Lesson 1: What is Solar Energy?

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

Lesson 1: What is Solar Energy?

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 sunlight’s 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.

Lesson 2: Determining Power

Consumption Demands
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.

o 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.

o Add the Watt-hours needed for all appliances together to get the total
Watt-hours per day which must be delivered to the appliances.

 Calculate total Watt-hours per day needed from the PV modules

o After determining the total watt-hours per day, multiply it by 1.3 (the
energy lost in the system). In doing so, you’ll be able to get the total Watt-hours per
day that needs to be provided by the panels.

Lesson 3: Sizing the PV modules

 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

o 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.

 Calculate the number of PV panels for the system

o 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.
 Lesson 4: Battery Sizing
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, you’ll get the required Ampere-hour capacity of
the deep cycle battery.

Lesson 5: Solar Charge Controller Sizing

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.

Lesson 1: Ohm’s Law

Objectives
 At the end of the session, you will be able to: 

 Know the basic scientific laws involving electronics

 Identify Ohm’s and Power law
 Explain the formulas and computations involved in understanding the different
scientific laws

Introduction
In this lesson, you will learn the different scientific lessons involved in basic electronics
and be familiarize with the formula that goes with it.

Lesson 1: Ohm’s Law

Ohm’s Law
Ohm’s 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.

Lesson 2: Power Law

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 [2]
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 = I2 x R [2]
Power law can be simply stated as:

P = V x I [2]

Lesson 3: Electronic Components

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

Lithium-ion Battery

You will be using a 3.7V 220mA 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

 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

3 Pin 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

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:

1. 2 pieces of 1 k ohm ¼ W resistor

2. 1 piece of 10 k ohm ¼ W resistor
3. 1 piece of 2W 10 ohm resistor
Diodes
 1N5819 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. For the solar night lamp
you will be using the 1N5819 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

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.

Lesson 4: Testing Instruments

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

Analog 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.

Lesson 5: Basic Soldering Procedure

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

Watch VIDEO
1. Clean the surface of the PCB

o A clean surface is very important for a strong, low resistance solder joint.

 Component Placement

o 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

o 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

o Once the component lead and solder pad have heated up, you are ready
to apply solder.

o 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.
 o 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

o Once the joint is made, you should inspect it. Check for shorts with
adjacent pads or poor flow. If the joint checks out, move on to the next.

Assembly of Solar Night Light

Watch Video
1. Snug fit the solar module PVC pipe into the PVC coupling.
2. Attach the solar module assembly to the soda bottle to put together the whole
lamp.
3. 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 pocedure.

Lesson 1: Printed Circuit Board

Preparation
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 odour of the solution will be avoided.

Printed Ciruit Board Preparation (Part 1)

Watch video
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.

1. Cut printed circuit board (PCB) based to the required size of 1 inch by 3 inches.
2. Cover the copper side of the board with a layer of masking tape.
3. 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.
4. 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, you’ll be removing the unnecessary copper particles from the PCB thus
permanently transferring the design on the board. You’ll 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.

1. Use gloves before using the etching solution (ferric chloride).

2. Using tape, attached the PCB at the bottom of the plastic container copper side
up.
3. Pour the required quantity of the etching solution in a plastic container.
4. Soak the designed PCB into the etching solution for about 10 to 20 minutes.
5. Through visual inspection, check if the etching is completed. The exposed
copper parts of the board should be matte in color signifying that the copper is
removed from the board and the plastic part is exposed.

Printed Ciruit Board Preparation (Part 2)

 Watch Video
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.

1. Fill another plastic container with clean water.

2. 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.
3. Using the tweezers, remove the soaked PCB and dry it with a clean dry cloth or
tissue.
4. Remove the remaining masking tape on the board.
5. 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.

1. 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.
2. As an alternative, you may position the PCB in front of ample light to see if the
etching is done correctly.

Lesson 2: Soldering Electronic

Components
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
Watch video

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:
1. Soldering iron
2. Soldering lead
3. Long nose plier
4. Wire cutter
5. Etched PCB board
6. 1 pc. 2W 10 ohm resistor
7. 1 pc. 1/4W 10k ohm resistor
8. 2 pcs. 1/4W 1k ohm resistor

Procedure:
1. 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.
2. Each resistor has designated islands to connect on the PCB. Refer to the
diagram for the proper positioning of each resistor.
3. Solder the 2W10 ohm resistor (brown) followed by the 2 1kohm resistors (red)
and lastly the 10k ohm resistor (red).
4. The resistors should be slightly elevated from the PCB having at least 1-2mm
space between the body of the resistor and the board.

