and modules

Electrical output and the current produced
are directly proportional to the level of solar irradiation.

54

Ambient influences on cells and modules

Increasing module temperature leads to decreasing power output.
Example:
Silicon cell

55

Ambient influences on cells and modules

In regions with little rainfall or with long
dry seasons, dust may accumulate on the
modules and reduce efficiency by 10-25%.

Module efficiency may drop

by more than 50% if 3% of
module surface are covered
with dirt.

Example:
PV modules after 2 months without rain in the area of Los Angeles.
Efficiency dropped at approx. 10% (estimated by the owner).

56

PV cell interconnection and module design

Production failures and damages
of the module structure spoil
efficiency and reduce lifetime
of the module.
Defect:
Delamination PV cell encapsulation
(EVA foil)

57

Ambient influences on cells and modules

Shading must be avoided !!!
Shading from distant trees, roofs, chimneys
etc. creates soft or diffuse shadow
which reduces irradiation and reduces
power output of the whole module.
When cells are connected in series,
overall output is adjusted to the output
of the weakest cell.

Examples of partial cell shading that can reduce

PV module power reduced by half

Hard shadow from blankets, bird drops

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

58

Ambient influences on cells and modules

Azimuth and tilt angle are influencing module efficiency
Azimuth =
Orientation to the sun
Optimum is South.
Tilt angle =
Inclination of the
PV module/array.

59

Modules & arrays

1.
2.

Electrical characteristics of PV cells

Ambient influences on cells and modules
a)
b)
c)
d)
e)
f)

3.
4.

Irradiation
Temperature
Dust and dirt
Shading
Direction to the sun (azimuth)
Tilt angle

PV cell interconnection and module design

Module interconnection and array design

60

PV cell interconnection and module design

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

61

PV cell interconnection and module design

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

62

PV cell interconnection and module design

Selection of cells and module design are depending on the specific
application and demand.
Example: Charging 12V solar batteries
Charge controller specification:
Max. charging current:
8A
Charging voltage:
14 V
Required module voltage: 18 VOC

Sample module specification

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

Example: Module specification

63

PV cell interconnection and module design

Module structure
has to protect the cells
and to ensure functionality
over 25 years lifetime of the module.

64

PV cell interconnection and module design

Quality standards and certificates for PV modules.
Quality standards:
International Electronical Commission (IEC):
IEC 61215
IEC 61646

Crystalline silicon PV modules

design qualification and type approval
Thin-film PV modules
design qualification and type approval

IEC 61215 and IEC 61646 are covering external conditions to

which modules are exposed, for example mechanical stress,
climatic conditions, aging.
IEC 61730

PV modules safety qualification

Part 1: Requirements for production
Part 2: Requirements for testing

65

PV cell interconnection and module design

Quality standards and certificates

66

PV cell interconnection and module design

Production failures and damages
of the module structure are spoiling
efficiency and reducing lifetime
of the module.
Visual inspection and performance
tests are recommended before
delivery.
Defect:
Gap due to
poor sealing

Defect:
Excessive
glue mark

Defect:
Scratch on glass

67

Module interconnection and array design

Modules can be connected in series or in parallel

Modules behave in principle

like the cells they are
composed of.

It is urgently requested
to use always the same type
of modules in an array !

68

Module interconnection and array design

Selection of modules and array design are first of all determined by the
specific application and power demand.
(1) Power demand:
Voltage required:

600 W
12 V

PV Modules (12 V):

Option a:
Option b:
Option c:

(2) Power demand:

Voltage required:

600 W
24 V

Array design:
12x50 W
6x100 W
3x200 W

2 x (3 x 100 W) in serial (option b)

Array design:
All modules in parallel (option b)

69

Module interconnection and array design

Parallel arrays
which are connected
in serial must be
equal.

For example:
10 modules with
12 V / 50 Wp each

70

MODULE 3
SOLAR PV SYSTEM
COMPONENTS

71

Components

1.
2.
3.
4.
5.
6.
7.

