Electro Mechanical Equipment

Operation and Maintenance

NTQF Level -III

Unit of Competence: Install and Maintain Solar

Energy System for Water Pumps

Module Title: Installing and Maintaining Solar

Energy System for Water Pumps

LG Code: EIS EME3 M09 L0 01-027

TTLM Code: EIS EME3TTLM0219 v1

LO1: - Plan and Prepare for

Installation

Learning Guide for ---------------- Date: Feb. 2018

Version: 1 Author: – Trainees Development Team
Developed by: Ferede Lemi (Electro-mechanical Engineering Professional
Instructor of Athlete Kenenisa TVET Polytechnic)
Dated on: February 09-19, 2019 held on YEBA Hotel Workshop
Venue

Learning Guide for ---------------- Date: Feb. 2018

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 Instruction Sheet Learning Guide #27

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics
• Solar Energy
▪ Solar radiation
• Principle of solar energy
• designing Pumping system
• Load calculations
• selecting Appropriate location
• designing Pumping system using solar energy data of the area
• installation Tools and testing devices
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
• understand Solar Energy
o Solar radiation
• Understand principle of solar energy
• design Pumping system
• conduct load calculations
• select Appropriate location
• design Pumping system using solar energy data of the area
• understand and identify installation Tools and testing devices

Learning Instructions:
1. Read the specific objectives of this Learning Guide.

2. Follow the instructions described in number 3 to 20.

3. Read the information written in the “Information Sheets 1”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.

Learning Guide for ---------------- Date: Feb. 2018

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4. Accomplish the “Self-check 1” in page __.

5. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 1).
6. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However,
if your rating is unsatisfactory, see your teacher for further instructions or go back to
Learning Activity #1
7. Submit your accomplished Self-check. This will form part of your training portfolio.

8. Read the information written in the “Information Sheet 2”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
9. Accomplish the “Self-check 2” in page __.

10. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 2).
11. Read the information written in the “Information Sheets 3 and 4”. Try to understand
what are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
12. Accomplish the “Self-check 3” in page __.

13. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 3).
14. If you earned a satisfactory evaluation proceed to “Operation Sheet 1” in page _.
However, if your rating is unsatisfactory, see your teacher for further instructions or
go back to for each Learning Activities .

Learning Guide for ---------------- Date: Feb. 2018

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 Information Sheet-1 Solar Energy

Introduction
Solar radiation is a perennial source of energy, available all over our planet, free of charge and
entirely renewable. Photovoltaic systems, once installed, do not need any fuel input and do
not emit greenhouse gases. They receive and automatically convert the solar radiation into
electricity, do not contain any mobile parts and thus require very limited maintenance. Solar
systems therefore have highly reduced running and maintenance costs compared to engine
powered water systems.
1.1. Solar Energy
What is Solar Energy?
“Solar Energy” refers to radiant heat and light from the sun.
• It is renewable, which means it cannot be used up.
• It is harnessed and converted to heat or electricity
using various technologies such as Solar Heating and Solar Photovoltaics (conversion to
electricity).

Learning Guide for ---------------- Date: Feb. 2018

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Figure 1.1: How Solar energy works

Applications or uses Solar energy

1. Lighting
2. Communication
3. Powering electrical gadgets
4. Water pumping
5. Charging appliances

Learning Guide for ---------------- Date: Feb. 2018

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 Self-Check 1 Written Test

Directions: - Answer all the questions listed below and write your answer on the space
provided

Name __________________

1. What is solar energy? (2pts)

2. What is application or uses of solar energy? (1pts)

3. Can solar energy be used up? If not, explain. (2pts)

Score = 6pts
Answer Sheet
Rating: ____________
Name: _________________________
Date: _______________

Short Answer Questions

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 Information Sheet-2 Principle Of Solar Energy

Introduction
In this module, an introduction of the basic electric theory is provided, necessary to
understand the functioning of solar systems. The concepts of voltage, current, resistance,
losses, electric power and electric energy will be presented, as well as the difference between
direct current and alternating current.

2.1. Electricity Basics

A. Measuring Electricity

Voltage (V): the potential difference in electrical charge between two points measured in
volts.

Current (I): the flow of electrons in a circuit/wire between two points measured in
amperes.

Volts = Power ÷ Currents V = P ÷ I Volts

Current = Power ÷ Volts I = P ÷ V Amperes

B. There are two types of current:

1. Alternating Current (AC) is the type of current most commonly used in households to
power electrical appliances (for example TVs, refrigerators, radios and computers). Grid
supplied electricity is alternating current.

2. Direct Current (DC) is produced by PV modules and stored in batteries.

Figure 2.1a: Direct Current Figure 2.1b: Alternating Current

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Resistance (R): the opposition to the flow of electrical current in the material through
which it is passing measured in ohms the potential difference in electrical charge between
two points measured in volts.

Resistance = Volts ÷ Current R = V ÷ I Ohms

Power (P): the rate of energy conversion measured in watts.

Power = Volts x Current P=VXI Watts

Energy (E): refers to the capacity for work i.e. the power used over time,
measured in watt-hours.
Volts
Energy = Power x Time E=Pxt Watt-Hours

Example:
If a solar panel produces 2 Amps of electricity at 12 volts, the total power it produces is 24
Watts. (2 Amps x 12 Volts = 36 Watts)

C. Electrical Circuits
Loads and power sources in a circuit can be connected in series or parallel. Systems may
use a mix of series and parallel wiring to achieve the required voltages and amperages.

WATTS (Power) WATT-HOURS (Energy)

A watt is the amount of power that a A watt-hour is the amount of energy that a
solar panel can produce or that a light solar panel can produce or a light bulb can
bulb consumes. consume in a certain a number of hours.

Figure 2.2a: Series Connections Figure 2.2b: Parallel Connections

increase voltage but does not increase increase current but voltage is not
current. affected.

Learning Guide for ---------------- Date: Feb. 2018

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2.2. Energy that will be produced by a solar system
It is wise to have a discussion with a few solar panel installers on how various factors can
affect solar energy output.

Solar panels show the amount of power that is expected to be produced under
conditions that are ideal, which is known as the maximum power rating.

The amount of electricity produced by the solar panel depends on a couple factors:

• Does sporadic shade block sunlight from directly hitting the roof?
• What is the average amount of sunlight that the roof receives?
• What is the size of the solar panels and what is the efficiency of the cells of the
solar
panel at converting energy?

The seasons and the weather have an effect on the sunlight that hits the roof. Also
there is a variation in sunlight depending on the time of day. In these cases using the
max power rating by itself will give an inaccurate prediction as to the power that
can be expected. Nonetheless your location will give you the ability to calculate solar
panels expected output.

Factors such as power, inverter efficiency and wiring will on average cause the
solar system to lose energy and will only give up to 80% of its capacity.

Keeping in mind a solar panel watt rating, location, and electricity produced grid cost, a
solar calculator will give a table with estimation of the amount of solar power to expect.

We enter the data as shown in the picture bellow

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 A. Solar Panels

Figure 2.3: a) Solar Panels (Left); b) Solar Panels its working mechanism as solar energy
converter to electric energy (right)

What are solar panels?

Solar panels are devices that allow for the input of sunlight, and convert this sunlight into
electricity. As shown in figure 2.3a. The shape of solar panels can vary in different
rectangular shape and a combination of these rectangular shaped panels are installed and
used to produce the electricity. The solar panel consists of solar cells which are
semiconductor devices that change the sunlight into electricity or direct current. The cells
make up a module. The PV photovoltaic modules comprise of photovoltaic cell circuits that
are enclosed and "sealed in an environmentally protective laminate". The solar panel
includes from one or more "PV modules assembled as a pre-wired, field-installable unit".
The PV Array is the full unit that generates the power and includes all the elements just
discussed.

The sun is a living fireball whose rays reach one side of the spherical earth during day time.
Scientists have employed modern tactics to develop the solar cells that can directly convert the
energy from sunlight to electrical power. Solar cell is an electronic device that converts energy. The
Greek term „Photovoltaic‟ refers to the process of electricity generation from light. When a series of
Photovoltaic or Solar Cells is put together, they form a Solar Panel. The panels absorb energy from
the sun which is converted to electricity by the solar cells, see figure 2.3b.

Learning Guide for ---------------- Date: Feb. 2018

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 B. What constitutes a solar panel?

Figure 2.4: Silicon Element description in a periodic table

Figure 2.5: Silicon Atom Nomenclature

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The primary element that makes up a solar panel is its solar photovoltaic cell which
does the conversion from the sunlight to electricity. Accordingly, 80% of solar
panels are made up of solar cells made of crystalline silicone meaning
"monocrystalline, polycrystalline, amorphous silicon, or hybrids". The cells are
placed in a grid like design.

Silicon is a semiconductor and the fourteenth component in the periodic table (see figure 2.4).
It has 4 valences (electrons at the outer shell), see figure 2.5. Silicon particles offer valence
electrons to achieve stability. To aggravate this stability, doping atoms are embedded into the
silicon. Silicon can be combined with Bromine (positively doped) and can be combined with
Phosphorus (negatively doped), see figure 2.7.

Furthermore the 20% are made up of solar cells which are made mostly from Cadmium
Telluride and a small portion of CIGS or Copper Indium Gallium Selenite. These cells have
an advantage of being low cost and therefore can be made into large single sheets.

Figure 2.6: a) Closer look at the semiconductor layers (Left-Side) b) Photons coming
from the sunlight create a state of unbalance (Right -Side)

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Figure 2.7: Closer look at solar cells

Solar panels are sealed hermetically or in an airtight manner in order to protect

them, and are then covered in a glass that is non-reflective which protects the cells
against environmental damage. The composite is then put into a frame that is rigid
and sturdy. This frame prevents deformation due to freezing weather as well as
strong winds. Also, the frame would include a hole that allows drainage and
prevents water from building up on the device which can cause a reduction in what
is outputted. The solar panel's back is also sealed and is the area in which you can
find the junction box.

Learning Guide for ---------------- Date: Feb. 2018

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 Self-Check 1 Written Test

Directions: - Answer all the questions listed below and write your answer on the space
provided

Name __________________

1. Describe briefly the differences between AC and DC currents? (2pts)

2. Show formula of calculations for Electric Power, Resistance and Voltage. (3pts)
3. If the values, at a certain point, of current (I) is 10A and resistance ® value is 3
ohms, what would be the calculated values of Voltage (V) and Power(P)? (4pts)
4. How can you describe characteristics of voltage and current in both series and
parallel electric circuit connections? (3pts)
5. What solar panel? (2pts)
6. Describe the characteristics and uses of silicon and cadmium including positive
and negative doping mechanisms in a solar panels (4pts)
7. What is photovoltaic, how it works? (3pts)

Score = 19pts
Answer Sheet
Rating: ____________
Name: _________________________
Date: _______________

Short Answer Questions

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 Information Sheet-3 Designing Pumping System

Introduction

Although this subject is not specific for the use of solar systems, we still want to
pay attention to it, because it is a crucial subject for the design of drinking water
systems, and a basic input for all further calculations and system dimensions.

