Documentos Basic Tech Solar Training Manual FEF 08 ENG 84e8a4fd

Technical solar training manual
Basic design and installation training guide
Date: June 2008

Purpose: Document to support staff of business development service agencies to build the
technical capacity of solar dealers, enabling them to design and install good solar
energy systems for rural households and small businesses and advice their customers
adequately
Aimed user: Solar business development service providers and technical trainers of solar
dealers/technicians (e.g. Solar.Now! employees)
Organization: Free Energy Foundation, The Netherlands
Status: Practiced in Tanzania, Uganda, Zambia, Ghana, Ethiopia

With the financial support of

Buitenlandse
Zaken
Foreword
This manual is part of an overall set of strategies to simulate local entrepreneurship for small solar appliances for rural
electrification. These strategies fall into three categories: those meant to boost the chain and business development for
small solar appliances in off-grid rural areas; those meant to upgrade the technical domain of the private actors involved;
and those meant to strengthen their marketing and sales capacity. Each of these comes with a comprehensive pedagogical
guide and specific technical manuals.

Solarentrepreneurshipdevelopment

Chain/BusinessDevelopment TechnicalTraining MarketingandSalesSupport

Supply
Income Demand
Study Light>exposure > income
Market Market
I Chain Home Business Assessment

improvement
Lantern
Supplier(I) Prospect
Acquisition SBA Promotion
II Family
Innovation
Dealer(II) MFI Household
Potential
Sales

III Network(III)
SalesAgent
Backup Customer
Consultancy AfterSales

The technical training strategy is geared at enabling both commercial and technical staff in the technical aspects of solar
energy, so they can design and install small solar systems correctly and adequately answer the questions that prospects or
clients may have. Eventually this is bound to result in more sales, and more rural people satisfying their basic energy needs
for illumination, powering their communication equipment [radios, TVs, cell phones] and if possible, earn a bit of extra
income. This may entail a number of small solar applications and training levels:
x Solar Lanterns. The lower rural middle class segment may not have the purchasing power for small solar home systems,
and my with to satisfy their need for illumination. There is thus a viable market in certain areas for solar lanterns or
small LED lights, of 5 to 10 Watts, to provide this market segment with basic energy services (lighting). Retailers, sales
agents and technicians are trained in the characteristics of this product, its parts and the maintenance and repairs
involved.
x Solar home systems. As most rural middle class families have no access to basic energy services but wish to extend
their effective day length and connect to the outside world, there is a good market for affordable solar home systems
of 12 to 20 Watts, that allows them to charge batteries that feed a couple of bulbs, the radio, a phone charger and
eventually maybe a TV. Retailers, sales agents and technicians, yet also promotion staff of NGOs and saving banks
are, first, trained in the basics of their design and installations. Later they may also be provided more advanced
training, eg. to elaborate on electricity detail, and do tailor-made sizing and installation of bigger systems.
x Backup systems (inverters). Especially in peri-urban setting or in rural settings, there may be a grid but it may be too
unreliable. In such cases, back-up systems, which allow middle class families to charge batteries on the grid when its on
and feed their lights and basic equipment from batteries. This can also be a good diversification strategy for solar
entrepreneurs, as the technical details are very similar to those of the bigger solar home systems. Retailers and
technicians are therefore trained in the details that come with the sizing and installation of these systems.
x Solar Business Applications (SBA). Solar home systems may not only be used to save on kerosene expenses, but
also to earn an income. Phone and dry cell charging, powering shavers, lighting restaurants, shops and bars are
commonly applied micro-businesses that use solar systems. For each of these a technical and economic fact sheet is
elaborated. Retailers are trained in assembling and exploiting these solar business applications.
x Innovative new products. There are a number of new solar appliances that the retailer may wish to be informed and
trained about: such as, pack and go home kits, solar sign posts, and so on.
The crucial step here is the basic training in solar home system design and installation, as all the rest follows on o this. This
guide summarizes the experience gained in this basic technical training.
Basic design and installation training guide Page 2

Table of Contents
Foreword ........................................................................................................................................................................................2
Table of Contents..........................................................................................................................................................................3
1. Why......................................................................................................................................................................................4
2. Whom ..................................................................................................................................................................................4
3. Where ..................................................................................................................................................................................4
4. When....................................................................................................................................................................................4
5. How ........................................................................................................................................................................................4
6. Which (tools) ......................................................................................................................................................................6
Annex 1 Presentation
Annex 2 Background document (handout)
Annex 3 Worksheet designing
Annex 4 Placemat systems options
Annex 5 Sunhour sheet
Annex 6 Installation guide
Annex 7 Wire thickness sheet
Annex 8 Fault finding sheet
Annex 9 Maintenance checklist

The Basic Design and Installation of Small Solar Home Systems

1. Why
A solar system is different from normal technical electricity installations, because it is direct current (DC). Some rules are
different. Also, because it is a system, automatically it is a bit more complex, because elements of the system have to work
together.
Experiences in the field show that often installations are done wrongly, which is damaging the potential of the solar
market. Also it shows that a good and intimate knowledge of the system design is quite essential in the sales process, as
solar is a relatively new and unknown technology.
2. Whom
The training is meant for dealers, technicians and even others that require a basic insight in how to do solar installations,
such as employees of NGOs or saving banks who wish to engage in small affordable solar electrification. The primary aim
is to train a network of technicians that can actually do proper installations in the field, linked to start-up or existing
retailers. This way, retailers can guarantee that they do not only sell good solar systems, yet also that these are properly
installed and maintained. Sometimes the technicians are employed by the retailers, sometimes they have a more free-lance
relation, yet sometimes the technicians are also sales agents for the retailer.
3. Where
As this is a training it should be carried out in a training environment. Always try to give it in a conducive [yet cheap and
easily accessible] venue. A shop a not the most ideal location for giving a training since the dealers will be distracted by
customers who come in. Therefore it is recommended to arrange for example a classroom in the local school to give the
training. A classroom has several other advantages like good tables and chairs and a blackboard. Conference centers
may also be used for training. The venue should have plenty of space to carry out practical sessions.
4. When
When training is given, the following schedule is recommended for a one-day training.
Hour Theory and practical training - BASIC

1 What is solar energy? What are the advantages of solar energy?
2 Components: solar panel, charge controller, battery, lights.
Calculations with system sizing sheets. Do practical calculations on examples.
3 During coffee break: show open voltage from panel in sun.
4 Explanation on cost comparison and other tools (fault fining, placemat, etc)
5 Practical: Assemble a solar system. All attendees should know how to connect a basic system.
6 Practical: Fault finding in a solar system. All attendees should also know how to do this.
7 Practical: Assemble a demo board. Questions attendees
The basic approach here is a training, as skills have to be transferred to technicians that are already knowledgeable in
electrical systems. A very practical hands-on approach is followed. Yet, it is likely that follow-up coaching visits will greatly
enhance proper internalization of the design and installation skills. Also a technical hot-line by cell phone, e-mail or text
messaging may be considered to allow the trained technicians to resolve technical questions in practice.
5. How
Step 1. Preparation. Call the retailers a week before, visit them and the technicians that they works with to get to
know each other, pass the invitation and get more information on common training needs. Find a suitable
venue and arrange for the seminar.
Step 2. Theory. A basic solar training consists of general and technical aspects of solar energy. Depending on the
type of students the training should be adapted to meet the interests of the listeners. Basically the following
aspects are to be mentioned:
What is photovoltaic solar energy? How does photovoltaic solar energy work? What are the basic
components of a solar system?
Solar panel: What is a solar panel? How does a solar panel work? What different types of solar panels
exist?
Quality of solar panels: How should you install a solar panel? How should you maintain a solar panel?
Guarantee and the expected lifetime of solar panels?
Specifications of solar panels

