SOLAR TECHNICAL

LESSONS

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 INSTALLATION OF SOLAR
ROOFTOP SYSTEM

Introduction

The sun delivers its energy to us in two main forms: heat and
light. There are two main types of solar energy systems,
namely, solar thermal systems that trap heat to warm up water,
and solar PV systems that convert sunlight directly into
electricity.

When the PV modules are exposed to sunlight, they generate

DC electricity. An inverter then converts the DC into AC
electricity, so that it can feed into one among the building’s AC
distribution boards without affecting the standard of power
supply.

A solar photovoltaic (PV) system mounted on a rooftop of a

building may be a mini power plant that converts solar power
into electricity to satisfy the power requirements or feed into the
grid.

Although anyone can install a solar rooftop system, the

dimensions of the installation vary significantly counting on the
availability of space, amount of electricity consumed by the
property, and the ability or willingness of the owner to take a
position the capital required.

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 TYPES OF SOLAR PV
SYSTEM

There are two main sorts of solar PV systems: grid-connected

(or grid-tied) and off-grid (or stand-alone) solar PV systems.

1: Grid-connected or On-Grid solar PV systems

Most application of solar PV is grid-connected. Most solar PV

systems are installed on buildings or mounted on the bottom of
the land isn't a constraint.

For buildings, they are either mounted on the roof or integrated

into the building. The latter is additionally referred to as Building
Integrated Photovoltaics (“BIPV”). With BIPV, the PV module
usually displaces another building component, e.g. pane or
roof/wall cladding, thereby serving a dual purpose and offsetting
some costs.

A building has two parallel power supplies, one from the solar
PV system and therefore the other from the facility grid. The
combined power supply feeds all the hundreds connected to the
main ACDB.

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 The ratio of solar PV supply to power system supply varies,
counting on the dimensions of the solar PV system. Whenever
the solar PV supply exceeds the building’s demand, excess
electricity is going to be exported into the grid. When there is no
sunlight to get PV electricity in the dark, the facility grid will
supply all of the building’s demand.

A grid-connected system is often efficient thanks to reducing

your dependence on utility power, increasing renewable energy
production, and improving the environment.

2: OFF-GRID SOLAR PV
SYSTEMS
Off-grid solar PV systems are applicable for areas without a
power system. Currently, such solar PV systems are usually
installed at isolated sites where the facility grid is way away,
such as rural areas or off-shore islands.

But they can even be installed within the town in situations

where it is inconvenient or too costly to tap electricity from the
facility grid.
An off-grid solar PV system needs deep cycle rechargeable
batteries like lead-acid, nickel-cadmium, or lithium-ion batteries
to store electricity to be used under conditions where there is
little or no output from the solar PV system, like during the night.

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 DIFFERENCE BETWEEN
OFF-GRID AND ON-GRID
SOLAR PV SYSTEM

Planning to install a solar power system at your home or

business but getting confused between off-grid versus on-grid
solar systems. Then these differences will be really helpful.

For creating the proper choice, we would like to know the key
differences between off-grid and on-grid solar systems.

ON-GRID SOLAR PV
SYSTEMS

On-grid solar systems generate power only when the utility

power system is out there and
directly connected to the utility
feed.

On-grid systems send excess power generated to the utility grid

once we are overproducing.

These are the foremost cost-effective and simplest systems to

put in. Such systems can pay for themselves by offsetting the
bills in 3-8 years. On-grid systems can either be put into place
with or without net metering.

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 In the case of an on-grid system with net metering, while
calculating the monthly bill, the solar energy fed to the grid is
netted at an equivalent tariff at which the grid power is sold to
the buyer.

The most important downfall of an on-grid system is that it

doesn't provide power during a grid outage.

OFF-GRID SOLAR PV
SYSTEMS

Off-grid systems allow us to store and save our solar energy in

batteries which are to be used when the facility grid goes down.

It is meant to be entirely self-sustaining. The simplest thing

about off-grid solar plants is that they supply power for critical
loads when the facility grid is down.

The biggest downside for off-grid systems is that they cannot

cater to the facility demand of all of our loads since the value
and volume of batteries would be prohibitive.

Such systems require tons of more specialized equipment to

function. These systems are not only costly and sophisticated to
put in but also are not very environment-friendly.

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 Another major disadvantage of an off-grid system is that one
cannot completely believe the facility company as a backup.

So, before we create our choice, we have to confirm and think

about whether our property can sustain itself without power at
certain intervals or not.

REQUIREMENTS FOR THE

INSTALLATION OF
SOLAR PV SYSTEM

1: ELECTRICAL
INSTALLATION LICENCE

An electrical installation refers to any electrical wiring, fitting, or

apparatus used for the conveyance and control of electricity in
any premises. A solar PV system installed within such premises
forms a part of the consumer’s electrical installation and will
comply with the wants stipulated within the Electricity Act.

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 Under the Electricity Act, the Energy Market Authority (“EMA”)
licenses all nonresidential electrical installations with demand
exceeding 45-kilo volt-ampere or kVA. For residential electrical
installations and non-residential electrical installations with
demand below the edge 45kVA, no electrical installation license
is required.

The license requires the owner of the electrical installation to

interact with a LEW to require a charge of the electrical
installation and suits the relevant safety standards and
requirements.

2: ELECTRICAL SAFETY
STANDARDS AND
REQUIREMENTS

A grid-connected solar PV system operates in parallel with the

supply is taken into account
facility grid supply. The power grid
the source and therefore the electrical installation with the solar
PV system connected is taken into account.

There are international product standards on PV modules and

electrical components. For example, PV modules should suit the
wants of IEC 61215 for crystalline silicon terrestrial PV modules
or IEC 61646 for thin-film terrestrial PV modules. In addition, PV
array junction box, PV generator junction box, and switchgear
assemblies should suit the wants of IEC 60439-1.

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 3: APPLICATION OF
ELECTRICAL
INSTALLATION LICENCE

Your LEW (Licensed Electrical Worker) is going to be ready to

advise you whether you would like
to use EMA for an Electrical
Installation Licence for the utilization or operation of the
electrical installation within the premises of your building.

If an Electrical Installation Licence is required, your LEW will

submit the license application to EMA on your behalf. If you
have already got an Electrical Installation Licence issued by
EMA, you would like not to apply for a separate license for the
solar PV system within equivalent premises.

4: CONSERVATION AND
D E V E L O P M E N
T C O N T R O L
REQUIREMENTS

At the present, there is no specific requirement or control by the

Urban Redevelopment Authority
(“URA”) on the utilization of
installations like a solar PV system. However, conservation

projects, or projects within the Central Area are subject to URA’s

Urban Design evaluation process.

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 The quality development control guidelines apply to projects
which will not be subject to conservation or urban design
requirements.
If a solar PV system is installed on the rooftop of a top floor, then
the top floor guidelines will apply. Likewise, if a solar PV system
is installed on raised structures sort of a pavilion, then the
pavilion guidelines will apply.

5: STRUCTUR
AL SAFETY

AND LIGHTNING
PROTECTION

A : S T R U C T U R
A L S A F E T Y

To make sure safety, some measures and steps require to be

taken or considered when installing a solar PV system onto a

replacement or an existing building. For brand spanking, new

building developments, the planning of the structure must take

into consideration the loading of the solar PV system installation,

a bit like the other equipment mounted onto a building structure.

For existing buildings, knowledgeable structural engineers could

also be required to hold out an inspection of the roof structure
and do a calculation on the structural loading.

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 If the roof is unable to face up to the loading of the solar PV

system then the structural plans will be got to be submitted to
the Building and Construction Authority (“BCA”).

