298-4578

Solar panels
Issued March 1999
RS stock numbers 194-082, 194-098, 194-105, 194-111, 194-127, 194-133
194-149, 194-161, 194-183, 768-071, 768-087
Data Pack F
Dat a Sheet
A range of com m ercial grade thin film am orphous silicon and
industrial grade polycrystalline photovoltaic m odules. These
panels are suitable for charging both nickel cadm ium and
dryfit batteries.
Principle of operation
Solar panels w ork on the principle of the photovoltaic effect.
The photovoltaic effect is the conversion of sunlight into
electricity. This occurs w hen the PV cell is struck by photons
(sunlight), freeingsilicon electrons to travel from the PV
cell, through electronic circuitry, to a load (Figure 1). Then
they return to the PV cell, w here the silicon recaptures the
electron and the process is repeated.
Amorphous silicon
Solarex thin film am orphous silicon m odules are
m anufactured using autom ated processes sim ilar to those
used for sem iconductor m anufacturing. These processes
result in a m onolithic m odule precision-layered w ith
conductive and sem iconductive film s. These film s are laser-
scribed, using a patented m ethod, into individual solar cells.
The lasers ability to scribe cleanly and precisely produces a
superior product in several respects:
G C ell divisions are very narrow , allow ing m ore m odule
surface to be devoted to pow er production. Thus, a
m odule of given size generates m ore pow er.
G V oltage characteristics and overall perform ance at low
light levels are im proved.
The series and parallel connections betw een cells (w hich
determ ine the m odules voltage and current output) are
com pleted internal to the m odule (Figure 2), resulting in an
ultra-reliable m odule w ithout solder joints.
Polycrystalline silicon
Polycrystalline silicon cells are m anufactured using 99.999%
pure silicon feedstock nuggets available to the
sem iconductor chip m anufacturers. The nuggets are m elted
dow n in a vacuum furnace w ith a little boron and allow ed to
cool very slow ly so that a pure crystal lattice of P-type
m aterial is form ed. The resulting block is quartered and then
sliced into 0.2m m w afers using either a hole saw or a w ire
saw (Figure 3).
Fused
silica
99.99%
Crusher with
vibratory/screen
separation
Ball mill Mixer slip
(with water)
Slip castings Ceramic
vessels
UCP
(silicon ingot)
Sizing
(silicon brick)
Slicing
(silicon wafers)
Silicon wafer
(114mm sq 0.3mm)
Feedstock silicon
(crystal nuggets) 99.999%
Light source
Glass supastrate Conductive
oxide
Metal Amorphous
silicon
+
Application
External circuit
Light
(photons)
Negative layer Positive layer
Figure 1 Principle of operation
Figure 2 Module internal structure
Figure 3 Cell production process
298-4578
2
By a patented process the N -type m aterial is form ed as a
very thin layer on one face of each w afer by spraying w ith a
phosphorous com pound gas and baking. This is follow ed by
the addition of an anti-reflective filter coating to the upper
surface and conductive layers to both faces. The layer on the
front face is optim ised in the form of a grid in order to allow
the m axim um am ount of light to pass through to the N -type
m aterial w hilst distributing the m axim um num ber of
electrons (Figure 4).
C ells are then tested and m atched together w ith cells of
sim ilar perform ance for building up into series and parallel
m atrices to give the PV m odule the desired electrical
characteristics.
Construction
Am orphous silicon solar plate (RSstock no. 194-098)
This am orphous solar plate is a m onolithic construction
consisting of several layers of conducting and sem i-
conducting m aterials deposited onto a solar grade glass
superstrate. Each plate com es unfram ed w ith integral flying
leads.
Low/ Medium power amorphous modules
(RSstock nos. 194-105and 194-111)
These am orphous silicon solar m odules consist of several
layers of conducting and sem i-conducting m aterials
deposited onto a solar grade glass superstrate. Each m odule
com es com plete w ith a low profile im pact reinforced
LEX A N fram e w hich protects the back and edges of the
panel and 1.2m of 2 core 18aw g flying leads.
Main features of the panels:
G Full laser patterning: A patented process using a
com puter-controlled laser interconnects all solar cells.
This m axim ises m odule active area and cell current w hile
m inim ising the area of the interconnects.
G Laser isolation: The plate is encircled by a laser scribe to
establish reliable isolation. In the final unit, each part is
surrounded by a thin, inactive border that acts as a barrier
to edge corrosion.
G Black appearance: A patented optical coupling
technology, com bined w ith a tightly controlled
m anufacturing process, creates uniform black
appearance.
