Module 1:Solar Power Technology

Session Objectives
At the end of the session, you will be able to:
Explain what solar energy is
Identify how solar energy works
Describe the process of turning solar energy into consumable
electricity
Explain the system used in solar power generation technology
Introduction
In this lesson you will learn how renewable energy such as solar
energy is used as a means to fill in problem of electricity
scarcity in a way that is affordable and environment friendly.

What is Solar Energy

Solar energy is energy provided by the sun. It is energy in the form
of solar radiation that makes solar electricity production possible.
Solar power is the direct or indirect conversion of sunlight into
electricity. Direct conversions are done through the use of
photovoltaics (PV) while indirect conversions are done using
concentrated solar power (CSP).
Photovoltaic, which means light and electric, (PV) cells are
used to directly produce electricity through solar energy. These are
cells made from materials that exhibit photovoltaic effect or
when sunlight hits the cell, the photons of light excite the electrons
in the cell, causing them to flow thus generating electricity.
In photovoltaic system, solar cells produce direct current (DC)
power which change with the sunlights intensity. For practical use,
it usually requires conversion to certain desired voltages or
alternating current (AC), through the use of inverters.
Concentrated solar power systems use lenses or mirrors and
tracking system to focus a large area of sunlight into a small
beam.

Session Objectives
At the end of the session, you will be able to:
Understand the different components of solar power generation
technology
Explain how solar power generation works
Identify how solar power generation is used in everyday energy
consumption
Introduction
In this lesson, you will learn the initial steps in employing the
solar power generation technology in different households.

Determining Power Consumption Demands

In determining the power consumption demands, you will be able to
estimate the amount of energy needed to be supplied by the solar
PV system.
1. Calculate the total Watt-hours per day for each appliance
used.
Make a list of all the appliance and/or loads that you are going
to run using the PV system. To determine the wattage, most
appliances have a label on the back that indicates the wattage.
Specification sheets, local appliance dealers, and the product
manufacturers can also be used as reference.
Add the Watt-hours needed for all appliances together to get the
total Watt-hours per day which must be delivered to the
appliances.
2. Calculate total Watt-hours per day needed from the PV
modules
After determining the total watt-hours per day, multiply it by 1.3
(the energy lost in the system). In doing so, youll be able to get

SIZING THE PV MODULES

Sizing the PV modules will help you find out the appropriate size of PV
module that will produce an amount of power suitable for your daily
consumption.
To find out the sizing of the PV module, you need the total peak watt
produced needs. The peak watt (Wp) produced depends on the size
of the PV module and climate of the site location.
1. Calculate the Watt-peak rating needed for PV modules
To get the total Watt-peak rating needed for the PV panels
needed to operate the appliances, you will need to divide the
total Watt-hours per day needed from the PV modules by 3.43.
2. Calculate the number of PV panels for the system
After getting the Watt-peak rating needed for PV modules, divide
it by the rated output Watt-peak of the PV modules available to
you. If the answer resulted to any fractional part, just increase it
to the next highest whole number. The answer you got will be the
number of PV modules required.

BATTERY SIZING
A deep cycle battery is recommended to be used in PV systems. It is
specifically designed to be discharged to low energy level and rapid
recharged or cycle charged and discharged day after day for years.
Make sure that the battery is large enough to store enough energy to
operate the appliances even at night and cloudy days.
Follow these steps to find out the size of the battery:
1. Calculate the total Watt-hours per day used by appliances.
2. Divide the total Watt-hours per day used by 0.85 for battery loss.
3. Divide your answer from the previous step by 0.6 for depth of
discharge.
4. Divide your answer from the previous step by the nominal battery
voltage.
5. Multiply your answer from the previous step with days of autonomy
or the number of days that you need the system to operate when
there is no power produced by PV panels. In doing do, youll get the