We first introduce the general method and parameters for establishing the water
consumption need of the target population of a community. After this, we introduce
parameters for calculating the production requirements for the water system.

3.1. Calculating the water needs

3.1.1. Project or system horizon and lifetime of system elements

A project horizon is established to take into account the use of the system in the future,
with a certain population growth. What you effectively do, is over-dimension the system
so that it will still be large enough in that future. The longer the time horizon is, the higher
the degree of over- dimensioning compared to the current situation.

The choice of the project horizon is essentially a choice of investment policy. The further
you look into the future, the less certain are the projections made. For example, it is very
difficult to foresee the habits of water use of a population in 10 years, let alone in 20 or 25
years. In order to make projections, the only thing you can work with is the knowledge
and information now available, and to assume that current trends will continue in the
future.

The availability of investment funds, and the way they are used, are an important factor.
Generally, a shorter time horizon will bring along less investment costs for a water supply
system because it brings along smaller dimensions of infrastructure. This way, more
systems can be constructed with the same amount of funds. With a longer time, horizon,
you take better account of the future generations, but the investments costs will be higher.

The common technical lifetimes of different components of the systems are an important
factor to take into account. These lifetimes can be estimated as follows:

Learning Guide for ---------------- Date: Feb. 2018

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Figure 3.1. Lifetime of water system elements

The choice of horizon is also a matter of financial planning and management. If you choose
a horizon of 10 years, does that mean that the system will also be written off in ten years,
even if most components have a much longer lifetime? Do you foresee financial
reservations for the extension or replacement of the components of the system? Are these
reservations included as part of the water price? If so, how do you manage these savings?
If not, how does one guarantee the investments required in the future and the continuity
of the water provision?

Each choice of horizon has its advantages and disadvantages. Once the water system has
been constructed, there is little flexibility in its components. You could add storage
capacity, but this is expensive. The highest flexibility can be found in the type of pump
installed, as well as in the number of solar panels installed. The pump is the component
with the shortest lifetime, which gives the opportunity to install a pump of larger capacity
each 5-10 years if required (and if the capacity of the borehole allows).

3.1.2. Population and population growth factor

The design population of the project at the time of project horizon (Pn ) is calculated in
function of the current population P0, the population growth factor Tc and the project in
years (n), using the following formula:

The table underneath presents the values of the multiplication factor (Pn / P0) for different
project horizons and growth factors:
Learning Guide for ---------------- Date: Feb. 2018
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Figure 3.2. Values of the multiplication factor for different project horizons and
growth factors

For instance, a population growth factor of a Country X is 2%. This growth rate is
shown in the first row of the table above.

3.1.3. The service factors

The service factor (TD) is the percentage of the population served by the water system,
divided by 100. This factor is established by the policies and objectives of the investment
project. Thus, TD is used as multiplication factor, to calculate the number of people served
by the system.

The value of TD cannot surpass 1,00. This value means that the investment is
aiming to reach 100% of the population. Usually, the TD value is between 0,80 and
0,95. To calculate the number of people served by the system Pser, multiply Pn with
TD:

3.1.4. Specific consumption.

The specific consumption Csp is the (hypothesis of the) water consumption per
person per day, expressed in liters/capita/day (l/c/d) or in liters/day/capita
(l/d/c). Also, this water consumption level is based on the objectives and strategies
of the project. It is often informed by the desired consumption level for a good
hygiene level of persons and households involved, or by national or international
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norms and standards of acceptable water consumption levels.

The total consumption is calculated by the following formula:

3.1.5. Growth of specific consumption.

In some cases, it is assumed that the specific consumption will increase over time. For this
a specific consumption growth rate is used: Tsp. The specific consumption in year n can
be calculated in an identical way as is done for the population growth rate.

The growth rate of the specific consumption of Country X is 2,6%. At the same
time, it recognizes that the current levels of water consumption are not yet 20
liters per day nowadays, and can better be estimated at a level of 12 l/c/d.

According to the standards for dimensioning water systems in Country X is, the
specific consumption will reach the 20 l/c/d in the year 2032. In order to calculate
the water consumption, the following table is used:

Figure 3.3. Estimated growth of specific consumption in Country X is.

In order to do a simpler calculation, you can combine the population growth rate
with the consumption growth rate, and calculate the total growth factor. This is
done by multiplication. In the case of Country X is, the total growth rate is the
population growth rate plus the consumption growth rate, 2% Td + 2,6% Tc =
4,6% per year.

This way, the calculation of the consumption in a certain year can be done
using the following equation:

Learning Guide for ---------------- Date: Feb. 2018

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 3.1.6. Other water needs

Depending on the policy of the project, it is possible that also other than domestic
water needs are taken into account, like water needs for schools, mosques,
churches, or health posts and clinics, or livestock needs. Often, such norms and
standards are available from the Water Authorities of the country.

3.2. Calculating the water production requirements

After having calculated the water consumption needs, there are two factors that
are usually taken into account to determine the production requirements: the
system water losses and the days of peak water use.

3.2.1. System Efficiency

The efficiency of the system E is the percentage of water produced that is actually
consumed (and paid) by the water users. Water produced but not consumed or paid is
water loss. You can (roughly) distinguish two causes of losses: losses caused by leaking
pipes or joints, and losses caused by illegal You should calculate with a factor 1/E to
calculate the production needs from the consumption needs. In newly constructed
systems, often an efficiency of 90 – 95% is assumed.

3.2.2. Peak day factor

Not during all days, it can be assumed that the water consumption is average. Some days of
the year have exceptionally high-water demand, which can be caused by several reasons,
like a community festivity, an exceptionally hot day, or because of some other reason. In
some cases, a peak day factor is used as multiplication factor for dimensioning the system.
If this peak day factor is used, usually a value between 1,1 and 1,4 is chosen.

It is a policy and design decision whether or not to use this peak day factor, and
what value should be chosen. As we have seen, the system is already designed for
the most critical month. In almost all other months, the system is already
sufficiently powerful to meet peak day requirements.

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The factor is used as multiplication factor between (average) water demand and
required production capacity of the system.

3.2.3. Daily peak use factor

This factor needs to be mentioned as well. It is a factor used to take into account
the fluctuations of water consumption during the day. Usually, there are two peak
use periods during the day in a community: one in the morning between 7.00 and
9.00 am, and one in the evening between 17.00 and 19.00 pm.

This factor is used to calculate the need for water stocking, and also for calculating
the dimension (pipe diameters) of the distribution network, so it does not play a
role in calculating the total water production needs per day.

3.3. Data collection

One of the biggest constraints in designing drinking water systems and especially solar
drinking water systems is the availability of data concerning population and water use. It
is very important to have correct data of population when designing a new system and
data concerning the use of water of existing systems for purposes of modifying the system,
financial planning (how much money will be received), etc. Water consumption data
should be collected on a daily basis and throughout the years to be able to calculate the
growth of the system. In practice the recording of the production will be the easiest. For
this purpose, a water meter needs to be installed on the head of the borehole.

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Figure 3.1 Layout of the solar water pumps

3.4. Selection of the Water Source

The type of water source and its location relative to the places where the water is to be
provided defines the configuration of the watering system. The water source will either be
subsurface (well) or surface (pond, stream, or spring). Wells are preferable because of the
improved water quality and consistency. However, wells are expensive to drill,
particularly where water tables are deep. Surface water sources may vary seasonally, such
that the amount and quality of the water is low during the summer when it is needed
most.

For wells, the following needs to be determined:

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 • Static water level

• Seasonal depth variations

• Recovery rate and

• Water quality

This information may be obtained by the well driller for a new well. For most wells, water
quality is not an issue if not used for human consumption.

For surface water sources, the following needs to be determined: Seasonal variations and
Water quality, including presence of silt, organic debris, etc.

3.5. Water Storage

The size and cost of the water storage system will depend on the amount of water
required per day. AC pumping systems connected to a utility power grid are generally
designed to run on demand with a specified flow rate. Unlike grid-tied systems, solar
pumping systems are designed to provide certain quantity of water per day. Water is
pumped during sunlight hours and stored in a tank.

The daily requirement is simply the total of all water required during a 24-hour period.
Tanks are used to store water for use during the night or periods of cloudy weather and
are usually large enough to hold three to five days of daily water output. For agricultural
use, a large amount of water has to be supplied on a periodic basis. Hence, the system
should have a tank large enough to hold at least one and half times the required limit.

3.6. Design of the Flow Rate of the Pump

For instance, designing the flow rate of the pump that is required for irrigating different
crops farm land approaches may be as follows:

And also, most of the crops cultivated in India use 3000 m3/ha to 20000 m3/ha of water.
Table 3.1 shows the water requirement of the various seasonal crops in India. In this
chapter, the water needs for rice cultivation in an area of 1 ha (2.47 acres) for 120 days is
considered, which is 46 m3/ha/day.

Hence, the water required for an average of 120 days is 5,600 m3/ha/day (120×5600
m3/ha) or 56,00,000 L/ha for the entire cultivating period.
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Table 3.1 The water requirement of the various seasonal crops (especially in India)

 Daily flow rate = 5600 × 1000 / 120 = 46667 L/ha/day

 Flow rate per minute = 46667 / (5.3 × 60) = 146 L/ha/min

 Flow rate per second = 146 / 60 = 2.44 L/ha/s

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 Self-Check 1 Written Test

Directions: - Answer all the questions listed below and write your answer on the space
provided

Name __________________

1. Describe briefly that even though there is no specific relationships with solar
system, why you need to learn for how to design pumping system? (3pts)
2. Show formula of calculations for water need, water production requirements and
population growth? (3pts)
3. Explain how to collect data? (base on population, water resources etc) (2pts)
4. What tasks should be completed before you select pumps? (3pts)
5. Demonstrate how to calculate flow rates of pumps? (2pts)

Score =14pts
Rating: ____________
Answer Sheet

Name: _________________________ Date: _______________

Short Answer Questions

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 Operation Sheet 3 Designing Pumping System

Direction: Select any of appropriate village or groups of community nearby you

Step 1- Determine their water need as per standard

Step 2-Calculat the water production requirement

Step 3- Collect and analysis necessary data

Step 4- Select appropriate water source type, pump type and pump capacity based on step 1, 2
and 3

Step 5- Determine capacity of a required Storage

Step 6- Design flow rates of the pump you selected

Step 7- Determine the volume of water to be pumped each day for the group you selected

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 Information Sheet-4 Load Calculations

4.1. Total Dynamic Head (TDH) for the Pump

Figure 4.1 depicts the head pressure that a well pump works against, which is called the
total dynamic head (TDH).

Figure 4.1 Total dynamic head for the pump

The two factors required for calculating the TDH are the desired flow rate and the total
amount of lift required.
 Flow Rate
It is the volume of fluid, which passes per unit time.
 Vertical Lift
Submersible well pumps provide lift to overcome head pressure.

