PPT_-_Solar_Panel_Installation_Technician.pptx

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Solar Panel
Installation
Technician
Sector: Electronics
(ELE/5901)

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Course Objectives
After completion of this course, the participant would be able to
• Understand the fundamentals of PV solar systems
• Ensure effective functioning of solar energy system after installation
• Understand the Solar PV Technology and usage
• Gain knowledge about proactive maintenance
• Assess the installation site, understanding the installation
• Understand the pre-requisites, arranging for installation materials, mounting
and installing the panels at customer’s premises

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Course Outline
 Unit 1: Solar PV Essentials
 Unit 2: Core Skills/Generic Skills
 Unit 3: Professional Skills
 Unit 4: Understanding the Work Requirement
 Unit 5: Collecting Material for Installation and Ensuring Quality of Material
and Handling
 Unit 6: Organizational Context
 Unit 7: Understanding Installation and Material Usage Procedure and
Assessing Mounting
 Unit 8: Installing the Panel and Connecting the System and Check for
Functioning
 Unit 9: Completing the Work and Following Quality and Safety Procedures
 Unit 10: Interacting with Supervisor And Coordinating with Colleagues
 Unit 11: Following safety measures and Participating in drills and workshops

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Unit - 1
Solar PV Essentials

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Objectives
• Global overview of Power Development
• Global overview of Renewable Energy
• Development including Solar
• National overview of Power Development
• National overview of Renewable Energy
• The Need of Solar Power, Benefits, Application of
• Solar Energy
• Solar Power Myths
• Basics on solar energy and power generation systems

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Objectives
• Basic principles of Solar Power (Solar Photovoltaic, Solar Thermal, Dish Type,
Solar Tower)
• Manufacturing process for Solar Photovoltaic and Solar thermal
• Use and handling procedure of solar panels, energy storage, control and
conversion
conversion
• Basic electrical system and functioning of various electrical devices
• AC and DC Supply essentials
• Components of Solar Systems
• Mechanical equipments and its functioning
• Maintenance procedure of equipments

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Objectives
• Site survey, design and evaluation of various parameters
• Tools involved in installation of system
• Quality and process standards
• Occupational health and safety standards
• Waste management and disposal procedures and standards
• Importance of wearing protective clothing and other safety gear while
carrying out installation

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Introduction
• Energy development is the field of activities focused on obtaining sources of
energy from natural resources.
• These activities include production of
conventional, alternative and renewable sources of energy, and for
the recovery and reuse of energy that would otherwise be wasted.
• Energy conservation and efficiency measures reduce the demand for energy
development, and can have benefits to society with improvements
to environmental issues.

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Global Overview of Power Development
• The past 15 years have seen unprecedented change in the consumption of
energy resources.
• Unexpected high growth in the renewables market, in terms of investment,
new capacity and high growth rates in developing countries have changed
the landscape for the energy sector.
• We have seen the growth of unconventional resources and improvements in
technology evolution for all forms of energy resources.
• This has contributed to falling prices and the increased decoupling of
economic growth and GHG emissions.
• Most countries have achieved a more diversified energy mix with a growth in
community ownerships and an evolution of micro grids.

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Global Overview of Renewable Energy Development
including Solar
• There are several developments and on-going trends that all have a bearing
on renewable energy, including the continuation of comparatively low global
fossil fuel prices; dramatic price reductions of several renewable energy
technologies (especially solar PV and wind power); and a continued increase
in attention to energy storage.

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National Overview of Power Development
• India’s power sector is one of the most diversified in the world.
• Sources of power generation range from conventional sources such as coal,
lignite, natural gas, oil, hydro and nuclear power to viable non-conventional
sources such as wind, solar, and agricultural and domestic waste.
• Electricity demand in the country has increased rapidly and is expected to
rise further in the years to come.
• In order to meet the increasing demand for electricity in the country,
massive addition to the installed generating capacity is required.

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National overview of Renewable Energy Development
including Solar
• India ranks third among 40 countries in EY’s Renewable Energy Country
Attractiveness Index, on back of strong focus by the government on
promoting renewable energy and implementation of projects in a time
bound manner.
• The Indian solar industry has installed a total of 2,247 megawatts (MW) in
the third quarter of 2017, from 1,947 MW in the second quarter of 2017.
• The cumulative installed capacity reached 7,149 MW in the first nine months
of 2017, covering more than one-third of total new power capacity addition
in 2017.

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Solar Energy
• Solar energy is, simply, energy provided by the sun.
• This energy is in the form of solar radiation, which makes the production of
solar electricity possible.
• Electricity can be produced directly from photovoltaic, PV, cells.
(Photovoltaic literally means ―light and ―electric.)

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Solar Radiation
• Solar radiation is radiant energy emitted by the sun from a nuclear fusion
reaction that creates electromagnetic energy.
• The spectrum of solar radiation is close to that of a black body with
temperature of about 5800 K.
• About half of the radiation is in the visible short-wave part of the
electromagnetic spectrum.
• The other half is mostly in the near-infrared part, with some in the
ultraviolet part of the spectrum.

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The Need of Solar Power
• Solar energy is a major renewable energy source with the potential to meet
many of the challenges facing the world.
• There are many reasons to promote its share in the energy market.
• This power source is increasing in popularity because it is versatile with
many benefits to people and the environment.

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Importance to Environment Protection
• Solar is a safe alternative which can replace current fossil fuels like coal and
gas for generation of electricity that produce air, water, and land pollution.
• The electricity generation from fossil fuels causes pollution of air leading to
acid rain, damaged forest areas, and affected agricultural production leading
to huge losses.
• Nuclear power pollutes water and land and has caused environmental
catastrophes.
• Use of solar energy will eliminate these unsafe, unclean consequences from
using conventional fossil fuels.

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Social and Economic Benefits
• Solar energy's greatest attraction is that it can be produced on a small scale
directly by the end consumers in contrast to large centralized conventional
energy sources controlled by large corporations.

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Advantages of Solar Energy
• Renewable Energy Source: Among all the benefits of solar panels, the most
important thing is that solar energy is a truly renewable energy source. It can
be harnessed in all areas of the world and is available every day.
• Reduces Electricity Bills: Since you will be meeting some of your energy
needs with the electricity your solar system has generated, your energy bills
will drop. How much you save on your bill will be dependent on the size of
the solar system and your electricity or heat usage.
• Diverse Applications: Solar energy can be used for diverse purposes. You can
generate electricity (photovoltaic) or heat (solar thermal). Solar energy can
be used to produce electricity in areas without access to the energy grid, to
distil water in regions with limited clean water supplies and to power
satellites in space.

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Advantages of Solar Energy
• Low Maintenance Costs: Solar energy systems generally don’t require a lot
of maintenance. You only need to keep them relatively clean, so cleaning
them a couple of times per year will do the job.
• Technology Development: Technology in the solar power industry is
constantly advancing and improvements will intensify in the future.
Innovations in quantum physics and nanotechnology can potentially increase
the effectiveness of solar panels and double, or even triple, the electrical
input of the solar power systems.

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Disadvantages of Solar Energy
• Cost: The initial cost of purchasing a solar system is fairly high. Although the
government has introduced some schemes for encouraging the adoption of
renewable energy sources, for example, the Feed-in Tariff, you still have to
cover the upfront costs.
• Weather Dependent: Although solar energy can still be collected during
cloudy and rainy days, the efficiency of the solar system drops. Solar panels
are dependent on sunlight to effectively gather solar energy.
• Solar Energy Storage Is Expensive: Solar energy has to be used right away, or
it can be stored in large batteries. These batteries, used in off-the-grid solar
systems, can be charged during the day so that the energy is used at night.

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Disadvantages of Solar Energy
• Uses a Lot of Space: The more electricity you want to produce, the more
solar panels you will need because you want to collect as much sunlight as
possible. Solar panels require a lot of space and some roofs are not big
enough to fit the number of solar panels that you would like to have.
• Associated with Pollution: Although pollution related to solar energy
systems is far less compared to other sources of energy, solar energy can be
associated with pollution. Transportation and installation of solar systems
have been associated with the emission of greenhouse gases.

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Conversion of Sunlight to Electricity
• Photovoltaic technology converts sunlight into electricity and is emerging as
a major power source due to its numerous environmental and economic
benefits and proven reliability.
• Enough free sunlight falls on earth to supply our energy needs for years to
come.
o Environmental Benefits: As PV generates electricity from light, PV
produces no air pollution or hazardous waste. It doesn't require liquid or
gaseous fuel to be transported or combusted.
o Economic and Social Benefits: Sunlight is free and abundant.
Photovoltaic systems allow you to generate electricity and store it for use
when needed.

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Photovoltaic System
• A complete system includes different components that should be selected
taking into consideration your individual needs, site location, climate and
expectations.

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Major System Components
• The functional and operational requirements will determine which
components the system will include.
• It may include major components as; DC-AC power inverter, battery bank,
system and battery controller, auxiliary energy sources and sometimes the
specified electrical loads (appliances).

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Types of PV Systems
• Photovoltaic-based systems are generally classified according to their
functional and operational requirements, their component configuration,
and how the equipment is connected to the other power sources and
electrical loads (appliances).
• The two principle classifications are Grid-Connected and Stand Alone
Systems.

