off-grid solar installation manual.
Contents
1. Quetsol S A Ben Dana 2012 Nueva Libertad Community Huehue tenango Guatemala yi a Ba f f Small Scale Offgrid Solar PV Installation Manual A complete installation guide for Solar PV systems up to 235W or one solar panel Written in collaboration with Quetsol primarily for applications in Guatemala atso Small Scale Offgrid Solar PV Installation Manual Contents SS AY ea ccs E E E A E EE 3 TOO e E secs teaevoesateacesdastesenaenerieescrueec 4 E EE E E E ET A E A E E E cane T E E EA A T 4 SUNN OY O teen racer E POE E A O EA T E E ASE E A E A E T T 5 A Solar Panel sscmiisiiiteriisonicni niceness esinaine i a aiai nainii 5 B Accommodate the Battery Regulator and Inverter s ssssssssssssserssressrrrerrresrersrerssrresrersreresrers 5 C EEn a 18 a E E E E AEA 5 D NAS SUE ssessessssessessssessrsessrsresesrrsresrerrseosesresessesreseoreseosesresesresroseorrseoseereseoresreseereseoseeeee 6 General Installation Requirements cccescccssscecesececesecccenecceeneeceesceseuececaneceseeceseeeseeucesseecessuecensneeeeees 6 A SOVAIE PAWVCN a E E E eacehaeisset ce qcoviecnsceecsmncncune 7 1 Test Voc with a multi meter electrical tester ssessnssssenesssrssssrrnessrresrereersrresrrresssrresreressreee 7 2 NIG OSE SOU TOF Ne pane loenn R Ea 7 2 1 Optimal Inclination for the Solar Panel cccccsssccccessececesececcesscceseeseceeeeeeceseeeeceeseusecet2. A Once connected to the solar panel the positive and negative cables should never be in contact Therefore when the distance to the charge controller has been determined it s advisable to cut one cable and then the other rather than the two together Seperate cuts in twin cable with exterior insulation e q cable TSJ2 14 R Quetsol Small Scale Offgrid Solar PV Installation Manual Twist the exterior cover on each side of the cut pulling to separate Cut points that are still joined When the cables are exposed cut them individually and tape up the ends Insulate the ends with tape f The cable will often pass by the edge of a roof sheet where it comes into the house It s better to protect the area of contact to prevent damage in the wind 15 R Quetsol Small Scale Offgrid Solar PV Installation Manual Cable protected from the roofing sheet edge with insulating tape or a plastic bottle B Installing the Battery Regulator and Inverter 1 Choose a place for the battery The battery should be placed where there is a minimal possibility for contact with fire water or other hazards It has to be under a roof with no leaks and not in the kitchen It shouldn t get in the way of the people in the house It should be accommodated on a table as on the floor it can be knocked over easily and more cabling will be needed 2 Mount the Regulator and Inverter on the wall The Regulator and the Inverter are s
3. generation with Solar Panels without connection to the electrical grid This needs at least one battery so that the energy can be used when there is no sun This Manual is relevant to installations of one single solar panel or lower than 235W Isc Short Circuit Current The short circuit current is the current across a solar cell when the voltage is zero or when the solar cell is in short circuit Published in the technical data on the underside of a panel it s one of the main parameters of a Solar Module Normally it s quoted under Standard Test Conditions STC 1000 W m solar irradiation 25 C cell temperature Solar Panel A module that makes use of energy from solar irradiation This guides refers to Photovoltaic Panels to generate electricity Regulator Charge Controller This balances the voltage of the Solar Panel Battery and DC Circuits and monitors the State of Charge SOC of the battery It protects the battery from overcharging by the panel and disconnects DC loads when voltage is low to prevent over discharge MC4 Terminals Connecters for the DC solar cable In general they are the industry standard Voc Open Circuit Voltage Difference in Electrical Potential between two terminals of a device when no external charge is connected Under these conditions there is no external electrical current between the terminals Voc of a solar panel should be published in the technical plaque on its underside It is quoted ac