Charge controller: What is a charge controller? Why do you need a charge controller? How does a
charge controller work? How should you install a charge controller? What happens if you do not use a
charge controller?
Specifications of charge controllers
Battery: What is a battery and what do you need a battery for? What is the difference between car and
solar batteries? Different types of solar batteries? How should you install a battery? How should you
maintain a battery?
Appliances: What kind of appliances can you connect? Saving energy? Can you connect appliances that
work on AC?
Step 3. Calculations on systems. In order to be able to sell a functioning system, any salesman or technician should
be able to calculate system specifications. Larger systems with more panels are required if more appliances
are to be used. The basis steps in any system calculation are the same and mentioned below:
Calculate for each appliance the daily energy consumption (Watts * hours = Wh)
Summarize daily consumptions of all appliances to find the total consumption (Wh)
Calculate the daily energy generation by one panel (Watts * hours = Wh) Note that the number of hours
that a solar panel generates electricity is normally set to 5 for amorphous solar panels.
Divide the total daily energy consumption by the daily energy generation of one panel and find the
number of panels required.
Divide the total daily energy consumption by the system voltage, multiply with 3 and divide by the
maximum discharge rate of the battery (50% for lead acid and 75% for gel) to find the size of the
battery (Ah).
Multiply the number of panels with the maximum current from a panel to find the maximum current for the
charge controller (A).
Step 4. Practical training: Installing a basic system. Any retailer and technician should be able to build a basic
system consisting of a small solar panel [12 to 20 Watts], a small charge controller, a small battery [20 to 40
Amp-hours], a light [4 to 6 Watts] and a phone charger. This step is repeated twice: first [in groups] to get at
grips with the installation, and later [after the fault finding session and individually] to assemble a
demonstration kit.
Step 5. Practical training: Measuring open voltage and short circuit current of a panel. To demonstrate that the
energy output of a solar panel depends on the amount of sunlight on it, the panel can be taken outside to
measure the open voltage (Vopen) and the short circuit current (ISSC). This experiment demonstrates very clearly
that the energy output decreases when the solar panel is turned away from the sun or if the sunlight is being
blocked by any object. It induces trainees to install panels properly in the right direction and with the right
angle.

Step 6. Practical training: Fault Finding. All technicians should be able to find the faults in a basic system with the use
of some basic tools like a screwdriver and a voltmeter. The purpose of this training is to teach people how to
solve the most simple faults. Faults which can be introduced are:
Switch off the main switch of the charge controller;
Remove the fuse in the battery cable;
Reverse the battery connection (interchange +/-);
Disconnect a wire inside the light;
Wrap plastic around one of the wires and reconnect it;
Use an empty battery;
Use a broken light;
The best way to start any fault finding procedure is to look at the status of the charge controller. Lights
indicate whether the battery is being charged and whether the battery is full or empty. In annex 8 a
schematic fault finding procedure is given which uses the indication lights on the charge controller.
Step 7. Practical training: Assembling a demonstration kit. This is the summit of the training all retailers should have
their own demonstration kit, mounted into a wooden suitcase or a triangular box. This way the trainees prove
that thy have mastered the installation skills correctly, or, alternatively, if the demo systems does not work,
how to find the fault and correct it. Naturally, this enhances also the possibilities of the retailers to start off
with their promotion and marketing practice. As the panels and batteries in a demo kit are normally smaller
than those in a regular solar home system they will also be requested to recalculate the number of hours that
the appliances can be used, thus re-practicing their design skills.

Step 8. Follow-up. All attendees receive a full handout (annex 2) and the most important sheets (Designing
worksheet; System sizing placemat ; Sunhour sheet ; Installation sheet ; Wire thickness sheets ; Fault finding
sheets; Maintenance checklist see annexes 3 to 9). This way they will be able to go over the contends again
if needed. Yet also, with each one follow-up action plan is agreed on including: practical coaching visit
during or after installation, a technical hotline (over the phone or by text messaging or e-mail) and, possibly
follow-up training.
The training is supported with a generic presentation see annex 1.
6. Which (tools)
The following things should be taken to give a proper basic technical training or on the design and installation of small
solar home systems:
x This training guide and the background document (annex 2)
x The presentation (annex 1)
x Enough copies of the hand-outs: Designing worksheet; System sizing placemat ; Sunhour sheet ; Installation sheet ; Wire
thickness sheets ; Fault finding sheets; Maintenance checklist see annexes 3 to 9
x Signed certificates of attendance (as many of the attendees wish to put these in their shops, as a proof that they
attended a solar training and are qualified)
x Demonstration kits
x Loose panels, batteries, controllers and DC appliances, of different makes, in large enough quantity to have all
participants assemble full systems in sets of two or three.
x Handyman tools: screwdrivers (small flat and star type), combination pliers, knife, hammer, voltmeter (preferably with
ampere measuring option).
x Mounting frames.
x All participants should come with a panel, a small charge controller, a small battery, a light or a phone charger and a
wooden demonstration kit suitcase or box, so as to assemble their own suitcase.

Technical training - basic - presentation 30-06-2008
Aim : Provide insight in installing small

solar systems (<20 W) and
understanding its principles
Time : one day practical and one day
Content presentation
Introduction
theory
Brainstorm
Theory
Tools
Projects
Closure
1. Theory
Background on energy theories
Calculation and sizing
Q lit
Quality
2. Tools
3. Practical:
Installation of the demonstration suitcase
How to do installations
What to bring!
Tools needed
Introduction
Brainstorm
Theory
Tools
Projects
Closure
1
Energy : ability to do work (in Joules, J

or Watt hour)
Kilo joule = 1000 joule
Mega joule = 1,000,000
1 000 000 joule
Watt hour used for electricity

One watt hour = constant one watt
supply over 1 hour
Power : the rate at which energy is

supplied (energy per unit time)
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Irradiance 1350 W / m 2 Midday
At earth : 1000 W / m2
2
Panel angle important 1000 W / m
Panel efficiency depends important!