TDH = Pumping Level + Vertical Rise + Friction Loss

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For a deep well,

 The static water level (SWL) to ground level is 45 m.

 The height from the well ground level to the inlet of the storage tank is 1.2 m.

 The height from ground to storage tank is 1 m.

Equation (4.1) gives the Darcy-Weisbach equation for calculating

the head loss,

(4.1)

where, is the head loss due to friction (m), l is the length of the pipe (m), and dh is the
hydraulic diameter of the pipe (for a pipe of circular section, this is the internal diameter
of the pipe) (m), v is the average flow velocity, experimentally measured as the volumetric
flow rate per unit cross-sectional wetted area (m/s), g is the local acceleration due to
gravity (m/s2), and f is a dimensionless parameter called the Darcy friction factor.

For laminar flow,

(4.2)

For Turbulent flow,

Re > 3000 (4.3)

Darcy friction loss calculation for a 1-inch pipe is 40.76 m.

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Darcy friction loss calculation for a 1.25-inch pipe is 14.18 m.
Therefore, the TDH of the SPVWPS (for a 1-inch pipe) = 45 + 1.2+ 1 + 40.76 = 88 m, and
the TDH of the SPVWPS (for a 1.25-inch pipe) = 45 + 1.2 + 1 + 14.18 =60 m.

4.2. Pump Selection and Associated Power Requirement

The pump is selected considering the induction motor and BLDC motor pump to deliver
the water. Table 4.2 gives the rating selected for operating the solar pump to deliver
47000 L/day.

Table 4.2 Selection of power rating of the solar pump

4.3. Type of motor Phase Power Voltage Current PV array

Induction Motor 3 Ph 1 HP 300 V 5 A 900 Wp

BLDC Motor 3 Ph 1 HP 300 V 4.3 A 900 Wp

4.4. Sizing of the PV Array

PV arrays are installed so that they maximize the amount of direct exposure to the sun.
This means placing the array in an area clear of shading from buildings and trees, in a
southward direction, and at an angle equal to the latitude of the location. The PV array is
specified in terms of wattage and voltage. It is a standard procedure to increase the
specified wattage by 25% (multiply by 1.25) to compensate for power losses due to high
heat, dust, aging, etc.

The total power of the PV array is (300 × 4.3) = 1290 Wp for the BLDC water pumping
system. For this work, as an example, SOLKAR make panels are used.

Table 4.3 provides the specifications of this panel at standard test conditions (STC), that is,
irradiation level G = 1000 W/m2; temperature T = 25oC; air mass AM = 1.5

Table 3.3 Specifications of SOLKAR PV Panel at STC

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Learning Guide for ---------------- Date: Feb. 2018
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 Self-Check 1 Written Test

Directions: - Answer all the questions listed below and write your answer on the space
provided

Name __________________

1. What is Total Dynamic Head (TDH)? (2pts) How can you determine it? (3pts)

2. Describe water loss? (3pts)

3. Write down deep well levels? (3pts)
4. How can you select pumps based on induction motor consideration? (3pts)
5. What is PV sizing? How do size it? (4pts)

Score = 13pts
Answer Sheet Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Operation Sheet 3 Designing Pumping System

Direction: Select any Pumping station nearby you

 Determine the total dynamic head

 Determine water pump flow rate and water loss

 Determine whether the pump is selected considering the induction motor not

 Calculate the pump rate from the number of sunlight hours (based on peak sun)

 Select the pump referring to catalogues of reputed manufacturers concerned

 Calculate and select appropriate size of solar PV array

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 Information Sheet- 5 Selecting Appropriate Location

5.1. Identifying a Site

Careful selection of the exact location for placement of the system is crucial to continuous
and reliable system operation. Exposure to shadowing from cut hillsides, trees, utility
poles or any other objects during sunlight hours will reduce power capacity and should be
avoided.

5.2. To Select a Site

Shading critically affects a photovoltaic array’s performance. Even a small amount of

shade on a PV module can reduce the module’s performance significantly. It is essential to
have a clear understanding of the sun’s path across the horizon from the east to the west.

Unfortunately, it is not possible or practical to monitor the sun exposure at a site through
long-term observation. Solar contractor installation professionals have developed tools to
provide quick insight to the solar window at a specific location.

In principle these tools evaluate a site by creating a Sun Chart. If a site is partially shaded,
the sun chart will determine the amount of available sunlight.

The sun chart will determine if the solar modules will be shaded from direct beam
radiation during critical times of the day or year. Unwanted shading can occur from trees,
vegetation, structures, other arrays, poles, and wires. Shading is often

a greater problem during winter months when the sun’s altitude is low and shadows are
longer. For locations in the northern hemisphere, shadows cast on December 21st are the
worst case through-out the entire year.

When a site is being considered, be sure that the following parameters are considered:

 Assure the array is not shaded from 9 a.m. to 3 p.m. on any day (this is the optimum
solar radiation collection time known as the solar window).

 Assure the array is not shaded in any month of the year during the solar window.

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  Identify the obstacles that shade the array during the solar window.

 Eliminate any shading, or move the array to avoid shading, or contact

TESSCO Technologies to increase the size of the array to offset losses due to shading at the
site location.

• Keeping the above factors in mind when installing the Ventev Solar Power Systems
will help ensure optimal, reliable performance of your system based on the
original, specified design parameters.

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 Self-Check 1 Written Test

Directions: - Answer all the questions listed below and write your answer on the space
provided

Name __________________

1. Describe briefly what affects photovoltaic critically? (2pts)

2. What is the sun chart?. (3pts)

3. What conditions may affect power capacity of sunlight? (8pts)

Score =8pts
Answer Sheet
Rating: ____________
Name: _________________________ Date: _______________

Short Answer Questions

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 Identifying and Selecting Solar System
Information Sheet-6
Components

Introduction

There are many factors to be considered while designing a solar pumping system.
This chapter provides the information to select a pump, controller, sensors, solar
array, wiring, and piping for the solar pumping system. A simple solar water-
pumping system that is installed for a pumping operation includes the PV array, the
controller, the pump, and accessories.

The size of the array and the pump will be determined by several factors. In this
chapter, the methodology used to determine the size of the system is described.

6.1. System Description

Figure 6.1 shows the various components of the system, which includes the solar PV
(Photovoltaic) array, a boost converter that acts as the Maximum Power Point Tracker
(MPPT), a three-phase full bridge inverter and the AC motor, which drives the centrifugal
water pump. A unique step-by-step procedure for the simulation of photovoltaic modules

Figure 6.1 Block diagram of the solar photovoltaic water pumping system

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A solar photovoltaic (SPV) water pumping system consists of the following components

A. PV Array:
Selecting a suitable array size based on the load requirement, here in this case an AC
motor operating a centrifugal or helical pump.
Should be mounted on a suitable structure with a provision of tracking the sun or with a
fixed tilted position to obtain the optimum incidence of sunlight over the array panels.

B. Electric Control Boxes in a solar pumping system (Pump Control Unit/

Controllers):
The pump controller is a highly specialized item and can vary significantly between
manufacturers. A technical term for a pump controller is a ‘linear current booster.’
The purpose of the pump controller is to regulate and match the flow of DC
electricity to the needs of the pump. In this manual, we only talk about AC water
pumps operating on solar panels, so without batteries. The pump control unit
usually contains the following components:

• MPPT
• Inverter
• Control boxes

Certain types of pumps (for example the small SQFlex pumps of Grundfos) have a
control box integrated in the submerged part of the pump that is placed in the
borehole. This way, they are less sensible to overheating. Other pumps are
delivered with a separate control box placed above ground level.

1. Maximum Power Point Tracker (MPPT)

Selecting power converters to convert the electrical power from the SPV array to
the load effectively. To convert and obtain the maximum power, the Maximum
Power Point Tracker (MPPT) is used.

A pump control unit can be equipped with a Maximum Power Point Tracker. In
this device, the charge controller looks at the DC output of the solar panels,
changes it to high frequency AC, and figures out what is the best voltage and
current to operate the pump. It takes this figure, and converts the AC current
back to DC, but to a different DC voltage and current to exactly match the best
voltage for pump operation.

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Most modern MPPT's are around 93-97% efficient in the conversion. The power
gained by a MPPT is around 10-15%, so the net effect of a MPPT is a power gain of
around 10%.

Figure 6.2 Two different examples of MPPT’s

2. Inverter
Selecting the appropriate power converters such as the DC-AC converter (inverters) to
transfer the power from the MPPT to the AC motor.

Direct current can be converted to alternating current using an inverter. This

conversion cannot be made without the loss of some power. Almost all solar installations
that drive water pumps have an inverter.

There are variable frequency inverters and fixed frequency inverters. For
pumps, the variable frequency inverter is most often used. This type adjusts the
output frequency of the AC current depending on the amount of sunshine
received by the panels. With this frequency regulation, the pump speed is
regulated, and by consequence the pumping power.

For power supply to an electric grid from a solar installation, a fixed frequency
inverter is used, because the grid requires a fixed frequency (mostly of 50 Hz).

3. Control boxes
Control unit to track the PV voltage and current to meet the reference value and to

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have a simplified control of the AC motor to deliver constant throughput.

Control boxes are electronic devices with in-built feedback loops that provide an
automatic response to undesired situations. There are situations in which we want
the system to shut down or the pump to stop pumping immediately, in order to
prevent (further) damage of the system, or in order to optimize the functioning of
the system. Five of such situations are the following:

1. Lack of water in the borehole.

Without water in the borehole, it is better to stop the pump. The pump motor
is cooled because water flows around it in the borehole. Without (sufficient)
water flow, the motor is at risk of overheating, and this can seriously damage
the motor. It makes no sense anyhow to have the pump running when there
is no water in the borehole. So, a sensor is placed within the pump, which
automatically sends an “emergency” signal to the control box when the water
level in the borehole is too low.

2. Overheating of the electric motor of the pump.

Overheating of the motor can have a number of reasons, one of which is lack
of water in the borehole. But also other reasons can cause overheating of the
motor, for example a mechanical defect in the motor itself. So a good quality
motor is equipped with a sensor for overheating that sends a signal to the
control box that switches off the power supply in case of overheating.

3. The water storage tank is full.

Further pumping makes no sense. In this case, a sensor can be placed in the
storage reservoir to detect this situation. This sensor will provide a signal to
the control box, so that pumping will stop.

It is a design choice whether or not to use such a sensor. In some situations, it can
be decided to use the overflow of the tank for additional purposes, like irrigation of
a vegetable garden or watering of cattle. In such cases, no such sensor will be
installed and used.

4. Over-voltage or over-current -The system can be automatically

switched off in case of too high voltage or current. For example, in case
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 of a short-circuit in the system.
5. Inverse polarity-A protection of the system in case wires are wrongly connected.