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Grid-Connected
• Grid-connected or utility-intertie PV systems are designed to operate in
parallel with and interconnected with the electric utility grid.
• The primary component is the inverter, or power conditioning unit (PCU).
• The inverter converts the DC power produced by the PV array into AC power
consistent with the voltage and power quality required by the utility grid.

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Stand Alone System
• Stand-alone PV systems are designed to operate independent of the electric
utility grid, and are generally designed and sized to supply certain DC and/or
AC electrical loads.
• Stand- alone systems may be powered by a PV array only, or may use wind,
an engine-generator or utility power as a backup power source in what is
called a PV-hybrid system.
• The simplest type of stand-alone PV system is a direct-coupled system,
where the DC output of a PV module or array is directly connected to a DC
load.

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Electrical Components of a Solar Panel System
• Solar Panels: Solar panels are the most noticeable component of a solar
electric system. The solar panels are installed outside the home, typically on
the roof and convert sunlight into electricity.
• Solar Array Mounting Racks: Solar panels are joined into arrays and
commonly mounted in one of three ways: on roofs; on poles in free standing
arrays; or directly on the ground. Roof mounted systems are the most
common and may be required by zoning ordinances.
• Array DC Disconnect: The Array DC disconnect is used to disconnect the
solar arrays from the home for maintenance. It is called a DC disconnect
because the solar arrays produce DC (direct current) power.

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• Battery Pack: Solar power systems produce electricity during the daytime,
when the sun is shining. Your home demands electricity at night and on
cloudy days – when the sun isn’t shining.
• Power Meter, Utility Meter, Kilowatt Meter: For systems that maintain a tie
to the utility grid, the power meter measures the amount of power used
from the grid. In systems designed to sell power the utility, the power meter
also measures the amount of power the solar system sends to the grid.
• Backup Generator: For systems that are not tied to the utility grid, a backup
generator is used to provide power during periods of low system output due
to poor weather or high household demand. Homeowners concerned with
the environmental impact of generators can install a generator that runs on
alternative fuel such as biodiesel, rather than gasoline.

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• Breaker Panel, AC Panel, Circuit Breaker Panel: The breaker panel is where
the power source is joined to the electrical circuits in your home. A circuit is
a continuous route of connected wire that joins together outlets and lights in
the electric system.
• Charge Controller: The charge controller – also known as charge regulator –
maintains the proper charging voltage for system batteries. Batteries can be
overcharged, if fed continuous voltage.

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DC and AC Disconnects
• The DC and AC disconnects of a PV system are manual switches that are
capable of cutting off power to and from the inverter.
• Some inverters have disconnects with switches integrated into their
structure.
• Other systems use an integrated power panel to support the inverter(s) and
their associated disconnects in an organized arrangement.
• In still other cases, you will need the appropriate disconnects separately to
work with an inverter.
• The disconnects are used to stop power from a renewable energy system
reaching the inverter.
• Disconnection prevents the current being produced from going beyond the
disconnect point to a downed utility grid or damaged component.

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Mechanical Components
• Rails: PV modules cannot be directly fastened to the roof of the building, for
example. They require a structure that holds modules together that is later
fastened to the roof or the ground.
• Splices: When the PV system requires longer spans than the default length of
the rails, splices are used to extend and connect rails to each other. Splices
are usually provided by the same rail manufacturers.
• Clamps: In order for the PV modules to be fastened to the rails, clamps are
usually used to secure the connection between the rails and the modules. PV
modules are usually installed adjacent to one another.
• Roof Mount: In case the PV system is installed on rooftops, consider
elevating the rails a couple of inches against the roof to allow for ventilation
and lower temperature operating ranges.

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• L-foot: L-foot utilizes screws that are fastened to the rafters or trusses from
one side, and the other side will be attached to the rails. L-foot can be
directly used to allow some roof ventilation; however, when the L-foot is not
long enough to satisfy the ventilation requirements.
• Tile Hooks: Roofs come in different shapes and materials. In the case of
ceramic tile roofs, roof tile hooks can be directly used as roof attachment
equipment that allows the rails to be fastened to the roof by going
underneath the tiles.
• Roof Mount: PV systems can use S-5 clips or applied weight (i.e. sand or
concrete) to fasten the rails to the roof.
• S-5 Clips: In order for a PV array to be fastened to a metal roof (flat or tilted),
manufacturers have developed solutions to allow rooftop installation
without roof penetration. This solution includes an innovative clip that is
called "S-5" and bites from one side to the metal roof.

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• Applied Weight: Another solution to allow rooftop installation without roof
penetration and is done using weight that holds the array to the roof. The
applied weight can utilize sand or concrete, based on the design.
• Ground mount/Pole Mount: Reinforced concrete bases are usually used for
ground and pole mount systems with steel structure attached to the rails.
• Wiring: Wiring acts to ensure other solar energy components are
interconnected, and can pass energy from one device onto another. PV Wire
is commonly used to move energy from the Solar Modules to the Inverter(s),
and then be transformed to be sent for another product within the
photovoltaic array supply chain.

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Photovoltaic Mounting System
• Photovoltaic mounting systems (also called solar module racking) are used to
fix solar panels on surfaces like roofs, building facades, or the ground.
• These mounting systems generally enable retrofitting of solar panels on roofs
or as part of the structure of the building.

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Types of Mounting System
• Reclining Mounting Systems: A new metal mounting system for inclining
photovoltaic panels has been officially patented. It has an ability to change
the angle towards the South.
• Fixed Mounting Systems: A fixed metal mounting system, covering the needs
for projects in the fields, flat and sloping surfaces and on roofs & the design
and development department takes care of all unique technical needs for
each project, providing in each case tailor-made research analysis and
construction.
• Roof Mounting: The solar array of a PV system can be mounted on rooftops,
generally with a few inches gap and parallel to the surface of the roof. If the
rooftop is horizontal, the array is mounted with each panel aligned at an
angle.

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Types of Mounting System
• Ground-mounted: Ground-mounted PV systems are usually large, utility-
scale photovoltaic power stations. The PV array consists of solar modules
held in place by racks or frames that are attached to ground based mounting
supports.

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Site Survey & Assessment for Solar PV Installations
• It’s customary for a PV system integrator to do a Site survey and collect
information about local conditions and issues before any proposal is made.
• The information collected is then combined with the load patterns and the
customer preferences to make a final proposal.
• There are lots of aspects in doing a site survey for an installer.
• The amount of details a site surveyor collects depends on the scope of
project.
• A detailed analysis might be required if it involves industrial and commercial
entities involving lot of equipment and appliances.

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Assess the Site Level Pre-requisites for Solar Panel
Installation
• The Installer had to come out and do a site survey.
• An engineer had to actually climb up on the roof, take measurements,
inspect to see if we have visibility to the south, and use this funky solar
pathfinder device to determine the times of day that particular areas would
be shaded.

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Designate Future/Proposed Array Location
• Installer should detail the location and the square footage of the proposed
solar array area relative to the home on a project specific site plan.
• There are multiple options for locating a solar array in a residential setting,
including mounting the array on the roof or on the ground.
• If the proposed solar array location is on a surface that does not fall under
the specification’s basic assumption of a single family home with a pitched
roof that offers adequate attic access.

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Identify Orientation (azimuth) of Proposed Array
Location
• Installer should detail the orientation of the roof plane(s) for the proposed
array location on an Architectural diagram and record the orientation in
degrees on the Checklist.
• South facing orientation = 180o, East = 90o, West = 270o.

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Identify Inclination (tilt or roof pitch) of Proposed
Array Location
• Installer should detail the inclination (tilt or roof pitch) for the proposed
array location on an architectural drawing and record the inclination in
degrees on the Checklist.
• Horizontal or flat roof = 0o, Vertical roof = 180o.

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Conduct a Solar Shading study on Proposed Array
Location
• Installer should conduct a comprehensive shading study, which documents
the impacts of permanent and seasonal shading on the proposed array
location.
• The installer should record the site’s monthly and/or annual percent shading
impacts from the solar shading study.

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Site Map of the Location where Installation has to be
Carried Out
The Installer will need the following site information for each proposed
assessment:
• Location of site (ZIP code or latitude and longitude coordinates).
• Orientation of proposed array surface (azimuth in degrees).
• Roof inclination/pitch at proposed array surface (degrees off of horizontal).
• Percent shading at proposed array location (monthly or annual input
options).

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Hazards and Precaution Of Solar Energy
• Lifting and arranging unwieldy solar panels, the potential for falls off many-
storied rooftops, panels that heat up as soon as they’re uncovered – these
are some of the serious hazards that solar workers face.
• They’re also subject to the risks of traditional roofing, carpentry and
electrical trades – some of the most injury-prone occupations around.
• Safety issues are common for solar installations, but proactively putting
preventive measures in place can help mitigate on-the-job injuries.

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Lifting and Handling Solar Panels
• Solar panels are heavy and awkward to lift and carry.
• Loading and unloading panels from trucks and onto roofs can cause strains,
sprains, muscle pulls and back injuries as well as cumulative trauma that
stresses the spine.
• The panels can also heat up quickly when exposed to sunlight, causing burns
if not handled safely.

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Ladder Safety
• Solar construction often involves working on roofs and from ladders.
• Choosing the right ladder and using it properly are essential.

