PV 4
DEPARTMENT OF ENERGY
RENEWABLE ENERGY MANAGEMENT BUREAU
MANUAL
for
User Training
of
Solar PV System
June 2009
This manual was developed by the Department of Energy (DOE) through the
technical assistance under the Project on Sustainability Improvement of
Renewable Energy Development for Village Electrification in the Philippines
which was provided by the Japan International Cooperation Agency (JICA).
TABLE OF CONTENTS
1
OBJECTIVE I
TARGETS I
TRAINING METHOD I
TRAINING MATERIALS I
TRAINING COMPONENTS II
AMENDMENT OF THE MANUAL II
LIST OF ANNEXES
ANNEX 1
ANNEX 2
: User Training Manual for Battery Charging System (BCS)
: User Training Manual for Solar Home System (SHS)
ii
1 OBJECTIVE
The objective of this manual is to guide the trainers who instruct PV system
users under the Barangay Electrification Project (BEP) of the DOE. The training
of PV custom users is one of the requirements for the sustainable operation of
PV systems. Moreover, the trainers must acquire accurate knowledge for
effective training of PV System users. Therefore, we edited this manual based on
the experiences gained from many PV projects.
2 TARGETS
Targets of user training are Barangay Power Association (BAPA) technicians
and individual users.
3 TRAINING METHOD
Even if users were trained, they usually forget what they have learned or have
misunderstandings about what they were taught. Therefore, the user training
should be held periodically not only during system installation, but also after
installation. Likewise, hands-on training is necessary for practical and effective
training. It is better to have interaction with the participants during training
rather than just giving lecture. All users must be provided with a users manual.
4 TRAINING MATERIALS
The training materials are listed below.
Training material
BAPA technician
Training text
R (for technician)
Handout
R (for technician)
Volt-mater
R
Current-meter
R
Hydrometer
R
Distilled water
R
Pencil
R
R: Recommended, A: According to need
Individual user
R(for user)
R(for user)
R
R
R
R
A
Separate training materials should be prepared for BAPA technician and user.
Also the training text should be made in accordance with type of PV system
such as Solar Home System (SHS) and Battery Charging System (BCS). A
technician manual, a user manual and a user guide can be used in the training
as handout. These materials should be simple by using pictures, photos, and
quizzes. In addition, to translate to local dialect is helpful for understanding of
users.
DOE and JICA developed the technician and user manuals for both SHS and
BCS in 2008. Both manuals are provided in ANNEX 1 and ANNEX 2.
5 TRAINING COMPONENTS
Training components should cover 5 basic areas (1.Outline of PV system, 2.Role
of main components, 3.Operation & management, 4.Periodic check &
maintenance, 5.Troubleshooting). Points covered in the training are listed below.
Component
Training Points
a) PV module converts solar energy into Electricity (DC)
Outline of PV b) Output power of PV module changes daily and instantly.
system
(according to weather, season, and time etc.)
c) Output power of PV module is affected by shadow and damage
a) Explain specification of main components of PV system
b) Explain configuration of PV system using picture
c) Role of main components (charge controller and/or LVD) are:
1. Over charge protection, 2. Over discharge protection
3. Reverse polarity protection, 4. Over load protection
a) How to operate PV system
b) System voltage is 12VDC. Only appliances of 12VDC can be used.
c) Major misconceptions regarding PV systems are:
Operation &
1. Wrong connection,
2. Overuse of electricity
Management
3. Inappropriate modification, 4. Inadequate replacement
d) Explain how many hours they can use their appliances with example
e) Explain affect of overuse
a) Explain checkpoints for each components and maintenances
Periodic check
b) Periodic checking is important for problem prevention.
& maintenance
c) How to check and handle battery.
a) Troubleshooting is effective for the prevention of the further PV system
damage.
Troubleshooting b) Explain usual problems and corresponding solutions
c) Explain how to check PV system if trouble is found.
d) Make clear communication system in case trouble is occurred.
Items which required special care should be explained repeatedly as
Importance
importance.
