Training to assemble

a Solar Urja Lamp (SoUL)

- A solar study lamp

Student Solar Ambassadors

1
Student Solar Ambassadors
Workshop
on
2nd October 2018
 Sensitization video

Shine with Solar Energy

(English)

3
 Overall Plan

Scale of the Event

 1 Day
 29 Indian States
 100,000+ Students across India to
receive Solar lamps
 Pan- India Event

• 1,00,000 students will

learn to make their
solar study lamp in
this Pan-India Event
happening
simultaneously in all
the Indian states on
2nd October 2018

• All the participating

students to get the
digital certificate
 Guinness Book of World Record

Most solar LED lights made and lit simultaneously

 1,00,000 students
 29 states
 800+ Volunteers

Unique and world’s largest solar lamp assembly workshop

 About
Student Solar
Ambassadors Workshop
 Objective of the Workshop

 Encourage use of clean

energy amongst future users
of technology by
demonstration

 Encourage education boards

to include hands on training of
solar lamps as part of their
curriculum
 Pilot Students Solar Ambassador Workshop

Venue JNV* Raigad and JNV* Khargone

Students Trained 875
Training Time 1 Day at both the locations (Nov’ 17)
*Jawahar Navodaya Vidyalaya (JNV)
 Glimpses from
Student Solar Ambassador Workshop
at
JNV Raigad & JNV Khargone
(Nov’17)
Solar Ambassadors at the conclusion ceremony: Shining
faces after making their own lamp.
 Video Insights to the
Student Solar
Ambassador Workshop
 Training Agenda
Agenda on the day of the workshop
Time Particulars
10:00 AM – 10:30 AM Introduction and sensitization to Solar
Energy
10:30 AM – 11:15 AM Intro to Solar Lamp components, physical
testing and Toolkit components
11:15 AM – 01:00 PM Technical Testing
01:00 PM – 02:00 PM Lunch Break
02:00 PM – 03:30 PM Step by step assembly of solar lamp

03:30 PM – 03:45 PM Snack Break and GWR briefing

03:45 PM – 04:30 PM Gather at Gymkhana
Basics of Solar Energy
 Solar Energy & Types

Light
Energy

Thermal
Energy

18
 Applications of Solar Energy
Thermal Energy Light Energy

19
 Working Principle of SoUL

1. Solar Energy
6. Electric Energy
Solar Panel P.C.B. gets converted into
DC Circuit. light energy
Switch
2. Solar Load LED
Energy gets LED
converted Indicator
into electric
energy
4. Electric 5. Chemical
3. DC Current Energy gets Load Wire Energy gets
converted converted
into chemical into electric
energy energy

20
Technical Session
 What is SoUL Kit and Tool Kit?

SoUL Kit Tool Kit

22
 Let us understand
the components of both the kits
 SoUL Kit Introduction

Physical
Components of SoUL Kit

Components

Technical
Components
24
 Physical components of SoUL Kit

1.LED cap 2.Reflector 3. LED face 4. Switch Cap

5. Gooseneck 6. Base top 7. Base bottom 8. Screws

25
 Technical Components of SoUL Kit

1. Solar Panel 2. Battery 3. Load LED

26 4. Load wire 5. PCB

Testing of Components
 Testing of SoUL Components
Testing

Physical Testing Technical Testing

28
Physical Testing of Components
 Physical Testing (1/6)

Base top
1.Check for any scratches or breakage
2.Check all the screw mounting holes and
switch/indicator LED/gooseneck
mounting points

Base bottom
1.Check for any scratches or breakage
2.Check all the screw mounting holes and
the slots provided for battery and slot for
DC jack

30
 Physical Testing (2/6)

LED cap
1.Check for any scratches or breakage
2.Check the mounting points for load LED and
screw
3.Check the opening for gooseneck

LED face (Transparent)