4. kie neinn inon ELENERI OE e iLE Ei 21 3 Install the bulb sockets and connect to the negative distribution lin sssssssesseeeseeserrresrrssn 22 4 Install the SWITCNES ccccesssssccccsessseccccseessecccsseeeececsseeseeeecsseuseeecessauseceeesseusseeeesauaseesessegaaeeees 24 D COME ONNE 2 sree ts sce nceione E E E E E EEEE 25 atso Small Scale Offgrid Solar PV Installation Manual 1 Connect the cables from the Panel to the Regulator essessssessensssrenssrrrsesrrresrreresrrrssrrerererresene 25 2 Connect the DC lighting circuit to the charge controller ne e ssssseessrsesseeressresrrssrrsrrserrseresrererens 25 Se CND OVC T acta ce nctee E E tere csnncaceses sieve ctnanincs E E A E EE E E 25 Appendix 1 Elecirical CONMECTIONS eisirean anni EEA TEE 25 ALI Simple YS OIC UMS nesicsersdiunuk sea seo ae 25 ALZ CV IOS GOWN oe a E E N ETE 26 A1 3 Joints with connector blocks ssesssssesssssessssssrressssrresssserrsssssrressssreresssseressseerressseeressseereessene 28 Appendix 2 Optimal Tilt Angle for a solar panel in Guatemala ssssssssnsssseresseeserrrresrrrrssreresrrrreseeress 29 Appendix 3 Installations with More than one Dattery ccccccsscccssscccesececeseceeseceeescessecessecessueeesens 29 EE LE N A I E TE PE PE P N ca tesun A E E N A A E E N T 31 Glossary AC Alternating Current Electrical current in which the magnitude and the direction vary cyclically Commonly used A C refers to the for
5. of the year Latitude in Guatemala is 14 37 15 N Optimal tilt for summer use angle of latitude 20 gt 5 For a water pump for example Optimal tilt for winter use angle of latitude 20 35 For example an offgrid solar system with year round demand including winter Optimum tilt for maximum total generation during the year is equal to angle of latitude gt 15 For a grid connected installation for example 3 Fixing the Solar Panel to the Roof A Always take great care on the roof to avoid accidents Remember that the rain makes a galvanized metal roof very slippery You should use boards to spread your weight over the roof sheets Only step where there is an interior beam below indicated by a line of screws R Quetsol Small Scale Offgrid Solar PV Installation Manual These steps explain how to fix a Solar Panel to a corrugated metal sheet type roof using aluminium angles Cut the two lengths of aluminium angle at solar panel width 20 cm leaving a 10cm overhang on either side of the Panel Fix one length of aluminium to each end of the panel 1 Position the first length of aluminium at the edge of the panel to mark the positions of screws The horizontal part of the angle should be facing away from the panel not positioned underneath it 2 The screws should be positioned so that the heads on the inside of the frame do not scratch the underside of the panel A scratch could rui
6. Controller Chose the cable gauge according to the Quetsol technical guide Cab e Selection in small Off grid Solar Energy Installations Measure the amount of cable needed for the cable run to look neat including changes in direction Prepare the ends to connect to the battery Remove enough exterior insulation of TSJ cable for the wires reach the two poles of the battery Prepare the ends with crimped terminals for battery connection Mark cable polarity with black and red insulation tape at the ends Clip the cable to the wall 4 Prepare the Inverter cables Inverters for offgrid solar often come supplied with the battery connection cables This Manual explains the steps for connection with crimp terminals Make sure to buy terminals that are large enough for the threaded connection points on the battery and to fit the cable gauge Remove the crocodile clips for battery connection They present a risk of inverse connection 17 R Quetsol Small Scale Offgrid Solar PV Installation Manual With the first cable measure how much insulation it s necessary to remove for the cable to enter to When positioning the terminal on the end of the cable make sure that no strands stick out The inverter cable is very thick so a few strands can be cut if necessary The end of the cable should reach the end of the tube and there shouldn t be bare cable on the entry to the terminal Place the terminal cable in the teeth of the cr
7. able but some installers use these screw terminals In any case to use the terminals it s better to prepare the cables with the same crimp connectors instead of merely twisting the bare wire 19 Ratso Small Scale Offgrid Solar PV Installation Manual First prepare the positive terminal with its Regulator and Inverter cables Then prepare the negative terminal in the same way To attach each terminal to the lead point of connection on the battery it can be opened with pliers and then forced down with a hammer Tighten completely with a fixed spanner or socket 6 Connect the cables from the battery to the regulator Following the indications on the Regulator which nominate them 1 2 the inlets from the battery should be connected first This is to balance the system voltage according to the battery Once this is carried out the LEDs green orange and red should come on one after the other finishing with the constant illumination of the orange LED on the Morningstar SHS Regulators Order of Regulator connections Morningstar diagram For connections to the Regulator User the right size screw driver First slacken the terminal screws completely 20 R Quetsol Small Scale Offgrid Solar PV Installation Manual Ensure that no cable strands are left outside the terminals Completely tighten the terminal screws C Lighting Circuit 12Vdc 1 Install the main DC distribution line Once the c
