CHAPTER 1

INTRODUCTION

1.1 Background of the study

This project involves the conversion of sunlight into electric power

directly using the photovoltaic (PV). The Mono-crystalline solar panel is a

photovoltaic system which captures energy from the sun and turns it to

electricity. The mono-crystalline make use of silicon element which is very

durable and give its discharge in abundant. To make solar cells, Mono-

crystalline silicon is form into bars and cut into wafers, which indicates that

the silicon used is a single crystal silicon, because the cells is compose of

single crystals.

The demand for electricity in the nation is constantly increasing and

conventional energy resources are diminishing and even threaten to be

depleted. Solar energy is readily available and renewable; hence it provides

a safe, clean, substitute to the increasing problem of over dependence on

plants, generators etc. which constitute no air pollution resulting from the

exhaust of plants and generators; this has given the generation of electricity

through solar an edge. The solar panel is noiseless because it constitutes no

moving part in the system; it is durable, reliable and requires little or no

1
 maintenance practice to sustain it. Moreover, the solar system has an edge

especially where electricity cannot be sent through transmission lines.

The amount (voltage) of electricity so generated through the solar

power system depends on the intensity of the solar energy incident on the

solar panel and the configuration of the panel. This research work uses PV

modules to convert sunlight into electricity with respect to the principle of

photoelectric effect. This is the process whereby sunlight is absorbed by the

solar panel thereby causing excitation of electrons or other charge-carrier to

a high energy level.

Finally, the success of this study will be beneficial to the society at

large because the relatively expensive but higher quality component is more

likely to perform better (saving energy and thus cost) and may be able to

recover its cost in the long run.

1.2 Problem statement

In our country today interrupted power supply has been a serious issue

and it makes life difficult and unbearable because firms, industry, churches,

shopping malls, schools and even business centers etc, depends on power

supply for their day to day running activities. However, some have resulted

to plant and generators to enable them meet up. But these machines, with

2
 their emission of gasses to the atmosphere pose health challenges. If

constant electricity must be assured, all the setbacks would be forestalled.

This is exactly what this project intends to proffer solution to.

1.3 Aim and objectives

The aim of this project is to assemble a 250watts mono crystalline

photovoltaic solar panel, and this will be achieved with the following

objectives:

i. To achieve higher efficiency rate of electricity since they are made of the

highest grade silicon.

ii. To provide a solar panel that will last much longer.

iii. To provide a solar panel that will be more efficient in warm weather.

iv. To implement a solar panel that is more space efficient.

1.4 Significance of the Project

The mono crystalline solar panel is useful in many ways. It captures

energy from sun and turns it into electricity. Because the cell is composed of

a single crystal, the electrons that generate a flow of electricity have more

room to move. As a result, a mono crystalline panel are efficient than its

counterpart. Most significantly, the solar panel serves as an alternative

source of electrical power supply which is needed in our society.

3
1.5 Methodology

This project follows ‘cradle to gate’ approach. A life cycle inventory

of a photovoltaic power plant with a 250watts peak capacity is built up. The

scope and system boundary are described below:

Pegboard
assembling

Spacer Drilling &

arrangement Monocrystalline smoothing
solar cell

Solar cell spacing

Cabling with First testing

tabbing wire
Installed
PV system
Painting Mounting
system

Final testing for full

voltage and current
operation

Figure1.1: Block Diagram of a Mono-crystalline PV Solar Panel Module

4
1.6 Scope of the Project

The scope of this project shall cover the following areas;

i. The selection of the solar cell, tab/bus wire, peg board, Plexiglas, UV

protector sealant etc.

ii. Design analysis of the solar panel

iii. The economic analysis (bill of engineering measurement and evaluation).

iv. Testing and experimentation of the system.

1.7 Report Layout

This report is made up of six chapters, chapter one being the

introductory part of the project as represented below;

Chapter 1: Background of the project

This gives an introduction to the general concept of power, the significances

and objectives which the project report seek to achieve. It also explains the

scope of the project and problem statement.

Chapter 2: Literature Review

It gives the historical and theoretical background of the project, a study of

the previous methods used and a critical analysis of the new approach and its

significance in comparison with previous method.

