Introduction to Solar Photovoltaics Module 57101-11

Annotated Instructor’s Guide

Module Overview
This module is designed for trainees who wish to pursue a career in solar energy. It covers the basic
concepts of PV systems and their components. It also explains how PV systems are sized, designed, and
installed. Successful completion of this module will help prepare trainees for the North American Board
of Certified Energy Practitioners (NABCEP) PV Entry Level Exam.

Prerequisites
Prior to training with this module, it is recommended that the trainee shall have successfully completed
Core Curriculum. It is also suggested that the trainee shall have completed the following modules from
the Electrical curriculum: Electrical Level One, Modules 26101 through 26111; Electrical Level Two, Modules
26201, 26205, 26206, and 26208 through 26211; Electrical Level Three, Modules 26301 and 26302; and
Electrical Level Four, Modules 26403 and 26413.

Objectives
Upon completion of this module, the trainee will be able to do the following:
1. Identify photovoltaic (PV) applications and advantages.
2. Identify system components and their functions.
3. Identify safety hazards associated with PV installations.
4. Trace a basic electrical circuit and perform calculations using Ohm’s law.
5. List PV system sizing considerations.
6. Identify PV electrical and mechanical system design considerations.
7. Describe the tasks required to complete a site analysis.
8. Identify the effects of the environment on panel output.
9. Describe how to install a simple grid-connected PV system.
10. Explain how to assess system operation and efficiency.
11. Recognize the tasks required when performing PV maintenance and troubleshooting.
12. Identify appropriate codes and standards concerning installation, operation, and maintenance of PV
systems and equipment.

Performance Tasks
This is a knowledge-based module; there are no performance tasks.

Materials and Equipment

Markers/chalk Torque wrench
Pencils and scratch paper Sun path calculator
Whiteboard/chalkboard Site survey checklist
Solar Photovoltaic Systems Installer PowerPoint® Angle finder
Presentation Slides (ISBN 978-0-13-257135-7) Camera
Multimedia projector and screen Compass
Computer Calculator
Appropriate personal protective equipment Tape measure
Access to various installed PV systems Ladder
Digital AC/DC meter Various types of solar panels and mounting
Clamp-on ammeter system components
Pyranometer Inverter
Infrared thermal device Batteries
(continued)
Charge controller Copy of the latest edition of the
AC and DC disconnects National Electrical Code® (NEC®)
Panel with breaker for inverter connection Module Examination*
Conduit and wire
* Single-module AIG purchases include the printed exam and performance task sheet. If you have
purchased the perfect-bound version of this title, download these materials from the IRC using your
access code.

Safety Considerations
Ensure that the trainees are equipped with appropriate personal protective equipment and know how
to use it properly. Ensure that all trainees are briefed on appropriate field safety procedures, including
fall protection, electrical hazards, sun exposure, and battery hazards. If the training center does not have
various simple PV systems set up on site, this module will require that the trainees visit one or more job
sites in order to view installed PV systems. Ensure that trainees are briefed on site safety policies prior
to any site visits.

Additional Resources
This module presents thorough resources for task training. The following resource material is suggested
for further study.
IEEE 1547, Standard for Interconnecting Distributed Resources with Electric Power Systems, Latest
Edition. Los Alamitos, CA: Institute of Electrical and Electronics Engineers (IEEE).
National Electrical Code® (NFPA 70®), Latest Edition. National Fire Protection Association (NFPA):
Quincy, MA.
Occupational Safety and Health Standard 1910.302, Electric Utilization Systems, Latest Edition.
Washington, DC: OSHA Department of Labor, U.S. Government Printing Office.
Photovoltaic Systems, Second Edition. James P. Dunlop. Orland Park, IL: American Technical
Publishers.
Standard for Electrical Safety in the Workplace® (NFPA 70E), Latest Edition. National Fire Protection
Association (NFPA): Quincy, MA.
UL Standard 1703, UL Standard for Safety, Flat-Plate Photovoltaic Modules and Panels, Latest Edition.
Camas, WA: Underwriters Laboratories.
UL Standard 1741, Standard for Inverters, Converters, Controllers and Interconnection System Equipment
for Use with Distributed Energy Resources, Latest Edition. Camas, WA: Underwriters Laboratories.
Uniform Solar Energy Code, Latest Edition. Ontario, CA: International Association of Plumbing and
Mechanical Officials (IAPMO).
Teaching Time for This Module
An outline for use in developing your lesson plan is presented below. Note that each Roman numeral in
the outline equates to one session of instruction. Each session has a suggested time period of 2½ hours.
This includes 10 minutes at the beginning of each session for administrative tasks and one 10-minute
break during the session. Approximately 40 hours are suggested to cover Introduction to Solar Photovoltaics.
You will need to adjust the time required for hands-on activity and testing based on your class size and
resources.

