DAY 16: INSTALLING PHOTOVOLTAIC e.

Battery Box - or battery enclosure, protects the

SYSTEMS battery from physical/weather damages
f. Support Structure (single and double
UNIT 1: PLANNING AND PREPARING FOR PV
module) - mounts the PV panels at appropriate
INSTALLATIONS
angles to maximize the collection of sunlight
LESSON 1: TOOLS AND INSTRUMENTS FOR PV needed to produce electricity
INSTALLATIONS g. Variable Power Supply - adjusts (restricts or
increases) the voltage and sometimes the current
TOPIC 1: TOOLS AND EQUIPMENT for the power source to the circuit
h. Inverter
 Tools
a. Spirit Level - bubble level, used to indicate
if a surface is parallel or perpendicular
relative to the earth through the location of TOPIC 2: MEASURING INSTRUMENTS
the bubble
 Magnetic Compass
b. Hack Saw - used to cut metal
 Measuring Tape
c. Pliers (electrician, long nose, side cutter) -
 Multimeter
used to hold, bend and compress objects
such as wires, etc.  Clamp Meter
d. Screwdriver - used to drive in screws that  Hydrometer
attaches the parts/materials together and in  Battery Cell Tester
place  Inclinometer
e. Combination Wrenches (open and box,
6mm-14mm) - the open end is used to
tighten or loosen while the box end is used LESSON 2: CONSTRUCTING THE WIRING
for gripping nuts and bolts DIAGRAM FOR THE PV SYSTEM
f. Wire Stripper - used to remove the
TOPIC 1: SERIES, PARALLEL & SERIES-
insulation around the electric wire
PARALLEL CONNECTIONS
g. Tools Holster - it's a belt that can hold and
carry the tools used by an electrician  Series
h. Claw Hammer - used to drive nails into
wood as well as to shape metal
i. Crosscut Saw - used to cut wood
j. Electrician's Knife - used to peel off wires
or to cut electric tape
k. MC4 Crimper - used to crimp/compress
wires like pliers; to combine two metallic
ends of cables and cable connectors and
should be used when the power is off
l. MC4 Spanner - used to tighten and loosen
the connectors - Series connection means one positive terminal
m. Pipe Bender - used to shape copper/steel of a panel is connected to another panel’s
pipes into bends and angles that the system negative terminal.
requires - With this kind of wiring, the voltage of the array
n. Pipe Threader - used to cut pipes and increases but the amperage is the same.
deburrs the edges of the pipes as well - This is mostly used for smaller systems that use
 Equipment MPPT controllers since MPPT controllers can
a. DC Drill - can be used to make round holes as accept higher voltage input.
well as to drive in screws/fasteners - Downside of such kind of wiring is that the
b. PV Panel panels are dependent on one another to properly
c. Solar Charge Controller perform. If one panel is shaded, it will affect the
d. Battery performance of the whole string.
 Parallel

- A PV system that uses parallel connection has

the positive terminals of each panel connected
to each other, same with the negative terminals
which means it requires the use of branch
connectors or combiner box.
- This kind of connection produces higher
amperage, but the voltage stays the same. This
allows the system to have more panels without
exceeding the operating voltage limits.
- This is mostly used for smaller systems that use
PWM controllers.
- However, having high amperage requires the use
of very thick wires as it cannot travel long
distances.
 Series-Parallel

- This is the most common kind of wiring used in

the Philippines.
- A string of two or more panels that are series-
connected to each other is parallel-connected to
other strings.
- As it is a combination of series and parallel
wiring, both voltage and amperage increase.
- Ideal for larger systems.

