Contents

Solar photovoltaic &thermal system installer

1. Introduction of solar energy
2.
3. Sun path diagram & radiation
4. Photovoltaic effect
5. Electrical characteristics of cells
6. Basic of solar PV system
7. Installation & commissioning
8. Solar PV panel
9. Series & parallel connection
10. Technical specification of panel
11. Blocking & bypass diode
12. Solar charger controllers
13. Basic of batteries
14. Series & parallel connection
15. Technical specification
16. Solar inverters
17. ON grid & OFF grid system
18. Site survey and check list

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CHAPTER 1 :-
Introduction

1.1 Energy :- the capacity of a physical system to do work.

There are two main forms of energy are known as :-

1. Potential energy
2. Kinetic energy

1.2 Sources of energy- there are two types of sources of energy on the
basis of availability on the earth.

Fig 1.1 types of energy resources

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1.3 Renewable energy :-
Renewable energy is a form of energy, which comes directly from natural
resources such as sunlight, wind, rain, tides and geothermal heat. It does not
have a limited supply and thus can be used again and again. Further, it will not
get exhausted like non-renewable energy sources such as coal, oil and gas. Most
of the renewable energy comes from the sun. Solar energy is produced from the
constant heat and light given out by the sun. But sun drives the weather too.
Renewable energy sources can be put down as:

1. Radient Solar Energy

2. Biomass Energy
3. Wind Energy
4. Hydro Energy
5. Geothermal Energy
6. Ocean Energy

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CHAPTER 2

2.1 SOLAR ENERGY :-

sun is the primary source of energy. Sunlight is a clean and renewable source of
energy. Solar energy in the form of radient light and heat emitted by the sun .
The source of all energy given out by the sun lies in its core. In this
hydrogen atoms are fused together to make helium. This results in release of a
large amount of energy at the rate of 3.86x1026 Joules per second. Solar energy
has been in use since long for heating and drying etc. Presently, it is being used
for lighting homes and buildings, producing electricity and heating water etc.
More the amount of solar energy received by us on earth, more useful it will be.

2.2 Solar energy specification/spectrum

1. X – Ray
2. UV
3. Visible Light (400nm – 700nm)
4. Infrared radiation
5. Micro Waves
6. Radio waves

Fig 2.2

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2.3 Advantage of solar system
1. Clean
2. Sustainable
3. Free
4. Cut your electricity bills.
5. Sell electricity back to the grid
6. Provide electricity to remote places
7. Cut your carbon film

2.4 Challenge of solar power

1. Less efficient and costly equipment
2. Part time
3. Reliability depends on location
4. Grid parity yet to be achieved
5. Favourable solar policies
6. No solar power generation on cloudy days and night
7. Lock of faith of finances in implementation of government policies
8. Lack of skill manpower

2.5 Types of solar energy

1. Solar thermal (water heating & cooking)
2. Solar photovoltaic cell (electricity production)

2.5.1 Solar Thermal :-

solar thermal technologies captures the heat energy from the sun and use
it for Heating or the Production Of Electricity. This is different from the
photovoltaic solar panels.
Some example of solar thermal is water heater, solar cooker, parabolic
throughs, linear Fresnel reflector, central receiver / heliostats, parabolic
dishes.

Fig 2.3 (a)Solar hot water system

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2.5.2 Solar PV System :-

Solar PV systems directly convert sunlight into electricity. There are two types
of solar PV systems exists. Standalone or off-grid PV systems and grid
connected or on-grid PV systems.Standalone systems are generally smaller in
size and distributed.

Fig

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Chapter 3
3.1 Solar Photovoltaic Cell
Solar Cell:-
The cell converts the sun light into electricity into electricity, which can be
used to sun household application and lighting.

Photovoltaic Cell: -

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Module :-

1. Frame
2. Glass
3. Encapsulant
4. Solar cells
5. Encapsulant
6. Back sheet
7. Junction box

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Panel / String

In a module we connect all cell in series connection but in panel & array connect as
requirement.
MC-4 connector is used in connection to wires.
For wire it has double case used & copper has tin layer on its top.
It made IP68
It has used 4mm2 wire for solar panel.
Other connector is MC – 3 & MC – 6.

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The manufacturing process:-
1. Purifying the silicon
2. Making single crystal silicon
3. Making silicon wafers
4. Doping
5. Placing electrical contacts.
6. The anti. Reflection coating
7. Encapsulating the cell

Diode is connected in 2 condition solar array.