5
Chapter 3: Materials and Methods

This gives the technical description of the components used in assembling,

including the reasons behind their choice. It also gives the details of the

methods used in realizing the project, which includes both the research

methods and circuit architecture.

Chapter 4: Design Analysis and construction

In this chapter, the step by step approach in determining the values of the

circuit components based on the project goals are clearly given. It also gives

details of the procedure followed in implementing the realized circuit

diagram on the circuit board and packaged of the device.

Chapter 5: Test Result Analysis and Discussion

After implementing the circuit, various tests were carried out on different

blocks of general block diagram to verify the block design specifications.

Those results are presented and discussed in this chapter.

Chapter6: Conclusion and Recommendations

The final achievement in this project, including the knowledge acquired, is

stated in this chapter. A set of recommendation are also made as it concerns

areas requiring possible improvement and usability of the final products.

6
 CHAPTER 2

LITERATURE REVIEW

2.1 Historical Background

Solar power is the conversion of sunlight into electricity either

directly using photovoltaic (PV) or indirectly using concentrated solar power

(C.S.P). The CSP uses the lenses or mirrors the photovoltaic effect converts

light into an electric current using photovoltaic effect. The solar panel

system is not a today’s advent. In-fact, before the 18th century many

scientists had developed and contributed to the development of the solar

system.

Edmond Bacquerel (1839), born in Paris; discovered that when two

electrodes were placed in an Electrolyte, a voltage develops when sun light

falls upon the electrolyte; this gives the basic principle of solar power. Other

Authors threw more light on the solar panel system.

Albert Einstein (1905) famous for a wide variety of scientific milestones, but

most people was not aware paper work on photo-electric effect. He

formulated the “photon theory of light” which describe how light can.

7
 Liberate electrons on a metal surface. Years later, he submitted his paper and

was awarded the noble prize for the scientific breakthrough he had recorded.

Daryl Chapio et al (1954) of bells labs are credited with the world’s first

photovoltaic cells (Solar cells). In other words, these are the men that made

the first devices that converted sunlight into electrical power. The three

Scientist joined Forces and presented their solar battery powering a small toy

windmill and a radio at efficiency of 6%. The key to their success

achievement was the ability to diffuse boron into silicon in a process known

as “Doping”.

Dr. Elliot Bernard (1970s); with funding from Exxon Corporation design

much lower cost solar cells using lower-grade silicon and cheaper housing

which brought the cost per watt down. Installation far from mains electricity

like oil rugs, terrestrial installation etc. used the solar cells in preference to

the expensive and cumbersome type of batteries previously used.

2.2 Theoretical Background

Hundreds of solar cells (also called photo-voltaic cells) make up a

photovoltaic (PV) array. Solar panels are the components of solar arrays

that converts radiates light from the sun into Electricity that is then used to

power electrical devices, Heat and cool homes and Businesses. Solar cells

8
 contain materials with semiconducting properties in which their electrons

become excited and turn into an electrical current when struck by sunlight.

2.3 Existing methods

Dr. Bruno Lange (1931), a German scientist predicted that, in the not distant

future, huge plants will employ thousands of these plates to transform

sunlight into electric power…that can compete with hydroelectric and

steam-driven generators in running factories and lightning homes. But

Lange’s solar batteries worked no better than Fritts’s, converting far less

than 1% of all incoming sunlight into electricity-hardly enough to justify its

use as a power source.

University of Delaware (1972) developed a photovoltaic research in their

laboratories which culminated to one of the world’s first PV powered house-

“solar one”. Using the model known today as “the solar feed-in” surplus

electricity generated during the day is fed back into the grid.

While there are dozens of variations of solar cells, the two must common

types are those made of crystalline silicon (both Mono-crystalline and Poly-

crystalline) and those made with what is called Thin film Technology.

