Installation Manual of the Solar Weather

Monitoring Station

Site Name:- 170MWp MAINSTREAM SOLAR PV PROJECT CHILE

P.O/Ref # :-
1.General Prior Installation Details

 Location Selection

 Civil Work

 Tripod Installation
1.1 Location Selection:

Firstly, we must select the location which near to the MCR/Control Room or any ICR. Take a
sufficient distance away from solar panel to avoid the shadow. Also take care of that, there
is no shadow will coming on weather monitoring station so that choose the location which is
away from any building and tree.

Fig 1(a). Location selection

1.2 Civil work:

Does 5 holes, 3 for tripod foundation and remaining 2 for tripod and data logger earthing.
The depth of holes should be at least of 0.75 meter (Varies with site conditions) for
structure strength and proper grounding. The foundation holes are taken equal side at the
angle of 120-degree Tripod foundation should be up to the ground level, and the foundation
bolt arrangement are like as half dip and half free for further adjustment. Installation will
always start next day to the day of civil work for foundation strengthening.

1.3 Tripod Installation:

Loosen all the nut with help of spanner, stretch all the three legs with equally distance from
each other at the angle of 120 degree each. Set the tripod stand in foundation bolt and
make sure that all the three side are set at zero level with the help of split leveller. Tighten
all the bolts of stand and foundation bolts as well. Now we have three poles, two poles are
the length of approx. 1.25 metres each and remaining one is boom pipe. Take 1.25 metre
Pole and insert it at the centre of the tripod, now take the second one and fix above the first
pipe. Tighten all the pipe properly with the help of pipe wrench. Now install the boom pipe
in T-shape at top of the tripod. Fix the lightning assister (L.A.) at the top of the station as
shown in picture and lay the wire from L.A. to the ground earing rod.

Note: Please make sure that the earthing is done with the rule of WMO specification
(fill the earthing pit with proper chemical)

Fig 1(b) : Top overview of tripod legs

2. Sensors and Accessories Mounting & Their
Connection with Datalogger

 Temperature Sensor and Radiation Shield

 Wind Speed & Direction Sensor
 Pyranometer
 Module Temperature Sensor
 Soiling Measurement Instrument
 Enclosure
 Solar Module
 Datalogger
 Battery Backup
 Electrostatic Discharge and Lightning Protection
2.1 Temperature and Relative Humidity Probe and Radiation Shield

2.1.1 Material Description (For EE181 AT/RH Sensor):

1). EE181 Sensor Probe
2). RAD10E-Radiation Shield

Fig 2(a) Temp/RH Probe inserted in Radiation shield

2.1.2 Tools Required:

1). Spanner Set

2.1.3 How to Install EE181?

Installation in a RAD10E 10-Plate Shield
1. Loosen the nut on the entry gland at the bottom of the shield.
2. Insert the sensor into the gland as far as it will go.
3. Using an adjustable wrench, tighten the nut on the gland until the sensor is held
firmly in place. Do not over tighten.

2.1.4 Mount the Shield

1. Attach the radiation shield to the tripod mast, using the supplied U-bolt or band
clamp.
2. Route the cable to the data logger and secure the cable to the mounting structure
using cable ties.
2.1.5 Wiring to Data logger

Wire Colour, Function and Termination to Datalogger

Sr.no Wire Colour/Code Wire Function Termination to Datalogger wiring
panel
1. Yellow Temperature Signal SE(+)
2. Blue Humidity Signal SE(-)
3. Red Power 12V
4. Clear Shield G
5. Black Signal Reference G
Table1: wiring connection for EE181
2.2 Wind Speed & Direction Sensor

2.2.1 MeteoWind2 Barani Wind Speed and Direction Sensor

This anemometer is designed to measure horizontal wind velocity in the fields of

meteorology, wind energy assessment and climate research. For winter operation it is
equipped with a 25W automatic heater. In combination with snow shedding cups, it
significantly reduces icing and snow buildup.

