Download - Solar PV Kadugannawa
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Solar Project @ Kadugannawa (Project 01)
About Site
Site located 120Km east of Colombo in one of the most scenic areas in the hillsof sabaragamuwa. Namely Gadadessa Estate. (50Arcre)
Building
2 storied Resort Bungalow.Height : 30ft
Structure : Wooden
Rooftop : Wood/MetalSituation : Hill Top
Usage : Guest Bungalow/2 Luxury rooms, ONLY for the VVIP s
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Item List
1.Solar Panel 8 Nos2.UNIRAC Solar Panel Mounting System.3.PV Fuse Box (15 A)4.DC Surge Protector Delta Brand5.Safety Switch 30A 3Pole -Squre D 2 Nos6.Charge Controller Out Back FLEXmax 607.2000VA /24V-230V Outback Inverter8.740Ah Battery Bank 6V/370Ah 8nos- 4X2 Series Parallel combination9.AC Out Distribution Box10.160A Merlin Gerin Breaker Switch11.HRC Fuse 200A-2 Nos12.Wires /Lugs /Conduits/casing/Silicone glue and other fixing accessories
Used Tools/Equipments for Installation
1.Drill Machines2.Hacksaw3.Wire Cutters4.Cable Lug Tool5.Digital Multi meter6.Digital Clamp Meter7.Screw Drivers (F/P)8.Com Flier9.Nose Flier10.Tester11.Hammer12.Ratchet /Box spanner set/wrench13.Wire Striper14.Scar Folding 4 sets15.Measurement Tape16.Level17.Compass
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Item Description
1. Solar Panel
Brand Model Watts Volts (Voc) AmpsImp(Isc)
Grape Solar DJ-220P 220 29.4 (35.87) 7.48 (8.4)
2. UNIRAC Solar Panel Mounting System.
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3. PV Fuse Box (15 A)
Installed in between Solar Panel & Safety
Switch. 15A Fuses for Positive & Negative
Lines.
4. DC Surge Protector Delta Brand
Surge Protector installed in Fuse Box IN Put side.
(Main in coming side).Red Wire Positive Terminal
Black Negative Terminal
Green Earth Terminal
Earth Wire 6mm Standard Earth Wire
5. Safety Switch 2 Nos
Brand Name : Squre D
Ampere : 30A
Pole : 3P
1.One for 15A Fuse Box to Charge Controller2.Charge Controller to Battery Bank
Note: Charge Controller Out put Ampere is 60 A. But
Safety switch 30A. So combine all 3 Pole for Disconnect
Positive Terminal. Negative wire permanently connectedthrough the Battery bank and
Charge Controller.
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6. Charge Controller Out Back FLEXmax 60
Brand name Outback
Max Ampere 60AMax I/P Voltage 150V DC
Programmed for 24V DC system & Battery Bank Absorb Voltage set
point 29.6V/Float Voltage set point 27.6V
10.30 Am Data 09 July 2010PV side Voltage 108V
Out put Ampere 47.5A
7.2000VA /24V-230V Outback Inverter
Input Voltage 24V DC
Out Put Voltage 230V AC/50Hz
Rated I/P Side Ampere 100AContinuous Power 2000VA
Continuous AC Current 8.7A
Efficiency 90%Harmonics 2%
8.740Ah Battery Bank 6V/370Ah 8nos
Deka MK Battery, Flooded, 6V, 370Ah, LTP, 8L16-DEKA
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9.AC Out Distribution BoxMetal Enclosure
40A Main Switch/Trip Switch
16A/10A MCB (F&G Brand)
10.160A Main Breaker SwitchAmpere 160A
Brand Merlin GerinPole 3P
Model NS160N
11.HRC Fuse 200A-2 Nos200A HRC Fuse and Base
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12. Wires /Lugs /Conduits/casing/Silicone glue and other fixing accessories
Installation
1.Rack and panel Installation
Panels Faced to South Side. Angle 10-15 degrees. For all joints/connections usedStainless Steel / Galvanized Nut & Bolts. Used Waterproof Silicone for Roof Mounting L
Foot base.
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Panel Mounting Brackets
Mounting Surface is very narrow. So anymistake panels can SLIP !
Suggestion,
If panels directly mount to AL bar using
S/S nut and Bolts we can away from thisdoubt.
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2. Panel Wiring & Down Conductor
Used 4X2 method. Two sets of 4 panels. This 4 panel connected is Series And
parallel connected to other 4 panel set.
