Renewable Energy

By Dr. Ramy Ahmed

LECTURE 4: PV system calculations. 1

Biography
Dr. Ramy Ahmed

Ph.D. in Electrical Engineering. (Photovoltaic Power Enhancement)

Power and Machines Department

Faculty of Engineering
Misr University for Science and Technology (MUST).

Communication between PV systems. TU Graz University, Austria

Project Director, renewable energy –SEKEM Companies Group (Eco energy).

* SEKEM solar pumping in El-WAHAT (Design and Installation) PV plants to provide a solar PV
supply for pivot (rotation), surface pumping, and Submersed Pumps as well. (3 MW)
* 128 kW of PV system for the campus of Heliopolis University. 200 kW of PV system for ISIS water
factory. (On-grid)
* STS-Med demo plants. 6 kW Provide a sustainable source of energy by a CSP station for producing
electricity and cooling.
* Solar irrigation project by (FAO). 60 kW PV plant to Provide a sustainable source of energy for
lifting irrigation water (and potentially for other uses in non-irrigation period). (On-grid)
* Renewable Energy projects, and other related activities all-over Egypt.

2
Projects

3
Course Distribution
COURSE CONTENTS:
1. Introduction of Renewable Energy Sources.
2. Photovoltaic Energy System
3. Wind Energy System
4. Energy Storage Devices
5. Integration of Renewable Energy Sources
6. Distributed Generation
7. Project.

4
References:

5
Class RULES

No mobile

Don’t Come Late

6
 Off-Grid Solar System
The prices of solar panels have been falling gradually but instructables
the cost of an off-grid solar system setup is rising steadily.
However, anyone with basic knowledge of Electricity and a toolbox can install it on their own. This will reduce the overall
system cost substantially and you will learn a lot.
In order to build a basic off-grid solar system, you will need the following components:
1. Solar panel
2. Charge Controller
3. Battery
4. Inverter
5. Balance Of System ( Cable, Breaker, Meter, Fuses, and MC4 connectors)
In this lnstructable, I will guide you step-by-step on how to choose the appropriate components of your Off-Grid Solar
System and then guide you on how to connect and set them up properly.
Supplies:

Components Required ;
1. Solar Panel ( Amazon/ Solar Panel )
2. Charge Controller (Amazon/ Aliexpress)
3. Battery ( Amazon)
4. Inverter (Amazon/ Aliexpress)
5. Remote Meter ( Amazon I Aliexpress)
6. WiFi Adapter ( Aliexpress)
7. Temperature Sensor ( Amazon I Aliexpress)
8. DC Breaker ( Amazon / Banggood / Aliexpress)
9. AC Breaker ( Amazon/ Aliexpress / Banggood)
10. DC Busbar ( Amazon/ Aliexpress / Bang good)
11. Fuse Box (Amazon/ Aliexpress / Banggood)
12. DIN Rail ( Amazon / Aliexpress )
DIY Off-Grid Solar System V2.0: Page 1
13. Cables (Amazon / Banggood / Aliexpress)

14 . MC4 Co nnect or ( Am azon / Aliexpress Banggoo d)

15. Terminal Lugs ( Amazon/ Aliexpress / Banggood )

16. Cable Tie ( Amazo n/ Aliexpress / Banggood)

Tools Required :
1. Wire Stripper ( Amazon/ Aliexpress / Banggood)
2. Crimping Tool ( Amazon / Aliexpress Banggood )
3. Plier (Amazon/ Aliexpress)
4. Screwdriver ( Amazon/ Aliexpress / Banggood)
5. MC4 Spanner ( Amazon/ Aliexpress / Banggood)
6. Spanners (Amazon / Banggood / Aliexpress)

-----
MP p T
S O A R CAGE CONTROLLER

i
$ 9

DIY Off-Grid Solar System V2.0: Page 2

I
t I
+
l I 1,
I
I [ •
J
I
J I
I r l
r
I j
L l .
f
I

l fj
I
J

I '

DIY Off-Grid Solar System V2.0: Page 3

 fl r i

MP P T
-----
$ O u #ACNAGE CCWTROLLER

~I . ' I l
l l

https://youtu.be/X_0AecD6E1 M
Step 1: How It Works ?

The off-grid solar system means you are not connected in any way to the utility grid. The system utilizes batteries to store
energy produced from solar panels.
Solar Panel:
The solar panel converts sunlight into electricity. Photovoltaic cells on the solar panel absorb the sun's energy and
convert it to DC electricity.
Charge Controller:
The current from the solar panel feeds into a charge controller, which controls how much current goes to a battery.
Charge controllers prevent batteries from being over-charged and over-discharged.
Battery:
It stores energy generated from the solar panel during the day.
Inverter:
It converts the DC (Direct Current) power from the battery bank or solar panels to AC (Alternating Current)
 can run your AC appliances, such as TV, Fan, Fridge, Water Pump, etc.

Charge Controller

Sun
4
0C Load

I
Step 2: Basic Electricity Rules
-■
...,
Q

£e
.
t

.
.

=.· Inverter
AC Load

Ohms Law Relationship Battery

Current ( I ) = Voltage (V) / Resistance (R)

It is easier to remember the Ohms law relationship by using the above picture (
Ohms Triangle). By knowing any two
values of the Voltage, Current, or Resistance quantities we can use Ohms Law to
find the third missing value.
Voltage ( V ) :

V (volts) = I (amps) x R (Q)

Current ( I ) :

I (amps) = V (volts)/ R (Q)

Resistance ( R ) :
= V (volts)/ I (amps)
R (0 )

Power ( Watt) = Voltage ( Volt) x Current (Amp)

Energy (Watt-hours)= Power (Watts) x Time ( Hours)
Capacity= Current (Amp) xTime ( Hours)

DIY Off-Grid Solar System V2.0: Page 5

 V
v=IX R -VR .

@= I

Step 3: 6 Steps of DIV Off-Grid Solar

The following 6 steps are required for building a DIV Off -Grid Solar System:

1. Calculate Daily Energy Consumption

2. Select the Battery

3. Select the Solar Panel

4. Select Charge Controller
5. Select Inverter

6. Balance of System ( BOS)

In the next steps, we will discuss in detail the above points .

Step 4: Calculate Your Daily Energy Consumption

Figuring out your daily energy consumption ( Watt-Hours) is the first step for designing an off-grid solar system.

Energy Consumption (Watt-Hours) =Power(Watts) x Time (Hours)

You can get t he power rat ing from t he power label ( Name Plat e ) of t he appliance or you can measure t he act ual pow er
consum pt io n by using a w at t m et er. I have used my w at t m et er to measure t he power consum pt io n of a few ap pliances.

Manual Calculation:
If you're running a 2 No s of 6W LED bulb for 5 ho urs a day, 1 No of Fan (SOW) for 4 ho urs, 1 No of Lapt op (65W ) for 3 hrs,
and a WiFi Ro ut er (6W ) for 24 ho urs.

1. LED Bulb: 2 x 6W x 5 hr= 60WH

2. LED TV: 1 x 65W x 3 hr = 19 5W H

DIV Off-Grid Solar System V2.0: Page 6
3. Ceiling Fan: 1 x SOW x 4 hr = 320W H

4. W iFi Ro ut er: 1 x 6W x 24 hr = 14 4WH

Total =719WH
You can calculate the energy consumption manually as shown above or use an Online Calculator

DIY Off-Grid Solar System V2.0: Page 7

DIY Off-Grid Solar System V2.0: Page 8
 I,_
r
I
,

DIY Off-Grid Solar System V2.0: Page 9

 I I

DIV Off-Grid Solar System V2.0: Page 10

 Name Plate Rating

Panasonic

Power = 70W
Sen1, N

DIV Off-Grid Solar System V2.0: Page 11

 ]grand Panasonic
Annual Energy Model No. / Year : TH-40F2010X2018
Consumption (kWh/Year) EquipmentType : LEDTV
Screen Size : 101.5cm

95 U n d er test
a
Conditions when tested in
ccordance with relevant
Actual energy cons umption willdepend
POWER SAVINGS GUIDE L " " " onhow the equipment is used.
standards.