Topic Planned Time

Sessions I and II. Introduction; Applications
A. Introduction ____________
B. Applications ____________
1. Standalone Systems ____________
2. Grid-Connected Systems ____________
3. Grid-Interactive Systems ____________
4. Utility-Scale Solar Generating Systems ____________
Session III. Ohm’s Law and Power
A. Ohm’s Law and Power ____________
1. Applying Ohm’s Law to Series and Parallel Circuits ____________
2. Ohm’s Law and Power ____________
3. Series and Parallel Circuits in Solar PV Systems ____________
4. Peak Sun and Power ____________
Sessions IV and V. PV System Components
A. PV System Components ____________
1. PV Panels ____________
2. Inverters ____________
3. Batteries ____________
4. Charge Controllers ____________
5. BOS Components ____________
Session VI. Safety Considerations in PV Systems
A. Safety Considerations in PV Systems ____________
1. Fall Protection ____________
2. Battery Hazards ____________
3. Electrical Hazards ____________
4. Meter Safety ____________
Sessions VII and VIII. Site Assessment
A. Site Assessment ____________
1. Customer Interview ____________
2. Power Consumption ____________
3. Roof Evaluation ____________
4. Array Orientation ____________
5. Equipment Location ____________
Topic Planned Time
Sessions IX and X. System Design
A. System Design ____________
1. Panel Nameplate Data ____________
2. Solar Array Sizing ____________
3. Inverter Selection ____________
4. Battery Bank Sizing ____________
5. Selecting a Charge Controller ____________
6. Adjusting PV Conductors ____________
Sessions XI and XII. Installation
A. Installation ____________
1. Forces Exerted on the Panels/Support System ____________
2. Roof-Mounted Installations ____________
3. Ground-Mounted Installation ____________
4. Electrical System Installation ____________
5. Assessing System Output Power ____________
Sessions XIII and XIV. Maintenance; Troubleshooting
A. Maintenance ____________
B. Troubleshooting ____________
1. Loose or Corroded System Connections ____________
2. Inverter Losses ____________
3. Heat Fade ____________
4. Burnt Terminals ____________
5. Bypass Diode Failure ____________
Sessions XV. Codes and Standards; Emerging Technologies
A. Codes and Standards ____________
B. Emerging Technologies ____________
Session XVI. Review and Testing
A. Module Review ____________
B. Module Examination ____________
1. Trainees must score 70 percent or higher to receive recognition
from NCCER.
2. Record the testing results on Training Report Form 200, and submit
the results to the Training Program Sponsor.
Site Assessment Module 57102-11
Annotated Instructor’s Guide

Module Overview
A thorough site assessment is essential to the installation of an efficient system that meets the customer’s
needs. This module introduces the trainee to the site assessment process for a photovoltaic system.

Objectives
Upon completion of this module, the trainee will be able to do the following:
1. Determine customer needs:
• Determine electrical load and energy use by review of utility bills, meter readings, measurements,
and/or customer interviews.
• Estimate and/or measure the peak load demand and average daily energy use for all connected
loads.
2. Assess any site-specific safety hazards and/or installation considerations.
3. Identify and use the tools and equipment required for conducting site surveys for PV installations.
4. Identify, select, and sketch a suitable location for PV array installation, including proper orientation,
sufficient area, adequate solar access, and structural integrity.
5. Select suitable locations for installing inverters, control(s), batteries, and other components.
• Identify essential loads for battery systems.
• Identify opportunities for the use of energy-efficient equipment/appliances, conservation, and
energy management practices.
6. Acquire and interpret site solar radiation and temperature data to establish performance expectations
and use in electrical system calculations.