Components of
PV system
6 AMENDMENT OF THE MANUAL
The DOE shall review this manual annually, and amend it, if necessary,
according to the surrounding circumstances in rural electrification of the
country. The amended manual shall be fully authorized among the DOE and
approved by Director of Renewable Energy Management Bureau of the DOE.
ANNEX 1
User Manual
for
Battery Charging System (BCS)
What is Solar PV system?
Electricity from Solar Energy
User Manual for
Battery Charging System (BCS)
PV Module converts Solar energy into Electricity(DC)
What
is solar PV system?
Components of BCS
Role of main component
How to use user system
Maintenance
Troubleshooting
Importance
Charging
Battery
Irradiance (kW/m2)
What is Solar PV system?
1.0
1.0
1.0
0.8
0.8
0.8
0.8
0.6
0.6
0.6
0.6
0.4
0.4
0.4
0.4
0.2
0.2
0.2
0.2
Sunny / Cloudy
Cloudy
Solar Energy
PV Module
Electricity (DC)
Input
Conversion
Output
Which is correct?
1.0
Sunny
Rain
Continue
next day
Generation power changes daily
Chargeable power also changes
Components of BCS
Components of BCS
Battery Charging Station
1.Solar PV Module
User System
2.Charge Controller(C/C)
4.Junction Box
5.Cable
1.LVD
6.Lamp
(Low Voltage Disconnect)
11W *2pcs
3.Cable
3.Battery lug
7.Switch
(SW)
belong to BAPA
5.Support
Structure
4.Clip
2.Battery
12V - 40Ah
Battery Charging Station belongs to BAPA.
BAPA has responsibility for managing it.
Role of main component
User has responsibility for taking care of user system.
Battery and LVD belong to BAPA. BAPA has responsibility for managing them.
Role of main component
Charge Controller of BCS
Low voltage disconnect (LVD)
CFL Lamp
Charge Controller
Charge Controller
LVD
1. Overcharge Protection
1. Over-discharge Protection
2. Reverse Polarity Protection
For those protections, SW of C/C will be turned OFF automatically
LVD
Short
circuit
2. Reverse Polarity
Protection
LVD
3. Over Load
Protection
For those protections, SW of LVD will be turned OFF automatically
How to use user system
How to use user system
Charging of battery
Connection of battery
1.Confirmation of SW position
SW of lamps should be turned off
2.Connection of battery
Battery should be connected at correct
BCS
polarity and tightly by battery lugs
3.Check of LED on LVD
If no LED turns on, check connection
User System
Take care of
polarity & tightness
Battery shall be charged periodically
Charging interval : 5 7 days, depending on weather
If green LED turns on, you can use system
How to use user system
10
How to use user system
Display on LVD
Disconnection of battery
LED
BATTERY CAPACITY
1.Confirmation of SW position
SW of lamps should be turned off
FULL
HALF-FULL
Green
Yellow
2.Disconnection of battery
RESET button
Battery is disconnected from battery lugs
Condition
<Timing of disconnection of battery>
)
11
Red
Operation of LED
1. After connecting battery
Red LED will stay ON for 3 seconds
If no LED is ON, press the RESET button
2. Battery level is full
Green LED will turn on
3. Battery level is middle
Yellow LED will turn on
4. Battery level is low
Red LED will turn on Need to recharge
5. Reverse connection etc.
All LED will not turn on
1.When its users turn to charge
2.When protective function of LVD operates
(Over-discharge protection: , Other cause:
LED
EMPTY
12
How to use user system
How to use user system
What is
wrong?
Usable appliances and hour
Charging interval: 5 days
Using
6W
3.5 hr
3.5 hr
7.0 hr
3.0 hr
3.0 hr
1.5 hr
6.0 hr
1.5 hr
Over load
Charging interval: 7 days
Using
Common : 11W Lamp * 2
Extra
: Radio * 1
6W
2.5 hr
2.5 hr
5.0 hr
2.0 hr
2.0 hr
1.5 hr
4.0 hr
1.5 hr
In rainy season, you should reduce your power usage
Can not use
AC appliances
DC 12V
13
How to use user system
14
Check Points and Maintenance
Prohibited matter
Objects
Battery
Incandescent bulb Halogen lamp
Remove or reconnection
of cable
Large power consumption
6V
These matters cause
reduction of battery life
and trouble of LVD.
