INTERNSHIP REPORT ON

SOLAR PV INSTALLATION
FROM
SUNRAYS GREEN ENERGY

FROM:
Yogesh S. Khandare
2ND YEAR ELECTRICAL ENGG.
GOVT. COLLEGE OF ENGG.
NAGPUR
 SUNRAYS GREEN ENERGY
FLAT NO. 3 PL NO. 13 128 MAYUR COLONY KOTHRUD PUNE – 411029
Keshav Kunj Apartment, Infront of Radhika Vihar, Chhatrapati
Chowk, Latur - 413512. EMAIL - [email protected]

REF/ SGE/22-23/454 DATE:09/05/2023

Mr. Yogesh Sanjay Khandare,

Govt. Collage of Engineering,
Nagpur.

CERTIFICATE
To Whom It May Concern
This is to certify that Mr. Yogesh Sanjay Khandare Roll No. 75. student of Government Collage of
Engineering Nagpur worked under my supervision during his internship period from 25/04/2023 to
09/05/2023 and he worked at the SUNRAYS GREEN ENERGY. I am pleased to state that he worked hard in
preparing this report and he has been able to present a good picture of the concerned works. The
information and findings presented in the report seems to be authentic.

Mr. Yogesh Sanjay Khandare possesses a good moral character and pleasing personality. His participation
and performance in this Internship were found to be satisfactory.

I wish him every success in life.

Vishal B. Todkar
SUNRAYS GREEN ENERGY.
(DIRECTOR - CTO) – 9850305775
[email protected]
 ACKNOWLEDGEMENT
I would like to express my sincere gratitude to SUNRAYS GREEN ENERGY for
providing me with an internship opportunity at your organization. The training and
practical experience I received in the SOLAR PV INSTALLATION field have been
invaluable to my personal and professional growth. Throughout my internship, I was
able to work on a variety of projects related to industrial automation and control
systems. I gained hands-on experience with SOLAR PV MODULES AND THEIR
INSTALLATION. I also learned about the importance of proper control panel wiring
and adhering to safety and regulatory standards. The expertise and guidance of the
skilled professionals at SUNRAYS GREEN ENERGY have been instrumental in
shaping my understanding of industrial automation and control systems. The practical
knowledge I gained during my internship has already proved useful in my future
endeavors. I would like to express my sincere appreciation for the time and resources
that you invested in me during my internship. I am grateful for the opportunity to have
worked with such an experienced and dedicated team.
 INTRODUCTION

The purpose of this internship report is to document my experience working with solar
PV modules and their installation at SUN-RAYS GREEN ENERGY. As an intern
in the engineering department, I had the opportunity to work on a variety of projects
related to industrial automation and control systems. The main objective of my
internship was to gain practical experience in the application of solar PV modules and
installation and to develop my skills in this area.

ABSTRACT
This report describes solar energy and Its Maintenance. Solar Energy is referring to as
the energy from the sun; the conversion of the sunlight into electricity gives you Solar
power. It allows any user with necessary receiving components to receive the sun for
its utilization by using photovoltaic (PV). Photovoltaic convert light into an electric
current and this current can be converted into alternating current (AC) using an inverter
and also stored using a well-arranged battery for use in homes for illumination and for
appliances at home.

INTRODUCTION
Solar energy in recent years has attracted more attention to people due to inefficiency
and unavailability of power for different use in homes and industries. It is a well-known
fact that the world is facing a major threat of fast exhaustion of the fossil fuel reserves
like in India where our source of energy is from natural gas and water. There has been
general outcry against lack of constant power supply to help our industries and home
appliances. This has brought about the urgent need to explore other means of power
generation such as solar energy. Research has been into the development of reliable
and strong systems to harness energy from nonconventional energy resources. Solar
power source has experienced a tremendous rapid growth in the past ten years and is
Pollution free source of abundant power. This paper lists the basic components needed
for installation of solar energy at homes; this includes the solar panels (PV modules),
Charge controller, Battery, Inverter, Connecting wires.

COMPONENTS OF A SOLAR POWER

Solar design and installation are absolute easy thing one can do but with proper
knowledge, training and skill with some money to purchase the equipment’s. Some of
the components you need for installation of solar energy are listed below:
 • Solar system
• Solar panels (photovoltaic PV modules)
• Charge controller
• Battery
• Inverter
• connecting wires
• Appliances (like Bulb, TV, Fan etc.)