Prerequisites
Prior to training with this module, it is recommended that the trainee shall have successfully completed
Core Curriculum and Solar Photovoltaic Systems Installer, Module 57101-11. It is also suggested that
the trainee shall have successfully completed the following modules from the Electrical curriculum:
Electrical Level One, Modules 26101 through 26111; Electrical Level Two, Modules 26201, 26205, 26206,
and 26208 through 26211; Electrical Level Three, Modules 26301 and 26302; and Electrical Level Four,
Modules 26403 and 26413.

Performance Task
Under the supervision of the instructor, the trainee should be able to do the following:
1. Given the results of a customer interview and the sample house drawing provided, complete a site
survey and checklist.

Materials and Equipment

Markers/chalk Sample electric bills
Pencils and scratch paper Pictures of sagging or obviously bad roofs,
Whiteboard/chalkboard marginal roofs, and good roofs
Solar Photovoltaic Systems Installer PowerPoint® Picture with roof and lot dimensions, roof angle,
Presentation Slides (ISBN 978-0-13-257135-7) and number of panels
Multimedia projector and screen Several addresses with good aerial views available
Computers with Internet access on the Internet
Appropriate personal protective equipment Compass
Selection of assessment tools Solar Pathfinder™, if possible
(continued)
Sufficient copies of a completed customer interview Module Examinations*
Sufficient copies of the sample house drawing Performance Profile Sheets*
* Single-module AIG purchases include the printed exam and performance task sheet. If you have
purchased the perfect-bound version of this title, download these materials from the IRC using your
access code.

Safety Considerations
Ensure that the trainees are equipped with appropriate personal protective equipment and know how
to use it properly. Review safety guidelines associated with working on or around photovoltaic systems,
including fall protection. Emphasize the importance of proper housekeeping.

Additional Resources
This module presents thorough resources for task training. The following resource material is suggested
for further study.
Aerial photographs:
Terraserver: www.terraserver.com.
Google Earth: www.google.com.
USGS: http://edcsns17.cr.usgs.gov.
AMtec Solar (combiners) website: www.amtecsolar.com.
Electric Power Glossary of Terms: www.osha.gov.
Florida Solar Energy Center website: www.fsec.ucf.edu.
National Geophysical Data Center website: www.ngdc.noaa.gov.
National Oceanic and Atmospheric Administration website: www.noaa.gov.
Solar Pathfinder™ website: www.solarpathfinder.com.
Solar Power Calculator website: www.findsolar.com.
Solar Source Institute website: www.solarsource.net.
Surrette/Rolls Battery website: www.surrette.com.
University of Oregon Solar Radiation Monitoring Laboratory website: solardat.uoregon.edu.

Teaching Time for This Module

An outline for use in developing your lesson plan is presented below. Note that each Roman numeral in
the outline equates to one session of instruction. Each session has a suggested time period of 2½ hours.
This includes 10 minutes at the beginning of each session for administrative tasks and one 10-minute
break during the session. Approximately 10 hours are suggested to cover Site Assessment. You will need to
adjust the time required for hands-on activity and testing based on your class size and resources. Because
laboratories often correspond to Performance Tasks, the proficiency of the trainees may be noted during
these exercises for Performance Testing purposes.