PV Modules
Batteries
Charge controllers
Inverters
Cables and wiring
Connectors
Mounting systems

72

Batteries
Energy storage is required in most off-grid PV applicatons
(except solar pumping)
Grid-plate battery

Rechargeable lead-acid batteries

are the most common type of
batteries used for PV systems.
Storage capacities in the range of
0.1 kWh to 100 kWh.
Batteries are built from 2 V cells
(e.g. 6 cells for a 12 V block).

Charging voltage is higher

than battery voltage
( e.g. up to 14.5 V charging power for a 12V battery).

Battery types:
Grid-plate battery (solar batteries). Solar gel battery
Gel batteries.
Tubular plate batteries.

Battery design
Bloc batteries.
Individual cells (tubular plate).

Tubular plate
solar batteries
(cell design)
73

Batteries
ATTENTION: Vehicle starter batteries must not be used in PV systems !
Vehicle starter battery

Solar battery
Grid-plate batteries
with thicker plates,
hardened grids and
low acid content:

Grid-plate batteries with a

large number of
thin plates:
Large active surface area.
High starting current to be
provided over a few seconds.
Only very small discharge per
cycle in normal operation.
Very low cycle resilience.

Extremely short life time of

car batteries when used for
solar systems!

Increased cycle resilience.

Reduced corrosion.
longer service life.

Exide battery

Lifetime (in cycles) depends on the discharge per cycle.

For example:

100 % discharge = reducing battery lifetime.

70 % discharge ~ 200 cycles.
50 % discharge ~ 400 cycles
20 % discharge ~ 1000 cycles

Cycle resilience and deep discharge protection are

improved in so-called deep cycle batteries.
Proper charge control saves battery lifetime and cost!
74

Batteries
From single batteries to battery banks
Parallel connection of batteries
The
The

terminal is connected with the

terminal is connected with the

terminal of the next battery.

terminal of the next battery.

The battery bank has the same voltage as a single battery.

Capacity of the battery bank is rating equal to the sum of the individual batteries
capacities.

75

Batteries
From single batteries to battery banks
Series connection of batteries
The terminal is connected with the
terminal of the next battery.
In serial connection, a battery bank has the same capacity as a single battery.
Overall voltage is rating equal to the sum of the individual batteries voltages.

76

Batteries
From single batteries to battery banks
Series-Parallel connection of batteries
Series and parallel connection are use in combination.
Capacity (Ah) and voltage are increasing.
This is done to make a battery bank with large capacity
and larger voltage out of several smaller, lower voltage batteries.

24 V battery bank

77

Components
1.
2.
3.
4.
5.

Batteries
Charge controllers
Inverters
Cables and wiring
Mounting systems

79

charge controllers
Matching voltage of the PV array and the systems to that of the battery.
Charge voltage must be higher than
battery voltage:
Standard example:
Battery nominal voltage: 12V
Charge voltage:
up to 14.5 V
PV nominal voltage:
15-18 V
(e.g. NOCT = 45C)

Discharge voltage is decreasing while

the battery is discharging (discharge
current stays almost constant).

During times of high irradiance & low

temperature (e.g. 0C), MPP of the PV array
may increase up to ~21 V, MOC up to ~25V.
Therefore, the battery must be protected
against overcharging.
During times of low / no irradiance, PV voltage
breaks down and the battery starts to discharge
via the PV array.
Protection against self-discharging via the PV
array, increases overall efficiency of the system.

Deep discharge is reducing battery lifetime

dramatically.
Therefore a specific discharge cut-off voltage is
to be respected in order to save battery life.
80

charge controllers
Series controller
When the charge cut-off voltage is reached, a series controller interrupts the
module power using S1 and switches it back on after a defined voltage drop.
This creates an oscillating state of constant switching operations around the charge
cut-off voltage, as well as permanent forward losses.
S2 is used to interrupt battery power when the battery voltage drops below a
defined discharge cut-off limit.