• The Solar system

Solar System can be defined as the Sun and everything that orbits the Sun which also
include the planets and their satellites. It can also be called a group of celestial bodies
orbiting another star. In this paper, solar system refers to the system that includes Earth
and the Sun. With about 300 clear and sunny days in a year, the calculated solar energy
incidence on India's land area is about 5,000 trillion kilowatt-hours (kWh) per year (or
5 EWh/yr.). The solar energy available in a single year exceeds the possible energy
output of all of the fossil fuel energy reserves in India. The daily average solar-power-
plant generation capacity in India is 0.30 kWh per m2 of used land area, equivalent to
1,400–1,800 peak (rated) capacity operating hours in a year with available,
commercially-proven technology.
In June 2015, India began a ₹40 crore (US$5.0 million) project to measure solar
radiation with a spatial resolution of 3 by 3 kilometers (1.9 mi × 1.9 mi). This solar-
radiation measuring network provides the basis for the Indian solar-radiation atlas. 121
solar radiation resource assessment (SRRA) stations have been installed across India
by the National Institute of Wind Energy, Ministry of New and Renewable Energy to
create a database of solar-energy potential. Data is collected and reported to the Centre
for Wind Energy Technology (C-WET). Among the parameters measured are Global
Horizontal Irradiance (GHI), Direct Normal Irradiance (DNI) and Diffuse Horizontal
Irradiance (DHI)

• Solar panels (photovoltaic PV modules)

A solar cell or photovoltaic cell can be defined as a device that converts light directly
into electricity by the photovoltaic effect. Solar Photovoltaic systems generate
electricity directly using sunlight. Solar thermal systems actively or passively collect,
transport, and utilize solar energy to generate heat. The generation of voltage across the
p-n junction in a semiconductor due to the absorption of light radiation is called
photovoltaic effect. The Devices based on this effect is called photovoltaic device. The
solar panel converts the solar energy (energy from the sun) to electricity which charges
the battery. For more effective use, more than one solar panel are electrically connected
to form array for the purpose of collecting a good amount of sun to charge the battery
which will be capable of supplying a home the amount of electricity needed. Solar
panel connections are done in two different ways for efficient useful work. The two
ways of connecting solar PV are as
follows:
Series connections.
Parallel connections.

• Series connection
Series connection simply is connecting solar panel positive terminals to negative
terminals of another. It gives output voltage equals the sum total of the voltage of the
entire module in the string and the output current equals the equivalent of the current
for a single solar. In series connection all the currents are equal while the voltages are
the sum of individual voltages. By Series connecting, the voltage equals the sum of
those panels, being in series, the amperage is equal
 • Parallel connection
Parallel connection simply is connecting the solar panel positive terminals to positive
terminals of next and negative terminals to negative terminals of next. When using this
type of connection, your voltage remains the same but your amperage is the total sum
of the panels being used. That is to say, it gives output voltage equals the equivalent
voltage of a single solar panel in the string and the output current equals the sum total
of all the current of the solar panel in the string.

By parallel connected solar panel gives more current (amperage) the sum of individual
currents, the voltage is equals
 • Charge Controller
Charge controller ensures is used to charge your batteries, it ensures that the battery is
not over-charged or over-discharged; it stops receiving from the solar panel when the
battery is fully charged and switches off every DC load connected to it when the battery
is discharged to the minimum level. These charge controllers regulate the charging of
your batteries because they are programmed. The quality of these programs determines
the lifespan of your batteries. This is the reason only quality charge
controllers should be used, because batteries are the most expensive part of any solar
system installation. DC loads are taken directly from the charge controller. The
procedure for selecting Charge controller is by determining the operating voltage of the
PV array and the current, i.e., the charge controller must be sized to handle maximum
current and voltage produced by the solar PV array.