on:
Angle
If all energy is
2

taken per m
Solar panel type
Angle
1000 W
Atmosphere Power for
PC computer
Age of solar panel
Irradiance = Sunhours
Introduction
Brainstorm
Theory
Sunhours depend on REGION!!! (tool
Tools
Projects
Closure
sunhours)
2
Production
W=V*A AC versus DC
Panel = Wp installed
W * h = production DC system, standard 12 V (next page)
H = sunhours (depend on region)
Storage
Battery: Measured in Ah
Consumption Control W*h = V * A * h
Inverter = Total appliances = W Controller = A Wh/V = Ah (divide
W/V = A production panel by 12 V) =
Appliances = W * h
battery size
Current (I in Amp) Rate of flow of Potential difference Difference energy
electrons through (volts, V) between ends of
circuit conductor
Direct current DC Does not change Resistance (Ohm, R) Property conductor
direction with time opposing the flow of
current, creating heat
Alternating current
Introduction Changes regularly with Electric Power (Watt, Rate energy supply
Brainstorm
AC Theory time, switch back P, W)
Tools
Projects
Closure
Solar panel:
Short circuit current (Isc) I-V curve

3,5
Peak Power (Wp) 3
2,5
Curren
Current (A)
Open circuit voltage (Voc) 2

Current (A) irradiance low)
1,5
1 Current (A) high temperature
0,5
Changes with: 0
0 5 10 15 20 25
Volt
Irradiance
Temperature!!!
Technology Crystalline - Crystalline - Multi-junction Amorphous
mono Poly
Efficiency 11-16 % 9-13 % 6% 3-6 %
Light barrier Direct light Direct light Indirect light Indirect light
Technology
Introduction Silicon cells, one Silicon cells, Gasification of Gasification of
Brainstorm
Theory
piece different silicon silicon
Tools
Projects
Closure
3
Battery is used for energy storage

Keep in mind:
Good batteries are expensive, but worth it
Batteries g
get old, and wear out
Keep them clean and protected
Batteries can be dangerous if misused!
Storage capacity: in Ah (is maximum)
Depth of discharge : how much can be
used of maximum
Batteries need to be kept full most times!
Batteries have life cycles : they diminish
with bad use!
Introduction
Brainstorm
Theory
Tools
Chemical reaction lead acid battery :
Projects
Closure
Pb + PbO2 + 2 H2SO4-> a PbSO4 + 2 H2O
Battery types:
SLI automotive batteries
Modified / portable automotive batteries
C ti electrolyte
Captive l t l t GEL cells ll
Lead calcium maintenance free batteries
Motive/ traction batteries
Stand by batteries
PV flooded deep cycle batteries
Introduction
Brainstorm
Theory
Tools
Projects
Closure
4
Series and parallel

Batteries
Panels
Why series or parallel?
How series or parallel?
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Charge controller is used for protection

of panel and battery
Maximum Ampere needs to be larger
th maximum
than i currentt iin system!
t !
Indicated panel working and battery
levels
Without controllers, the management of

LOAD needs to be very good
Introduction
Brainstorm
Theory
Tools
Projects
Closure
5
Appliances and the DC-DC converter
Mind that 220-240 V AC appliances can

not be connected to a 12 V DC system!!!
Lights produce heat and light. Make use

of energy saving lights.
A Voltage Converter, can run small

radios with lower than 12 V requirements
Introduction
Brainstorm
Theory
Tools
Projects
Closure
PRACTICAL
-Calculus
-Quality
Q li
-Workshops
Introduction
Brainstorm
Theory
Tools
Projects
Closure
6
The next sheets will give some

calculation exercises for the attendant to
practise
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Daily Consumption:
Basic:
Multiply the wattage of every appliance by the hours of daily use, and add those up.
Measured in Watt Hours.
Advanced:
Taking into account average use, relief weekends, and personal load shedding.
Daily Production:
Basic:
Multiply the Daily Consumption by 1.5 to compensate for loss and produce reserve capacity to the
battery.
Advanced:
Determine the required level of extra charge. Based on average use, spikes in use, the weather
patterns, finances, internal load shedding options, and most important customer wishes.
Example: A customer who wants high security, where we would add 100% or more.
Example: A customer who wants no added charge, where we would only add 10% to compensate for
loss.
Panel size:
Basic:
Divide the Daily Production by that countrys related sun hours.
Divide then by y the p
panel size, and round up.
p
Measured in Watts.
Advanced:
Understand what sun hours are, where the number comes from. How to interpret it. I believe it to be
important to know all numbers used in a sizing so it can be applied to different situations.
(like different regions and countries)
Calculate different options. Different configurations of panels can yield the same result at different
prices. Price should not always be the determining factor, but does count heavily. Take into
Introduction
account that mounting multiple panels costs extra to.
Brainstorm Take in to account the decisions for Daily Production when looking at rounding up or down.
Theory
Tools
Let weather conditions weigh on the decision between amorphous and crystalline panels.
Projects
Closure
7
Battery size:
Basic:
Multiply the Daily Consumption by 3. (for 2 rainy days)
Multiply by 1 1/3 (1.33) to compensate for taking only 75%.
Divide by 12 volts to get the rating in Amp Hours.
Advanced:
Determine the required amount of reserve capacity with the customer. Take into account all other
sizing (this could include sizing from a production point of view instead of a consumption
sizing.
point of view)
Example: A smaller size might be accepted if working with a generator as backup.
Example: A larger size might be required when off time can not be accepted even in the worst of
conditions.
Understanding the calculation of 75% based on deep cycle batteries discharged to 75% DOD. Ability
to modify for different types of batteries.
Financial and practical considerations are important in deciding in what form to supply the capacity.
(2 volt tabular, 12 volt deep cycle, 24 volt, gel, )
Charge controller size:
Basic:
Divide the total panel wattage by 12.
Measured in Amps.
Advanced:
Divide the total panel wattage by the systems running voltage. Usually no less the 12.7 (float
charge)
charge).
Add up all appliance wattages, and divide by 12 volt. This ensures that turning on all appliances at
the same time is not dangerous.
Cable size:
Basic:
Know the length, calculate the current, look up the thickness.
Measured in mm2.
Advanced:
Introduction Understand why thickness is important, how it influences the system.
Brainstorm Understand that thickness is related to the material, and our sheet is for copper wire.
Theory
Tools Possibly teach the formula, but I would not recommend that.
Projects
Closure
Calculus 1 : Get the amount of sunhours

for your country region
Calculus 2 : From load to amount of
panels
Calculus 3 : Calculate the amount of
output of several arrays of panels
Calculus 4 : At a certain output and load
requirement, what size battery is needed
Calculus 5 : Calculate the size of the
charge
g controller at certain currents
Calculus 6 : Calculate from different
load requirements a whole system
Calculus 7 : Get the correct wire
Introduction
Brainstorm
Theory
thickness at a particular installation
Tools
Projects
Closure
8
Check the sunhour sheet.

Where is your region?
What is the irradiance?
How do we make sunhours from that?
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Question 1, how much installed panels? :

Customers wants 2 x 11 W light for 4
hours.
Customers want 1 tv of 80 W for 6 hours.
Customer want radio of 20 W for 6 hours,
and 6 lights 5 W for 4 hours.
Customer wants ironing, 1000 W for 2
hours.
Customer wants a fridge, 30 W for 24
hours.
Introduction
Brainstorm
Theory
Tools
Projects
Closure
9
What is the output of?