B : L I G H

T N I N G
P R O T E
C T I O N

Given a particular location, solar

PV systems are exposed to the
threat of lightning strikes. As lightning can cause damage to the
PV modules and inverters, extra
care must be taken to make
sure that proper lightning protection is provided for the solar PV

structure.
system and the entire

The inverters should be protected by appropriately rated surge

arrestors on the DC side. It is a good practice to also install
surge arrestors on the AC side. Structures and PV module
frames must be properly grounded.

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6: CONNECTION TO THE
FACILITY GRID

If a solar PV system is meant to satisfy only a fraction of the

be got to be interconnected
electricity load then the system will
with the facility grid to satisfy the rest of the consumer’s needs

for electricity.

If a solar PV system must be grid-connected then the

interconnection is vital to the security of both consumers and
electrical workers and the protection of the kit.

7 : S A L E O F
S O L A R P V

E L E C T R
I C I T Y

The surplus electricity generated from a grid-connected solar PV

is often sold back to the power grid. The arrangements needed

to enable this sale of solar PV
electricity vary, depending on
whether you are a contestable or non-contestable consumer.

Contestable consumers: These consumers are non-

residential consumers who use quite 10,000 kWh of
electricity a month.

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Contestable consumers have a choice of who they want to shop

for their electricity from. They will purchase electricity from a
retailer, directly from the wholesale market, or indirectly from the
wholesale market through SP Services.

Non-contestable consumers: These consumers consist of

all the residential electricity users and non-residential
consumers who use but 10,000 kWh of electricity a month.
These consumers are furnished with electricity by SP
Services.

S A F E T Y G
U I D E L I N E S
B E F O R E I N S

T A L L A T I O N
OF SOLAR SYSTEM

1 : G E N E R A
L S A F E T Y
G U I D E
L I N E S

Before starting installation work, identify all personal health and

the project site.
safety risks associated with

After identifying all possible risks,

suggest ways to mitigate the
risks so that they are corrected before proceeding with the

installation and commissioning work.

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A wrong safety assessment will impact the installation schedule

and will end in serious injury to the installer and other personnel
within the vicinity.

Risk involved during PV System Installation

Falling from the roof.

Electrocution - When the wiring of the PV modules serial
creates a solar battery with a DC voltage, it reaches a
“deadly” voltage (≥120 V DC).
Injuries from lifting and installing heavy inverters.
Injuries from falling objects from roofs.
Exposure to the Sun.
Insect bites – some insects could also be poisonous.
Cuts and bumps.
Thermal burns.

P E R S O N A
L S A F E T Y

R E S O U
R C E S

At least one partner should be there at the worksite (never

work alone).
Safety plan
& first-aid kit.
An understanding of safety practices, equipment, and
emergency
procedures.

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 Safety helmet & eye protection.

Proper measuring equipment like electrical & dimensional
equipment.
Appropriate safety harnesses when performing on the roof.
Tape, wire nuts, or cable connectors to guard cable
terminals.
Fire extinguisher
Appropriate ladder
Appropriate lifting equipment
Suitable labels on all equipment, wiring, etc.

2 : E L E C T R I C

A L S A F E T Y
G U I D E
L I N E S

As per data made available by the Ministry of Home Affairs,

Government of India, there are about 10,000 accidental deaths

per annum in India as a
result of electrocution.

Major causes for these fatal accidents are snapping off the
conductor, contact with live wire/ equipment, leakage current,

defective tools and apparatus, negligence on safety measures,

and inadequate maintenance of electrical wiring.

In a grid-connected PV system, multiple numbers of PV modules

are connected in series producing a DC voltage of 150V – 850V
as input to the grid-tied inverter. Similarly, the output of an
inverter is going to be 230V or 415V AC.

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Therefore, in the event of any fault or leakage, any metallic part

of a grid-connected solar PV system can potentially cause
severe electric hazards within the sort of shock, arcing, and fire.

Hence only certified electricians trained in solar PV installation

are to be engaged to put in, operate and maintain electrical
components and equipment during a grid-connected PV system.

The following procedures must be followed by the PV system

installers and supervisors:

Ensure all personnel safety resources are available and in

good condition.

Check all electrical measurement equipment for function and

accuracy.

Check the prevailing earthing system at the project site using

the world resistance tester.

Confirm that there are not any uninsulated electrical cables

passing through the installation area.

Rope in the working area during installation and don't allow

children to enter.

Never disconnect a wire before you have got checked the

voltage and current.

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Don't presume that everything is connected and dealing as

designed.

Don't trust switches to work perfectly and don't believe in

schematics.

Always reaffirm the isolation procedure.

Always “test before you touch” to determine whether circuits

are live or not.

Make sure that the earthing structure is completed and

tested before fixing the modules.

Don't connect the module in series while fixing the modules

on the structure.

Strings should be connected when the system is prepared

for commissioning.

Make sure that no exposed DC cables are hanging and lying

on the roof.

Make sure that the string cable joints are not exposed and
soaked in water.

Tighten the string cable joints (MC4 or equivalent) using

appropriate tools and not by hand.

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 Ensure all DC/AC cable joints are protected and inside a

combiner box having IP65 or above.

All DC/ AC cables must be shielded from any possible

physical damage.

Ensure all DC/AC cable joints are protected and inside a

combiner box having IP65 or above.

All DC/ AC cables must be shielded from any possible

physical damage.

3 : F I R E

S A F E T Y
G U I D E
L I N E S

A grid-connected solar PV system consists of several modules,

a connected serial that produces
DC voltage starting from 150V
to 850V.

With such a variety of DC voltage,

it is very easy for an electrical
arc to be established and hence subsequent fire as a result of
loose connections or short-circuit within the system.

Fire in a PV system primarily results from poor installation,

wrong system design, underrated cables, loose connection, poor
operation and management, incorrect or faulty equipment.

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 The absence of isolator switches most significantly damages

DC cables as a result of mechanical stress, the action of
animals, or vermin.

Below is the list of general requirements for fire safety in

rooftop solar PV systems:

A : A C C E S S ,
P A T H W A Y S ,
AND SMOKE
VENTILATION

Solar PV system should be installed such that it provides the

following:

Ensures convenient
access to the roof.
Provides pathways to specific areas of the roof.
Provides fire escape from the roof.

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B: LOCATION AND
ROUTING OF DC CABLES

Solar PV system should be installed such that it provides the

following:

Make sure that no exposed DC cables are hanging and lying

roof.
on the
All DC cables must be shielded from any possible physical
damage.
DC combiner boxes should be located such conduit runs are
minimized.
Place DC cables separately from AC cable routes and
distinctly marked with “DC cables”.
Cable trays must be covered by a lid and must not have
sharp edges and bends.
When cables trays or conduits cross pathways it should be
covered by a bridge made from strong and durable material.

C : S Y S T E M
I S O L A T I O N

Solar PV system should be installed such that it provides the

following:

Load-breaking DC isolators must

be installed to separate the
PV arrays and inverter.

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 DC isolator must have mechanisms for independent manual

operation.
DC isolators won't be polarity sensitive.
Be installed in an accessible area.

D : M A R K
I N G A N D

S I G N
A G E

Marking is required to supply emergency responders with

appropriate warning and guidance so that they can work their

way around the system and
the way to isolate it.

This will facilitate identifying energized conductors or wires that

connect the solar modules to the inverter, as these should not
be cut when venting
for smoke removal.

IEC 62548 indicates the subsequent signs (using local language

or using appropriate local warning symbols)

Sign in the least points of isolation of all sources of supply

(PV array DC isolator, Inverter AC isolator).
Sign at main service disconnection switch.
Sign at the distribution board to which the availability from
the inverter is connected.
Sign at DC cables and combiner boxes.