Topic Planned Time

Session I. Introduction; Determining Customer Needs
A. Introduction ____________
1. Assessment Tools and Equipment ____________
B. Determining Customer Needs ____________
1. Energy Loads ____________
2. Available Sunlight ____________
3. Mounting Options ____________
Topic Planned Time
Session II. Mounting Surface Information; Acquiring
and Interpreting Site Solar Data
A. Mounting Surface Information ____________
1. Inspecting Proposed Installation Areas ____________
2. Inspecting Attic Spaces ____________
3. Roofing Materials ____________
4. Spacing ____________
5. Anchoring ____________
B. Acquiring and Interpreting Site Solar Data ____________
1. Identifying Sun Paths and Intensity Levels ____________
2. Shading at the Customer’s Location ____________
Session III. Locations for BOS Components; Documenting Site Assessment;
New Technology
A. Locations for BOS Components ____________
1. Support and Security Structures ____________
2. Combiners ____________
3. Charge Controllers ____________
4. Batteries ____________
5. Inverters ____________
6. Disconnects ____________
7. Grounding ____________
B. Documenting Site Assessment ____________
C. New Technology ____________
D. Laboratory ____________
Given the results of a customer interview and the sample house drawing
provided, have the trainees complete a site survey and checklist. This
laboratory corresponds to Performance Task 1.
Session IV. Review and Testing
A. Review ____________
B. Module Examination ____________
1. Trainees must score 70 percent or higher to receive recognition from
NCCER.
2. Record the testing results on Training Report Form 200, and submit the
results to the Training Program Sponsor.
C. Performance Testing ____________
1. Trainees must perform each task to the satisfaction of the instructor to re-
ceive recognition from NCCER. If applicable, proficiency noted during
laboratory exercises can be used to satisfy the Performance Testing
requirements.
2. Record the testing results on Training Report Form 200, and submit the
results to the Training Program Sponsor.
System Design Module 57103-11
Annotated Instructor’s Guide

Module Overview
This module describes system design considerations, including array configurations, component selection,
and wire sizing. It also covers bonding, grounding, and the selection of overcurrent protection and disconnects.

Prerequisites
Prior to training with this module, it is recommended that the trainee shall have successfully completed
Core Curriculum and Solar Photovoltaic Systems Installer, Modules 57101-11 and 57102-11. It is also sug-
gested that the trainee shall have successfully completed the following modules from the Electrical cur-
riculum: Electrical Level One, Modules 26101 through 26111; Electrical Level Two, Modules 26201, 26205,
26206, and 26208 through 26211; Electrical Level Three, Modules 26301 and 26302; and Electrical Level Four,
Modules 26403 and 26413.

Objectives
Upon completion of this module, the trainee will be able to do the following:
1. Identify appropriate system designs and array configurations based on user loads, customer expecta-
tions, and site conditions.
2. Determine the size and capacities for major system components based on user load, desired energy
production, autonomy requirements, and costs.
3. Determine the PV module layout, orientation, and mounting method for optimum system production
and integrity.
4. Determine the ampacity requirement for all components and wiring of the PV system.
5. Select the appropriate conductor types and sizes for each portion of the electrical circuit.
6. Identify the appropriate size, rating, and location of required overcurrent protection and power
disconnect devices.
7. Determine the appropriate size, rating, and location for bonding, grounding, and surge suppression.

Performance Task
Under the supervision of the instructor, the trainee should be able to do the following:
1. Given a completed site assessment, design a grid-connected PV system.

Materials and Equipment

Markers/chalk Several battery catalogs
Pencils and scratch paper Several solar panel specification sheets
Whiteboard/chalkboard PV system, working
Solar Photovoltaic Systems Installer PowerPoint® Photos of several site locations, with their city,
Presentation Slides (ISBN 978-0-13-257135-7) state, and insolation factors
Multimedia projector and screen Two or three copies of the NEC®
Computers with Internet access A couple of wire specifications for the trainees to
Appropriate personal protective equipment determine wire sizes
Several multimeters An electrical diagram of a PV system with the
A list of battery requirements including: grounding and disconnects removed
Current load Factor values for determining array size
Inverter efficiency Completed site assessment
DC system voltage Module Examinations*
Days of autonomy Performance Profile Sheets*
Battery design discharge limit
* Single-module AIG purchases include the printed exam and performance task sheet. If you have purchased
the perfect-bound version of this title, download these materials from the IRC using your access code.
Safety Considerations
Ensure that the trainees are equipped with appropriate personal protective equipment and know how
to use it properly. Review safety guidelines associated with working on or around solar PV systems.
Emphasize the importance of proper housekeeping.

