Solar PV Kadugannawa

8/7/2019 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

[email protected]

Documents

Solar PV Kadugannawa