1 x 12 W panel, in 6 sunhour region
1 x 85 W panel, in 5,5 sunhour region
Introduction
Brainstorm
Theory
Tools
Projects
Closure
What size of battery is needed?

Output panels 60 Wh per day, storage
days 2, load demand 50 Wh per day
Introduction
Brainstorm
Theory
Tools
Projects
Closure
10
What charge controller is needed if?
Installed Watt Peak of Panel Array = 300

Wp
Installed Watt peak of Panel Array = 20
Wp
Installed Watt peak of Panel Array = 3 x
20 Wp
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Question: A family wants 4 12 W lights, for 4 hours a day, a small radio (20 W)
for 2 hours and charge a mobile phone very day. What system?
How:
1. Calculate for each appliance the daily energy consumption (Watts * hours =
Wh)
2. Summarize daily consumptions of all appliances to find the total
consumption (Wh)
3. Calculate the daily energy generation by one panel (Watts * hours = Wh)
Note that the number of hours that a solar panel generates electricity is
normally set to 5 for amorphous solar panels.
4. Divide the total daily energy consumption by the daily energy generation of
one panel and find the number of panels required.
5. Divide the total daily energy consumption by the system voltage, multiply
with 3 to deal with 3 cloudy days (3 days of storage!!!) and divide by the
maximum discharge rate of the battery (50% for lead acid and 75% for gel)
to find the size of the battery (Ah).
6. Multiply the number of panels with the maximum current from a panel to find
the maximum current for the charge controller (A).
Introduction
Brainstorm
Theory
Tools
Solution:
Projects
Closure
11
Use the wire thickness sheet.

Question 1, how thick need the wires to
be?:
For system of 50 Wp panels, panel 6
meter away, one light 8 meter away, one
light from controller 12 meter away.
Question 2, how thick need the wires to

be?:
For system of 12 Wp panel, panel 12
Introduction
meter away, controller to battery 8 meter,
Brainstorm
Theory
Tools
Projects
controller to farthest light is 20 meter.
Closure
Solar panel amorphous :

Check if the sealing is good, water/air inside
Check the weight of the panel, good Q is glass
Solar panel crystalline :
Check for certificates
Controller :
Check if the connections are good, voltmeter
Battery :
Check if sealed correctly
y and Voltage
g is ok
(above 12.5V)
Inverter :
Low quality will consume a large amount of
Introduction
Brainstorm
Theory
power
Tools
Projects
Closure
12
Workshop 1 : discussion round - What do we require to install a basic

solar system?
Workshop 2 : Install the demo kit. Example of basic system.
Workshop 3 : Measuring open voltage &short circuit current

Take outside to measure the open voltage (Vopen) and the short
circuit current (ISSC) when the panel is pointing directly to
the sun.
Point it away from the sun or put it in the shade, measure the
open voltage and short circuit current.
What do you observe?
Workshop 4 : Measure strength of battery with voltmeter
Workshop 5 : Fault finding

How dod you find
f d faults?
f l ?
At each stage try to measure the voltage or current.
This simplifies the fault finding since it excludes many
components.
Introduction Workshop 6 : What to do after installation?
Brainstorm
Theory
Tools
Projects
Closure
Put all component ready for the

demonstration suitcase
Tool: the installation checklist
First write it down on paper!
Also write down what is needed for AC

system
Introduction
Brainstorm
Theory
Tools
Projects
Closure
13
Add to system: Bring:

Battery BOX, Hammer
station for charge Screwdrivers
controller and Voltmeter
switch Wires
Frame for panel Switches
Sockets
Bulb holders
Cable clips
Nails
Screws
Connection
strip
Introduction
Battery clips
Brainstorm
Theory
Tools
DC sockets
Projects
Closure
What do we require more for an AC

installation?
Inverter
L
Longer wires
i
Insight in LOAD and amount of hours
Larger charge controller
More panels and batteries (likely)
Introduction
Brainstorm
Theory
Tools
Projects
Closure
14
Install the demonstration suitcase
What are elements to keep in mind:

Have all tools ready
Do not SHORTCIRCUIT
Have all small screws and nails ready
Carry spare parts
The polarity in the bulb is correct
The switches are connect
Measure with voltmeter all steps!
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Connect the battery to the controller

1. Polarity: plus on plus, min on min (+ to +, - to -)***
2. Short-circuit: protect the battery by a box (In cool
place (shade), use a fuse for protection)
Connect the panel to the controller
3 Cooling: Space between panel and roof (10 cm)
3.
Controller: Mount it free from ground (inside house), install where
it can be seen, connect wires to the battery, loads and panels.
4. Efficiency: Angle facing equator and sun (A solar
panel generates more electricity when it receives more sunlight.
Install for high receive of light.
Usually this is done by fixing a panel on the roof free of shade
and pointing it at the sun at noon. )
5. No shade on the solar panel
Connect the appliances to the controller + general installation
6. Installation: Easy access, firm and neat presentation
7. Cable protection: from rain , sun and damage
8. Wire thickness: : depends on current and distance
Introduction
Brainstorm
Theory
Tools
Projects
Closure
15
Open voltage
Short circuit current
Introduction
Brainstorm
Theory
Tools
Projects
Closure
Voltage
Introduction
Brainstorm
Theory
Tools
Projects
Closure
16
The suitcase has been installed

The trainer will change something
The trainees will have to check what is

wrong, using the controller and the volt
meter
Introduction
Brainstorm
Theory
Tools
Projects
Closure
AFTER INSTALLATION (USE MAINTENANCE

CHECKLIST):
ROLEPLAY: trainer is customer, trainee is solar dealer
Use appliances the TIME the solar technician told you!
Make the GREEN light on controller burn everyday!!!
1. Clean: if there is dust on the panel, less sunlight, less

power
2. Keep your battery clean and refill if necessary (not
sealed)
p
3. Depending g on the quality
q y used,, y
your battery,
y, controller
and light bulbs have to be replaced
Introduction
Brainstorm
Theory
Tools
Projects
Closure
17
What did we learn?
Theory of energy
How to do an installation of a small

solar system
What to bring during the installation
Introduction
Brainstorm
Theory
Tools
Projects
Closure
1. What is solar?
2. What components do you need to install a
basic solar system?
3. What do I do in order to have a TV work on
the solar system?
s stem?
4. What are the types of solar panels?
5. What is the use of the charge controller?
6. Compare the deep cycle and acid solar
batteries?
7. Why are batteries connected in parallel
when solar panels are connected in
parallel?
8. On my charge controller, the solar panel
indicator is off, what do you think might be
problem?
Introduction
Brainstorm
9. Why do we do system sizing?
Theory
Tools
Projects
10. What is the use of the demonstration kit?
Closure
18
The Basics about Solar Energy and the Design
and Installation of Small Solar Systems
Background document
Free Energy Foundation