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 PREPARATION BEFORE
INSTALLATION

Designers or installers of remote photovoltaic systems encounter

unique challenges in planning the logistics of transporting tools

installation site.
and materials to the system

There might not be many electrical

supply stores nearby, so
proper planning is required. Since each remote site has unique
installation characteristics, you ought to visit the location before
the installation.

During this first visit, you ought to make an inventory of all tools
and materials which will be required for the installation.

During the design visit of the location, you ought to obtain

detailed site-specific information needed to design and install the
system in one trip.

Topographic maps or detailed directions to the location must be

obtained before departure. The specified personnel and safety
gear will depend on the length of stay and conditions to be
encountered.

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 You should bring paper and a pencil to record all observations
and measurements. A 100-foot tape is adequate for many
measuring tasks. An inclinometer is beneficial for leveling and
quickly measuring sloped surfaces. A solar sitting device or
Solar Pathfinder is extremely helpful for assessing site shading.

The Solar Pathfinder's compass is used if needed. A lightweight

camera is additionally invaluable. Initial site visits must be
thorough enough to urge accurate information needed to finish
the design and plan the installation.

T O O L S U
S E D F O R
INSTALL
ATION

Checklists are developed for an installation of a 12-V DC, stand-

alone PV power grid requiring a pole mount, battery storage,

and controller.

The list assumes that the system

will power incandescent and
fluorescent lighting during a previously constructed shelter.

We should check certain installation tools to make sure that they

are in operational condition and have no missing parts before

departure. Some tools also are more fragile than others. We
should have a backup for these tools.

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 BASIC TOOLS

Pencil
Volt-ohm-ampere meter
with a spare battery
Sockets and wrench

bits
Drill
Hand operated drill

Screwdriver
Tape
measure
Hacksaw blade
Knife
Wirecutter
Wire strippers
Slip joint pliers
Torpedo level
First aid kit

I N I T I A L S
I T E V I S I T

TOO LS

Maps

Inclinometer
Compass

GPS
Paper

measure
100-foot tape
Solar sitting device

Camera

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INSTALLATION TOOLS

Pencils
Tape
measure
Rope

String line

C-clamps
Hole saw
Wood
chisel
Utility knife
Drill bits
Torque wrench
Drill bit extender
Volt-ohm-ampere meter
Level
Prick punch
Slip joint
Pliers
Slotted screwdrivers
Wirecutter
Soldering iron
Flashlight
System operations literature
Toolbelt
Drill
Nut driver bits
Paddle bits

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 Brace and bit

Socket set with extender
File
Adjustable wrench
Hand saw
Hack saw
Hammer
Combination square
Wire stripper/crimper
Needle-nose pliers
Black polyethylene
Component product literature
Plastic bags

R O O F T O P
S O L A R P V

S Y S T E M I N S
T A L L A T I O N
P R O C E

D U R E

Before starting the installation process, the installer must

undergo all installation documents
and verify the quantity and
availability of listed equipment, accessories, and tools for the
installation and commissioning
of the solar PV system.

Verification of the number and availability must be done before

starting the installation procedure to attenuate the danger of

project delay or an incomplete job that happens due to the non-

availability or shortage of the equipment, accessories, and tools.

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 The installation and commissioning procedures for grid-

connected solar PV systems are presented in twelve steps.
These steps are to be followed in sequence.

Step 1: Site survey and shadow analysis

Step 2: Installation of PV array mounting structure
Step 3: Installation and testing of structure earthing system
Step 4: Installation of PV modules
Step 5: Earthing of PV Module Frames
Step 6: DC cabling
Step 7: AC cabling and installation of inverter
Step 8: System protection and safety
Step 9: Placing of signage
Step 10: Pre-commissioning tests
Step 11: Commissioning the system
Step 12: Anti-Islanding functionality test

Let us discuss the steps more deeply

STEP 1: SITE SURVEY

AND SHADOW ANALYSIS

The site parameters that influence the performance and

reliability of a PV system are access to radiation, near or far

shadow, ambient temperature, airflow and ventilation, wind
speed, the height of the building,
terrain, orientation, dust level
and pollution, salinity, humidity, extreme weather, etc.

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 Several parameters are likely to be variable from one site to a

different even within the same geographic area.

Therefore, it is crucial to plan a solar PV project to suit the

location parameters and also to pick the proper components and
customize the planning accordingly to make sure better
performance and safety.

An inaccurate site assessment will cause the wrong design and

installation of a PV system, which eventually follows into poor
maintenance, poor performance, and unreliable system
functioning.

MUST-HAVE
TOOLS FOR

SITE SU
RVEY

Personal protective equipment (as applicable to site

condition).
A Solar Pathfinder or Sun eye to spot/determine the shadow-
free
area.
A compass to record direction (a Mobile app is available).

A measuring tape/ digital distance meter to live distance.

An angle measuring equipment
(a Mobile app is available).
A notebook.
A working partner (Never survey a site alone).

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 TASKS TO BE
PERFORMED DURING
SITE SURVEY

A: DETERMIN

E PV ARRAY
L O C A T I O N C
O N D U C T I N G
S H A D O W
A N A L Y S I S

out the space which is free
Perform shadow analysis to seek
from shadow all days of the year.
Make sure that the PV array
will have safe access for
maintenance and fire safety.

Make sure that the PV array has ample space for air cooling.
Make sure that modules are
shielded from theft and
vandalism.

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 B: DETERMINE A
SUITABLE LOCATION
FOR INVERTERS AND
OTHER ELECTRICAL
EQUIPMENT

Location of string combiner

box, inverters, and instruments
should be placed in such a way that their access is

controlled.
Minimum distance from the
PV array to scale back losses.
Protection from the environment as required by the inverter

class.
The inverter should be installed in such an area where there
is enough space for cross ventilation, heat dissipation, and
maintenance.
The situation of overcurrent protection devices or load-
breaking disconnecting means should be at the top of the
cable that is electrically most remote from the PV modules.

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 C: IDENTIFY CABLING
ROUTES AND THEIR RUN
DISTANCE

Determine cable routes and hence cable-supported array

location, combiner box location, inverter location, and site of the

main switchboard.

Cable routes are not always the shortest paths of the cables.
The cable routes need to be decided supported wiring rules,
considering the security of cables and personnel alike.

P L E A S E F O
L L O W T H E

S T E P S B
E L O W :

Verify the situation of kit and routing of the cable at the

location and measure cable
and compare with the
drawing/design documents.

Determine the length of the conduit or cable tray required for

the installation.

Prepare the cables consistent with the length and size as

determined after site measurement.

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 STEP 2: INSTALLATION
OF PV ARRAY MOUNTING
STRUCTURE

Failure of PV array mounting structures happens due to the

strong winds and it may be a rising concern in Indian solar
projects today.

It is quite common for PV array mounting structures to be

conceptualized and designed primarily to enhance energy
generation considering area-specific angle and use of tracking
facility etc.

A large number of solar PV systems are reported to be damaged

due to inadequate design consideration for wind loading.

Besides the strength and wind loading capacity, a mounting

structure must make sure that the PV array receives optimum
radiation and reduces temperature loss by allowing enough air
circulation.

It is also important to make sure that factors like structure

design, placement, orientation, tilt, and shading are aligned with
the electrical string design and selection of the inverter.

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 WIND LOADING ON PV
ARRAY MOUNTING
STRUCTURE
The entire state of Assam falls
under “Very high damage risk
zone A and zone B” with a basic wind speed of 180km/ hour and

above consistent with IS 875 Part 3: Wind Loads on Buildings

and Structure.