 Blocking diode
 Bypass diode

Diode rating maximum: - 10Amp

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A standard voltage of a cell in module is o.5 voltage.

Parameters: -
Maximum power (Pax): - 230W
Maximum power voltage (Vim): - 29.49V
Maximum power current (Imp): - 7.80A
Open circuit voltage (Vic): - 37.20V
Short circuit current (Sic): - 8.39A
Module efficiency (nm): - 14.3V
No. & type of solar cells: - 60 in series/6n(156*156mm)
maximum system voltage: - TUV: DC 1000v/UL:
DC 600v
Series fuse rating: - 15A
Performance tolerance: - +-3%
Operating temperature: - _40 to 90 c
Storage temperature: - -40 to90
Dimensions: - 1626*990*50
mm/64*39*1.96 in
Weight: - 20.6 kg/44.09 lbs
Output terminal (Tyco j-box): - 1394462-4(-)/6-1394461-
2(+)

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Type of panel

1. SINGLE/MONO-CRYSTALLINE SILICON SOLAR CELL

This is the most established and efficient solar cell technology till date, having a
higher Module efficiency up to around 22%. The Cell and Module fabrication
technology is well developed and reliable. These cells are manufactured from
single silicon crystal. During manufacturing, C-Si crystals are cut from cylindrical
ingots and therefore the cells do not completely cover a square solar cell
Module.

2. MULTI-CRYSTALLINE SILICON SOLAR CELL (POLY-SI OR MC-SI)

The production of Multi-crystalline cells is more cost-efficient. These are

manufactured by cooling a graphite mould filled with molten silicon. In this
process, liquid silicon is poured into blocks that are subsequently sawed into
plates. During solidification of the material, crystal structures of varying sizes are
formed. These cells have Module efficiency of around 15-17%.

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 3. Thin film solar cell technology
In this approach, thin layers of semiconductor materials are deposited on asupporting substrate, such as a
large sheet of glass. These are fundamentally
different in their composition and their production from crystalline photovoltaic
Modules. In general, thin-film Modules are made by coating and patterning
entire sheets of substrate, generally glass or stainless steel, with micron-thin
layers of conducting and semiconductor materials, followed by encapsulation.
Typically, less than a micron thickness of semiconductor material is required,
100-1000 times less than the thickness of Silicon wafer.

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In parallel condition voltage increase & current is constant.
In series connection current is increase & voltage is constant.

Angle for maximum O/P value.

W= L+15
S=L-15
Solar water heater angle 35-45
For want constant o/p value
We plant our panel on latitude.
In Jaipur latitude is 26

Panel Side- South mostly use for panel direction side. Other is south west.
For latitude we use GPS.
For angle jinxing we use angle meter.
For find side direction side we use campus.
Angle meter is=Inclinometer.
Best place for solar Panels.
SouthFacing roof, adequate space.
No shading time of year, future tree growth).
Roof structure, condition.

Angle/Tilt calculation-
Winter = (Latitude *0.9) +29 degree
Summer= (Latitude*0.9)-23.5 degree
Spring and fall= (Latitude-02.5 degree
For module structure we use GI& Al
Mosely, we use GI because it is cheap.
GI= Galvanised Iron

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Module Structure---
1. Seasonal Tilt
2. Double poles static structure (Oblast)
3. Roof top structure
4. Seasonal Tilting structure
5. Single pole static structure
6. Single pole tilting structure

For Good/ Perfect Installation-

- Chose right angle and direction
- Chose shading tree area
- No damage when handling PV module
- Chose install without any tensile stress
- Chose the right connector
- Use right crimping toll for crimp connector
- Matching the module together in a perfect way
- Use grounding system

Ballast--- (structure)

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CHAPTER 4 :-

4.1 Solar Charger Controller-

A charger controller, or charge regulator is basically a voltage and/or current
regulator to keep batteries from overcharging.
Mostly batteries need around 14 to 14.5 volts to get fully charged.
4.1.1 Types of solar charger-
1. PWM (pulse with modulation)
2. MPPT (Maximum power point tracking)

1. PWM (PULSE WIDTH MODULATION) SOLAR CHARGE CONTROLLER

Fig

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4.1.2 MPPT (Maximum Power Tracking): -
MPPT is electronic tracking usually digital .
The charge controller looks at the output of panels & compares it to the battery
voltage. It then figures out what is the best power that the panel can put out to
charge the battery. It takes this and converts into the best voltage to get
maximum Amperes into the battery.
Most moderm MPPT’S are 93-97% efficiency in the conversion. You typically
get a 20 to 45% power gain in winter and 10 – 15% power gain in summer.
Gain is depending on whether temperature battery charger state and another
factor
They can save considerable money of large system since they provide 10 to 30
% more power to the battery.