1. Check for any scratches or breakage
2. Check the screw fixing point

31
 Physical Testing (3/6)
Reflector
1. Check for any scratches or breakage
2. Check the screw fixing point

Gooseneck
1. Check that there are no cuts anywhere.
2. Check that the gooseneck is neither too flexible
nor too tight
3. Blow from one end of the gooseneck and observe
the whistling sound
4. Check if the length of the gooseneck is 1 feet

32
 Physical Testing (4/6)

Load Wire
1. Check that both the wires are not cut from
anywhere
2. Check that the wire connector is connected
firmly to the load wire
3. Check that the wire length is 17 inches

Load LED
1. Check that there is no breakage or scratch on
the LED strip
2. Both the terminals should have solder pads
3. It should have a +ve and -ve marking

33
 Physical Testing (5/6)

Battery
1. Check that the wire connector is
connected to the terminal wires firmly
2. Check that both the wires are not cut
from anywhere
3. Check that the plastic sleeve of the
battery is not torn
4. Following details
• name of the manufacturer
• battery chemistry (LiFePO4),
• operating voltage (V)
• battery capacity (mAh)
• manufacturing year

34
 Physical Testing (6/6)
PCB ( Printed circuit board)
1. Check that there is no breakage
2. Press the switch repeatedly and check that it
does not get stuck while pressing
3. All three legs of indicator LED are soldered
properly
4. Check that the DC socket is properly soldered
5. Check that all the connectors are soldered
properly to the PCB

Solar Panel
1. Check that there are no scratches or breakage
in the glass, frame, junction box, or body of the
panel.
2. Check that there is no cut in the panel wire
3. Check that the connector pin is not damaged
4. Check that the wire length is 2.5 meters
35
 Introduction to Tool Kit

36
 Components of Tool Kit

1. Toolbox 2. Multimeter 3. Soldering iron

4. Iron stand 5. Solder wire 6. Screw driver

7. Glue 8. Testing jig

37
 Introduction to Multimeter

Probes Multimeter

Black(-) Red(+)
Knob setting for
voltage
measurement(20A)

Knob setting for

current
measurement(10A)

Current Voltage
measurement measurement
port Common port

Note: Different models of multimeter may have different specifications and settings.
Please refer to the operation manual of the respective multimeters.
 Introduction to Testing Jig

Solar input
Led input

Solar panel

Multimeter ports Load LED

Full charging Charging

Testing Zig Battery connector

Supply connector
Discharge
Technical Testing of Components
Sr Technical
Specification / Criteria Picture
No component
Maximum power, (Pmp) 2.5Wp
Maximum power voltage, (Vmp) 4.90V
1 Solar Panel Open circuit voltage (no-load), (Voc) 6.0V
Current on maximum power, Imp 510mA or 0.51A
Short circuit current (no-load), Isc 540mA or 0.54A
Rechargeable LiFePO4 (Lithium ferrous phosphate)
2000mAh (Ability)
2 Battery 3.6V (Maximum voltage)
3.2V (Terminal voltage)
3.0V (Minimum voltage)

40mA (Low intensity drain current)

3 PCB
130mA (High intensity drain current)

Teflon coated
4 Load Wire
Length = 17 Inch

5 Load LED 1.0W (Watt) (Maximum power)

41
 Technical Testing of
SoUL Lamp Kit Components
Sr No. Component Test

1 Solar panel Measure voltage (Voc) and current (Isc)

2 Battery Measure terminal voltage

3 Load LED Test LED light

4 Load wire Test continuity of the load wire

5 PCB Test switch, indicator LED, and DC socket

42
 Solar Panel Test
• Mono-crystalline or Poly-crystalline silicon cells
• 2.5m cable length
• 10 solar cells

43
 Information on Solar Panels

Company's
name
Power

Voltage
Current

44
 Precautions in testing Solar Panel

Test the panel Do not check

in sunlight panel in the
shadow

45
 Technical Testing: Solar Panel

Solar Panel
Test

Voltage test Current test

(Voc- open (Isc- Short
circuit circuit
voltage≥ 5V) current> 0A)