SOLAR CHARGE CONTROLLER SIZING

The solar charge controller is used to maintain the proper
charging voltage on the batteries. It is typically rated
against Amperage and Voltage capacities. In selecting the
solar charge controller, it should match the voltage of PV
array and batteries and then identify which type of solar
charge controller is suitable for your system. You have to
make sure that the solar charge controller has sufficient
capacity to handle the current from the PV array

Module 2:Basic Electronics

Session Objectives
At the end of the session, you will be able to:
Know the basic scientific laws involving electronics
Identify Ohms and Power law
Explain the formulas and computations involved in
understanding the different scientific laws

OHMS LAW
Ohms law is a very simple and practical tool in
understanding electric circuits. It simply states that in
metallic conductors at a constant temperature and in a zero
magnetic field, the current flowing is proportional to the
voltage across the ends of the conductor, and is inversely
proportional to the resistance of the conductor.
By using the letters V, I and R to express the relationships
defined in Ohms Law gives three simple formulae:
V = IR or I = V/R or R = V/I
Each of which shows how to find the value of any one of
these quantities in a circuit, provided the other two are
known. For example, to find the voltage V (in Volts) across a
resistor, simply multiply the current I (in Amperes) through
the resistor by the value of the resistor R (in Ohms).
Using these formulae the values of V I and R written into
the formula must be in its BASIC UNIT i.e. VOLTS (not
millivolts) Ohms (not kilohms) and AMPERES (not micro
Amperes )etc.

Power Law
The Power Law states that the power dispersed in a
device is inversely proportional to the squared value
of the voltage across it:
P = V2/ R
It can also be stated as the power dispersed in a
device is directly proportional to the squared value of
the current going through it:
P = I2x R
Power law can be simply stated as:
P=VxI

Session Objectives
At the end of the session, you will be able to:
Identify the different electronic components used in solar night lamp
Explain their purpose in the construction of a solar night lamp
Introduction
In this lesson, you will learn the different electronic
components used in a solar night lamp and their purpose

LED Lamp
For the solar night light, you will be using a lamp that is a single
high power 1W LED with an operating voltage of 3.2 V to 3.6V
and a maximum current rating of 350mA.
A 10 ohms resistor as the current limiter is used in the prototype
to reduce the current draw to 100mA when drawing power from
the 3.7V lithium battery. The LED heat sink temperature is
observed to remain stable at 30 degree Celsius at this current.

Lithium-ion Battery
You will be using a 3.7V 2200mA rechargeable lithium-ion battery that is
commonly used as cells for laptops and camera battery packs. It was
chosen due to its longer service life and higher power density.
The high cell voltage makes it possible to power the LED using a single
cell thus making the light simple, easy and cost effective to build. At
100mA current, the battery will have storage of 20 hours for the LED
lamp at full charge. At 12 hours of operation, the daily depth of the
discharge is 60%.
An overcharging controller will not be used since the solar module to be
used is too small to overcharge the battery under daily use. Since the
lithium battery can tolerate deep discharge, no over-discharge controller
is needed. Elimination of the overcharge and over-discharge controllers
simplifies the design of the lamp.

Solar / Photovoltiac Module

The solar module delivers a daily energy requirement for 12 hours
of LED light consuming 100mA will require 1.2AH. At a voltage of 3.7
with 80% charging efficiency an average of 3.28 effective sun hours
per day (Philippine setting), the required solar module is 1.7Wp.
The locally available solar module used is 1W module with 10 poly
crystalline cells that is ideal for charging the 3.7V lithium-ion
battery.

Master Switch
To disconnect the battery from the circuit, a separate manual
3P slide switch is added. The addition of the switch will
prevent the lamp from turning on in its dark container during
storage and transport. It is also a safety requirement when
shipping the equipment.