Block diagram: -

A buck converter is a voltage step down and current step up converter.

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Battery: -
An electric battery is a device congesting that convert stored chemical energy
into electrical energy.

Normally battery has two type :-

1. Primary (non rechargeable as cell)
2. Secondary (rechargeable as phone)
Battery parameters: -
Type LiFe PO4 battery
Model TB-12100FS
Nominally voltage 12volts
Typical capacity 100Ah
Max continuous discharge current 50A
Max pulse discharging current 100A
Work voltage range 8v-14.6v
Size 300*200*75mm
Weight 13.5Kg
Charging temperature 00C ~ 450C
Discharging temperature -200 C ~ 600 C
Storage temperature 50 C ~ 350 C

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Battery backup: -
BBT = battery AH*Volt
Battery charging time: - battery AH/charging rate
Charging Rate = AH of 10 %
Solar battery = C – 10 cost toughs (long life)
Car battery = C – 20 low cost (small charge)
Hear C means charging

Venders of battery
1. Exide
2. Luminous
3. Su-kam
4. Okaya
5. Green vision
6. HB 2

Type of solar batteries

1. Flooded types
2. Get
3. AGM (Absorbed glass mat)

Flooded types AGM

1. Low cost High cost
2. Small lifetime about 2-4 years Long lifetime about 5-7 years
Types of flooded Low chemical reaction with

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CHAPTER 6

Solar inverter: -
It is a device which convert dc power into ac power

Solar inverter has reference voltage

Types of inverter: -
1. Square wave power inverter
2. Modified sine wave power inverter
3. True sine wave power inverter
4. ON grid /grid tie power inverter
5. OFF grid power inverter
6. Hybrid power inverter

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Vendors of inverters
1. SMS solar
2. Power gain
3. General electric
4. Green vision
5. HBL
6. Delta
7. ABB
8. Schieder electric

More application: -
1. Solar car
2. Solar cooker
3. Solar heater
4. Parabolic dishes
5. Calculators 15mW
6. Lenten 10W
7. Solar power plant 15 mW
8. Solar roof 5kw
9. Street light 75w
Scale of photovoltaic system 5,6,7,8,9.

Vendors of solar (IN India): -

1. Total power solar system ltd.
2. Adani solar
3. Vikram solar pvt. Ltd.
4. Emmvee Group
5. Waaree engrgies ltd.
6. Moser baer solar group
7. Websol energy system ltd.
8. Photon energy system ltd.
Vendors of solar (IN world): -
1. Bp solar
2. Evergreen solar
3. Innergy solar

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 4. Kyocera solar
5. Isofofon solar
6. Unisolar
7. Sanyo solar

Solar energy proposition in India: -

Economic value: -
Coincides with the normal peak demand during daylight hours
Mitigates peak energy cost brings total energy bills downs
Obviates the need to build as much addition generation and translation capacity.

Geographical location: -
India receives adequate solar radiation for 300 days amounting to 3000 hours
sunshine.
Almost all the region receives 4-7 Kwh of solar radiation per squre meter.

Power stronger: -
Electricity losses in India during transmitting and distribution have been
extremally high
Theft of electricity common in most part of urban India, amounts to 1.5
percent of India’s GDP.

Ye upar likhna h

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Safety :-
The condition of being protected from harm or other non-desirableoutcomes.
A person who tends to be safe work more efficiently.