The PV array mounting structure

for any site in Assam shall be
designed to face up to not but 180km per hour wind speed for
the areas under zone B and 200km per hour wind speed for the
areas under zone A.

Design of wind pressure must be calculated over basic wind

speed, multiplying by the factors derived for the height of the
building, topography, pressure coefficient supported roof type
and slope, exposure category, and important factor as per IS
875 (Part 3) or ASCE-7.

P R O T E C T I O
N A G A I N S T

CORRO
SION

The steel structure is going to be hot-dip galvanized and

therefore the aluminum structure
is going to be anodized. These
coatings protect the structure from corrosion.

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 Do not drill, weld, or cut the structure at the location. This may
damage the coating and corrosion may be accelerated.

TILT ANG
LE AND

ORIENTATION

The recommended tilt angle of a module mounting structure to

minimize wind pressure is <15° for a flat surface.

However, a minimum tilt of 10° should be maintained for the

natural cleaning of modules. The ideal orientation of a fixed PV
Array should face towards true south (in the northern
hemisphere).

However, for structural uniformity and to accommodate more

capacity on a limited space of an RCC flat roof, the orientation
could be aligned with roof orientation.

A deviation up to 30° with respect to true south will not have a

major impact on energy generation. In the case of an inclined
roof, PV modules should always be installed at the same tilt and
orientation of the roof. A racked mounting structure over an
inclined roof is not recommended for strong wind zones.

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 MOUNTING FRAME SIZE

A mounting frame may be a single
table of mounting structures
where PV modules are fixed either in landscape or portrait

position.

As the design wind load is proportionate to the projected area

normal to the wind, the selection of mounting frame size will
decide wind pressure on the PV array.

Since, Assam is situated in very high damage risk wind zones, it

is of utmost importance to pick the proper mounting frame size
and module position to minimize wind load and keep the solar
plant safe.

It is recommended that, for an RCC flat surface, not more than

one module in the landscape (parallel to the roof surface) should
be installed during a racked mounting structure.

The portrait position of the module shall be avoided to minimize

effective wind area. The recommended frame size for a flat roof
shall be 1 x 1 (landscape) and it shall not be above 1 x 5
(landscape) during a single row.

In the case of an inclined roof, modules are going to be installed

within the same angle as that of the roof. No racking of modules
shall be permitted on an inclined roof. The recommended frame
size for an inclined roof shall be 1 x 1 (portrait or landscape) and
it shall not be above 1 x 5 (landscape) or 1 x 10 (portrait) during
a single row.

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 DETERMINING SPACE
BETWEEN TWO ROWS

Space between two rows is often

determined by analyzing the
sun’s position for solstice (21st December) as explained within
the procedures for
shadow analysis.

During this case, the thing which

will create a shadow is that the
PV array (row) on the south. The minimum space between two

rows shall be above the maximum length of the shadow at the

desired time of the day say, 8.00 am within the morning and
3.00 pm within the afternoon (local time) for the lowest position
of the sun on 21st December.

The length of the shadow is going to be determined by the

azimuth and altitude of the sun during the specified time and the
differential height of the lowest point of the row within the north
and the highest point of the row within the south.

A C C E S S T O P
V M O D U L E S

F O R M A I N
T E N A N C E

While installing PV arrays on the RCC flat roof, leave adequate

space from the parapet wall to avoid shadows on the modules

and also for the maintenance work.

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This will be determined by analyzing the sun position and height

of the parapet wall as described earlier.

A minimum gap of 0.5m between two rows should be maintained

for the movement of maintenance personnel for cleaning or
other maintenance work.

An additional walkway could also be provided in between the

rows to enable safe cleaning and maintenance of PV modules.

V E N T I L A T
I O N F O R

COOLING
OF PV
MODULES

The temperature of a crystalline solar cell increases while PV

modules are in operation.

As temperature increases, the efficiency of the module

decreases. Therefore it is important that there must be adequate
ventilation for airflow on the backside of the PV modules to get
rid of the generated heat to minimize the power loss.

It is recommended that, when PV modules are installed on an

RCC flat roof, a minimum clearance of the structure from the
roof level should be 300mm

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 In the case of an inclined roof, a clearance of 100 -120mm

should be maintained between roof material and solar modules
to make sure that the natural ventilation and cooling of PV
modules take place effectively and efficiently.

Insufficient cooling will end in high module operating

temperatures and lower outputs from the modules.

E N S U R E T H A
T T H E R E I S

NO LEAKAG
E ON THE

ROOF

Installation of a PV array mounting structure on the roof requires

drilling of holes through building
material which makes the roof
susceptible to leakage in cases of rain.

Leakage from the roof after installation of solar PV modules may

be a common problem as a result of poor installation practice.

Therefore, it is important to understand the best practices of

installation to stop rainwater leakage.

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The following key points should be kept in mind before
installation to make the system Leakproof:

Avoid drilling RCC roofs, instead use concrete ballast and

adhesive materials to repair the structure.

Use proper flashing methods and sealant materials for

metallic and tiled inclined roofs.

Use synthetic sealant which cures underwater and may

handle temperature up to 100 - 120°C.

Always fasten the roof attachments on the crest (top of

corrugation) to repair the attachment.

Never drill on the trough (bottom of the corrugation).

Elevate the sealing area above possible water level. just in

case of a low slope roof, seal the bottom of the flashing.

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STEP 3: INSTALLATION
AND TESTING OF
STRUCTURE EARTHING
SYSTEM

After installation of module mounting structure, subsequent

steps are to be taken to supply an endless equipotential bond
between mounting structure and module frames.

Procedures for Installing and Testing

Verify the earthing conductor routing plan.

Prepare earth terminal bar/conductor, lugs, clamps, earthing

rod, and earth pit as per drawing.

Ensure all module frames and every part of mounting

structures are electrically bonded.

Use proper WEEB for bonding.

Find the simplest location for earthing pit where the soil is
wet and resistivity is least

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 Attach the earthing terminal bar/wire with earthing rod.

Connect terminal bar to structure.

Ensure all the connections are neat and tight.

Test earthing continuity and resistance of earth electrode

after installation.

Important Note

If there is no lightning system installed for the system, the

conductor which is used to earth the exposed metallic frames of
the PV array shall have a minimum size of 6mm square copper
or equivalent.

When a lightning protection system is installed, the minimum

size of the conductor shall be 16mm square copper or
equivalent.

PV array bonding conductors should run as close to the positive

and negative PV array and or sub-array conductors as possible
to reduce induced voltages due to lightning.

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Procedures for measurement of earthing continuity and
earth electrode.

Short the P1 and E1 terminals of the world resistance tester.

Connect the electrode under test to the E1 terminal of the

earth resistance tester.

Using a hammer, dig an electrode at a distance (D) of a

minimum of 30 meters from the test Electrode.

Connect this electrode to the E2 terminal of the earth

resistance tester.

Using a hammer, dig another electrode in between both the

electrodes at 50% of D.

Connect this electrode to P2 of the terminal.

Take the readings by rotating the handle of the Earth

resistance tester or pressing the push button.

Repeat the above procedure by changing the situation of the

middle electrode to 40% and 60% of D.

To get the resistance of the electrode, take the mean of

those three readings.

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 STEP 4: INSTALLATION
OF PV MODULES

Modules should be installed after the earthing system of the

structure is constructed.

The installer needs to understand properly about handling,

packaging, and storage of PV modules so that modules do not
get damaged during the method of installation.