Additional Resources
This module presents thorough resources for task training. The following resource material is suggested
for further study.
IEEE 1547, Standard for Interconnecting Distributed Resources with Electric Power Systems, Latest
Edition. Los Alamitos, CA: Institute of Electrical and Electronics Engineers (IEEE).
National Electrical Code® (NFPA 70®), Latest Edition. National Fire Protection Association (NFPA):
Quincy, MA.
Occupational Safety and Health Standard 1910.302, Electric Utilization Systems, Latest Edition.
Washington, DC: OSHA Department of Labor, U.S. Government Printing Office.
Photovoltaic Systems, Second Edition. James P. Dunlop. Orland Park, IL: American Technical
Publishers.
Standard for Electrical Safety in the Workplace® (NFPA 70E®), Latest Edition. National Fire Protection
Association (NFPA): Quincy, MA.
Solar insolation for U.S. major cities: www.solar4power.com.
Solar panels, solar power generation, and photovoltaic system comparison chart:
www.bdbatteries.com.
UL Standard 1703, UL Standard for Safety, Flat-Plate Photovoltaic Modules and Panels, Latest Edition.
Camas, WA: Underwriters Laboratories.
UL Standard 1741, Standard for Inverters, Converters, Controllers and Interconnection System
Equipment for Use with Distributed Energy Resources , Latest Edition. Camas, WA: Underwriters
Laboratories.
Uniform Solar Energy Code, Latest Edition. Ontario, CA: International Association of Plumbing and
Mechanical Officials (IAPMO).

Teaching Time for This Module

An outline for use in developing your lesson plan is presented below. Note that each Roman numeral in
the outline equates to one session of instruction. Each session has a suggested time period of 2½ hours.
This includes 10 minutes at the beginning of each session for administrative tasks and one 10-minute
break during the session. Approximately 25 hours are suggested to cover System Design. You will need to
adjust the time required for hands-on activity and testing based on your class size and resources. Because
laboratories often correspond to Performance Tasks, the proficiency of the trainees may be noted during
these exercises for Performance Testing purposes.

Topic Planned Time

Sessions I–VII. Introduction; Stand-Alone System Design; System Wiring
A. Introduction ____________
B. Stand-Alone System Design ____________
1. The Electrical Load ____________
2. Battery Selection ____________
3. Solar PV Panel Selection ____________
4. Charge Controller Selection ____________
5. Inverters ____________
6. System Design and Equipment Review ____________
Topic Planned Time
C. System Wiring ____________
1. Wire, Cable, and Raceway ____________
2. Wiring Diagram ____________
3. Solar Array Wiring ____________
4. Battery and Controller Wiring ____________
5. Inverter Wiring ____________
6. Overcurrent Protection and Disconnects ____________
Sessions VIII–IX. Grid-Tied Systems
A. Grid-Tied Systems ____________
1. Grid-Tied System Component Selection ____________
2. PV System Grid Interface ____________
B. Laboratory ____________
Given a completed site assessment, have trainees design a grid-connected
PV system. This laboratory corresponds to Performance Task 1.
Session X. Review and Testing
A. Review ____________
B. Module Examination ____________
1. Trainees must score 70 percent or higher to receive recognition
from NCCER.
2. Record the testing results on Training Report Form 200, and submit
the results to the Training Program Sponsor.
C. Performance Testing ____________
1. Trainees must perform each task to the satisfaction of the instructor
to receive recognition from NCCER. If applicable, proficiency noted
during laboratory exercises can be used to satisfy the Performance
Testing requirements.
2. Record the testing results on Training Report Form 200, and submit
the results to the Training Program Sponsor.
System Installation and Inspection Module 57104-11
Annotated Instructor’s Guide

Module Overview
This module explains the process of installing a solar photovoltaic (PV) system, inspecting the entire
system, and then activating the system.

Prerequisites
Prior to training with this module, it is recommended that the trainee shall have successfully completed
Core Curriculum and Solar Photovoltaic Systems Installer, Modules 57101-11 through 57103-11. It is also
suggested that the trainees shall have successfully completed the following modules from the Electrical
curriculum: Electrical Level One, Modules 26101 through 26111; Electrical Level Two, Modules 26201, 26205,
26206, and 26208 through 26211; Electrical Level Three, Modules 26301 and 26302; and Electrical Level Four,
Modules 26403 and 26413.