G Tin-oxide glass coating: This patented process offers
exceptionally uniform conductivity and light absorption.
Polycrystalline panels
Low power modules
(RSstock nos. 194-127and 194-133)
These m odules consists of high efficiency polycrystalline
silicon w afers bonded to an alum inium substrate w hich is
lam inated betw een an ethylene vinyl acetate front sheet and
a tough EV A TedlarTM backsheet. Each m odule com es
com plete w ith a black plastic fram e, an integral stand and
0.8m flying leads.
Medium/ High power modules
(RSstock nos. 194-149, 194-161, 194-183, 768-071
and 768-087).
These m odules have the sam e basic construction as the low
pow er m odules.
Features of these panels include:
Solarex Mega Cell
G A dvanced polycrystalline technology
G 11.4cm 11.4cm cell generates superior current.
Reliable outside bussing
G Extends m odule life
G Resists electrical breakdow n
G A unique, patented titanium dioxide A R
(anti-reflective) coating for optim um light absorption
and pow er output
G Tem perature range 40C to + 90C or 40C to
+ 85C at 85% relative hum idity.
Framed versions
Tempered low-iron glass
G H igh transm issivity
G H ail and w ind resistant to JPL block V standards
G W ill w ithstand hailstone of 25.4m m diam eter at a
term inal velocity 52m ph.
Heavy-duty frame
G C orrosion resistant alum inium alloy
G A rchitectural grade bronze anodised finish
G W ithstands 129m ph (208km /h).
Weatherproof junction box (20W, 32W and 53W
versions only)
G N EM A 4X rated. UL rated term inal block
G Industry standard openings and fittings.
Generous frame clearance
G Prevents electrical breakdow n
G Im proves m odule reliability.
Unframed version
Low profile and lightweight
G The unfram ed types have a low profile of
approxim ately 9m m and are lightw eight, the 18W
version w eighs only 1.49kg.
External circuit
Load
Electricity (Electrons)
Sunlight (photons)
Top electrical
contact redundant
fingers or conductive
film
Base contact
conductive layer
Photosensitive
semiconductor
material layers
Figure 4 Polycrystalline cell structure
298-4578
3
Simple photovoltaic system
A photovoltaic (PV ) system m ay have a m inim um of tw o
com ponents, the m odule and the load to be pow ered. A n
exam ple of such a system w ould be a sim ple ventilation fan
driven directly by a m odule during hot and sunny w eather.
For tw enty-four hour a day operation a battery and blocking
diode are required, w hilst for UK all year round operationa
voltage regulator is also recom m ended in order to protect
the battery from the effects of overcharge, typically during
the sum m er.
Note: The solar regulator includes a blocking diode and
therefore a blocking diode should only be incorporated in
a system w hen the solar regulator is not being used.
Spectral sensitivity of silicon cells
Figure 6 show s the relative response of crystalline silicon
cells to the ultra-violet, visible and infra-red spectrum .
Response is fairly even to m ost of the visible w avelengths
and the near infra-red. A m orphous (thin-film ) silicon favours
the blue end of the spectrum .
The crystalline cells are m ade from boron doped silicon
w afers and are 12% efficient. The am orphous range of
m odules is m anufactured using autom ated thin film
processes w here precision layers of conductive and sem i-
conductive m aterials are sprayed onto glass and laser
scribed to produce individual cells w ith an efficiency of 7% .
A ll m odules are optim ised for daylight operation w here
current is proportional to light intensity and voltage rises
very quickly at low light intensities. Both the am orphous and
polycrystalline panels w ill operate in m ost U K daytim e
w eather conditions.
Electrical specifications
Standard test conditions (STC ) the pow er of a m odule is
given at STC w hich is defined as follow s:
1. A light intensity of 1kW /m
2
(equivalent to full sun).
2. A spectral distribution of A M 1.5 (A M A ir M ass = 1/cos
w here is the angle of the sun to the vertical).
3. A cell tem perature of 25C .
The definition of air m ass is as follow s:
A ir m ass, defined as 1/cosu (w here u is the angle betw een
the sun and directly overhead) is a useful quantity in dealing
w ith atm ospheric effects. A ir m ass indicates the relative
distance that light m ust travel through the atm osphere to a
given location. Because there are no effects due to air
attenuation im m ediately outside the earths atm osphere, this
condition is referred to as air m ass zero (A M 0). A ir m ass one
(A M 1) corresponds to the sun being directly overhead. A ir
m ass 1.5 (A M 1.5), how ever, is considered m ore
representative of average terrestrial conditions and is
com m only used as a reference condition in rating
photovoltaic m odules. Figure 7 show s the relative distance
through the earths atm osphere that the suns rays m ust pass
at tw o tim es during the day.
