Installation of

Stand-Alone System components

T1/T2 Training

Slide 1
Learning Objectives

1 Explain electrical hazards and the installation

procedures for mechanical and electrical components

Explain the steps required to install pole mounted PV

2 systems

Describe the importance of finding secure location

3 against falling objects, theft, and vandalism

List installation requirements for wiring and battery

4 banks
Slide
2
Quality PV System Installation

Site Survey (see Site Survey session)

Installing Mechanical Components

Installing Electrical Components

Slide
3
Installing Mechanical Components on Roof

 Locate unshaded areas

between 9 am and 3 pm Roof Area (m2) per Array Size

Module
 Ensure that there is sufficient Watts/m2
1 kW 2 kW 4 kW 6 kW 8 kW

roof area available (primarily 65 15 31 62 93 124

dictated by module watts per 118 8 17 34 51 68

m2) 129 8 15 31 46 62

140 7 14 29 43 57
 Face the tilt angle at 151 7 13 27 40 53
appropriate levels 161 6 12 25 37 50

Provide for at least 10cm

Source: HomePower

space behind the module for
ventilation or shingles
Slide
4
Installing Mechanical Components on Roof Cont’d

 If on the roof, try mounting

near the ridge or eaves to
avoid leaks
 Fasten metal parts of module
mounts with bolts or screws,
never use nails
 Fasten mountings to the
wooden frame of the house,
not just to metal roofing or Source: Fafa Island, Tonga

shingles

Slide
5
Installing Mechanical Components on Poles

 Install foundation and pole

 Install modules and electrical
enclosure
 Install electrical wiring and
equipment USP, Fiji

A Residence, Tonga
Slide
6
Mounting Rail Installation for Roof
 Standoff mounts are the most
common way Wooden frame
location

 Mounting points should be on the

wooden frames of the house

http://voctec.asu.edu USP, Fiji Elementary School, Tonga Slide

7
PV Module Attachments for Roof

 PV modules should be
installed with the long
module dimension
perpendicular to the rails to
minimize the wind load and
the length of rail required

Gary Lee

Slide Source: Jim Dunlop Solar

8
Examples of Good Roof Installations

 Good roof installations

 Provide good air flow
 Are supported by house
frame(s)
 Have latitude tilted
 Have identical modules
 bad roof installations
 have dissimilar modules

Slide
9
Examples of Bad Roof Installations

Module not properly Module mismatch due to two

secured for wind load different orientations

Horizontal tilt; at least 5o tilt Module mismatch due

need to drain off rain water to shading
Slide Source: Tetra Tech
10
Maintenance of modules

 Be aware of falling objects

(e.g., coconuts) because they
1, 2, 3
can cause PV damage
1. Shatter glass
2. Break the solar cells
3. Cause shock hazard on rainy
days
4. Corrode the solar cells 4&5

5. Reduce performance and

lifetime
Slide Source: Tonga Islands
11
Theft & Vandalism

 Theft and vandalism are a big

problem in some countries that can
cause failure for a program
 Security aspects are of paramount
importance

Slide
12
Theft & Vandalism – Wrong Solutions

PV module stored inside a building PV modules under a metallic cage

Due to fear of theft, the PV module A metallic cage with PV modules

is stored inside the building. Staff underneath is built to protect PV
is responsible for placing the modules from theft. This system is
module outside, on a daily basis, severely compromised of the power
but was on vacation at the time of output from the PV modules by
a visit to the site. reducing the incident light on the PV
Source: Tetra Tech modules. Slide Source: USAID
13
Electrical Hazards
 Four main types of electrical injuries:
 Electrocution or death due to electrical
shock
 Injuries from electrical shock
 Burns
 Falls (caused by a shock)
 Three factors can cause electrical accidents: Source: JiCA

 Unsafe equipment and/or installation

 Workplaces made unsafe by the environment
 Unsafe work practices
Slide Source: Jim Dunlop Solar
14
Preventing Electrical Hazards

 Wear nonconductive Class E hardhat

 Wear electrical hazard rated foot
protection
 Use properly grounded or double-
insulated power tools
 Tools with damage or worn power
cords should be removed from
service

Slide Source: Jim Dunlop Solar

15
Preventing Electrical Hazards

 Work on electrical equipment and

circuits in a de-energized state
using lockout and tagout
procedures
 When working on energized
equipment is unavoidable, use the
appropriate Personal Protective
Equipment (PPE), including
helmets, face shields, gloves and
flame-resistant clothing
 Beware of overhead power lines
and buried electrical conductors
Slide Source: Jim Dunlop Solar
16
Input Voltage, Current to Charge Controller, &
Inverter in a Stand-Alone System
 Power input for the charge
controller comes from PV array
 Output voltage of PV array shall
not be higher than the input
voltage of charge controller