9
Gerald Pearson (1954) of Bells Lab developed the mono crystalline solar

cells also called “single crystalline” cells are easily recognizable by their

color. They are made out of what are called “silicon ingots”, a cylindrically

shaped design that helps optimize performance in the silicon world, the more

pure the alignment of the molecules, the more efficient the materials is at

converting sunlight into electricity, which is an attribute of a mono-

crystalline solar cells of which its efficiency has been documented at upward

of 20%. Essentially, designers cut four sides out of cylindrical ingots to

make the silicon wafers that make up the mono crystalline panels.

Beyond being most efficient in their output of electrical power, Mono-

crystalline solar cells are also the most space efficient. This is logical since

you would use fewer cells per unit of electrical output. In this way, the solar

arrays made up of mono-crystalline take up the least amount of space

relative to their generation intensity. Another significant advantage is that

they also last the longest of all types. Many manufacturers offer warranties

of up to 25 years on this type of PV system.

The Polycrystalline Solar cells

Calvin Fuller (1981) of Bells Lab discovered the Polycrystalline solar cells

also known as poly silicon and multi silicon cells were the first solar cells

10
ever introduced to the industry, in 1981. Made from cast square ingots large

blocks of molten silicon carefully cooled and solidified. They consist of

small crystals given the materials its typical “metal flake effect”.

However, polycrystalline is less efficient than its Mono-crystalline solar PV

system operated at a 13-16% efficiency again this is due to the fact that the

material has a lower purity. Due to this reality, polycrystalline is less space-

efficient, as well. One other drawback of polycrystalline is that it has a lower

heat tolerance than Mono-crystalline, which means they don’t perform as

efficiently in high temperatures.

Karl Boar (1972) established the institute of energy conversion (IEC);

located at the University of Delaware this was established to pioneer

research on thin film solar cells. This is made by depositing one or more

thin layers or thin film (TF) of photovoltaic material on sub straight such as

glass, plastic or metal. The thin film Cells are said to be flexible and lower in

weight. Thin Film Technology has always been cheaper and the lab cell

efficiency for CBTE and CIGS is now beyond 21%, outperforming Multi-

crystalline, the dominant currently used in most solar PV system

11
Dye-sensitized solar cells

Brian O’ Regan and Michael Gratzel ( 1988) were the co inventors of the

modern version of a Dye solar cells popular known as the Gratzel Cells a

dye sensitized (DSSC, DSC, DYSC or Gratzel Cell) is a low cost solar cell

belonging to the group of thin film solar Cells. It is based on a

semiconductor form between a photo-sensitized anode an electrolyte, a

photo-electrochemical system. DSSC has a number of attractive features; it

is simple to make using conventional row-printing techniques, its semi-

flexible and semi-transparent which offers a variety of uses not applicable to

glass-based systems, and most of the material used are low cost.

The solar window

Derek Markhan (2012), suggest that Solar window modules are created by

applying ultra-thin layers of liquid coatings produce ultra-small solar cells

and form groups called ‘arrays’. Because of the family of material that is

being used and the architectural design pattern, the final product is generally

referred to as an organic photovoltaic solar array (OPV). The coating of

these solar windows produces world’s smallest functional cells, (measure

less than ¼ the size of a grain of rice) and can be applied at room

temperature.

12
2.4 New Innovations

The Mono-crystalline being the first variety of solar panel as

compared to other solar panels, converts the most amount of solar energy

into electricity. This is also the most preferred choice because it poses no

threat to the environment unlike some solar films which uses cadmium

telluride which is not environment friendly. Furthermore, its high efficiency

of about 26.7% cannot be sidelined, because its yield more power output

with that regard compared to other solar cells.

The third generation of solar cells includes a number of thin film

technologies often described as emerging photovoltaic most of above have

not been commercially applied and are still in the research invested into

these technologies as they promise to achieve the goal of producing low

cost, high efficiency solar cells.

Limitations of the project

i. We do not yet have enough manufacturing capacity for solar panels.

ii. The amount of the sun that could be collected

iii. The radiation of sun is nearly fixed; the place that could be used to pave

solar panel is limited.

iv. We cannot exploit all of sunlight to electricity because biosphere needs it.
13
 v. We do not yet have enough storage at low enough cost for load balancing;

its output is intermittent, needs grid, battery or other buffering system to

work together in large quantities.

vi. They are a great deal of bogus political and financial resistance to solar and

other renewable spearheaded by those who stand to lose trillions of dollars

when fossil fuels loose nearly all market values.