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 Self-Check 1 Written Test

Directions: - Answer all the questions listed below and write your answer on the space
provided

Name __________________

1. List Solar equipment commonly required in solar water pumping installation and
maintenance (4 pts )
2. What is Solar Module? (2pts)
3. Write the function the main components of Solar systems(3pts)

Score = 9pts
Answer Sheet Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

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 Identifying and Selecting Solar System
Operation Sheet 1
Components
Direction: Identifying and Selecting Solar System Components Procedure

1.1. The Solar system components identifying process:

First, the design has to begin with the water required for drinking or
irrigation proposes over a period of time and the water source where the
pump can be installed.

1.2. Solar system components selecting procedure.

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Electro Mechanical Equipment
Operation and Maintenance
NTQF Level -III

Unit of Competence: Install and Maintain Solar

Energy System for Water Pumps

Module Title: Installing and Maintaining Solar

Energy System for Water Pumps

LG Code: EIS EME3 M09 L0 01-028

TTLM Code: EIS EME3TTLM0219 v1

LO2:- Installation of Solar Energy

Equipment

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 Instruction Sheet Learning Guide #28

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics
• Series and/or parallel connections solar modules
• Installing Solar system components
• Installing Pump
• Installing Grounding and lightning protection
• inspecting the system
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
• do series and/or parallel connections solar modules
• Install Solar system components
• Install Pump
• Install Grounding and lightning protection
• inspect the system

Learning Instructions:
15. Read the specific objectives of this Learning Guide.

16. Follow the instructions described in number 3 to 20.

17. Read the information written in the “Information Sheets 1”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
18. Accomplish the “Self-check 1” in page __.

19. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 1).
20. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However,
if your rating is unsatisfactory, see your teacher for further instructions or go back to
Learning Activity #1
21. Submit your accomplished Self-check. This will form part of your training portfolio.
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22. Read the information written in the “Information Sheet 2”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
23. Accomplish the “Self-check 2” in page __.

24. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 2).
25. Read the information written in the “Information Sheets 3 and 4”. Try to understand
what are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
26. Accomplish the “Self-check 3” in page __.

27. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 3).
28. If you earned a satisfactory evaluation proceed to “Operation Sheet 1” in page _.
However, if your rating is unsatisfactory, see your teacher for further instructions or
go back to for each Learning Activities .

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 Series and/or parallel connections of solar
Information Sheet-1
modules

Introduction

In this chapter, the solar cell, solar panel and solar array are introduced and explained
with their basic characteristics. The effects of irradiance level and temperature are
presented. Attention is paid to how and where to place and locate a solar array in a water
system, and what can be done against theft and vandalism. The effect of shadow is
explained. As last subject, we introduce the electric losses and the electric efficiency.

1.1. The solar panel

PV cells are combined to make solar panels, also called modules. The PV cells are grouped
together, and encased in glass or clear plastic in order to protect the cells, whilst in the
same time allowing the sun light to reach the cells. The glass or plastic often has an anti-
reflective coating to minimize reflection of light from the panel. The panels have such a
size that they yield a reasonable amount of electricity, but are still easy to handle and
transport.

There are many producers of solar panels, and they produce panels of many different
sizes, depending on the need of the customer and the application they are used for. The
price of solar panels have dropped enormously in the last 40 years. Compared with the
year 1970, the prices have gone down by as much as 90%, and it is expected that they will
drop further. Because of this price reduction, solar panels have become more and more
interesting as alternative energy source.

Much research and development are being carried out to increase the efficiency of the
cells and panels. The most efficient PV cell currently has an efficiency of around 25%.
However, this type of cell is very expensive, and for that reason cannot yet compete with
the lower priced PV cells available.

The most important characteristics of a solar panel are:

• How much voltages it produces (in full sunshine conditions)

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 • How much current it produces (in full sunshine conditions)

How much power and energy it produces?

1.1.1. The Photovoltaic cell

The basic element of a solar panel is the photo-voltaic cell, or PV-cell. Solar panels are built
from a number of such cells. They are made of semiconducting materials that can convert
sunlight directly into electricity. When sunlight strikes the cells, it dislodges and liberates
electrons. An electron carries a very small electric load. When electrons start to move, they
produce a direct electrical current (DC).

The cells may be round, square or some other shape.

Each cell produces about 0,5 Volt, no matter what the
size is. The number of amperes a cell can produce does
depend on its size; larger cells produce more amperes.
As each cell only produces about 0,5 Volt, many cells
have to be connected in series to produce a high enough
voltage. Usually there are from 30 to 36 of these cells on
a panel intended to charge a 12 V battery.

Figure 1.1. Photovoltaic cell

Most commercial PV cells are made from silicon. There are three general types:
monocrystalline, multi-crystalline, and amorphous or thin film cells.

Figure 1.2: Different cell types

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Single crystal or monocrystalline cells are made using silicon wafers cut from a single,
cylindrical crystal of silicon. This type of PV cell is the most efficient, with approximately
15% efficiency.

This efficiency means that 15 % of the energy of the sun beam is converted into electricity.
It is also one of the most expensive to produce. Multi-crystalline or polycrystalline
silicon cells are made by casting molten silicon. They crystallize into a square solid block
of intergrown crystals. Multi-crystalline cells are less expensive to produce than
monocrystalline ones, due to the simpler manufacturing process and lower purity
requirements for the starting material. However, they are slightly less efficient, with
average efficiencies of around 12%.

Amorphous silicon PV cells are made from a thin layer of non-crystalline silicon placed on
a rigid or flexible substrate. They are relatively easy to manufacture and are less expensive
than monocrystalline and polycrystalline PV, but are less efficient with efficiencies of
around 6%. Their low cost makes them the best choice where high efficiency and space
are not important.

1.2. Solar Arrays

Solar arrays consist of a group of solar panels, placed together in a certain configuration.
The panels are grouped together in order to produce the right amount of voltage, and
sufficient current and power for the purpose they serve.

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 Figure 1.3. Composition of a solar array

1.3. Parallel and Serial Configuration

Basically, solar panels can be connected in series, or parallel.

a) Series Connection

When electrical elements are connected end to end, they are said to be connected in series.
To connect two wires in series, one end of the first wire is connected to one end of the
second wire, creating a single wire as long as the two together. This is like connecting two
batteries of 12 V to make 24 V. When more voltage is needed than a single panel can
provide, additional panels are connected in series. If one panel provides 24 V, two panels
in series will provide 24 + 24 = 48 V. For every 24 V panel connected in series, the voltage
will increase by another 24 V.

The amount of current (Amperes) provided by panels in series is the same as that
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provided by one panel because the same electricity flows through all the panels, as they
are connected in one line. As power in Watts equals Volts * Amperes, the power increases
as panels are added. (see figure 1.4 and 1.5)

Figure 1.4 Solar PV panels connected in series to meet the voltage Requirement

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Figure 1.5 Series and parallel connections

b) Parallel connection

When the voltage from a single panel is sufficient, but the amount of current needed is not
enough, panels can be connected in parallel. If one panel provides 4 Ampere in bright
sunlight, two panels in parallel will provide 4 + 4 = 8 Amperes. For each of these 4A panels
connected in parallel, an extra 4 A will be produced in bright sunlight. As power in Watts
equals Volts * Amperes, the power increases as panels are added.

Note that for both series- and parallel-connected panels, the power increases as the
number of panels is increased. Two panels in parallel produce the same power as two
panels in series, but the voltage and amperage are different. (see Figure 1.5 and 1.6)

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Figure 1.6 Solar PV panels connected in series and in parallel to meet both current
and voltage requirements

For the control of speed, the electric motor rating is selected to have a DC voltage of 400
V. To supply the required power to the motor from the PV system, 20 PV panels are
connected in series to provide (16.5 V × 20) 330 V to the maximum power point
tracking (MPPT). The MPPT provides the rated supply voltage for the motor to operate

1.4. Current-Voltage Diagram

Each solar cell, and each combination of them into solar panels and solar arrays, has a
current- voltage relation. This means that at a certain voltage V, they can deliver a certain
current I. Now remember that the most important purpose of a solar panel or array, is that
it gives us electric power. This is the multiplication of V and I. So: not only I and not only V
but maximum P = V * I

The open circuit voltage Voc is the voltage of a cell or solar panel in the situation that
no electric current is flowing. In this case, the panel is not used, but it is placed in full
sunshine conditions: It is the maximum voltage situation that can occur. In this situation,
no power is produced, because V = Vmax, but I = zero Ampere. Vmax is important because
it represents the maximum voltage a system can produce. The materials used must be able
to withstand this voltage.

When the panel is connected and electricity is flowing, the voltage produced will drop.

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When there is no resistance in the line, the situation is called short-circuit. At this
situation, the voltage will drop to virtually zero, whilst the current is at maximum (Imax).
This maximum current is also indicated as Ish (Current at short-circuit) or Icc (French for
current at “court circuit”). But the power produced in this situation is zero, because V = 0.

Maximizing the power means optimizing the relation between Voltage (V) and
current (A). The Voltage-Current diagram is a characteristic of the cell or panel. The shape
of this diagram is presented in the following figure:

Figure 1.7 Voltage-Current Diagramme

In this figure, the orange line represents the current voltage diagram. The relation
between the voltage and the current is optimal, when the size of the square enclosed by
the curve has the largest surface. In this situation, the current is ImaxP and the Voltages is
VmaxP. The size of this square represents the power produced. So, the optimal relation
between the voltage and the current is at the Maximum Power Point (MPP), as indicated in
the figure.

A Maximum Power Point Tracker (MPPT) is an electronic device that automatically adjusts
the voltage to produce the maximum power of the solar array in place.

A very important characteristic of a solar panel is how much power it can produce in full
sunshine

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conditions. This figure is called Peak Watt (Wp) or Watt Crête in French (Wc).

1.5. Current-Power Diagram

For a single PV cell, but also for a solar panel, one can construct a current-power diagram.
On the x- axis, the voltage is displayed, and on the vertical axis, the produced power in
Watts in displayed. This will typically produce a curve like the blue line in the following
figure:

Figure 1.8 Current-Power Diagram

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1.6. Effect of Irradiation

Figure 1.9 Relation between irradiance and PV output.

The current-voltage diagram presents the power output of the PV cell or panel at full
sunshine conditions. The current production of the cell (or module) is almost proportional
to the irradiance. This means that if the irradiance G is at 50%, then also the current
production will be at 50% of the maximum production. In the next figure, this relation is
shown for a solar panel of 50 Watt and 18V.

Note that also the voltage output drops at low irradiance levels, but not as much as the
current. In the figure above, the voltage output of the panel is 18V at maximum irradiance,
and 16V when irradiance is 200 W/m2 .

1.7. Effect of temperature

It is important to remember that when a cell is exposed to light, it will convert around
15% of the irradiance into electricity. The rest of the energy is converted into heat,
resulting in a rise of temperature of the cell and panel. As a result, the cell will operate at a
temperature above the ambient temperature.

