MECH 432 Lab – Solar Photovoltaics

Learning Outcomes
• Be able to identify and describe the main elements of a solar PV power system that
includes battery storage.
• Determine an appropriate measure of efficiency for the conversion of incident solar
energy into electrical energy for a given solar photovoltaics (PV) system.
• Calculate the efficiency when a solar PV panel is stationary relative to the sun and while
it follows the sun about one axis of rotation.
• Demonstrate with data the effect that temperature has on the conversion efficiency of
the solar PV system.

Questions to Investigate and Answer

1. Compare the energy converted by the solar PV system while in static versus tracking
modes. Describe the similarities and differences in the two modes. Be sure to discuss any
data anomalies or potential outliers.
2. Compute the % difference in total energy collected between the two operating modes.
Use the static mode as the basis of comparison.
3. Even though tests were not performed simultaneously, what conclusion(s) can be
drawn? Reflect on the two different plots and use rational, scientific-based arguments
for your conclusion(s). What does the physics dictate?
4. Are the PV module efficiencies significantly different for the static and tracking tests?
Why, or why not? What would you consider a significant difference? Why?
5. Does your definition of efficiency include the effects of tracking? If so, how? If not, how
could it? Does it matter?
6. What temperature effects, if any, do you see on the power output of the module during
the two tests? Quantify and explain
7. Refer to the I-V graph on the manufacturer’s data sheet for the RWE Schott ASE-300-
DFG/17 module (Appendix B). Using the plot for Gsun=1000 W/m2 and T=50°C, did the
module operate near its maximum power point (MPP), accounting for temperature and
irradiation differences?

Test Equipment
This lab uses a solar PV system on a cart that represents an off-grid installation consisting of a
PV module, disconnect, batteries, inverter, charge controller, and one-axis tracking. The system
is wired with proper grounding, disconnects, breakers, and GFI load receptacles. The cart also
houses a data acquisition panel where solar irradiation, PV voltage, PV current, module
temperature, and ambient temperature are displayed and available for computer data logging.
See Fig. 1.
The PV module is mounted to a “tilt and roll” type tracking system, where the PV module “tilt”
is manually adjusted and the “roll” is produced by a geared stepper motor controlled by a
closed-loop LED sensor and indexer.
The tilt angle is equivalent to the sun’s zenith angle, which refers to the angle of the sun’s direct
rays with respect to vertical. See Fig. 2. If the PV module’s tilt angle is equal to the zenith angle
at solar noon and its surface azimuth is due south, then the sun’s rays will have normal
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incidence at solar noon. The zenith angle can be computed from latitude and time of year.
Appendix A gives the solar noon zenith angle for Chico during the month of September. The
hour angle gives the sun’s position based on the time of day with respect to solar noon (0°). Each
hour before noon subtracts 15° and each hour after noon adds 15°. With daylight savings time,
solar noon in Chico occurs at approximately 1:08 pm on Sept 1 and 12:58 pm on Sept 30.

sun

II II

II II

S N
Figure 1. Sketch of solar PV cart

Sun's position relative to location on earth

(http://www.esrl.noaa.gov/gmd/grad/solcalc/glossary.html).

Figure 2. Solar PV orientation and solar direction angles.

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The primary performance measure to be determined from this laboratory experiment is the PV
system efficiency:
DC power delivered to battery bank IV
η PV = =
Incident solar energy rate Gsun A
where 𝐼𝐼 = dc current supplied to battery bank (A)
𝑉𝑉 = dc voltage supplied to battery bank (V)
𝐺𝐺𝑠𝑠𝑠𝑠𝑠𝑠 = solar irradiation (W/m2) normal to module
𝐴𝐴 = PV module surface area (m2)
PV system efficiency defined above is the ratio of the dc electric power generated to the solar
irradiation available to the module. DC electrical power depends on the type of semiconducting
materials used in the cells, the module design, the temperature of the module, and losses in the
system components. Solar irradiation is a function of latitude, longitude, day, time, and
orientation of the module relative to the sun. Solar irradiation is measured by a pyranometer in
the plane of the module.
PV module temperature shows a natural variation due to the amount of solar irradiation,
ambient temperature, wind speed, and transient heating during start-up. Increased PV module
temperature decreases power output by 0.47% per °C above the standard test conditions (STC)
of 25°C for the module used in this experiment. The temperature will be monitored by adhesive
thermocouples mounted on the underside of the module.

Equipment, Sensors, and Instrumentation

• Compumotor stepper motor driver, indexer, and RP240 interface panel
• RWE Schott ASE-300 PV module
• Xantrex C-60 Charge Controller
• Xantrex DR1512 Inverter-Charger
• Werker 12V, 125 A-hr sealed batteries (3)
• Xantrex DC175 Breaker Box
• T-type thermocouples (8)
• LI-COR LI-200SA pyranometer
• Omega DPi32 process meters, Cruising Equipment e-Meter
• Digital inclinometer

Data Acquisition System and Measured Parameters

• Fluke Hydra data logger
• PC with Hydra data acquisition software
• Solar irradiation
• PV voltage
• PV current
• PV module temperature
• Ambient temperature

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Special Precautions
• Keep hands and objects away from exposed battery terminals.
• The PV module and cart are heavy. Do not let any wheel of the cart roll onto soft
surfaces such as grass or dirt.
• Be sure module is supported before making adjustments.
• Connect ground wire to ground rod before turning anything on.
• Watch for pinch points when manually back driving the stepper motor
• If it is raining or rain is imminent, DO NOT take solar PV cart outside.