2.5 Summary of the Review

It often beats the imagination how mere sunlight (solar power) can be used

to generate electricity. Solar power generates electricity by converting solar

energy through the principle known as photovoltaic principle (the process

between radiation absorbed and the electricity induced).

A number of solar cells are electricity connected to each other structure or

frame called the photovoltaic module. The module is arranged in series to

form the array. Generally speaking, the greater the area of the array, the

more electricity it can produce.

14
 CHAPTER 3

MATERIALS AND METHOD

3.1 Materials

For this project work, the following parameters were considered:

Load estimation of the building, system component of the solar panel which

comprises of the pegboard assembly, solar cell assembly installed PV

system, final testing for full voltage/ current operations

For this project work, 0.25KVA (250 watt) is the estimated load of the

facilities (project wok). The below analysis gives a breakdown of the

component used in this project.

1) Pegboard (backing board)

2) Spacer

3) Mono crystalline solar cell

4) Tabbing/bus wire

5) Plexiglas

6) Silicone sealant

7) UV-protection sealant

8) Flux pen

15
 9) MC4 connectors

3.1.1 Pegboard Assembling

The pegboard, also known as the backing board is perforated thin bard

made out of non-conductive materials such as wood, plastic or glass. For

cost effective propose wood is being used in this project work. This backing

board is being drilled with evenly spaced holes which enables a free passage

of the cells wire.

Figure 3.1: Diagram of backing board

3.1.2 Spaced Arrangement

Usually referred to as solar spacers, this is designed to assist solar PV

module installations. This ‘spacer’ allow us to achieve a consistent pattern

and maintain uniformity in the solar panels. Furthermore, it helps ensures

that all the panels used are laid equidistance from each other, providing

symmetrical and professional finish.

16
 Figure 3.2: Diagram of a spacer

3.1.3 Mono-crystalline solar cell

To make solar cell from Mono-crystalline solar panels, silicon is

formed into bars and cut into wafers. These types of panels are called

“Mono-crystalline” to indicate that the silicon used is single-crystal

Figure 3.3: Diagram Mono-crystalline solar cell

3.1.4 Tabbing/bus wire

A tab wire is used to connect a solar cell in series to get the require

voltage needed. The solar cells were connected in rows (series) making sure

the wire is around 18:20mm thick to carry the current better. The tabbing
17
 wire is made out of solid copper coated with solder for easy flow which

required the use of solder when connecting cells together. The burst wire

looks like a tab wire but is much wider. The burst wire is used to carry the

current across each row. It ranges from 2.5mm-5mm which depends on the

power of the panel and size of the solar cell that is being used.

Fig 3.4 Diagram a tabbing/ bus wire

3.1.5 Installed Photovoltaic System

The above process involves the interconnections of cell to cell which

form a module and also the interconnection of modules which forms an

array. Some distinct processes involved for the above to be completed are:

drilling and soldering, painting of the box, wiring the panel, attaching of

Plexiglas using the appropriate screws and drill.

18
 a) Drilling and soldering: the backing board is being drilled with respect to

the position of the solar cells wire and soldering done to the bus wire by

connecting some connectors alongside.

b) Painting of the box: this process keeps the box cooler which helps the cell

to perform better when they are cool. One major advantage is that it helps

the panel to last longer.

3.1.6 Attaching of Plexiglas

Plexiglas panels are made of acrylic material which means that they

can be easily cut with a hand saw. Plexiglas allows 90 percent of light rays

to pass through it to the solar cells. Despite allowing this much light through

to the solar cells, Plexiglas protects the solar cells very well from wear,

ensuring that they last as long as possible.

Figure 3.5 Diagram of a Plexiglas

3.1.7 Silicone sealant (SN-502 all weather) –low modulus: SN-502 all weather

sealant-LM is a one part, construction grade, low modulus, RTV Natural

19
 silicon sealant. It is suitable for a wide range of sealing and glazing

applications were durability and reliability is required, it has a superior

resistant to UV-Radiation, vibration and weathering etc. it adheres to a

variety of non-porous substrates such as glass, ceramics, tiles, aluminum,

plywood and composite panels etc.