Panasonic
Mo d el NO. TH-4 0F20 1D X
LED TV
'! , ) -~II \ / - ''.,1:.,-,1: If . ·~
Marketed tr
Pa n a s oni c. r d i a yt Lt d

Serial No..

DIV Off-Grid Solar System V2.0: Page 12

 Step-1: Daily Energy Consumption

LEDBulb 6 2 12 5 60

Laptop 1 65 195

Ceiling Fan 80 1 4 320

WiFi Router 6 1 6 144

Total = 719

Step 5: Select the Battery

The battery is used to store the energy produce by the Solar Panel during the day. It is an essential part of an off-grid
solar system, and provide a constant source of stable and reliable power that allows to power devices when the sun is
down.
The cost of the battery is contributing a large portion of the entire project cost. here we will discuss in detail so that you
can select the right battery for your off-grid solar installation.
Batteries are categorized according to 1. Application & Construction 2. Chemistry
1. Applications: Automotive and Deep-Cycle
2. Chemistry: Lead Acid, Lithium, and NiCd
Automotive Battery:
This type of bat tery is designed to provide a very large amount of current for a sho rt period of time. This surge of current
is needed to turn the engine over during starting. Therefore lots of thin plates are employed to achieve maximum
surface area and as a result higher starting current in starting batteries.
Application: Automobiles ( Car & Bike)
Deep-Cycle Battery:
A deep cycle battery is designed to provide a steady amount of current over a long period of time. This type of battery is
also designed to be deeply discharged over and over again. To accomplish this, a deep cycle battery uses thicker plates.
This will lead to lower surfaces and accordingly less instant power, unlike the starting batteries.
DIV Off-Grid Solar System V2.0: Page 13
Application: Renewable Energy

+ +
1111111111111111111
III/[III

Automotive Battery Deep Cycle Battery

Step 6: Lead-Acid Battery Vs Lithium-Ion Battery

Two of the most common battery chemistry types are lithium-ion and lead-acid. Apart from these NiCd is also used for
the renewable application, but here I will discuss only the first two.
Lead-acid batteries are made with lead, while Lithium batteries are made with the metal lithium. Lithium and lead-acid
batteries can both store energy effectively, but each has unique advantages and drawbacks.
1. Lead-acid Battery:
The lead-acid battery is a tried-and-true technology that costs less, but requires regular maintenance and doesn't last as
long.
Flooded Lead-Acid (FLA):
These types of bat teries are submerged in wat er.These must be checked regularly and refilled every 1-3 mont hs to keep
them working properly. It also needs to be installed in a ventilated place to allow battery gases to escape.
Sealed Lead-Acid (SLA):
DIV Off-Grid Solar System V2.0: Page 14
SLA batteries co me in two types, AGM (Absorbent Glass Mat) and Gel, which have many similar properties. They require
lit t le to no maint enance and are sp ill-proof . The key diff erence in AGM vs. gel bat t eries is that gel batt eries tend to have
low er charge rat es and out put. Gel bat t eries generally can't handle as much charge current , which means t hey take
lo nger to recharge and out put less pow er.

2. Lithium Battery:
Lithium is a premium battery technology with a longer lifespan and higher efficiency, but you'll pay more money for the
boost in performance.
The Lithium batteries that are employed in solar systems are Lithium Iron Phosphate (LiFeP04) which have great thermal
stability, high current ratings, and a long life cycle. This new technology lasts longer and can be put through deeper
cycles. They also require no maintenance or venting, unlike lead-acid batteries. The main downside for lithium batteries is
their higher price compared to lead-acid batteries at the moment.
Which Battery Should You Choose?
If you need a battery backup system, both lead-acid and lithium-ion batteries can be effective options. However, it's
usually the right decision to install a lithium-ion battery given the many advantages of the technology - longer lifetime,
higher efficiencies, and higher energy density.
If you are planning to live off the grid full-time, you should go with Flooded Lead Acid (if you don't mind regular
maintenance) or the premium Lithium option for heavy use.
If you want to install the solar in a small cabin or a vacation home, you'll only be there a few times a year. In this case, you
won't be able to provide the regular maintenance which is required for Flooded Lead-acid batteries. Then, I will
recommend spending some extra amount to buy a Sealed Lead Acid battery instead.

I '
le

tt

DIV Off-Grid Solar System V2.0: Page 15

 - Negate
terminal

Lead Acid Battery Lithium Battery

Step 7: Factors Determine the Battery Bank Size

The following factors determine the battery bank size:

1. Daily power consumption
2. System voltage ( 12V / 24V /48V)
3. Depth of Discharge ( DOD)

In the previous step, we have already calculated the daily power consumption. In the next few steps, we will learn more
details above factors.

DIV Off-Grid Solar System V2.0: Page 16

 Step-1: Daily Energy Consumption

LEDBulb 6 2 12 5 60

Laptop 1 65 195

Ceiling Fan 80 1 4 320

WiFi Router 6 1 6 144

Total = 719

Step 8: System Voltage

A battery is recognized with its voltage (V) and capacity measured by amp-hours (AH). To provide the desired system
voltage, one can wire the batteries in series and parallel.
Series Connection:
Connecting batteries in series add the voltage of the two batteries, but it keeps the same amperage rating (also known as
Amp-Hours).
Example: Connecting two 12V/100AH batteries in series will produce 24V, but the total capacity remains the same
(100AH).
Parallel Connection:
Parallel connections will increase your current rating (Amp-Hours), but the voltage will stay the same. It's important to
note that because the amperage of the batteries increased, you may need a heavier-duty cable to keep the cables from
burning out.
Example: Connecting two 12V/100AH batteries in parallel will produce 12V, but the total capacity will be increased to
200AH.

Image credit.:epsolarpv

DIV Off-Grid Solar System V2.0: Page 17

: 12v/200AH
24V/100AH

IIIJIJ HIJI[ IIJII JIIIII[L I I I IIII[IL 1111111111111111111

1111111111 111 I 111 I III II 111 111111

Series Connection Parallel Connection

DIV Off-Grid Solar System V2.0: Page 18

 »)

m
j h a
" 1 4

I
z _' ' H! / 4 it
.

e
Ir-,,_.

Step 9: Depth of Discharge

The battery's Depth of Discharge ( DOD) is the percentage of the battery capacity that can be safely drained without
damaging the battery.
As you can see in the above figure, the more a battery is allowed to discharge, the shorter its lifespan. Deep cycle
batteries are designed to discharge 80% of their capacity but are recommended to choose a value of around 50% as a
good trade-off between longevity, cost.
Fora deep cycle battery, 50% andforalithium battery 80% DODis consideredasgoodpractice.

DIV Off-Grid Solar System V2.0: Page 19

100%

DIV Off-Grid Solar System V2.0: Page 20

 1 0 Cycle Life of a Lithium Ion Battery
3 . 5 ~ - - - , . - - - - - - - - - - - - - - - - - - - - - - - - - -
- B e s t Curve Fit
0 Data
3

2.5
-G
13)
0
>,
2
~c
ID
t .
J
_g) 1.5 - =

9
O
1

0.5
- I

o------------------------------
10 20 30 40 50 60 70 80 90 100
Depth of Discharge (%)

Step 10: Battery Sizing

Battery Capacity (AH)= Daily Energy Consumption (Watt-Hour)/ ( System Voltage x DOD)
Example:
Daily energy consumption =719WH( Calculated in the earlier step)
System Voltage = 12V
DOD = 50% for Flooded Lead Acid Battery
Battery Capacity= 719WH / ( 12V x 0.5 ) = 119.8AH
You have to select a battery with a capacity of more than 119.8AH. The nearest value available in the market is 120AH.
Battery Selected: 12V / 120AH
I have purchased 1S0AH by considering fut ure expansion.