April 2008
Table of contents
Photovoltaic solar energy ........................................................................................................................................... 2
What is photovoltaic solar energy? ...................................................................................................................... 2
How does photovoltaic solar energy work? ........................................................................................................ 2
What are the basic components of a solar system? .......................................................................................... 3
Solar panel .................................................................................................................................................................... 3
What is a solar panel?............................................................................................................................................ 3
How does a solar panel work? .............................................................................................................................. 4
What different types of solar panels exist? ....................................................................................................... 4
Quality of solar panels ........................................................................................................................................... 5
How should you install a solar panel? .................................................................................................................. 5
How should you maintain a solar panel? ............................................................................................................. 6
Guarantee and expected lifetime of a solar panel .......................................................................................... 6
Specifications of solar panels ................................................................................................................................ 6
Charge controller.......................................................................................................................................................... 7
What is a charge controller? ................................................................................................................................. 7
How does a charge controller work? .................................................................................................................... 8
How should you install a charge controller? ........................................................................................................ 8
Specifications of charge controllers ...................................................................................................................... 9
Battery ............................................................................................................................................................................ 9
How should you install a battery? ....................................................................................................................... 11
How should you maintain a battery? .................................................................................................................. 11
Specifications of batteries .................................................................................................................................... 11
Appliances ................................................................................................................................................................... 12
Photovoltaic solar energy
What is photovoltaic solar energy?
Photovoltaic solar energy is the conversion of energy that comes from the sun (light) into
electricity which can be used to power up appliances in the house. Good examples of
appliances which can be powered with solar energy are:
o Lights
o Telephone charger
o Radio
o Television
Especially low energy consuming appliances are suitable to be powered with solar
energy. By having solar energy a customer:
o Does not need a generator anymore for low energy usage;

o Does not need kerosene lights anymore;
o Has the luxury of electricity when and where grid electricity fails.
o During the day the electricity output of a solar panel varies because of the
changing irradiation from the sun. This can be demonstrated with the following
graph.
How does photovoltaic solar energy work?

Energy which comes from the sun as light is transformed into electricity when it touches a
solar panel. This electricity is then going through a wire to a battery where it can be
used for later use. The more light a solar panel receives, the more electricity comes out
of it. A solar panel only generates electricity during daylight and not at night. Since it
makes little sense to only have lights running during daytime, a battery is required to
store the electricity for use at night.
2
Analogy with water storage
Drinking water (electricity) can be harvested by collecting water from the roof (solar
panel). The water is conducted through pipes (wires) to a drum (battery) where it can
be stored for later use. All components are necessary. It makes no sense collecting
water (electricity) if there is no drum (battery) since then it can only be used during the
rain (sunshine).
What are the basic components of a solar system?

A photovoltaic solar system consists of the following components which are all necessary
in any basic system: solar panel, charge controller, battery, appliances. These
components will be discussed in the following sections.
Solar panel
What is a solar panel?

The solar panel is the device which transforms light from the sun into electricity. A
physical process is used to do this. The more light a solar panel receives, the more
electricity is produces. Furthermore, the more solar panels are connected, the higher the
electricity supply will be.
A solar panel is like a roof to collect water. You need the roof to collect water. The
bigger the roof the more water you will collect. Therefore the bigger the solar panel,
the more electricity you will collect.
3
How does a solar panel work?
A physical process is used to convert the sunlight into electricity. Depending on the type
of the solar panel it is sensitive to specific frequencies in the solar spectrum.
Constructionofaphotovoltaiccell
Raysofsunlight
Current
collectors
Silicon/arsenic
layer
Electricalcurrent Silicon/boron
layer
What different types of solar panels exist?

There are many different types of solar panels. The two most important types are
(mono and poly) crystalline silicon panels and amorphous silicon panels. They have some
very important differences:
Amorphous Silicon Crystalline Silicon

Colour Brown / black Blue
Efficiency Low (5% practical) High (15% practical)
Price / kWh Low (100%) High (150%)
Energy output per m2 Low (+/- 40 W/m2) High (+/- 120 W/m2)
Works on indirect sunlight (when cloudy) Yes No
Because of the different specifications the different panels need to be used in different
circumstances. Crystalline silicon panels are to be used when space is scarce and costs
are of less importance. Amorphous silicon panels are to be used when space is less
4
important than costs. This makes amorphous silicon panels very suitable for use in
African rural areas.
Quality of solar panels

Many different manufacturers produce solar panels. Many of them produce panels
which have a low quality. Only very few create panels with high quality standards. The
physical process of changing sunlight into electricity is a process done by complex
chemical layers inside the panel. These chemicals are very sensitive to oxygen and
should therefore be protected against air. The glass blocks oxygen but in poor quality
solar cells, this oxygen can still enter from the edges. Therefore it is important that the
edges have an airtight sealing. In high quality panels this is usually made of plastic
which is firmly attached to the glass. At the current state of technology, high quality
panels should last for approximately 20 years. Unfortunately, sometimes it is very hard
to measure the quality of the panel at the beginning of its lifetime.
EnergyOutput[Watts]
Life time[Years]
A customer should always be advised to buy a high quality panel to avoid complaints
about non working systems later on.
How should you install a solar panel?

x Position and Angle
As stated before a solar panel generates more electricity when it receives more
sunlight. Therefore it should always be installed in that way that during the day (or
during the year) it receives as much sunlight as possible. Usually this is done by fixing a
panel on the roof free of shade and pointing it at the sun at noon. In some specific
5
cases a tracking system can be designed. A tracking system is a manual or automatic
system which points the solar panel to the sun to increase the yield. For most southern
hemisphere locations, the solar panel should be mounted on a roof pointing to the north
and on an angle to the horizontal of 5 to 15 degrees (to the location of the sun at
noon).
x Cooling
Furthermore it is important to leave space between the panel and the roof. A panel
works better when it is being cooled properly. If there is space between the roof and
the panel, air, working as a cooling agent can flow around it.
How should you maintain a solar panel?

Solar panels require little maintenance. To increase the amount of light to be received it
is important that a solar panel is clean. The front side should therefore be cleaned with
cloth and normal water. Do not use chemicals! Furthermore it is important to check
regularly that trees have not been growing in front of the panel, creating a shade.
Guarantee and expected lifetime of a solar panel

High quality panels have an expected lifetime of approximately 20 years.
Manufacturers of high quality panels usually give a 10 years guarantee on the panels.
Note that the guarantee is only valid if and only if the panel is physically intact and if
the serial number has been recorded by the salesman.
Specifications of solar panels

Solar panels have many specifications. The most important values are:
x Peak power (Wp)
The peak power is the maximum power that a solar panel can give when it is being
operated in full sunlight. The higher the peak power, the higher the energy output of
the panel will be.
x Open voltage (Vopen)
The open voltage is the voltage which is measured when the panel is not connected to
anything but a voltmeter and pointed to the sun. The open voltage can be used to
6
determine whether is panel is positioned in the right way. The higher the open voltage,
the higher the energy output of the panel will be.
x Short circuit current (Issc)
The short circuit is the current which is measured when the panel is not connected to
anything but a current meter to measure the short circuit current. The higher the short
circuit current, the higher the energy output of the panel will be.
Charge controller
What is a charge controller?