Resistors
Resistors are one of the most commonly used electronic components
that create specified values of current and voltage in a circuit. Basically
the function of a resistor is always to be against the flow of current
through it and the strength of this opposition is called as its resistance.
There are different kinds of resistors that vary in size and color
depending on the power that they carry.
For the solar night limp, you will be using three types of resistors in
varying power:
2 pieces of 1 k ohm W resistor
1 piece of 10 k ohm W resistor
1 piece of 2W 10 ohm resistor

DIODES
A diode is an electronic component that is used to direct flow of
electricity into one direction and blocks the flow in the opposite
direction. They can also be considered as one-way valves used in
various circuits as a form of protection. For the solar night lamp
you will be using the1N5819 Schottky barrier diode.
The Schottky barrier diode is commonly used in electronics. Its
unique properties enable it to be used in a number of ways.
Schottky diodes are used in many applications where other types
of diode will not perform as well. It has a low turn on voltage, a
fast recovery time because of the small amount of stored charged
which means it can be used in high speed switching function and a
low junction capacitance.

TRANSISTORS
Transistors can be considered as a type of switch or gate for
electronic signals and also regulates the current or voltage
flow. They can be used as amplifiers or switching devices. As
amplifiers, they are used in high and low frequency stages,
oscillators, modulators, detectors and in any circuit needing to
perform a function. In digital circuits they are used as
switches. For the solar night lamp, you will be using:
1.IRF510 transistor
2.General purpose transistor 9014.

Session Objectives
At the end of the session, you will be able to:
Identify the different testing instruments needed in constructing a
solar night lamp
Identify the use of different testing instruments

Introduction
In this lesson, you will learn the importance of testing instruments
in basic electronics. Electronics can be a complicated field to get
into if proper precautions are not taken. Testing instruments lets
you assess the product even before construction is complete.
There are different types of testers but for the constructions of
solar night lamps, you will only need a multitester or also known
as a voltmeter.

Multitester
Multitester or also called as a multimeter is a device that can be used to
gather data about electrical circuits. It combines several measurement
functions in one unit. It may include several features like the ability to
measure voltage, current, and resistance.
Multitesters can use analog or digital circuits. They are usually used in
basic fault finding and basic field service work. They can also be used to
troubleshoot electrical problems in assortment of industrial and
household devices.
The most basic measurement provided by a multitester is continuity that
determines whether a circuit is complete or not. For this type of test, the
device is set to ohms and AC or DC depending on the current to be
measured, before the probes on the device are inserted into the circuit.
It will read out 0 and 0.05 ohms if the circuit is complete. If a measure of
infinity is revealed, it indicates that the circuit is open and can be
considered a problem.

Session Objectives
At the end of the session, you will be able to:
Identify the proper soldering techniques
Follow the steps in soldering
Identify the use of soldering
Introduction
In this lesson, you will learn and follow the basic soldering techniques
employed in constructing a solar night lamp.

Basic Soldering Procedure

Clean the surface of the PCB
A clean surface is very important for a strong, low resistance solder joint.
Component Placement
In general it is best to start with the smallest and flattest components (resistors,
ICs, signal diodes) and then work up to the larger components (capacitors, power
transistors, transformers) after the small parts are done.
Apply Heat
Apply a very small amount of solder to the tip of the iron. This helps conduct the
heat to the component and board, but it is not the solder that will make up the
joint.
Apply Solder To The Joint
Once the component lead and solder pad have heated up, you are ready to
apply solder.
Touch the tip of the strand of solder to the component lead and solder pad, but
not the tip of the iron. If everything is hot enough, the solder should flow freely
around the lead and pad. You will see the flux melt liquify as well, bubble around
the joint (this is part of its cleaning action), flow out and release smoke.
Continue to add solder to the joint until the pad is completely coated and the
solder forms a small mound with slightly concave sides. If it starts to ball up, you
have used too much solder or the pad on the board is not hot enough.
Inspect The Joint and Cleanup

