QP SGJ/Q0111 P.V.

Project Helper

NOS 0131: Assist in installation and Maintenance of

off grid solar system

Unit 3.5: Installation and Maintenance of Small Solar System

Unit 3.5: Installation and Maintenance of Small Solar System

Unit Objective:
At the end of this Unit you will be able to
1. understand the operation principle of small Solar lighting system
2. identify the different devices used in the small Solar lighting system
3. maintain the small Solar lighting system

3.5.1: Overview of Small Solar System

At the end of this topic you will be able to

1. identify the components of typical small Solar lighting system
2. operate the small Solar lighting system

3.5.1.1 Introduction

A small solar system is the off grid solar lighting system for the house. The light sources
uses Solar Photovoltaic (SPV) module as the primary source of energy. System stores electric
energy during the day time and powers a fluorescent or LED lamp and Fans during the night. It
has necessary devises to store electricity such as rechargeable battery and charge controller.

Figure 3.5.1 Components of Small solar system

3.5.1.2 Requirements on small solar system

The small solar home system does not need to set up the transmission line or route the cable, and
no any special management and control are required. It can be installed in any indoor such as
house temple, farm house etc.

Following are the basic requirements of a qualified small solar system during design process:
1. Learn general information of the meteorological conditions in the area.
2. Select the cost-effective solar panel, controller, battery and a series of components.
3. Adopt effective measures to protect the system.

These conditions ensure to design a reasonable solution and realize the significance and value of
the existence of small solar system.

3.5.1.3 Overview of small solar system

 Basic components
The system consists of:
1. Solar cell
2. LED bulbs
3. DC Fans
4. SPV mounting structure
5. Control box (charger, controller, battery)

 Operation principle

Figure 3.5.2 Block diagram of solar street light system

1. The SPV Module receives solar radiation during the day time and converts it into
electrical energy.
 2. Converted electrical energy is stored in the battery through solar charge controller or
simply charge controller.
3. Loads such as bulb and Fans are connected to the controller output through switches
4. Using the switches the loads can be turned ON and OFF whenever necessary
5. During operation at night if battery voltage reduces below its critical value the charge
controller will turns off the LED light to protect battery from deep discharge

3.5.1.4 Current situation and Development

From the current situation of the LED, there are still many problems which shall be further
improved. For example,
1. The quality of the LED bulb
2. Package problem
3. Power driver issue
4. Battery cost and Life
5. The lifetime of the electronic components.

3.5.2: Device in small solar system

At the end of this topic you will be able to

1. identify different devices of small Solar lighting system
2. identify different types of batteries used in small Solar lighting system
3. identify different charge controllers used in small Solar lighting system
4. identify different bulbs and fans used in small Solar lighting system

The solar street lighting system consists of many sections. In this chapter, only the Solar panel,
the Battery, the Controller and the Led lights are briefly introduced.

3.5.2.1 Solar Photovoltaic module

The solar panel is one of the most important parts of small solar system, as the solar panel will
convert solar energy into electricity. The solar panels used for the small solar system is of rage
from 10W to 100W and all 12V rating.

3.5.2.2 Battery

Battery will store the electricity from solar panel during the day and provide energy to the Load
during night. The life cycle of the battery is very important to the lifetime of the light and the
capacity of the battery will affect the backup days of the lights.
3.5.2.2.1 Types of Batteries

For small home lighting system usually 7Ah to 100Ah Lead acid batteries with C10 ratings are
preferred.

3.5.2.2.3 Precautions on battery

1. The Two batteries cannot be connected in parallel, because the battery's internal
resistance is different and it will form a circulation inside the batteries.
2. Moreover, a fuse must be set to protect the battery.
3. It is also necessary to consider local weather conditions in case of excessive rainfall,
moisture and Temperature.

3.5.2.3 Solar Charge Controller

The Solar charge controller is the intelligent core of the whole small solar system; it controls the
entire system's normal operation and automatically prevents the battery from overcharge, or deep
discharge. Its basic functions must also have light control.

3.5.2.3.1 Types of charge controllers

Based on the controlling algorithm there are two types of charge controllers used in solar street
light system

3.5.2.3.1.1 PWM charge controller:

This is simple DC buck regulator and regulates power with PWM signal. They are compact and
cheaper but not efficient than that of MPPT.

3.5.2.3.1.2 Maximum Power Point tracking (MPPT)

Output power of the solar panels is not only linked with light intensity, but also with load
current. From V-I curve of the solar cell we can find the existence of a maximum power point. In
order to obtain most energy in sunlight, it is necessary to take measures to make load
characteristics of the solar cells can automatically trace changes of the climate conditions. The
solar panels Maximum Power Point tracking (MPPT) technology is proposed for this problem.

There are currently several common control strategies:

A. Hill Climbing and perturb and observe (P&O).

B. Fuzzy Logic Control.
C. Fractional Short-Circuit Current
Note: Usually, if the power of the system is less than 1KW then PWM charge controlle r is
preferred.

