Solar Project @ Kadugannawa (Project 01)

About Site

Site located 120Km east of Colombo in one of the most scenic areas in the hills
of sabaragamuwa. Namely Gadadessa Estate. (50Arcre)

Building
2 storied Resort Bungalow.
Height : 30ft
Structure : Wooden
Rooftop : Wood/Metal
Situation : Hill Top
Usage : Guest Bungalow/2 Luxury rooms, ONLY for the VVIP s
Item List
1. Solar Panel – 8 Nos
2. UNIRAC Solar Panel Mounting System.
3. PV Fuse Box (15 A)
4. DC Surge Protector – Delta Brand
5. Safety Switch – 30A 3Pole -Squre D – 2 Nos
6. Charge Controller – Out Back – FLEXmax 60
7. 2000VA /24V-230V Outback Inverter
8. 740Ah Battery Bank – 6V/370Ah 8nos- 4X2 Series Parallel combination
9. AC Out Distribution Box
10. 160A Merlin Gerin Breaker Switch
11. HRC Fuse 200A-2 Nos
12. Wires /Lugs /Conduits/casing/Silicone glue and other fixing accessories

Used Tools/Equipments for Installation

1. Drill Machines
2. Hacksaw
3. Wire Cutters
4. Cable Lug Tool
5. Digital Multi meter
6. Digital Clamp Meter
7. Screw Drivers (F/P)
8. Com Flier
9. Nose Flier
10. Tester
11. Hammer
12. Ratchet /Box spanner set/wrench
13. Wire Striper
14. Scar Folding 4 sets
15. Measurement Tape
16. Level
17. Compass
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.

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 Controller

2. 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 connected
through the Battery bank and
Charge Controller.
6. Charge Controller – Out Back – FLEXmax 60

Brand name Outback

Max Ampere 60A
Max 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 2010

PV 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 100A

Continuous 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

9. AC Out Distribution Box
Metal Enclosure
40A Main Switch/Trip Switch
16A/10A MCB (F&G Brand)

10. 160A Main Breaker Switch

Ampere 160A
Brand Merlin Gerin
Pole 3P
Model NS160N

11. HRC Fuse 200A-2 Nos

200A HRC Fuse and Base
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 used
Stainless Steel / Galvanized Nut & Bolts. Used Waterproof Silicone for Roof Mounting L
Foot base.
Panel Mounting Brackets

Mounting Surface is very narrow. So any

mistake panels can SLIP !

Suggestion,
If panels directly mount to AL bar using
S/S nut and Bolts we can away from this
doubt.
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 Protector

DIN 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 Enclosure
upside.

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 interconnected
all 3 Poles for disconnect Positive Terminal. Negative terminal directly
interconnected(Battery Bank and Charge controller)

5. Battery Bank
6V/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 Breaker

Those items are connected in between battery bank and Inverter. Outback recommend
Fuse rating is 200A and 125A Vacuum Breaker. (Air Breaker) I couldn’t find this
type of breaker from Sri Lanka at the moment. So I used 160A 3Pole AC/DC Main
breaker for this thing. (Merlin Gerine).200A HRC fuses installed in Metal Enclosure.
Used 50mm2 Copper wire and Lugs. Wire Length around 5Ft
 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 all
Connections, 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 position

2. 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 panel
4. Switch ON Inverter Main Breaker
5. Checked all Ampere rates/Voltages In & Out using Clipon Meter.

10.30 Am Data 09 July 2010

PV side Voltage 108V
Out put Ampere 47.5A
Inverter Idling Amp 0.7A (DC)
With Load (23W) 1.7A (DC)
EQUIPMENT ROOM
TIME TABLE

Date Time Start/Finish Work Attend

30th/06/2010 7.00Pm -8.30Pm Scar folding fixing 3Persons
(4sets) Janaka
Dumindu
Manoj
30th/06/2010 8.30Pm- 11.00Pm Inverter room 1Person
Arrange Manoj

01/07/2010 Rainy/High wind -- --

Day
(Difficult to work
roof area due to
rain & Wind)

02/07/2010 8.00Am - 5.00Pm Solar Rack 3Persons

Installation Dinesh/Manoj-full
Rainy Day Solar Panel day
Installation (4
Panels) Janaka-11Am to
5.00Pm)

07/07/2010 8.00AM-1.10PM Rack & 4 Panel 3Persons

Installation Gunawardana
2.00Pm –5.30Pm Panel Wiring Amila
Lay Down
conductor and Manoj
Earth Wire

08/07/2010 8.30AM-2.00PM Power room 4Persons

Wiring/Equipment Gunawardana
2.35PM-8.30PM s Installation Amila
Dumindu
Manoj
09/07/2010 8.15AM-9.30AM Double-check all 3Persons
wiring/connections Gunawardana
& Power up the Amila
System. Manoj
Wiring Diagram
SPECIAL THANKS

Direct Support

1. Mr. Bede Cooray – CEO Vinseth Group Of Companies

2. 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 Thisera
2. Dinesh
3. Janaka

I’m thankful to all who help me to complete this Solar System successfully.

Manoj D. Galbadaarachchi
Engineer- Maintenance & Energy
Vinseth Group
gamanoj@yahoo.com