Electrical Engineering Department,

Govt. Polytechnic Panchkula

1. Chapter-1: Check site conditions, collect
tools and raw materials
2. Chapter-2: Installation of Solar Panel
3. Chapter-3: Coordinate colleagues at work
4. Chapter-4: Safety at workplace
5. Chapter-5 : Concept of Solar Tracking
System
Check site conditions,
collect tools and raw
materials
 Check site condition, collect tools and raw
material

Introduction:- The demand for solar electric systems grows,

progressive builders are adding solar photovoltaics (PV) as an option
for their customers. This overview of solar photovoltaic systems will
give the builder a basic understanding of:

• Evaluating a building site for its solar potential

• Common grid-connected PV system configurations and components
• Considerations in selecting components
• Considerations in design and installation of a PV system
• Typical costs and the labor required to install a PV system
• Building and electric code requirements
• Where to find more information
Basic on Solar energy
Solar energy is a powerful source of energy that can be used to
heat, cool, and light homes and businesses.
Solar Energy Basics
■ Solar Photovoltaic Technology. Converts
sunlight directly into electricity to power homes
and businesses.
■ Passive Solar Technology. Provides light and
harnesses heat from the sun to warm our homes
and businesses in winter.
■ Solar Water Heating.
■ Solar Process Heat.
■ Concentrating Solar Power.
Power Generation system
Solar energy generation is one of fastest growing and most
promising renewable energy sources of power generation
worldwide. Nowadays, the electrical energy becomes one of the
basic needs in our daily life, which makes increasing demand for it.
As a major source of electrical power generation fossil fuels are
depleting day by day and also its usage raises serious
environmental concerns. These reasons force the development of
new energy sources which are renewable and ecologically safe.
The renewable energy sources include wind, solar, water, biomass
and geothermal energy sources. Out of which, solar energy has the
greatest potential in the long term and is predicted to play a major
role in coming years. It is the cheapest method of generating
electricity compared with other energy sources.
Solar-powered photovoltaic (PV) panels convert the
sun's rays into electricity by exciting electrons in
silicon cells using the photons of light from the sun.
This electricity can then be used to supply renewable
energy to your home or business.
Uses and handling procedure of solar panel:-
Uses:-
● As heat for making hot water, heating buildings and
cooking.
● To generate electricity with solar cells or heat engines.
● To take the salt away from sea water.
● To use sun rays for drying clothes and towels.
● It is used by plants for the process of photosynthesis.
Handling procedure of Solar
panel:-
Solar panels are heavy and awkward to lift and carry. Loading and
unloading panels from trucks and onto roofs can cause strains,
sprains, muscle pulls and back injuries as well as cumulative
trauma that stresses the spine. The panels can also heat up
quickly when exposed to sunlight, causing burns if not handled
safely.
Safety measures for solar workers:
● Lift each solar panel with at least two people while applying safe lifting
techniques.
● Transport solar panels onto and around the work site using mobile
carts or forklifts.
● Never climb ladders while carrying solar panels. To get solar panels
onto rooftops, use properly inspected cranes, hoists or ladder-based
winch systems.
● Once unpackaged, cover panels with an opaque sheet to prevent heat
buildup.
● Always wear gloves when handling panels.
Energy storage:-
One way solar power storage can be accomplished is by using a battery bank to
store the electricity generated by the PV solar power system. A battery solar
power storage system is used in a grid-tied PV system with battery backup and
stand-alone PV systems.
The major components of a battery solar power system are...
Charge Controller: Prevents the battery bank from overcharging by
interrupting the flow of electricity from the PV panels when the battery bank is
full.
Battery Bank: A group of batteries wired together. The batteries are similar to
car batteries, but designed specifically to endure the type of charging and
discharging they'll need to handle in a solar power system.
System Meter: Measures and displays your solar PV systems performance
and status.
Main DC Disconnect: A DC rated breaker between the batteries and the
inverter. Allows the inverter to be quickly disconnected from the battery bank
for service.
■ Lighting control - turns attached light on and off based on dusk and
dawn. Many controllers are configurable, allowing settings for a few
hours or all night, or somewhere in between.
■ Display- may show voltage of battery bank, state of charge, amps
coming in from solar panel.
Conversion
process:-
Photovoltaic energy is the conversion of sunlight into electricity. A
photovoltaic cell, commonly called a solar cell or PV, is the technology used
to convert solar energy directly into electrical power. A photovoltaic cell is a
nonmechanical device usually made from silicon alloys.
Solar-powered photovoltaic (PV) panels convert the sun's rays into electricity
by exciting electrons in silicon cells using the photons of light from the sun.
This electricity can then be used to supply renewable energy to your home or
business.
Control of Solar power
A solar charge controller manages the power going into the battery bank
from the solar array. It ensures that the deep cycle batteries are not
overcharged during the day, and that the power doesn't run backwards to
the solar panels overnight and drain the batteries.
Types of controller:-
1. Pulse width modulation solar charge controller.
2. Maximum Power Point Tracking solar charge controller
The key features of solar charge controller:-
■ Multistage charging of battery bank:-changes the amount of power
set to the batteries based on its charge level, for healthier batteries.
■ Low voltage disconnect - turns off attached load when battery is low
and turns it back on when the battery is charged back up.
CONVERSION PROCESS
 Basic electrical system and
functioning
Components of A Residential Solar Electric System