Fig 2(b): MeteoWind2 Wind Speed and Direction Sensor

2.2.2 How to Install MeteoWind2?

1. Loosen the 2 x M4 mounting screws on the wind sensor.

2. Route the sensor cable and connector inside the mounting tube with 2 x M4
mounting screws.

3. Using an Allen key, tighten the screws until the sensor is held firmly in place. Do not
over tighten.
4. Fix the mounting tube of sensor to the tripod or tower.
 5. Secure the cable to the mounting tube and tripod or tower using cable ties.

2.2.3 Wiring to datalogger: -

Wire Colour, Function and Termination to Datalogger
Sr.no Wire Colour/Code Wire Function Termination to Datalogger wiring
panel
1. White Power +ve 12-24VDC
2. Brown Power -ve G
3. Green Signal +ve C8
4. Yellow Signal Reference C7

Table 2: Wiring Table for Wind Sensor

2.3 Pyranometer (SMP10)

The following items are included with SMP series pyranometers:

1 Pyranometer
2 Sun shield
3 Cable, pre-wired with connector (8 pins for SMP series)
4 Calibration certificate
5 Instruction sheet

2.3.1 Location for installation of pyranometer:

The site/ location for the pyranometer should be free from any obstructions to the
hemispherical view from the plane of the sensing element.

Tools Required:
1) Spanner set.

2.3.2 How to Install SMP series?

The CM255 is mounting of pyranometer provides square platform for mount the SMP10
pyranometer. The CM255 attaches to horizontal pipes on tripod. Or module structures in
plant as shown in Figure.

a) Installation Procedure:

GHI (Global Horizontal Irradiance) / POA(Plane of array)

Step-1: Put the CM255 Pyranometer mounting plate on horizontal pipe of tripod or on
extended pipe in module structure with the help of U-Clamp. And Tieghten the nut of U-
Clamp with the help of spanner.

Step-2 : Now fix the SMP pyranometer tightly on CM255, with the help of two Stainless steel
nut-bolt.

- For GHI the bubble of the pyranometer should be in center.

For POA the pyranometer should be tilt in south direction as particular angle(in degree)
given by client.

Fig 2(f): Pyranometer Installation

1) SMP10 pyranometer Arrangement on tripod.

2) Pyranometer Arrangement on module structure. As GHI (global horizontal

irradiance) and POA (plane of array).
 2.3.3 Levelling: For GHI (Global Horizontal Irradiance)

Accurate measurement of the global radiation requires proper levelling of the

detector surface. Level the instrument by turning the two adjustable feet to bring
the bubble of the spirit level centrally within the marked ring. For easy levelling, first
use the screw nearest to the spirit level.

Note It is ideal that the bubble should be completely within the marked ring. However, in fact, the
pyranometer is level within the specified accuracy when the bubble is at least half within the ring.

Fig 2(e): Levelling of Pyranometer

2.3.4 Fitting the connector and cable

Locate the plug correctly in the pyranometer socket, it only fits one way, and push it in.
Screw the plug locking ring hand tight. Over-tightening may damage the waterproof seal.
Secure the cable so that it cannot blow in the wind or cause a shadow on the instrument.
- The connector of the pyranometer should be in north direction.

Note The cable should be arranged with a curve below the instrument so that water drips o rather than
running along the cable up to the connector.

Fig 2(f): Connector Fitting

2.3.5 Fitting the sun shield

Finally, clip on the sun shield to prevent excessive heating of the radiometer body. The
bubble level is visible through the top of the sun shield for routine checks and the shield
‘tail’ helps to protect the connector.

Fig 2(g): Fitting of Sunshield

2.3.6 Wiring to datalogger for SMP Series: -

Wire Colour, Function and Termination to Datalogger
Sr.no Wire Colour/Code Wire Function Termination to Datalogger wiring
panel
1. White Power +ve 12V
2. Black Power -ve G
3. Green Signal +ve RG1(+)
4. Brown Signal -ve RG1(-)
5. Shield Ground G
Table 3: Wiring Table for SMP Series Pyranometer
2.4 Module Surface Temperature Sensor: -

2.4.1 CS240 Module Temperature Sensor: -

The CS240 temperature sensors use a precision 1000-ohm

class A platinum resistance temperature detector to
measure temperature from –40 to 105 °C. They are
designed for measuring the back-of-photovoltaic (PV)
module temperature but also can be used to measure the
surface temperature of other devices. The CS240 can be
measured with a 2-wire or 4-wire configuration and is compatible with most Campbell
Scientific data loggers.