The value of air m ass at any given tim e and location can be
easily calculated using the relations show n on next page. The
higher the value of air m ass, the greater the attenuating effect
of the atm osphere.
Sun
Sun
Angle of incidence
= 60
Air mass = 1.0
Air mass = 2.0
Earths surface
Limit of atmosphere
Earth
Directly overhead
(zenith)
UV Visible IR
100
R
e
l
.

r
e
s
p
.
%
300 500 700 900 1100
Wavelength, nanometer
PV
array
Solar shunt
regulator
RS stock no.
194-082
Blocking
diode
Battery
Load
+

RS stock no. 261-299

Figure 5 A simple photovoltaic system
Figure 6 Spectral response of silicon
photovoltaic cell
Figure 7 Suns angle of incidence versus
distance through atmosphere
298-4578
4
G uaranteed perform ance all m odules carry a lim ited
w arranty covering perform ance:
C rystalline products are guaranteed to produce at least
90% of the specified m inim um pow er output for a period of 5
years.
A m orphous products are guaranteed to produce at least
80% of the specified Im p (current at m axim um pow er) at STC
w ith the voltage fixed at V m p.
Electrical characteristics at STC
Sm all low pow er m odules
Medium to high power modules
The m edium to high pow er m odules (table below ) are
labelled detailing the individual characteristics of their actual
perform ances at STC . The pow er output of N O C T N orm al
O perating C ell Tem perature at an am bient tem perature of
20C is also printed on the label.
N otes:1. The 20W , 32W and 53W versions are suitable for both 6
and 12V operation and are user configurable, see
installation details.
2. The M SX light series are the unfram ed versions.
Model MSX-005 MSX-01 SA-0640
RSstock nos. 194-127 194-133 194-098
Specified load voltage (V ld) 3.3V 7.5V 7.5V
N om inal battery voltage 2.4V 6V 6V
Typical current at V ld (Ild) 150m A 150m A 45m A
O pen circuit voltage (Voc) 4.6V 10.3V 12.0V
Short circuit current (ISC ) 160m A 160m A 54m A
Tem perature coefficient of
voltage per C 16m V 37m V 30m V
Tem perature coefficient of
current per C 0.15m A 0.15m A 0.05m A
Suns rays
Earth
Vertical
h = height
Shadow
S
Suns rays
A ir m ass = 1+ (
s
)
2
h

A ir m ass = 1
cos
Legend: V
PP
V oltage at peak pow er
I
PP
C urrent at peak pow er
V
O C
O pen circuit voltage
I
SC
Short circuit current
m V /C of V
O C
Tem perature coefficient of open circuit voltage
A /C of I
SC
Tem perature coefficient of short circuit current
N O C T N om inal O perating C ell Tem perature 49C (V LX M odules)
45C (M SX M odules)
M odel SA -1 SA -5 M SX -5 M SX -10 M SX -20 V LX -32 V LX -53
RSstock nos. 194-105 194-111 194-149 194-161 194-183 768-071 768-087
V pp (V ) 17.5 17.5 17.5 17.5 17.1 17.2 17.2
Ipp (m A ) 80 20 270 580 1170 1860 3080
V
oc
(V ) 24.0 23.0 21.2 21.2 20.8 21.3 21.3
I
sc
(m A ) 110 340 290 600 1270 2010 3330
m V /C of V
oc
-65 -60 -72 -72 -73 -73 -73
A /C of I
sc
10 300 275 500 1200 1500 2500
Pm ax @
3.1 7.3 18.5 29.1 48.2
N O C T - m A
I
pp
@
275.5 590 1194 1896 3140
N O C T - m A
298-4578
5
I-V characteristics with varying light intensity
Polycrystalline cells each give approxim ately 0.45 V olts
w hen illum inated dependent upon the light intensity and the
load but independent of surface area. The im portant
characteristic w hich m akes them so suitable for supplying
electrical pow er is that the voltage builds up quickly to a
reliable plateau at very low light levels (about 8% of peak
intensity). This m eans that voltages suitable for battery
charging are reached even on a dull day. C urrent, how ever,
is directly proportional to both light intensity and surface
area.
The graph above show s that there is no significant drop in
cell voltage until insolation drops to 80W /m 2.
Design considerations for the mounting
and installation of the small low power
modules
G reat care m ust be exercised during the design stage to
ensure that both the edges and rear of O EM (fram eless)
m odules are protected from the environm ent as w ell as
insulating them from stress through dynam ic, static or
therm al sources.