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Trips and Falls
• Trips and falls are a common hazard of all construction jobs, including solar.
• They can happen anywhere on the jobsite, especially off roofs or ladders.
• Rooftop solar installations are especially hazardous because the work space
diminishes as more panels are installed, increasing the risk of falls.

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Solar Electrical Safety
• Solar electric (photovoltaic or PV) systems include several components that
conduct electricity: the PV solar array, an inverter that converts the panel’s
direct current to alternating current, and other essential system parts.
• When any of these components are “live” with electricity generated by the
sun’s energy, they can cause injuries associated with electric shock and arc-
flash.
• Even low-light conditions can create sufficient voltage to cause injury.

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Personal Protective Equipment
• Personal Protective Equipment is an essential part of every solar installation.
• It’s the employer’s job to assess the workplace for hazards and provide the
PPE deemed necessary for the employee’s safety.
• Hard hats, gloves and steel-toed shoes with rubber soles are among the
commonly required PPE for solar projects.

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Summary
At the end of this module you have become familiar with the:
• Global overview of Power Development
• Global overview of Renewable Energy
• National overview of Power Development
• National overview of Renewable Energy
• The Need of Solar Power, Benefits, Application of
• Solar Energy
• Solar Power Myths
• Basics on solar energy and power generation systems

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Summary
• Basic principles of Solar Power (Solar Photovoltaic, Solar Thermal, Dish Type,
Solar Tower)
• Manufacturing process for Solar Photovoltaic and Solar thermal
conversion
conversion
• Basic electrical system and functioning of various electrical devices
• AC and DC Supply essentials
• Components of Solar Systems
• Mechanical equipments and its functioning
• Maintenance procedure of equipments

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Summary
• Site survey, design and evaluation of various parameters
• Tools involved in installation of system
• Quality and process standards
• Occupational health and safety standards
• Waste management and disposal procedures and standards
• Importance of wearing protective clothing and other safety gear while
carrying out installation

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Unit - 2
Core Skills/Generic
Skills

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Objectives
• Read product and equipment manuals, installation manuals, etc.
• Read warnings, instructions and other text material on product labels,
components, etc.
• Fill in job completion form after installation activities have been completed
• Clearly communicate installation and design instructions to team
• Clearly communicate customer’s requirements
• Communicate the constraints and quality requirements to team

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Introduction
Training in solar panel installation and the common hazards associated with this
work are crucial. Workers should:
• Be familiar with the types and brands of solar panels they are working with.
• Read the installation manuals.
• Survey job sites for hazards before work begins and create a work plan.
• Make sure all tools and equipment are available to complete installation
safely and properly.
• Wear all necessary personal protective equipment—which can include
sturdy work boots, gloves and safety glasses.

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Introduction
Since solar panels are often installed at heights, the following safety precautions
should be kept in mind. Workers should:
• Use proper ladder safety techniques when accessing all elevated areas.
• Hoist materials instead of trying to take them up ladders manually.
• Evaluate the height and the roof pitch to determine if fall protection or
safety barriers are required.
• Stay away from elevated edges.
• Watch for openings in the roof such as skylights and vents—solar installation
technicians have died due to of falls from roofs and through skylights.

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Introduction
Because solar panels generate electricity, precaution needs to be taken to
prevent electric shock. Workers should:
• Know and understand the voltage and the flow of electricity through the
system.
• Lockout/tagout electrical sources during work.
• Never cut or modify solar panels unless they have specific manufacturer’s
instructions.
• Never sit or step on solar panels.
• Never install systems near combustible or flammable materials.
• Stop work if there is severe weather or high winds. Solar panels are large and
bulky and can take flight off of roofs in high winds.
• Not work in rainy or wet conditions—the nature of the work could expose
installers to electrical shock.

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Load Supported
• They are usually the largest single influence on the size and cost of a PV
system.
• A PV system designer can minimize a PV system’s cost by efficiently using the
energy available.
• The first step is to estimate the average daily power demand of each load to
be use.
• It is important to note that one should be thorough, but realistic, when
estimating the load.
• A 25 percent safety factor can cost a great deal of money.

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Type of Loads
• While estimating the load, it is necessary to calculate for both AC and DC
loads.

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Hours of Operation
• An hour of operation is an important factor.
• This value helps us determine the exact consumption of electricity (kWh) of
each appliance.
• Calculating this value will help the designer in the first level assessment of
the size of the solar system that will be needed to power the site under
consideration.
• More importantly the time of operation during the day will enable a designer
to do a more accurate sizing of the PV system.

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Days of Autonomy
• Autonomy refers to the number of days a battery system will provide a given
load without being recharged by the PV array or another source.
• General weather conditions determine the number of ―no sun days which is
a significant variable in determining the autonomy.
• Local weather patterns and microclimates must also be considered.
• Cross-check weather sources because errors in solar resource estimates can
cause disappointing system performance.

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Space Available
• For setting up 1 kW SPV system without batteries, the required shade free
area is 100 sq. ft.
• Knowing the installation site before designing the system is recommended
for good planning of component placement, wire runs, shading, and terrain
peculiarities.
• The primary requirement in selecting the space is that, it should be shade
free.
• Shading critically affects a PC array’s performance.
• Even a small amount of shade on a PV panel can reduce its performance
significantly.
• For this reason, minimizing shading is much more important in PV system
design.

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Solar PV System Sizing
• Determine Power Consumption Demands: The first step in designing a solar
PV system is to find out the total power and energy consumption of all loads
that need to be supplied by the solar PV system as follows:
o Calculate total Watt-hours per day for each appliance used. Add the
Watt-hours needed for all appliances together to get the total Watt-
hours per day which must be delivered to the appliances.
o Calculate total Watt-hours per day needed from the PV modules Multiply
the total appliances Watt-hours per day times 1.3 (the energy lost in the
system) to get the total Watt-hours per day which must be provided by
the panels.

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• Size the PV Modules: Different size of PV modules will produce different
amount of power. To find out the sizing of PV module, the total peak watt
produced needs. The peak watt (Wp) produced depends on size of the PV
module and climate of site location. We have to consider ―panel generation
factor which is different in each site location. To determine the sizing of PV
modules, calculate as follows:
o Calculate the total Watt-peak rating needed for PV modules. Divide the
total Watt-hours per day needed from the PV modules (from item 1.2) by
3.43 to get the total Watt-peak rating needed for the PV panels needed
to operate the appliances.
o Calculate the number of PV panels for the system. Divide the answer
obtained in item 2.1 by the rated output Watt-peak of the PV modules
available to you. Increase any fractional part of result to the next highest
full number and that will be the number of PV modules required.

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• Inverter Sizing: An inverter is used in the system where AC power output is
needed. The input rating of the inverter should never be lower than the total
watt of appliances. The inverter must have the same nominal voltage as your
battery.
• Battery Sizing: The battery type recommended for using in solar PV system is
deep cycle battery. Deep cycle battery is specifically designed for to be
discharged to low energy level and rapid recharged or cycle charged and
discharged day after day for years. The battery should be large enough to
store sufficient energy to operate the appliances at night and cloudy days. To
find out the size of battery, calculate as follows:
o Calculate total Watt-hours per day used by appliances.
o Divide the total Watt-hours per day used by 0.85 for battery loss.
o Divide the answer obtained in item 4.2 by 0.6 for depth of discharge.
o Divide the answer obtained in item 4.3 by the nominal battery voltage.
o Multiply the answer obtained in item 4.4 with days of autonomy.

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• Solar Charge Controller Sizing: The solar charge controller is typically rated
against Amperage and Voltage capacities. Select the solar charge controller
to match the voltage of PV array and batteries and then identify which type
of solar charge controller is right for your application. Make sure that solar
charge controller has enough capacity to handle the current from PV array.
o Determine power consumption demands.
o Size the PV panel.
o Inverter sizing.
o Battery sizing.
o Solar charge controller sizing.

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Summary
• Reading of product and equipment manuals, installation manuals, etc.
• Reading of warnings, instructions and other text material on product labels,
components, etc.
• Filling in of job completion form after installation activities have been
completed
• Ways of clearly communicate installation and design instructions to team
• Ways of clearly communicate customer’s requirements
• Communicating of the constraints and quality requirements to team

69
Unit - 3
Professional Skills

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Objectives
• Purpose and specification of tools used in maintenance activity
• Operate/use different tools such as screw driver, inspection fixtures, wire
cutter, pliers, tester, spanner, etc.
• Handle tools and equipments and maintain them in a good condition
• Interact with supervisor to understand the daily production target
• Interact with co workers in order to co ordinate work processes
• Reflective thinking
• Decision making
• Critical Thinking

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Introduction
• All modules come with a permanently attached junction box and #12 AWG (4
mm2) wire terminated in PV connectors. Your dealer can provide additional
extension cables to simplify module wiring.
• Exercise caution when wiring or handling modules exposed to sunlight.
• When disconnecting wires connected to a photovoltaic module that is
exposed to sunlight, an electric arc may occur. Arcs can cause burns, start
fires or otherwise create safety problems. Exercise caution when
disconnecting wiring on modules exposed to sunlight.
• Photovoltaic solar modules convert light energy to direct-current electrical
energy, and are designed for outdoor use. Proper design of support
structures is the responsibility of the system designer and installer.
• Modules may be ground mounted, pole mounted, or mounted on rooftops.
• Do not attempt to disassemble the module, and do not remove any attached
nameplates or components. Doing so will void the warranty.