46
 Availability of Testing Jig

Without Testing Jig (click here to go to slide 42 if testing jig is not available)

With Testing Jig (click here to go to slide 52 if testing jig is available)

47
Without Testing Jig
 Solar panel 'Voc' test
If the testing jig is not available,
you can test the Voltage of a
solar panel as seen in the figure:

Steps:
1) Connect the probes as shown
in the image:
- Black probe in COM
- Red probe in VΩ
2) Set the knob pointer at 20V.
3) Insert the red probe in the
solar panel DC Pin and place
the black probe on the outer
metal contact of the pin as
shown in the figure.
4) Voltage should be> 5V

49
 Solar Panel 'Current (Isc)' test
If the testing jig is not available,
you can measure the current of
solar panel as shown in the
figure

Steps:
1) Connect the probes as shown
in the image:
- Black probe in COM
- Red Probe in A
2) Set the knob pointer at 10A
3) Insert the red probe in the
solar panel DC Pin and place
the black probe on the outer
metal contact of the pin as
shown in the figure.
4) Current should be> 0A

50
 Battery Voltage Test
• Rechargeable LiFePO4 (Lithium ferrous phosphate)
• 2000 mAh (capacity)
• 3.2 V (Operating voltage)
• Acceptable battery voltage≥ 3.2V

51
 Terminal Voltage Test
If the testing jig is not available,
you can measure the voltage of
the battery as shown in the
figure:

Steps:
1) Connect the probes as shown in
the image:
- Black probe in COM
- Red probe in VΩ
2) Set the knob pointer at 20V
3) Connect the multimeter pins to the
battery slots as shown in the figure
4) Measure voltage in multimeter.
5) Voltage should be≥ 3.2 V
Note: The multimeter probes should
not touch with each other.
52
 Load LED testing
• No test required if testing jig not available
• Light emitting diode (LED)
• Power – 1W

53
 Load Wire Test
• Length-17 inch; Teflon coated
• Black - negative (-ve); Red - positive (+ve)

54
 Load Wire Continuity Test

Load wire continuity

test
Knob setting for
continuity check 1) Connect the probes as
shown in the image:
- Black probe in COM
- Red probe in VΩ
2) Knob should be set at
the buzzer 🔊symbol
3) Continuity of one strand
of load wire should be
tested at a time
4) The Buzzer will beep if
the wire is continuous

55
 PCB Testing
• PCB–Printed circuit board
• Indicator LED test (charging, discharge and full charge)
• DC socket test

DC Socket Battery Socket

Switch

Load Wire Socket

Indicator LED

56
 PCB testing

LED testing
If testing Jig is not
available:

Steps
1) Connect the Battery at
the battery slot in the PCB
2) Connect the solar panel
to the DC socket of PCB as
shown in the figure
3) Place the solar panel in
bright sunlight

Indicator LED should blink

57
With Testing Jig
 Solar panel 'Voc' test
Steps:
Set the knob 1) Connect the probes as
at 20 V shown in the image:
- Black probe in COM
- Red probe in VΩ
2) Set the knob pointer at
20V
3) Connect the multimeter
pins to the “Multimeter” port
in the testing jig as shown.
4) Connect DC pin of the
solar panel to the “Solar
Panel” port in the testing jig
as shown.