MODULE 3:ASSEMBLY OF THE SOLAR NIGHT LIGHT

Session Objectives
At the end of the session, you will be able to:
Follow the proper health and safety preparations in PCB
preparation
Identify the different steps in PCB Preparation
Explain the importance of each step involved in PCB
preparation

Introduction
In this lesson you will learn how to prepare the PCB which is
an integral part of the technology in a solar night lamp. You
will learn the correct processes in etching, printing, and
cleaning of the PCB. You will also be able to follow the
safety precautions used in such processes

Safety in Preparing the Etching Solution

Etching Solution or ferric chloride is a very dangerous solution and
should be handled properly. Make sure that in preparing the
etching solution, you are wearing the proper personal protective
equipment such as gloves and a face mask.
The etching solution should be placed in a plastic container rather
that metallic so that no chemical reactions will take place.
It would be recommended if you do the etching process in a well
ventilated place so that possible suffocation from the odor of the
solution will be avoided.

Printed Ciruit Board Preparation (Part 1)

Printing
Printing is the technique used in transferring the design to be followed to the
actual PCB wherein the other electronic components will be assembled.
Cut printed circuit board (PCB) based to the required size of 1 inch by 3
inches.
Cover the copper side of the board with a layer of masking tape.
With a printed copy of the PCB layout, copy the black lines on the diagram
representing the non conductive line onto side of the board covered in
masking tape using a marker and ruler.
Using a cutter and ruler, cut out the lines drawn with a marker that will later
serve as the non conductive lines in the design.
Etching
By etching, youll be removing the unnecessary copper particles from the
PCB thus permanently transferring the design on the board. Youll be using a
dangerous etching solution or ferric chloride so it is important to follow the
proper personal protective equipment. After using the etching solutions
(ferric chloride) please dispose the used solution and empty bottles properly
and wash your hands thoroughly.
Use gloves before using the etching solution (ferric chloride).
Using tape, attached the PCB at the bottom of the plastic container copper
side up.
Pour the required quantity of the etching solution in a plastic container.

Printed Ciruit Board Preparation (Part 2)

Cleaning
Cleaning is very important in completing the etching process and making
sure that it is successful. Proper cleaning of the PCB ensures you that no
etching solution is left on the board that could damage the followed
design.
Fill another plastic container with clean water.
In the container, soak the etched PCB in the water for a minute. It is
recommended that you clean the board under running water for better
results but cleaning it as mentioned can also be done.
Using the tweezers, remove the soaked PCB and dry it with a clean dry
cloth or tissue.
Remove the remaining masking tape on the board.
If there are still some parts of copper bridging to the other sides, you
might have to redo or re-etch that part.
Testing
You may use tools such as voltmeters with continuity testers to ensure
that the etching and boundaries are properly done.
A reading should not register to the tester to make sure that the etching
process is properly done. If a reading is registered in the tester, it means
that the islands are connected.
As an alternative, you may position the PCB in front of ample light to see

Session Objectives
At the end of the session, you will be able to:
Know the different safety precautions in soldering
Identify the different electronic components in solar night
lamp construction
Perform the different steps in mounting and soldering of
electronic components in a solar night lamp

Introduction
In this lesson, you will be able to follow the safety guidelines
intended in the process of mounting and soldering of electronic
components for the solar night lamp.
You will also be able to identify and properly attached the different
electronic components with the use of different mounting and
soldering techniques.

Occupational Health and Safety

It is important to follow necessary steps that ensure your safety while
constructing the solar night lamp. For each step, make sure that you
are wearing the required protective equipment and following the
proper usage of the tools.
In the process of mounting and soldering, you must wear a face mask
to avoid inhaling the fumes that is produced by the soldering iron. It
is also suggested that you wear protective gloves during the
soldering process but it may make it a bit difficult for you to have a
feel on the soldering and harder to handle the different components
due to their small sizes.