72
Introduction
• Do not apply paint or adhesive to the module.
• Do not use mirrors or other hardware to artificially concentrate sunlight on
the module.
• When installing modules, observe all applicable local, regional and national
codes and regulations. Obtain a building and/or electrical permit where
required.

73
Safety Precautions for Installing a Solar Photovoltaic
System
• Solar modules produce electrical energy when exposed to sunlight.
• Only connect modules with the same rated output current in series. If
modules are connected in series, the total voltage is equal to the sum of the
individual module voltages.
• Only connect modules or series combinations of modules with the same
voltage in parallel. If modules are connected in parallel, the total current is
equal to the sum of individual module or series combination currents.
• Keep children well away from the system while transporting and installing
mechanical and electrical components.
• Completely cover all modules with an opaque material during installation to
prevent electricity from being generated.
• Do not wear metallic rings, watchbands, ear, nose, or lip rings or other
metallic devices while installing or troubleshooting photovoltaic systems.

74
• Use appropriate safety equipment (insulated tools, insulating gloves, etc.)
approved for use on electrical installations.
• Observe the instructions and safety precautions for all other components
used in the system, including wiring and cables, connectors, DC-breakers,
mounting hardware, inverters, etc.
• Use only equipment, connectors, wiring and mounting hardware suitable for
use in a photovoltaic system.
• Always use the same type of module within a particular photovoltaic system.
• Under normal operating conditions, PV modules will produce currents and
voltages that are different than those listed in the date sheet. Data sheet
values are applicable at standard test data.
• Short-circuit current and open-circuit voltages should be multiplied by a
factor of 1.25 when determining component voltage ratings, conductor
ampacity, fuse sizes and size of controls connected to the module or system
output.
Safety Precautions for Installing a Solar Photovoltaic
System

75
General Installation
• Drainage holes must not be covered with parts of the mounting system. The
junction box has a breather port which must be mounted facing downward
and cannot be exposed to the rain. The junction box should be on the higher
side of the module when it is mounted in order to orient the breather port
correctly.
• Do not lift the module by grasping the module's junction box or electrical
leads.
• Do not stand or step on module.
• Do not drop the module or allow objects to fall on the module.
• Do not place any heavy objects on the module.
• Inappropriate transport and installation may damage the module glass or
frame.

76
Mechanical Installation
Selecting the Location:
• Select a suitable location for installation of the module.
• For optimum performance, the module must be facing true south in
northern latitudes and true north in southern latitudes.
• For detailed information on optimal module orientation, refer to standard
solar photovoltaic installation guides or a reputable solar installer or systems
integrator.
• The module should not be shaded at any time of the day.
• Do not install the module near equipment or in locations where flammable
gases can be generated or collected.

77
Mechanical Installation
Selecting the proper mounting structure and hardware:
• Observe all instructions and safety precautions included with the mounting
system to be used with the module.
• Do not drill holes in the glass surface of the module. Doing so will void the
warranty.
• Do not drill additional mounting holes in the module frame. Doing so will
void the warranty.
• Modules must be securely attached to the mounting structure using four
mounting points for normal installation.
• Load calculations are the responsibility of the system designer or installer.
• The mounting structure and hardware must be made of durable, corrosion
and UV-resistant material.
• The modules have been evaluated by UL for mounting using the 8 provided
mounting holes in the frame.
• Each module (or series string of modules so connected) shall be provided
with the maximum series fuse as specified.

78
Mounting Methods
Mounting with Bolts
• The module must be attached and supported by at least four bolts through
the indicated mounting holes.
• Depending on the local wind and snow loads, additional mounting points
may be required.
• The modules have been evaluated by UL for a maximum positive or negative
design loading of 30 lbs/ft.

79
Mounting Methods
Mounting solar modules with bracket on flat roof and ground
• Fasten bracket on flat roof or ground first, fasten solar modules on bracket,
use nuts to fasten bracket.
• The bracket would endure 20 years, and is made of anticorrosive material.
Temperature zinc steels and Stainless steel is recommended.
• The bracket should be solid enough to resist continuous load, pressure from
wind ,snow, earthquake and other outside force.
• Use insulation materials to isolate different metal like stainless steel,
aluminium. This would prevent corrosion.
• Insert screw into flat gasket ，insert screw into installation hole both on the
modules and supporting frame
• Insert screw into flat gasket and spring gasket, then apply nut on the screw
fasten it.

80
Electrical Installation
• Do not use modules of different configurations in the same system.
• This module is supplied with Multi Contact connectors for electrical
connections.
• Wiring should be #12 AWG, 4 mm2 (minimum) and must be temperature
rated at 90 °C (minimum).
• Completely cover system modules with an opaque material to prevent
electricity from being generated while disconnecting conductors.
• Determine overcurrent, conductor ampacity and size requirements.
• For best performance, ensure that positive and negative DC wires run closely
together avoiding loops.

81
Maintenance
• Clean the glass surface of the module as necessary. Use water and a soft
sponge or cloth for cleaning. A mild, non-abrasive cleaning agent can be used
if necessary. Do not use dishwasher detergent.
• Electrical and mechanical connections should be checked periodically by
qualified personnel to verify that they are clean, secure and undamaged.
• Check the electrical and mechanical connections periodically to verify that
they are clean, secure and undamaged.
• Problems should only be investigated by qualified personnel.
• Observe the maintenance instructions for all other components used in the
system.
• Artificially concentrated sunlight shall not be directed on the module.

82
Shutting Down the System
• Completely cover system modules with an opaque material to prevent
electricity from being generated while disconnecting conductors.
• Disconnect system from all power sources in accordance with instructions
for all other components used in the system.
• The system should now be out of operation and can be dismantled. In doing
so, observe the all safety instructions as applicable to installation.

83
Summary
• Purpose and specification of tools used in maintenance activity
• Operating/using of different tools such as screw driver, inspection fixtures,
wire cutter, pliers, tester, spanner, etc.
• Handling of tools and equipments and maintain them in a good condition
• Interacting with supervisor to understand the daily production target
• Interacting with co workers in order to co ordinate work processes
• Reflective thinking
• Decision making
• Critical Thinking

84
Unit - 4
Understanding the
Work Requirement

85
Objectives
• Understand the individual work requirement and areas of operation
• Interact with the supervisor in order to understand the installation targets
for the day and/or week
• Understand the location of installations and optimise the route plan
• Plan the day’s activities and the complete work plan for each installation
• Coordinate with the various departments and persons involved in installation
• Operation such as design, logistics, material handling and stores
• Minimise absenteeism and report to work on time

86
Introduction
• The technician is responsible for analyzing the customer’s utilities from the
start of the contract, including electrical usage and current rate structure.
• It is vital that usage and rate structure data is included in the system design
to ensure that the customer receives a system that is well-suited to that
particular situation in order to maximize the system’s economic impact.

87
Quality Management Plan
A Quality Management Plan should include:
• System equipment specifications.
• System equipment testing.
• Inspection protocol/inspector qualification.
• Design best practices.
• Providers’ installation guidelines with explicit quality standards.
• Safety policies.
• System commissioning.
• Upstream and downstream QA activities with explicitly defined corrective
action protocols.

88
Site Data
Additional site data to be recorded includes:
• Roof information
o Dimensions.
o Locally required minimum roof setback dimensions from ridge,
hips/valleys.
o Type of roof covering (e.g., composition shingle, tile, standing seam
metal).
o Underlayment type and lap dimensions.
o Roof condition (roof covering, sheathing, and roof framing).
o Location of obstructions (e.g., vents, equipment, skylights, satellite
dishes, snow guards, roof heaters).
o Safety or liability considerations like falling snow and ice near access
points.

89
Site Data
• Structural information
o Local design wind speed and source of information.
o Local ground snow load and source of information.
o Design roof snow load.
o Framing lumber dimensions.
o Rafter or truss spacing.
o Maximum rafter span, or longest truss top chord panel length between
struts.
o Lumber species and grade (indicate whether identified in field or
assumed).
o Sheathing thickness and type.

90
Site Data
• Electrical information
o Service type and size, MSP main busbar, and breaker size.
o Service panel make and model.
o Availability of breaker spaces.
o Meter location relative to the home.
• Potential locations for new equipment
o Inverter.
o Conduit run.
o PV modules.
o Service disconnect.
o Monitoring equipment.

91
Production Estimate
• There are multiple tools for estimating PV system production, with more
options becoming available every year.
• The key features for a tool include accurate weather data, shading
functionality, adjustable system derate factors, component hardware
selection, and monthly energy production estimates.

92
System Design
Technicians should ensure that system design and feasibility estimates are made
using reliable data. Key factors of PV system design include:
• System design in accordance to building and safety requirements.
• Accuracy of collected site data (e.g., roof dimensions and slope, existing
electrical equipment locations, shade analysis).
• Proper application of all applicable codes.
• Consideration of customer priorities (e.g., aesthetics, maximizing power
production, equipment manufacturer preferences, equipment location
preferences).
• Appropriate level of detail in the design drawings such that the installation
team encounters a minimum number of unknown obstacles onsite.
• Proficiency with design software.
• Necessary information for all applicable AHJs for procuring all permits and
approvals.