8. anel and the Regulator B Accommodate the Battery Regulator and Inverter e Choose a place for the battery e Fix the Regulator and Inverter to the wall or a board e Prepare the cables between the battery and the regulator e Prepare the inverter cables e Carry out the connections to the battery e Connect the battery cables to the Regulator C Lighting Circuit e Install the main DC Lighting cables e Prepare the bulb sockets e Fix the lamp holders to the ceiling and connect to the main lighting cable e Install switches R Quetsol Small Scale Offgrid Solar PV Installation Manual D Comissioning e Connect the Solar Panel cables to the charge controller e Connect the DC load circuit to the charge controller e Handover the system to the client General Installation Requirements It s important that the cables and equipment are made to look neat Horizontal and vertical cables should be straight and kept out of sight above beams etc Where cables run the same way it s preferable to install them together Cable splices should be meticulously carried out to minimise risk of short circuits They should be completely covered with insulation tape All cables should be mechanically supported to a high standard It s better if they are run via the highest possible path in order to be out of reach Cables should be clipped at least every meter Be very careful when installing the clips to avoid scratching puncturing the
9. ariation from the VOC printed on the back of the panel the variation depends on the solar irradiation at that moment 2 Choose a spot for the panel It s essential that the Panel is facing as close as possible to O south in the Northern hemisphere South of the Equator the Panel should face North Use a good quality compass to determine which side of the roof faces south Ratso Small Scale Offgrid Solar PV Installation Manual This side of the building faces south white arrow deviation around 25 However it s more important that there s no object in front of the Panel that could affect its performance with shading such as buildings trees or topography The shade of an object depends on its height general shape and position in relation to the Panel so it s difficult to predict without a calculation using the exact measurements But if there s a possibility that the shade could affect the Panel s performance if the object is higher than the Panel it s better that it is positioned elsewhere If it s necessary to choose it s better for the panel faces west or east if it would be affected by shading facing south 2 1 Optimal Inclination for the Solar Panel Appendix 2 has more information on this However the inclination of the Panel is usually determined by the roof pitch The optimum angle to generate maximum solar gain is a function of latitude but also the use and efficiency of the solar system over the course
10. cable Take great care to respect polarity throughout the whole installation Twin cable in Guatemala usually has white insulation for both conductors Quetsol s policy is to use the corrugated side as the positive This means that the negative conductor is the cable with smooth insulation sometimes printed with text If the cable has two colours then white is used as the positive and black as the negative It s preferable to mark the polarity of splices with insulation tape red for the positive cable and black for the negative The 6 cables connected to the Regulator should also be labelled with a ring of insulation tape and the points of connection to the battery at least the positives Labelling polarity R Quetsol Small Scale Offgrid Solar PV Installation Manual Avoid working on live cables to reduce the possibility of a short circuit For this and other reasons it s preferable to connect the DC lighting circuit to the Regulator when the other parts of the installation are completed A Solar Panel 1 Test Voc with a multi meter electrical tester Expose the panel to sunlight Make sure that Tester s the dial and the electrical leads are in the right position for measuring DC voltage 7 AC voltage Sie ka Ww Se Lead positions to measure voltage Make contact between the Solar Panel s cables and the Tester s conductors Note down the voltage It should be within a range of v