■ Solar Panels. Solar panels are the most noticeable

component of a residential solar electric system. ...
■ Solar Array Mounting Racks. ...
■ Array DC Disconnect. ...
■ Inverter. ...
■ Battery Pack. ...
■ Power Meter, Utility Meter, Kilowatt Meter. ...
■ Backup Generator. ...
■ Charge Controller.
Function of Solar Power:-
A solar power panel is able to function using the solar energy which is
derived from the sun. ... The solar panels installed on the rooftops
absorb sun's light (photons) from the sun. 2. The silicon and the
conductors in the panel convert the sunlight into Direct Current (DC)
electricity which then flow into the inverter.
It is important to understand exactly how solar panels work, and
how they can be used to produce electricity for the average home.
1. The solar panels installed on the rooftops absorb sun’s light
(photons) from the sun.
2. The silicon and the conductors in the panel convert the sunlight into
Direct Current (DC) electricity which then flow into the inverter.
3. The inverter then converts DC to AC (alternating current) electrical power
which you can use at your home.
4. Excess electricity that is not used by you can be fed back to the grid.
5. When your solar panels produce less power than what is required by you
at home, you can always buy electricity from the utility.
Mechanical Equipment
■ Stringer machine for photovoltaic cells;
■ Layup station;
■ Automatic station with conveyor belts for manual
bussing or Automatic Bussing Machine;
■ Electroluminescence Test;
■ Laminator with buffers;
■ Automatic framing machine;
■ Automatic silicone dispenser;
■ Eva and backsheet cutting machine;
Maintenance procedure of equipment
● The timely and regular cleaning of solar cells and PV panels.
● Regular maintenance of all thermal-based components.
● Servicing of HT side equipment on an annual basis.
● Diagnosis and tests pertaining to low solar power production.
● Testing and upkeep of circuits.
Site Survey:-
What exactly is a Site Survey?
A Site Survey is done to collect information about various aspects such as
local conditions, physical details of the site (including the roof), and the
consumer’s power consumption needs. Some of the information collected is:
■ Local climatic conditions.
■ Physical details of the site (including the roof).
■ The consumer’s power consumption needs.
■ Shading on the roof and so on.
Site surveys are often done manually by skilled manpower, on the basis of
which a 3D model of the site is prepared, which is used for the system
design. A site survey consists of an inspection of the area of installation of
solar panels to see if the proposed site is suitable. As a solar installer,
when checking a potential site, you will primarily check for whether the
roof will be able to support the extra load of the solar system, and if during
peak hours there is no shade obstructing the panels.
The main objectives of a site survey are:
1. Ensure a site is free from shade due to obstacles such as water
tanks, AC units, staircase, etc.
2. Clear access for maintenance at the site
3. Appropriate orientation to the sun
4. Obtain dimensions of the roof structure
5. Aesthetics of the installation
6. The energy consumption of the consumers.
Basic information about the site/location:
Address/Plant Name: For identification
Latitude and Longitude: For obtaining the satellite image of the site