Active area
A m odules active area the frontal area that generates
electrical pow er is a critical design consideration in using
any photovoltaic product. If this area is covered by a
m ounting bezel, pow er m ay be reduced and the product
m ay cease to function. For optim al perform ance, the active
area m ust never be shaded.
C B B
D
D
F
A
Active area E
Front face of module
2 4 6 8 10 12 14 16 18 20 22 24 28
Voltage
T = 75C
T = 50C
T = 25C
50
100
150
200
250
300
350
400
C
u
r
r
e
n
t

(
m
A
)
5W (RS stock no. 194-111)
0.7
0.6
0.5
0.4
0.3
0.2
0.1
2 4 6 8 10 12 14 16 18 20 22 24
Voltage
C
u
r
r
e
n
t

(
A
)
T = 75C
T = 50C
T = 25C
T = 0C
10W (RS stock no. 194-161)
T = 75C
T = 50C
T = 25C
T = 0C
5W (RS stock no.194-155)
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Voc
Voltage (V)
10%
8%
50%
100% = 1kW/m
2
C
u
r
r
e
n
t
100%
Figure 8 I-V characteristics at reducing light
intensities
Figure 9a I-V characteristics with varying
temperature
Polycrystalline panel
Figure 9b I-V characteristics with varying
temperature
Amorphous silicon panel
Figure 10 Active area of modules
298-4578
6
Active area dimensions
Mechanical and dimensional details for
the medium/ high power modules
1W amorphous module (RSstock no. 194-105)
Mechanical characteristics
Weight: 0.4kg
Dimensions: D im ensions in brackets are in centim etres.
Unbracketed dim ensions are in inches.
5W amorphous module (RSstock no. 194-111)
Mechanical characteristics
Weight: 1.5kg
Dimensions: D im ensions in brackets are in centim etres.
Unbracketed dim ensions are in inches.
Mechanical characteristics
Output cable: 15 feet long, A W G 18-2, polyethylene
jacketed.
Weight:
RSstock no. 194-161 M SX -10 1.5kg
RSstock no. 194-149 M SX -5 0.77kg
Dimensions: D im ensions in brackets are centim etres.
Unbracketed dim ensions are in inches.
Dim. A Dim. B Dim. C
M SX -5 9.82 10.59 9.25
(RSstock no.194-149) (24.9) (26.9) (23.5)
M SX -10 16.54 10.59 9.25
(RSstock no.194-161) (42.0) (26.9) (23.5)
0.30
(0.8)
0.31
(0.8)
0.33
(0.8)
0.38
(0.9)
0.89
(2.3)
0.31
(0.8)
0.33
(0.8)
0.67
(1.7)
B
A
Front view
Back view
x x
Section X-X
End view
#18-2
output
cable
Junction
box
0.89
(2.3)
0.67
(1.7) C
13.62
(34.59)
1.81
(4.60)
10.00
(25.40)
11.75
(29.85)
12.87
(32.69)
13.63
(30.53)
0.82
(2.09)
0.38
(0.97)
0.27 dia (4) holes
(0.69)
Side view
Front view
13.0
(33.01)
12.52
(31.8)
12.21
(31.02)
0.14
(0.356) dia
4 places
3.12
(7.92)
4.87
(11.59)
4.87
(12.37)
0.43
(1.09)
Side view Front view
A B C D E F
Type (mm) (mm) (mm) (mm) (mm) (mm)
(RSstock no.
194-105)
M SX -005 114.3 7.49 57 9.86 95.8 71.88
(RSstock no.
194-111)
M SX -01 127 5.84 115.32 10.39 106.22 127
(RSstock no.
194-098)
SA -0640 54.86 6.35 139.7 3.176 48.52 152.4
298-4578
7
Mechanical characteristics
Weight:
RSstock no. 194-183 M SX -20 2.95kg
Dimensions: D im ensions in brackets are centim etres.
Unbracketed dim ensions are in inches.
Mechanical characteristics
Weight
RSstock no. 768-071 V LX -32 3.5kg
RSstock no. 768-087 V LX -53 5.5kg
Dimensions: D im ensions in brackets are centim etres.
Unbracketed dim ensions are in inches.