TOPIC 2: WIRING DIAGRAMS FOR PV

SYSTEM DESIGNS
 TOPIC 3: SELECTING THE CORRECT
BALANCE OF SYSTEM (CABLES,
CONNECTORS, AND FUSES)
 Wires
- Wires are like water hoses. If the hose is too
narrow, it will be harder for the water to flow. If
the hose is too long, the water will not have
better flow than if it were shorter.
- Wires are usually measured in American wire
Gauge (AWG).
- The lower the AWG, the bigger the wire
meaning there's less resistance and higher
current capacity.
A. How Thick Should the Wire Be?
1. Find out the maximum current (A) that the
device needs to carry. If only the power rating
(W) is available, just divide the indicated watts
by 12 or 24, depending on the voltage of the
device.
2. Determine the length of the wire needed. Since
longer cables tend to cause higher voltage drops,
the thickness of it should make up for it.
3. Use this table to find out the thickness of the
wire:
4. If you want to be more accurate, you can use this
formula to calculate the cable size:
Minimum Cable Size (mm2) = 0.0546 x Current (A) x
Length (m)
 MC4 Connectors
- MC4 connectors or multi-contact with a 4mm²
contact assembly are electrical connectors
usually used in connecting solar panels. To
properly seal, the cable should be the right
diameter. Remember to NEVER connect and
disconnect the connectors when there is sun on
the PV panels or if they are connected to a
battery as it is dangerous to do so.
A. Crimping Procedure
Male MC4 Coupler
1. See how much of the end of the cable will you
need to strip off the insulation. There is a mark
on the metal that shows how deep the wire
should enter it; this is usually about 10 to 15mm.
2. Insert the wire into the metal and crimp using a
crimping tool.
3. Insert the metal crimp into a screw nut. Once
inserted, you will not be able to take it out due to
the non-return clip inside the plastic housing of
the screw nut.
 4. Insert the cable into the connector until you hear
a click. This means that the crimp is now locked
into the plastic housing of the connector.
5. Check if the rubber washer is flushed around the
cable. If you do not use a 4mm cable, the
connector will not have a good grip on it and
will be able to spin around it which can damage
the connection.
Female MC4 Coupler
6. Strip the cable insulation by 15mm and do the
second to fifth steps for the male MC4 coupler.
7. Test if the cables work with the MC4 connector
before you connect it to the solar panels or the
solar charge controller.
 FUSES
- Fuse, according to the Philippines Electrical
Code, is "an overcurrent protective device with a
circuit-opening fusible part that is heated and
severed by the passage of overcurrent through
it".
- Basically, fuses are used to prevent the wiring
from getting too hot and from getting damaged
in case of a short circuit.
- For example, if the inverter short circuits, the
fuse between it and the battery will cut the
circuit in time to prevent the battery from
possibly exploding and the wires from catching
fire.
- Another example is if one of the PV panels in an
array short circuit, without a fuse, the current
from other panels will choose to go through the
wire connected to that PV panel increasing the
current going through it into an amount more
than what the PV panels can carry.
B. How to Determine if the PV Array Needs
Fuses
To determine if a PV array needs fuses, you will
need to know the short circuit current of the array and its
maximum series fuse rating.
a. Example 1:
Isc of each PV panel = 5.78 A
Maximum Series Fuse Rating - 15 A (as indicated
on the specs sheet sticker at the back of the panel)
Isc of the PV array = 5.78 A x 4 = 23.12 A
If the Isc of the PV array is greater than the
maximum series fuse rating, then MC4 fuses must be
used here, and the size of the fuse should match the
maximum series fuse ratings.
b. Example 2:
Isc of each PV panel = 5.78 A
Maximum Series Fuse Rating = 15 A (as indicated
on the specs sheet sticker at the back of the panel)
Isc of the PV array = 5.78 A x 2 = 11.56 A
If the Isc of the PV array is less than the maximum
series fuse rating, fuses are not needed.
C. Ensuring Good Connections
- Make sure that the ends of the cables are strong
and have low resistance, otherwise there's no
point in using high quality cables.
- Some devices can be directly connected to bare
wires though most of the time you'll need to use
appropriate terminals.
- Use the right terminal for the cable gauge.
- Larger uninsulated terminals can be soldered on
but make sure to not let it run or drip down the
wire to avoid inflexible weak spots.
- If you can, use the proper tools to attach the
cables.
- You can cover the joints using heat-shrink
insulation for a cleaner look.
TOPIC 3: SELECTING THE CORRECT
BALANCE OF SYSTEM (CABLES,
CONNECTORS, AND FUSES)
 Crimping and Assembling MC4 Connectors
a. You will need:
- MC4 connectors
- PV wires
- MC4 crimp
- Wire Stripper
- MC4 spanner
LESSON 3: WIRING PV SYSTEMS
TOPIC 1: WIRING PV PANELS
 3 ways to wire PV panels
- Series
- Parallel
- Series-parallel
 TOPIC 2: WIRING GRID-TIE PV
SYSTEMS