The open circuit voltage (Voc) of the PV cell decreases by 2,3 mV per ˚C increase in
temperature,

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Figure 1.10 Relation between Temperature and Power

which amounts to almost 0,5%/ ˚C. This means that a rise in temperature of 10 ˚C causes
the cell to be 5% less efficient.

In this figure, the effect of a temperature is displayed. At 40 ˚C, the module produces less
voltage, and thus also the power output reduces compared to the situation of 20 ˚C.

In order to make optimal use of the panel, it is important that the panel is ventilated. If
mounted on a roof, it is good to have some ventilation space between the roof and the
panel. Metal roofing like corrugated iron sheets can become very hot themselves when
exposed to full sunshine conditions. It is not therefore not advisable to mount solar panels
on an iron roofing.

Usually, manufacturers of panels indicate the performance characteristics of the panel on

a sticker on the back side of the panel. This sticker displays the performance under
Standard Test Conditions (STC). The panels are tested with an irradiation of 1000 W/m2
and a cell temperature of 25 °C. These test conditions do not represent operating
conditions, because the irradiation will almost always be lower, and the cell temperature
almost always higher especially in African conditions.

The Nominal Operating Cell Temperature (NOCT) is the temperature the cells will
reach when operating in an ambient temperature of 20 ˚C at 800 W/m2 (G = 0,8) and a
wind speed of less than 1 m/s. The NOCT is a characteristic of the solar panel. This NOCT
often around 48 °C, depending on the construction of the panel. A cell operating in an
ambient temperature of 30 ˚C will have an even higher cell temperature than the NOCT
value. If this rise in ambient temperature of 10 ˚C also results in a rise of cell temperature
of 10 ˚C, you should reduce the expected power output by 10° C x 0,5% = 5%.

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 Self-Check 2 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. What is solar panel? (3pts)
2. Write the difference between Series and parallel solar panel connections?
Describe by using current (Ampere) and Voltage (volt) and power (watt) values
determinations(4pts)
3. Describe for current-voltage, current-power and voltage-current diagrams
and effects irradiance with PV array output (6pts)

Answer Sheet
Score = 13pts
Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Q1.__________________________________________________________________________
______________________________________________________________
Q2.__________________________________________________________________________
_________________________________________________________

Q3.__________________________________________________________________________
___________________________________________________

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 Operation Sheet #1 Series and Parallel Connections of Solar panels

Directions Collect PV arrays and appropriate tools

 Connect the PV arrays in Series and Parallel

 Determine the similarities and differences of Current, Voltage and power

accordingly

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 INSTALLING SOLAR SYSTEM
Information Sheet-2 COMPONENTS

2.1. Determining the Solar Module Tilt Angle

The sun’s height above the horizon is called altitude, which is measured in degrees above
the horizon. When the sun appears to be just rising or just setting, its altitude is 0 degrees.
When the sun is true south in the sky at 0 degrees azimuth, it will be at its highest altitude
for that day. This time is called solar noon.

A location’s latitude determines how high the sun appears above the horizon at solar noon
throughout the year. As a result of the earth’s orbit around the sun with a tilted axis, the
sun is at different altitudes above the horizon at solar noon throughout the year.

Photovoltaic module(s) or arrays work best when the sun’s rays shine perpendicular (90
degrees) to the cells. When the cells are facing the sun in both azimuth and

altitude, the angle of incidence is “normal”, as shown in Figure 2.1

Figure 2.1: Angle of Incidence on a Solar Module

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Seasonal changes of the sun’s altitude must be considered to optimize a system’s
performance. When the array is installed, it should be tilted at an angle that yields the
highest value of insolation during the worst-case month in the year. This ensures that the
system is designed to meet the load demand and keep the battery fully charged in the
worst month for the average year. The following general guidelines outline a rule of thumb
tilt angle of a solar module for different seasonal loads.
For example,
 Winter loads Northern Hemisphere: Tilt angle = site latitude + 15°
 Winter loads Southern Hemisphere: Tilt angle = site latitude – 15

The best method to determine the optimal tilt angle is to perform a site survey; contact
TESSCO Technologies for assistance with these professional services.

More sunlight per square foot falls on a perpendicular surface (90Deg angle to the sun’s
rays is optimal) Less sunlight per square foot falls on a horizontal surface.

2.2. Assembling and Mounting the Solar Module Support Structure

The load capacity, equipment size and geographic location of the Solar Power System
purchased determines the number of solar modules needed. Also, mounting
configurations are driven by the pole size and number of solar modules needed.

The following figures show various pole mounting configurations for the solar modules
and how the module interconnect conduit assembly is installed in a 2-solar module mount
assembly.

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Figure 2.2: Pole Mounted Module Figure 2.3: Dual Arm Single Module
Mount

Figure 2.4 shows how the interconnect conduit assembly is installed on a two module

assembly.

Figure 2.4: Two Module Mount with Module Interconnect Conduit Assembly

2.3.1. Assembling and Mounting Guidelines

Figure 2.5 illustrates the proper orientation and wiring configuration for connecting the
junction boxes of multiple modules.

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Figure 2.5 Module Junction Box connection

Be certain to position the modules such that the junction boxes are on the same side in the
series. For easiest access, use the junction box penetration hole toward the center of the
module for attaching the 90 degree connectors. Instructions for connecting multiple
modules follow.

• Lay the modules face down on a flat, protected surface when attaching the support
rails to prevent damaging the glass and to eliminate electrical hazard.

• Take great care in the use of hand tools in the vicinity of modules’ back surface. The
module back surface materials are easily punctured, and any opening in the back
surface will allow the entry of moisture which can shorten module service life. If
punctures occur, seal with a non-acidic, commercial grade RTV sealant.

• Remove the junction box hole tab closest to the middle of the module. Attach the 90
degree connectors as shown in Figure 2.5.

• Connect wiring to the terminals in the configuration shown in Door Wiring

Diagram for the system delivered.

• Look for specific manufacturer’s instructions in the packaging, and if found, follow
them carefully.

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 2.3.2. Mounting the Battery Enclosure

The physical size and weight of the batteries varies depending on storage capacity
dictated by design requirements. The batteries are housed in the bottom of the enclosure
which is attached to the pole.

2.3.3. Mounting Enclosure to Pole

a. Take the two clamps/U-bolts from the hardware bag for the appropriate pole size,
hex nuts, bolts and washers.

b. Position the battery box against the pole and install the clamps/U-bolts loosely
using hardware described above.

c. Position the enclosure against the north side of the pole (opposite the array, to take
advantage of any shading available for reduced heat on the battery(s) and
electronics in the enclosure) and tighten the bolts (Check for level before
tightening), with the conduit knockouts on the bottom.

2.4. System Wiring

CAUTION: Remove all fuses and turn OFF all circuit breakers before beginning any wiring.

1. Grounding

a. Ground the support rails in accordance with site Local codes.

b. Ground the enclosure according to local codes.

2. Load Wiring

a. Locate the wiring diagram on the door.

b. Wire the load equipment to the Solar Controller terminal blocks according to the
wiring diagram, carefully observing correct polarity.

3. Array Wiring

The customer load requirements, geographic location of the system, and available sunlight
are among the factors that dictate the number of modules provided with the system and

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determines the circuit wiring configuration specific to the site needs. The Solar Module
has a junction box located on the back side of the module. The junction box is designed to
accommodate standard wiring and/or conduit connections. All wiring and electrical
connections should comply with the National Electrical Code (NEC), Article 690 Solar
Photovoltaic (PV) Systems. A cable clamp with a minimum rating of IP65 must be used to
maintain the weatherproof integrity of the junction box. Bypass diodes are preinstalled at
the factory.

The following figures illustrate the various module wiring configurations of the Solar
Power Systems. To determine the module wiring configuration for your system, locate the
wiring diagram on the door of the enclosure for your system and compare the module
wiring to your system.

4. Single Module Solar Module Wiring

CAUTION: Remove all fuses and turn OFF all circuit breakers before beginning any wiring.

Keep solar modules face down on a flat surface and/or cover the module(s) face with a sun
protective cover while wiring.

Shorting solar module terminals together can damage the modules, so use care in handling
connected wiring.

Figure 2.6 illustrates the terminal connections on a single solar module.

Figure 2.6: Single Module Terminal Wiring

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 5. The process for wiring a single module panel terminal block:

1. Open the solar module junction box by loosening the screws.

2. Connect #10 AWG black wire from the solar module terminal two (2) to the terminal
block that connects to the Solar Controller Terminal three (3).

3. Connect #10 AWG red wire from solar module terminal 3 to the fuse block that connects
to Solar Controller Terminal four (4).

6. Multiple Modules Connected in Series

Figure 2.7 shows the wiring configuration for multiple modules connected in series.

This configuration allows solar modules to be grouped to match voltage levels required in
the system design (two 12 Volt modules wired in series converts to a 24 Volt system).
Note and carefully observe polarity while connecting the modules.

Figure 2.7: Multiple Solar Modules Connected in Series

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Carefully observe and note polarity when wiring the modules. Steps for wiring modules in
series as shown in Figure 2.7 include:

1) Open the solar module junction boxes on all modules by loosening the screws.

2) Connect #10 AWG black wire from terminal two (2) (negative) on the first solar
module in the series to the Solar Controller Terminal three (3) (negative).

3) Connect #10 AWG red wire from terminal three (3) (positive) on the last solar
module in the series to the terminal block that connects to the Solar Controller
Terminal four (4) (positive).

4) Connect a #10 AWG black wire from terminal two (2) (negative) on the first
module in the series to terminal three (3) (positive) of the second module in the
series.

5) Repeat step three until all modules have been wired together.

6) Connect #10 AWG red wire from the last module in the series terminal 3 to the fuse
block that connects to Solar Controller Terminal four (4).

7. Multiple Modules Wired in Parallel

Multiple modules wired in parallel as illustrated in Figure 15 enables power wattage to be

incrementally increased while retaining the voltage levels of each individual module (i.e. If
the modules in the figure are 12 volts each, then 12 volts are presented to the Solar
Controller with the power capacity of all three combined.

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Figure 2.8: Multiple Solar Modules Connected in Parallel

Figure 2.9 illustrates the junction box used in wiring multiple modules in parallel.

Figure 2.9: Solar Module Junction Box

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The steps involved in wiring multiple modules in parallel include:

1 Remove the strain relief locknut from the conduit end marked "ARRAY". Insert the end
into the junction box, replace the locknut and tighten.

2 Terminate the 30” interconnect cable as shown in Figure 2.5.

3 Terminate the wire ends as shown in the Door Wiring Diagram and Figure 2.7 (Red +,
Black -). Tighten the terminal screws to no more than 21 in-lbs. Check your connections to
make sure they are the correct polarity. Close and secure the cover.

4 Locate the hole in the back or bottom of the battery enclosure.

5 Remove the strain relief locknut from the conduit end. Insert the conduit end into the
battery enclosure, replace the locknut, and tighten.