Series solar charge controller

81

charge controllers
MPP charge controllers
An MPP tracker essentially consists of a regulated DC/DC converter.
MPP power is determined every few minutes.
The DC/DC converter is the set so that it takes the optimum power from the PV
array and adjusts it to the charge voltage of the battery.
In this way, optimum use is made of the available solar energy.
MPP charge controllers are useful in combination with larger PV arrays or when
using high voltage modules/arrays

MPP Tracking Solar Charge Controller 10 Amp 12/24V

82

charge controllers
Sample
Specifications

83

Components
1.
2.
3.
4.
5.

Batteries
Charge controllers
Inverters
Cables and wiring
Mounting systems

84

Inverters
Inverters are needed to use conventional 230V AC loads in off-grid solar
applications (e.g. UPS in urban solar home system.
Optimum requirements :
Sinusoidal AC with stable voltage and
frequency.
Good conversion efficiency, even in partial
load range.
High overload capacity for switch-on and
starting sequences.
Tolerance against battery voltage fluctuations.
Economic standby mode with automatic load
detection.
High electromagnetic compatibility (EMI
suppression)
Surge voltage protection.
Bidirectional operation (AC/DC conversion +
DC battery charging from AC generators).
85

Inverters
Sine-wave inverters
Best fulfilling the
above mentioned
requirements:
Working on the
principle of pulse
width modulation.
Suitable even for
operation sensitive
electronic
equipment.
Complex circuitry.
Higher in price than
square wave
inverters.

86

Inverters
Square-wave inverters
Cheaper than
sine-wave inverters
DC is chopped into a 50Hz alternating current with square characteristic.
DC voltage is stepped up using a transformer to a voltage of 230V.

87

Components
1.
2.
3.
4.
5.

Batteries
Charge controllers
Inverters
Cables and wiring
Mounting systems

88

Cables and wiring

For DC systems, cable diameters are very important
The bigger the load (W)
and the longer the distance (m),
the bigger is the required
cable diameter (mm).

General rule:

DC requires bigger cable diameters than AC.

12 VDC requires bigger cable diameters
than 24, 36 or 48 VDC.
(for the transmission of the same power over the same distance)

Losses in Voltage are increasing:

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

Formula for the calculation of the required cable

diameter A in mm:
length m power W
Amm
m
insert here
voltage 2 V losses Cu

mm
56
for copper cables
(38 for aluminium)

If the calculated diameter is not exactly fitting to

available standard cables,
choose the next bigger standard cable.
Standard cables: 0.5 0.75 1.0 1.5 2.5 4.0 6.0 10 16 25 35 50 -70 95 ... mm.
89

Module interconnection and array design

Specific solar cables increase safety and efficiency
In order to ensure earth fault and short-circuit
proof cable laying,
+ and poles must not be laid together in the
same cable.
Standard cables are normally approved up to
60C temperature. Outdoor module cables may
reach higher temperatures.
Solar cables are double-insulated and approved
for up to 125C.
Connectors must be touch-proof and sealed.

Proper connections are necessary to avoid

excessive losses.
Poor contacts can lead to the occurrence of
arcing and increase fire risk.

Connectors
Sealing caps

Fasteners
90

III. Components
1.
2.
3.
4.
5.

Batteries
Charge controllers
Inverters
Cables and wiring
Mounting systems

91

Mounting Systems
Panel must be stable,
even in strong wind.

Roof integrity must be maintained.

92

MODULE 4
DESIGN OF SOLAR SYSTEM

93

Planning and design guidelines

Recommended
planning procedure

94

Planning and design guidelines

On-site visit and site survey
Checklist:
Type and location of consumers.
Existing power supply on site: public grid
Existing electrical installation; okay

diesel generator
none.
needs improvement none

Location and available space for the PV array (checked with meter - drawing)
Possibility to orientate the PV array to the south (checked with compass).
Buildings, trees, bushes south of the PV array (distance and height - drawing).
Overhead cables ( electricity, telephone) which could shadow the PV array (distance and
height).
Distance between PV array and consumers (checked with meter - drawing).
Sufficient space for batteries/charge controllers/inverters. open space in a building
Cabling requirements and barriers (cable lengths checked with meter drawing).
Required site protection (e.g. against vandalism or theft - description).