Ideal probe
5) Measure voltage in
connections multimeter by placing the
solar panel in bright sunlight.
6) Voltage should be> 5V
59
 Solar Panel 'Current (Isc)' test
Steps:
Set the knob 1) Connect the probes as shown
at 10A in the image:
- Black probe in COM
- Red Probe in A
2) Set the knob pointer at 10A
3) Connect the multimeter pins
to the “Multimeter” port in the
testing jig as shown
4) Connect DC pin of the solar
panel to “Solar Panel” port in the
Ideal probe testing jig as shown
connections
5) Measure current in multimeter,
by placing the solar panel in
bright sunlight.
6) Current should be> 0A

60
 Battery Voltage Test
• Rechargeable LiFePO4 (Lithium ferrous phosphate)
• 2000 mAh (capacity)
• 3.2 V (Operating voltage)
• Acceptable battery voltage≥ 3.2V

61
 Terminal Voltage Test

Set the knob

Steps:
at 20 V 1) Connect the probes as
shown in the image:
- Black probe in COM
- Red probe in VΩ
2) Set the knob pointer at 20V
3) Connect the multimeter
pins to the “Multimeter” port
to the testing jig as shown.
4) Connect the battery to the
“Battery” port in the testing jig
as shown
Ideal probe
connections
5) Measure voltage in
multimeter.
6) Voltage should be≥ 3.2 V

62
 Load LED testing
• Light emitting diode (LED)
• Power – 1W

63
 LED testing
LED

LED
Input

Testing jig

Battery
64
 Load Wire Test
• Length-17 inch; Teflon coated
• Black - negative (-ve); Red - positive (+ve)

65
 Load Wire Continuity Test

Load wire continuity

test
Knob setting for
continuity check 1) Connect the probes
as shown in the image:
- Black probe in COM
- Red probe in VΩ
2) Knob should be set at
the buzzer 🔊symbol
3) Continuity of one
strand of load wire
should be tested at a
time
4) The Buzzer will beep if
the wire is continuous

66
 PCB Testing
• PCB–Printed circuit board
• Indicator LED test (charging, discharge and full charge)
• DC socket test

DC Socket Battery Socket

Switch

Load Wire Socket

Indicator LED

67
 Test of ‘Indicator LED’- Full Charge
Battery full charge
indicator
Solar Input 1) Connect the Battery
at the Supply Point on
the testing jig
2) Connect “Full
Charge” connector
from the testing jig to
the PCB
3) Connect “Solar
Input” pin of the
testing jig to the PCB
4) Indicator LED glows
constantly green if the
Full Charge Testing Zig
Full charge Indicator
LED is working fine
Battery

68
 Test of ‘Indicator LED’- Discharge

Battery discharge
indicator
1) Connect the Battery
at the Supply Point on
the testing jig
2)Connect “Discharge”
connector from the
Discharge testing jig to the PCB.
3) Press the switch on
PCB, the indicator LED
will blink red once

Testing Zig

Battery

69
 Test of ‘Indicator LED’- Charging
Solar Battery charging
indicator
Input 1) Connect the Battery at
the Supply Point on the
testing jig
2) Connect “Charging”
connector from the
testing jig to the PCB
3) Connect “Solar Input”
pin of the testing jig to the
PCB
4) If the Indicator LED
Testing Zig blinks green light, the
‘Indicator LED’ charging
is fine

Battery Charging
70
 Test of Switch

LED Testing low mode and

high mode operation
1) Connect the Battery at
the Supply Point on the
testing jig
2) Connect “Charging”
connector of testing jig to
the PCB
2) Connect “LED”
connector from the testing
jig to the PCB
Battery 3) Press the switch once for
Charging low mode and twice for
high mode

71
 Important Guidelines

First-aid box should be Glue should not fall on any Wait till the glue gets dried
present in the training venues other part of the lamp

Do not inhale the Do not put excess force Do not put excess force Always keep the
smoke of the soldering while screwing while screwing soldering iron on the
soldering stand

72
 Screws in Lamp
Total screws in the lamp: 7

To fix LED cap,

1 Big screw Small Screw
1 Reflector, load LED and
(6.5 mm)
LED face

3 Small
To fix PCB to the base Big Screw
2 screw (4.5
bottom
mm)

To fix base bottom and 3 Big screw

3
base top (6.5 mm)

Total 7 screws

73
 Steps to
Assemble
the Solar Study Lamp
 Phase- 1/19

Hold the gooseneck horizontally and apply 1

drop of glue to one end of the gooseneck
75
 Phase- 2/19

Insert the glue applied end in the

opening of the LED cap
76
 Phase- 3/19

Place the dust proof cap in the slot provided

77
 Phase- 4/19

Apply glue to the

dust proof cap from
the lower side of the
base top by applying
1 drop of glue

Note:
Take precaution
while applying the
glue, as the glue may
splash out and fall on
the hands of the
assembler.