DIV Off-Grid Solar System V2.0: Page 21

I I

LUMII

TALL TUBULAR BATTERY

STATUTORY WARNING
It is mandated by law that used batteries must not be
disposed+off in any manner other than deposit ing the same
with the dealer, manufacturor, or registered recyclor
appointed by th& Company at their designated collection
centers. For mor details, please visit www.luminousindia.com
CAUTION
• Keep sparks, flames, cigarettes, etc. away.
These can cause EXPLOSION leading to SEVERE INJURY,
Protect naked eyes. Contact with acid can cause BLINDNESS.
· Keep away trom CHILDREN,
• Explosive gas.
· Pay attention to the instruction manual,
• Contact with acid can cause SEVERE BURNS/INJURY.

MONT.NS
WR9MI% E Lr1 12so 587

Step 11: Select the Solar Panel

Solar Panel converts the sunlight into electricity. A specific amount of sun's energy can be converted to electricity by the
solar panel since they are not 100% efficient and they cannot trap the full energy of sunlight. Most of the solar panels are
less than 20% efficient, which means that they can just trap about 20% of sunlight energy.
Commonly they are 3 types: Monocrystalline, Polycrystalline, and Thin Film.
1. Monocrystalline:
Monocrystalline solar cells are more efficient because they are cut from a single source of silicon.
As monocrystalline solar cells are made out of a single crystal of silicon, electrons are able to flow easier through the cell,
which makes the efficiency higher than other types of solar panels. The efficiency can range from 17% to 22%.
Because of the way that monocrystalline panels are manufactured, they end up costing more than other kinds of solar
panels.
2. Polycrystalline:
DIV Off-Grid Solar System V2.0: Page 22
Polycrystalline solar cells are blended from multiple silicon sources and are slightly less efficient. The multi ple silico n
cryst als in each solar cell make it harder for elect ro ns to flow . This cryst al st ruct ure mak es t he efficiency rat e of
polycrystalline panels lower than monocrystalline panels. Polycrystalline panel efficiency ratings will typically range from
15% to 17%.

Polycrystalline solar panels are cheaper to produce than monocrystalline panels. Most of the residential installations use
Polycrystalline solar panels.

3. Thin Film:
Thin-film solar panels are made by depositing a thin layer of a photovoltaic substance onto a solid surface, like glass.
Examples of these photovoltaic substances include Amorphous silicon (a-Si), Cadmium telluride (CdTe), Copper indium
gallium selenide (CIGS), Dye-sensitized solar cells (DSC).
The main advantage of amorphous solar cells is that they can generate electricity in weak light conditions. However, the
main problem of amorphous solar cells is the low photoelectric conversion efficiency, which is about 10-13% only.
Which One You Should Choose?
For most residential solar panel installations, it makes the most sense to install monocrystalline panels. Although you
have to pay a higher price, you get better efficiency and a sleeker aesthetic than you would with polycrystalline panels.
If you're on a tight budget, however, polycrystalline panels might make more sense for you.
Thin-film solar cells are most ly used in large scale operat ions, such as ut ilit y or indust rial solar inst allat ions because of
their lower efficiency ratings.
I will alw ays recommend purchasing a good brand solar panel. A good brand solar panel company alw ays invest s heavily
in the quality of its manufacturing process, as well as in its reputation.
Image credit:epsolarpv

'.
'·,
'·. \'

•, \

\ \

DIV Off-Grid Solar System V2.0: Page 23

I
t I
+
l I 1,
I
I [ •
J
I
J I
I r l
r
I j
L l .
f
I

l fj
I
J

I '

DIV Off-Grid Solar System V2.0: Page 24

 I 11111111
111111111111
111111111111
1111111111
111111111
111111111111
Monocrystalline
111111111111
Polycrystalline Thin-Film

DIV Off-Grid Solar System V2.0: Page 25

 Top Solar Panel Brand

SUNPOWER Sota
JinKo

@LG « .c ! canaurlan'Soolar ■
1 1

LONGI Solar

6 wIA«co' aceuus
_JASOLAR Tinasolar

Step 12: Factors Determine the Solar Panel Sizing

The sizing of the solar panel used in an off-grid system depends on the following factors:
1. Daily energy consumption
2. Number of Peak sun hours
3. Solar panels efficiency

Step 13: Peak Sun Hours

The first step for sizing the solar panel is to determine the amount of sunlight received where you live. While the amount
of sunlight your panels receive is import ant , a more accurat e represent at ion of the amount of energy your panels can
produce is peak sun-hours.
What is Peak Sun-Hours?
The peak sun hours is the number of hours per day during which the average solar irradiance (sunlight ) is 10 00 watts per
square meter (W/ m2) or 1 kilowatt per square met er (kW/ m2).

Onepeaksun hour =1000 W/m2 or 1kWh/Im2 ofsunlight

Example: lf a given location receives a total of 6,650 Wh/m2 of solar radiation over the course of a day, then that location
gets 6.65 peak sun hours. You can see the above picture for a clear understanding.
The following factors affect the number of peak sun hours:

DIV Off-Grid Solar System V2.0: Page 26

1. Geographical Location: Solar panels installed at a different location, receive different amounts of sunlight. The panel
installed near the equator receive maximum sunlight, as it is closer to the sun.

2. Time of Day: The amount of sunlight falling on the solar panel, varies throughout the day, based on the sun's posit ion
in the sky. It receives maximum at noon and a minimum during the morning and evening.
3. Season: Maximum amount of sunlight received during the summer and minimum amount during the winter .

Imagesource:Solar Energy International and Global Solar Atlas

12-1 am 1-2 am 3-4 am 4-5a m 5-6 am 6-7am 7-8 am 8-9 am 9-10 am 10-11 am 11-12 pm
T
rT rT rT r T TT TT ' n ut '
750Why0 + u w n y m
700 wh'm

100 Wh/m?
+ 250 Wh/m?
+ 400 Wh/m?
+ 700 Wh/m?
-+ 750 Wh/m?
6,6s0 w/m? }> '
+ 950 Wh/m?
+ 1,000 wh/m? 6.65 peak sun hours
+ 1,100 wh/m?
+ 250 Wh/m?
+ 250 Wh/m?
+ 400 Wh/m?
c
+ 400 Wh/m? G SOLAR ENERGY
INTERNATIONAL
+ 100 Wh/m? 6 2018 Solar Energy International

Area Under Curve = Solar Insolation

Equal Area

1 kW/ I

c £
0
; .0;
.g 0
U 5
0
cr
U or
I. . e
o 0
0
u 6
l e l . w . L t d .
Time of Day s] T i m e o f Day

- . Peak Sun Hours

DIV Off-Grid Solar System V2.0: Page 27

Step 14: How to Calculate Total Peak Sun Hours?

The solar irradiance map can show you the amount of solar energy your location receives on an average day during the
worst month of the year.
To find out the amount of solar insolation in your area, you can use the Global Solar Atlas. Follow the following steps:
Step-1: Search your location
Step-2: Choos the PV system configuration ( e.g- Small residential )
Step-3: Click on Annual Average ( Daily Average in kWh/m2 per day)
Step-4: The number is the peak sun hours
As per the Global Solar Atlas, New Delhi, India receives 5.093 kWh/m2 per day
Peak Solar Radiat ion = 1 kW/ m2 ( So lar Panels are rat ed at an input rat ing of 1kW/ m2.)
Peak Sun Hours = 5.093/1 =5.093 Hours
If we consider the worst scenario, we have to choose a number lesser than that obtained in the above. So here I have
chosen 4.5 Hours.