A charge controller is the heart and the brains of a solar system. It controls the power
output of the panel and the power flowing to the appliances. Furthermore it gives
information (with indication lights) to the customer about the current state of the solar
system.
x Why do you need a charge controller?
A charge controller is a device which a customer should connect in a solar system. It has
several functions:
o Prevention against overcharging the battery and thus increasing the lifetime of
the battery;
o Prevention against deep discharging the battery and thus increasing the lifetime
of the battery;
o Optimising the solar panel output;
o Giving information to the user about the current state of the solar system.
o Prevention against overcharging the battery
If a battery is overcharged, the lifetime of the battery decreases dramatically.
Therefore the charging should stop when the battery is full. The charge controller
measures the voltage of the battery and with it the charging state. If the voltage level
is high enough it stops charging.

If you collect water (electricity) on your roof (panel) and store it in a drum (battery),
you should stop filling (charging) the drum (battery) when it is full. Otherwise the drum
7
(battery) will be flooded (overcharged) and it can burst. Valves (charge controller) are
to be used to stop the filling (charging).
x Prevention against deep discharging the battery
If a battery is discharged too deep, its lifetime decreases dramatically. Therefore the
discharging should stop when the battery is low. The charge controller measures the
voltage of the battery and with it the charging state. If the voltage level is too low, it
stops discharging by switching of the appliances. Sometimes this can be annoying but it
is a necessity to prevent the battery from being damaged.
x Optimising the solar panel output
A solar panel gives the most electricity when it is operated at a specific output voltage.
The charge controller can control the output voltage of the panel and with it the power
output of the panel. A solar panel will give more electricity when it is being operated
together with a charge controller.
x Giving information to the user about the current state of the solar system
A charge controller gives information to the user with indication lights. In this way the
user can determine whether the battery is full or empty and whether the solar panels
are charging the battery. By having the indication lights, the charge controller is a
perfect point to start when finding the fault in a malfunctioning system.
How does a charge controller work?

A charge controller measures the voltages of the panel and the battery and operates
electrical switches based on these voltages.
How should you install a charge controller?

The charge controller should be mounted free from the ground on a dry place.
Therefore it is usually placed inside a house. Furthermore it should be mounted in such a
position that the user can see the indication lights easily. After mounting it, the wires to
the panel, to the battery and to the appliances can be connected.
x What happens if you do not use a charge controller?
Some customers prefer not to use a charge controller in their solar system because of
the expenses. This however should always be discouraged since operating a system like
8
this is decreasing the power output and the lifetime of the battery.
Specifications of charge controllers

Charge controllers have a number of specifications. The most important values are:
x Operating voltage (V)
This is the voltage at which the charge controller is to be operated.
x Maximum current (A)
The maximum current a charge controller can handle should not be exceeded to
prevent the charge controller from getting damaged. When more panels are
connected, more current will be generated and a charge controller which can handle a
larger current should be selected.
The pictures above show the inside of a charge controller. The big blocking diode that
stops reverse current at night can be seen in the right figure.
Battery
x What is a battery and what do you need it for?
A battery is a device to chemically store electrical energy (only Direct Current DC) for
later use. In solar energy, electricity is generated during the day when there is sunlight.
However, the electricity is often to be used during the night for example for lighting.
Therefore the electricity should be stored for some time. The usual way to do this is by
using a battery.
9
When water (electricity) is collected on the roof (solar panel) during the rainy days
(daytime), it should be stored for later use. Therefore the water (electricity) is to be
pumped in a drum (battery).
x What is the difference between car and solar batteries?
A battery works with a chemical process. In car appliances a battery is used to start an
engine. This is done by drawing a lot of current for only a couple of seconds at the
time. In solar systems however, electricity is to be withdrawn during a number of hours
when the appliances are switched on. Therefore the whole design of a battery for use
in solar systems differs from car batteries. The main difference is that solar batteries
have thicker lead plates inside to withstand the longer time that current is to be
withdrawn.
If car batteries are used in solar systems, they are used for applications where they
never designed for. It will work for some time but already after some months the
batteries will break down and another investment for new batteries is required.
Analogy with cars
A car battery is not the identical to a solar battery. Compare this with cars. A tractor is
a car and a sports car is a car. Both are cars but it is not good to drive with your
tractor on the highway or with your sports car in the mud. Both have a power which is
indicated in horsepower but still they are different and you should not interchange. For
batteries this is similar. Car batteries and solar batteries both have the same voltage
and a value in Ah. Still they should never be interchanged.
x Different types of solar batteries
Different types of solar batteries exist. All solar batteries have thick lead plates and
are specifically designed for solar systems. Lead acid batteries are the most common
but they require maintenance. Gel batteries in contrast are maintenance free, have a
higher discharge rate but they are more expensive.
Normal lead acid Deep cycle

Availability High Low
Maintenance Yes No
Discharge rate 50% 75%
Price Low High
10
It depends on the system specifications whether to select a lead acid battery or a
maintenance-free deep cycle gel battery.
How should you install a battery?

A battery should be installed on a relatively cool and dry place. The lifetime of a
battery decreases when it is operated in a hot environment. Therefore it should be
located in the shade. It is very important that a battery is never short circuited (never
directly connect + and - !!!) and that it is being operated with a fuse that protects is
from short circuit. Furthermore it is strongly advised to use a battery in combination with
a charge controller to prevent it from being overcharged or deep discharging.
Furthermore it is advisable to put a battery in a box to prevent people from putting

objects on top of the battery which sometimes can create a short circuit. The clamps
should be connected to the poles with Vaseline in between. Never use ordinary grease
since this will increase the resistance in the system and therefore introduce losses of
energy.
How should you maintain a battery?

Most of the batteries require maintenance. Inside a battery is a fluid. The level of this
fluid is very important for the functionality of a battery. Therefore the fluid levels
should be checked regularly and the battery should be filled if necessary. Only use
distilled water to do this. Never use acid or regular water since this damages the
chemical materials inside the battery. Furthermore it is important to keep a battery
clean to prevent discharging current running over the top of a battery.
Specifications of batteries
Charge controllers have a number of specifications. The most important values are:
x Operating voltage (V)
This is the normal operating voltage of the battery. For most batteries this is 12 volt.
x Energy content (Ah)
Any battery has a specific energy content which is given in Ampere hours. This can be
easily translated into the normal quantity for electrical energy (Wh) by multiplying it by
the operating voltage. Wh = V * Ah.
11
Imagine that a customer wants to use more water (electricity). He will need a bigger
roof (solar panel) to collect it but he will also need a bigger drum (battery) to store it.
Without this bigger drum (battery), collecting more water with a bigger roof (solar
panel) makes no sense.
Appliances
x What kind of appliances can you connect?
Solar systems are very suitable for low energy consuming appliances. This makes it very
suitable to power some lights, a phone charger or a radio. A solar system works on
12V DC (direct current) and this is also what comes out of the system. Therefore the
appliances should also be working on 12V DC.
x Saving energy
Solar energy is very useful to create light at night or to power up a radio for luxury for
multiple hours. However, the energy output of a solar system depends on the number of
panels and therefore on the amount of money invested. If a customer consumes too much
energy, he will empty his battery and the charge controller will switch off the
appliances. Therefore it is important to save energy whenever possible. In this way the
investment can be limited. Saving energy can be done by reducing the number of hours
that an appliance is switched on and by using energy saving appliances.
x Can you connect appliances that work on AC?
Solar systems generate 12 volt DC (direct current) electricity. Some appliances however
require 240 V AC (alternating current) electricity. Some examples are televisions and
computers. It is possible to transform 12 V DC into 240 V AC by using an inverter.
Unfortunately an inverter uses energy to do this transformation. Depending on the
quality of the inverter the power required to transform DC to AC can go up to as much
as 50% of the actual energy use. In other words: by using inverters a lot of electricity is
being thrown away. Therefore any customer should always be advised not to use
inverters if not really necessary. Many appliances are also available for 12V DC.
12
Aim : for the dealer and technician to be able to design any solar system based on load requirement
Worksheet designing a solar system