78
 Phase- 5/19

Hold the gooseneck horizontally and apply 1

drop of glue to the other end of the gooseneck
79
 Phase- 6/19

Insert the glue applied gooseneck in the base

top, such that the LED cap is facing in the
switch’s direction of the base top
80
 Phase- 7/19

Insert load wire through the bottom of the

base top

81
 Phase- 8/19

Load wire should exit from the other end

82
 Phase- 9/19

• Solder load wire with LED

• Observe the (+ve) and (-ve)
terminals/solder pads on load LED strip
○ Red wire is soldered to +ve terminal
○ Black wire is soldered to -ve terminal
Note: Soldering must be done under the
supervision of a skilled trainer
 Phase- 10/19

Place load LED in LED cap properly

84
 Phase- 11/19

Connect the load wire connector to PCB

85
 Phase- 12/19

Connect the battery with PCB

86
 Phase- 13/19

Press the switch and check the

operation of LED
87
 Phase- 14/19

• Tighten PCB with small screws in base bottom

• Connect load wire and battery into their
respective sockets on the PCB correctly
88
 Phase- 15/19

Tighten the base top and base bottom

with 3 big screw (6.5mm)
89
 Phase- 16/19

Stick the product code stickers as shown above

90
 Phase- 17/19

Place the reflector properly in the LED cap

91
 Phase- 18/19

Fit reflector and LED face with a 9.5mm (big)

screw in LED cap

92
 Phase- 19/19

Pasting the MNRE and program’s sticker

93
 Lamp Test
Low Mode and High Mode

Plug in solar pin

Low Mode High Mode
in the DC socket

94
 Seal Sticker

How much do
Sticker Name Where to put it?
you have?
To be added on base
Seal sticker bottom and base top 1
behind gooseneck

95
 SoUL Packaging

• After successful testing of Solar Urja Lamp,

pack the lamp and solar panel in the
respective packaging box

• The following items should be packed in the

packaging box:
1. Solar Lamp
2. Warranty Card
3. User Manual

96
 Items in Soul box and Panel box

97
 Put the solar panel in the box

98
 Packaging

Finished product with packaging

99
 Pledging Non-Violence to Environment
International Day of Non-violence
2nd October 2018
Today on International Day of Non Violence I humbly stand
here, with a solemn pledge:

 To protect, preserve, and nurture our environment for a

gratifying present and green future;
 To be conscious of my own actions to not cause harm to
our nature;
 To show courage to speak up condemning action that
damage our environment;
 To be compassionate, responsible global citizens to ensure
peaceful co-existence of all living beings in the world.
 Our Partners

Ministry of New and Ministry of Human Institute of IIT Bombay

Renewable Energy Resource Electrical and Diamond Jubilee
Development Electronics 2018
Engineers

Jawahar Energy Efficiency Atal Innovation Techfest, IIT Bombay

Navodaya Services Limited Mission
Vidyalaya
Documentation session begins
 Documentation required
 Distribution Information Sheet
 List of teachers involved in the workshop
 Feedback from Trainers
 Testimonials from Students (2 each per location)
 Testimonials from Teachers (2 each per location)
 Testimonial from Principal (from every location)
 Photos of the event day (upto 10 per location)
 Up to 20 seconds Video of the event day

103
Distribution Information Sheet

Record
on the
day of
the event
 Thanks !!!

105