Instructions for Installation of PV modules

1: Handling and Packaging

a: Solar modules should be stacked, packed, and transported

vertically and separators should be placed between each
module. Horizontal stacking should be avoided.

b: Due to many unavoidable reasons, the modules are required

to be stacked horizontally.

Also, additional protection is to be added to the four corners of

every module and not more than six modules should be packed
in one box.

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 2: Loading, transport, and unloading

a: Modules could also be damaged externally or internally,

causing micro-cracks while loading, transport, and unloading.

Any external damage or breakage is visible but internal damage

to cells is not visible by the eye and thus precaution during
loading, transportation, and unloading should not be
underestimated if there is no visible damage to the modules.

b: To avoid breakage and micro-cracks during loading,

transportation, and unloading of modules, the modules must be
packaged properly.

Rough handling during loading and unloading and walking on

the package must be avoided. While carrying the modules in a
truck on a bumpy road, the speed of the truck must be controlled
and kept at a minimum to avoid vibration and jerking.

c: Do not use a knife to chop the zip-ties, instead, use wire-

cutting pliers.

3: Storage of PV modules

a: Almost like packaging, solar modules should be stacked,

packed, and stored vertically and separators should be placed
between each module. Horizontal stacking and storing should be
avoided.

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 b: If due to unavoidable reasons, the modules are needed to be
stacked and stored horizontally, a good buffer material should
be introduced between each module and round the modules.
NOT more than six modules should be stored together.

4: Module Installation

a: PV modules are often fixed either by the bolt method or by the

clamp method.

b: Understand and follow manufacturer installation manual and

recommendations.

c: Use personnel safety equipment while installing the modules.

d: Use of insulated tools and gloves while working with modules.

e: Don't tread on the PV module as this may damage the solar

cells inside the module.

f: Ensure electrical connectors are well shielded from the

ingression of water and dust.

g: Don't install or handle PV modules under gusty winds and if

there is rain.

h: Use appropriate tools and equipment provided or

recommended by the manufacturer.

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 STEP 5: EARTHING OF PV
MODULE FRAMES

After physical installation, PV module frames are to be bonded

together and connected to the main earthing conductor of the

mounting structure.

The conductor which is used to earth the exposed metallic

frames of the PV array shall have a minimum size of 6 mm
square copper or equivalent.

PV array bonding conductors shall run as close to the positive

and negative PV array and or sub-array conductors as possible
to scale back induced voltages thanks to lightning.

The earthing conductor must be properly fastened to the module

frame to make of sure good contact. PV module frames have an
anodized coating which is alumina and it works as insulation.

S T E P 6 : D C
C A B L I N G

It is important to minimize drop loss within the cables for the

desired performance of
solar PV systems.

Ensure that aggregate drop altogether DC cables is a smaller

amount than 3% as recommended by IEC 62548 PV array
design requirements.

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a: Module wiring or stringing

After physical installation and establishment of earthing bond of

the frames, PV modules are connected in series electrically to
make a string.

Precautions to require while wiring modules:

Only a trained and qualified installer should perform all

wiring,
Use chrome steel clamp or UV protected cable tie to repair
cables,
Do not connect all the modules in series to avoid high DC
voltage,
Final connections are going to be done when the system is
prepared for commissioning,
Ensure electrical connectors are well protected against
corrosion and soiling,
Make sure that the connectors are corrosion-free, clean with
absolutely no gaps between the contacts,
Do not allow any inflammable liquids/gases near the
installation area.

Follow the steps below in sequence for module wiring or

stringing:

1: Review the DC cable wiring diagram,

2: Review module interconnection (string or series) diagram,

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3: Make sure that there is not any bare cable in module wire,
4: Connect DC cable connector (MC4 or equivalent) properly
with a crimping tool,
5: Connect number of modules serial following the schematic
provided,
6: Attach the cables with cable tie wraps to the module frame or
rails,
7: Ensure minimum looping in cable,
8: Ensure NO cable is hanging loose,
9: Label the terminals with the “+” and “-” sign using a cable tag.

b: Installation of DC Combiner Box

DC combiner boxes are generally installed after the installation

of your PV modules.

Procedures to follow:

Review the DC combiner box internal wiring diagram,

Prepare the diagram if there is no wiring diagram,
Check all components, like fuses, DC isolator, and SPD
(Surge Protective Device),
Make sure that the cable glands are of appropriate ratings
and size,
Check IP (Ingress Protection) rating and verify if there is any
violation of IP rating,
If DC combiner box is pre-wired, check if all wiring is
completed per the drawings,
Install the combiner box up and identify the marked location

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 Install conduit for cabling,
Keep the DC isolator in OFF position,
Place the fuse disconnects within the circuit condition,
Install the SPD (surge protective device).

c: Installation of DC cable from PV array to DCCB and DCCB

to the inverter

DC cables are installed after installation of DC combiner box, to

attach PV arrays on one side and therefore the inverter on the
opposite side.

DC cables should be installed within the conduits or cable tray

with lid. Installation of DC cables shall be undertaken with care
such the likelihood of line-to-line and line-to-earth faults
occurring is minimized.

All connections shall be verified for tightness and polarity during

installation to scale back the danger of faults and possible arcs
during commissioning, operation, and future maintenance.

Particular attention must be taken to make sure that the

protection of wiring systems against external influences and all
cables must be shielded from mechanical damage.

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Procedures to follow:

Review the DC wiring diagram,

Install conduit/cable tray from roof to DC combiner box,
Secure all conduits/cable trays to the building,
Pull the DC cables through conduit/cable tray from roof to
the DC combiner box,
Leave excess wire at both ends (roof and combiner Box),
Use sealing materials (silicon) to stop leakage into the
conduit and therefore the penetration at the roof,
Terminate DC cables in DC combiner box,
Install cable connectors (MC4 or equivalent) at both ends
and tag cable with “+” and “-“ sign,
Tighten the cable connector using appropriate tools,
Test the cables to make sure correct polarity labeling,
Keep all connectors open (OFF),
Use cable glands consistent with the size of the cables,
Tighten the cable glands using appropriate tools,
Use an EDPM rubber hole stopper to dam unused holes
within the combiner box.

S T E P 7 : A C
C A B L I N G

A N D I N S T A L
L A T I O N O F
INVERTER
When DC cables and DC combiner
boxes are installed, the
subsequent step is to put in AC cables and therefore the
inverter. Ensure that total drop altogether AC cables is a smaller
amount than 2% consistent with IEC 62548.

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 Procedures to follow:

Install the conduit/cable tray,

Pull the conductors through conduit or cable tray,
Leave excess conductor or cable near each equipment
terminal,
Read inverter installation and operation manual carefully,
Make sure that there is adequate ventilation for the inverter,
Make sure that there is no direct sunlight falls on the
inverter,
Mount the inverter with accessories provided by the
manufacturer,
Ensure that there is no grid supply to the inverter,
Complete the installation from the inverter to the AC isolator
and energy meter as per the drawing,
Install the earthing connection as per the inverter installation
manual,
Tighten the cable glands using appropriate tools

S T E P 8 :
S Y S T E M
PROTECTION AND
SAFETY

1: Earthing system configurations

Internationally, earthing systems are classified as TN System,

TT System, and IT System.

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 TN system: It has one or more points of the source of energy

directly earthed and therefore the exposed and extraneous
conductive parts of the buyer side installation are connected by
means of protective conductors to the earthed point of the
source i.e. there is a metallic path for earth fault currents to be
due the installation to the earthed point of the source.

TN systems are further sub-divided into TN-C, TN-S, and TN-C-

S systems.

TT system: It has one or more points of the source of energy

directly earthed and therefore the exposed and extraneous
conductive parts of the installation are connected to the
electrodes which are electrically independent of the source
earth.