Objectives
Upon completion of this module, the trainee will be able to do the following:
1. Review the site assessment report, system design documents, and permits, and inspect the installa-
tion site.
2. Perform a job safety analysis (JSA) and deploy safety systems as needed.
3. Use system drawings and manufacturer’s instructions to plan the installation and to inventory the
project materials and tools needed for the job.
4. Locate structural members and install mounting hardware and raceway.
5. Inspect photovoltaic (PV) system components prior to installation.
6. Install the mechanical parts of the PV modules (panels) and balance-of-system components.
7. Install, label, and terminate electrical wiring and devices in accordance with local and national codes.
8. Activate and test the system to verify overall system operation.

Performance Task
Under the supervision of the instructor, the trainee should be able to do the following:
1. Install and commission a system.

Materials and Equipment

Markers/chalk Stud finder
Pencils and scratch paper Multimeter
Whiteboard/chalkboard Hydrometer
Solar Photovoltaic Systems Installer Set of panel output specifications
PowerPoint® Presentation Slides Bill of Materials for a PV system installation
(ISBN 978-0-13-257135-7) Charge controller and user manual
Multimedia projector and screen Inverter and user manual
Computers with Internet access Combiner and user manual
Appropriate personal protective equipment Disconnect switches
Roof anchors Wiring diagram for solar PV system
Harnesses and lanyards Wire and raceway catalogs
Air-filtering respirator Job safety analysis for each task in an installation
ESD protection Site design plans
Sufficient drills, torque wrenches, and tools for Section of a roof with shingles
panel installation Roofing sealant
(continued)
FLA batteries, dry End clamps, 16 sets
Electrolyte Mid clamps, 6 sets
Flange connections, both good and slightly Solar panels, boxed
damaged Module Examinations*
Sufficient standoffs, mounting beams, grounding Performance Profile Sheets*
lugs, sliders, and associated hardware
* Single-module AIG purchases include the printed exam and performance task sheet. If you have pur-
chased the perfect-bound version of this title, download these materials from the IRC using your access
code.

Safety Considerations
Ensure that the trainees are equipped with appropriate personal protective equipment and know how to
use it properly. Review safety guidelines associated with working on or near PV systems. Emphasize the
importance of proper housekeeping.

Additional Resources
This module presents thorough resources for task training. The following resource material is suggested
for further study.
AMtec Solar (combiners) website: www.amtecsolar.com.
Florida Solar Energy Center website: www.fsec.ucf.edu.
Sample wiring diagram for solar PV system: www.freesunpower.com.
Solar panel terms: www.osha.gov.
Surrette/Rolls Battery website: www.surrette.com.
Solar Source Institute website: www.solarsource.net.
University of Oregon’s Solar Radiation Monitoring Laboratory website:
http://solardat.uoregon.edu.