If you are situated in North America, you can use this reference chart, to get the number of peak sun hours.
Reference for Solar I nsolation Map: NREL

SOLAR RESOURCE MAP

GLOBAL HORIZONTAL IRRADIATION @WQRW lliAHK.131WUP ESMAP LEE9

' 2

Long-terr average of global horizontal irradiation[GHI]

Daily totals: 22 2.6 3.0 3.4 3.8 4.2 4.6 5.0 5.4 5.8 62 6.6 7.0 7.4
whfm!
Yearly totals: 803 949 1095 1241 1387 1524 1680 1826 1972 2118 2264 2410 2556 2702

G roup. furded by ESMA, nd p ep 'ed by

Step 15: System Efficiency

You will never get the rated power from the solar system because there are few losses associated with it like:
1. Soiling Loss: Loss due to dust deposition on the solar panel

DIV Off-Grid Solar System V2.0: Page 28

2. Shading Loss: Loss due to shadow by trees and building near to the panels
3.Wiring Loss: Loss arises in the int er panels cabling and cable from panels to the battery bank.
The typical efficiency is 70% ( considered the worst sit uat ion )

Clean Dusty

DIV Off-Grid Solar System V2.0: Page 29

Step 16: Solar Panel Sizing
DIV Off-Grid Solar System V2.0: Page 30
You can use the below formula to determine the solar panel wattage :

Solar Panel Watt= Daily energy consumption ( WH) / ( Peak Sun Hour x system efficiency)

Daily energy consumption= 719W H

Peak Sun Hour= 4.SHrs

Panel Watt= 719 / ( 4.5 x 0.7) = 228.25W

We have to buy a solar panel with a rating more than the above -calculated value. The nearest value of the panel available
in the local market was 250W or 260W.

I have purchased a 260W because t he price bet w een t he tw o panels was not much diff erent.

Final Rating: 250W / 12V

How Many Solar Panels Required?

If the power calculated in the above higher than a single panel, you have to purchase more panels, in that case:
Number of solar panels=Required solar panels (Watts)/ Selected panels Watt
Example:
Required panel watt = 1320W
Solar panel selected = 330W
Number of panels = 1320 /330 = 4

You have to purchase 4 numbers of 330watt panels.

DIV Off-Grid Solar System V2.0: Page 31

Step 17: How to Wire Solar Panels?

You can connect the solar panels in the following 3 ways:

DIV Off-Grid Solar System V2.0: Page 32

1. Series: Current remains the same while the voltage of the panels will be added to each other.

2. Parallel: Voltage remains the same while the number of currents will be added.

3. Series-Parallel: Strings of series panels connected in parallel

When deciding between the above three configurations, two important facts to consider are the maximum input

voltage

of your charge controller and the type of charge controller ( PWM or MPPT ).

To connect the solar panels in the above 3 configurations, you need MC4 Connectors and spanners to connect and

disconnect them. I have already written separate lnstructactables on this.

Note:Every charge controllerhas limits on howmuch voltage itcan accept (maximum input voltage). You

mustensure that

thepowercoming in fromyoursolarpanels neverexceeds this number.

Image credit:epsolarpv

DIV Off-Grid Solar System V2.0: Page 33

Series Connection Parallel Connection

■
I
I

EE!
i I

z I■■■m-1s11111 s teas
s

I
24 Volts 200
Watts Output 12 Volts 200 Watts Output

Series - Parallel Connection

I I
I --• I -
mm
I I
1 1 ' + p
- -
I
- EE!
-. aEE
24 Volts 400
Watts Output

All of the panels are 100Watts and 12V

DIV Off-Grid Solar System V2.0: Page 34

DIV Off-Grid Solar System V2.0: Page 35
Step 18: Charge Controller Selection

It is a device that is placed between the Solar Panel and the Battery Bank to control the amount of electric energy
produced by Solar panels going into the batteries. The main function is to make sure that the battery is properly charged
and protected from overcharging.
As the input volt age from the solar panel rises, the charge cont roller regulat es the charge to the batteries prevent ing any
overcharging and disconnect the load when the battery is discharged.
Types of solar charge controllers
There are currently two types of charge controllers commonly used in PV power systems :
1. Pulse Width Modulation (PWM) Controller
2. Maximum Power Point Tracking (MPPT) Controller

DIV Off-Grid Solar System V2.0: Page 36

DIY Off-Grid Solar System V2.0: Page 37
DIV Off-Grid Solar System V2.0: Page 38
 a

SOLAR CHARGE CONTROLLER

9
E•

Step 19: PWM Solar Charge Controller

PWM stands for Pulse Width Modulation, which stands for the method it uses to regulate charge. Its function is to pull
down the voltage of the solar array to near that of the battery to ensure that the battery is properly charged. In other
words, they lock the solar panel voltage to the battery voltage by dragging the Solar panel Vmp down to the batteries
system voltage with no change in the current.
It uses an electronics switch ( MOSFET) to connect and disconnect the solar panel with the battery. By switching the
MOSFET at a high frequency with various pulse widths, a constant voltage can be maintained. The PWM controller self•
adjusts by varying the widths (lengths) and frequency of the pulses sent to the battery.
When the widt h is at 100%, the MOSFET is at full ON, allowing the solar panel to bulk charge the battery. When the widt h
is at 0% the transistor is OFF open circuit ing the Solar panel prevent ing any current from flowing to the battery when the
battery is fully charged.

DIV Off-Grid Solar System V2.0: Page 39

DIV Off-Grid Solar System V2.0: Page 40
 PWM Charge Controller

Pww= T L _ u

+ + -

Solar Panel Battery Load

DIV Off-Grid Solar System V2.0: Page 41

Step 20: MPPT Solar Charge Controller

MPPT charge controller extracts the maximum power from the PV module by forcing the PV module to operate at a
voltage close to the Maximum Power Point (MPP). It has been designed to adjust its input voltage to utilize the
maximum power out put of the solar array and then transform this power to supply the varying volt age requirement. The
input voltage is varied by using a DC/DC converter.
MPPT controllers do this via an adaptive algorithm that follows the maximum power point of the Solar panel/array and
then adjusts the incoming voltage to maintain the most efficient amount of power for the system.
The performance advantage of an MPPT controller is substantial (10% to 40%) when the solar cell temperature is low
(below 45°C). They are more efficient than the PWM controller. The efficiency of a typical MPPT controller is around 94•
99%.
To fully exploit the potential of the MPPT controller, the array voltage should be substantially higher than the battery
voltage. The MPPT controller is the best solution for higher power systems.

DIV Off-Grid Solar System V2.0: Page 42

 n o 4 4 2 1 4

-----
MrpT
SOLAR CHARGE CONTROLLER

DIV Off-Grid Solar System V2.0: Page 43

 MPPT Charge Controller

DC/DC Convertor
r--------,
] Inductor[
I - H u
I
I l
9
I 1
I 11111
G
I
I
I
L I _J
I

+ +

Solar Panel Battery Load

DIV Off-Grid Solar System V2.0: Page 44

 \ I
·\
• I
'
'T - -- - -\- I

1
', \
I
I I
-} 1
I 1,
l i
I
I ',
-t--·
I
I
- l - d
1 I
I
lI
I
I
l

DIV Off-Grid Solar System V2.0: Page 45

Step 21: Sizing of Charge Controller :

Choosing the most suitable charge controller requires two steps:

1 • Voltage Selection: The charge cont roller volt age shall be mat ched wit h the syst em volt age. The st andard
configurations are 12, 24, and 48 volts. If you are wiring your batteries for 12 volts you need a charge controller that is
rated at 12 volts.
Some controllers are voltage specific, meaning that the voltage cannot be changed or substituted. Other more
sophisticated controllers include a voltage auto-detect feature, which allows it to be used with different voltage settings.
2. Current Selection: To select the proper Charge Cont roller, you have to know the maximum out put current of the solar
panel and Battery Voltage.

The maximum possible current in the system =( Solar panel Wattage/ System voltage) x Safety factor
Safety Factor :
We use a standard factor to account for all Solar panel output-boosting circumstances like a sunny day with a very clear
snowpack. (additional light reflected off the snow). That factor is 1.3 or 130%
PY Charge Controller - Upper Voltage Limit
Charge controllers have an upper voltage limit. This refers to the maximum amount of voltage they can handle from the
solar array. Make sure you know what the upper voltage limit is and that you don't exceed it or you may end up burning
out your solar charge controller.
Sample Calculation
Example
Consider a 260W solar panel is used to charge a 12V battery bank.
1. Voltage Rating:
The voltage rating of the charge is controller shall be equal to the system voltage i.e 12V in this case.
2. Current Rating:
Rating = ( Solar panel Wattage/ System voltage) x Safety factor (1.3)
Rating = ( 260W / 12V) x 1.3 =28.16A

So, the solar charge controller rating is selected as 30 Amps /12 Volt

DIV Off-Grid Solar System V2.0: Page 46

Step 22: PWM or MPPT?