Dim.A Dim.B Dim.C
V LX -32 23.28 19.72 18.38
(RSstock no.768-071) (59.1) (50.0) (46.7)
V LX -53 36.88 19.72 18.38
(RSstock no.768-087) (93.7) (50.0) (46.7)
0.30
(0.75)
0.31
(0.8)
0.33
(0.85)
0.38
(1.0)
0.89
(2.3)
0.31
(0.8)
0.33
(0.85)
0.67
(1.7)
Section X-X
0.89
(2.26)
1.97
(5.0)
End view
Back view
Front view
C
A
X X
0.67
(1.7)
B
Junction
box
Dim. A Dim. B Dim. C
M SX -20 16.5 0.75 8.29
(RSstock no.194-183) (42.1) (1.9) (21.1)
19.76
(50.2)
B
Junction
box
0.38 (1.0)
dia mtg
holes.
C
B
18.38
(46.7)
A
2.13
(5.4)
0.437
(1.1)
1.063
(2.7)
1.968
(5.0)
Section X-X
Back view
Side view
0.69
(1.8)
Front view
X X
298-4578
8
Installation and mounting
Orientation
W hen installing photovoltaic m odules, be aw are that they
generate m axim um pow er w hen facing the sun directly. The
fixed position w hich approxim ates this ideal over the course
of the year, thus m axim ising annual energy production, is
facing due south (in the northern hem isphere) or due north
(in the southern hem isphere) at the angle listed in the table
below .
Note: These orientations are true, not magnetic north
and south.
Tilt angle
The table below show s the fixed angle above horizontal at
w hich m odules should be installed in order to m axim ise
annual energy output. A t som e installations, it m ay be cost-
effective to adjust the tilt seasonally. A t m ost latitudes,
perform ance can be im proved during the sum m er by using
an angle flatter than the charts recom m endation; conversely,
a steeper angle can im prove w inter perform ance.
If m odules are not cleaned regularly, it is recom m ended that
they are not m ounted at an angle flatter than 15. Flatter
angles cannot take full advantage of the cleansing action of
rainfall.
Shading
Locate m odules so they are as free as possible from shading
during all seasons, particularly during the m iddle (the m ost
energy-productive) part of the day.
Mounting
The am orp hous m od ules and the p olycrystalline lig ht
m od ules can b e m ounted via the integ ral holes. It is
im portant that the m ounting hardw are is not over tightened
or that the m odule is bent during installation.
M odules can also be m ounted on a flat w ooden surface, such
as 12in thick plyw ood. Such an installation, how ever,
prevents natural airflow from cooling the back of the m odule,
an effect w hich enhances m odule perform ance slightly. If this
enhancem ent is desired, the installation should allow airflow
across the m odule back.
The 5W and 10W polycrystalline panels have a m ulti-m ount
fram e. This consists of dual channels oriented parallel to the
edge and back of the m odule. The channels accept the
heads of 516in or 8m m hex bolts, and allow the m odule to
be rear- or side-m ounted. The channels prevent the bolt
heads from turning.
The 20W , 32W and 53W polycrystalline panels have a
universal m ount fram e. This fram e can be m ounted via the
six 10m m holes in the dual channels. To m ount the m odule
on a pole use the tw o centre holes.
MSX-20, VLX 32 and 53 modules wiring
for 6V or 12V operation
The tw o strings of 18 cells w hich m ake up the m odules m ay
either b e connected in series or parallel for 12V or 6V
operation as show n in Figure 11. Positive conductors have
red insulation w hilst the negative ones are grey. The m odule
is shipped in 12V configuration. A ll other finished m odules
are configured as 12V and cannot be altered.
6 5 4 3 2 1
Grey
()
Gre
()
Red
(+)
Red
(+)
Terminal strip numbering

+
6V cell
string
6V cell
string
12V nom.
output

+
()
(+)
6
5
4
3
2
1
12V wiring
simplified module schematic

+
6V cell
string
6V cell
string
6V nom.
output

+
()
(+)
6
5
4
3
2
1
6V wiring
simplified module schematic
Latitude of site Tilt angle
0-4 10
5-20 A dd 5to local latitude
21-45 A dd 10to local latitude
45-65 A dd 15to local latitude
65-75 80
Figure 11 Wiring schematics
9
Figure 12 Worldwide insolation availability maps
These maps indicate worst case (wintertime) solar radiation based on a Solar Array tilted towards the sun at
an angle equal to the latitude of the location +15.