Details person at the plant (Name, Designation, E-Mail ID and Mob No):
For contact details
Information regarding the Electrical Energy Sources:
Sanctioned load from the grid (kVA): Since state policy does not permit
more than the specified amount, and varies for different states
Connected Load
Installed capacity & voltage of transformers
Actual connected load (KVA)
Power Units consumption per Month / Day
Average Unit Cost – Grid
Important Parameters in Solar Panel Installations
■ Maximum Power (Pmax) Pmax is the highest power output of a
solar panel under standard test conditions (STC). ...
■ Voltage at Maximum Power (Vmp) The Vmp is the voltage
generated by the solar panel when the power output is highest. ...
■ Current at Maximum Power (Imp)
Tools involved in installation of system
Site Assessment Tools
1. 50-100 ft. tape measure
2. Solar Pathfinder (evaluates the solar energy potential at a site)
3. Compass (not needed if you’re using a Solar Pathfinder)
4. Maps (reference for location latitude and magnetic declination)
5. Digital camera
Additional Tools to Consider (especially for multiple
installations)
1. DC clamp-on ammeter
2. Reciprocating saw / Jig saw
3. Right angle drill
4. Conduit bender
5. Large crimpers
6. Magnetic wristband for holding bits and parts
7. C-clamp
Basic Tools Needed for Installation
1. Angle finder
2. Torpedo level
3. Fish tape
4. Chalk line
5. Cordless drill (14.4V or greater), multiple batteries
6. Unibit and multiple drill bits (wood, metal, masonry)
7. Hole saw
8. Hole punch
9. Torque wrench with deep sockets
10.Nut drivers (most common PV sizes are 7/16”, ½”, 9/16”)
11.Hacksaw
12.Tape measure
13.Blanket, cardboard or black plastic to keep modules from going “live”
during installation
14.Heavy duty extension cords
Quality and process standards
The quality of photovoltaic solar panels is an important factor to consider
for any solar plant project on the roof or on the ground.
The qualities are following:-
a. The guarantee
b. Price
c. Manufacture, Solar panel technology
d. Efficiency of the solar panel
e. The by Pass box and the cables:
f. The frame of the solar panel:
g. Temperature coefficient
A high temperature coefficient is a sign of a lower quality solar
panel. A reasonable number is around 0.5%, also the best solar
panels down to 0.3% while 0.7% indicates a poor coefficient in terms
of performance and thus a photovoltaic equipment not very reliable.
Standards generally used in photovoltaic modules:
IEC 61215 (crystalline silicon performance), 61646 (thin film
performance) and 61730 (all modules, safety)
ISO 9488 Solar energy—Vocabulary.
UL 1703 from Underwriters Laboratories
UL 1741 from Underwriters Laboratories
UL 2703 from Underwriters Laboratories
CE mark
Electrical Safety Tester (EST) Series (EST-460, EST-22V, EST-22H,
EST-110).
Safety measures for solar workers:
■ Lift each solar panel with at least two people while applying safe lifting
techniques.
■ Transport solar panels onto and around the work site using mobile
carts or forklifts.
■ Never climb ladders while carrying solar panels. To get solar panels
onto rooftops, use properly inspected cranes, hoists or ladder-based
winch systems.
■ Once unpackaged, cover panels with an opaque sheet to prevent heat
buildup.
■ Always wear gloves when handling panels.
INSTALLATION OF
SOLAR PANEL
 INSTALLATION OF SOLAR PANEL