With a PWM controller, the current is drawn out of the panel at just above the battery voltage, whereas with an MPPT
controller the current is drawn out of the panel at the panel maximum power voltage ( Vmp). To understand this concept ,
let's take an example.
Example: Consider a 100 Watt panel with a current(lmp) of 5.75A & voltage (Vmp) of 17.40V connected to a 12 V lead•
acid battery.
PWM Controller
With a PWM controller, the panel voltage would be dragged down near to the voltage of the battery but the current stays
the same at 5.75 amps. This happens because Solar Panels behave like a current source, so the current is determined by
the available sunlight.
Now the power (P)= Vbat x Imp= 12V x 5.75A = 66.6W. So the Solar panel is now behaving like a 66-watt panel.
MPPT Controller
With an MPPT controller, the panel voltage will operate at voltage close to the Maximum Power Point (MPP), and the
current stays the same at 5.75 amps.
Now the Power= Vmp x Imp= 17.4 x 5.75 =100W
This equates to a loss of 100W-66.6W = 33.4W
DIV Off-Grid Solar System V2.0: Page 47
However the above calculation is overly-optimistic as the voltage drops as temperature increases; so assuming the panel
temperature rises to say 30°C above the standard test conditions (STC) temperature of 25°C and the voltage drops by 4%
for every 10Ci.e. a total of 12%.

Then the power drawn by the MPPT will be 5.75A * 15.3V = 88W

Power loss = 88-66.6 =21.4W, i.e. 21 % more power than the PWM controller.
Which One Should I Purchase?
When you are finding which type of solar charge cont roller to purchase, you need to know about their funct ionalit y and
features.
1. PWM controller is best for small off-grid power applications that don't need any other features and has no much
budget. If you just want the basic and economical charge controller then the PWM controller is the best option for you .
2. MPPT controller is best for a larger system ( Off-grid power station, RV Solar Power, Boat, Hybrid Solar Power, etc.) .
When the solar array voltage is substantially higher than the battery voltage, then MPPT is the best controller. e.g.
Connecting a 72cell solar panel, for charging a 12V battery.
You can look at the above comparison table for PWM and MPPT Solar Charge Controllers.

You can read a nice document on selecting the PWM or MPPT charge controller prepared by victronenergy.
Image credit.: epsolarpv

4 a a a 4

MpT
[ Cu AR CHA RGE CONTROL L E R

DIV Off-Grid Solar System V2.0: Page 48

 PWM MPPT
f ·

PROS
These controllers are inexpensive. The cost is 1/3 More expensive than a PWM controller. The cost
- 1/2 of a MPPT controller. is 2-3 times of PWM.

P\WM controllers are available in sizes up to 60 You can get sizes up to 80 Amps.
Amps

Efficiency is low. Up to 30% higher charging efficiency. (especially

in cool climates)
> -> -

CONS
The Sola r in put no mina l volt a ge must ma tch the MppT cont rollers are more expensive.
battery bank nominal voltage. Cannot be used
efficiently with 60-cell panels.

PWM controllers have limited capacity for system MPPT units are generally larger in physical size.
growth.

DIV Off-Grid Solar System V2.0: Page 49

 vwind n a t i o n
www.windnatiyon.corr
clean ]power to the people

100W Polycrystalline Photovoltaic Solar Panel

Part #: SOL-100P-01

Maximum Power (Pmax): 100 Watts

Open Circuit Voltage (Voc} b a l l = a l l
Short Circuit Current (lsc): [6.32 Amps
Max Power Voltage (Vpm): Vo l i s .·u

Max Power Current (Imp): 5.75 Amps

Max System Voltage: 1000 VDC (600 VDC UL)

Dimensions: 40.0" x 26.4" x 1.2"

(1015mm x 670mm x 30mm]
Weight: 18.7 lbs [8.5kg]
Max Series Fuse Rating: 8 Amps
Nom Operating Cell Temp: 48 C [+/-2 ]

DIV Off-Grid Solar System V2.0: Page 50

 7 MppT; 100 \W

6
lpwm 25°€
5 - PWM: 81 W

-
4
<
c
4 --
3
l»
Cl)
3
E 2
3
ao
(
2

1
Vpwm
0 0
0 5 10 15 20 25
Voltage (V)

Step 23: Inverter Selection

Solar inverters are one of the most important components of a solar panel system. They're responsible for converting
direct current (DC) electricity from your solar panels to alternating current (AC) electricity to power your appliances.
If you are only running DC loads straight off your battery bank, you can skip this step. But, if you are powering any AC
loads, you need to convert the direct current from the batteries into alternating current for your appliances.
Common Types Of Inverter:
1. Square Wave
2. Modified Sine Wave
3. Pure Sine Wave
Square wave inverter is cheaper among the all but not suitable for all appliances. Modified Sine Wave output is also not
suit able for cert ain appliances, such as a fridge, microwave oven, sensit ive elect ronic equipment , Laser print ers, and most
kinds of motors.
Typically modified sine wave inverters work at lower efficiency than pure sine wave inverters.
So as per my opinion choose a puresine woveinverter.

Image source: unboundsolar

DIV Off-Grid Solar System V2.0: Page 51

 r

Fun E,
•DIV Off-Grid Solar System V2.0: Page 52
 Modified Sine Wave Pure Sine Wave

CURRENT CURRENT

DIV Off-Grid Solar System V2.0: Page 53

Step 24: How Inverter Are Rated?

The inverter is rated for Continuous Watts and Surge watts

1. Continuous Watts :
Continuous watts is the total amount of watts the inverter can support indefinitely. A 2000 watt inverter can power up to
2000 watts continuously. It is also called the nominal AC output power of the inverter.
If you want to run multiple appliances at the same time, just add up the power rating of the equipment that is running
together at the same time.
Example: Running a Fan (80W /200W), 2 nos of LED Light (6W), Laptop (65W), and WiFi Router (6W) at the same
timeTotal Continuous Watts = 80+12+65+6= 163W
2. Surge Watts ( Peak Watts ):
Surge watts is the amount of power the inverter can support for a very short time, usually momentary. A 2000 watt
inverter rated at 4000 surge watts can handle up to 4000 watts momentarily while starting things like motors .
In the above picture, you can see the drill draws 471.6W for a short time period.
In our case, the surge power is applicable for the ceiling fan during the starting which is approximately 200W .
Total surge watt = 200+12+65+6 = 283W

Select the inverter thatshouldsupportboth ofthese values.

DIV Off-Grid Solar System V2.0: Page 54

 $
et. be
l SURGE PROTECTED =

DIV Off-Grid Solar System V2.0: Page 55

DIV Off-Grid Solar System V2.0: Page 56
 Moel: IP1500-12-Plus < T Eseves°
Input Voltage: 10.8-16.0VDC
Output Volta ie: 220/230VAC 50/6011z
Continuous Output Power: 150OW ROHS
T
HV. 010 'O
Waveform: Pure Sine Wave

ITT
0.2.2218825€+E\F-$000
HUI ZHOUEPEVER TECHNOLOGY CO.LTD. Made in China
-
Ad: No.103.D0g0.ng• Ce1yang SveetZhcngai Hgt-ech Zane Huzhou China

Step 25: Inverter Voltage & Frequency

The next rating you have to look at when sizing an inverter is the input /output voltage and output frequency .
Input Voltage/ System Voltage:
For correct solar syst em sizing, your solar panels, invert er, and bat tery bank all need to use the same volt age. i.e system
voltage.
In the earlier steps, we have selected 12V battery and solar panel, so the input voltage of the inverter must be 12V .
Output voltage:
The common output voltage of an AC outlet is 120/240VAC, based on the location.
Output Frequency:
The two common Inverter output frequencies are 50/60Hz, based on the location.
Before buying the inverter check your country's voltages/frequencies used for domestic appliances.