Equipment Operating Procedure

Setup
1. Move PV cart outside through the breezeway and into parking area just outside LANG
122. Align the cart and long side of solar pv module with the south azimuth angle
identified by a chalk like between two small steel pins mounted flush into the sidewalk.
Lock cart wheels. Pull out cart support legs so they touch the ground and lock into place.
2. Gently wipe dust from PV module surface with a damp cloth if needed.
3. IMPORTANT: attach the ground cable to the grounding rod with the clamp. Be sure that
the brass terminal on the ground wire is in direct contact with the grounding rod and
the brass clamp compresses the two.
4. Attach digital inclinometer to leveling plate on the underside of the solar pv module and
level module so the short side is horizontal by manually back-driving the stepper motor.
5. Re-position the digital inclinometer 90 degrees to align with the long side of the solar
module. Release the bike seat tube clamp and loosen the large nuts on the thread shaft.
Begin pushing the end of the module furthest from the mounting bracket vertically
upward. Set the tilt angle by turning the adjustment nuts on the threaded pipe until the
module is at the proper zenith angle (tilt). See Appendix A for zenith angles. Secure both
nuts. Recheck the side-to-side level and adjust if necessary.
6. Confirm that there are no loose wires, tools laying on equipment, objects within ten feet
of the cart, rain, or other potentially dangerous condition. If so, alert your lab instructor
immediately.
Start-Up
1. Turn on main breakers to AC outlets located in electrical box above inverter/charger.
2. Turn ON circuit breaker switch labeled “Battery Disconnect”. Wait several seconds for
inverter to run through its automatic diagnostic check. You will hear clicking sounds.
3. Turn ON inverter/charger by pressing small black micro switch on front of
inverter/charger panel. Micro switch is left of other dials.
4. Turn ON circuit breaker “PV Panel Disconnect” on the left of the DC disconnect box.
5. Turn ON “Disconnect Charge Controller”on the right side of the DC disconnect box.
After about 20 sec, charge controller display will indicate charging voltage and current
supplied to batteries from PV module.
6. Switch ON power to data display meters located on the north end of the cart. Make sure
pyranometer “Send” switch is sending signal to meters. Check solar irradiation and
temperature values. A typical fall day should be seeing 700 to 1000 𝑊𝑊/𝑚𝑚2 irradiance.

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 7. Connect the solar irradiation, PV voltage, PV current, and thermocouple data logging
leads to appropriate jacks on data acquisition panel. Note: the protruding tab on the
connector plugs indicate ground. Be mindful of polarity when inserting in socket.
8. Move pyranometer “Send” switch so signal is sent to data logger.
9. Connect power strip from computer/data logging cart to AC outlets on PV cart.
10. Turn on computer and wait for it to boot up. Log into Windows.
11. Start Hydra software.
12. Turn on Fluke Hydra data logger.
13. Load PV experiment setup file.
14. Select “Edit Hydra Config” from Setup menu.
15. Set measurement scan to “slow” and enter a 30-second time interval for sampling data.
16. Click “Data File” and make sure “Enable Data Recording” is checked.
17. Click “Select Data File” and enter a unique filename for your team’s data.
18. Select the desktop location for saving the file.
19. Confirm time tag is set to “Elapsed Time” and data recording is set to “Append to file”.
Click OK and return to main Hydra window.
20. Make sure PC indicates correct time and date.
Tracking Mode
1. Switch stepper motor controller Compumotor RP240 power ON.
2. Confirm Compumotor green light is on; if not, consult instructor.
3. Go to stepper motor controller HMI (RP240 display). If it does not show a menu, press
MENU RECALL.
4. Press F1 button for “RUN”.
5. Press F1 button again for “FIND”.
6. Toggle F1 button until “MOTIO8” is displayed, then press ENTER. Motor will orient
module normal to sun based on closed-loop LED intensity feedback control.
7. Once module is aligned with sun, Compumotor will maintain single-axis tracking and
data logging can start.
8. To stop tracking, press yellow STOP button on RP240 interface panel.
9. Verify that all channels are recording data on the Hydra data logger “Quick Plot”.
Remember to click “Start” to display real-time data.
10. Collect approximately 60 minutes of data.
Static Mode
1. Stop data collection on the Hydra Data Logger software. Data is automatically saved
into the team’s data file. Restarting the data collection will append the data to the
existing file. No need to rename the file. Elapsed time will restart at zero whenever data
logging is stopped and restarted.
2. Turn off motor controller equipment.
3. Back-drive the stepper motor to move module into desired position.
4. Turn on motor control equipment to stabilize module but do not run a motion file.
5. Data logging can begin. Collect approximately 60 minutes of data.
Shutdown
1. Download data file (csv) to a flash drive. Be sure to identify each recorded channel
number with the measured parameter.

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 2. Exit Hydra software, turn off Hydra data logger, shut down Windows, power off PC,
unplug power cords and unplug all data acquisition leads from PV cart panel.
3. Switch off power to data display meters.
4. Switch OFF power to the motor control equipment.
5. Switch OFF Charge Controller and PV Module Disconnects.
6. Switch OFF Inverter-Battery Disconnect.
7. Remove system ground and wind up on cart.
8. While holding the module with one hand, be careful it can be HOT!, manually back-
drive the motor with your other hand to ease the module back to its original tilted
position where it rests against the frame stop.
9. Return equipment to LANG 122.

Appendix A
Solar Noon Zenith Angles for Chico, CA during September (no leap year)
SEPT Angle (deg) SEPT Angle (deg)
1 32.01 16 37.92
2 32.39 17 38.32
3 32.77 18 38.72
4 33.16 19 39.12
5 33.55 20 39.53
6 33.94 21 39.93
7 34.33 22 40.34
8 34.72 23 40.74
9 35.12 24 41.14
10 35.51 25 41.54
11 35.91 26 41.95
12 36.31 27 42.35
13 36.71 28 42.75
14 37.11 29 43.15
15 37.51 30 43.55

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Appendix B

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