11. cording to Standard Test Conditions STC Tools Compass Volt meter Pliers Ratchet crimping tool Hammer Screw drivers Fixed Spanners Wire Cutters Spirit level Tape measure Marker pen Stanley knife Battery drill with two charged batteries Hacksaw drill bits including a 3 8 socket bit and a screw driver bit ladder Material The success of the installation depends on arriving prepared with the right kit Solar Panel Charge Controller Inverter Battery Cable for different parts of the installation Cable clips MC4 Connectors Solar Cable Hexagonal roof screws 3 and other sizes 4 nails Threaded hexagonal bolts 5 16 x 11 2 5 16 nuts and washers Silicone Angle aluminium 50mm x 50mm x 2 5mm 3m Wooden board around 30cm x 3cm x 160cm Crimp connectors for batteries Crimp connectors for splicing Light bulb sockets Switches Energy saving 12V bulbs Self tapping screws wall plugs Cable ties Red and black electrical tape Ratso Summary Small Scale Offgrid Solar PV Installation Manual Regulator Solar Panel DC Loads gaa AC Loads f p Erp elas Sel ee ed j Oy os tray Inverter ms i 4 5 AD ak ah E Seta as ee Ree a ae os ee CR iwe i T The Installation can be divided into 4 different parts A Solar Panel e Choose position and fix the solar panel to the roof e Connect the cable to the solar panel e Install the cable between the P
12. crewed to the wall above the battery It s preferable that the Regulator is out of the reach of children This is also the case for the Inverter but before mounting to the wall ensure that its cables will reach the battery Possibly the inverter will have to be installed upside down for this reason Mounting on a wall of planks Screw directly using self tapping screws Mounting ona cinder block wall It s better to mount a small board first The best way to fix to blocks or bricks is with screws and wall plugs e Make holes in the board making sure that the holes will give it a level position 16 R Quetsol Small Scale Offgrid Solar PV Installation Manual e Mark the position of these holes in the wall behind and drill the wall with hammer drill Drill into the wall as far as you need for the wall plug e Put the wall plugs in with a hammer if needed e Screw to the wall with screws long enough to pass through the board and fill the whole plug Alternatively in Guatemala the blocks are usually soft enough for nails Ensure there is enough space on the board between the nails for the Regulator and the Inverter Mounting in Adobe wall Self tapping screws normally achieve a good fixing in adobe meaning the Inverter and Regulator can be mounted with no board It s important to start with the Regulator flush to the wall on a part of the wall that s level 3 Prepare the cables between the Battery and the Charge
13. e two options for the 100W solar panel The option of two 90Ah batteries provides an example of configuration in parallel Solar Panel Estimated optimal Batteries selected Total Capacity Surette Rolls 27 HT 90 12V 90Ah x 2 in parallel o 1 x Trojan T175 12V 150Ah o 150Ah 12V Batteries connected in parallel Voltage stays the same Capacity increases 4b S Example 2 x Surette Rolls 27 HT 901 12V 90Ah For one 100W solar panel 12V Total Capacity and Voltage 180Ah 12V Batteries connected in series Voltage increases Capacity stays the same a ii F ii r 1 1 j Me wT Example 2 x Victor 12V 200Ah For 1 235W SOV panel Total battery capacity and voltage 200Ah 24V 30 atso Small Scale Offgrid Solar PV Installation Manual Rules for safe battery installation Use thick cable for link connections between the batteries 2 AWG gauge The terminals for these links must be very well done with no bare cable visible Tighten the screws of the battery terminals according to the torque recommended by manufacturers The main positive and negative cables should be the same length and should be connected to opposite sides of the bank of batteries This is to create an equal path length for the flow of electrons Draw a diagram of the connections Never mix batteries of different types Never measure battery current across terminals Use the right size fuse if it is necessary to
14. es with consistent solar irradiation through the year the tilt angle can be the same as latitude However in temperate zones of Guatemala the optimal tilt angle of latitude 20 gt 35 Optimal tilt angle for maximum total generation during the whole year is the same as latitude gt 15 For example a grid connected solar energy installation Appendix 3 Installations with more than one battery Small installations with just one solar panel normally need just one battery Nevertheless for 100 235W installations it s possible that two batteries will be needed to achieve the required voltage and capacity Sometimes just one battery at the necessary voltage and capacity will be more expensive than combining two weaker batteries The voltage of a group of batteries number of batteries connected together in series x voltage of one battery The capacity of the group number of batteries connected together in parallel x capacity of one battery Never mix different types of battery This table recommends the battery configuration for different solar panels between 100W and 235W With no consumption profile for design optimal capacity is based on the panel s daily generation in Guatemala assuming 4 5 Peak Sun Hours with 2 autonomy days and 50 Depth of 29 atso Small Scale Offgrid Solar PV Installation Manual Discharge The capacity of the batteries selected is slightly less than the optimal to minimize costs There ar