TOPIC 3: WIRING OFF-GRID PV References

SYSTEMS
TOPIC 4: WIRING HYBRID PV SYSTEMS
TOPIC 5: WIRING PV DIRECT SYSTEMS
Electrical Hub EIM Toolbox. (June 14, 2020). Part
6.1 - Solar Wire Sizing | DIY Solar Setup guide with
computation | Do-it-yourself Solar. [YouTube].
Retrieved from
Renogy Solar. (August12, 2013). Renogy: How to
connect your Solar Panels in Series and Parallel Pt. 1.
[YouTube]. Retrieved from
EXPLORIST life - DIY Campers. (May 31, 2020).
How to Wire Solar Panels in Series Parallel.
[YouTube]. Retrieved from
EXPLORIST life - DIY Campers. (n.d.). How to
Wire a Soalr Disconnect for a DIY Camper Electrical
System. EXPLORIST.life DIY Campers. Retrieved
from https://www.explorist.life/how-to-wire-a-solar-
disconnect-for-a-diy-camper-electrical-system/
Newkirk, M. (December 2, 2016). How Solar Power
Works - On-Grid, Off-Grid and Hybrid Systems.
Clean Energy Reviews. Retrieved from
https://www.cleanenergyreviews.info/blog/2014/5/4/h
ow-solar-works
Hinren Engineering. (February 3, 2020). Topologies
of Hybrid Solar PV System. [YouTube]. Retrieved
from
KALECKY TV. (June 9, 2021). PAANO
GUMAGANA ANG HYBRID SOLAR POWER
SYSTEM SETUP?. [YouTube]. Retrieved from
Rural Integrated Development Service - Nepal. (n.d.).
Solar Photovoltaic - Wind Turbine Hybrid RAPS
System. RIDS-Nepal. Retrieved from
http://www.rids-nepal.org/index.php/Solar_Photovolt
aic_
%E2%80%93_Wind_Turbine_Hybrid_RAPS_Syste
m.html
heliatosSolar. (January 21, 2020). Connecting 10W
PV Panel to a Solar Pump. [YouTube]. Retrieved
from
SOLAR MAG. (January 2, 2020). Solar Water
Pumps: Things To Know and Tips For Use [2020].
Solar Magazine. Retrieved from
https://solarmagazine.com/solar-water-pumps/
LESSON 4: SAFETY MEASURES
TOPIC 1: ELECTRICAL SAFETY
 Philippine Electrical Code
- Set by the Professional Regulation Commission
- “To establish basic materials quality and
electrical works standards for the safe use of
electrical for light, heat, power,
communications, signaling, and for other
purposes”
- “Practical safeguarding of persons and property
from hazards arising from the use of electricity”
- Contains provisions that are considered
minimum requirement necessary for safety
- If done, with proper maintenance, installed
system will essentially be free from hazards
- Highly recommended that a licensed electrical
practitioner be consulted for any electrical
requirements
- Lack of proper maintenance can lead to fire
hazards, electrocution, serious injury or death.
- Installed system should be inspected and tested
by a licensed electrical practitioner at least once
a year.
- Adhere to the fundament principles of Section
131 of International Electrotechnical
Commission Standard
 Contains fundamental principles
protection for safety that encompass
protection against thermal effects,
overcurrent, fault current, and overvoltage.
 Wiring Considerations
- All splices must be in the junction box, not
inside a conduit.
- Make sure that it’s lizard and rodent-proof.
- Use DC breakers and surge protection devices to
further protect the system from malfunctioning
or accidents.
- Pinched wires lead to ground faults
- Beware of fake components like fake circuit
breakers.
- Use high quality components since PV systems
usually last for a long time
TOPIC 2: WORKMANSHIP
Electricity can be lethal, so it is very important
that the PV system installed is safe to use.
Remember the following to prevent accidents:
 Make sure that the PV system does not have any
bare wires.
 Use Liquid-Tight Flexible Metal Conduit
(LFMC), Intermediate Metal Conduit (IMC),
and/or Rigid Metal Conduit (RMC) for exposed
wires.
 Never use Flexible PVC hose if exposed to the
sun.
 For cables that are exposed to the sun, use
double-insulated rigid conduits.
 For more security, use PV-1F cables for the
wires on the roof even if they are already in a
conduit.
 Have extra UV resistant ties on hand for annual
inspections.
 Fill the inside of the conduit with sealant to
prevent water from going in through the ends.
 Deburr sharp edges to prevent damages to the
wires.
 Strap down wires that are more than 12 inches.
TOPIC 3: FALL PROTECTION AND PPEs
 Fall Protection
of - Full body harness and rope are mandatory if the
height is over 8 ft and extremely mandatory if
the pitch is over 30°
- Make sure that the ladders that you're using are
sturdy, secured, and properly pitched.
- Remember that mild shocks are not fatal buy
falls are.
- It is better to use rechargeable drills because
they are faster and are cordless.
- Always find out where the nearest hospital is in
case on accidents.
- Watch out and be careful of high-tension power
lines because aluminum railings and HV lines
are not compatible.
 PPEs
 a. Mask  Staging Area
b. Safety goggles A. The staging area is the central area for keeping
c. Hard hat components, tools, and equipment that are not
d. Safety gloves in-use while the installation is ongoing.
e. Safety belt/harness Consider the following when setting up your
f. Fire resistant clothing staging area:
g. Safety shoes - Access to the roof
h. Earmuffs - Access to the main service panel
i. Hairnet - Distance from the road
j. Reflective Vest - Safety from theft
k. Electrician’s Holster - Safety from unexpected weather occurrences