 Power input for the inverter

comes from battery
 Output voltage of battery shall
not be higher than the input
voltage Slide Source: Jim Dunlop Solar
17
Installing a Controller
 There should NEVER be more than 2
meters of wire connecting the
controller to the battery
 Controllers should be solidly mounted
to the building walls inside a room
that is neither very cold nor hot
 Wires coming from the controller
should be fastened to the building
structure within about 6 cm of the
connections so no pulling on the wire
will occur at the controller

Slide
18
Effect of Wire Size on Voltage

 Wire size
 The smaller the wire, the more
electrical pressure (volts) is
needed to force a certain current
(amperes) through the wire
 To get higher voltage, more
batteries and PV panels must be
installed at much higher cost than
the cost of larger and shorter wires If the wire is too thin,
not enough electricity will flow!
 The use of appropriate wiring size
is important

Slide Source: Energypedia

19
Objective
4
Wiring Methods

 Wiring methods used in PV systems include standard types

of conductors, raceways and fittings used in building
electrical systems, in addition to special cables, connectors
and other methods specifically identified for use in PV
systems.
 Environmental exposure requires PV array conductors to
have insulation rated for high temperatures, wet locations,
and sunlight resistance.

Slide
20
Cable Current Rating – Influence of Cable Size

 Current carrying/rating capacity

(CCC) is dictated by the cable size or
cross sectional area (CSA) of the Cross Sectional
Current
Carrying
cable Area (mm2) Capacity (A)

2 15
 CCC should never be exceeded for a 3.2 20

given wire size (do not attempt to 5 25

force larger current than shown in 7.5 45

15 70
the last column of the table)

Slide
21
Voltage Drop – Influence of Cable Size and Length

 Voltage drop increases with smaller

cable size and longer cable lengths.
 Ohm’s law is used to calculate voltage drop
 Vdrop = (2 x L x I x ρ) ÷ A
• Vdrop = voltage drop (Volts)
• I = current (Amps)
• ρ = resistivity of copper wire (Ω/m/mm2) = 0.0183 Ω/m/mm2
• L = route length of cable (meters)
• A = cross sectional area (CSA) of cable (mm2)
Slide
Source: SEIAPI
22
Voltage Drop – Example
 Consider a stand-alone PV system that operates nominally
at 12 V with an output current of 7.5 A. The output circuit
uses 5 mm2 cable and one-way circuit distance is 10
meters.
 The voltage drop in this circuit is:
Vdrop = (2 x L x I x ρ) ÷ A
Vdrop = (2 x 10 x 7.5 x 0.0183) ÷ 5
Vdrop = 0.55 V
 Based on the nominal system operating voltage of 12 V, this
0.55 V drop amounts to:
 0.55V/12V = 0.11 ~ 5%
Slide
23
Voltage Drop – Influence of Cable Size

 Voltage drop increases with smaller cable size

Voltage drop in volts per 10 meters of one-way length of twin cable

Slide
Source: SEIAPI
24
Voltage Drop – Influence of Cable Length
 Voltage drop increases with longer cable length
Maximum Distance in meters to produce 5% (0.6V) voltage drop (12V system)
Current (A) 1 mm2 1.5 mm2 2.5 mm2 4 mm2 5 mm2 6 mm2 10 mm2 16 mm2
1 16.4 24.6 41.0 65.6 82.0 98.4 163.9 262.3
2 8.2 12.3 20.5 32.8 41.0 49.2 82.0 131.1
3 5.5 8.2 13.7 21.9 27.3 32.8 54.6 87.4
4 4.1 6.1 10.2 16.4 20.5 24.6 41.0 65.6
5 3.3 4.9 8.2 13.1 16.4 19.7 32.8 52.5
6 2.7 4.1 6.8 10.9 13.7 16.4 27.3 43.7
7 2.3 3.5 5.9 9.4 11.7 14.1 23.4 37.5
8 2.0 3.1 5.1 8.2 10.2 12.3 20.5 32.8
9 1.8 2.7 4.6 7.3 9.1 10.9 18.2 29.1
10 1.6 2.5 4.1 6.6 8.2 9.8 16.4 26.2
11 1.5 2.2 3.7 6.0 7.5 8.9 14.9 23.8
12 1.4 2.0 3.4 5.5 6.8 8.2 13.7 21.9
13 1.9 3.2 5.0 6.3 7.6 12.6 20.2
14 1.8 2.9 4.7 5.9 7.0 11.7 18.7
15 1.6 2.7 4.4 5.5 6.6 10.9 17.5
16 1.5 2.6 4.1 5.1 6.1 10.2 16.4
17 2.4 3.9 4.8 5.8 9.6 15.4
18 2.3 3.6 4.6 5.5 9.1 14.6
19 2.2 3.5 4.3 5.2 8.6 13.8
20 2.0 3.3 4.1 4.9 8.2 13.1
Slide
Source: SEIAPI
25
Conductor Types
 Two types of single-conductor cables
are permitted for use with exposed
connections between PV modules
within PV array source circuits:
 USE-2 is rated for 90oC wet or dry,
600 volts, and is sunlight resistant
 PV wire is a double-insulated,
sunlight-resistant conductor rated
for 90oC in wet locations, and for
600, 1000 or 2000 volts. PV wire is
intended for use with higher voltage
and ungrounded PV arrays
Slide Source: Jim Dunlop Solar
26
Terminating Conductors