15. have a fuse It should be installed in main positive battery cable Remove jewellery before starting work Use the right tools It s better to work with insulated tools Disconnect any battery charger or electrical load before working Use goggles to protect your eyes and wash your hands immediately after working Reference Fotovoltaica Manual de Dise o y Instalaci n Solar Energy International 2007 31
16. impling tool Make sure it is positioned to crimp the interior metal tube not just the exterior insulation Pull the terminal to ensure the crimp is strong Repeat the whole process with the other cable Clip the cable to the wall in its path to the inverter The other end of the cables can now be connected to the Inverter it usually comes supplied with terminals for this purpose 5 Connect the cables to the Battery The Inverter and the Regulator cables are ready to be connected to the threaded battery terminals The positive and negative cables are connected together 18 Cocetso Small Scale Offgrid Solar PV Installation Manual Positive and Negative cables connected to the battery together Inverter Cables Regulator Cables gt a e e _ Completely tighten the screws on the battery with a fixed spanner to ensure good connections A Take care with the ends of cables between the Battery and the Regulator they are now live The negative and positive should never come into contact If you haven t connected to the Inverter yet this is also the case with the Inverter cables When tightening connections to the battery always make sure that the metallic tool never touches the opposite pole 5 1 Terminals for connecting multiple cables to the battery The quality of connection to the battery is important to reduce voltage drop and the risk of over heating Crimp connectors are prefer
17. ist the cables together When positioning the terminal on the end of the cable make sure that no strands stick out of the interior metal tube The end of the cable should reach the end of the metal tube and there shouldn t be bare cable on the entry to the terminal 3 Completely tighten the terminal screws Make sure it s strong by pulling Protect with tape If the two wires are too thick to fit in together connect with one each side of the terminal block 28 Ratso Small Scale Offgrid Solar PV Installation Manual Appendix 2 Optimal Tilt Angle for a solar panel in Guatemala The optimal tilt angle for maximum solar gain is a function of latitude but also the use and efficiency of the solar system during the year A panel with a steeper tilt be exposed to more solar irradiation in winter months when the sun is lower although the average solar irradiation m day would be higher if the tilt were the same as latitude Latitude in Guatemala is 14 37 15 N A solar pumping system for example would require a tilt angle for maximum solar gain during summer months to cope with the heaviest demand for pumping Optimal tilt for summer months angle of latitude 20 gt 5 For year round electrical load an offgrid solar system should be installed in a way that captures maximum solar irradiation during winter the months when it s most difficult to keep the battery charged In Ecuador and other tropical countri
18. ith red tape as explained in B6 When the panel is connected to a Morningstar SHS Regulator a green LED should light up on the left The State of Charge LEDs should change from orange to green showing that the battery is well charged 2 Connect the DC lighting circuit to the charge controller Label polarity below the terminals Screw in the light bulbs and ensure each one turns on 3 Client hand over Ensure that the people of the house understand how the system works and how to maintain it They should be left with a System User Manual showing this information Appendix 1 Electrical Connections A1 1 Simple wire splicing Remove 1 of insulation from the cut end of each cable Twist the strands of the first cable together Separate the second cable into two parts ensuring the strands of each part are well twisted together 25 Q Quetsol Small Scale Offgrid Solar PV Installation Manual Position the first cable between the two parts of the other Wrap one part around the first cable moving downwards and ensuring tight contact Bend the end of the splice downwards Wrap up with insulation tape Te ES A1 2 Crimped joints Crimp terminals are usually available in Celasa Guatemala 26 R Quetsol Small Scale Offgrid Solar PV Installation Manual Measure and strip the insulation required for the cable to enter up to the midpoint of the terminal Twist the strands together Repeat with