LESSON 5: PRE-INSTALLATION PROCEDURES TOPIC 3: COMMON ERRORS IN PV

INSTALLATION
TOPIC 1: PRE-CONSTRUCTION
MEETING  Remember that prevention is always better than
cure. This saying is also true for accidents in
 Consider conducting a pre-construction
PVS installation. It is better to prevent than deal
meeting on the day of the installation. This
with the repercussions of unsafe practice. Hence,
will:
it is important to anticipate common errors in
- help everyone involved in determining
installation to prevent them.
responsibilities and accountability;
- be an opportunity to relay targets in terms of
schedule and completion;
- create an avenue for discussing safety and health UNIT 2: INSTALLING THE PV SYSTEM
concerns. LESSON 1: INSTALLATION PROCEDURES FOR
PV COMPONENTS

TOPIC 2: SITE INSPECTION TOPIC 1: INSTALLING GRID-TIE PV

SYSTEMS
 Roof Inspection
- Check the condition of the shingles  A grid-tied PV system is a type of PV system
- There should be no cracks or dents that generates electricity all while connected to
- No curling edges the utility grid. This system consists of solar
- No warping/sagging panels, an inverter, a distribution panel, and grid
A. A Professional roofing technician should connection equipment.
check the ff:
- No rusting
- No missing shingles
- No loose nails
TOPIC 2: INSTALLING OFF-GRID PV
- Check the attic for signs of consideration that
SYSTEMS
could affect electrical wiring
- Locate the rafter lines for marking the layout of  Also known as a stand-alone PV system, this
the PV array. type of system is not connected to the electrical
 Safety Inspection grid. It consists of solar panels, an inverter,
A. Inspect the areas of the site for safety battery banks, and a charge controller.
hazards.
- Inspect the integrity of fall protection devices TOPIC 3: INSTALLING HYBRID PV
such as harness and scaffolding. SYSTEMS
- use the right size of the extension ladder  Hybrid systems generate electricity from
- locate evacuation areas in case of natural multiple sources, not just from solar energy.
calamities These power sources may include photovoltaic,
 wind, micro-hydro generators, engine-driven  The installation ends with the notice of
generators, etc. completion but the job of the technician still
 This system consists of two or more energy includes securing excess materials and getting
sources, an inverter, battery banks, and a charge the tools and equipment back to the main office.
controller.
TOPIC 4: INSTALLING PV DIRECT
SYSTEMS

 The Direct PV system is the simplest out of all

the types of PV systems. It only consists of a PV
array connected to the equipment being
powered.

LESSON 2: COMPLETING THE INSTALLATION

OF THE PV SYSTEM

 What are the SOPs after installation?

- Final Checks
- Notifying Completion of Work
- Safekeeping of Tools and Excess Materials
- Cleaning the Work Area
TOPIC 1: FINAL CHECKS

 Final checks are standard procedures for PV

systems installation. This procedure confirms
whether the installation has been completed
before the system is tested and put to work.
 Who does the final checks?
Foreman/Contractor/Commissioning
TOPIC 4: CLEANING THE WORK AREA
Technician
 Before leaving the work site, it’s good practice
to clean the work area. This final step is both a
safety measure and a practice of customer
service excellence.
TOPIC 2: NOTIFYING COMPLETION OF
WORK

 When final checks have been done, the

technician must inform his/her supervisor about
the completion of work.
 This step may seem insignificant but in
contractor/subcontractor arrangements, it will
safeguard the technician from payment issues
and lawsuits.
 This step will also signal the end of installation
and the beginning of testing and commissioning.
A written notice of completion may be required.

TOPIC 3: SAFEKEEPING OF TOOLS AND

EXCESS MATERIALS