93
Equipment Requirements
• Solar Photovoltaic Modules
o Flat-Plate Photovoltaic Modules and Panels.
o Crystalline Silicon Terrestrial PV Modules.
o Thin-Film Terrestrial PV Modules.
o Manufactured using an ISO-9001 quality management system.
• Inverters: Arc fault protection is required for inverters.
• Racking Systems: For installation criteria for rack mounting PV systems and
clamping devices for flat-plate PV modules and panels. It is intended to
address product safety concerns for electrical rack mounting systems and
clamping devices pertaining to ground/bonding paths, mechanical strength,
and suitability of materials.

94
Equipment Requirements
• Monitoring: A monitoring system with connectivity is recommended,
including regular performance and availability alerts.
• Electrical Components
o UV exposure for connectors/cables.
o UV exposure for junction boxes.
o Wire Positioning Devices.
o IP-rated enclosures.

95
System Construction
System Grounding and Bonding
• Proper grounding and bonding is the most important safety element of an
installed PV system.
• The purpose for the Equipment Grounding (EG) system is to ensure that
there is no hazardous voltage between any exposed metal parts of a system
and Earth.
• If there is a Lightning Protection System (LPS) existing on the building, the
Engineer of record should make a determination as to whether, and how, to
bond the array EG to the LPS main ground.
• It is essential that if a current-carrying conductor of a PV output circuit is
grounded (a “grounded system”), that it be bonded to ground at only one
point.
• “Ungrounded” systems do not have a bonding connection between a
current-carrying conductor of the PV output circuit and ground.

96
System Construction
• Ground-fault Detection: A particular hazard still exists for systems using
inverters with “fused” ground fault detector interrupter (GFDI) protection,
which many string inverters still incorporate. The situation of having a blown
GFDI fuse, with no defined path for any fault current to earth, can have
severe consequences for safety of personnel, structures, and equipment.
• Marking (Labeling): Strict conformance to system marking (or labeling)
requirements of PV systems and their components is crucial for the safety of
operators, service personnel, emergency responders, and others. Ideally, all
required and desired labeling language is included in the design drawings.
• Mechanical Components: Though a PV system’s purpose is electrical in
nature, it is very important that the components are mechanically installed
in a manner appropriate for the local environment. This holds true for all
types of installations, but is particularly important for residential rooftop
installations due to

97
System Construction
• Mounting Systems: PV modules are typically attached to roofs via purpose-
built metal (usually aluminum) mounting systems. Module mounting systems
must be listed for the application and capable of withstanding the uplift (due
to wind) and downward forces (e.g., snow-load) to which they could
potentially be exposed based on the specific location of the installation.
• PV Modules: There are a variety of module construction types available
today (e.g., metal-framed, frameless, building-integrated, “peal and stick”),
but the majority of PV modules used in residential applications are
aluminum-framed, poly- or mono-crystalline, glass-enclosed laminates.
Regardless of construction type, care must be taken to comply with all
manufacturers’ instructions concerning the transportation, storage,
mounting, grounding, and connecting of the PV modules.

98
System Documentation
• Technicians should store basic customer and system information for the term
of the initial customer agreement.
• Outlining the minimum documentation that should be provided for grid-tied
residential PV systems will ensure transparency to investors of basic system
components, information on design and installation, and O&M
requirements.
• Additional data representing the consumer credit worthiness is not included
in this list.

99
Summary
• Individual work requirement and areas of operation
• Interacting with the supervisor in order to understand the installation targets
• Location of installations and optimize the route plan
• Planning of the day’s activities and the complete work plan for each
installation
• Coordinating with the various departments and persons involved in
installation
• Minimising of absenteeism and report to work on time

100
Unit - 5
Collecting Material for
Installation and
Ensuring Quality of
Material and Handling

101
Objectives
• Arrange for and collect the solar panels as per customer’s requirement
• Ensure that the quantity of modules / panels match the voltage requirement
of the system
• Arrange for mounting stands as per design
• Arrange for tools and consumables required for
• Mounting the solar panels
• Decide on the workforce required and arrange for team
• Ensure that only company recommended quality
• Materials are used unless specified by customer
• Ensure all the materials procured are QC passed
• Ensure that module is not damaged and the outer glass is not broken

102
Objectives
• Material handling
• Requirement and follow the standard operating procedure while moving
them
• Cover the glass module with an opaque
• Material to ensure that there is no electricity generation before installation
• Ensure standard module handling procedure such as two people should lift a
module, module should not be carried on head, etc.
• Ensure that modules are stored in a way that it is not damaged by falling or
by any external disturbance

103
Site Safety Plan for Preparing Solar PV Installation
• Installing solar systems is a risky business. Lifting and arranging unwieldy
solar panels, the potential for falls off many-storied rooftops, panels that
heat up as soon as they’re uncovered – these are some of the serious
hazards that solar workers face.
• They’re also subject to the risks of traditional roofing, carpentry and
electrical trades – some of the most injury-prone occupations around.

104
Every Worksite Presents Different Risks
No two worksites are the same. Before a solar installation begins, it’s essential
for the installer to visit the site, identify the safety risks and develop specific
plans for addressing them. Plans should include:
• Equipment to be used for safe lifting and handling of solar panels.
• Type and size of ladders and scaffolding if needed.
• Fall protection for rooftop work.
• Personal protective equipment for each installer.

105
Lifting and Handling Solar Panels
Safety measures for solar workers:
• Lift each solar panel with at least two people while applying safe lifting
techniques.
• Transport solar panels onto and around the work site using mobile carts or
forklifts.
• Never climb ladders while carrying solar panels. To get solar panels onto
rooftops, use properly inspected cranes, hoists or ladder-based winch
systems.
• Once unpackaged, cover panels with an opaque sheet to prevent heat
buildup.
• Always wear gloves when handling panels.

106
Ladder Safety
• Select the ladder that best suits the need for access – whether a stepladder,
straight ladder or extension ladder. Straight or extension ladders should
extend a minimum of three feet above the rung that the worker will stand
upon.
• Select the right ladder material. Aluminium and metal ladders are the most
commonly used today and may have their place on the job, but they’re a
serious hazard near power lines or electrical work. Use a fiberglass ladder
with non-conductive side rails near power sources.
• Place the ladder on dry, level ground removed from walkways and doorways,
and at least 10 feet from power lines and secure it to the ground or rooftop.

107
Trips and Fall
• Keep all work areas dry and clear of obstructions.
• For fall distances of six feet or more, take one of three protective measures:
install guardrails around ledges, sunroofs or skylights; use safety nets; or
provide each employee with a body harness that is anchored to the rooftop
to arrest a potential fall.

108
Solar Electrical Safety
• Solar electric (photovoltaic or PV) systems include several components that
conduct electricity: the PV solar array, an inverter that converts the panel’s
direct current to alternating current, and other essential system parts.
• When any of these components are ―live‖ with electricity generated by the
sun’s energy, they can cause injuries associated with electric shock and arc-
flash.
• Even low- light conditions can create sufficient voltage to cause injury.

109
Maximum Voltage of Solar PV
• As a general rule, grid-tied PV designers configure arrays to generate a high
DC voltage.
• A high voltage minimizes inevitable current losses as electricity flows
downstream to the inverter.
• But there's a limit on how high you can go with DC voltage in your home.
• The National Electric Code (NEC) states that residential circuits are limited to
a maximum of 600 volts.

110
Voltage at Open Circuit (VOC)
• This is the voltage that is read with a voltmeter or millimeter when the
module is not connected to any load.
• You would expect to see this number listed on a PV module's specification
sheet and sticker.
• This voltage is used when testing modules fresh out of the box, and used
later when doing temperature corrected VOC calculations in system design.

111
Personal Protective Equipment
• Personal Protective Equipment is an essential part of every solar installation.
• It’s the employer’s job to assess the workplace for hazards and provide the
PPE deemed necessary for the employee’s safety.
• Hard hats, gloves and steel-toed shoes with rubber soles are among the
commonly required PPE for solar projects.

112
Measurement of Voltage & Current before Installation
of PV System
• An important step in kicking off a successful PV installation is verifying
module operation.
• This includes checking the open-circuit voltage (Voc) and short-circuit
current (Isc) of each module on the ground—before it gets mounted.

113
Measuring Voltage
• Before turning on the meter: Plug the red lead into the jack and the black
lead into the ―COM jack.
• Set the dial for DC volts and the appropriate value range for the given Voc.
• Connect the red lead to the positive connector or terminal on the module.
Connect the black lead to the module’s negative connector or terminal.

114
Measuring Current
• While it isn’t recommended to measure the short-circuit current of multiple
modules wired together, we can measure the Isc of a single module.
• For dependable readings, the current measurement should be done with the
module receiving good solar exposure (unshaved and directly facing the sun
on a sunny day).
• When working with modules that have pre-attached quick- connect cables, it
is easiest to measure (Isc) with a clamp meter.

115
Troubleshooting
• Most modules carry an initial power warranty that guarantees operation
within 10% of its rated output, minus the tolerance variance.
• If measurements are less than that, and irradiance and temperature impact
have been accounted for, you might need to replace the module.
• Your meter’s accuracy may influence the measurements, making it tough to
call if you are not too far off from the expected limits.
• If all module measurements deviate from the expected values, then your
meter’s accuracy is more suspect.