Soldering Resistors
Resistors are one of the most commonly used electronic components
that create specified values of current and voltage in a circuit. There
are different kinds of resistors that vary in size and color depending
on the power that they carry.
Materials Needed:
Soldering iron
Soldering lead
Long nose plier
Wire cutter
Etched PCB board
1 pc. 2W 10 ohm resistor
1 pc. 1/4W 10k ohm resistor
2 pcs. 1/4W 1k ohm resistor
Procedure:
Cut the terminals of resistors to required size (refer to sample). Make
sure that you cut enough of the resistor for it to have a feet-like
structure.
Each resistor has designated islands to connect on the PCB. Refer to
the diagram for the proper positioning of each resistor.
Solder the 2W10 ohm resistor (brown) followed by the 2 1kohm
resistors (red) and lastly the 10k ohm resistor (red).
The resistors should be slightly elevated from the PCB having at least

Soldering Diode
A diode is an electronic component that is used to direct flow of
electricity into one direction and blocks the flow in the opposite
direction. They can also be considered as one-way valves used in
various circuits as a form of protection.
Materials Needed:
Soldering iron
Soldering lead
Long nose pliers
Wire cutter
1 pc. 1N5819 diode
Procedure:
Cut terminals of diode into size enough for it to have a feet-like
structure.
Refer to the diagram for the proper position of the diode on the PCB.
When soldering, make sure that the white strip/line on the body of
the diode is following the proper body orientation (refer to diagram).
Solder the terminals of the diode.
Check if the diode is properly attached on the PCB by gently pushing

Soldering Transistors
Transistors can be considered as a type of switch or gate for electronic
signals and also regulates the current or voltage flow.
Materials Needed:
Soldering iron
Soldering lead
Long nose plier
Wire cutter
1 pc. S9014 transistor
1 pc. IRF510 transistor
Procedure:
Solder general purpose 9014 transistor (Bipolar Junction Transistor)
upright onto the board. The flat side of the transistor should be facing
the IRF510 transistor and will be facing the board when bended.
Solder IRF510 transistor (Metal Oxide Semiconductor Field Effect
Transistor). Refer to the diagram for the proper orientation of the
transistor. Make sure that you follow the proper soldering technique to
properly attach the transistor.

Soldering the Switch

Materials Needed:
Soldering iron
Soldering lead
1 pc. 3 pin switch
Procedure:
Refer to the diagram for the proper position of the switch on
the PCB.
Solder the switch to the PCB taking note of the place of the
terminals.

Mounting the Battery

Materials Needed:
Soldering iron
Soldering lead
Wire cutter
1 pc. lithium-ion 3.7v 2200mAH battery
2 inches of black and red stranded wire
Procedure:
Place the battery on top of the plastic side of the PCB.
Using the glue gun, attach the battery to the board by applying
glue to the sides of the battery.
Solder a black stranded wire to the negative end of the battery
and red stranded wire to the positive end.
Solder the other ends of the wire to the designated island on the
PCB.

SOLDERING THE LED

Materials Needed:
Soldering iron
Soldering lead
Small glass fuse
Glue gun
Glue stick
1 pc. 1W HD LED
1 pc. 1 inch x 1 inch PVC Coupling
12 inches black and red stranded wires
6 inches of inch transparent hose
Platic bottle cap
Procedure:
Hold the LED face down and solder a drop lead on the back metal part.
Solder a drop of lead on the fuse.
Position the fuse with the lead side close to the back of the LED. Heat both to melt the lead and
quickly but safely attach the fuse to the LED. Hold the fuse in place for about 8 seconds to
ensure that the fuse has completely attached itself to the back of the LED.
Cut 12 inches of black and red stranded wires.
Attach the red stranded wire to the positive end of the LED and the black to the negative end.
Cut 6 inches of inch transparent hose.
Prepare a bottle cap where the lamp will be mounted. Bore a hole on the cap to let the wire pass
through.
Insert the stranded wire from the LED lamp into the plastic hose.
Glue the plastic hose to the bottle cap.
Insert a 1 x 1 PVC coupling without thread on top of the cap and let the wire through the
coupling. Apply glue on the cap and the coupling to hold them in place.