DIV Off-Grid Solar System V2.0: Page 57

 Model: IP1500-12-Pu s T E eev es °
Input Voltage: 10.8-16.0VDC
Output Voltage: 220/230VAC 50/60HZ
Continuous Output Pow er: 15 00W RoHS
SV. 151 HV: 010

ifria~" c c 8
022218+25&A+E\F-N,15
HUZ HOUEPEVER TECHNOLOGY CO. LTD. Made in China
Add: No103.D0gingRd,Cerjyang Street.2hong«ai Hight-echZone.HuizhouChina

Step 26: Inverter Efficiency

The efficiency of an inverter indicates how much DC power is converted to AC power. Some of the power can be lost as
heat, and also some stand-by power is consumed for keeping the inverter in powered mode.
The general efficiency formula is ninv= Pac/ Pdc
Here Pac is AC power output in watts and Pde is DC power input in watts.

Step 27: Inverter Sizing

Total Continuous Watts =168W

Total Surge Watts =238
Inverter efficiency = 95%
Continuous Watts Required= 168/0.95 = 176.8
Surge Watts required = 238/0.95 =250.5W
Input Voltage= 12V

DIV Off-Grid Solar System V2.0: Page 58

For India, the AC voltage and frequency is 230V and S0Hz.

Fina Inverter Rating:

Continuous watts= 200W

Surge W atts= 400W

Input Voltage= 12V

AC Output: 230V/50Hz

Step 28: Selecting the Solar Cable

The current generated from the solar panels should reach the Battery with minimum loss. Each cable has its own ohmic
resistance. The voltage drop due to this resistance is according to Ohm's law

V = Ix R (Here V i s t he volt age drop across the cab le, R is t he resist ance and I is t he current ).

The resistance ( R) of the cable depends on three parameters:

1.Cable Length: Longer the cable, the more is the resistance

2. Cable Cross-section Area: Larger the area, the smaller is the resistance

3. The material used: Copper or Aluminum. Copper has lesser resistance compared to Aluminium In this application,
copper cable is preferable.

You can calculate the cable size by using RENOGY online calculator.

You need to enter the following parameters:

1. Solar Panel Operating Voltage (Vmp)

2. Solar Panel Operating Current (Imp)

DIV Off-Grid Solar System V2.0: Page 59

3. Cable Length from Solar Panel to Battery

4. The expected loss in percentage

The first two parameters ( Vmp and Imp) can be easily found from the specification sheet on the backside of the solar
panel or from the datasheet. The cable length depends on your installation . The loss percentage considered for good
design is around 2 to 3%.

In the earlier step, we have already finalized the Solar panel, the rating. From the Solar panel specification sheet Vmp =
36.7Vand Imp= 6.94A ( rounded off to next higher number i.e 37V and 7A). Let the distance between the Solar panel
and the Bat tery is 30 feet and the expected loss is 2%. By using the above values in the online calculat or by RENOGY, The
cable size is 12 AWG.
The calculation screenshot is also attached for reference.
You can buy the Solar cables from Amazon or Aliexpress
You can read my lnstructables on How to Make the MC4 Connector.
Note: The voltage grade of the cable should be matched with the Solar Panel maximum system voltage.

Step 29: Selecting the Correct Size Power Inverter Battery Cables

It is very important to be sure you are using the appropriate cable size for your inverter/battery. Failing to do so could
lead to your inverter not supporting full loads and overheating, which is a potential fire hazard. Use this as a guide for
choosing the proper cable size, and be sure to contact a professional electrician or our tech team with any additional
questions you may have.
1. What size inverter do you have?
2. What is the DC voltage of your battery bank?
DIV Off-Grid Solar System V2.0: Page 60
3. Now divide the inverter's wattage by your battery voltage; this will give you the maximum current for your cables.

Example Calculation:

Current (Amps) = Power (Watts)/ Voltage (Volt)

Consider 1500 Watt inverter connected to the 24V battery bank. (1500 W)/(24 Vdc)=62.5 A So, 62.5 A is the maximum
current that the cable needs to support in order to properly provide the current to the inverter. The next higher size
available on the table is 1 00A.
Use the above chart as a guide to determine which size cable will be best for your application.
In our example, we can see that 2/0 AWG cable would be appropriate.
NOTE: For distances over 10 feet, the voltage drop over the cables will occur due to resistance through the wiring. If you
will need to run cables longer than 10 feet, it is recommended that you increase the cable size in order to compensate for
voltage loss. If you are unsure about your application feel free to give us a call and we will be able to assist you in findi ng
the right cable.

Step 30: Sizing of Fuses I Breakers

Fuses and circuit breakers are primarily used to protect the system wiring from catching fire or getting damaged if a
short circuit occurs. They are not necessary for the system to run properly, but it is recommended for safety purposes
only.
There are three different locations where fuses or breakers must be installed:
1. Between the charge controller and solar panel
2.Between the charge controller and battery bank
3.Between the battery bank and inverter
You can add one more breaker at the inverter output.

DC Breaker / Fuses:

As per NEC, the DC fuse or breaker size can be determined as per the following equation:
Circuit ampacity=ShortCircuitCurrent(sl c)X1.56
Example-1:

A 315 Watt module with an lsc rating of 9.12A.

To calculate the fuse size required between the string and the charge controller, you take 9.12 x 1.56 = 14.7 and round up
to the next trade size of 15A.

Example-2:

Fuse between the battery bank and inverter= (continuous Watts/ Battery Voltage) x 1.56
A 1 000W /12V inverter draws= 1000/12 =83.3A,
Circuit Ampacity = 83.3 x 1.56 = 130A, round up to the next standard trade size which will be 150A.
AC Breaker/Fuses:

AC Breaker is placed at the inverter output and the Outlet for AC appliance.
The above NEC ampacit y formula also changes on the AC side of the circuit. Instead of 1.56, the mult iplier is 1.25. And in
place of the sho rt -circuit current , you must use the maximum or cont inuous out put current listed on the inverter
specificat ion sheet.

DIV Off-Grid Solar System V2.0: Page 61

Circuit Ampacity =Inverter AC output current X1.25
Example-3:
let's assume a 1500W inverter with an AC output of 6.SA max.
Circuit Ampacity = 6.5 x 1.25 = 8.12A, round up to the next standard trade size which will be 1 0A.

DIV Off-Grid Solar System V2.0: Page 62

 IEC/EN 6094 7-2

PH
Tref 25C
Ue= 50V= lcu= 6kA
Ue= 440V= l u= 10k4 (C): li = 8.5ln
Ue= 220V= lcu= 20kA lcs= 75%lcu
Uimp =6kV Deg 3 Cat A

EI.II'EE3

Step 31: Gather the Components and Tools

In the previous steps, we have already finalized the main components required for our Off-Grid Solar System. Now it is
time to gat her the component s, I will alw ays recommend buying all the component s from a reput ed brand. I have used
the charge controller, inverter from EPEVER, solar panel from Waree, and battery from Luminous.
Apart from the 4 main components, there are few other components that are required for the off-grid system. They are
listed below:
1. Solar Cables
1. Breakers/ Fuses
2. DC Busbars / Fuse Box
4. MC4 Connectors
DIV Off-Grid Solar System V2.0: Page 63
5. Cable Ties

6. Metering Device

7. Temperature Sensor

Tools Required:
To successfully install the off-grid solar system, you need a few basic tools like:
1. Wire Stripper
2. Crimping Tool
3. Plier
4. Screwdriver
5. MC4 Spanner
6. Spanners
After purchasing all the components and tools, we can move for the installation.