Voltage 29.4 V X 4 = 117.6V
Current 7 .48 X 2 = 14.96 A
Down Conductor
Wire Size :Used 6mm2 two core copper wire and 6mm single core Standard
copper Earth wire
Wire Length : 22Meters*
*No any Joints
*40 A / 3.08Ohms per 1Km- Kelani Cable Sri Lanka
3.PV Fuse Box & DC Surge ProtectorDIN Mount type fuse Base with 15A Fuses for Positive and Negative terminals. Items
are installed in Metal Enclosure. DC Surge Protector also installed in this Enclosureupside.
4. Used Safety switches for Charge controller input side (6mm2 Wire 1.5Ft) & out put
Side(18mm2 Copper wire 6Ft).
Safety Switch rated Ampere is 30A. For the Battery Bank Side interconnectedall 3 Poles for disconnect Positive Terminal. Negative terminal directly
interconnected(Battery Bank and Charge controller)
5.Battery Bank6V/370Ah- 8 nos Flooded type Battery. Inverter Input Voltage is 24V so battery bank
also interconnected 4X2 method. Used 50mm2 wire and 50mm Lugs for interconnect
battery bank/HRC Fuse/Main Breaker and Inverter.
6.HRC Fuse & 160A Main BreakerThose items are connected in between battery bank and Inverter. Outback recommend
Fuse rating is 200A and 125A Vacuum Breaker. (Air Breaker) I couldnt find this
type of breaker from Sri Lanka at the moment. So I used 160A 3Pole AC/DC Mainbreaker for this thing. (Merlin Gerine).200A HRC fuses installed in Metal Enclosure.
Used 50mm2 Copper wire and Lugs. Wire Length around 5Ft
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7.Inverter
Connected outback Cooling fan wires to Aux out position.
Inverter Output Used power Distribution Box(Main switch/Trip and MCBs(16A/10A) used 6mm wire
8. All Items are connected to the Wooden Sheet. And finally double checked allConnections, Polarity, Eathing system (6mm Wire/6ft 1.5Dia GI Pipe) and others.
Power Up the System
1.PV input and all battery Breakers are kept off position2.Turn ON the battery Breaker (Safety Switch)
Programme/set the charge controller System Voltage 24A, Battery Bank Absorb
Voltage set point 29.6V/Float Voltage set point 27.6V and other Outback recommend
necessary settings (Both are kept Auto Modes)
3.Connected Load to AC Out panel4.Switch ON Inverter Main Breaker5.Checked all Ampere rates/Voltages In & Out using Clipon Meter.
10.30 Am Data 09 July 2010PV side Voltage 108V
Out put Ampere 47.5A
Inverter Idling Amp 0.7A (DC)With Load (23W) 1.7A (DC)
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EQUIPMENT ROOM
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TIME TABLE
Date Time Start/Finish Work Attend
30t
/06/2010 7.00Pm -8.30Pm Scar folding fixing
(4sets)
3Persons
Janaka
Dumindu
Manoj30
t/06/2010 8.30Pm- 11.00Pm Inverter room
Arrange
1Person
Manoj
01/07/2010 Rainy/High wind
Day(Difficult to work
roof area due to
rain & Wind)
--
--
02/07/2010 8.00Am - 5.00Pm
Rainy Day
Solar Rack
InstallationSolar PanelInstallation (4
Panels)
3Persons
Dinesh/Manoj-fullday
Janaka-11Am to
5.00Pm)
07/07/2010 8.00AM-1.10PM
2.00Pm 5.30Pm
Rack & 4 PanelInstallation
Panel Wiring
Lay Down
conductor and
Earth Wire
3PersonsGunawardana
Amila
Manoj
08/07/2010 8.30AM-2.00PM
2.35PM-8.30PM
Power room
Wiring/Equipment
s Installation
4Persons
Gunawardana
AmilaDumindu
Manoj
09/07/2010 8.15AM-9.30AM Double-check allwiring/connections
& Power up the
System.
3PersonsGunawardana
Amila
Manoj
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Wiring Diagram
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SPECIAL THANKS
Direct Support
1.Mr. Bede Cooray CEO Vinseth Group Of Companies2.Mr. Sarath Vijayananda Director Operations (Vinseth Group Of Companies)
Engineering Support
3.Mr. Barana Ranaweera Engineering Consultant (Vinseth Group/ Intel USA)
Financial Support
1. Mr Nihal Weerawarna Director Admin & Planning (Vinseth Group)
4.Miss Rozalie Fernando Accountant
Other Support
1.Dumindu Thisera2.Dinesh3.Janaka
Im thankful to all who help me to complete this Solar System successfully.
Manoj D. GalbadaarachchiEngineer- Maintenance & Energy
Vinseth Group