4.5
4.5
4.5
4.5
4.0
4.0
4.5
4.0
4.0
4.5
3.5
3.5
3.0 3.0
2.0
2.0
3.5
4.0 4.0
4.5
4.5
4.0
4.0
4.5
5.0
3.5
3.5
3.0
3.0
2.5
2.5
15
0
10
20
30
40
50
60
3.5
60
50
40
30
15
0
1.5
2
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.0
5.5
6.5
7.0
6.0
7.0 7.5
6.0
4.0
3.5
3.5
3.0
2.5
2.0
1.5
0.8
0.6
0.4
4.0
3.5
5.0
4.0
4.5
5.0
5.5
5.5
5.0
4.5
4.0
3.5
3.5
3.0
6.5 5.0
6.5
7.0
7.5
3.0
5.5
Eastern hemisphere insolation map (winter)
Eastern hemisphere insolation map (winter)
Daily average insolation levels in the
United Kingdom
The follow ing tables of m ean daily ESH (equivalent sunshine
hours) m ay be used to calculate the size of m odule required:
Legend: O T O ptim um tilt angle (degrees from
horizontal)
H H orizontal
V s V ertical south facing
Sot South facing at optim um tilt
(D ata taken from Climate in the UKISBN 0 11 412301 2)
Notes:
1. For areas of higher or low er latitude in the U K
appropriate insolation levels m ay be extrapolated
from the figures show n.
2. The data above should be used w ith care as these
figures w ere gained from idealsites, please consider
all the potential perform ance derating factors listed
below .
3. If sizing a system outside the UK then an approxim ate
guide to m ean daily w intertim e (w orst case) insolation
levels is given in the follow ing m aps:
Equivalent sunshine hours
kWhrs/ m
2
/ day
Summer Winter
Location (OT)
mean for June mean for Dec
H Vs Sot H Vs Sot
Plym outh 65 5.56 2.85 4.20 0.69 1.35 1.40
M anchester 68 5.17 2.80 3.86 0.46 0.88 0.91
G lasgow 71 4.94 2.76 3.62 0.33 0.64 0.65
298-4578
298-4578
10
Module performance derating factors
It is appropriate to consider the m any factors w hich can
d erate the p erform ance of a solar m od ule p rior to
com pleting any sizing calculations:
a) Tem perature as a guide the typical cell operating
tem perature w ill be 20C to 25C higher than am bient.
b) C leanliness the m odules active area should be cleaned
off periodically to m aintain perform ance.
c) Production tolerances these are catered for w ith an
appropriate safety factor in the sizing calculation.
d) Reflection/Refraction if the m odule is m ounted behind
glass or som e other clear m edium then reflection and
refraction w ill typically account for losses of 20% .
e) Shadow ing during sunny conditions the possibility of
shadow s falling across the m odule should be reduced to
a m inim um as the perform ance of all cells w ill be
reduced to that w ith the low est output.
f) A zim uth and tilt angle as an exam ple it w ill be seen
from the U K insolation tab le ab ove that horizontal
m ounting gives excellent sum m er perform ance b ut
m inim al in w inter for best all year round perform ance
the m odule should be fixed at an angle of latitude + 15,
facing true south.
g) Spectral distribution of light the perform ance of Solarex
m odules is optim ised for daylight. Perform ance under
artificial light sources m ust be found by m easurem ent.
Daily system load
In order to ensure reliable system operation all year round it
is im perative that the w orst case daily load in w inter is
know n. It is also very im portant to ensure that adequate
account is taken of quiescent loads, sw itching losses and if a
voltag e reg ulator is em p loyed its ow n consum p tion
characteristics.
Battery sizing
The battery stores energy from the m odule enabling the
system load to operate day or night. D ue to the vagaries of
the w eather w e m ust allow for long p eriod s of b elow
average insolation in order to ensure reliable operation. In
effect this m eans that the battery size is calculated to allow
for a certain num b er of days w ithout energy input, the
system autonom y. A t U K latitudes this should not be less
than 20 days.
W e m ust also consider several im portant points;
a) that should this situation occur it is not advisable to allow
the battery to discharge to 0% capacity
b) capacity reduces w ith tem perature
c) the effects of self discharge and charging efficiency m ay
be significant
d) battery capacity is a function of discharge rate.
Typically, therefore, do not discharge the battery below its
30% charge state and allow for a 10% capacity reduction in
w inter. Thus a system supplying a load consum ing
0.75A h/day w ould require a battery capacity of:
0.75 20 1.3 1.1 = 21.45A h
Battery choice The RS D ryfit range of sealed lead acid
batteries is ideal for solar system s having high charge
efficiency, low self-discharge and good recovery from high
discharge.
Module sizing
H aving determ ined the load requirem ents and local
insolation the last step is to calculate the size of m odule
required.
SA =
L SF
ESH
SA = System A m ps (to be provided by m odule)
L = Load
SF = Safety factor (use 1.2)
ESH = Equivalent sunshine hours
(kW hrs/m
2
/day)
Example: Thus for a system consum ing 0.75A h/day all year
round in the M anchester area w ith a m odule facing true
south, tilted at latitude + 15 (= 68) and unshadow ed:
SA = (0.75 1.2)/0.91 = 0.99 A m ps
From the table of m odule perform ance characteristics w e
w ill see that the M SX -18 m odule has an I
PP
of 1.06 am ps. This
is the correct choice as the sm aller M SX -10 only has an I
PP
of 0.58 A m ps.