19. lient has specified where s he wants the lights in or outside the house the main cable between the Regulator and the bulbs can be installed Choose the cable section according to the Quetsol Technical guide Cable Selection in small Offgrid Solar Energy Installations 2 Prepare the light bulb sockets The DC bulbs supplied by Quetsol have their positive connection in the middle of the threading with the negative contact on the side Positive i Positive in middle Positive in middle A V in an g Of jd Yj Negative on the side on the side As aresult the polarity of the bulb socket has to be e Positive middle connection e Negative side connection y _ ee n Bulb socket right way up Bulb socket upside down Positive in middle ay Negative connection oC Positive connection a 1 te 21 R Quetsol Small Scale Offgrid Solar PV Installation Manual To switch off the bulb the switch disconnects the positive line in the circuit Therefore every bulb socket has to be prepared with e Switch cable middle connection terminal the other cable from the switch is connected to the Positive of the DC Distribution line e Cable connected to the Negative of the DC distribution line connection terminal on the side These cables need to comply with the Quetsol Technical guide Cable Selection in small Of fgrid Solar Energy Installations Obviously it will be necessary to first verify the dis
20. m in which electricity is supplied to homes and businesses compatible with most appliances 110 V at 60 Hz Solar Array 2 or more Solar Panels connected together Battery Capacity Amp Hours Ah The value of a battery The required capacity is calculated according to the energy needed for electrical loads and the number of autonomy days DC Lighting Circuit 12V DC bulbs together with their bulb sockets switches and cabling This circuit is connected to the Charge Controller for automatic disconnection if the battery is discharged Low energy bulbs are recommended gt 10W DC Current always maintains the same polarity meaning it s important that the bulb socket connections are correct DC Direct Current Electrical Current across a conductor between two points of different potential In contrast to Alternating Current A C the electrical charge always flows in the same direction in other words the terminals of greater and lesser potential are always the same This means that the positions of the Positive and Negative are very important The energy generated by a solar panel and stored by a battery is normally Direct Current DC Inverter Device which converts D C input voltage to A C output An Inverter in Guatemala will change the Direct Current of a battery normally 12V to 110V for use in the majority of common electrical appliances atso Small Scale Offgrid Solar PV Installation Manual Offgrid Solar Energy Electrical
21. n the panel Also make sure the length of aluminium is flush with the panel frame 3 Drill the aluminium with a drill bit Imm larger than the screw 7mm in this case 4 You can mark the second angle according to the holes positions in the first 5 Hold the aluminium to the edges of the panel again to mark the position of the holes in the frame before drilling R Quetsol Small Scale Offgrid Solar PV Installation Manual 6 Use threaded hexagonal screws 5 16 x 1 4 Hold the screw head with pliers inside the frame as you tighten the nut with a spanner A At this point it s better to carry out whatever work is necessary to extend the solar panel s cables before the solar panel is permanently fixed to the roof This is explained in Section 6 Fix the solar panel to the roof 1 Position the lower aluminium angle above an interior roof beam The roof screws can be used as a guide Although this panel is anchored with a plank the photo shows the plank positioned above a roof beam f f i 7A i The roof screws serve as a guide 2 Mark two holes in the horizontal angle so that they are above the upper profile of the sheet This minimizes the ingress of rain The fixing is done with hexagonal roof screws Drill the aluminium with a 3 16 drill bit ee e _ 3 You can now fix to the beam using 33 roof screws Use the battery drill with a 3 8 socket bit If the screw slides on the corrugated roof sheet i