Solar energy system components:-

The four major components of a solar energy system are the
panels, inverter(s), racking and solar battery storage unit(s) (if
desired).
■ Panels
Solar panels are the most visible element of your system, which is
why you’re likely the most familiar with it.The way that solar panels
work is that the panels generate DC electricity as sunlight, or solar
irradiation, stimulates electrons to move though solar cells that are
in-built into the solar panels.
Technology – Polycrystalline or Monocrystalline Panels?
Monocrystalline panels consist of singular large crystals, are darker
in colour, even in aesthetic consistancy and, as a result of the
production process, the corners of cells are usually missing.
Polycrystalline panels consist of multiple smaller crystals, can be
light or dark blue in colour and have variation in texture where some
patches are lighter than others.
■ Inverters
Inverters are a crucial part of any solar energy system. Their purpose
is to convert the DC electricity that the solar panels produce into 240V
AC electricity, which is what powers everything in your home. The
inverter is a hardworking piece of equipment that works constantly
throughout the lifetime of your system – so it tends to be the piece
most likely to have faults.
■ Racking
The third main component of a solar energy system is the
racking/mounting. This is what securely attaches your panels to your
roof. Racking / mounting will not be a decision you need to lose sleep
over. Any reputable solar provider will use quality racking equipment
from brands like Radiant or Sunlock, which are Australian made
■ Batteries
Batteries are used to store energy generated during the day to be used
throughout the night when the system is no longer generating power.
Battery technology is quickly developing into a more feasible option for
those who primarily use their energy in the evenings. We have installed
battery systems for major clients such as PCYC Queensland and
schools like Bundaberg Christian College, who operate sporting facilities
and boarding colleges that require energy throughout the night.
■ Charge controller
A charge controller is an important component in a battery based solar
system and are not used in straight grid tie systems. The primary role is
to manage charging the battery bank, prevent it from overcharging and
many control the rate of the current and voltage at which it charges.

Series and Parallel Connection in Solar system

The following image is a great example of series and parallel wiring.
Series Wiring:
Series wiring is when the voltage of a solar array is increased by wiring
the positive of one solar module to the negative of another solar module.
This is similar to installing batteries in a flashlight. As you slide the
batteries into the flashlight tube the voltage increases
Parallel Wiring:
Parallel wiring increases the current (amps) output of a solar array
while keeping the voltage the same. Parallel wiring is when the
positives of multiple modules are connected together and all the
negatives for the same modules are connected together.
Series Parallel Combination:
Here is an example of what is found in most large solar systems, a
series and parallel wiring combination.
Pole mounting
Photovoltaic mounting systems (also called solar module racking)
are used to fix solar panels on surfaces like roofs, building facades,
or the ground. These mounting systems generally enable retrofitting
of solar panels on roofs or as part of the structure of the building
(called BIPV).
Angle of tilt for Solar Panel:-
The “tilt angle” or “elevation angle” describes the vertical angle of
your solar panels. “Azimuth angle” is their horizontal facing in
relation to the Equator. Solar panels should face directly into the sun
to optimize their output.
The optimum tilt angle is calculated by adding 15 degrees to your
latitude during winter, and subtracting 15 degrees from your latitude
during summer. For instance, if your latitude is 34°, the optimum tilt
angle for your solar panels during winter will be 34 + 15 = 49°.
Placement of solar panel mounting
The most optimum direction to face your solar panels is
somewhere between south and west. It is at this location that
your panels will receive the maximum sunlight throughout the
day.
If your roof does not face the right direction, then surface
mounted panels or pole mounted panels may be your best bet.
Site Surveying Method
● Roof Orientation and Shading Analysis- Helpful in in
identifying the suitable location for Solar Panel installation.
● Roofing Details – Study the roofing details to install the right
solar PV system.
● Load Analysis – Helpful to understand the energy needs of
the building.
Evaluation parameters for Solar system:-
The following are the parameters you should evaluate on:
● Grade – Solar panels come in Grades A, B & C (Grade A being the highest
quality)
● Tier of the manufacturer – Organizations such as BNEF have come up with
ranking of the solar panel manufacturer, classifying them into one of three Tiers
(Tier 1 being the highest)
● Efficiency – Solar panels have efficiencies ranging from 13%-24%
● Performance under low light conditions – Some solar panels can generate
higher amounts of electricity than other panels with the same
● Temperature coefficient – Solar panels with lower temperature coefficient (and
higher temperature tolerance) lose less of their efficiency at higher
temperatures
● Warranties available – Solar panels come with performance warranties, which
range from Standard to Linear
● Presence of anti-PID features – Solar panels also come with features to tackle
PID or Potential Induced Degradation, a characteristic that can cause
significant harm to the panel within the first few years of installation.
SAFETY AT WORK
PLACE
 SAFETY AT WORK PLACE