Note: A regulator w ould be required in this system thus the
daily load is inclusive of its pow er requirem ents.
15
0
20
30
40
10
50
60
4.5
5.0
5.5
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
4.5
60
50
40
30
15
0
0.3
1.5 1.0
1.5
2.0
2.5
1.5
1.5
2.0
2.5 3.5
4.0
4.0
5.0
5.0
5.5
5.5
5.5
5.5
5.5
4.5
4.0
3.5
1.8
2.6
5.5
1.1
0
1.4
5.0
3.0
1.3
Western hemisphere insolation map (winter)
Western hemisphere insolation map (winter)
298-4578
11
Regulation
In the UK w ith its high ratio of sum m er to w inter insolation it is
alm ost alw ays essential for a solar system to be fitted w ith a
voltage regulator to protect the battery against the effects of
overcharge during the long sum m er days. A regulator w ould
not be required if during the period of operation of the
system the daily load w as m atched to the m ean m odule
output. Regulators incorporate blocking diodes that prevent
battery discharge through the m odule at night, so in an
unregulated system a blocking diode w ould be required. A
suitable blocking diode w ould be a 1N 5401 (RS stock no.
261-299) 3A , 100V .
Shunt regulator (RSstock no. 194-082)
The perform ance specifications of the shunt regulator are as
follow s:
N om inal voltage
________________________________
12.0V
M axim um input current
__________________________
6.0A
Shunt set point voltage
__________________________
13.8V
Q uiescent current
____________________________
< 1.0m A
Blocking diode voltage drop
______________________
0.4V
Tem p. coeff. of output voltage
______________
45m V /deg C
The three output leads are colour coded as follow s:
RED
____________________________
SO LA R M O D ULE + ve
BLA C K
________________________________
C O M M O N ve
YELLO W
________________________________
BA TTERY + ve
Each 1.0m m
2
lead is 220m m in length and term inated w ith an
M 4 spade term inal.
Regulator status is indicated by a single, green LED w hich is
illum inated w hen the set point voltage of 13.8V is reached
and shunting of the m odule output com m ences. W hen
battery voltage drops to 12.8V the LED is extinguished and
the m odule output is redirected to the battery.
The m atrix below provides general guidelines for choosing
either a blocking diode or a regulator.
Glossary of solar terms
Air mass A m easure of distance that light travels through
the earths atm osphere.
Ampere-hour A m easure of electrical charge.
Array A collection of photovoltaic m odules, electrically
w ired together and m echanically installed in their w orking
environm ent.
Block V M odule qualification tests designed and conducted
by the Jet Propulsion Laboratory. M odules undergo electrical
perform ance m easurem ents and m echanical tests, such as
therm al cycling, hum idity-freezing, cyclic pressure loading,
hail-im pact and tw isted m ounting surface requirem ents.
Blocking diode A device for preventing a reverse flow of
current through photovoltaic m odules (also called a series
diode or an isolation diode).
Bypass diode A device placed in parallel w ith a
photovoltaic m odule or group of m odules allow ing a route for
the current under conditions of shading and cell failure (also
called a shunt diode).
Cell efficiency The ratio of the electrical energy produced
by a photovoltaic cell (under full sun conditions) to the
energy from sunlight falling upon the cell.
Design tilt The tilt of the array at w hich design and sizing
calculations are m ade. O ften the design tilt is optim ised for
energy output under prescribed conditions.
Diffuse radiation Sunlight received indirectly as a result of
scattering due to clouds, fog, haze, dust or other substances
in the atm osphere.
Direct radiation Light that has travelled in a straight path
from the sun (also referred to as beam radiation). A n object
in the path of direct radiation casts as a shadow on a clear
day.
Fill factor The ratio of m axim um pow er to the product of
open-circuit voltage and short-circuit current. Fill factor is
the squarenessof the I-V curve shape.
Flat-plate array A photovoltaic array in w hich the incident
solar radiation strikes a flat surface and no concentration of
sunlight is involved.
Grid-connected A n energy producing system connected
to the utility grid (also called utility-interactive).
Grounding C onnection to a large conducting body (such
as the earth), w hich is used as a com m on return for an
electrical circuit and as an arbitrary zero potential.
Holes V acancies, w here electrons should norm ally be in a
perfect crystalline structure.