IT system: It has the source either unearthed or earthed

through a high impedance and therefore the exposed conductive
parts of the installation are connected to electrically independent
earth electrodes.

2: Protection against Overcurrent

Overcurrent within a PV array may result from earthing faults in

array wiring or from fault currents due to short circuits in
modules, junction boxes, combiner boxes, or module wiring.

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 3: Protection against effects of lightning and overvoltage

To guard the DC system as an entire, surge protective

devices shall be fitted between active conductors and
therefore the ground at the Inverter end of the DC cabling
and the array.

All DC cables should be installed so that positive and

negative cables of an equivalent string and therefore the
main array cable are bundled together, avoiding the creation
of loops within the system.

Long cables over about 50 m should be protected by a surge

protective device (SPD).

4: Lightning Protection System (LPS)

The need for a lightning protection system is to be assessed in

accordance with IEC 62305-2 and if required, it should be
installed in compliance with IEC 62305-3 or IS 2309.

The lightning protection system must be able to provide

coverage for the full plant. According to the National code of
India 2016, vertical air terminals are required for shielding roof-
mounted installations like solar PV systems.

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 The protection angle should be considered as per Table 6 of
SP7 (National code of India 2016). A design consistent with the
rolling sphere method should be a finished zone of protection
(for example, 1m rod at 0.5m height from the panel at four
corners protects approximately 12m x 9m area).

The maximum height of the air- termination rod above the panel
should be restricted to 0.5m considering the influence of shadow
from the air terminal.

5: Voltage rating of DC Protection Devices

All system protection devices must have a voltage rating of a

minimum of the PV Array. The PV array will attain a maximum
voltage at the rock bottom expected temperature at the
installation site.

6: System Isolation

According to Central Electricity Authority (Technical Standards

for connectivity of Distributed Generation Resources)
Regulations, 2013, there should be a manually operating
isolating switch between distributed generation resource and
electric system, which shall meet the subsequent requirements:

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 Allow visible verification that separation has been
established.
Indicators to point out closed and open positions.
Be capable of being readily accessible and be capable of
being locked in the open position.
Might not be rated for load-break.
Be located at a height of 2. 44 m above ground level.

S T E P 9 : P L
A C I N G O F

S I G N
A G E
It is vital to possess appropriate
signage at the PV system to
attenuate any hazardous situations associated with the project

site.

Place the subsequent signage in appropriate locations, as

applicable. The signs should be visible from a minimum of 0.8m.

Procedures to follow:

A “Solar DC” sign shall be located on all PV array and PV

(string) junction boxes.

Sign indicating “Live during daylight” shall be attached to all

or any DC junction boxes and switches.

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 The double pole isolator (disconnecting means) at the
inverter should be labeled “PV Array DC Isolator”.

A fire emergency information sign is required at most

building switchboards.

The prevailing main switch within the switchboard should be

labeled “Main Switch”.

The AC Isolator at the inverter should be labeled as “Inverter

AC Isolator”.

A wake-up call at the switchboard should be installed

indicating that dual supplies exist and both normal and solar
supplies should be disconnected when performing on the
switchboard.

If the grid system is connected to a distribution board, then a

wake-up call should be installed at that distribution board.

A symbol informing people of the shutdown procedure

should be located during a prominent position. This sign
shall state the circuit voltage and short current of the array.

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 STEP 10: PRE-
COMMISSIONING TESTS

process, a pre-commissioning
After completion of the installation
test has got to be performed. Conducting a pre-commissioning

test is extremely important to make sure there are not any wrong

the system.
connections within

Procedure to be followed in sequence:

Make sure that the PV arrays (string or strings) are in

segments (maintain below 70V).
Remove the string fuses if installed.
Confirm that isolators AND circuit breakers are within the
‘OFF’ position.
Make sure that the PV array DC isolator and inverter AC
isolator are within the ‘OFF’ position.
Make sure that the inverter is turned OFF.
Measure and ensure that no voltage is present across any
string.
Measure and ensure that no voltage is present on the output
side of the DC combiner box.
Check the continuity of the cables and complete the array
cabling.
Confirm that the polarity of every array connection is correct.
Measure and record the circuit voltage of every string.
Measure irradiance, ambient temperature, and cell
temperature at an equivalent time.

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 Observe variation between effective (string) voltage and
measured (string) voltage.
If there is a variation greater than 5% in VOC (open circuit
voltage) then investigate the matter.
Check the polarity at the input to the PV array DC isolator.
Measure and record the circuit voltage (Voc) at the input to
the DC isolator.
Check the polarity and continuity between the PV array DC
isolator and the inverter.
Check the continuity between the inverter and therefore the
inverter AC isolator.
Check the continuity between the kWh meter and therefore
the inverter AC isolator.
Measure the voltage of the grid on the output (grid side) of
the inverter AC isolator.
Measure the resistance of the world system.
Conduct insulation testing of AC and DC cables.

STEP
11:

COMMISSIONING THE
SYSTEM

When you are sure that the conductors and connections are

acceptable and therefore the system has successfully passed

the pre-commissioning testing, then it is time to commission the
system.

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 Procedures to be followed in sequence

Refer to the inverter system manual and follow the start-up

procedure.

Check the inverter display and ensure that the solar battery
is supplying power to the utility grid.

Measure either the AC or DC current employing a clamp

meter and compare inverter output.

Measure the DC input voltage and ensure that it is within the

operating limits of the inverter.

Measure the AC output voltage out of the inverter.

S T E P 1 2
: A N T I -
ISLANDING
FUNCTIONALITY TEST

Unintentional islanding (anti-islanding) can have undesirable

equipment integrity.
impacts on customer and utility

If unintentional islanding is sustained for a big period of time

then personnel safety could become a cause of concern.

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 To manage these risks, a series of functionality tests are to be
performed.

This test must be conducted during noontime on a sunny

day.
PV system shall produce quite 20% of the rated output of the
PV array or the inverter whichever is a smaller amount.
If there is quite one inverter, tests should be administered for
every inverter.

Tests to be performed in Sequence

Test 1: Inverter must cease supplying power within two

seconds of a loss of mains.

STEP 1: Keep DC supply from the solar battery connected to

the inverter.
STEP 2: Place the voltage probe within the inverter side of the
AC main switch (on the load side of the switch).
STEP 3: Close up the AC main switch through which the inverter
is connected to the grid.
STEP 4: Measure the time taken for the inverter to cease
attempting to export power with the timing device and then
record it.

Test 2: Inverter must not resume supplying power until

mains are present for quite 60
seconds.

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 STEP 1: Keep DC supply from the solar battery connected to

the inverter.
STEP 2: Place the present probe within the inverter side of the
AC main switch (on the load side).
STEP 3: Activate the AC main switch through which the inverter
is connected to the grid.
STEP 4: Measure the time taken for the inverter to re-energize
and begin exporting power with a timing device and then record
it.

1: Photovoltaic Array installation

The major aspects of putting the PV array are to choose the

appropriate mounting system and to make the proper
installation.

Once we have installed the array, we have to verify whether the

array is functioning according to the manufacturer's specification
or not.

a: Mounting System Considerations

The first step in completing a security system installation is to

carefully select the PV array's location.

Electrical equipment should be shielded from unnecessary

environmental exposure and should be mounted in such a way
that it facilitates convenient regular system maintenance.

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 The PV array should be located as near as possible to the load

to attenuate power loss from long wire runs.

PV modules are expensive, lightweight, and compact, making

them susceptible to theft. So some sort of security arrangement
should be made.