6 Connect the array wires to the terminals marked “Array +” and “Array -” (Red positive,
Black negative).

8. Wiring and Installing the Battery

Battery(s) are shipped separately and not installed in the enclosure before shipment.
Observe the following guidelines when working with batteries.

CAUTION: Electrical Burn Hazard

A short-circuited battery can produce thousands of amperes that will melt hand tools and
cause severe burns. Take great care when handling the batteries and installing their
interconnection wiring.

CAUTION: Wear eye protection and gloves. Remove all metal that can come in contact
with battery terminals.

TIP: Keep the array, batteries, and loads as close together as possible. Due to electrical
resistance of the interconnect wires, the electrical output drops over long distances.

Shorter distances between the components of the PV power system minimize voltage drop
and will also reduce wiring costs.

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CAUTION: Use extreme care in placing the battery(s) into the enclosure, being careful not
to short battery terminals to the enclosure casing.

NOTE: Consult the wiring diagram on the enclosure door of the delivered system to
determine the configuration of the battery(s) supplied. Locate that configuration in this
section then follow the installation instructions herein for your system.

To accommodate varying load requirements, the Ventev Solar Power Systems come
equipped with the number of batteries and various battery amp-hour capacities required
to meet design. The number of batteries depends on the required load and geographic
location where the system will be installed. 12 Volt and 24 Volt solar power systems are
provided and since all batteries used are 12 volts, the batteries are often connected in
series to yield 24 volt capacity. With amp-hour capacities designed to fit load demand,
geographic location, and available sunlight, the battery capacity and physical size varies
from system to system.

9. Single Battery Connection

Figure 2.10 illustrates a single battery configuration.

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Figure 2.10 Single Battery Connection

The dashed lines indicate wiring that must be connected on site after the batteries are
positioned and anchored.

10. To Install and Wire a Single 12 Volt Battery

1 Remove the appropriate punch-outs from the battery label to indicate the month and
year of installation (6 = 2008). This step is very important for tracking battery
performance and warranty information.

2 Set the battery into the enclosure.

3 Connect the RED lead(s) to the POSITIVE (+) terminal of the battery using the bolts,
washers, and nuts provided. Tighten battery connections to 100 in-lbs.

Take care not to short circuit the battery terminals with the wrench to the negative
terminal or to the enclosure casing.

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4 Connect the BLACK lead(s) to the NEGATIVE (-) terminal of the battery in the same way,
observing the same precautions.

5 Make sure that the battery terminals are completely covered by the insulating boots.

11. Multiple 12 Volt Batteries in Parallel

Connecting 12 Volt batteries are in parallel enables incremental increase in amphour

capacity. For example, two 40Amp-Hour batteries connected in parallel increases total
capacity to 80Amp-Hours. Figure 18 shows the wiring configuration for parallel battery
connection.

Figure 2.11 Parallel 12 Volt Battery Configuration

The dashed lines indicate wiring that must be connected on site after the batteries are
positioned and anchored.

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To Install and Wire Multiple Batteries in Parallel

1. Remove the appropriate punch-outs from the battery labels to indicate the month and
year of installation (6=2008). This step is very important for tracking battery performance
and warranty information.

2. Set the batteries into the enclosure.

3. Connect the RED leads to the POSITIVE (+) terminals of each battery using the bolts,
washers and nuts provided. Tighten battery connections to 100 in-lbs.

Take care not to short circuit the battery terminals with the wrench to the negative
terminal or to the enclosure casing.

4. Connect the BLACK leads to the NEGATIVE (-) terminal of the batteries in the same
manner, observing the same precautions.

5. Make sure the battery terminals are completely covered by the insolating hoods.

12. Multiple Batteries Connected in Series

Connecting multiple batteries in series increases the overall voltage by the number of
batteries multiplied by the voltage of each. Given the two batteries in Figure 2.12 are 12
volts, the resulting voltage is 24 volts.

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Figure 2.12 Multiple Batteries in Series

The dashed lines indicate wiring that must be connected on site after the batteries are
positioned and anchored.

DANGER: Closing the fuse holder to energize the system may create sparks. Never
energize the system in the presence of explosive vapors. Close all fuse holders to energize
circuitry.

After the mechanical and electrical installation is complete, check the integrity of all
electrical terminations and mechanical fasteners. Perform the electrical checkout
described below.

1) Check the solar module orientation using a compass (or GPS); make sure it is facing
true south.

2) Check all mounting fasteners to make sure the mounts are secure.

3) Test the polarity, voltage, and amperage produced by the array. On a clear sunny
day, the readings should be approximately equal to those listed specifications for
the system.

4) Check the voltage of the batteries. The voltage should be approximately 12 VDC.
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 5) Verify the "CHARGING" light on the Solar Controller is ON. If it is not ON, recheck all
connections for tightness. Ensure that the controller has been set for the correct
battery type.

6) Turn on the load and verify its proper operation. Perform a series current draw
reading while the load is operating and confirm that they are within the design
limits of the system.

7) The solar power system is now fully functional.

8) Recheck all electrical connections at the battery bank and the charge controller.

9) Close and secure the enclosure

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 Self-Check 2 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. Write at list three components of Solar system and their uses(6pts)
2. What is the purpose use of battery in solar system? (4pts)
3. Describe the junction box purpose of use in PV solar equipment
installation and list down the components to be configured with its terminals?
(5pts)

Answer Sheet
Score =15pts
Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Q1.____________________________________________________________________
___________________________________________________________________

Q2.____________________________________________________________________
_______________________________________________________________________
Q3.____________________________________________________________________
_______________________________________________________________________
______

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 Operation Sheet #1 Installing Solar System Components

Directions:
 Implement solar equipment procedural installation performance in installation field, if
appropriate. If not, just demonstrate at your learning workshop areas as appropriate.
 Identify and collect required equipment and tools for Solar equipment installation
 Follow and implement all safety rules and regulations Additional information for the
Operator

The tasks to be implement are as follows:

1. Mount solar module at appropriate direction and position (apply it for single
module and multiple module)
2. Wire solar equipment such as battery, junction box, terminals and PV array
using single solar module and multiple module
3. Inspect, test (if defects, correct) and the verify for operationality of the solar
equipment you mounted and wired under steps 1 and 2

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 Installing Grounding and Lightning
Information Sheet-3 Protection

2.1. Installing Grounding and Lightning Protection

Grounding

c. Ground the support rails in accordance with site Local codes.

d. Ground the enclosure according to local codes.

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 Self-Check 2 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. Describe how to ground when wiring solar component? (3pts)
2. Explain what methods are to be use to protect lighting problems for solar
system installation? (4pts)

Answer Sheet
Score = 7pts
Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Q1.____________________________________________________________________
____________________________________________________________________
Q2.____________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
______________________________________________________________________

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 Operation Sheet #1 Installing Grounding and Lightning Protection

Directions:
 Implement solar equipment procedural installation performance in installation field, if
appropriate. If not, just demonstrate at your learning workshop areas as appropriate.
 Identify and collect required equipment and tools for grounding and lightening protection
installation
 Follow and implement all safety rules and regulations Additional information for the
Operator

The tasks to be implement are as follows:

1. Install appropriate grounding and lightening protection as per rules and
regulations (apply it for single module and multiple module)
2. Inspect and test for rectifications

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Electro Mechanical Equipment
Operation and Maintenance
NTQF Level -III

Unit of Competence: Install and Maintain Solar

Energy System for Water Pumps

Module Title: Installing and Maintaining Solar

Energy System for Water Pumps

LG Code: EIS EME3 M09 L0 01-029

TTLM Code: EIS EME3TTLM0219 v1

LO3: - Maintenance and

Service

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 Instruction Sheet- 1 Learning Guide #29

This learning guide is developed to provide you the necessary information regarding
the following content coverage and topics
• Maintenance and services
▪ system maintenance
• Periodic/preventive maintenance
• Troubleshooting
This guide will also assist you to attain the learning outcome stated in the cover page.
Specifically, upon completion of this Learning Guide, you will be able to –
• Conduct Maintenance and services
o system maintenance
• do periodic/preventive maintenance
• Troubleshoot

Learning Instructions:
29. Read the specific objectives of this Learning Guide.

30. Follow the instructions described in number 3 to 20.

31. Read the information written in the “Information Sheets 1”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
32. Accomplish the “Self-check 1” in page __.

33. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 1).
34. If you earned a satisfactory evaluation proceed to “Information Sheet 2”. However,
if your rating is unsatisfactory, see your teacher for further instructions or go back to
Learning Activity #1
35. Submit your accomplished Self-check. This will form part of your training portfolio.

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36. Read the information written in the “Information Sheet 2”. Try to understand what
are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
37. Accomplish the “Self-check 2” in page __.

38. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 2).
39. Read the information written in the “Information Sheets 3 and 4”. Try to understand
what are being discussed. Ask you teacher for assistance if you have hard time
understanding them.
40. Accomplish the “Self-check 3” in page __.

41. Ask from your teacher the key to correction (key answers) or you can request your
teacher to correct your work. (You are to get the key answer only after you finished
answering the Self-check 3).
42. If you earned a satisfactory evaluation proceed to “Operation Sheet 1” in page _.
However, if your rating is unsatisfactory, see your teacher for further instructions or
go back to for each Learning Activities .

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Information Sheet-1 Maintenance and Services

Objectives:

To give detail information regarding the types of preventive maintenance and

breakdown maintenance work to be done in solar PV pumping system. Again,
this chapter also includes the common types of problems that occur in such
systems and their troubleshooting methodology.

1.1. Routine Maintenance and Preventive Maintenance

It does not take much time and money to regularly maintain a solar PV
pumping system but it may take a lot to repair the system if it fails.
Regular maintenance makes the difference between a PV pumping system
that works without problems for years and one that is always breaking
down. While installing PVWPS every care must be taken to minimize the
cable losses as far as possible by keeping pump and PV arrays as close as
possible. The PV array is to be installed carefully at a proper location to
avoid shadowing of any part of the array or other obstructions throughout
the year. The array should be inclined facing south in case of Northern
Hemisphere. Solar pumps should not normally require more than a simple
maintenance, which only demand rather basic skills. The main problem
with them is lack of familiarity.

1.1.1. PV Array

• Check the PV array/panel mounting to make sure that it is strong

and well attached. If it is broken or loose, repair it.

• Check that the glass is not broken. If it is, the PV array/panel will
have to be replaced.

• Check the connection box to make sure that the wires are tight
and the water seals are not damaged.

• Check to see if there are any shade problems due to vegetation or

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 new building. If there are, make arrangements for removing the
vegetation or moving the panels to a shade-free place.

1.1.2. Wires

• Check the wire covering (insulating sheath) for cracks

or breaks. If the insulation is damaged, replace the wire. If the wire is

outside the building, use wire with weather-resistant insulation.

• Check the attachment of the wire to the building to make

sure, that it is well fastened and cannot rub against sharp

edges when the wind blows.