3.5.2.4 LED Bulbs and Fans

DC LED bulbs are the lighting element in the small solar system. They are efficient and low
cost. the manufacturer like Syska has many ranges of bulbs with different wattage ratings. The
wattage ratings are 3W, 5W, 7W, 9W

Fig 3.5.3 LED bulb

The user can opt for the bulb based on the lighting requirement and the wattage capacity of the
system.
DC fans are usually aTable fans with wattage rating from 15W and ceiling fans with wattage
ratings from 25W to 40W.

3.5.2.5 Mounting structure

Mounting structures are used to mount the panels in the particular direction and azimuth angles.
It is made up of steel with rust resistance paint.

Fig.3.5.4 Mounting Structure

3.5.2.6 Battery box

Battery boxes are used to safe guard the battery and charge controller. the box also protects
battery and controller from unauthorized person.

3.5.3: Installation of Small Solar System

At the end of this topic you will be able to

1. select proper place to install small Solar lighting system
2. describe the process of civil work involved in the installation of small Solar lighting
system
3. describe the electrical connections involved in the installation of small Solar lighting
system

3.5.3.1. Place of Installation

Small Solar systems are installed either in house, temple or farm houses etc. Since Small Solar
system uses the sun light as the source of energy, the place of installation of SPV module must
be
1) Free from shadows caused by the trees
2) Free from shadows caused by the buildings or any erected structures
3) Place must be appropriate for the fixing the mounting structure
4) Near to the Battery and charge controller

3.5.3.2 Fixing the mounting structure

The mounting structure is a metal frame with the pillar as discussed earlier. It needs a proper
wall, Pillar or Foundation with cement concrete.
The installation of the mounting structure shall be
1. Perpendicular to the earth surface
2. SPV surface inclined towards True south with proper inclination angle.

Once these conditions meet, the mounting structure is fixed with nails or cement concrete.
3.5.3.3 Electrical connections

The electric connections are made as shown in the figure

Figure 3.5.5: circuit diagram of typical Small home lighting system

3.5.4: Maintenance of Small Solar System

At the end of this topic you will be able to

1. describe the importance of the maintenance of the small Solar lighting system
2. describe the process battery maintenance in small Solar lighting system
3. describe the process of SPV module maintenance in small Solar lighting system
4. describe the process of charge bulb and fan maintenance in small Solar lighting system

3.5.4.1: Importance
Battery is charged only by SPV module and therefore during rainy season this product will not
work beyond 1 day of Autonomy and the light must be manually switched OFF during rainy
season. If not the battery will be dead immediately

3.5.4.2 Routine Maintenance

A solar electric system that is properly maintained requires very little maintenance. The routine
maintenance includes Battery, SPV modules, Controller, Luminary and all electrical contacts.

3.5.4.3 Battery maintenance

Batteries require regular and careful maintenance. For a longer life batteries should:
1. Be cleaned for every 6 months
2. Have their electrolyte level checked
3. Be kept in a high state of charge
3.5.4.3.1 Cleaning (once a month)

Carry the battery outside when cleaning to avoid spilling of acid. Keep water nearby to rinse
spills.

3.5.4.3.2 Checking and Topping up Electrolyte level (monthly)

1. Remove caps of each of the cells one at a time and check the level of electrolyte. Acid
Level should be within two centimeters of the top battery. If you can look inside the
battery, check the plates to see their condition
2. If the electrolyte level is down, add ionized distilled water till it is about two centimeters
below the top of the battery.

Note:
1. Do not add rainwater collected in metal containers
2. Do not add acid, tap water or tonics to the battery

3.5.4.3.3 Checking the state of Charge

Note: Be careful not to use low charged batteries

1. If the battery is in the state of low charge, reduce the use of load and allow the battery to
be charged by a module
2. With large systems (schools, hospitals) keep records of the battery, state of charge, age
and performance. This allows users to judge more easily whether a battery needs
replacement.

3.5.4.3.4 Equalizing Charge

An equalizing charge is a hard charge from a grid or generator powered battery charger that takes
a battery a bit above its normal full state. It causes bubbling which mixes up the acid inside the
battery, it also helps remove accumulated sulphate from the battery during the cloudiest months
of the year.

3.5.4.4 Module Maintenance

Cleaning of the SPV module needs careful attention as it is mounted on a single pole at a height
of 12/15 feet and must be done every month as it is mounted in the field and dust accumulations
can be fast.
Keeping the glass surface clean is the most important task. Dust and shade will reduce the
electric output. Clean the module with water and if necessary a mild soap. Do not allow a plant
or a tree to shade the panel

3.5.4.4.1 Checking Connections

Inspect the junction box on the back of each panel to make sure that the wiring is tight. Make
sure those wires have not been chewed by rats and that there are no insects etc, living in the
junction boxes

3.5.4.4.2 Wiring and control

If the wiring is installed properly, there should be no wiring problems for the life of the system.
However, it is useful to check the wiring of the system at least once a year, especially in places
where it might be damaged by animals, tampered with or accidently pulled.

3.5.4.5 LED bulb and Fan Maintenance

1. Clean the fan for regular interval

2. Put oil for bushes of the shaft
3. Replace burnt out bulbs