Solar PV Installer Train the Trainer Class -Assignment

As part of the 5-day training week “Training of Trainer” participants will be asked to prepare and
conduct an own training session in the field of Solar PV Installation.

Sessions will last 20 – 30 minutes after which each participant will receive constructive feedback
from his/her fellow participants, the didactical coach as well as a national and international expert.

All participants are requested to select a topic out of the list provided below, or to propose an
individual topic. To avoid redundancies, each topic can only be selected by one person according to
the proceeding “first come – first served”.

After choosing your topic you may start preparing your session to be held on the third or fourth day
of your training class. Each topic is described in the following pages with indication of the respective
passage in the SCGJ Handbook as well as a list of core competencies and learning objectives. Please
consider these aspects as well as own further research when preparing your session.

Please consider the mentioned core competencies and learning objectives of each session.

In case of further questions please contact your Master Trainer:

- For TOT Kolkata (8-12 April 2019): Mr. Arpo Mukherjee, [email protected]

Sources: Suryamitra Participant Handbook

Content
Solar PV Installer Train the Trainer Class -Assignment............................................................................. 1
1. Mounting System ........................................................................................................................ 3
2. Installation of mounting structure .............................................................................................. 4
3. Module mounting, cabling connection ....................................................................................... 5
4. Safety on site ............................................................................................................................... 6
5. DC cable installation .................................................................................................................... 7
6. Dismantling cable and crimping termination .............................................................................. 8
7. Grounding of system ................................................................................................................... 9
8. Testing of Solar Array ................................................................................................................ 10
9. Earthing and wiring test ............................................................................................................ 11
10. Maintenance.......................................................................................................................... 12
11. Troubleshooting .................................................................................................................... 13
12. Work safety during PV installations ...................................................................................... 14
13. Identification of safety hazards ............................................................................................. 15
14. Safety at heights and work health......................................................................................... 16
15. Start-up of a Grid Connected System .................................................................................... 17
16. Testing of batteries and charge controller ............................................................................ 18
 1. Mounting System
Referring Unit 7.2 Pages 114-116

Different types of mounting systems, flat roof und pitched roofs with corrugated iron

Core Competency:

Describe the importance of the different types of mounting systems

Learning Objectives

▪ Choose the right material for different roof types

▪ Identify the obstacles regarding ambient adversities (wind and aggressive environment)
▪ Explain different types of mounting systems for flat or pitched roofs
▪ Identify the various structural attachments used during installation
▪ Pay always attention to safety instructions
▪ Analyze structure of roof
▪ Consider the structural analysis of the site

FFlat roof mounting Pitch roof on corrugated iron

Rail system for flat roof Rail system for flat roof
 2. Installation of mounting structure
Referring Unit 7.2.1. – 7.2.4. Pages 117- 125

Different types of installation techniques and systems with clamps simple and as inlay

Core Competency

Demonstrate the importance of used or needed material for rail systems

Learning Objectives

▪ Choose the right tools

▪ Identify the significance for stability
▪ Connect profile segments
▪ Avoid fierce mechanical clamping
▪ Describe the difference between Aluminum and SS of segments
▪ Install mounting systems in a professional way
▪ Take responsibility for a good visual appeal of the installation

Clamps for corrugated iron Inlay system on fiber cement plates

Rail system for flat roof Single bucket system

 3. Module mounting, cabling connection
Referring Unit 7.32 – 7.3.3 Pages 127-129

Core Competency

Explain the correct mounting and cabling of modules

Learning Objectives

▪ Describe how to do mounting of modules without mechanical stress

▪ List potential damages when handling PV module glass surfaces inaccurately.
▪ Advise installation of cables without cable tensile stress
▪ Choose the right connector
▪ Have the right tools available for crimping connectors
▪ Follow safety instructions
▪ Matching the modules together in a perfect way, different connector types and its obstacles
▪ Mounting and connecting modules with different types of connectors in a safe and secure
way
▪ Give an example how to match the modules together in a perfect way, different connector
types and its obstacles

„Flying“ cable connection Perfect cabling example

Wrong cabeling and faulty connector Example of MC and Sunclix connectors

 4. Safety on site
Referring Unit 8.1 – 8.1.5 Pages 135- 137

Core Competency

Commit to safety plan, inspection of equipment and usage of installation toolkit

Learning Objectives

▪ Explain safety precautions when working on site

▪ Implement the safety
▪ Keep the site always clean and free of debris
▪ Clarify the maximum working voltage
▪ Select Personal Protective Equipment (PPE)
▪ Check your staff

Disorder on site Bad waste management

Debris blocks safety ways Correct usage of PPE

 5. DC cable installation
Referring Unit 8.3 – 8.3.3 Pages 145 – 149

Core Competency

Install conduits and cables, connect modules together

Learning Objectives

▪ Prepare conduit and cable routing plan

▪ Select the correct cable type in color and gauge
▪ Support and secure conduit
▪ Avoid cable tensile stress
▪ Develop installation in a logic way
▪ Avoid cable jumble or disorder
▪ Consider always installation rules
▪ Protect cable against UV and aggressive environment
▪ Be aware of high DC voltage

DC cable not fixed in array Irresponsible DC distribution

Cable loops must be avoided Correct DC installation

 6. Dismantling cable and crimping termination
Unit 8.3.4 Pages 151 – 152

Core Competency

Explain the importance of a correct stripped wire or dismantled cable

Learning Objectives

▪ Dismantle in a professional way cables and wires of different types

▪ Choose always the right tool for the corresponding cable
▪ Communicate about the risks of a wrong stripped insulation
▪ Explain safety precautions when working with sharp tools
▪ Reduce failures due to wrong cable connection
▪ Dismantle in a professional way cables and wires of different types
▪ Choose always the right tool for the corresponding cable or wire