116
TMPV4 Solar Installation Kit
• The TMPV4 Solar PV Tool Kit holds a comprehensive array of solar testing
and installation tools and accessories.
• With this stunning kit you will have everything you require to successfully
install, test and maintain solar installations.
• With equipment that allows work on both MC3 and MC4 PV systems, this is
the ideal solar panel testing kit for MCS accredited engineers.

117
PV150 Solar Installation Test Kit
• The PV150 solar installation test kit transforms the way PV systems are
tested.
• It replaces the three separate instruments which installers have had to use
for commissioning tests in the past; combining earth / ground continuity,
insulation resistance, open circuit voltage, short circuit current, operating
current (using supplied AC/DC current clamp) and DC operating power test
functions into one handheld unit.
• Simple and safe MC4 and Sunclix PV test leads are provided for fast and easy
direct connection to the PV modules, strings or array.

118
PV210 Solar Installation Tester
• I-V curve tracing, in accordance with IEC 61829.
• Memory for up to 999 test results.
• Wirelessly receives irradiance and temperature measurements from Solar
Survey 200R. Displays measured I-V and power curves on an Android device.
• Instantly send PDF reports from the field back to the office.

119
Solar Link Photovoltaic Test Kit
• Comprehensive test kit for all PV commissioning tests including irradiance.
• Wireless connectivity between PV150 and 200R for simultaneous
measurements.
• Measure and record irradiance at same time as electrical commissioning
tests.
• USB download of results and storage of memory for 200 test records.
• Includes everything required to meet international and National
requirement.

120
Solar Survey Irradiance Meters
• Suitable for both Solar PV & Solar Thermal Installers.
• Built-in digital compass and inclinometer.
• Dual channel temperature measurement.
• Measures true irradiance (using a PV reference cell) as required by USA state
standards.
• 200R features 'Solar link' for wireless connectivity with the PV150 installation
tester.
• Data logging (Solar Survey 200 only).

121
Solar Cert Elements v2
• Intuitive and easy to use.
• Display and compare I-V and power curves.
• Compare results with manufacturer's data.
• Create installation schematic diagrams.

122
Seaward Solar Power Clamp
• High performance instrument for measuring AC and DC Power.
• Power Factor Measurement.
• Harmonic Analysis to measure inverter performance.
• Rugged, robust and handheld.
• Active backlight and inbuilt cable illuminating torch.

123
MC3 and MC4 Connector Leads
• Due to large number of PV panel manufacturers, there has become a variety
of connectors utilized in the PV industry.
• You may need different leads for different jobs, and hence the reason
Seaward provides different leads to connect directly into their PV100 /
PV150 Installation testers.
• MC3 and MC4 are some one of the connectors, so don’t find out you have
the wrong leads.

124
Solar Survey Mounting Bracket
• Evaluate and identify potential safety hazards and injuries.
• Evaluate the specific work situation.
• Understanding potential injuries from identified hazards.
• Implement the site safety plan and Maintain clear work area.
• Clarify the maximum working voltage.
• Select required Personal Protective Equipment (PPE).
• Measure current and voltage on equipment before proceeding with work.
• Inspect and demonstrate the use of electrical installation toolkit.
• Inspect and maintain safety equipment.
• Inspect and maintain testing equipment.
• Demonstrate situational awareness.

125
Summary
• Arranging for and collect the solar panels as per customer’s requirement
• Ensuring that the quantity of modules / panels match the voltage
requirement of the system
• Arranging for mounting stands as per design
• Arranging for tools and consumables required for
• Mounting the solar panels
• Deciding on the workforce required and arrange for team
• Ensuring that only company recommended quality
• Materials are used unless specified by customer
• Ensuring all the materials procured are QC passed
• Ensuring that module is not damaged and the outer glass is not broken

126
Summary
• Material handling
• Requirement and follow the standard operating procedure while moving
them
• Cover the glass module with an opaque
• Material to ensure that there is no electricity generation before installation
• Ensuring of standard module handling procedure such as two people should
lift a module, module should not be carried on head, etc.
• Ensuring that modules are stored in a way that it is not damaged by falling or
by any external disturbance

127
Unit - 6
Organizational Context

128
Objectives
• Understand the individual work requirement and areas of operation
• Interact with the supervisor in order to understand the installation targets
• Understand the location of installations and optimise the route plan
• Plan the day’s activities and the complete work plan for each installation
• Coordinate with the various departments and persons involved in installation
• Minimise absenteeism and report to work on time

129
Introduction
• Solar energy is genesis for all forms of energy.
• This energy can be made use of in two ways the Thermal route i.e. using heat
for drying, heating, cooking or generation of electricity or through the
Photovoltaic route which converts solar energy in to electricity that can be
used for a myriad purposes such as lighting, pumping and generation of
electricity.
• With its pollution free nature, virtually inexhaustible supply and global
distribution- solar energy is very attractive energy resource.

130
Solar Panel Policy
• Economic Value: The generation of solar electricity coincides with the normal
peak demand during daylight hours in most places, thus mitigating peak
energy costs, brings total energy bills down, and obviates the need to build
as much additional generation and transmission capacity as would be the
case without PV.
• Geographical Location: India being a tropical country receives adequate solar
radiation for 300 days, amounting to 3,000 hours of sunshine equivalent to
over 5,000 trillion kWh. Almost all the regions receive 4-7 kWh of solar
radiation per sq mtrs with about 2,300–3,200 sunshine hours/year,
depending upon the location.
• Power Shortage: Electricity losses in India during transmission and
distribution have been extremely high over the years and this reached a
worst proportion of about 24.7% during 2010-11. India is in a pressing need
to tide over a peak power shortfall of 13% by reducing losses due to theft.

131
Solar for Grid Connected Electricity
Grid interactive solar energy is derived from solar photovoltaic cells and CSP
Plants on a large scale. The grid connection is chosen due to following reasons:
• Solar Energy is available throughout the day which is the peak load demand
time.
• Solar energy conversion equipments have longer life and need lesser
maintenance and hence provide higher energy infrastructure security.
• Low running costs & grid tie-up capital returns (Net Metering).
• Unlike conventional thermal power generation from coal, they do not cause
pollution and generate clean power.
• Abundance of free solar energy throughout all parts of world (although
gradually decreasing from equatorial, tropical, sub-tropical and polar
regions). Can be utilized almost everywhere.

132
Solar for Off-grid Solutions
Remote power systems are installed for the following reasons:
• Desire to use renewable - environmentally safe, pollution free.
• Combining various generating options available- hybrid power generation.
• Desire for independence from the unreliable, fault prone and interrupted
grid connection.
• Available storage and back-up options.
• No overhead wires- no transmission loss.
• Varied applications and products: Lighting, Communication Systems,
Cooking, Heating, Pumping, Small scale industry utilization etc.

133
Renewable Energy Certificates (RECs)
• Renewable Energy Certificates are an avenue to further monetise your
rooftop solar PV plant.
• RECs are available for rooftop plants of 250 kW or greater capacity. Every 1
MWh (1,000 units) of energy generated is eligible for 1 REC.
• These RECs are traded on power exchanges, where they are sold to
organisations that need to satisfy a Renewable Purchase Obligation (typically
utilities).

134
Net Metering
• Several state policies mention net metering.
• It refers to an incentivising model where excess power generated by the
rooftop plant (such as power generated on weekends or national holidays)
can be pumped into the grid, and the generator receives a credit for the
number of units supplied to the grid against the number of units received
from the grid i.e., it is as if the meter ran in reverse when power flowed from
the rooftop plant into the grid.

135
Summary
• Individual work requirement and areas of operation
• Interacting with the supervisor in order to understand the installation targets
• Location of installations and optimise the route plan
• Planning of the day’s activities and the complete work plan for each
installation
• Coordinating with the various departments and persons involved in
installation
• Minimising of absenteeism and report to work on time

136
Unit - 7
Understanding
Installation and
Material Usage
Procedure and
Assessing Mounting

137
Objectives
• Understand the customer requirement on installation
• Ensure that all appropriate materials are available during installation time
• Ensure that the installation meets the local
• Building rules and regulations
• Ensure to disconnect PV module from any electric sources such as batteries,
inverters, etc., before working on the module
• Check that the module is defect free before installing
• Ensure to take specified measures such as fire resistance, corrosion
resistance for the module during installation
• Understand the type of mounting and other accessories required
• Assess the degree of inclination and angle of tilt of PV module for the
specific area, locality or region to enable the system absorb maximum
annual sunlight

138
Objectives
• Ensure that sunlight falls perpendicular to the PV module to absorb
maximum energy
• Ensure that panels are mounted in a place where there is no shade at any
time of the year
• Ensure that mounting is strong to withstand wind, rain, etc.
• Ensure that any special construction requirement for mounting is done by
following acceptable quality standards, especially, in rooftop installations
• Use approved tools for mounting
• Set the mounting fixture firmly at the desired location

139
Installation of Electrical Components
• The components vary depending on whether batteries will be used in your
system.
• Solar electric systems are a popular choice among renewable energy options
due to the relatively low maintenance requirements and the long lifetime of
many of the system components.
• Because there are no moving parts, and thus little chance of mechanical
failure, most solar electric systems will continue to produce power for 30
years or more.