Mounting the Solar Module

Materials Needed:
Soldering iron
Soldering lead
Small glass fuse
Glue gun
Glue stick
Epoxy glue
1 pc. 5V 1W solar module
1 pc. 1 inch x 5 inches PVC Blue Pipe
3 inches black and red stranded wires
Procedure:
Prepare the solar module and lay it on the table with the solar cell facing
down to expose the connectors at the back.
Cut 3 length of stranded wires.
Strip the ends of the stranded wire and solder on the positive and the
negative terminals of the solar module.
Heat up the glue gun and drop glue on the soldered terminal connection
of the solar module to hold the wire in place.
Run the wires through the PVC pipe and mount the pipe on the back of
the solar module on the slanted end of the pipe.
Apply epoxy on the edge of the pipe where it meets with the solar
module surface. Hold the pipe in place until the epoxy can hold it in

Session Objectives
At the end of the session, you will be able to:
Identify the proper wiring techniques in creating a solar night lamp
Know the safety precautions in wiring a solar night lamp
Explain how to properly attached the PV module and LED lights
through wirings

Introduction
In this session, you will learn the proper wiring techniques used in the
solar night lamp construction.

Wirings
Wiring the LED Module to the PCB
Solder the positive terminal of the LED to the PCB where the 10ohm
resistor is connected.
Solder the negative terminal of the LED to the designated island on the
PCB.
Wiring the Solar Module to the PCB
Solder the positive terminal of the solar module to the anode of the
diode and the negative wire to the negative foil of the board.
Slowly insert the board into the pipe leaving the switch and lamp
terminals exposed

Assembly of Solar Night Light

Snug fit the solar module PVC pipe into the PVC coupling.
Attach the solar module assembly to the soda bottle to put
together the whole lamp.
Cover the solar module or bring the lamp into a dark room to
test if the solar night light is properly working. Refer to the
testing module for the proper procedure.

Module 4:TESTING,
TROUBLESHOOTING and
MAINTENANCE

Session Objectives
At the end of the session, you will be able to:
Identify the different steps in testing and troubleshooting of the
solar night lamp
Identify the different problems you may encounter in constructing a
solar night lamp
Perform the different steps in troubleshooting the problems
encountered in making a solar night lamp

Introduction
In this lesson, you will learn the different testing process to make
sure that a solar night lamp is properly constructed.
You will also learn to identify the different instances that would
require troubleshooting for solar night lamp and be able to perform
the appropriate troubleshooting procedure.

Testing
Test the solar night lamp if it works to make sure that you properly
assembled the components together.
Procedure:
Make sure that the solar night light is switched on
Cover the solar module or bring the lamp into a dark room. The LED
should light up when the solar module is covered or is in a dark room
Uncover the solar module in a well lit/lighted room or outdoor during
daylight. The lamp should automatically turn off in doing so.

Troubleshooting
The light does not turn ON when the solar module is covered or
the lamp is in the dark.
Check if the switch is ON. Check if the switch has poor connection or
soldered points.
Check the voltage on the terminals of the LED, it should register at
least 3 volts. Check the connection if there is a very low voltage. Fix
possible open or shorted connections and solder points.
If there is 3V or more at the LED terminal, it is possible that the LED
lamp is busted. Replace the LED.
Check if the battery voltage is still above 3V. Allow the battery to
charge of the voltage is low.
The light turns on but does not turn off when the solar module
is exposed to light
Check the PCB of possible short circuits of open connections.
Check if the voltage between the solar module connection points
increases if the solar module is exposed to strong light and decreases if
the solar module is covered from light. If not, the solar module may be
defective. Replace the solar module.
The voltage between the negative and Collector of the transistor should
be zero when the solar module is exposed to light and goes low when