95

Planning and design guidelines

(3) Basic systems design
Select the key elements of the required systems design
Required solar/electrical system components:
PV module/array
Charge controller
Battery/battery bank
Inverter
Backup power supply (diesel)
____________________
____________________
Consumers devices to be supplied with power:
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
96

SOLAR SYSTEM DESIGN

STEP-1 ( Power Consumption)
APPLIANCE WATTS
Ceiling fan

QTY

TOTAL
WATTS

HRS/DAY

TOTAL
WATT-HRS

115

02

230

20

4600

Energy
Saver

24

02

48

06

308

TOTAL

139

04

278

26

4908

Total Watts = 300W

TOTAL WATT-HRS= 5 KWHRS PER DAY = 5 units per day

97

SOLAR SYSTEM DESIGN

STEP-2 ( Watts to be generated)

TOTAL WATT-HRS= 5 KWHRS PER DAY = 5 units per day

Multiply loss factor = 5000 x 1.3 = 6500 Watt-Hours per day
Total peak hours = 5
Total watts generated = 6500/5 = 1300 W

98

SOLAR SYSTEM DESIGN

STEP-3 ( Watts Peak Required to be generated)

TOTAL WATT-HRS= 5 KWHRS PER DAY = 5 units per day

Multiply loss factor = 5000 x 1.3 = 6500 Watt-Hours per day
Total peak hours = 5
Total watts generated = 6500/5 = 1300 W
Let we use 100W solar panels = 1300/100 = 13 Panels

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SOLAR SYSTEM DESIGN

STEP-4 ( Inverter sizing)

TOTAL WATT- of all appliances = 300 W

Safety = 30%
Total Load watts = 300 x1.3 = 390 Watts
Inverter Size = 400W

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SOLAR SYSTEM DESIGN

STEP-5 ( Battery sizing)
Battery Voltage = 12 V

Autonomy = 2 days
Battery capacity =

Total watt-hours x 2
------------------------------0.85 x 0.5 x 12

Battery = 5000 x 2
------------------ = 1960 Ahrs
0.85 x 0.5 x 12
Let we use 200AHR battery
Total number of batteries of 200AHr each = 10

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SOLAR SYSTEM DESIGN

STEP-6 ( Charge Controller)
One string = 06 panels
Each String has short circuit current = 07 Amp
Charge controller size = 7x2 = 14 Amp /12V
Solar Charge Controller = 15 or 20 Amp

300 W Solar Off-Grid System

Energy Generated = 5 Kwhr per day average
Operational Hours = 16.66 Hours per day
Solar PV Module = 100W QTY 12
Charge Controller = 20 Amp/12V
Inverter = 400W /12V QTY 01
Battery = 200AHR/12V QTY 10
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COMPLETE INFROMATION FOR OFF-GRID SYSTEM DESIGN

TOTAL WATTS LOAD AND LOAD PROFILE

TYPES OF APPLIANCES
TOTAL OPERATIONAL HOURS PER DAY
AUTONOMY - OPERATION TIME WOTHOUT SUN
SPACE AVAILIBILITY FOR SOLAR PANELS AND
SHADING
DC CABLE LENGTH AND ROUTING

Price of system varies as per maximum load in watt, hours of operation

And autonomy
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MODULE 5
INSTALLATIONCOMMISSIONING- OPERATION

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Installation and commissioning

General safety guidelines
When installing off-grid PV systems, all the precautions taken when working on any
electrical system need to be observed.
Batteries in these systems present additional dangers.
Before carrying out any task, the relevant section of the manufacturers manual
should be read.
Components should be checked to make sure they are not damaged.
Components should be connected/disconnected in the correct sequence.
Work should only be done in dry conditions.
No work should be done on PV arrays, if there is any lightning in the area.
Systems should be inspected and tested before commissioning.