• Battery
Battery stores the electrical charge produced by the solar panel during the day. It helps
the output of the solar panel when it cannot supply enough electricity to the system.
Batteries are a major cost of any solar system and are the most friable component in
the solar system. Battery should have sufficient Amp hour storage to supply the needed
power during the cloudy weather. Batteries can be either shallow cycle discharge (for
automobiles) or deep cycle discharge (for PV system).
A shallow-cycle batteries discharge only between 10% and 20% of their Ah
capacity/day discharging beyond this point without recharging shortens the battery life.
Deep-cycle batteries are designed to allow a discharge of 60% to 80% of its Ah
capacity. A battery discharged at a rate of 1 amp will have a higher Ah capacity than a
battery discharged at a rate of 4 amps. A battery which can deliver 1 amp for 100 hours
has a capacity of 100Ah @ C100. The same battery may only deliver 4 amps for 20
hours. Then its capacity is 80Ah @ C20. C100 means discharged over 100 hours, C20
means discharged over 20 hours. Batteries are connected in series and parallel.
• Inverter
This is what will turn the 12-volt DC current into 110-120 volts AC current for use in
powering your household electrical devices. An inverter is device that changes direct
current (DC) from the battery to alternating current (AC) to be used for AC appliances.
The battery provides DC voltage to the inverter, and the inverter converts the DC
voltage to normal AC voltage. The output of a solar PV system can be either DC or AC
depending on the type of electrical load it is meant to power. If it is used to power a
DC load, then there is no need for an inverter. However, inverter is required when the
electrical load is AC. One can choose to go for solar inverter; solar inverters have some
special functions with the photovoltaic arrays like maximum power point tracking and
anti-islanding protection. There are two types of inverters which include modified sine
wave and pure sine wave inverters. Note: the size of the inverter should be around three
times what you plan to use it for, this is because the consumer products do not always
use the best components and this is a way to ensure your unit will last longer than when
you purchase an undervalued unit and push it to burn out. Before you buy an inverter,
you need to take cognizes of the following:
i. The maximum load; the rating is larger than wattage of all the ac loads to be
run at any one time
ii. The maximum surge; Inverter is designed to surge if motors will be
connected.
iii. The output voltage
iv. The input battery voltage requirements

• Connecting Wires
They are used to connect one component to the other. The generated electricity (electric
current) flows through them to the load. The recommended size of cables is 2.5mm.

THE STEP-BY-STEP INSTALLATION OF SOLAR ENERGY

Solar power plant installation is very easy. But before the actual work begins, the most
important issues that you must have done are to know the total electricity consumption
for the household, this can be done by taking a physical view of all the appliances to
check their power ratings to know the capacity of all the system components and the
total number of panels, batteries and the capacity of charge controller and the
appropriate inverter needed. Now the components are conveyed to the site a day before
the actual installation. The stages in the installation include
1. Arrange the photovoltaic PV modules:
After bringing out the PV with the ratings behind the panel, the information you will
see is the maximum wattage, voltage, and amperes. After that, wire the panel according
to the required need but I prefer the parallel connection (the voltages remain the same
while the currents are added). Then mount the PV on the rooftop of the building with a
few inches gap and parallel to the surface of the roof. Solar PV can also be mounted on
the ground. The solar array is usually best placed in perpendicular to the sun’s rays,
which change continuously over the course of the day and season. The most suitably
location and inclination for a PV mounting is east front and slope of 30-
40ͦ
2. Charge controller:
The next thing to do after the setting up the solar PV array is to connect the charge
controller (which you know is to ensure that the battery is not over-charged or over-
discharged) directly from the output terminals of the solar PV using lighter gage wires.
Note: DC loads can be directly connected to the charge controller. After the connection,
we move to next step which is connecting the battery
3. Battery:
The batteries are properly connected either in series or parallel connection depending
on your need, and then connect the battery to the charge controller at the port
selected/indicated for it in solar charge controller. The next thing to connect is the
inverter.
4. Inverter:
The next setup is the inverter, as we discussed above the inverter converts the DC
supply from the solar PV into the battery to AC supply in order to power our AC loads.
Connect the battery terminal to the inverter with 2.5mm cable. Finally, from the
inverter you connect to the external load in the house. The rating of the inverter should
be the same with rating of the PV array

MAINTENANCE OF SOLAR PV SYSTEMS

Solar panels have no moving parts, and therefore no potential points of mechanical
failure. Therefore, properly installed PV system requires very little maintenance. After
the installation of solar system for household use, best maintenance practice is to
inspect the equipment especially batteries and modules, to make sure all electrical
contacts are tight. We can keep the solar PV operational through two maintenance
techniques which include the preventive and corrective maintenance. Let us look at
maintenance of the different components of the solar system which include:
1. Solar PV Maintenance
You should wash the PV array, during the cool of the day, when there is a noticeable
buildup of dust and dirt. Periodically inspect the system to make sure all wirings and
supports are intact. Furthermore, check for tree growth that has shaded your modules
and also check for birds’ nests in your modules and junction boxes. Review the output
of the system annually (assuming the array is clean) to see if the performance of the
system is close to the previous year's reading. Do not scratch the glass casing of the
module.

2. Battery Maintenance
Battery is very important component in the solar system; therefore, proper care should
be taken. For long life, battery should be cleaned monthly; the electrolyte level should
be checked and kept in a high state of charge. When cleaning batteries, beware of the
battery acid and do not short the terminals. Carry the battery outside when cleaning to
avoid spilling acid, keep plenty of water nearby to rinse spills.