DIV Off-Grid Solar System V2.0: Page 64

DIV Off-Grid Solar System V2.0: Page 65
DIV Off-Grid Solar System V2.0: Page 66
DIV Off-Grid Solar System V2.0: Page 67
 t
•

DIV Off-Grid Solar System V2.0: Page 68

Step 32: Wiring Diagram

Solar Panel :
The connection of solar panels depends on the maximum input voltage and current of the charge controller. MC4
connectors are used to connect the solar panels in series/parallel.
Battery Bank :
Battery banks should be wired to match your system voltage, which is the voltage allowed by your DC appliances or AC
inverter. Copper cable or busbars are used to connect the battery in series and parallel.
Charge Controller:
The charge controller has 3 terminals: 1. Solar 2. Battery 3. DC Load.
You have to connect the wires from the solar panel, battery bank, and DC load to the respective terminal. During
connection ensure the polarity is correct.
Inverter:
Connect the inverter input terminal to the battery bank. During connection ensure the polarity is correct.
Protection :
Though the charge controller and inverter have inbuilt fuses for protection, you can put external fuses and breakers for
more safety and reliability of the system. You can see the above picture for different locations of the breakers/fuses.
For a larger system, you need light ing protect ion. I will updat e you more about it lat er.
SAFETY:
/tis important to note that we are dealing with the DCcurrent. So thepositive (+) is to be connectedtopositive (+) and
negative (-) with negative (-) from SolarPanelto Charge Controller. Ifitgets mixedup, the equipmentcango burstandmay
catch f re. Soyou need to be extremely careful when connecting these wires. It is recommended to use 2color wires i e. red and
black colorforpositive (+) andnegative (-). Ifyou don't have a redandblack wireyou may wrap redandblack tap at the
terminals.

DIV Off-Grid Solar System V2.0: Page 69

 CHAGE CO NTRO LLER

0C LOAD Ac toAo
INVERTER

+
4

cc DC
= AMC.t MCB

L N E

F
.
£e

BATTERY
..

H e m

......, ---------1
MFPT .. ;
r e m . .
 d i e

pyy Of-Grid Solar System v2.~: Page 71

https://www.instructables.com/ORIG/FMR/V9FE/KHEUEQA4/FMRV9FEKHEUEQA4.pdf

DIV Off-Grid Solar System V2.0: Page 72

e l

'
Download
'I!!!
Step 33: Power Distribution

If you want to use a single DC load, you can connect directly to the Charge controller load terminal. Ensure the voltage
rating of the load is matching with the load terminal voltage.
But If you want to run multiple DC loads at the same time, then you need a DC busbar or Distribution Box. Connect the
busbar/ distribution box input to the charge controller load terminal and connect the loads to the output terminals of
the distribution box.
Note: The tot al load current shall not cross the maximum limit of the charge cont roller load terminal. If the load current
exceeds the charge controller load terminal limit, you have to connect the busbar/distribution box directly to the
battery.

DIV Off-Grid Solar System V2.0: Page 73

SC&AR PAN EL CHARG E CONTR OLL ER
u s

;-
I
I

I= i
Ea
p
% a d d ii

t
FUSE BOX

BATTERY

DIV Off-Grid Solar System V2.0: Page 74

 CHARGE CONTROLLER
WAAREE

"
d

LI
DC LOAD
'I
Li

..." ..
II
t

«
Al T

d 4 4
4

Ai
t
MP>T
- A - £ r - A , - M r - W ·T- --- A -- .
~ ., -
l
i
1

I
M

'

72 Cells SOLAR PANEL DC

uzu=eusshgali n •
r L i T w t A f T H r

12V BATTERY

DIV Off-Grid Solar System V2.0: Page 75

 ire
in uish

• ;°
+
«;
.
'j
'
j

di

Step 34: Metering and Data Logging :

If you are interested to know how much energy is produced by your solar panel or how much energy is consumed by the
appliances you have to use meters. Besides this, you can monitor the different parameters in your off-grid solar system
by remote data logging.
DIV Off-Grid Solar System V2.0: Page 76
Most of the good charge controller and Inverter have their inbuilt LCD display to monitor the parameters. Besides this,
you can monitor the same parameter by using a remote meter or WiFi adapter.

In t his proj ect , I have used an Epever TRIRO N Series MPPT charge cont ro ller and an IPow er-Plus Series Invert er bot h of
which have an LCD display for mo nit o ring. Apart from t his, t here is provision for rem ot e mo nit oring thro ugh t he RJ45
com m unicat io n port. For rem ot e mo nit oring, I have used a rem ot e met er MT75 and eBox-W IFl-01.

You can follow the above wiring diagram to connect the MT75 and eBox -WiFi.

MPp T
SOLAR CHARGE CONTROLLER

DIV Off-Grid Solar System V2.0: Page 77

 fl r i

MP P T
-----
$Ou#ACNAGE CCWTROLLER

~I . ' I l
l l

DIV Off-Grid Solar System V2.0: Page 78

 728
¢

-----;

$ 9

DIV Off-Grid Solar System V2.0: Page 79

 m o 4 2 1 4

e0 a
• S

$OLAR C H A R GE CON TOLLE

#
RS485-1M2$

DIV Off-Grid Solar System V2.0: Page 80

 Solar controller (one set) MT75
-·

•
«e... - ·+8

£l
it+

~
+
Relay interface
enable switch E« -·----,
Ea ON - mg « e a ] r e «

I
,,. -,
I

l J
I
Ii e r
RS485 t

...
@ RS485
Relay
interface
DC load 3
qi»

Power cable
RS485 cable
Relay interface
connection cable Battery Inverter (one set) AC load
(Local switch OFF)

i
c~ E-01
----.pi i l,,
~ .~ Q•
Solar controller (one set) I
leb-WIFl-01 @l )-

-l - - - + 11 l· l •

·e ·•••• £l
«re
A RS485-1M2s } Pc

4 ~--►~----' - - - - · - - - - • ~
ti a r

• i i j ! t
.h ( i rla
L. jl
a . . . ,
t
• ·
1
u175
a

I
i ! ! i ' {
g J ae 4 ]''l;_ll]

l J t t t

l
l "

,,
... _ ,
,,II .·... I i
'{#◄-\ I]
} Dcload ' Rea»Rue2'
enable switch gfRely

--
t
Power cable
Sett ON
a « a Power cable (option) ·..·. - d e • ,1interface
----
_ _,,_,iliiiili
RS485 cable
Relay interface
connection cable Battery Inverter (one set)
(Local switch OFF)
+3
AC load

DIV Off-Grid Solar System V2.0: Page 81

Step 35: Battery Temperature Monitoring

Why Temperature monitoring is Required?

The battery's chemical reactions change with temperature. As the battery gets warmer, the gassing increases. As the
battery gets colder, it becomes more resistant to charging. Depending on how much the battery temperature varies, it is
important to adjust the charging for temperature changes. So it is important to adjust charging to account for the
temperat ure effects. The temperat ure sensor will measure the bat tery temperat ure, and the Solar Charge Cont roller uses
this input to adjust the charge set point as required.

I have used a remote temperat ure sensor for measuring the battery temperat ure. Connect it to the temperat ure port
given in the charge cont roller.

Step 36: Conclusion

I have shared my knowledge gat her over the past few years, I hope it will be useful for all. If you like this Inst ructables,
share it and like it.

DIV Off-Grid Solar System V2.0: Page 82

I have part icipat ed in t he Bat t ery Pow ered Cont est . please vot e for me.

I will regularly upd at e t his lnst ruct ab les, please keep in touch for more updat ed info rm at ion on t he So lar Syst em .

Thank You!

r •

,r
I
,.f,
!
al
if

., • . 4
4
... .d-
,t

# #
f

' ..
t + ..
4

t r
. i
l

] al . d

Fant~stico trabajo. Claro, y muy bien estructurado. FELICIDADES

DIV Off-Grid Solar System V2.0: Page 83

 Outstanding ! This is the best DIY I have ever read. I will start my own grid based on your
I nstructables.
Do you know what needs to be done in order to connect it to the standard grid ?
I have seen this project (in French) https://www.soleilpourtous.fr/fonctionnement-avantage•
solaire-plug-play
Clear and concise information thanks for sharing!!

[i] Why did you use two pole circuit breakers?

Thanks for taking the time for making this information available. Your documentation completely
covers all the aspects of the design and construction for an off grid system and has been a
tremendous help to me.

Great Explanations! Too informative!

Many Thanks!