Equivalent sunshine hours
kWhrs/ m
2
/ day
Summer Winter
Location (OT)
mean for June mean for Dec
H Vs Sot H Vs Sot
Plym outh 65 5.56 2.85 4.20 0.69 1.35 1.40
M anchester 68 5.17 2.80 3.86 0.46 0.88 0.91
G lasgow 71 4.94 2.76 3.62 0.33 0.64 0.65
65.0
20.0
1.5
Green LED
RS Stock No.
194-082
Solar Shunt
Regulator
5.0
10.0
Dia. 4.5
40
220.0
(
+
)
S
O
L
A
R
(
-
)
C
o
m
m
(
+
)
B
A
T
T
37.0
40.0
298-4578
Hybrid systemA pow er system consisting of tw o or m ore
pow er generating subsystem s (e.g. the com bination of a
w ind turbine and a photovoltaic system ).
InsolationThe am ount of sunlight reaching an area. Usually
expressed in w atts per square m etre per day.
Junction box A protective enclosure into w hich w ires or
cables are led and connected.
Load Electrical pow er being consum ed at any given
m om ent. The load that an electric generating system
supplies varies greatly w ith tim e of day and to som e extent
season of year. A lso, in an electrical circuit, the load is any
device or appliance that is using pow er.
Maximum power current (Imp) The corresponding
current for the m axim um pow er point on an I-V curve.
Maximum power point (Pmax) The desired operating
point on an I-V curve w here the product of the current and
voltage (pow er) is m axim ised.
Maximum power voltage (Vmp) The corresponding
voltage for the m axim um pow er point on an I-V curve.
Module A num ber of photovoltaic cells electrically w ired
together, usually in a sealed unit of convenient size for
handling and assem bling into panels and arrays.
Nominal operating cell temperature (NOCT) The
photovoltaic cell junction tem perature corresponding to
nom inal operating conditions in a standard reference
environm ent of 1kW /m
2
irradiance, 20C am bient air
tem perature, 1m /s w ind, and electrically open circuit.
Open-circuit voltage (Voc) The voltage output of a
photovoltaic device w hen no current is flow ing through a
circuit.
Panel A num ber of m odules w ired together, w hich in turn,
can be w ired to other panels to form an array.
Parallel connected A m ethod of connection in w hich
positive term inals are connected together and negative
term inals are connected together. C urrent output adds and
the voltage rem ains the sam e.
Peak sun hours The equivalent num ber of hours at peak
sun conditions (i.e. 1kW /m
2
) that produces the sam e total
insolation as actual sun conditions.
Photovoltaic cell The basic device that converts light into
dc electricity; the building block of photovoltaic m odules.
p-n junction The junction form ed at the interface betw een
tw o differently doped layers of sem iconductor m aterial, one
layer being doped w ith a positive-type dopant, the other w ith
a negative-type dopant. A n electric field is established at the
p-n junction w hich gives direction to the flow of light-
stim ulated electrons.
Series connected A m ethod of connection in w hich the
positive term inal of one device is connected to the negative
term inal of another. the voltages add and the current is
lim ited to the least of any device in the string.
Short-circuit current (Isc) The current flow ing freely from
a photovoltaic cell through an external circuit that has no load
or resistance; the m axim um current possible under norm al
operating conditions.
Solar constant The rate at w hich energy is received from
the sun just outside the earths atm osphere on a surface
perpendicular to the suns rays. A pproxim ately equal to
1.36kW /m
2
.
Standard test conditions (STC) Test conditions in a
standard reference environm ent of 1kW /m
2
, 25C cell
tem perature, and 1.5 air m ass spectrum .
Thick cells C onventional cells, such as crystalline silicon
cells, w hich are typically from 4 to 17m m thick. In contrast,
thin-film cells are several m icrons thick.
Thin-film cells Photovoltaic cells m ade from a num ber of
layers of photo-sensitive m aterials. These layers are typically
applied using a chem ical vapour deposition process in the
presence of an electric field.
Voltage regulator A device that controls the operating
voltage of a photovoltaic array.
Watt A m easure of electrical pow er or am ount of w ork
done in a unit of tim e. O ne A m p of current flow ing at a
potential of one V olt produces one W att of pow er.
RSC om ponents shall not be liable for any liability or loss of any nature (how soever caused and w hether or not due to RSC om ponentsnegligence)
w hich m ay result from the use of any inform ation provided in RStechnical literature
RSC om ponents, PO Box 99, C orby, N orthants, N N 17 9RS Telephone: 01536 201234
A n Electrocom ponents C om pany RS C om ponents 1998