Solar PV Panel Design Course

Lesson 1 • PV Cell Types and Materials

Examines monocrystalline, polycrystalline, and thin-film cell technologies. Connects material properties to efficiency, cost, and application suitability.

Lesson 2 • System Architecture Overview

Introduces grid-tied, off-grid, and hybrid system topologies. Orients students to the full system before detailed component study begins.

Lesson 3 • Photovoltaic Effect and Solar Radiation

Covers the physics of the photovoltaic effect and solar irradiance concepts. Establishes the scientific basis for all subsequent PV design decisions.

Lesson 4 • PV Module Construction and Ratings

Details how cells are assembled into modules and how nameplate ratings are established. Provides the vocabulary needed to read datasheets accurately.

Lesson 1 • Solar Geometry and Sun Path

Explains declination, hour angle, azimuth, and altitude across seasons. Accurate sun-path knowledge drives tilt and orientation decisions in later chapters.

Lesson 2 • Site Survey and Structural Assessment

Teaches physical site inspection, roof load evaluation, and ground-mount soil assessment. Structural findings constrain mounting and array design choices.

Lesson 3 • Irradiance Data Sources and Tools

Surveys satellite-derived and ground-measured irradiance databases and simulation tools. Students learn to retrieve and validate data for a target location.

Lesson 4 • Energy Consumption and Load Profiling

Guides students to analyse utility bills and build hourly load profiles. Load data sets the system size target addressed in Chapter 3.

Lesson 1 • Energy Yield Simulation Methods

Compares simplified hand-calculation methods with hourly simulation software. Students run a simulation and interpret output reports.

Lesson 2 • Array Sizing Fundamentals

Introduces the peak-sun-hour method and offset percentage approach to array sizing. Provides the core calculation framework expanded in subsequent sections.

Lesson 3 • System Losses and Derate Factors

Catalogues soiling, wiring, mismatch, and temperature losses that reduce real output. Accurate derate factors are essential for credible yield estimates.

Lesson 4 • Battery Storage Sizing

Covers depth of discharge, days of autonomy, and round-trip efficiency in storage sizing. Prepares students for hybrid and off-grid designs introduced in Chapter 6.

Lesson 1 • Layout Drawing and Documentation

Produces dimensioned site plans, elevation views, and module placement drawings. Complete documentation supports permitting and construction in later chapters.

Lesson 2 • Module Orientation and Tilt Optimization

Determines optimal azimuth and tilt angles for fixed and adjustable mounting systems. Optimisation balances annual yield, shading, and structural loading.

Lesson 3 • Row Spacing and Inter-Row Shading

Calculates minimum row spacing to limit inter-row shading losses to acceptable levels. Row spacing directly affects land use and system cost.

Lesson 4 • Structural Load Analysis

Applies wind, snow, and dead-load calculations to mounting system design. Structural adequacy is verified before finalising the mechanical specification.

Lesson 1 • DC Wiring and Conductor Sizing

Applies ampacity tables and voltage-drop limits to select DC conductors and conduit. Proper conductor sizing ensures safety and minimizes resistive losses.

Lesson 2 • String Sizing and Inverter Matching

Calculates string voltage and current across temperature extremes to match inverter input windows. Correct string sizing prevents inverter damage and yield loss.

Lesson 3 • Inverter Technology Selection

Compares string, central, microinverter, and power-optimiser topologies for different applications. Inverter choice affects yield, monitoring, and maintenance strategy.

Lesson 4 • Grounding and Bonding Design

Establishes equipment grounding, system grounding, and lightning protection requirements. Proper grounding protects personnel and equipment from fault currents.

Lesson 1 • Off-Grid System Validation and Testing

Performs load bank testing, autonomy verification, and generator transfer testing. Validation confirms the system meets design specifications before client handover.

Lesson 2 • Battery Bank Design and Selection

Selects battery chemistry, configures series-parallel banks, and sizes for autonomy and cycle life. Battery bank design must align with the BMS integration covered in Chapter 6.

Lesson 3 • Generator Sizing and Integration

Sizes backup generators and designs automatic transfer and charging logic. Generator integration ensures reliability when solar and battery resources are insufficient.

Lesson 4 • Hybrid Inverter and Control Strategy

Configures hybrid inverter operating modes, priority logic, and demand response settings. Control strategy determines how solar, battery, grid, and generator sources interact.

Lesson 1 • Battery Management System Integration

Connects battery management systems to inverters for charge control and state-of-charge monitoring. BMS integration is foundational for hybrid and off-grid systems in Chapter 7.

Lesson 2 • Transformer and AC Collection Design

Designs step-up transformers, AC collection circuits, and medium-voltage connections for larger systems. Transformer sizing and impedance affect power quality and losses.

Lesson 3 • Grid Interconnection Requirements

Covers anti-islanding, voltage and frequency ride-through, and interconnection application processes. Grid compliance is mandatory before any system can export power.

Lesson 4 • Commissioning and Grid Energisation

Executes pre-energisation checks, inverter startup sequences, and utility witness testing. Commissioning validates that the electrical design performs as specified.

Lesson 1 • Long-Term Performance and Asset Management

Projects 25-year energy output, degradation curves, and repowering decision points. Asset management planning maximises return on investment over the system lifetime.

Lesson 2 • Fault Detection and Diagnostics

Applies string-level monitoring, IV curve tracing, and thermal imaging to locate faults. Early fault detection minimises energy loss and prevents equipment damage.

Lesson 3 • Monitoring System Architecture

Designs data acquisition systems, communication networks, and SCADA integration for PV plants. Monitoring architecture determines the granularity of performance data available.

Lesson 4 • Preventive Maintenance Procedures

Schedules and documents cleaning, torque checks, electrical testing, and vegetation management. Preventive maintenance sustains performance ratio and extends equipment life.