1. Requierement (DC/AC) 2. Modules 3. Battery & controller 4. Designing
FREE ENERGY EUROPE RG03
Input = output. Only what goes in, can Drawing for map of designed system:
come out. The requirement determines / = / =
the size of any solar system. Wh h Wp V A A
Number of items x Watt x hours use = Irradiance Wp of solar The current in A that the charge controller
Total in Wh (or Solar Units) (sunhours) array should be able to handle is at least the
Load/Item Watt Hours Total output of the solar array in A.
-> Tracking
(add 20-50%
sunhours)
100% +
(100% - DoD)
/ x x
Wh V Days %
Dept of
Number of Discharge
storage days =
= Select enough solar panels Ah

W W Wh to reach the indicated target.
+ Reach the required battery capacity
Any type of panel will do.
Loss/reserve: New install (15%)x If panels are connected in an by adding batteries in series or
longwire(20%); old install(25%) Wh array, they should be of same parallel. Use series if 12 V is to be
type and size. reached.
Total Wh required to be
produced by the system
Wh
IMPORTANT: IMPORTANT: IMPORTANT:

Use a DC to DC converter Make a frame for the panel Make a battery (& controller) Meters of wire: use wire thickness sheet
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Item/brand # Specs Costs

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Reminder (for DC) : Reminder : Reminder : Reminder :
DC converter Frame Box station Battery clips
DC to DC phone charger Cable clips
DC/AC socket(s)
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1 0,1 0,1 0,2 0,2 0,3 0,6 0,8 1,1 1,4 1,7 2,0 2,2 2,5 2,8 3,1 3,3 4,5 5,6
2 0,1 0,2 0,3 0,4 0,6 1,1 1,7 2,2 2,8 3,3 3,9 4,5 5,0 5,6 6,1 6,7 8,9 11,2
3 0,2 0,3 0,5 0,7 0,8 1,7 2,5 3,3 4,2 5,0 5,9 6,7 7,5 8,4 9,2 10,0 13,4 16,7
4 0,2 0,4 0,7 0,9 1,1 2,2 3,3 4,5 5,6 6,7 7,8 8,9 10,0 11,2 12,3 13,4 17,8 22,3
5 0,3 0,6 0,8 1,1 1,4 2,8 4,2 5,6 7,0 8,4 9,8 11,2 12,5 13,9 15,3 16,7 22,3 27,9
6 0,3 0,7 1,0 1,3 1,7 3,3 5,0 6,7 8,4 10,0 11,7 13,4 15,1 16,7 18,4 20,1 26,8 33,5
7 0,4 0,8 1,2 1,6 2,0 3,9 5,9 7,8 9,8 11,7 13,7 15,6 17,6 19,5 21,5 23,4 31,2 39,0
8 0,4 0,9 1,3 1,8 2,2 4,5 6,7 8,9 11,2 13,4 15,6 17,8 20,1 22,3 24,5 26,8 35,7 44,6
9 0,5 1,0 1,5 2,0 2,5 5,0 7,5 10,0 12,5 15,1 17,6 20,1 22,6 25,1 27,6 30,1 40,2 50,2
10 0,6 1,1 1,7 2,2 2,8 5,6 8,4 11,2 13,9 16,7 19,5 22,3 25,1 27,9 30,7 33,5 44,6 55,8
11 0,6 1,2 1,8 2,5 3,1 6,1 9,2 12,3 15,3 18,4 21,5 24,5 27,6 30,7 33,7 36,8 49,1 61,3
12 0,7 1,3 2,0 2,7 3,3 6,7 10,0 13,4 16,7 20,1 23,4 26,8 30,1 33,5 36,8 40,2 53,5 66,9
13 0,7 1,4 2,2 2,9 3,6 7,2 10,9 14,5 18,1 21,7 25,4 29,0 32, 6 36,2 39,9 43,5 58,0 72,5
14 0,8 1,6 2,3 3,1 3,9 7,8 11,7 15,6 19,5 23,4 27,3 31,2 35,1 39,0 42,9 46,8 62,5 78,1
15 0,8 1,7 2,5 3,3 4,2 8,4 12,5 16,7 20,9 25,1 29,3 33,5 37,6 41,8 46,0 50,2 66,9 83,7
16 0,9 1,8 2,7 3,6 4,5 8,9 13,4 17,8 22,3 26,8 31,2 35,7 40,2 44,6 49,1 53,5 71,4 89,2
17 0,9 1,9 2,8 3,8 4,7 9,5 14,2 19,0 23,7 28,4 33,2 37,9 42,7 47,4 52,1 56,9 75,8 94,8
18 1,0 2,0 3,0 4,0 5,0 10,0 15,1 20,1 25,1 30,1 35,1 40,2 45,2 50,2 55,2 60,2 80,3 100,4
19 1,1 2,1 3,2 4,2 5,3 10,6 15,9 21,2 26,5 31,8 37,1 42,4 47,7 53,0 58,3 63,6 84,8 106,0
20 1,1 2,2 3,3 4,5 5,6 11,2 16,7 22,3 27,9 33,5 39,0 44,6 50,2 55,8 61,3 66,9 89,2 111,5
25 1,4 2,8 4,2 5,6 7,0 13,9 20,9 27,9 34,9 41,8 48,8 55,8 62,7 69,7 76,7 83,7 111,5 139,4
30 1,7 3,3 5,0 6,7 8,4 16,7 25,1 33,5 41,8 50,2 58,6 66,9 75,3 83,7 92,0 100,4 133,8 167,3
35 2,0 3,9 5,9 7,8 9,8 19,5 29,3 39,0 48,8 58,6 68,3 78,1 87,8 97,6 107,4 117,1 156,1 195,2
40 2,2 4,5 6,7 8,9 11,2 22,3 33,5 44,6 55,8 66,9 78,1 89,2 100,4 111,5 122,7 133,8 178,5 223,1
Lenght [meter]
45 2,5 5,0 7,5 10,0 12,5 25, 1 37,6 50,2 62,7 75,3 87,8 100,4 112,9 125,5 138,0 150,6 200,8 251,0
50 2,8 5,6 8,4 11,2 13,9 27,9 41,8 55,8 69,7 83,7 97,6 111,5 125,5 139,4 153,4 167,3 223,1 278,8
55 3,1 6,1 9,2 12,3 15,3 30,7 46,0 61,3 76,7 92,0 107,4 122,7 138,0 153,4 168,7 184,0 245,4 306,7
60 3,3 6,7 10,0 13,4 16,7 33,5 50,2 66,9 83,7 100,4 117,1 133,8 150,6 167,3 184,0 200,8 267,7 334,6
65 3,6 7,2 10,9 14,5 18,1 36,2 54,4 72,5 90,6 108,7 126,9 145,0 163,1 181,2 199,4 217,5 290,0 362,5
70 3,9 7,8 11,7 15,6 19,5 39,0 58,6 78,1 97,6 117,1 136,6 156,1 175,7 195,2 214,7 234,2 312,3 390,4
75 4,2 8,4 12,5 16,7 20,9 41,8 62,7 83,7 104,6 125,5 146,4 167,3 188,2 209,1 230,0 251,0 334,6 418,3
80 4,5 8,9 13,4 17,8 22,3 44,6 66,9 89,2 111,5 133,8 156,1 178,5 200,8 223,1 245,4 267,7 356,9 446,1
85 4,7 9,5 14,2 19,0 23,7 47,4 71,1 94,8 118,5 142,2 165,9 189,6 213,3 237,0 260,7 284,4 379,2 474,0
90 5,0 10,0 15,1 20,1 25,1 50,2 75,3 100,4 125,5 150,6 175,7 200,8 225,9 251,0 276,0 301,1 401,5 501,9
95 5,3 10,6 15,9 21,2 26,5 53,0 79,5 106,0 132,4 158,9 185,4 211,9 238,4 264,9 291,4 317,9 423,8 529,8
100 5,6 11,2 16,7 22,3 27,9 55,8 83,7 111,5 139,4 167,3 195,2 223,1 251,0 278,8 306,7 334,6 446,1 557,7
0,75mm2 2,5mm2 6mm2 80mm2 >80mm2
Aim: For technician to check system if not operationable, use any controller with indicators
Fault Finding Sheet