2.4.2 Tools required

- Kapton tape.

Fig 2(j): Kapton Tape

2.4.3. Installation:

- Placement on a Photovoltaic (PV) Module

The PV module may or may not have distinctive photocells. If the PV module does not have
distinctive photocells, center the sensor on the back of the PV module. If the module has
several distinctive photocells, center the sensor on the back of the photocell that is the
middle of the PV module.

- Mounting/Cable Strain Relief

Before mounting, the installers need to wash their hands and then clean the back of the PV
module or other device with ethyl alcohol.

Adhesive Mounting Strip

The CS240 include an adhesive mounting strip adhered to the flat surface of the aluminium
disk. To mount the sensor, remove the paper from the mounting strip and adhere it to the
back of the PV module or other device. The mounting strip must be adhered to a clean
surface for its adhesive to function properly.

Kapton Tape

Use Kapton tape for cable strain relief a yellow label on the cable indicates where the cable
must be secured, If the temperature might exceed 70 °C, Kapton tape is also required to
better secure the sensor to the measurement surface.

To ensure that the sensor disk and cable are adequately fastened to the measurement
surface, use three strips of Kapton tape in two places each:

1. For strain relief, place the first strip of tape across the cable just below the yellow
heat shrink, and rub the tape surface to remove bubble.

2. Place the other strips of tape on the first strip of tape and rub the tape surface to
remove bubbles. These strips of tape should be perpendicular to the first strip of
tape—forming an “H”.

3. To secure the sensor to the module surface, remove the paper from the bottom of
the disk and adhere the disk to the PV module Placement on a Photovoltaic (PV).

Fig 2(k): Installation of CS240 using Kapton Tape

4. Place a strip of tape across the sensor head, perpendicular to the cable and rub the
tape surface to remove bubbles. Rub as close as possible to the sensor disk. Do not
go over the sensor moulding with the tape; only put tape over the metal disk portion
of the sensor.
 5. Place the two other strips of tape on the ends of the sensor disk, perpendicular to
the first piece of tape and parallel to the cable then rub the tape surface into the
module surface. Shown in figure.

2.4.4 Wiring:

Datalogger Connection for the CS240 2-Wire Configuration

Table 6: Wire connection to datalogger

Datalogger Connection for the CS240 4-Wire Configuration

Table 6: Wiring connection to datalogger

2.5 Soiling Measurement Instrument : -

2.5.1 DUST IQ : The DustIQ instrument is a unique, high quality instrument designed
for measuring the light loss resulting from the soiling of the panel. The measured light
loss is an indication for the losses introduced by the soiling of the nearby PV panels too.

Dust IQ

2.5.2 Tools Required:

The tools required to fit the DustIQ instrument to a PV panel are:
1). Allen key 6 mm

Allen Key 6 mm

2). Spanner 13 mm

Spanner 13 mm

2.5.3 Connecting the cables to the DUST IQ

Connect the supplied data cable to the socket labelled Host.
Locate the 8 pin ODU plug correctly in the DustIQ socket, it only fits one way. The red
dot on the plug should be opposite of the red dot on the chassis part. Push it in to
secure whilst holding the plug by the end or by the grooved ring.

To unplug, pull the grooved ring back and then

pull out the plug.

2.5.4 Wiring to Data logger

Wire Colour, Function and Termination to Datalogger

Sr.no Wire Colour/Code Wire Function Termination to Datalogger wiring
panel
1. Yellow Signal +ve C6
2. Grey Signal Reference C5
3. Blue Common G
4. White Power 12V
5. Black Power Ground G
Table1: wiring connection for DUST IQ
2.6 Enclosure:

2.6.1 Enclosure Installation:-

- Before installing the enclosure, first fix the data logger and charge controller onto the
metallic plate inside the enclosure, Take out the plate from inside the enclosure box
and fix the data logger on the upper site of the plate with the use of mount balls and
screw comes with the data logger.