22. nel supports rather than aluminium angle 11 R Quetsol Small Scale Offgrid Solar PV Installation Manual The first job is to pass the rebar through a thick board so that it sits on the perimeter wall Position the holes in the board carefully so that they marry up with the rebar It should be held in place with rebar at each end Bend the rebar horizontally above the board How to fix the support board to the solar panel Choose a board that measures 40cm x width of the panel 60cm ina fit state to withstand the elements With the glass face down centre the board above the upper part of the frame Fix it in place with 4 hexagonal roof screws 13 but check according to the board thickness Use the battery drill with a 3 8 socket bit The board has to be flush with the surface of the panel s frame but it s important that the points of the screws do not touch the underside of the panel This part is very delicate and a scratch could ruin the panel First check that the screws are the right length for the panel as the frame thickness varies It s better to sink the heads into the board a little with a thick drill bit to allow it to sit flat Support board fixed to the panel s underside The Panel can now be positioned according to the desired angle of inclination Then the support board can be screwed down to the first board Use screws that are long enough to ensure plenty of thread in the first board and make sure
23. nstead of going through drill a hole in it first with a 3 16 drill bit for metal If you drill holes that are not used make sure to seal them with silicone If the building has metal beams use long bolts fastening the nut on the inside of the beam One installer on the roof clamps the bolt head while another installer in the attic tightens the nut A ladder will be needed on the inside 10 Q Cavetso Small Scale Offgrid Solar PV Installation Manual Fixing the upper part of the panel to the roof is more complicated There will not be a beam directly beneath it to fasten to 4 The installer in the attic positions a wooden board directly below the upper edge of the panel The board should be the width of the panel 60 cm with an equal overhang on each side This person has to push the board up against the inside of the roof while the installer on the roof screws through with 33 roof screws to hold it in place Support board on the inside of the roof for fixing the upper part of the solar panel 5 The upper aluminium angle can now be screwed to this board see step 3 It s easier to achieve a good fixing if the person on the inside carries on pushing upwards If the roof screws are not long enough use 4 nails 3 1 Fixing the Panel to a flat roof Ona Central American flat roof you can use the building s structural steel rebar as a base for installing the Panel In this example wooden boards are used as the pa
24. olar PV Installation Manual 4 Install the switches Switches are sometimes available in two types The switches in the photos below are not designed to screw to the wall In general they are installed with their cable hanging in the air below the bulb socket The others have holes on their backing so that they can be screwed to the wall Normally they are installed in the entrance of the room and the cable is clipped to the wall Switch connection Even though they need more cable it s preferable to use the wall mounted switches because supporting the cables improves the mechanical resistance of the electrical installation This reduces the risk that a hanging cable could be pulled out one day possibly damaging the installation The people of the house should be consulted about switch positions Firstly make sure that your cable is long enough between the switch the main Distribution line and the bulb socket It s important to have as few cable splices as possible The interior 24 R Quetsol Small Scale Offgrid Solar PV Installation Manual connection screws need to be well tightened making proper contact with their wires The switches which are not for wall mounting are harder to close with their outside cover D Comissioning 1 Connect the cables from the Panel to the Regulator Once the cables have been clipped to the Charge Controller you can make the connection Below the terminals mark the positive cable w
25. suneces 8 3 Fixing the Solar Panelto the ROOM seisccesicsscessetinwaavnctnesaadsesossoneoaevsnet ENEA 8 3 1 Fixing the Panel to a flat roof cc eecccccssscccceseccceesececceescceseeseceseeneceeseeeceessusecessenecessugeceeseees 11 Bi MMstalling the Solar GS siisii eaa aai aiaia aaa A i 13 6 1 SPICES NE Or Gre 0 aena EE A A E E EEEE AEE eres 14 B Installing the Battery Regulator and Inverter ssssesssesssenssrrssrerssrroserrsrerssrrssrerseresseeesrerseereseee 16 Ie CHOOSES DlACe TOF LNG DIle y eeren pie n r EENEN Oan 16 2 Mount the Regulator and Inverter on the wall ssssesssssenssseserersserssrersrrrssressrerssereseersrereseeesee 16 3 Prepare the cables between the Battery and the Charge Controller cccccccccceesccseseeeeeseeees 17 A Prepare the Inverter Cables ccssccsssscscssrescssrencusrencusrencusescsescscassencusrencustencustencessscsssenousrencusrs 17 5 Connect the cables to the Battery aii ce tects cdevetendat ost nostaansoacetatasumeuwhosdsnesneucdavaiaeseadsweantuaweeaieoents 18 5 1 Terminals for connecting multiple cables to the battery sssssssssssersesrrserrererrrrssrrererrrresses 19 6 Connect the cables from the battery to the regulator sesssssssseesesrenesrrrserrrresrrrrerreresrrereseerens 20 Ce Benine reut LVC eaer E NS 21 Te Install the main DC distribution INE sesscsenscusieressccennieeinnakhnnend ia ie 21 2 Prepare the lient OUID SOCKETS renare riirii nrnidane