Figure 3.6: Diagram of a silicone sealant

3.1.8 UV-protection sealant is used to protect the solar cells from high heat and it

is also used for the purpose of long lasting protection

Figure 3.7: Diagram of a UV-protection sealant

20
3.1.9 MC4 Connectors: are single-contact electrical connectors commonly used

for connecting solar panels. The MC in MC4 stands for the manufacturer

multi-contact and the 4 for the 4mm diameter contact pin. MC4s allows

strings of panels to be easily constructed by pushing the connectors from

adjacent panels together by hand, but require a tool to disconnect them to

ensure they do not accidentally disconnect when the cables are pulled. The

MC4 and the compactable product are universal in the solar market today,

equipping all solar panels produce since about 2011 which allow longer

strings to be created.

Figure 3.8: Diagram of a MC4 connector

3.1.10 Flux pen: these are small plastic containers with a spring loaded felt tip at

one end with a slight amount of pressure, the tip allow flux to wick through

the felt and onto the cell.

21
 Figure 3.9: Diagram of a flux pen

Advantages of flux pen over Normal soldering

 Since the tip valves closes between uses, evaporation is kept to a

minimum

 The unit is disposable; there are no needles or micro valves to keep

clean.

 Application is uniform so there is less chance of flux inconsistencies

22
 Figure 3.10 Diagram of a PV Mono-crystalline Solar Panel

3.2 Methods

Procedures for the construction of solar panel used in this project are

given below;

Dimension of solar cell = 6inches by 6inches (0.24mm by 0.24mm).

The solar panel construction was done in two stages:

Stage one:

Tapping of the solar cells and

Stage two:

Fabrication of solar panel frame

Table 3.1: Tapping of Solar cell

S/N MATERIALS TOOLS USED PROCEDURES DIAGRAMS

1. Silicon cell 6’’ Backing board The negative side of

by 6’’ the solar cell was

placed on the work

Solar Cell

table; flux pen was

Taping Wire

rubbed on the

horizontal mark on
23
 the solar cell.

The tabbing wire

was placed on the

flux o the line of the

cell and soldered on

the two lines.

2. The above procedure

was carried out for

the cells with the

tabbing wire

extended on the

solar cell

3. The reverse side

(positive side) of the

work table, flux pen

used to add flux on

the solar cell then

the tabbing wire

placed on the flux

then soldered as

24
 done with the

negative side of the

cell.

4. Silicon cell 6’’ Serial connection of

by 6’’ the solar cells with

the extruded tapping

wire on the negative

side of the cell joint

with the positive

side of the cell using

heat of soldering

iron and flux. The

cells were then

allowed to set for

some time.

25
 Table 3.2 Construction of the Solar Panel Frame

S/N MATERIALS TOOL USED PROCEDURES DIAGRAMS

1. Glass Glass cutter, The glass was placed on

Aluminum pencil, hack the worktable and marked 2m

1m

Bar saw, square 24’’ by 12’’ and cut with

worktable the help of the glass cutter

2. The aluminum angle bar

0.25m
was cut 1m long. It was

0.25m
marked off at distances

1m
0.25m
0.25m, 0.25m, 0.25m,

0.25m and square

0.25m
properly.

3. The edges of the angle bar 12

24
were chamfered 22.50 and

the two points on the 24

middle of the bar were 24

chamfered 450 12

26
4. Frame and Riveting The chamfered aluminum

Glass tools, Rivet bar was joint together

silicon gum with screws and hardener.

The silicon was placed on

the aluminum frame and

the glass placed on the

aluminum frame until

they stick together.

5. Frame glass Hardener The negative sides of the

& solar cells solar cell are placed on

the glass with the

hardeners on it to stick to

it. Same procedures were

carried out for the

remaining panels

Working Principle of the Solar Panel (Cells Connection)

This project research operates on the principle of Photovoltaic effect.