140
Equipment recommendations and installation methods.
• All electrical equipment should be listed for the voltage and current ratings
necessary for the application.
• PV modules should be listed to UL 1703 and warranted for a minimum of 5
years (20-25 year warranties are available).
• Inverters should be listed to UL 1741 and warranted for a minimum of 5
years (outside CA these may not be available).
• All exposed cables or conduits should be sunlight resistant.
• All required over current protection should be included in the system and
should be accessible for maintenance. All electrical terminations should be
fully tightened, secured, and strain relieved as appropriate.

141
Equipment recommendations and installation methods.
• All mounting equipment should be installed according to manufacturers’
specifications .All roof penetrations should be sealed with an acceptable
sealing method that does not adversely impact the roof warranty .
• Integral roofing products should be properly rated (e.g., class A roofing
materials) .All cables, conduit, exposed conductors and electrical boxes
should be secured and supported according to code requirements.
• PV Array should be free of shade between 9:00 a.m. and 4:00 p.m. This
requirement includes even small obstructions such as vent pipes and
chimneys. A small amount of shade can have a disproportionately high
impact on system performance.

142
PV Modules
• PV modules are known as solar panels or solar electric panels.
• We'll be using the terms interchangeably throughout this article although
"PV Module" is the more technically correct terminology.
• Solar provide electricity from sunlight.
• They are typically made of silicon crystal slices called cells, glass, a polymer
backing, and aluminum framing.
• Solar panels can vary in type, size, shape, and color.

143
Balance of System (BOS)
• In PV system terminology, everything besides the PV modules themselves is
called ―balance of system or BOS.

144
Solar Panel or PV Module Mounting Systems
• Solar panel mounting systems include hardware to permanently affix the
array to either a roof, a pole, or the ground.
• These systems are typically made of aluminum and are selected based on
the specific model and number of modules in the array as well as the desired
physical configuration.
• Solar Panels work best at cooler temperatures, and proper mounting allows
for cooling airflow around the modules.

145
Combiner Box
• A combiner box is an often-overlooked, yet essential part of most solar
electric systems.
• The combiner box is an electrical enclosure which allows multiple of solar
panels to be combined in parallel.

146
Solar Charge Controllers
• Every solar electric system with batteries should have a solar charge
controller.
• A charge controller regulates the amount of current the PV modules feed
into a battery bank.
• Their main function is to prevent overcharging of the batteries, but charge
controllers also block battery bank current from leaking back into the
photovoltaic array at night or on cloudy days, draining the battery bank.

147
Batteries for Solar Electric Systems
Batteries chemically store electrical energy in renewable energy systems. They
come in several voltages, but the most common varieties are 6 Volt and 12 Volt.
The three types of batteries that are most common to RE systems are:
• Flooded Lead-Acid Batteries (FLA)
• Sealed Absorbed Glass Mat Batteries (AGM)
• Sealed Gel Cell Batteries

148
Solar Inverters
• An inverter takes (DC) from batteries and turns it into (AC) which is used to
run most common electrical loads.
• There are two main classes of inverters, or grid-capable and, standalone
units.
• Off-grid inverters require batteries for storage. Straight grid-tied inverters
don’t use batteries and grid-capable inverters can work either with or
without batteries depending on system design.

149
DC and AC Disconnects
• No code-compliant system can live without disconnects.
• The DC and AC disconnects of a PV system are manual switches that are
capable of cutting off power to and from the inverter.
• Some inverters have disconnects with switches integrated into their
structure.

150
Installation of DC Combiner Box
• After selecting all of the panels, wires, inverters and any analytic software or
batteries or storage, you wouldn’t want to select the wrong combiner box
and accidentally undermine the entire setup.
• Like with any product selection, the project’s type, size and scope mean
everything when selecting a combiner box, and what works best for a
residential install doesn’t translate to commercial, and so on.
• Choosing the right combiner box for the job isn’t difficult, but you have to
understand the site, the other components and their relation to the
combiner.
• Keep these questions in mind when spacing your next job.

151
• How easy is it to install?
• Often, the right combiner comes down to its simplicity and the headaches it
removes from the project — its ease of deployment and installation.
• A box with pre-wired fuse holders with pigtails coming out can be a plug-
and-play solution that wouldn’t require a licensed electrician to install.

152
• What functions do you need?
• Your combiner box selection might just come down to a price point and
availability.
• For a residential installation, there are off-the-shelf solutions that pack in a
variety of potential configurations, saving the time and extra expense
involved with a custom solution.
• But there are so many new possible configurations of panels, and depending
on the other components in the system, the combiner may need to perform
more than the basic functions of combining circuits and fuses.

153
Installation of DC Energy Meters
• Specialty DC energy meter for monitoring solar PV energy generation, wind
turbine power generation, transport systems, cell towers, power distribution
in data centers, IT networks and other DC applications.

154
Battery Bank location & its Installation
• The battery bank of any off-grid renewable energy power system is one of
the most complicated and costly components in your installation.
• And it's important to get it right.
• A battery bank can be composed of a single battery or multiple,
interconnected batteries that work as one large battery at a required voltage
and amp-hour capacity.
• At Wholesale Solar, we've put together 12V, 24V, or 48 Volt battery banks for
use with most any application.
• Today’s batteries are better than ever, and so are the devices that regulate
and protect them.
• It is important to do your homework, however, when it comes to getting the
right batteries and maintaining them.

155
Prepare Battery Terminals and Install Battery
Interconnection Cables
Creating the Jumpers
• Once the batteries are fully charged, place them in the container and make
sure all the positive (+) terminals are on one side and negative (-) on the
other side.
• Measure from terminal to terminal to make the jumpers.

156
Preparing the Lid
• Now, add some holes in the lid to run the wires for the charge controller and
the inverter.
• You could just as easily put it inside the container for a more concealed look.
Prepare Battery Terminals and Install Battery
Interconnection Cables

157
Installation of Charge Controller & Inverter
• A charge controller, or charge regulator is basically a voltage and/or current
regulator to keep batteries from overcharging.
• It regulates the voltage and current coming from the solar panels going to
the battery.
• Most "12 volt" panels put out about 16 to 20 volts, so if there is no
regulation the batteries will be damaged from overcharging.
• Most batteries need around 14 to 14.5 volts to get fully charged.

158
Inverter
• An inverter should be installed in a controlled environment because high
temperatures and excessive dust will reduce lifetime and may cause failure.
• The inverter should not be installed in the same enclosure with the batteries
because the corrosive gassing of the batteries can damage the electronics
and the switching in the inverter might cause an explosion.
• However, the inverter should be installed near the batteries to keep resistive
losses in the wires to a minimum.

159
Installation of Conduits and Cables
• Today, designers and contractors face many options for protecting the
electrical cables and wiring systems in commercial PV installations.
• One such option is conduit, which is a type of raceway or closed channel that
guards wiring systems running through them against hazards over a system’s
lifetime.
• There are many factors to take into account to correctly size and select a
conduit material, from code-, job- and customer-specific requirements, and
making the right selection has a big impact on PV system performance.

160
Conduit Options
• Conduit used in solar installations is generally divided into two categories:
rigid and flexible.
• Each category can be further divided into metallic and non-metallic types.
• Some are UL listed, and those that are not may be considered recognized
components.
• Non-metallic conduit is made from plastics that have to meet the
performance requirements of steel while being much lighter, using materials
like Nylon, polypropylene or PVC.
• Metallic conduit can be made from galvanized steel, stainless steel, brass,
aluminum or nickel-plated brass. Some contain both metallic and non-
metallic materials to offer low fire hazard and anti-static capabilities,
external braiding and other features.

161
Do Cable Layout Planning in Solar Projects
• DC cable plays very important role while system designing and array layout
configurations of a solar power project.
• The cable planning should be in such a way that it can ensure a 25 year life
expectancy for the project.
• While we have limited experience in implementing MW scale solar projects,
DC cable management has become a critical factor to the project developers
and many times the plant outages are just because of the cable breakdowns.

162
Grounding System Installation
• PV system grounding encompasses issues ranging from equipment grounding
strategies, including bonding modules and grounding racking support
structures, to system grounding considerations, including grounding
electrode system options.
• Grounding PV systems correctly and effectively is difficult—and the topic is
frequently contentious—because there is no one prescription for either the
design process or the methods and materials.
• The difficulty of grounding PV systems also stems from the interactions of
dissimilar metals used for racking structures, module frames and grounding
devices.
• In addition, PV systems are frequently installed in harsh environments,
creating situations in which traditional equipment and methods for bonding
may not be adequate.

163
Installation Practices
Of all the elements of a solar installation, the grounding portion of the system
may well be the most important.
• First, it is required to ground all PV systems.
• Second, a properly grounded system will help protect you and your
employees from unintentional shocks and possible deaths.
• Third, it can help prevent fires in the system post-installation, avoiding
potential lawsuits from angry homeowners. In other words, properly
grounding your PV installation protects you.

164
Types of Grounding
• Most installers are familiar with equipment grounding (EG), which is the
most traditional and visible form of grounding. Grounding is designed to
keep installers — and anyone else who has to service the system in the
future — from coming into contact with electrical current.
• If it’s metal, it needs to be grounded ―That means the racking-and-
mounting, junctions, frames — everything. If the steel bonding to your
conduit is a metal pole, connect a copper conductor to it and conduct it to
the ground.
• The second type of grounding is called system grounding, one of the two
conductors coming out of the PV system will be grounded — normally it’s the
negative wire. All system-grounded conductor wires must be white and are
usually bonded to ground inside the inverter.