Usage of different battery
LVD
15
Maintenance
-Contact Technician
-Dust and moisture
-Cleaning (with dry cloth)
-Loose connection
-Retightening
-Rust of terminals
-Contact Technician
-Damage
-Contact Technician
-Loose connection
-Contact Technician
-Damage, malfunction
-Contact Technician
Cables
-Damage
-Repair or Replacement
Battery lug
-Rust
-Cleaning (with sandpaper)
Lamp
Direct connection
Check Points
-Electrolyte level
-Damage
-Repair or replacement
-Blown light bulb
-Replacement of the bulb
-Damage
-Repair or Replacement
General maintenance is cleaning
16
Battery Electrolyte level
Battery Handling & Connection
Which is correct?
Which is acceptable?
Keep electrolyte within the proper level (open the cap to check)
17
User system
Troubleshooting (1)
In these instances, contact technician
LVD
The usage hour of appliances is getting shorter than ever!
Indoor wiring
Abnormal
noise
Damage &
Deformation
Battery Load
Heat
+ - + -
Loose
connection
Battery
Possible Reason
Check point
Solution
Usage of appliance which is
large consumption
Specification of appliance
Reduce power usage
Loose connection
Connector, terminal
Retightening
Rust of battery lug
Condition of battery lug
Cleaning (with sandpaper)
<Switch>
*Damage
*Malfunction
Battery is weakening
Performance of battery
Contact technician
Malfunction of LVD
Operation of LVD
Contact technician
<Junction box>
*Damage
LVD can not operate properly!
<Cable>
*Damage
*Disconnection
*Short circuit
*Loose connection
Possible ReasonContact
<Lamp>
*Damage
Damage &
Deformation
18
Liquid spill
Moving house, Change of layout
19
Check point
Solution
Loose connection
Battery lug, terminal
Retightening
Misconnection of cable
Connection of cable
Reconnection
Damage of cable
Condition of cable
Contact technician
Malfunction of LVD
Operation of LVD
Contact technician
20
Troubleshooting (2)
Importance
Appliances can not use even with correct connection of battery!
Possible Reason
Check point
Solution
Failure of appliance
Condition of appliance
Repair/Replacement
Loose connection
Battery lug, terminal
Retightening
Battery can not charge fully
Condition of battery, C/C
Contact technician
Damage of cable, SW
Condition of cable, SW
Contact technician
Malfunction of LVD
Operation of LVD
Contact technician
Battery is weakening
Performance of battery
Contact technician
The interval of water refilling is getting shorter than ever!
Possible Reason
Check point
Solution
Leave battery at hot place
Ambient condition
Change in place
Over charge
Function of charge controller
Contact technician
Leakage of electrolyte
Damage of battery case
Contact technician
Battery is weakening
Performance of battery
Contact technician
BCS, Battery and LVD belong to BAPA. BAPA has
responsibility for management of those equipment.
User has responsibility to take care of user system
Including Battery and LVD.
Battery should be charged periodically according to
technicians instruction.
Useable hour of appliances changes by the charging
interval.
General maintenance is cleaning.
If you f a problem, please let technician know.
21
22
23
24
Last
Solar power systems are the precious
resources for you and your country.
You have big responsibility to prolong the life
of system.
It cannot be success without your proper
knowledge.
Please keep proper knowledge in your mind
and teach them to everybody.
ANNEX 2
User Manual
for
Solar Home System (SHS)
What is Solar PV system?
Electricity from Solar Energy
User Manual for
Solar Home System (SHS)
PV Module converts Solar energy into Electricity(DC)
What
is solar PV system?
Components of SHS
Role of main component
How to use user system
Maintenance
Troubleshooting
Importance
Irradiance (kW/m2)
More Solar Energy
More Electricity
Solar Energy
PV Module
Electricity
Input
Conversion
Output
Which is correct?