Teaching Time for This Module

An outline for use in developing your lesson plan is presented below. Note that each Roman numeral in
the outline equates to one session of instruction. Each session has a suggested time period of 2½ hours.
This includes 10 minutes at the beginning of each session for administrative tasks and one 10-minute
break during the session. Approximately 60 hours are suggested to cover System Installation and Inspection.
You will need to adjust the time required for hands-on activity and testing based on your class size and
resources. Because laboratories often correspond to Performance Tasks, the proficiency of the trainees
may be noted during these exercises for Performance Testing purposes.
Topic Planned Time
Session I. Introduction; Job Preparations  
A. Introduction ____________
B. Job Preparations ____________
1. Reviewing Site Assessment Reports ____________
2. Reviewing System Design Plans ____________
3. Inspecting Building Permits ____________
4. Inspecting Installation Sites ____________
Topic Planned Time
Sessions II and III. Safety  
A. Safety ____________
1. Housekeeping ____________
2. Fall Protection ____________
3. Containment ____________
4. PPE and Heat or Sun Protection ____________
5. Material Handling ____________
6. Batteries ____________
7. Electrical Safety ____________
Sessions IV–VII. Job Planning and Inventory of Materials and Tools; Installing  
Mounting Hardware and Raceways
A. Job Planning and Inventory of Materials and Tools ____________
1. Mounting Hardware ____________
2. Panels, Combiners, and Wiring to BOS Components ____________
3. BOS Components ____________
B. Installing Mounting Hardware and Raceways ____________
1. Preparing Installation Site ____________
2. Installing Mounting Hardware ____________
Sessions VIII and IX. Inspections of PV Components Prior to Installation  
A. Inspections of PV Components Prior to Installation ____________
1. Inspecting PV Panels ____________
2. Inspecting Combiner and DC Disconnect Switch ____________
3. Inspecting Charge Controller and Batteries ____________
4. Inspecting Inverters and AC Circuit Breakers ____________
5. Inspecting Raceway and Wiring ____________
Sessions X–XXIII. Installing PV Modules and BOS Components; Installing,  
Labeling, and Terminating Wiring per Code; Activating
and Testing PV System to Verify Operations
A. Installing PV Modules and BOS Components ____________
1. Installing the Combiner ____________
2. Installing a DC Disconnect Switch ____________
3. Installing the Batteries ____________
4. Installing the Charge Controller ____________
5. Installing the Inverter ____________
6. Installing the PV Panels ____________
B. Installing, Labeling, and Terminating Wiring per Code ____________
1. Labeling ____________
2. Checking Terminations ____________
C. Activating and Testing PV System to Verify Operations ____________
1. Final System Walkdown ____________
2. System Activation and Testing ____________
D. Laboratory ____________
Have trainees install and commission a system. This laboratory corresponds
to Performance Task 1.
Topic Planned Time
Session XXIV. Review and Testing  
A. Review ____________
B. Module Examination ____________
1. Trainees must score 70 percent or higher to receive recognition from NCCER.
2. Record the testing results on Training Report Form 200, and submit the results
to the Training Program Sponsor.
C. Performance Testing ____________
1. Trainees must perform each task to the satisfaction of the instructor to receive
recognition from NCCER. If applicable, proficiency noted during laboratory
exercises can be used to satisfy the Performance Testing requirements.
2. Record the testing results on Training Report Form 200, and submit the results
to the Training Program Sponsor.
Maintenance and Troubleshooting Module 57105-11
Annotated Instructor’s Guide

Module Overview
This module introduces the trainee to the components and operation of PV systems and describes how
to maintain and troubleshoot them.

Prerequisites
Prior to training with this module, it is recommended that the trainee shall have successfully completed
Core Curriculum and Solar Photovoltaic Systems Installer, Modules 57101-11 through 57104-11. It is also
suggested that the trainees shall have successfully completed the following modules from the Electrical
curriculum: Electrical Level One, Modules 26101 through 26111; Electrical Level Two, Modules 26201, 26205,
26206, and 26208 through 26211; Electrical Level Three, Modules 26301 and 26302; and Electrical Level Four,
Modules 26403 and 26413.

Objectives
Upon completion of this module, the trainee will be able to do the following:
1. Identify the tools and equipment required for maintaining and troubleshooting PV systems.
2. Measure system performance and compare to expected performance.
3. Perform system maintenance as recommended by the PV equipment manufacturer.
4. Perform diagnostic procedures, interpret the results, and implement corrective measures on a mal-
functioning system.
5. Verify system functionality, including startup, shutdown, normal operation, and emergency/bypass
operation.
6. Compile and maintain records of system operation, performance, and maintenance.

Performance Tasks
Under the supervision of the instructor, the trainee should be able to do the following:
1. Demonstrate typical maintenance procedures on an installed PV system and document the results.
2. Troubleshoot a malfunctioning system and document the results.