PPE (Personal protection equipment)

1. Safety helmet
Yellow – laborers
White – managers, engineers, supervisors and foremen
Blue - electricians, carpenters and technical operators apart from civil
workers
2. Safety shoes: -
Yellow – chemical /cement
Black – with steel protected plates
3. Safety belt
4. Nose mask
5. Safety goggles
6. Ear plugs
7. PVC hand gloves
8. Cotton hand gloves
9. Reflective jacket

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Solar installation tools: -
1. Multimeter: - voltage DC/AC current AC/DC resistance,continuity,
diode, transistor, capacitance measurement

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2. Clamp meter: -AC/DC current measurement

3. Magger: - insulation tester, resistance measurement

4. Compass: - for measuring direction

5. GPS: - to find latitude of place

6. Anemometer: - wind direction and speed
7. Pyranometer: - solar addition diction
8. Thermometer: - temperature measurement (gun type)
9. Inclinometer: - find the angle
10.Solar analyser: -
11.IR camera: - (thermal image) as a reflector

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Installation of commissioning: -
 Site survey for installation of solar PV system
 Assess the customer’s solar PV requirement
 Procure solar PV system components
 Install civil and mechanical parts of solar PV system.
 Install electrical components of solar PV system
 Test and commission solar PV system
 Maintain solar photovoltaic system
 Maintain work safety of solar PV system
 Costumer orientation for solar (feedback)
site survey for installation of solar PV system: -
1. GPS
2. Compass
3. Camera
4. Measuring tap
5. Survey form
6. Pen & pencil
7. Safety tools

Assess the site condition

Best location (spot for a PV array)
Total area available for module placement
Shading obstructions (if any)
Status of the roof
Load profile / total energy requirement
Status and size of the home’s main electric panels load
Available location for mounting electrical components (inverter, battery)

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Process solar PV system components
Prepare bill of material
Procure the components
Verity the components ON-sit

Install civil & mechanical parts

Get equipment foundation constructed
Install mounting system
Install photovoltaic modules
Install battery bank stand and invertor stand
Prepare earthing pits
Installation of LA
Laying the cables using cable try

Install electrical components of solar PV system

Prepare for solar installation
Install electrical components (SPV, invertor, battery, DC/AC disconnect box,
circuit breakers, wires etc.)
Install conduits and cables

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Get the grounding system installed
install battery bank (as required)

Test and commission

Perform visual inspection
Verify system grounding
Check continuity of the system and verify polarity
Inspect mechanical, civil and electrical installation components

Commission the system

Verify labling of solar PV system
Initiatestart-up procedures as per manufacturer installation and record energy
meter reading at start up
Measure and record voltage of energy storage system
Record and repair any anomalous condition
Document designed changes (if any)

Maintain solar photovoltaic system

Clean the solar panels periodically
Inspect the system periodically
Troubleshoot to identify faults in the system
Report and document completion of work
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Follow quality of safety procedures

Maintain work safety of solar PV system

Established and follow safe work procedure
Use and maintain personal protective equipment
Identify and mitigate safety hazards.
Demonstrate safe and proper use of required tools and equipment
Identify work safety procedure and instruction for working at height
Maintain work safety of solar PV system

Costumer orientation for solar: -

Record components and equipment warranty registration
Commissioning certification / forms
Built documents along with project photographs and permits
Operation and mentalisation documentation and customer operation manual

Demonstrated working procedure of solar PV system

Start up & shutdown
Safety procedures to the costumer
Maintenance procedures and provide basic training to maintain the system

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Solar PV system maintenance: -
Power circuit checklist
Incoming power to circuit & its integrity
Cheak of correct functioning of protection devices
Cheak visual cable continuity
Check for any sign of flash or burning small of devices
Control circuit checklist

AUTOMATION - Making products under the control of computers and

programmable controllers. Manufacturing assembly lines as well as stand-alone machine and
robotic devices fall into this category.
Automation is delegation of human control functions to technical equipment

Rope pf
 Designing of the Automation system
 Erection and Commissioning
 Application Engineering
 Maintenance and Troubleshooting of existing system

Variable Frequency Drives

This technology has several different names such
as :

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• Variable speed drives.
• Adjustable speed drives.
• Adjustable frequency drives.
• Frequency converter.

pump and fan applications.

• control and regulation.
• Speeding up or slowing down a machine or
process.
• Protection from overload currents
• Safe Acceleration

Conc
Significant energy savings
• Easy setup & programming
• Better design
• Competitive edge

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Operation determined by digital keypad
•Operation determined by external control terminals, keypad STOP is effective
•Operation determined by external control terminals, keypad STOP is
ineffective

Frequency Reference setting methods

• Stop Command method
• Start frequency
• Stop frequency (DC Braking starts)
• Torque Boost
• Frequency Skip

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