1.0
1.0
1.0
0.8
0.8
0.8
0.8
0.6
0.6
0.6
0.6
0.4
0.4
0.4
0.4
0.2
0.2
0.2
0.2
Cloudy
DC
1.0
Sunny / Cloudy
Less Solar Energy
Less Electricity
Power generation
changes daily
What is Solar PV system?
Sunny
Rain
Continue
next day
Generation power changes daily
Chargeable power also changes
SHS Components
SHS Components
SHS is Small, independent DC system
Most efficient and economical system
DC Compact Fluorescent Lights are easily available in local
market
Solar Home System consists of 4 components
SHS belongs to BAPA.
BAPA has responsibility for managing it.
PV Panel
1. PV Module
(Power Generation)
DC
2. Charge
Controller
(Battery Protection)
Most Important
Key Device
in PV system
DC
4. DC Appliances
DC System
Controller
(10A)
(DC Lights, DC Radio)
Compact Fluorescent light
(12V DC 11W)
DC
3. Battery
Switch
Battery
(Storage of Electricity)
40Ah
5
SHS Components
Role of main component
1. Solar PV Panel
Charge Controller (C/C) of SHS
4.Junction Box
5.Cable
Charge Controller
Charge Controller
6.Lamp
11W *2pcs
2. Charge
Controller
belong to BAPA
7.Switch
(SW)
3. Battery
User has responsibility for taking care of user system.
Solar PV Panel, Battery and Charge Controller belong to BAPA. BAPA has
responsibility for managing them.
1. Overcharge Protection
7
2. Reverse Polarity Protection
For those protections, SW of C/C will be turned OFF automatically
Role of main component
How to use user system
Usable appliances and hour
Charge Controller (C/C)
CFL Lamp
C/C
Using
C/C
Short
circuit
C/C
6W
3.5 hr
3.5 hr
7.0 hr
3.0 hr
3.0 hr
1.5 hr
6.0 hr
1.5 hr
Common : 11W Lamp * 2
Extra
: Radio * 1
1. Over-discharge Protection
2. Reverse Polarity
Protection
3. Over Load
Protection
For those protections, SW of C/C will be turned OFF automatically
How to use user system
In rainy season, you should reduce your power usage
10
How to use user system
What is wrong?
Prohibited matter
Incandescent bulb Halogen lamp
Remove or reconnection
of cable
Over load
Large power consumption
6V
Can not use
AC appliances
DC 12V
These matters cause
reduction of battery life
and trouble of CC.
Usage of different battery
Direct connection
11
12
Check Points and Maintenance
Check Points and Maintenance
Objects
Objects
PV Panel
Check Points
Maintenance
-Dirt or Obstacles on
the surface
-Cleaning (with water and soft cloth)
and Removal
-Shadow during
daytime
-Removal of the source
-Damage
-Contact Technician
-Direction
-Contact Technician
-Tilt angle
-Contact Technician
-Rust of the frame
Battery
-Painting after removal of the rust
General maintenance is cleaning
Battery Electrolyte level
Maintenance
-Electrolyte level
-Contact Technician
-Dust and moisture
-Cleaning (with dry cloth)
-Loose connection
-Retightening
-Rust of terminals
-Contact Technician
-Damage
-Contact Technician
Charge
Controller
-Loose connection
-Contact Technician
-Damage, malfunction
-Contact Technician
Cables
-Damage
-Repair or Replacement
Battery lug
-Rust
-Cleaning (with sandpaper)
-Damage
-Repair or replacement
-Blown light bulb
-Replacement of the bulb
-Damage
-Repair or Replacement
Lamp
13
Check Points
General maintenance is cleaning
14
Battery Handling & Connection
Which is correct?
Which is acceptable?