26. tance to the position of the switch to avoid connecting a wire that s too short to the bulb socket It s better to minimise cable splices in the whole installation each cable joint increases the total load on the battery 3 Install the bulb sockets and connect to the negative distribution line The bulb socket has holes so that it can be screwed to a beam To install it to a concrete roof wall plugs and screws will be necessary Ensure the cables aren t caught behind its edge during installation If necessary cut out a small cable channel with pliers For connections to the main Distribution line it s preferable to join to the continuous wire without cutting it rather than splicing the ends The steps are explained below How to connect to a cable without cutting it twin 2 core cable Separate the 2 wires with 2 pliers without damaging the insulation Allow enough room for the 22 A Cadetsot Repeat at a 2cm distance from the first cut Remove the insulation with a horizontal cut Small Scale Offgrid Solar PV Installation Manual Remove 1 of the insulation from the cut end of the cable to be connected Divide in 2 and twist the strands to the two parts together Position the first cable between them Wind one part round the first cable towards the right ensuring tightness Repeat with the other part in the other direction 23 Laso Screw the bulbs into their holders Small Scale Offgrid S
27. the second cable a When positioning the terminal ensure that no strands are outside the interior metal tube The end of the cable should be halfway down but stripped cable should not be visible on where it goes into the terminal Push the other cable into the other side of the terminal in the same way Position the terminal in the jaws of the crimping tool It should be positioned so that the metal tube is crimped not just the exterior insulation but without squashing the part of the terminal for the other cable EY e Pe Fully close the crimping tool On opening it the terminal and the cable are squashed together Make sure it s strong by pulling it Crimp the second cable in the other half Protect the joint with insulating tape 27 Q Quetsol Small Scale Offgrid Solar PV Installation Manual A1 3 Joints with connector blocks Connector blocks are available from various electrical suppliers in Guatemala Avoid buying dubious quality connectors some cause problems when tightening the screws If the terminal is big enough for two wires to fit in the same side this is preferable With both cables going into the same side of the terminal block 1 With the first cable measure how much insulation it s necessary to remove for the cable to enter to the end of the terminal and strip it Twist the strands together Repeat with the second cable bo pe 2 Completely slacken the terminal screws Tw
28. there is good contact between the two wooden surfaces 12 Laso Small Scale Offgrid Solar PV Installation Manual For extra support use wire between the rebar and the holes in the panel frame 6 Installing the Solar Cable To avoid piercing the roof the cable passes through to the inside of the house underneath the crest of the roof The best way to do this is to lead with a cable guide from the inside and tie it to the end of the cable on the roof The splices connections in the solar cable should be tucked underneath the board to protect them from the weather 13 R Quetsol Small Scale Offgrid Solar PV Installation Manual 6 1 Splices in the Solar Cable A Its better to splice extend the solar cable before the Panel is fixed down on the roof Chose the cable gauge according to the Quetsol technical guide Cable Selection in small OFF Grid Solar Energy Installations Make sure it s long enough to reach the Charge Controller It s best to make the connection with MC4 terminals as the Solar Panel cables come with these connectors It s the best way to minimize the possibility of water ingress and to reduce voltage drop Alternatively a cable join using crimp terminals offers better mechanical strength and less voltage drop than simply splicing the wires Appendix A1 2 Afterwards this cable can be run to the area planned for the Charge Controller leave it long until the Controller is in place
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