165
The Essentials of a Grounding System
• Grounding Electrode: A conducting object through which a direct connection
to earth is established. The grounding electrode is usually a ground rod but
can also be a UFER, underground metal water pipe, ground ring etc.
• Grounding Electrode Conductor (GEC): A conductor used to connect the
system- grounded conductor or the equipment to a grounding electrode or
to a point on the grounding electrode system. This is typically a wire that is
sized based on the potential fault current that could flow through it if
something went wrong in the electrical system.

166
The Essentials of a Grounding System
• Equipment Grounding Conductor (EGC): The conductive path(s) installed to
connect normally non–current-carrying metal parts of equipment together
and to the system grounded conductor or to the grounding electrode
conductor, or both. The GEC and the EGC must be sized according to the NEC
guidelines and must be either a bare copper conductor or an insulated
conductor with green insulation (with or without yellow striping).

167
Process of Grounding and Bonding a Solar PV Array
• The National Electrical Code (NEC) requires bonding electrically conductive
materials and equipment to establish an effective ground-fault current path.
• In general, bonding a piece of equipment means connecting it to an
equipment grounding conductor (EGC) that is bonded to the overall
grounding electrode system.
• The goal is to take all of the metal in a system that could become energized
during a fault (besides the current-carrying conductors) and connect them
together so they are effectively one piece of metal.
• That one piece of metal is then connected, by EGCs, back to the source of
power, completing a circuit for any fault current. Bonding prevents a host of
possible risks and dangers.

168
• Regardless of system voltage, equipment grounding is required on all PV
systems.
• Appropriate bonding and equipment grounding limits the voltage imposed
on a system by lightning, line surges and unintentional contact with higher-
voltage lines.
• It also limits the voltage-to-ground that can occur on normally non-current-
carrying metal components, ranging from frames and rails to conduit and
enclosures.

169
• A number of factors make the grounding and bonding of a PV system
difficult.
• PV systems are exposed to the elements, which can result in atypical
situations where the usual practices for bonding may not perform as
intended.
• Expansion and contraction from thermal cycling, as well as different
expansion rates for different materials – such as steel, aluminum, copper and
PVC – can result in loose connections over time, even when the equipment
was initially installed properly.

170
Summary
• Customer requirement on installation
• Ensuring that all appropriate materials are available during installation time
• Ensuring that the installation meets the local
• Building rules and regulations
• Ensuring to disconnect PV module from any electric sources such as
batteries, inverters, etc., before working on the module
• Checking of that the module is defect free before installing
• Ensuring to take specified measures such as fire resistance, corrosion
resistance for the module during installation
• Type of mounting and other accessories required
• Assessing the degree of inclination and angle of tilt of PV module for the
specific area, locality or region to enable the system absorb maximum

171
Summary
• Ensuring that sunlight falls perpendicular to the PV module to absorb
maximum energy
• Ensuring that panels are mounted in a place where there is no shade at any
time of the year
• Ensuring that mounting is strong to withstand wind, rain, etc.
• Ensuring that any special construction requirement for mounting is done by
following acceptable quality standards, especially, in rooftop installations
• Using of approved tools for mounting
• Setting of the mounting fixture firmly at the desired location

172
Unit - 8
Installing the Panel
and Connecting and
System and Check for
Functioning

173
Objectives
• Remove packaging of the solar panel carefully
• Handle the panels carefully without damaging the material
• Take safety measures and wear protection gear such as gloves to avoid
shock/injuries while handling modules
• Cover the module with opaque material while installing to avoid any current
generation
• Ensure that junction box in covered
• Disassemble any part of the module part during installation

174
Objectives
• Take necessary precautions for fire resistance of modules
• Use recommended material of solar cable and plugs for electrical connection
• Install spare fuse to avoid any short circuits as per company policy
• Mount the module on the fixture with the mounting rails using bolts and
nuts

175
Testing of Solar PV System
• A visual inspection checklist for the evaluation of fielded photovoltaic (PV)
modules has been developed to facilitate collection of data describing the
field performance of PV modules.
• The proposed inspection checklist consists of sections, each documenting
the appearance or properties of a part of the module.

176
Field Inspection for Mechanical, Electrical & Civil
Installation
Common Installation Mistakes with Array Modules and Configurations:
• Changing the array wiring layout without changing the submitted electrical
diagram.
• Changing the module type or manufacturer as a result of supply issues.
• Exceeding the inverter or module voltage due to improper array design.
• Putting too few modules in series for proper operation of the inverter during
high summer
• array temperatures.

177
Wire Management
• Array conductors are neatly and professionally held in place.
• One of the most important safety issues with a PV array is that the
conductors are properly supported.
• It is unacceptable for conductors to lay on roofing materials or come in
contact with sharp or abrasive surfaces.
• The installation methods for the exterior USE 2 conductors.

178
Wire Management
Common Installation Mistakes with Wire Management:
• Not enough supports to properly control cable.
• Conductors touching roof or other abrasive surfaces exposing them to
physical damage.
• Conductors not supported within 12 inches of boxes or fittings.
• Not supporting raceways at proper intervals.
• Multiple cables entering a single conductor cable gland.
• Not following support members with conductors.
• Pulling cable ties too tight or leaving them too loose.
• Not fully engaging plug connectors.

179
Module and Array Grounding
Creating this connection can be handled in a few specific ways:
• Some modules are designed to be grounded using a stainless steel thread
forming screw threaded into the module frame holding the EGC at a
grounding symbol. An isolating washer, such as a stainless cup washer is
often used to isolate the copper conductor from the aluminium frame to
prevent galvanic corrosion.
• Some modules can be grounded to their mounting structures with stainless
steel star washers Placed between the module and the support structure.
This creates an electrical bond while isolating the aluminium frame from
dissimilar materials such as galvanized steel. The EGC is attached to an
electrically continuous support member with a properly installed grounding
lug.
• Some modules can be grounded by properly installing a properly rated lay-in
lug to the grounding point on the module, or any unused mounting hole. The
EGC is run through this lay-in lug to bond the modules together.

180
Creating this connection can be handled in a few specific ways:
• Some modules are designed to be grounded using a stainless steel thread
forming screw threaded into the module frame holding the EGC at a
grounding symbol.
• Some modules can be grounded to their mounting structures with stainless
steel star washers Placed between the module and the support structure.
• Some modules can be grounded by properly installing a properly rated lay-in
lug to the grounding point on the module, or any unused mounting hole.

181
Common Installation Mistakes with Module and Array Grounding:
• Not installing a grounding conductor on the array at all.
• Using cad-plated Tek screws to fasten ground wires or lugs to modules.
• Using indoor rated grounding lugs on PV modules and support structures.
• Not protecting EGCs smaller than 6 AWG from physical damage.
• Allowing copper EGC to come in contact with the aluminum rails and module
frames.
• Assuming that simply bolting aluminum frames to support structures
provides effective grounding.

182
Common Installation Mistakes with Mounting Systems:
• Not using supplied or specified hardware with the mounting systems.
• Substituting Unistrut for special manufactured aluminium extrusions.
• Not installing flashings properly.
• Not using the correct roof adhesives for the specific type of roof.
• Not attaching proper lag screws to roofing members.
• Not drilling proper pilot holes for lag screws and missing or splitting roofing
members.

183
Conductor Ratings and Sizes
Common Installation Mistakes with Conductors:
• Not accounting for high operating temperatures in rooftop conduit.
• Specifying THHN conductors rather than wet rated conductors in drawings
where raceways are clearly located outdoors
• Specifying or installing THWN conductors in raceways that may exceed 60°C
without properly correcting the THWN conductors for this temperature.

184
Check Proper Sign Construction
• The signs should be of sufficient durability to withstand the environment
involved.
• For outdoor signs, the sign should be either metal or plastic with engraved or
machine printed letters, or electro photo plating, in a contrasting color to the
sign background.
• Plexiglas covered paper or laminated paper directories may also be
acceptable provided that the signs are sufficiently protected from the
environment involved.
• The signs or directories should be attached to the electrical equipment or
located adjacent to the identified equipment.

185
Check Proper Sign Construction
Check that equipment ratings are consistent with application and signs:
• Check that inverter has a rating as high as max voltage on PV Power Source
sign.
• Check that circuit breakers or fuses in combiner or fused disconnect are dc
rated at least as high as max voltage on sign.
• Check that inverter is rated for the site ac voltage supplied and shown on the
ac point of connection sign.

186
Insulation Resistance Measurement of Solar Panels
• The insulation resistance test is an electrical safety test and shows whether a
solar module offers adequate insulation.
• When measuring the insulation resistance of a solar panel that is generating
electricity, remember not to apply the standard method for measuring the
circuit’s insulation resistance and bear in mind that the photovoltaic cell
voltage affects the test voltage and that there is the risk of damaging other
equipment if the array is grounded.

187
Data Acquisition System
• Data acquisition is the process of sampling signals that measure real world
physical conditions and converting the resulting samples into digital numeric
values that can be manipulated by a computer.
• Data acquisition systems, abbreviated by the acronyms DAS or DAQ, typically
convert analog waveforms into digital values for processing.
• The data acquisition systems include various components.

PPT_-_Solar_Panel_Installation_Technician.pptx

PPT_-_Solar_Panel_Installation_Technician.pptx

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