Keep electrolyte within the proper level (open the cap to check)
15
16
Troubles
Troubleshooting (1)
In these instances, contact technician
PV Panel
C/C
Abnormal
noise
Damage &
Deformation
*Dust
*Shadow
*Crack
*Change of Orientation
& Tilt Angle
Heat
Battery Load
+ - + -
Loose
connection
Battery
Battery can not charge fully in spite of fine day!
Indoor wiring
Possible Reason
<Cable>
*Damage
*Disconnection
*Short circuit
*Loose connection
Solution
Weather condition/Overuse
User retraining
Overuse of load
Usage condition of load
User retraining
Loose connection, Rust
Connector, terminal
Retightening /Cleaning
<Switch>
*Damage
*Malfunction
Dirt on PV module
Surface of PV module
Cleaning
Shadow on PV module
Surrounding condition
Removal of the source
<Junction box>
*Damage
Damage of cable
Condition of cable
Repair /Replacement
Damage of PV module
Condition of PV module
If bad, Contact engineer
Malfunction of C/C
Operation of C/C
If bad, Contact engineer
Battery is weakening
Performance of battery
If bad, replace it
<Lamp>
*Damage
Damage &
Deformation
Check point
Battery level is too low
Liquid spill
Moving house, Change of layout
17
Troubleshooting (2)
Troubleshooting (3)
Charge Controller can not operate properly!
Possible Reason
Check point
The usage hour of appliances is getting shorter than ever!
Solution
Terminal
Reconnection /Retightening
Set voltage is shifted
HVD and LVD setting
Malfunction of C/C
Operation of C/C
Damage of PV module
Damage of cable
Direct connection between
battery and additional load
Connection of additional load Remove
User retraining
Effect of noise
Terminal voltage
De-noising/Grounding
Battery is weakening
Performance of battery
If bad, replace it
Type/voltage of battery is not
matched with C/C
Specification of battery and
C/C
Replacement of Battery
or C/C
Loose connection
18
Possible Reason
Check point
Solution
Specification of appliances
Reduce power usage
Rectify setting
Usage of appliance which is
large consumption
If bad, Contact supplier
Loose connection
Connector, terminal
Retightening
Condition of PV module
If bad, Replace it
Shade on PV module
Surrounding condition
Removal of the source
Condition of cable
Repair /Replacement
Damage of PV module
Condition of PV module
If bad, Contact engineer
Rust of connector
Condition of connector
Cleaning (with sandpaper)
Battery is weakening
Performance of battery
If bad, Replace it
Malfunction of C/C
Operation of C/C
If bad, Replace it
19
20
Troubleshooting (4)
Importance
Appliances can not use even with correct connection of battery!
Possible Reason
Check point
Solution
Failure of appliance
Condition of appliance
Repair/Replacement
Loose connection
Connector, terminal
Retightening
Battery can not charge fully
Condition of battery, C/C
If bad, Contact supplier
Damage of cable, SW
Condition of cable, SW
Repair/Replacement
Malfunction of C/C
Operation of C/C
If bad, Contact engineer
The interval of water refilling is getting shorter than ever!
Possible Reason
Check point
Solution
Overcharge
Function of charge controller
If bad, Contact supplier
Leave battery at hot place
Ambient condition
Change in place
Leakage of electrolyte
Damage of battery case
If bad, Replace it
Battery is weakening
Performance of battery
If bad, Replace it
Solar PV Panel, Battery and CC belong to
BAPA. BAPA has responsibility for
management of those equipment.
User has responsibility to take care of user
system including Solar PV Panel, Battery and
CC.
General maintenance is cleaning.
If you f a problem, call your technician.
21
22
23
24
Last
Solar power systems are the precious
resources for you and your country.
You have big responsibility to prolong the life
of system.
It cannot be success without your proper
knowledge.
Please keep proper knowledge in your mind
and teach them to everybody.
Department of Energy
Energy Complex
Merritt Road, Fort Bonifacio,
Taguig City, Metro Manila
TEL: 479-2900
FAX: 840-1817
Department of Energy
Energy Complex
Merritt Road, Fort Bonifacio,
Taguig City, Metro Manila
TEL: 479-2900
FAX: 840-1817