This is a process that converts sunlight (solar energy) to direct current

electricity. For this to take place, the solar panels have to be placed where
27
adequate photons can incident on it is usually placed at roof-tops. When

sunlight is incident on the solar cells on the solar panels, electrons are

knocked loose from the solar cells until a higher energy level is reached

whereby the electrons flow away through to an external circuit.

The physics behind this is that solar cells are made of two semi-

conductors joint together to form p-n junction. The p-type semi-conductors

have a high concentration of holes, while the n-type has a high concentration

of electrons. This joining enables excess electron from the n-type to diffuse

with the hole of the p-type. This movement of this excess electron to the p-

type exposes positive ion at the n-type while the movement of holes to the n-

type exposes negative ion on the p-type resulting in an electron field at the

junction forming the depletion region. Under such circuit condition, the

charge carrier exit (leaves) the solar panel as light generating current.

Cells can be connected in either series or parallel connection. Series

connections consist of cells connected end to end. When cells are connected

in series, their voltages add but their currents do not. The current of a series

connection is same as one cell; which is what is used in this project by

connecting the positive of the first solar cell with the negative cell of the

second solar cell, then negative of the second with the positive of the third

solar cell and so on. Parallel connection consists of cells connected side by
28
side. When cells are connected in parallel, their currents add, but their

voltage does not. This is achieved by connecting the positive of the first

solar cell to the positive of the second solar cell then the positive of the

second to the positive of the third solar cell. Connection of the two types can

obtain nearly any combination of voltages and current resulting in a wide

variety range of output power ratings.

Circuit diagram:

29
Figure 3.11: circuit diagram for a series connection of a mono-crystalline solar

panel

Since a solar cell only generates about 1 to 2watts of power, it is

necessary to combine them into solar power panels in other to generate more

power. Photovoltaic modules commonly called solar modules are the key

components used to convert sunlight into electricity. Solar modules are made

30
 up of semiconductors that are very similar to those used to create integrate

circuits for electric equipment. The most common type of semiconductor in

use which is also used for this project is made of silicon crystal. The

electricity produced is called direct current (DC) which charges a battery and

when an inverter is being added, it converts this DC voltage to AC voltage

needed directly for a useful work (though not part of this project report).

3.2 Sources Of Materials

During the course of this project work, that is, seeking for information on

how a 250w PV solar panel can be assembled with more efficiency. This

project led us to the internet site were we browsed and sort for materials

throughout the course of this project, and also other information centers such

as the Polytechnic Library, project books and oral interview with my project

supervisor, technologist and other Electrical Engineers.

31
 CHAPTER 4

DESIGN ANALYSIS AND CONSTRUCTION

4.0 System Design parameters

This chapter expatiates on each stage of the constructed work seen in

chapter (3), which deals with gathering of various materials for each stage.

The circuit diagram was used to assemble the solar cells on a pegboard

(which is light-weighted) the purpose of the light weighted pegboard used

was for easy carriage and mounting. Since the project work deals with the

assemblage of a PV solar panel, the various steps or procedures on how this

was achieved would be discussed under this chapter which includes;

(i) Cutting of the pegboard and putting frames together

(ii) Creating of holes on the pegboard for connection

(iii) Assembling the solar cells

(iv) Gluing the solar cells down

(v) Soldering Bus wire and the tabbing wire

(vi) Fixing of the Plexiglas into its frame

32
4.1 Cutting of the pegboard and putting frames together

This is the chosen surface at which the solar cells are being mounted

upon. The pegboard is being cut into size with a prerequisite dimension of

Formica of the same dimension was also cut and attached on the pegboard

using an evostic gum. This platform brings out the uniqueness of the solar

panel after the cells are being mounted on it. The size/dimension of the

pegboard was a factor of the number of solar cells needed for the aluminum

was also cut with regards to the dimension of the pegboard and holes made

for screwing of the Plexiglas to it.