INTRODUCTION:- The Occupational Safety and Health

Administration (OSHA) requires employers to implement safety
training and protection for their employees. Many solar installation
companies have taken OSHA’s requirements a step farther, creating
manuals of their own that detail the specific measures they require
to manage solar energy safely.
Maintaining the work area safe and secure:-
Every Worksite Presents Different Risks
No two worksites are the same. Before a solar installation begins,
it’s essential for the installer to visit the site, identify the safety
risks and develop specific plans for addressing them. Plans
should include:
● Equipment to be used for safe lifting and handling of solar panels
● Type and size of ladders and scaffolding if needed
● Fall protection for rooftop work
● Personal protective equipment for each installer
All equipment needed for the job should be inspected and verified
to be in good working order before being brought to the worksite.
Lifting and Handling Solar Panels
Solar panels are heavy and awkward to lift and carry. Loading and
unloading panels from trucks and onto roofs can cause strains,
sprains, muscle pulls and back injuries as well as cumulative
trauma that stresses the spine. The panels can also heat up quickly
when exposed to sunlight, causing burns if not handled safely.
Safety measures for solar workers:
Lift each solar panel with at least two people while applying safe lifting
techniques.
Transport solar panels onto and around the work site using mobile carts
or forklifts.
Never climb ladders while carrying solar panels. To get solar panels onto
rooftops, use properly inspected cranes, hoists or ladder-based winch
systems.
Once unpackaged, cover panels with an opaque sheet to prevent heat
buildup.
Always wear gloves when handling panels.
Ladder Safety
Solar construction often involves working on roofs and from ladders.
Choosing the right ladder and using it properly are essential.

Safety measures for solar workers:

Select the ladder that best suits the need for access – whether a
stepladder, straight ladder or extension ladder. Straight or extension
ladders should extend a minimum of three feet above the rung that the
worker will stand upon.
Select the right ladder material. Aluminum and metal ladders are the
most commonly used today and may have their place on the job, but
they’re a serious hazard near power lines or electrical work. Use a
fiberglass ladder with non-conductive side rails near power sources.
Trips and Falls
Trips and falls are a common hazard of all construction jobs, including
solar. They can happen anywhere on the jobsite, especially off roofs or
ladders. Rooftop solar installations are especially hazardous because the
work space diminishes as more panels are installed, increasing the risk of
falls.
Safety measures for solar workers:
Keep all work areas dry and clear of obstructions.
For fall distances of six feet or more, take one of three protective
measures: install guardrails around ledges, sunroofs or skylights; use
safety nets; or provide each employee with a body harness that is
anchored to the rooftop to arrest a potential fall.
Cover holes on rooftops, including skylights, and on ground-level work
surfaces
Solar Electrical Safety
Solar electric (photovoltaic or PV) systems include several components that
conduct electricity: the PV solar array, an inverter that converts the panel’s
direct current to alternating current, and other essential system parts. When
any of these components are “live” with electricity generated by the sun’s
energy, they can cause injuries associated with electric shock and arc-flash.
Even low-light conditions can create sufficient voltage to cause injury.
Safety measures for solar workers:
Cover the solar array with an opaque sheet to “turn off” the sun’s light.
Treat the wiring coming from a solar PV array with the same caution as a
utility power line. Use a meter or circuit test device to ensure that all circuits
are de-energized before working on them.
Lock out the power on systems that can be locked out. Tag all circuits you’re
working on at points where that equipment or circuit can be energized.
What are the hazards of solar power?
Hazards and Controls
Workers in the solar energy industry are potentially exposed to a variety of
serious hazards, such as arc flashes (which include arc flash burn and blast
hazards), electric shock, falls, and thermal burn hazards that can cause
injury and death.
Handling hazardous material
Hazardous Waste or Not?
Solar panel waste can include heavy metals such as silver, lead, arsenic and
cadmium that – at
certain levels – may be classified as hazardous waste.
Solar panels may be considered a waste when:
• A generator decides to discard unused solar panels: and
• Used solar panels are disconnected/removed from service and will not be
reused.
It is important to remember that some types and brands of solar panels are
hazardous waste
while other are not.
The following are some panels that do or may contain toxic material.
• CDTe solar panels may be a hazardous due to cadmium.
• Gallium arsenide (GaAs) panels may be hazardous due to arsenic.
• Some older silicon solar panels may be hazardous waste for hexavalent
chromium coatings.
• Newer, thin-film solar panels contain CIS/CIGS and may be hazardous due
to copper and/or
selenium.
Site Risk & Hazard
Assessment
 SOLAR
TRACKING
SYSTEM
SOLAR TRACKING SYSTEM

Introduction:-Trackers direct solar panels or modules toward

the sun. These devices change their orientation throughout the
day to follow the sun's path to maximize energy capture. ...
Because these trackers follow the sun vertically and horizontally
they help obtain maximum solar energy generation.
What are solar trackers?
A solar tracking system maximizes your solar system’s electricity
production by moving your panels to follow the sun throughout
the day, which optimizes the angle at which your panels receive
solar radiation. Solar trackers are typically used for ground-
mounted solar panels and large, free-standing solar installations
like solar trees.
When solar panels are exposed to sunlight, the angle at which the
sun’s rays meet the surface of the solar panel (known as the “angle
of incidence”) determines how well the panel can convert the
incoming light into electricity. The narrower the angle of incidence,
the more energy a photovoltaic panel can produce. Solar trackers
help to minimize this angle by working to orient panels so that light
strikes them perpendicular to their surface.
There are two types of solar tracking systems:
■ single-axis
■ dual-axis.
A single-axis tracker moves your panels on one axis of
movement, usually aligned with north and south. These setups
allow your panels to arc from east to west and track the sun as it
rises and sets.
● Single-axis trackers are nearly 32.17% efficient compared to a fixed
solar tracker mount panel.
These trackers follow the Sun from East to West, providing consistent
power output all day long.
The trackers generate 15-16% higher annual power as compared to a
static station of the same installed capacity.
Disadvantages:-
● Energy output is lower by single-axis tracker during sunny conditions
compared to dual-axis trackers
● Limited technological upgrade.
● Solar trackers are slightly more expensive than their stationary
counterparts, due to the more complex technology and moving parts
necessary for their operation. This is usually around a $0.08 –
$0.10/W increase depending on the size and location of the project.
Find the right solar setup for your property
Whether you want a ground-mounted solar array with solar trackers or a
rooftop system, it is always important to compare your options before
moving forward. On the EnergySage Solar Marketplace, you can solicit
quotes for both ground-mounted and rooftop solar projects from
qualified, pre-vetted installers in your area. If you are interested in a
tracking system, simply leave a note on your profile that you would like
quotes including solar trackers.