I too think this was a first-rate instructable . I still have one questio n and that is about mounting my
panels on a roof vs ground mount. What type of rail or clamp to use? Can you trust the roof to
take the load? So more structural in nature. If someone has seen a site that goes into details on
mounting please send the link my way...
W rhanks so much for your instructions. I'm volunteering to help Burning Man go renewable and my
task is to share renewable systems that Burners could use back home. This is a great system for
powering a home office. I'll be sharing it with Burners at their group event presentations in the
H.I.V.E Honey Lounge. I'll give you full credit and direct interested folks here.
https://hive.burningman.org/posts/honey-lounge-videos

I have wanted to go solar for some time . I've had numerous estimates and the la bor charges for
what I've been told is a three day job is unacceptable. This is the best discussion I've seen of the
ins and outs of an off grid system. I hope in the future you add to this permitting, fire safety and
using this as an on0grid system. Excellent contribution!
.g]
Excellent instructables. You are very clear and articulate. You are a good teacher. Keep up the

M good work.

Thanks for a great and informative article! Learned a lot!

- Excellent!Very well explained, informative article I've ever read!!

£ Your presentation was great, but I did find one item that you might want to fix. In step 17 the
diagram says all panels are 100 watts and 12 volts. The series connection should read 24 volts
100 watts output, not 200 watts output. Other than that it is one of the best instructables on solar
power I have read.
Thank You so much.
~ In step-17, The series connection should read 24 volts 200 watts output , not 100 watts output.
Whether you connect panels in series or parallel, the wattage will be added but the voltage and
current value will change depending on the configuration.

Example: The series connection of two 100W panels ( Vmp = 17.4V and Imp=5.75A ),
the current remains the same ( 5.75A) but the voltage will be doubled ( 34.8V).
Now the Power = Vmp x Imp = 34.8V x 5.75A = 200W
r.c:-1 So basically what you are saying is that the wattage will be times the number of matching panels,

m whether in series or parallel.

you are correct.

This MUST be one of the best lnstructables I have ever seen.

As a person who loves Green energy and has a Tesla Model X ready customised for when I can
DIV Off-Grid Solar System V2.0: Page 84
 drive (in about 2 years time!!) I HAD TO VOTE for a BRILLIANT lnstructable and will be definitely
considering making this in the future.
At the min though,
I have a lot of Green Energy stuff in the pipeline ...
You may even see some of this come onto my lnstructables page.

And yet again,

Brilliant lnstructable ...

Luke Hayes
Thank You so much.
7 have visited your lnstructables page, you have very nice stuff.
Glad to know that you liked my project and considered it for future to do list.

I have to agree with the other's .... this was a well, thought out, presentation that provided both a
nice "project build" but also an invaluable education in several of the areas presented. Great Job!!

Thank You so much.

vour words really motivate me.

l j
m° A most useful and informative lnstructable. Thank you so much for sharing your expertise!

to know that it is useful for you. Than You !

m°
Very well written and understandable. Thank you/

you like it.

Very well done, sir. Very well done, indeed.

Thanks a lot.

I agree, very informative & clear details, better than I could ever do.
I will add the following that may be of interest...
1. Please consider the potential for fire propagation when mounting power products on wood
board, it is worth doing a risk assessment.
2. The life of lithium battery is also dependent on how much time it is at full charge, not just the
discharge depth cycle . I charge my LiFePo4 to only about 80~85%,(CC chg only) this ensurer's
longer life (saving $$$).
3. Longer cables to inverter have higher inductance, this can put more ripple current stress on
inverter capacitors shortening life. It is best to always keep short as possible.
4. Lithium battery like being less than full charge, this is ideal for some cloudy days when a full
recharge is not possible. (lead battery don't like being discharged for extended time)
5. Lead battery has a fairly long tail current (slow ly reducing Amps in CV chg mode), I charge my
LiFePo4 battery with full current up to full {~80%), then stop & divert PV current to water heater.

Keep up the good work

Thank you so much.
!'2wil I really appreciate your feedback for improvement. I will definitely consider it.

That is well done ! From scope, orga nizatio n, graphics, grammar and spelling to system design,

m completeness and safety. I've never voted for contests but I have for this one !
you so much. Your vote means a lot to me.

DIV Off-Grid Solar System V2.0: Page 85

 Amazing instructable! Really hoping to take advantage of all this knowledge some day.

One minor point: step 13 , section 1 states that panels on the equator are more efficie nt due to
proximity to the sun. While they are closer at noon than (for example) a panel at either pole , the
difference is only the radius of the earth. Compared to an AU, that radius is extremely small. The
theoretical reductio n in power from a polar panel would be less than 0.0 1% (Can someone check
my math?). I think the other reasons you stated are much more applicable.

Again-amazing post! Probably the best one I've seen ever!

Im
Thank You So much.

Tres bien fait bravo de la part d un ancie n ~lectricie n de 72 ans , dommage que le pdf soit en
anglais . je vous remercie de ce beau travaille cordialement Japhret
You so much

Just wow. You are a born teacher my friend (I am an elementary school teacher so I know a good
one when I see it!). I'm about to buy land and build on it and thought solar might be the way to go
on a workshop. Alas, the la nd is way up in the snowy north and does not get enough sun to make
this feasible.
But still, I'm bookmarking your page ...
Well done, you got my vote!
11111 Thank You so much. Your vote means a lot to me.
!'2Mi1 I really wanted to know the feedback about my article so that I can write a DIV book on this topic
in the future.
'7111 This is one of the most informative, well written instructables I've read. You explained each part of
~ the process and the different types of equipment so well! I had solar panels installed on my
house a couple of years ago ; how ever, in the state of Virginia we are not allowed to go completely
solar or have any extra energy go back to the grid as a credit.

We are planning to sell within the next few years and build a new house on some land so
hopefully we'll be able to install our own on the new house.

Thanks for such information!

My pleasure!
!'2wi1 I hope my article may help you during installatio n of your new house.

m Very very good. thanks to share it

You so much.

Hello,
first of all, a very good instructable.
But I wouldnt use the charge controller you use, bes. the PV voltage is only 10 0V. For 4 Panels in
series, you need at least 150V. Second, the controller is only up to 24V batterys, 48V is better I
think.
The Inverter is also not so good, with no load it sucks 0,6A , this is 29W ! I think too much.
2SR Thank You!
!'2Mi1 Can you share the Specifications of your panel and charge controller?
IA-1 Great tutorial with to the point instructions. The steps are explained clearly and it is well
documented. Thank you for your time to construct this instructable and for sha ring. It assisted me
llil tremendously.
DIV Off-Grid Solar System V2.0: Page 86
3 Thanks a lot.
!'E.i Glad to know that my article is helpful to you.

11111 I really wanted to know the feedback about my article so that I can write a DIY book on this topic
ta the future.
• Turely amazing work and excellent presentation.

Thank You.

Excellent lnstructable! You've made this topic much more accessible for people new to the area
of solar energy for individual use.
EE Thanks a lot
!"&i I really wanted to know the feedback about my article so that I can write a DIY book on this topic
in the future.
" - • Excellent instructio ns, very detailed! I have a solar system installed on my pickup truck. I have
1111 been monitoring battery voltage at least every 15 minutes (sometimes every 10 seconds when
driving). After years of evaluating the data, it turns out, for my application (testing multiple
cellular/GPS tracking devices) a 100W panel was sufficient but my battery capacity was too low
(85 A/Hr). Previous truck had two 100W panels but to weather bad weather of 4 days of rain / no
sun, there is plenty of sun here in Texas to keep the batteries charged. After some consideration I
changed to two 85 A/ Hr batteries in parallel and no longe r have issues. I like your approach as it
is more scientific, informative, and covers all of the safety factors from wire size, fusing, DC
power distribution and even AC fusing.

Excellent article!

DIV Off-Grid Solar System V2.0: Page 87

 ASSIGNMENT

 Prepare a report showing:

 Steps needed for Off-Grid PV system design.

94
Next lecture:
Wind Energy System .

95
Thank You
Dr. Ramy Ahmed

96