National codes and working practices should always be complied with.

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Installation and commissioning

Electrical work on stand-alone PV systems and particular hazards
Never disconnect the batteries from the charge controller while the PV modules
are still connected to the charge controller.
The charge controller can be damaged by the high open circuit voltage of the modules.
Always disconnect the modules from the charge controller, before disconnecting the
batteries.
Always connect the batteries to the charge controller before connecting the modules to it.

Inverters are normally not reverse polarity protected.

If an inverter is connected incorrectly to a battery, it can be seriously damaged.
This will not be covered by the inverter warranty.
Fuses should not be removed when a circuit is under load to do so can cause arcing.

Correct DC polarity is to be observed when making all electrical connections.

Incorrect polarity can damage appliances and system components.

All wiring should be inspected and tested before commissioning. This includes:
Testing module/array open circuit voltage VOC and short circuit current ISC.
Verifying polarity.
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Installation and commissioning

Lightning protection
National codes need to be consulted.
Modules on roofs or on poles attached to buildings should not be higher than the
highest point of the building.
In regions with frequent thunderstorms, a double pole disconnect / isolator should be
installed (even on small systems), so that the PV array can be isolated from the rest of
the system, when there is a risk of lightning strike.

No work should be carried out on PV arrays if there is thunder or lightning in the area.

Grounding/earthing
It is in many countries not usual to ground/earth off-grid PV systems with only one or
two modules (<100 Wp) and with system voltages below 24VDC.
National codes need to be referred to.
If grounding/earthing is required, the inverter ground/earth terminal, the PV array
and the battery are connected to a single ground/earth electrode.
For inverter grounding/earthing requirements to refer to the inverter manual.

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Installation and commissioning

Battery safety
Battery manuals and instruction sheets should always be read.
Batteries are hazardous. The utmost care is called for when working on batteries.
(Sulphuric acid is corrosive in both liquid and vapour form.)
Hydrogen gas produced by vented batteries becomes explosive when mixed with
oxygen in the air. Battery rooms and enclosures must be vented at their highest point.
Pay attention to correct polarity when connecting cells/batteries to each other or the
inverters and other system components.
While working on batteries, remove metal jewelry such as rings, watches, chains.
Batteries should never be charged without a charge controller.
Tools should be insulated and placed on the floor, when not in use.
Battery temperatures should not exceed 50 C and batteries should not be exposed
to direct sunlight.
Used batteries are toxic waste and need to be recycled or disposed of correctly.
If the positive and negative terminal of a battery are connected (e.g. by a wrench or a
screw driver, the battery will short circuit. This can lead to explosion and fire.
108

Operation & Maintenance

1. Wise operation: Means the operation within designed limits.
2. Power management for maximum energy gain
3. Weekly or fortnightly cleaning of panels with wiper or with warm
water if the animal waste or some hard stints are there.
4. Continuous check of batteries charging and discharging through
solar controller.

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Operation & Maintenance

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

Cleaning the array

Necessary in dry and dusty areas or during longer dry periods.
Water with a small amount of soap is sufficient. Never use solvents !

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Operation & Maintenance

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

Additional services
Measuring system performance.
Cleaning the array.
Cutting back vegetation causing shade.
When any maintenance or servicing is being done on the PV module/array, the
module/array should be disconnected from the charge controller and the battery.
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Operation & Maintenance

2. Maintenance of the battery
Check in 6-monthly intervals:

Connections are sound and not corroded. Use terminal grease to avoid corrosion
Electrolyte level is sufficient top-up with de-ionized/distilled water if required.
Clean top of batteries to remove dirt, dust and moisture.
Check cell/battery voltage
In fully charged condition, disconnect from loads and power sources for at least half an
hour before checking voltage.

Check specific
gravity of
electrolyte
with hydrometer
in the event
of flooded cells.

112

THANKS
Faiz M BHUTTA

faiz@izhar-energy.com

113