3. Charge controller malfunction

Charge controller will be will go bad if the battery voltage exceeds the appropriate set
voltage for the type of battery used, and also the batteries are bubbling severely causing
a lot of moisture accumulation on the battery tops. Charge controller can go badly if
the battery bank capacity is not up to the rate.

SOME OF THE GENERAL PRECAUTION/MAINTENANCE

TO BE CARRIED ON THE SYSTEM INCLUDE:
1) observe the tightness of screws on all connector strips, controls; switches, etc. make
sure that they are well chewed. This is mostly important for old or exposed wire.
2) look at the junction boxes to make sure that insects have not build house there, and
also make sure they are watertight when exposed to the environment.
3) inspect switches to make sure they are in good operating manner
4) inspect the fuses to ensure no one is blown. If blown, find the cause and replace or
repair with a new one of the same size.
5) inspect the indicator lamps on the charge controller. The solar charge controller
indicator should be ON when the sun is up. If is not ON. Check to see if batteries are
being charged. Check whether the other LED indicator lamps are working (that is
battery full and low voltage).
6) Check grounding wires to make sure they are still intact.
 INTERNSHIP EXPERIENCE
During my internship, it had a great pleasure for me to get a chance to work in Sunrays
Green Energy. At the end of my training tenure, I wish to summarize the benefits
acquired over the period of training. This training certainly helped me in bridging the
gap between theory and practical. It provides me opportunity to learn under different
environment. It’s also helped me in analyses my gaps and Benchmarks.
This internship comprises of various technical divisions, where I had the opportunity
to work with the Solar PV system which is a growing sector in these days. I gained
quite a lot of things from this training and they are quoted below: • I understood the
scope and job responsibilities of the various departments of an engineering
organization.
▪ I got a chance to get the knowledge about basic components and understanding
the terms related to solar PV plant.
▪ During the training period I learnt working on PV Syst Photovoltaic software to
set up 100 KW solar PV rooftop plant. I also covered some new topics which
were not an academic subject like solar resource assessment, losses in electricity
generated from solar
▪ Photo voltaic plant, complete use of PV Syst Software.
▪ I also came to know the importance of responsibility & authorities allotted for
different task & successful accomplishment of the same as early as possible.
Thus, I confidently conclude that this training was the most beneficial and
enlightening experience, which is bound to help me in my future. I will forever
be grateful to Sunrays Green Energy for this internship experience. To be a part
of this online internship conducted by sunrays green energy under the guidance
of Mr. Vishal B. Todkar I learned a lot of new things and commercially
applicability
 RESULTS AND CONCLUSION:

▪ Overview: Overall, my internship experience provided me with valuable hands-

on experience in the solar PV installation in industrial automation systems. I was
able to develop my technical skills and gain a better understanding of the
practical considerations involved in the selection, installation, and maintenance
of these systems. My internship also gave me the opportunity to work with a
team of experienced engineers and learn from their expertise. I would highly
recommend this internship to other students who are interested in pursuing a
career in industrial automation and control systems.

▪ Results: During my internship at Sunrays Green Energy, I gained valuable

practical experience and developed my skills in the field of industrial
automation. Specifically, they helped me understand the importance of safety,
quality, and eff I got a chance to get the knowledge about basic components and
understanding the terms related to solar PV plant. During the training period I
learnt working on PV Syst Photovoltaic software to set up 100 KW solar PV
rooftop plant. I also covered some new topics which were not an academic
subject like solar resource assessment, losses in electricity generated from solar
Photo voltaic plant, complete use of PV Syst Software. I also came to know the
importance of responsibility & authorities allotted for different task & successful
accomplishment of the same as early as possible. Thus, I confidently conclude
that this training was the most beneficial and enlightening experience, which is
bound to help me in my future. I will forever be grateful to sunrays green energy
for this internship experience. anciency in industrial automation.
▪ Conclusion: Overall, my internship at Sunrays Green Energy was an invaluable
experience. I was able to gain practical experience and develop my skills in the
field of industrial automation, which will be invaluable as I pursue a career in
this field. I gained a better understanding of the importance of safety, quality,
and efficiency in industrial processes, and I am now better equipped to apply this
knowledge in my future work. I would like to express my appreciation to Sunrays
Green Energy for providing me with this opportunity and for the guidance and
support they provided throughout my internship. The skills and knowledge I
gained during my internship will help me to become a better industrial
automation professional, and I look forward to applying them in my future
career.