Photovoltaic module support structures should provide an easy,

strong, and sturdy mounting system. Most commercially
available photovoltaic modules are manufactured with aluminum
frames. These frames are strong, durable, corrosion-resistant,
and supply adequate support for the module to be mounted on a
support structure.

Weather-resistant, corrosion-free materials (such as anodized

aluminum, galvanized steel, and stainless steel) should be used
when fabricating a photovoltaic array mounting system.

The support structures got to be lightweight so that they are

often easily transported and installed.

Wooden racks are successfully utilized in many mounting

applications. Wood, however, requires more maintenance over
the lifetime of the system, making other mounting system
materials more desirable.

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 b: Bracket Mounting Systems

A simple bracket system can be used to mount a single solar

module. Two galvanized steel angle brackets are bolted to a
building's exterior walls or roof structure. The second pair of
compatible brackets are attached to the top frames of the solar
module.

When the two sets of brackets are mated, they form an easy,
durable, cost-effective mounting system for a single module
photovoltaic system.

Bracket systems are often constructed to pivot and tilt to

seasonally optimize the photovoltaic system performance.

c: Pole Mounting Systems

Arrays also can be mounted on a hardware system that bolts

onto a vertical pole placed permanently and securely within the
ground.

Generally, 2½ inch steel pipe works well for the bottom support.
Pole mounting hardware is often bought or fabricated out of 19-
gauge chrome steel.

This popular mounting technique is often seasonally adjusted to

optimize the system's performance.

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 d: Ground Mounting Systems

A ground-mounted array support structure uses a frame that is

bolted onto a prepared footings. A mounting frame often
consists of two parallel channel bars that form an easy rack.

Cross supports are bolted to the frame to extend lateral

structural support and to stop wind damage.

Non-Adjustable, extruded aluminum legs bolt to the frame to

carry the array at a predetermined angle.

Adjustable tilting support legs also can be fabricated to permit

manual seasonal tilt adjustments.

Metal that is mounted onto a concrete footing should be

galvanized steel since the lime content within the concrete can
corrode aluminum over time.

Additionally, nuts, bolts, and washers should be made from

chrome steel to supply durable, corrosion-resistant connections.

e: Tracking Mounting Systems

Solar photovoltaic array mounting tracks the sun in its daily path
across the sky which is a cost-effective and also an alternate
mounting system for some installations.

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 Passive tracking units do have not any motors, controls, or
gears. It uses the changing weight of a gaseous refrigerant
within a sealed frame to trace the sun.

These sophisticated trackers also are commercially available,

although they are not cost-effective for small-scale residential
systems.

The tracking unit must be mounted at an adequate height above

ground level to permit unobstructed movement above snow or
debris.

Tracking units generally enhance a system's annual

performance by approximately 25% to 30% but can add a big
cost to a system.

The economics of tracking mounts should be carefully evaluated

within the initial design phase.

2: Battery Installation

Installing a battery system starts with shipping. Remember that

batteries are heavy and may easily leak. Consequently, some
carriers won't ship liquid batteries. Even certain sealed batteries
contain some liquid called reserve electrolyte which will spill.

Upon arrival, check the batteries for any damage which will have
occurred during shipping. We should protect batteries at the
least times, including during transport and while boosting
charging before departure for the location. A lift charge is
required if the batteries are not fully charged.

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When boost charging with an AC-powered charger, confirm that

it does not exceed the charge termination voltage or charge at a
faster rate than the manufacturer specifies.

When batteries are charging, keep them far away from open
flames and sparks and open the vent caps to permit explosive
hydrogen gas to flee.

Keep the batteries far away from children, unauthorized

personnel, dust, and oil. When transporting batteries, it has to be
packed to avoid spillage and short circuits.

It has to be covered properly with an electrical insulator like

wood, tape, or insulated connectors.

Building a Battery Enclosure

The battery bank must be safely located to stop accidents, yet

provide for periodic maintenance.

When building a battery enclosure, we have to use the

subsequent guidelines:

Protect batteries from items that will accidentally fall from

above and cause a dangerous short circuit.

Protect batteries from freezing temperatures by insulating

the enclosure or locating the enclosure during a heated area.

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 Build proper vents within the battery enclosure to supply free

airflow and stop the build-up of explosive hydrogen gas.

The vents must be located high enough to properly vent

hydrogen gas, which is lighter than air.

Vents should be directed outdoors and screened to stop insects

and animals from blocking them.

Note that with free airflow the battery temperature will be about
an equivalent because of the average ambient air temperature.

Build the enclosure, box, or compartment so that they are

often locked and are accessible for maintenance.

Size the access to the enclosure to permit straightforward

removal and replacement of batteries. When placed within the
enclosure, the batteries or cells should have air space between
them.

Store the upkeep equipment and manufacturer's information

in a resealable bag or container inside the enclosure.

Build a robust level floor. Build the enclosure with material

that will not be damaged by corrosion from the electrolyte.
Use wood, plastic, or painted metal.

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3: Controller and Inverter Installation

Photovoltaic charge controllers are intended for specific solar

applications and they should not be used for other system
regulations unless specified by the manufacturer.

We have to read and follow the precise installation procedure

laid out in the manufacturer's instructions.

When installing controllers and inverters, we have to use the

subsequent guidelines.

The guidelines are:

Protect control hardware from excess dust, dirt, overheating,

and rough handling.

Remember that electrical equipment is sensitive and requires

careful handling. Some controllers require ventilation to stop
components from overheating.

Use common sense in locating and mounting controller units.

Install all system components far away from potential hazards,
such as overhanging tree limbs, heat sources, snowdrifts, and
debris build-up areas.

Cover the array with an opaque material when installing the

controller. Also, close up all loads to protect the installer and
equipment.

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 Use correct wire size and proper terminal fasteners.

Choose a controller with field adjustable set-points because

each different battery type has slightly different voltage
requirements.

Use an enclosure or metal box made especially for electrical

wiring. Controllers are mounted inside an enclosure to guard
them against dust, moisture, sunlight, insects, tampering,
and abuse.

Also, another electrical wiring is usually completed inside the

enclosure. The duvet of the enclosure protects people from
shock and maybe a good place to mount electrical metering.

Use some sort of over-current protection and switching in or

near the controller enclosure to protect the controller and
supply a way of disconnection between the array and
battery.

Fusing OR circuit breakers to protect the controller from an

excessive amount of charging current and protect the wiring
from an excessive amount of current within the event of a brief
circuit.

An excessive amount of current will overheat the wiring and

should cause a fireplace if not protected with fusing OR circuit
breakers.

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 Disconnect switching is employed to open the circuit between
the array, controller, and battery. Disconnect switching also turns
off the load. This switching is important for servicing the system
and just in case of emergency.

Note: Fuses are subject to corrosion from moisture. Circuit

breakers are less likely to corrode and more convenient.
Additionally, breakers have more concealed wiring.

4: Photovoltaic System Wiring

When wiring a PV system, it is vital to use correct electrical

boxes, wiring connections, and switches for every specific
application.

i: Electrical Boxes

All wiring connections must be made within an accessible

electrical box. The box must be securely fastened in place and
have a removable cover.

Electrical boxes are often either surface mounted or recessed

into a wall, ceiling, or floor. Electrical boxes that are exposed to
weather must be weather resistant and have weather-resistant
connectors.

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 Electrical boxes must be an adequate size for the amount and
size of wires contained within the box. Boxes used for switches
are often mentioned as switch boxes. These boxes are
rectangular in shape and use a canopy plate.