Materials and Equipment

Markers/chalk Solar panel, visibly worn or slightly damaged,
Pencils and scratch paper and the manufacturer’s specifications
Whiteboard/chalkboard Cat III/IV multimeter
Solar Photovoltaic Systems Installer PowerPoint® Pyranometer
Presentation Slides (ISBN 978-0-13-257135-7) Archimedes and refractive index
Multimedia projector and screen hydrometers
Computer Water cart, filler gun, and distilled water
Appropriate personal protective equipment Current-limiting battery charger
PV system, working Noncontact IR thermometer
Solar panel, clean and working Batteries, including both sealed and flooded lead
Solar panel, working but dirty with dust acid (FLA)
and debris Sufficient electrolyte
Manufacturer’s specifications and cleaning PV system performance evaluation form
instructions PV system maintenance record
Appropriate soap and cleaning equipment Data from an actual PV system check
(continued)
Selection of mounting hardware, some good and Manufacturer’s maintenance and lubrication
some damaged or corroded charts
Sufficient batteries for cleaning Two or three actual maintenance records
Sufficient inverters for cleaning and any necessary and logs
tools, such as soft brushes or cloths Module Examinations*
Manufacturer’s troubleshooting chart Performance Profile Sheets*
* Single-module AIG purchases include the printed exam and performance task sheet. If you have
purchased the perfect-bound version of this title, download these materials from the IRC using your
access code.

Safety Considerations
Ensure that the trainees are equipped with appropriate personal protective equipment and know how
to use it properly. Review safety guidelines associated with working on or around photovoltaic systems,
including fall protection and lockout/tagout. Emphasize the importance of proper housekeeping.

Additional Resources
This module presents thorough resources for task training. The following resource material is suggested
for further study.
Canadian Solar website: www.canadian-solar.com.
Florida Solar Energy Center website: www.fsec.ucf.edu.
Outback Power Systems website: www.outbackpower.com.
Solar panel terms: www.osha.gov.
Solar Source Institute website: www.solarsource.net.
Surrette/Rolls Battery website: www.surrette.com.

Teaching Time for This Module

An outline for use in developing your lesson plan is presented below. Note that each Roman numeral in
the outline equates to one session of instruction. Each session has a suggested time period of 2½ hours.
This includes 10 minutes at the beginning of each session for administrative tasks and one 10-minute
break during the session. Approximately 10 hours are suggested to cover Maintenance and Troubleshooting.
You will need to adjust the time required for hands-on activity and testing based on your class size and
resources. Because laboratories often correspond to Performance Tasks, the proficiency of the trainees
may be noted during these exercises for Performance Testing purposes.
Topic Planned Time
Session I. Introduction; Preventive Maintenance  
A. Introduction ____________
B. Preventive Maintenance ____________
1. Tools and Test Equipment ____________
2. Cleaning and Inspecting PV Equipment ____________
3. Evaluating Performance of PV Systems ____________
Topic Planned Time
Session II. Manufacturer-Recommended Maintenance Activities  
A. Manufacturer-Recommended Maintenance Activities ____________
1. Recommended Panel and Mounting Hardware Maintenance ____________
2. Recommended Combiner, DC Disconnect Switch, and Conduit ____________
Maintenance ____________
3. Recommended Charge Controller Maintenance ____________
4. Recommended Battery Maintenance ____________
5. Recommended Inverter Maintenance ____________
B. Laboratory
Have trainees demonstrate typical maintenance procedures on an installed
PV system and document the results. This laboratory corresponds to
Performance Task 1.
Session III. Troubleshooting  
A. Troubleshooting ____________
1. Alarms and Indicators ____________
2. Baseline Data ____________
3. Breaking Down a PV System ____________
4. Inverters ____________
5. Charge Controllers ____________
6. Combiners and Panels ____________
7. Manufacturer’s Troubleshooting Data ____________
8. Record Keeping ____________
B. Laboratory ____________
Have trainees troubleshoot a malfunctioning system and document the
results. This laboratory corresponds to Performance Task 2.
Session IV. Review and Testing  
A. Review ____________
B. Module Examination ____________
1. Trainees must score 70 percent or higher to receive recognition from
NCCER.
2. Record the testing results on Training Report Form 200, and submit the
results to the Training Program Sponsor. ____________
C. Performance Testing
1. Trainees must perform each task to the satisfaction of the instructor to
receive recognition from NCCER. If applicable, proficiency noted during
laboratory exercises can be used to satisfy the Performance Testing
requirements.
2. Record the testing results on Training Report Form 200, and submit the
results to the Training Program Sponsor.