4.2 Creating of holes on the pegboard for connected with the pegboard

With the pegboard now (coated) with the Formica a single solar cell

was placed on it inside the frame to get an idea of the dimension needed for

the holes to be punched around the board and then taking the solar cells back

out once the measurement was made. Drilling holes across board was then

very easy with this idea. Furthermore, we drilled two holes at the head of the

frame for the negative and positive connections to run out.

4.3 Assembling the Solar cells/Gluing the solar cells

Being the main work of this project, assembling of the solar cells was

carefully done due to its fragile nature. Taking into consideration its
33
 negative and positive part, that is, its positive part being placed on the

pegboard and its negative part facing up with regards to the holes created;

the solar cells were connected in series with a total of 32 cells using a

tabbing wire and a soldering iron to connect the solar cells together. Hence,

we then glued each solar cell to the coated pegboard using a silicon sealant.

4.4 Soldering Bus wire and Tabbing Wire

For this panel we have four (4) strings of solar cells to connect this

string of solar cells, we used a bus wire. This bus wire goes at the end of the

string to create one long string. Next after hooking all 4 strings of solar cells

up in series, we got 22 gauge bus wires ready for soldering. This was hence

linked to the tabbing wires at the sides of the solar cells which were hence

drawn to the output.

4.5 Fixing of the Plexiglas into its frame

The Plexiglas is a very important material used during the assembling

of solar cells to form a module. Being a preferred material for constructing

solar panels compared to the tempered glass, its holds up better in harsh

weather conditions and is more shatter resistance while still allowing 90% of

light to pass through it to the solar cells. The Plexiglas (Acrylic sheeting)

34
was to protect the solar cells from excess dust which would certainly

decrease the life span of solar panel.

Specification of the Solar Panel

Solar panel voltage ---------------------------------217.6

Solar cell efficient ----------------------------------

Cell Type --------------------------------------------Mono crystalline

Frame used ------------------------------------------Aluminum

Standard Test Condition (STC) ------------------1000w/m2

Maximum open circuit voltage (Voc) ----------18.89v

Minimum voltage at open circuit ------------------16.56

Glass used ---------------------------------------------Plexiglas

Voltage per cell --------------------------------------0.5volts

Number of cells --------------------------------------32 cells connected in series

Each cell produces a current of --------------------0.143amps

Total current produced -------------------------------3.45amps

Expected Life span of the solar panel -------------------------10 years

35
4.6 Interconnection of the various cells

The two terminal (red and black) of the output was gotten by the

connection of each cell in series using a bus wire and hence connecting it to

the tabbing wire through which the changes that is electrons and holes from

the negative and positive sides of the cells respectively passes through to the

output. This was tested at both high intensity of sunlight and low intensity

using a multi meter to get its open circuit voltage at maximum and open

circuit voltage at minimum

Table 4.1 BILL OF ENGINEERING MEASUREMENT AND EVALUATION

(BEME)

SN MATERIAL USED QTY UNIT TOTAL PRICE(N)

PRICE(N)

1. Pegboard 1 5000 5000

2. Spacer 5 250 1000

3. Mono-crystalline solar cell 50 1250 62500

4. Tabbing/Bus Wire 1 2850 2850

5. Plexiglas 1 5000 5000

36
6. Silicone sealant 1 2000 2000

7. UV Protection/ Protection 1 8750 8750

sealant

8. Flux pen 1 950 950

9. Aluminum frame 10000 10000

10. Transportation 5000

11. Miscellaneous 5000

TOTAL 103,050

37
 CHAPTER 5

TESTING, RESULTS AND DISCUSSION

5.0 Testing of the solar panel

The testing of each cell that makes up the circuit was carried out

effectively to ensure its working condition so as to produce a desired output

with regards to the series connection pattern adopted in this project work.

5.1 Testing solar panel for volts

Knowing fully well that the connection pattern used in this project

work was to increase the system (panel’s) voltage, hence the testing of the

solar panel for volts started by testing each of the solar cell connected in

series and the overall output voltage or open circuit voltage of the solar

panel. The below procedure was taken through the connection made by the

multi meter to the solar panel’s output

(i) To test solar panel voltage output, we put the solar panel in the multi

meter direct sunlight, and set the multi meter to “volts” setting

(ii) We touched the multi meter (red) positive lead to our solar panel’s

positive wire

(iii) We hence touched the multi meter (black) negative lead to our solar

panel’s positive wire

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5.1.1 Result Discussion

With regards to the series connection, each cell gave a voltage of

0.5volts mathematically speaking its total output voltage will give 16volts.