SOLAR PANEL INDICATOR BATTERY INDICATOR PROBLEM MEASURE SOLUTION
ON?
OFF?
Check: system is in daylight?

SYSTEM NOT WORKING PROPERLY
'PSUIFFOEDVTUPNFS(VJEFMJOFTPOJOTUBMMBUJPOBOENBJOUFOBODF
DIFDLMJTU
$IFDL-JTUBGUFS*OTUBMMBUJPO Always first try the lights and other appliances to see if they operate!
+ #ONNECTTHEBATTERYTOTHECONTROLLER
10 - 15 0OLARITYPLUSONPLUSMINUSONMINUS
!VOIDSHORTCIRCUITINGPROTECTBATTERYINABOX
W
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#ONNECTTHEPANELTOTHECONTROLLER
#OOLING3PACEBETWEENPANELANDROOFCM
%FFICIENCY!NGLEFACINGEQUATORANDSUN
.OSHADEONTHESOLARPANEL
2EDBROWNPLUSLIFE
/&&
#ONNECTTHEAPPLIANCESTOTHECONTROLLER
/.
GENERALINSTALLATION
)NSTALLATION%ASYACCESSFIRMNEATPRESENTATION
#ABLEPROTECTIONFROMRAINSUNANDDAMAGE
7IRETHICKNESSLENGHTDEPENDSONCURRENT
"LACKBLUEMINNEUTRAL
DISTANCEMAKEDISTANCESSHORTIN$#
$IFDL-JTUGPS.BJOUFOBODF !LWAYSUSEACONTROLLER5SEAPPLIANCESTHE4)-%TOLD-AKETHE'2%%.LIGHTONCONTROLLERBURNEVERYDAY
"EEJOHPS#JHHFSCBUUFSZ "OJOWFFUFSDIBOHFT
"EEJOHQBOFMT HJWFTNPSFTUPSBHF GSPN%$UP"$ OPSNBM
NPSFQPXFS #65/05.03&108&3 QPXFS

Battery Shop
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#LEANIFTHEREISDUSTONTHEPANELLESSSUNLIGHTLESSPOWER
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+EEPYOURBATTERYCLEANANDREFILLIFNECESSARYNOTSEALED
/.
$EPENDINGONTHEQUALITYUSEDYOURBATTERYCONTROLLER

ANDLIGHTBULBSHAVETOBEREPLACED$URINGLONGPERIODSOFRAIN
BRINGTHEBATTERYTOACHARGINGSTATIONCAUSEITWILLLEAKPOWER
4URNOFAPPLIANCESWHENNOTINUSE

Documentos Basic Tech Solar Training Manual FEF 08 ENG 84e8a4fd

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Technical solar training manual

Basic design and installation training guide

Date: June 2008

Basic design and installation training guide Page 2

Basic design and installation training guide Page 3

Hour Theory and practical training - BASIC

Basic design and installation training guide Page 4

Basic design and installation training guide Page 5

The training is supported with a generic presentation see annex 1.

Basic design and installation training guide Page 6

Aim : Provide insight in installing small

Energy : ability to do work (in Joules, J

Watt hour used for electricity

Power : the rate at which energy is

Irradiance 1350 W / m 2 Midday

Panel efficiency depends important!

Open circuit voltage (Voc) 2

Efficiency 11-16 % 9-13 % 6% 3-6 %

Battery is used for energy storage

Series and parallel

Charge controller is used for protection

Without controllers, the management of

Appliances and the DC-DC converter

Mind that 220-240 V AC appliances can

Lights produce heat and light. Make use

A Voltage Converter, can run small

The next sheets will give some

Calculus 1 : Get the amount of sunhours

Check the sunhour sheet.

Question 1, how much installed panels? :

What is the output of?

What size of battery is needed?

What charge controller is needed if?

Installed Watt Peak of Panel Array = 300

Use the wire thickness sheet.

Question 2, how thick need the wires to

Solar panel amorphous :

Workshop 1 : discussion round - What do we require to install a basic

Workshop 2 : Install the demo kit. Example of basic system.

Workshop 3 : Measuring open voltage &short circuit current

Workshop 4 : Measure strength of battery with voltmeter

Workshop 5 : Fault finding

Put all component ready for the

Tool: the installation checklist

First write it down on paper!

Also write down what is needed for AC

Add to system: Bring:

What do we require more for an AC

Install the demonstration suitcase

What are elements to keep in mind:

Connect the battery to the controller

The suitcase has been installed

The trainees will have to check what is

AFTER INSTALLATION (USE MAINTENANCE

ROLEPLAY: trainer is customer, trainee is solar dealer

Use appliances the TIME the solar technician told you!

Make the GREEN light on controller burn everyday!!!

1. Clean: if there is dust on the panel, less sunlight, less

What did we learn?

How to do an installation of a small

Free Energy Foundation

o Does not need a generator anymore for low energy usage;

How does photovoltaic solar energy work?

What are the basic components of a solar system?

$EPENDINGONTHEQUALITYUSEDYOURBATTERYCONTROLLER