• If someone has changed the wiring since the last check, make
sure that it is the correct size, that it has suitable insulation, that
the connections are properly made and that it is fastened
securely in its new place.

• If someone has added more wires to the PV system to operate

additional appliances, advise the owner that this may seriously lower
the reliability of the system. Advise increasing the panel and to handle
the increased load.

• Check the connections for corrosion and tightness.

1.1.3. Power Conditioner

• Check that the junction box is still firmly attached. If it is not,

attach it correctly with screws.

• Keep the junction box clean.

1.1.4. Appliances

• Turn on each appliance and check that it is working properly.

• Check that appliances are mounted securely. If loose or

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 incorrectly mounted, attach them securely.

• Clean all exposed parts of each appliance. Clean light bulbs and
plastic covers.

1.1.5. Pump:

• In case of submersible pump electrical connections have to be

checked at least once every six months

• The brushes, if any, are to be changed after six months of continuous use.

• The inverter connected to the pump has to be checked at least

once a month for proper operation.

Besides there are a number of simple faults that can arise which
needs immediate corrections:

• Poor electrical connection caused by dirty, wet or corroded

terminal or plugs

• Blocked strainers and filters on the pump

• Failure of suction pump due to loss of prime caused by faulty foot-

valve or air leaks in suction line (specially in case of surface pump)

• Leaking pipe and hose connections

• Leaking pump gland seal

• Some pumps need frequent replacement parts as suggested by its

manufacturers

• In case of positive displacement pumps, loosening of belts and

chains may occur hence requiring tension adjustments.

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 Self-Check 1 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
3. Describe how to Repair and service solar system component? (3pts)
4. Explain what methods are to used up for solar system maintenance and
service? (4pts)

Answer Sheet
Score = 7pts
Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Q1.____________________________________________________________________
____________________________________________________________________
Q2.____________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
______________________________________________________________________

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 Operation Sheet #1 Maintenance and Services

Directions:
 Implement solar equipment procedural installation performance in installation field, if
appropriate. If not, just demonstrate at your learning workshop areas as appropriate.
 Identify and collect required equipment and tools for grounding and lightening protection
installation
 Follow and implement all safety rules and regulations Additional information for the
Operator

The tasks to be implement are as follows:

3. Install appropriate grounding and lightening protection as per rules and
regulations (apply it for single module and multiple module)
4. Inspect and test for rectifications

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 Information Sheet-2 Periodic/Preventive Maintenance

In many cases the manufacturers may have special recommendations for routine
and preventive maintenance. These recommendations have to be strictly followed
for proper and safe operation of the complete system.

In each station there must be card mentioning the dates when routine and
preventative maintenance are carried out. If any fault has been observed it must be
registered in this card. This card must be accessible all the time at the site.

1.1.6. Monitoring and Evaluation of Installed water pumps

The purpose of Monitoring and Evaluation (M&E) is to make sure that the system
works properly and satisfy the users as foreseen in the design phase and in the
long run it becomes sustainable.

Monitoring and evaluations of installed pumps should be carried out after one
month of complete and successful installation to answer the following questions:

• Is the system performing as per the specification of supplier (this

may include parameters like discharge of water at specified total
dynamic head, ambient temperature and insolation)?

• Has the system brought positive social changes in the area?

• Have the suggestions and comments of users group been incorporated?

• Have the users paid back the loan component in time if any?

The same procedure mentioned above should be repeated after six months, twelve
months after a complete successful installation. Then after, monitoring and
evaluation be carried out once every six months.

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 Self-Check 2 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
1. List preventive maintenance activities for Solar system? (3pts)
2. What is preventive maintenance? (4pts)

Answer Sheet
Score = 7pts
Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Q1.____________________________________________________________________
____________________________________________________________________
Q2.____________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
______________________________________________________________________

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 Operation Sheet #2 Periodic/Preventive Maintenance

Directions:
 Implement solar equipment procedural installation performance in installation field, if
appropriate. If not, just demonstrate at your learning workshop areas as appropriate.
 Identify and collect required equipment and tools for grounding and lightening protection
installation
 Follow and implement all safety rules and regulations Additional information for the
Operator

The tasks to be implement are as follows:

1. conduct appropriate preventive maintenance as per rules and regulations (apply
it for single module and multiple module)

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 Information Sheet-2 Troubleshooting

1.1. Trouble Shooting

Well-designed, well-installed and well-maintained solar PV systems are reliable and

can have a long trouble-free life, but sooner or later there will be a failure. The process
of finding the cause of the failure is called troubleshooting. The process of making the
system work properly again is called repair.

1.1.1. Types of System Failure

There are three types of solar PV system failure:

Each type of system failure has a different cause and troubleshooting

methods are different.

Failure type 1: The system stops working entirely. None of the

appliances work.

Failure type 2: Some appliances work normally, others do not.

Failure type 3: The system works but runs out of power too quickly.

Each type of system failure has a different cause and troubleshooting

methods are different.

1.1.1.1. Failure type 1: Total system

If the system fails completely, the reason is usually a broken wire,

poor connection or controller failure. The problem is to isolate the
fault in the system.

• Fuse or circuit-breaker problem:

Make sure that all appliances are switched off. Check any fuse
or circuit- breaker in the panel to the whole circuit.
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 Corrective action: Disconnect the loads at the controller. If the
fuse is blown, replace it with the correct type and ampere
capacity of fuse. If the circuit-breaker is tripped, turn it back on.
If the fuse or circuit breaker blows again, there is a problem
with the wiring between the panel or with the controller.
Continue with this checklist. If the fuse or circuit-breaker does
not blow, reconnect the load and turn the appliances on. If the
fuse or circuit-breaker blows again, there is a short in the
appliance wiring or in an appliance.

• Faulty panel or panel wiring:

Disconnect the leads to the panel terminals of the charge

controller. Check the voltage across the two wires from the
panel when the sun is shining. If the voltage is less than 12 V,
there is a problem with the panel or the panel wiring. If the
voltage is 12 V or more, measure the amperes from the panel. If
the amperes are very low for the panel that is installed, the
connections to the panel may be loose or corroded. Also the
panel may be damaged.

Corrective action: Disconnect all the panels and carefully check

that each one is working properly (voltage and amperage).
Replace panels that are not working well.

Clean all terminals and wires: Reconnect the panels, making

sure that the correct wires are connected to the correct
terminals. Also make sure that the panels are not shaded.

• Faulty controller:

Check the voltage at the panel connections on the controller

when the sun is shining. If the voltage at the pump connection is
less than 13.5 V and the voltage at the panel connection is more
than 14 V, the controller has probably failed. Some types of
complex, computerized controllers cannot be tested with simple
voltmeters. If that type of controller is thought to have failed,
one have to replace the controller with one known to work
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 properly and wait to see if that cures the problem.

Corrective action: Replace the controller.

• Faulty wiring between controller and pump

Measure the voltage at the pump connections and controller

connections. If the voltage is more than 0.5 V lower at the
controller, there is a wiring problem.

Clean all connections and wires: Replace wires in connectors

and terminals and tighten all connections. Make sure that the
wire connecting the controller and the pump is the correct size
for the current being carried.

• Fuses or circuit-breakers

Check all fuses and circuit-breakers. If they have opened the

circuit there is a short circuit in the wiring or appliances. Check
all appliances and the wiring from the controller to the
appliances.

Corrective action: Fix shorted wiring or faulty appliances,

replace fuses and reset circuit-breakers.

• Wiring between controller and appliances

Turn on at least one appliance and check the voltage at the load
connections on the discharge controller.

Corrective action: Clean all connections, replace all wires that

are damaged or that are not the correct size for their length.

• Faulty switch

If there is one switch that controls all appliances, it may be the

problem. Using a short wire, connect across the switch
terminals. If the appliances work, then the switch is faulty.

Corrective action: Replace the switch.

Learning Guide for ---------------- Date: Feb. 2018
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 • Controller failure

Measure the voltage at the load terminals. If the load terminal

voltage is zero or much lower than other terminal voltage, the
discharge controller may not be working properly. Corrective
action: Replace the controller.

1. Failure type 2: Some appliances work but some do not

This type of failure is rarely due to PV panel. It may be caused by:

1. A faulty appliance switches

Use a short wire and connect the switch terminals together. If

the appliance works, the switch is faulty.

Corrective action: Replace the switch.

2. An appliance has been wrongly connected

Check the connection at the appliance. Make sure that wire of

the appliance is connected to the wire (+) of the controller.

Corrective action: Connect the wires correctly.

3. The wire size is too small or too long

Measure the length of the wire run.

Check to see if the wire is too small for its length.

Corrective action: Replace the wire with one of the correct size.

4. Connections are loose or dirty

Remove wires from all connections between the appliance and

the controller. Clean the wires and terminals. Replace the wires
and tighten the connections.

2. Failure type 3: The system works but runs out of power

Learning Guide for ---------------- Date: Feb. 2018

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 This is the most common problem with solar PV systems and can be
caused by many things acting alone or in combination. This may be
caused by:

1. Too little energy from the panels

The reason for this may be shading, damaged panels, wiring too
small or too long, dirty or loose connections, panels not facing in
the right direction or dirt on the panels.

Corrective action: Remove the cause of the shade or move the

panels so they are no longer shaded and are facing in the right
direction, clean and replace the panels if damaged, check the
wiring on the panels.

2. Incorrect adjustment of the charge controller

This may prevent the getting energy for the pumps. In some
cases, a special controller tester will be available but, when it is
not, it can be checked by asking the user to keep appliance use
to a minimum for several sunny days. Come to the site in the late
afternoon of the third or fourth sunny day while the sun is still
shining. Check the voltage at the connections and at the panel
terminals of the controller. If the two voltages are about the
same and they are both above 13 V for a 12 V system, or 26 V for
a 24 V system, then the charge controller is probably working
properly. Corrective action: Replace the controller and send the
old one for repair.

Learning Guide for ---------------- Date: Feb. 2018

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Troubleshooting

• Inspect the system: Many problems can be

located by simple inspection.

• Inspect the solar array: 1. Is it facing the

sun? (For details, see solar array orientation)

Is there a partial shadow on the array? If only 10% of the array

is shadowed, it can stop the pump.

Inspect all wires and connections

1. Look carefully for improper wiring (especially in a new

installation).

2. Make a visual inspection of the condition of the wires

and connections. Wires are often chewed by animals if
they are not enclosed in conduit (pipe).

3. Pull wires with your hands to check for failed connections.

Inspect the controller and junction box

1. Remove the screws from the bottom plate of the controller. Move
the plate downward (or the controller upward) to reveal the
terminal block where the wires connect.

2. Indicate a failure of the electronics. Look for burnt wires, bits of

black debris, and any other signs of lightning damage.