At maximum intensity of sunlight using a digital multi meter as the

measuring instrument, its maximum output voltage rose up to 18.89volts.

With regards to the above procedure, the aforementioned maximum output

voltage was observed.

5.2 Solar Panel Testing for Amps

It is a known fact that the current generated by the solar panel is

Direct Current (DC); hence to get the total current produce by each cell and

the total current produced by each cell and the total current produced by the

total series connected solar cells the below procedure was followed

(i) To test solar panel amperage output, we paced the solar panel under

the sun with high intensity, setting the multi meter to the “amps”

setting.

(ii) We touched the meter’s (red) positive lead to the solar panel positive

wire

(iii) We hence touched the meter’s (black) negative lead to the solar

panel’s negative wire

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5.2.1 Result Discussion

The amp reading in the meter gave a reading of 3.5 amps at maximum

sunlight intensity. Hence for each solar cell used in the assemblage of this

work it is certain that it produces a 0.143amps with regards to it rated

voltage of 0.5v and 3.45amps series connected solar cell.

5.3 Solar Panel Testing For Watts

The power rating of each cell was being imprinted by the

manufacturer. That means that the power rating of cell varies in prices.

Hence that used for this project work is rated 6.8 watts for each solar cell.

5.3.1 Result and Discussion

With regards to the aforementioned voltage per cell, the total power

rating mathematically speaking gave a 218watts which is the total power

rating of the solar panel

5.4 Solar Panel Testing for Efficiency

Measuring the amount of sunlight that solar panel systems are able to

convert in actual electricity is the performance parameter. The outcome

determines solar panel efficiency and it’s always measured in percentages.

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5.5 Reliability Test

This can be described as a measure of how reliable the project work can be

at different intensity of sunlight incident on the solar panel. It can be seen below

that the degree of sun ray on the panel is a prerequisite of its output at different test

type or condition.

Table 5.1 Reliability Measurement

TEST TYPE SOLAR INTENSITY

High Medium Low

Voltage 18.89 17.13 16.08

Wattage 218 189 137

Amperage 4.576 3.75 2.17

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 CHAPTER 6

CONCLUSION AND RECOMMENDATION

6.1 Conclusion

This section of the project report forms the concluding part of the

project report and takes a look at some of the problems encountered during

the progressive assemblage of the system and also brings in suggestion for

further improvement and/or enhancement of the solar panel or system

assemblage.

The sun is a powerful source of energy that helps our planet by giving

us clean reusable energy to power the society the use of this energy is free

does not create pollution and when used widely can help us become less

dependent on other costly and damaging forms of power supply.

The assemblage of the solar cell to form the solar panel module has given us

a wattage of 217.6watts which is lower compared to the specification given

by the school project coordinators team this was due to the following

reasons.

(i) Due to the fragile nature of the solar cells which so many were broken at the

course of assemblage as a result of low level of capability in handling of the

cells while assemblage for module

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(ii) Another shortcoming has been seen in the seen in the total output wattage

which is giving 217.6watts instead of the proposed 250watts specification.

This was as a result of the expensive nature of the cells with higher wattage

manufactures specification specifications.

6.2 RECOMMENDATION

This project has been viable for offices both private and public, school,

hospital and even living houses. This helps conserve energy and reduce the

expenses on electricity bills and other expenses that goes with lighting.

In consideration of its functionality and to enhance its performance

characteristics; thus, after the completion of this project work, the following

would be necessary so as to achieve high output efficiency.

(i) Solar cells at low cost of high wattage should be made easily available for

purchase

(ii) Further research should be made on the reduction in size of this solar cells

with an improve efficiency of the cells.

(iii) The solar panel module should be maintained regularly by cleaning its

surface and removing of debris so as to have maximum sunlight penetration

on the cells.

43
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