Electrician knifes Correct manteling of cable

Stripping plier Crimp cable sockets

 7. Grounding of system
Referring Unit 8.4. – 8.4.3 Pages 154 – 157

Core Competency

Demonstrate the correct grounding of array and all other components

Learning Objectives

▪ Determine grounding conductor size

▪ Get the grounding system installed for modules and array
▪ Assure correct connection of other grounded items of the site
▪ Respect the local grid code
▪ Calculate the correct gauge for earth wire

Wrong wire gauge for earthing Main grounding busbar

Complete earthing including pillars Single earthing of pillar

 8. Testing of Solar Array
Referring Unit 9.3 Pages 173- 176

Core Competency

Describe the optical and electrical approval of PV installation

Learning Objectives

▪ Make Trip Check like a pilot before lift off

▪ Verify system grounding and measure insulation resistance
▪ Verify polarity
▪ Measure DC voltages and current for each string and array
▪ Test mechanical stability and solidity
▪ Explain that poor quality conduit can cause expensive damage
▪ Implement rules for accident prevention
▪ Remind the visual appeal for client
▪ Repeat the importance of communication between members of staff

Mechanical correct? Partial shading

Loading Calculations correct? Wind load considered?

 9. Earthing and wiring test
Referring Unit 9.4 Pages 177- 179

Core Competency

Test ground faults, resistance and isolation of cables

Learning Objectives

▪ Perform continuity tests and tests for earthing and lightning protection
▪ Identify the importance of working meter and their interpretation
▪ Do a visual test of earthing and wiring
▪ Compare result of measurement with theoretical parameter
▪ Recognize the danger of leaking current

Single earthing wire Lightening protection necessary

Corrosion on module frame Sharp metal edges could lead to insulation fault
 10. Maintenance
Referring Units 10.1. – 10.2.4 Pages 191-203

Core Competency

Take time for maintenance of all components of system including cleaning of modules

Learning Objectives

▪ Clean the panels periodically

▪ Inspect the solar system periodically
▪ Explain why cleaning module with water in dry areas could be problematic
▪ Analyze possible dust formation
▪ Demonstrate that proactive maintenance could minimize losses
▪ Preparation of a maintenance plan
▪ Determine reading of parameter
▪ Demonstrate the importance of communication with responsible staff

Cleaning module with dry broom All burned connector

Maintanance for AC distribution box

 11. Troubleshooting
Referring Units 10.3 – 10.3.5 Pages 204-207

Core Competency

Describe troubleshooting with all parts of systems

Learning Objectives

▪ Troubleshoot to identify faults in the system

▪ Demonstrate the importance of communication within the team
▪ Identify wrong parameter
▪ Explain importance of contact with the manufacturer
▪ Describe how important is a 1st level support by distributor
▪ Derive advantage of a complete compilation of necessary manuals
▪ Pay attention for the need of a good network

Inspect all components Compare parameters

Inspect components Maintain contact with the manufacturer

 12. Work safety during PV installations
Referring Units 11.1 – 11.2 Pages 211-218

Core Competency

Explain basics and PPE (Personal Protective Equipment)

Learning Objectives

▪ Establish and follow safe work procedure

▪ Use and maintain personal protective equipment (PPE)
▪ Give an example for the importance of a daily revision of equipment
▪ Stimulate staff for following safe work procedure
▪ Identify First Aid Material and establish knowledge
▪ Demonstrate that communication with staff is absolutely essential

Respect safety rules Avoid electrical hazard

Respect signs Maintain work safety

 13. Identification of safety hazards
Referring Units 11.3 – 11.3.8 Pages 219 - 224

Core Competency

Personal and electrical hazards:

Electricity has been a modern convenience since its power was harnessed for home use in the late
19th Century, but it also comes with serious risks. That’s why it’s important to be on the lookout for
possible electrical hazards.

Learning Objectives

▪ Analyze environmental hazards associated with photovoltaic installations

▪ Identify electrical hazards
▪ Demonstrate personal safety hazards or work site hazards
▪ Develop mitigation strategies to reduce risks
▪ Pay attention to local risks

Respect installation rules and grid codes

 14. Safety at heights and work health
Referring Units 11.4- 11.4.3 Pages 225 – 228

Core Competency

Minimize tool hazards, installation of fall protection

Learning Objectives

▪ Identify personal safety hazards or work site hazards and mitigate hazards
▪ Inspect and install fall protection
▪ Identify the right fall protection for your site
▪ Importance of periodical tests for tools
▪ Prepare safety plan for fall protection
▪ Develop a plan for daily briefing of staff, focus on visual signs

Different examples of a fall protection

Fall down of a fall protection

 15. Start-up of a Grid Connected System
Referring Units 9.7 – 9.7.2 – 9.8 Pages 183 – 185

Core Competency

Demonstrate the start up of a grid connected system

Learning Objectives

▪ Prepare a check List for Start -Up

▪ Communicate 5 Safety Rules when working with grid connected systems
▪ Disconnect mains
▪ Prevent reconnection
▪ Test for absence of harmful voltages
▪ Ground and short circuits
▪ Cover or close of nearby live parts
▪ Measure and compare all necessary parameter of AC and DC
▪ Prepare a commissioning test report
 16. Testing of batteries and charge controller
Referring Units 7.4 Page 130 / Referring Units 9.6 Pages 180

Core Competency

Describe the testing of batteries and charge controller

Learning Objectives

▪ Identify types of batteries

▪ Prepare a commissioning report, later on a maintenance report
▪ Establish a testing plan of components
▪ Measure and compare all necessary parameter
▪ Commit to safety rules

Lead acid battery Lithium ion battery

Lead acid battery bank Incorrect filling of acid