Soldering Diode
Watch Video
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:
1. Soldering iron
2. Soldering lead
3. Long nose plier
4. Wire cutter
5. 1 pc. 1N5819 diode

Procedure:
1. Cut terminals of diode into size enough for it to have a feet-like structure.
2. Refer to the diagram for the proper position of the diode on the PCB.
3. When soldering, make sure that the white strip/line on the body of the diode is
following the proper body orientation (refer to diagram).
4. Solder the terminals of the diode.
5. Check if the diode is properly attached on the PCB by gently pushing it side to
side.

Soldering Transistors
Watch Video
Transistors can be considered as a type of switch or gate for electronic signals and also
regulates the current or voltage flow.

Materials Needed:
1. Soldering iron
2. Soldering lead
3. Long nose plier
4. Wire cutter
5. 1 pc. S9014 transistor
6. 1 pc. IRF510 transistor
 Procedure:
1. 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.
2. 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
Watch video
Materials Needed:
1. Soldering iron
2. Soldering lead
3. 1 pc. 3 pin switch

Procedure:
1. Refer to the diagram for the proper position of the switch on the PCB.
2. Solder the switch to the PCB taking note of the place of the terminals.

Mounting the Battery

Watch video
Materials Needed:
1. Soldering iron
2. Soldering lead
3. Wire cutter
4. 1 pc. lithium-ion 3.7v 2200mAH battery
5. 2 inches of black and red stranded wire

Procedure:
1. Place the battery on top of the plastic side of the PCB.
2. Using the glue gun, attach the battery to the board by applying glue to the sides
of the battery.
3. Solder a black stranded wire to the negative end of the battery and red stranded
wire to the positive end.
4. Solder the other ends of the wire to the designated island on the PCB.
 Soldering the LED
Watch video
Materials Needed:
1. Soldering iron
2. Soldering lead
3. Small glass fuse
4. Glue gun
5. Glue stick
6. 1 pc. 1W HD LED
7. 1 pc. 1 inch x 1 inch PVC Coupling
8. 12 inches black and red stranded wires
9. 6 inches of ½ inch transparent hose
10. Platic bottle cap

Procedure:
1. Hold the LED face down and solder a drop lead on the back metal part.
2. Solder a drop of lead on the fuse.
3. 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.
4. Cut 12 inches of black and red stranded wires.
5. Attach the red stranded wire to the positive end of the LED and the black to the
negative end.
6. Cut 6 inches of ½ inch transparent hose.
7. Prepare a bottle cap where the lamp will be mounted. Bore a hole on the cap to
let the wire pass through.
8. Insert the stranded wire from the LED lamp into the plastic hose.
9. Glue the plastic hose to the bottle cap.
10. 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

Watch Video
Materials Needed:
1. Soldering iron
2. Soldering lead
3. Small glass fuse
4. Glue gun
5. Glue stick
6. Epoxy glue
7. 1 pc. 5V 1W solar module
8. 1 pc. 1 inch x 5 inches PVC Blue Pipe
9. 3 inches black and red stranded wires

Procedure:
1. Prepare the solar module and lay it on the table with the solar cell facing down to
expose the connectors at the back.
2. Cut 3” length of stranded wires.
3. Strip the ends of the stranded wire and solder on the positive and the negative
terminals of the solar module.
4. Heat up the glue gun and drop glue on the soldered terminal connection of the
solar module to hold the wire in place.
5. 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.
6. 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 position.

Lesson 3: Wirings
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
Watch Video
Wiring the LED Module to the PCB
1. Solder the positive terminal of the LED to the PCB where the 10ohm resistor is
connected.
2. Solder the negative terminal of the LED to the designated island on the PCB.

Wiring the Solar Module to the PCB

1. 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.
2. Slowly insert the board into the pipe leaving the switch and lamp terminals
exposed

Lesson 1: Testing the Solar Night Light

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:
1. Make sure that the solar night light is switched on
2. 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
3. Uncover the solar module in a well lit/lighted room or outdoor during daylight. The
lamp should automatically turn off in doing so.
 Lesson 2: Troubleshooting the Solar
Night Light
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 the solar module is
covered. If not, transistor may be defective. Replace the transistor.