- Fix the charge controller with the help of screw, blow to the data logger. As shown in
figure.

Fig 2(n): Installation of Enclosure

- Fix the enclosure on tripod pole with the use of hose clamp, tighten the screw of hose
clamp using screwdriver or spanner.

Fig 2(o): Images of enclosure mounting accessories and completely installed enclosure via horse clamp
2.7 Solar Module:

2.7.1 Installation:

We have 50W solar module for charging 12V battery, Place the solar module just above the
enclosure and tilt according to the azimuth angle of your location. Tighten all the nuts of
solar module with the help of 10mm spanner and fixed it on pole with the help of U-clamps.
- The solar module should be in south direction.

Fig 2(p): Solar module installation

2.7.2 Wiring of Solar Module:

Use the two-core power cable for the wiring of solar module, crimp the ring type lug with
the two core wire, and fix the Red wire on positive (+) terminal and Black one on the
negative (-) terminal. Lay the cables through pole, use cable ties for secure the cable on
pole. And put the second end of the cable into gland of the enclosure. Do wiring of the same
cable into the charge controller. Wiring ports are available for solar (see above the port).
Place the red wire on positive terminal and black on negative terminal.
2.8 Data Logger

2.8.1 CR1000X:

 Step to install the data logger is already given, Do the wiring according to the wiring
diagram provided to you. Give the 12V power supply to the data logger from the
charge controller Load terminal. When connecting external power to the CR1000X,
remove the green POWER IN connector from the CR1000X face. Insert the positive
12 Vdc lead into the green connector, then insert the negative lead. Re-seat the
green connector into the CR1000X. The CR1000X is internally protected against
reversed external-power polarity. Should this occur, correct the wire connections
and the CR1000X will resume operation.

 Insert the micro SD card into the given port in the CR1000X.

 Do Wiring of all the sensors according to the wiring diagram which is already
provided to you by MeaTech.

 Now pick the Ethernet Cable (male-to-male) insert it into the RS232 (non isolated)
port given in the CR1000 series and insert the second end into the Ethernet port of
RV50 Modem for getting the data on email or specific IP.

Fig 2(q): Channel Classification of CR1000X datalogger

  To protect the data logger from surge or any short circuit, do proper chemical
earthing using copper rod through the metallic Ground LUG given in the data logger.
 The CR1000KD is a portable keyboard and display screen for our data loggers that
have a CS I/O port, including the CR1000X. It allows you to check the data logger's
status, display or plot sensor readings and stored values, and enter numeric data or
change port/flag state.

2.8.2 Wiring Panel:

Table 10: Channel specification and ports available in CR1000X

2.9 Battery (Power Supply)

First Make sure that you have 12V battery for power supply, Pick the power cable and do
wiring of battery using ring type Lug, Fix both leads on its place by using Bolt, Nut and
vessels. Tighten the screw by using spanner. Now take the second end of the power cable
and terminate the red lead in the positive terminal of charge controller and Black lead in the
negative terminal of the charge controller. The port for battery is already given in the charge
controller (read on the crimp).

Fig 2(r): Installation of battery and charge controller unit within enclosure

2.10 Electrostatic Discharge and Lightning Protection

Warning: Lightning strikes may damage or destroy the datalogger and associated sensors and power supplies.

Electrostatic discharge (ESD) can originate from several sources, the most common and
destructive being primary and secondary lightning strikes. Primary lightning strikes hit
instrumentation directly. Secondary strikes induce voltage in power lines or wires connected
to instrumentation. While elaborate, expensive, and nearly infallible lightning protection
systems are on the market, Campbell Scientific, for many years, has employed a simple and
inexpensive design that protects most systems in most circumstances. The system employs
a lightning rod, metal mast, heavy-gauge ground wire, and ground rod to direct damaging
current away from the datalogger. This system, however, is not infallible. The following
image displays a typical application of the system:
Fig 2(r): Demonstrating the flow of lightning spike through the LA & wire