Mock Installation Project I SS3 Solar Photovoltaic Installation & Maintenance Lesson Note

Class: SS3

Subject: Solar Photovoltaic Installation and Maintenance

Topic: Group Practical Design & Mock Installation Project

The Project Overview

For this practical, we are moving away from the blackboard. You will be divided into groups of five. Your mission is to design and “mock-install” a solar power system for a small 2-bedroom apartment.

What is a “Mock Installation”? It means we will go through every step a real professional takes—from talking to the customer to connecting the final wire—but we will do it in a controlled classroom environment to ensure everyone stays safe while learning.

Group Roles:

1. Project Manager: Keeps the team on schedule and handles the “Customer Interview.”
2. Sizing Specialist: Handles the math and chooses the right battery/panel sizes.
3. Safety Officer: Ensures everyone wears gear and checks for wire “hotspots.”
4. Installer (2 Students): Handles the physical mounting of panels and battery wiring.

Step 1 – The Site Survey & Load Audit

Before we touch a single screw, we must know what the house needs. A doctor doesn’t give medicine without checking the patient; a solar technician doesn’t install panels without a Load Audit.

Practical Task for the Group:

• List every appliance in the “Mock Apartment” (e.g., 5 LED bulbs, 2 standing fans, 1 LED TV, 1 Laptop).
• Check the “Wattage” of each.
• Estimate how many hours each will run.

The “Real World” Check: Look at the roof area provided for your group. Is there a chimney or a water tank casting a shadow? Use your Compass to find South. If you place your panels facing North in Nigeria, your project will “fail” because the batteries won’t charge fully.

Step 2 – System Design & Wiring Plan

Now that you have your numbers, you need to draw your map. In the solar world, we call this a Schematic Diagram.

Your Design Must Include:

• The Panel Array: Will you connect them in Series (to increase Voltage) or Parallel (to increase Amps)?
• The Protection Box: Where will you put the DC Breakers and the Surge Protector?
• The Battery Bank: How will you connect your two 12V batteries to match your 24V Inverter? (Hint: Use Series connection!).

Step 3 – The “Mock” Installation Phase

Now, the physical work begins. Even though we are in a workshop, treat every wire as if it is “Live.”

The Golden Rules for your Group:

1. Connect the Battery First: Always connect the battery to the Charge Controller before you connect the panels. If you do it the other way around, you might fry the controller’s “brain.”
2. Tighten the Terminals: A loose bolt creates heat. Heat creates fire. Use your spanners to make sure nothing wiggles.
3. Cable Management: Don’t let wires hang like “spaghetti.” Use cable ties to keep the installation neat and professional.

Final Testing & Presentation

Once the last wire is in place, it’s time for the Commissioning. This is the most exciting part!

The Checklist for Success:

• Voltage Test: Use your Multimeter to check the battery voltage.
• Charging Test: Does the controller show an “Arrow” pointing from the panel to the battery?
• Load Test: Switch on the bulbs. Do they flicker? Does the Inverter make a “happy” hum or a “sad” beep?

Group Presentation: Your group will stand by your project and explain:

• Why did you choose this specific battery size?
• What was the biggest challenge you faced during wiring?
• How did the Safety Officer ensure no one got shocked?

Teacher’s Note: Professionalism counts. A system that works but looks messy will get lower marks than a neat, well-organized system.