2. Open the junction box. Is the power in switch turned on? Pull on
the wires to see if any of them have come loose.

3. Inspect the grounding wires and connections.

4. Most controller failures are caused by an induced surge from nearby

lightning where the system is not effectively grounded. Ground
connections must be properly made and free of corrosion.

Learning Guide for ---------------- Date: Feb. 2018

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Check the low-water probe system:

If the controller indicates “Source low” when the pump is in the water, inspect the
low-water probe system. The probe is mounted on, or near the pump. If inspection
is not feasible, it can be bypassed the probe or test it electrically.

1. If the probe is not being used, there must be a wire between

terminals 1 and 2.
2. The probe is a cylindrical plastic device mounted on or near the
pump. It contains a small float on a vertical shaft. The float must be
able to move
3. up to indicate that it is submerged, and down to indicate that it is dry.
4. The probe must be positioned vertically (within about 10°).
5. The probe or a probe wire may be broken.
1. Inspect the wires for damage.
6. Does the pump run when the probe is out of the water? This can
happen if the float in the probe is stuck. In surface water, this can
happen from algae, a snail, or other debris.

Checkthe full-tank float switch

If the controller indicates “tank full” when the storage tank is not full, inspect the
float switch system. If the system has a float switch, it will be mounted in the tank.
If inspection is not feasible, it can be bypassed the switch or test it electrically.

1. If a float switch is not being used, there must be a wire

between the terminals.

2. Inspect the float switch. Is it stuck in the up position?

3. There are two types of float switch, normally-open and

normally-closed. Check to see that the wiring is correct for the type
that is used.

Force a quick start

If it is restored a connection or bypass the probe or float switch, there is no need to

wait for the normal time delay. Switch the on/off switch (or the power source) off
then on again. The pump should start immediately if sufficient power is present.
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Electrical Testing

A “multimeter” is required and a clamp-on ammeter is helpful. Test the solar array circuit

1. Open circuit voltage: This is “idle” voltage. It is normally high

because no current is being drawn (it’s doing no work).

Short circuit current or spark test: This is helpful if the pump is trying to
start or does not seem to get full power. Disconnect the array from the
controller before making this test.

(A short circuit at the array will only cause current slightly higher than
normal.) If there is no a DC amp meter, a spark that can jump 1/4” (6 mm)
indicates a good probability that the array is working properly.

3. Voltage under load (with pump running)

4. Current under load was connected to the controller with reverse

polarity? No lights will show on the controller. This will not cause damage.

Test the motor circuit (resistance test with power off), make this test if there is
proper voltage at the controller input but the motor does not run. It will confirm the
condition of the entire motor circuit, including the motor, pump cable and splice.

Test the running current of the motor circuit (AC amps), this is one of the most
useful trouble shooting techniques because it indicates the force (torque) that the
motor is applying to the pump. For greatest ease, use a clamp-on ammeter, available
from local electrical equipment suppliers. It allows to measure current without
breaking connections.

The current stays nearly constant as voltage and speed vary. The measurements
may vary by as much as 10% and more if temperature is out of the normal range.
Comparing the reading with the standards provided by manufacturers, this will
indicate whether the workload on the motor is normal for the lift it is producing.

Future changes may indicate pump wear, or change in the level of the water source.

Higher current (especially pump overload light) may indicate:

1. The pump may be handling excessive sediment (sand, clay). The

Learning Guide for ---------------- Date: Feb. 2018
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 total dynamic head (vertical lift plus pipe friction) may be higher than
expected it is.

3. There may be an obstruction to the water flow- sediment in the pipe,

ice in the pipe, a crushed pipe or a partially closed valve. (Is there a
float valve at the tank?)

4. Helical rotor models: Water may be warmer than 72°F (22°C). This causes
the rubber stator to expand and tighten against the rotor (temporarily, non-
damaging).

5. Helical rotor models: Pump may have run dry. Remove the pump
stator (outer body) from the motor, to reveal the rotor. If there is
some rubber stuck to the rotor, the pump end must be replaced.

To reset the over load shut off (red light), switch the pump controller off and on.

Lower current may indicate:

1. In a deep well, the level of water in the source may be far above the
pump intake, so the actual lift is less than expected. This is not a
problem.

2. The pump head may be worn, thus easier to turn than normal
(especially if there is abrasive sediment).

3. There may be a leak in the pipe system, reducing the pressure load.

4. Helical rotor models: Water may be colder than 46°F (8°C). This
causes the rubber stator to contract, away from the rotor. The pump
spins easier and produces less flow under pressure.

Test the low-water probe circuit

If the controller indicates “source low” when the pump is in the water, the low-
water probe system may be at fault. When the water level is above the probe, the
switch in the probe makes contact. That causes the applied voltage to drop toward
zero. The systems “sees water” and allows the pump to run. If the voltage is greater
than 3V, dry shut off is triggered. The low-water probe has an internal 1K resistor

Learning Guide for ---------------- Date: Feb. 2018

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in series with the switch. When closed (in water), the normal resistance is around
1000. To bypass the low-water probe (and activate the pump), connect a small
wire between the probe terminals in the junction box. Restart the controller. If the
pump runs, there is a fault at the probe or in the probe wiring. The wires may be
shorted (touching each other) or open (broken) or the moving part on the probe
may be stuck with debris, or the probe may be out of its normal, vertical position.

Test the full-tank float switch

If the controller indicates “Tank full” when the tank is not full, the float switch or
pressure switch system may be at fault.

1. If the remote switch circuit is not being used, there must be a wire
between the terminals.

There are two types of float switch, “normally open” and “normally closed”.

Check to see that the wiring is correct for the type that is used.

3. Most float switches are “normally open”. Disconnect a wire from the
terminals, and the pump should run. Connect a wire between the terminal, and
the pump should stop.

4. Most pressure switches (and some float switches) are “normally

closed”. Connect a wire between the terminals, and the pump should
run.

If the pump responds to the bypass tests above but not to the float switch,
the wires may be shorted (touching each other) or open (broken), or the
switch may be stuck

If the pump runs but flow is less than normal with

debris, or out of its correct position.

1. Is the solar array receiving shadow-free light? (It only takes a small shadow
to stop it.) Is it oriented properly toward the south, and tilted at the proper
angle?

2. Be sure you have the right pump for the total lift that is required, out of the

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 well up the hill. In the case of a pressurizing system, the pressure head is
equivalent to additional lift (1 PSI = 2.31 feet) (1 bar =10 m).

3. Be sure all wire and pipe runs are sized adequately for the distance.

4. Inspect and test the solar array circuit and the controller output, as
above. Write down the measurements.

There may be a leak in the pipe from the pump. Open a pipe connection and
observe the water level. Look again later to see if it has leaked down. There should
be little or no leakage over a period of hours.

1. Measure the pump current and compare it with the table in the previous section.
2. There is a “max. RPM” adjustment in the controller. It may have been set to
reduce the flow as low as 50%.

Has the flow decreased over time?

1. Is the AC motor current lower than normal? The pump end (pumping mechanism)
may be worn from too much abrasive particles (sand or clay) in the water.

2. Is the AC motor current higher than normal? Does not start easily in low
light?

This is likely to be related to dirt in the pump and/or pipe.

1. Look in the water tank or pipes to see if sediment has been accumulating.

2. Run the pump in a bucket to observe.

3. Remove the pipe from the pump outlet (check valve) and see if sand or silt
is blocking the flow.

4. If the check valve itself is clogged with dirt.

5. To help prevent dirt problems.

6. After years of use, it may be necessary to replace the pump end.

Electrical Testing

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These tests are extremely helpful when trying to assess the performance of a system,
or locate a fault.

Obtaining and using a multimeter Measuring current (amps) is easiest if you have a
clamp-on ammeter.

Probe input. Some meters give a choice of probe sockets. The negative (black) probe
always goes in the common socket. The + (red) probe input varies, and is specified
below.

Part 1 – Testing the Solar Array (DC)

This test refers to a 48V solar array with a pump set. The system voltage may vary.
The current is determined by both the array and the load (current draw of the pump
system). If the pump is not under full load (like in a bucket), the current may be as
little as 1 amp.

Range if the meter is “auto-ranging”, this does not apply. Otherwise, use the range
than the reading expected. For example, in Test1, “normal” voltage is around 80. The
proper range may be 100V or 200V, depending on the meter design.

Access open the junction box for access to the terminals. The appearance of the
wiring may vary.

Monitoring a Solar PV Pump System: Observe the output of the pump at the point of
discharge? If not, it may not know if it malfunctions. Consider installing a water
meter, or additional valves so that the flow can be directly observed.

Monitoring the water level in the storage tank: Will you be able to observe the level
of water in the tank? If one cannot easily see into your storage tank, here are some
methods of tank monitoring.

• Dipstick in the air vent

• Float with a visible rod that protrudes through the top of the tank

• Clear sight-tube alongside the tank

• Precision pressure gauge

Learning Guide for ---------------- Date: Feb. 2018

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 Self-Check 3 Written Test

Directions Answer all the questions listed below and write your answer on the space
provided
• Describe what troubleshooting in solar system pumping? (4pts)
• Explain what methods troubleshooting of solar pumping system? (4pts)

Answer Sheet
Score = 8pts
Rating: ____________

Name: _________________________ Date: _______________

Short Answer Questions

Q1.____________________________________________________________________
____________________________________________________________________
Q2.____________________________________________________________________
_______________________________________________________________________
_______________________________________________________________________
______________________________________________________________________

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 Operation Sheet #3 Troubleshooting

Directions:
 Implement solar equipment procedural troubleshooting performance in maintenace field, if
appropriate. If not, just demonstrate at your learning workshop areas as appropriate.
 Identify and collect required equipment and tools for troubleshooting
 Follow and implement all safety rules and regulations Additional information for the
Operator

The tasks to be implement are as follows:

1. Conduct troubleshooting activities on solar pumping system (apply it for single
module and multiple module)

Learning Guide for ---------------- Date: Feb. 2018

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 LAP Test Practical Demonstration

Name: _____________________________ Date: ________________

Time started: ________________________ Time finished: ________________

Instructions: Given necessary templates, tools and materials you are required to
perform the following tasks within 3 hours.

1. Plan and prepare Solar pumping system installation and maintenance.

2. Demonstrate solar pumping system installation

3. Repair and maintain solar pumping system.

4. Troubleshoot for solar pumping system

Learning Guide for ---------------- Date: Feb. 2018

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 List of Reference Materials

1. Training manual for Solar PV Pumping System (Prepared by: GRID Nepal in joint
venture with Center for Energy Studies Institute of Engineering, TU September 2014)
2. Solar Pumping (by Practica foundation-Author: Erik van de Giessen MSc; co-authors and
reviewers; Ebo Roek MSc ; Gertjan Bom MSc Stéphan Abric MSc; Robert Vuik MSc)
3. Installation, Operation and Maintenance Guide- 12, 24, and 48 Volt Systems (by
Ventev Innovations (A Division of TESSCO Technologies))

Learning Guide for ---------------- Date: Feb. 2018

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