 The following are basic

requirements for terminating
electrical conductors:
 Conductors or materials made of
dissimilar metals must not be
allowed to touch each other, and
any solders or corrosion inhibitors
used must be suitable for the
application.
 The ampacity of any connected
conductors must be evaluated at the
lowest termination temperature
rating.
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27
Connectors
 Connectors are used in PV
systems for PV module
connections and other
equipment as applicable, and
must be:
 Polarized and non-
interchangeable
 Guarded against contact with
live parts
 Latching or locking type
 Readily accessible connectors
operating at over 30 volts
require a tool for opening
http://voctec.asu.edu Slide Source: Jim Dunlop Solar
28
Objective
4
Grounding
 Proper grounding of PV systems reduces the risk of
electrical shock to personnel and the effects of lightning
and surges on equipment

Slide Source: Jim Dunlop Solar

29
Objective
4
Grounding
GOOD: Bad:
Lug attached to PV module Improperly installed grounding hardware

Lug is a lay-in lug made of solid Right hardware but wrong installation:
copper and then tin-plated. It has a The stainless-steel isolation washer has
stainless steel screw to hold the wire. been installed in the wrong sequence
and the copper grounding wire is being
pushed against the aluminum frame, a
condition sure to cause corrosion and
loss of electrical Slide
contact in the future.
Source:
30 John Wiles, New Mexico State University
Objective
4
Requirements for Battery Installations
 Unsealed batteries must be installed in ventilated
enclosures to prevent fumes, gases, or electrolyte spray
entering other areas, and the accumulation of explosive
mixture.
 Battery racks, trays and floors must be of sufficient strength
and resistant to electrolyte.
 Face shields, aprons, and rubber gloves must be used by
workers handling acids or batteries
 Water facilities for quick drenching of the eyes and body, for
flushing and neutralizing spilled electrolyte, and for fire
protection must be provided within 25 feet of battery
handling areas
 Sufficient working spaces and clearances must be provided
for any battery installations Slide
31
Objective
4
Battery System Ventilation

 Ventilation of explosive
battery gasses is required
 Vented battery cells must
incorporate a flame
arrestor, and sealed
batteries must have
pressure relief vents.

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32
Practice
 What are some general guidelines to follow when installing
PV systems?
 Ensure sufficient roof space
 Ensure proper ventilation
 Ensure proper tilt angles
 Mount directly to the frame of the structure
 Use screws, not nails
 Mount rails perpendicular to the long side of the module to
reduce wind load.
 Combine only similar modules

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33
Practice Cont’d
 What are the steps in the installation of pole-mounted PV
systems?
 Install foundation and pole
 Install modules and electrical enclosure
 Install wiring and equipment
 Ensure pole size, hole diameter, and installation depth are
sufficient for anticipated wind speeds

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34
Practice Cont’d

 List some external threats to the long-term operability of a

PV system and some methods for dealing with them.
 Falling objects (e.g., coconuts): be aware when choosing an
installation site
 Theft/Vandalism: install security fencing, employ a security
guard, design tamper-proof structures, and/or get the
community involved in the project

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35
Practice Cont’d
 What are some general guidelines to follow when wiring a
PV system?
 Ensure power and voltage matches (e.g., output of array
shouldn’t exceed the input on the charge controller, etc.)
 Don’t use excessive wiring
 Properly secure wiring
 Equipment should be installed in a reasonable temperate
room
 Utilize an appropriate wire size

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36
Summary – Key Points
 There are several requirements to install the mechanical
components of a PV module such as unshaded area, sufficient air
space, and mounting near the ridge
 PV modules on roof or pole should be installed with the long
module dimension perpendicular to the rails
 Falling objects can cause damage to the PV module, leading to
shattered glass, shock hazards, and breakage of solar cells
 To reduce theft and vandalism, use security fencing, employ
night watchman, maximize community involvement
 Proper grounding of PV systems reduces the risk of electrical
shock to personnel

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