Electrical boxes which are used for making wire connections are
called junction boxes. They are usually rectangular or octagonal
in shape and covered with a blank cover plate, making them
accessible when construction is complete.

ii: Wiring Connections

Electrical connectors perform one among the subsequent

connecting functions:

Wire to Wire Connections

The connection between wires is usually made with a wire nut,

split bolt, reducer, or crimped connector. Wire nuts are sized and
color-coded.

The crimp-type connector must be crimped employing a special

tool recommended by the manufacturer and is best used with
stranded wire.

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 Wire to Terminal Connections

Connections between a wire and terminal are usually made with

a hoop or spade-type connector.

These connectors are commonly used when connections are

frequently removed and reconnected or where the large wires
would be difficult to attach.

Wire, Cable, Cord, or Conduit to Electrical Box Connections

Connections between electrical boxes and wires, cables, cords,

or conduits must be secure enough to prevent wires from pulling
loose.

When exposed to weather, these connections must thread into

the box and make a watertight seal. A "drip loop" should be used
for outdoor wire.

iii: Common Electrical Connectors

Following are the common electrical connectors utilized in PV

system wiring:

Wire Nuts
Connectors are used to connect two or more wires. Twist the
wires together and screw the wire nut on until tight.

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 Crimp Connectors
Connectors are used to connect two wires. Both wires are
inserted inside the crimp connector, one from each end then
pressed with a crimping tool.

Ring Terminals
Crimp-on connectors maintain a connection even if the screw
loosens.

Spade Terminals
Crimp-on connectors to be used in non-vibrating applications.
They permit for quick disconnection.

Screw Lugs
Bolt-on connectors are used to connect large or multiple wires to
at least one terminal.

Flag Terminals
Connectors are used for securing wires where no electrical
connection is formed.

Cable Connectors or Romex Connectors

Connectors are used for connecting non-metallic sheathed
cables to a box.

Conduit Connectors
Connectors are used for connecting conduits to a box for interior
or dry applications.

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 Conduit Couplings
Connectors are used for connecting lengths of conduit for
interior or dry applications.

iv: Switches

Switches must be rated for a given voltage and for the quantity
and sort of current which will flow through them.

Type "T" switches are rated for DC use. Using AC-rated

switches or "quiet switches" for DC systems will end in a
shortened switch life because the contacts blow out from
repeated electrical arcing.

Under higher current conditions, the switch contacts may

become permanently fused, the switch then won't be able to
work then.

Disconnect switches are required for safe DC system operation.

PV panels and batteries are voltage sources that require
disconnect switches.

Safety switches OR circuit breakers are the foremost appropriate

switches to use for disconnecting PV panels, batteries, and
generators.

A safety switch is fused, thus providing overcurrent protection

between major PV system components. Circuit breaker used
here as a function to turn on over-current protection.

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 Key Points that must be remembered

Initial site visits must be thorough enough to supply accurate

information needed to style and plan the installation.

We have to check all tools to make sure that they are in

operational condition and have not any missing parts before
departure.

Photovoltaic module support structures should provide an

easy, strong, and sturdy mounting system.

We have to protect batteries in the least time, including

during transport and while boosting charging before
departure for the location.

We have to follow the rules for building the battery enclosure

and installing the battery bank.

We have to follow the rules for installing the controller.

All wiring connections must be made within an accessible

electrical box. The box must be securely fastened and have
a removable cover.

Disconnect switches are required for safe DC system

operation.

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 Solar PV System Design

A solar PV system design can be done in four steps:

Load estimation
Estimation of the number of PV panels
Estimation of the battery bank
Cost estimation of the system.
Base condition:2 CFLs (18 watts each), 2 fans (60 watts
each) for 6hrs a day.

1: The total energy requirement of the system (total load) i.e

Total connected load to PV panel system
= No. of units × rating of equipment
= 2 × 18 + 2 × 60 = 156 watts

2: Total watt-hours rating of the system

= Total connected load (watts) × Operating hours
= 156 × 6 = 936 watt-hours

3: Actual power output of a PV panel

= Peak power rating × operating factor
= 40 × 0.75 = 30 watt

4: The power used at the end-use is less (due to the lower

combined efficiency of the system
= Actual power output of a panel × combined efficiency
= 30 × 0.81 = 24.3 watts (VA) = 24.3 watts

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 5: Energy produced by one 40 Wp panel in a day

= Actual power output × 8 hours/day (peak equivalent)
= 24.3 × 8 = 194.4 watts-hour

6: Number of solar panels required to satisfy given estimated

daily load:
= (Total watt-hour rating (daily load)/(Daily energy produced by a
panel)
=936/194.4 = 4.81 = 5 (round figure)

7: Inverter size is to be calculated as:

Total connected load to PV panel system = 156 watts

An inverter is available with ratings of 100, 200, 500 VA, etc.
Therefore, the choice of the inverter should be 200 VA.

Cost Estimation of a PV System

1: Cost of arrays = No. of PV modules × Cost/Module

= 5 × 8000 (for a 40 Wp panel @ Rs.200/Wp)
= Rs.40000

2: Cost of batteries = No. of Batteries × Cost/Module

=1 × 7500= Rs.7500

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3: Cost of Inverter = No. of inverters × Cost/Inverter = 1 × 5000
= 1 × 5000 = Rs.5000
Total cost of system = A + B + C = 40000 + 7500 + 5000 =
Rs.52500
[Additional cost of wiring may be taken as 5% of total system
cost]

Assumptions Taken For Design

Inverter converts DC into AC power with an efficiency of

about 90%.

Battery voltage used for operation = 12 volts.

The combined efficiency of inverter and battery will be

calculated as :
combined efficiency = inverter efficiency × battery efficiency =
0.9 × 0.9 = 0.81 = 81%.

Sunlight available in a day = 8 hours/day (the equivalent of

peak radiation).

Operation of lights and fan = 6 hours/day of PV panels.

PV panel power rating = 40 Wp (Wp, meaning, watt (peak),

gives only peak power output of a PV panel).

A factor called the “operating factor‟ is used to estimate the

actual output from a PV module.

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 [The operating factor between 0.60 and 0.90 (implying the
output power is 60 to 80% lower than rated output power) in
normal operating conditions, depending on temperature, dust on
module, etc.]

Software Tools used for the Designing of Solar PV System

1: Aurora

It creates an entire engineering design and sales proposal with

just an electric bill and an address.

2: BlueSol

BlueSol Design simulates, via software, the behavior of the PV

system in all its components.

The schematic representation allows the designer to have a

precise view of the operation.

BlueSol Design integrates a CAD system that automatically

generates the single-line electrical diagram.

3: PVsyst

This is a user-friendly software, requiring only a few inputs for

the project area, desired capacity, solar module, and inverter.

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 We can use it for detailed study, sizing, hourly estimation, and
report generation. It is a handy design tool for PV system
design, simulation, and estimation.

4: Helioscope

3D design, rapid proposals, simulations, unlimited designs, live

support, single line diagrams, automatic CAD export, a library of
45,000 components, global weather coverage, shade reports up
to 5MW Systems.

5: Pylon

Pylon is very interesting because of its lightweight, usage-based

pricing model. It is available as an online Software as a Service
(SaaS) tool but does not have any monthly fees.

6: Homer

We can use this for simulation with multiple energy sources, add
multiple loads. We can add factors like wind speed, fuel cost,
and emissions penalties to the simulations.

It enables location search by name. But it is not specifically

designed for Solar PV. So some of the reports may not be as
comprehensive as from other solar PV-specific tools.

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 7: SolarEdge Site Designer

This is a free tool to help commercial solar installers to reduce

their design costs and include attractive 3D designs in their
proposals. SolarEdge uses either custom or satellite images to
design photovoltaic projects from the first stage to the very
installation.

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