Solar System For Railway Signaling

CAMTECH/S/2006/SP/1.
0 1
SOLAR PANEL
Introduction
Environmental pollution like deposition of carbon

dioxide in the atmosphere is increasing day-by-day
due to use of conventional energy sources such as
coal, petrol, diesel, etc. Also sources of such
conventional and non-renewable energy are
diminishing continuously on Earth, the formation of
which is a long process. Hence a need for alternative
energy sources was felt such as Wind energy, Bio-
energy, Solar energy. These are called as non-
conventional or renewable energy sources. Of which
Solar energy, which is abundant in nature and free of
cost, is considered to be the best and most popular
one. Solar energy is obtained through the use of
Solar cells. The Solar cells convert sunlight into
electrical energy, based on the principle of
photovoltaic effect.. Therefore, solar cells are
replacing other conventional energy devices and
finding way in wide range of applications.
Indian Railways is one of the biggest Central

Government organizations working under a single
management, which has biggest network all over the
country. It requires lot of energy to run the
equipments and engines, which are mainly operated
through diesel and electricity. As we know that
electricity is the best form of energy, which is used
widely in the operation of rolling stock as well as
Signalling gears such as Signals, Point machines,
Relays, Block instruments, Axle Counters etc. But at
Solar Panel March 2006
CAMTECH/S/2006/SP/1.0 2
many places it poses problems due to non-
availability of electricity for long period or erratic
power. It is well established that solar power is the
best-known conventional source of energy, which
can immediately be converted into electricity by
solar photovoltaic modules. The electricity so
obtained can directly be used to charge the batteries
used for equipments associated with the above-
mentioned gears. These batteries can be charged
even at the remote places where grid supply is not
available round the clock or not available at all. Thus
solar photovoltaic power may prove a boon for the
Railways in future. Therefore it is considered to
switch over to non-conventional sources of energy.
For this purpose, it is well thought to train the
manpower for using the system of non-conventional
energy.
1.1 Advantages and Disadvantages of Solar

Panel :
Advantages
 Fuel source for Solar Panel is direct and endless so

no external fuels required.
 Sunlight - free of cost.
 Unlimited life of Solar Modules , fast response and
high reliability.
 Can operate under high temperature and in open.
 Inherently short circuit protected and safe under any
load condition.
 Pollution free.
 Minimum Maintenance
 Independent working
 Operation is simple and no electrochemical reaction

and no liquid medium.
 Noise-free as there are no moving parts.
 No AC to DC conversion losses as DC is produced
directly.
 No transmission losses as installed in the vicinity of
the load.
 Suitable for remote, isolated and hilly places.
 Suitable for moving loads/objects
 Since it is in modular form, provision of future
expansion of capacity is available.
 It can generate powers from MilliWatts to several
MegaWatts.
 It can be used almost everywhere from small
electronic device to large scale MW power
generation station.
 It can be installed and mounted easily with minimum
cost.
Disadvantages
 Initial cost is high

 Dependent on sunlight
 Additional cost for storage battery.
 Climatic condition, location, latitude, longitude,
altitude, tilt angle, ageing, dent, bird dropping, etc.
affect the output.
 It has no self-storage capacity.
 Manufacturing is very complicated process.
 To install solar panel large area is required.

1. Photo Voltaic effect
Electricity can be generated directly from sunlight,

by a process called photovoltaic effect, which is
defined as the generation of an electromotive force as
a result of the absorption of ionizing radiation.
The photo voltaic effect can be observed in almost

any junction of material that have different electrical
characteristics, but the best performance to date has
been from solar cells made of Silicon.
DC Electricity
Fig 1:Photo Voltaic Effect

2. Solar Cell: Construction & Working
The basic building block of a photovoltaic system is

the Solar Cell, a semiconductor device having a
simple p-n junction and which when exposed to
sunlight produces DC electricity. The solar cell is
made up of “Semi-Conductor” materials that are
processed to make the device photovoltaic. The solar
cell is made of single crystal silicon, polycrystalline
and amorphous Silicon with an area of a few sq.
centimeters to 200 sq. centimeters and even more. A
thin p type silicon wafer is taken through phosphorus
diffusion process and by screen-printing technology
electrodes are made.
The P-N junction of the solar cell gives rise to diode

characteristics. Hence a solar cell is a PN junction
device on which front and back electrical contacts
are screen-printed. A sketch of typical psuedo-square
solar cell is shown in Fig.2 (a) & (b). The side, which
has negative polarity, is taken as front side and that
which has positive polarity is taken as backside. The
front or Negative side is exposed to sunlight for
conduction to take place.
Two Tinned copper strips work as terminal leads for

interconnection to other cells. For collection of
charge from the cell and conduction to terminal leads
on negative side, Silver Oxide lines are screen
printed horizontally and these are joined to terminal
leads at close spacing (refer Fig 2 a). These lines
cover only 5% of the total area of the cell, so that
these do not pose any hindrance to the exposure of
Sunrays. The back or Positive side is not exposed to
sunlight; hence Aluminium is coated on whole
surface for better conductivity (refer Fig 2 b).
Aluminium is coated instead of Silver Oxide as latter
is expensive hence not economical.
The operation of solar cells involves these major

processes:
i) Absorption of sunlight into semiconductor

materials
ii) Generation of charge carriers.
iii) Separation of +ve & -ve charges to different
regions of the cell to produce e.m.f.
Tinned Copp er
Strips
Silver Oxide lines
Fig 2 (a) Sketch showing front view of typical pseudo

square solar cell

Tinned Copper Strips
Aluminium coating
Fig 2 (b) Sketch showing rear view of typical pseudo square

solar cell
Fig. 2 (c): Solar Cell: Actual view (CEL make)

4. Solar Photo Voltaic (SPV) Module
The power generated by a single cell is small and

therefore several cells are interconnected in
series/parallel combination to get the required
voltage and current. When a number of solar cells are
connected in series to get a specific voltage the unit
so formed is called as Solar Module. Charging
batteries is the primary use of SPV module.
Therefore normally 36 cells are joined in series to
form a standard module, which is capable of
charging 12 volts battery.
A terminal box is provided on the backside of the

module for external connections. A Bypass diode is
connected across +ve and –ve in the terminal box.
Cathode of the diode will be at +ve terminal and
Anode will be at –ve terminal of the module. This
diode protects the module cells from overheating due
to shadowing of the module or any cell breakage.
Generally rating of bypass diode is 1.52 times of the

maximum current of module. The Repetitive Reverse
Peak Voltage Vrrm of the diode should be double the
string open voltage.
For Indian Railways Solar Photovoltaic Module is
manufactured as per RDSO Specification No. IRS:S
84/92. A typical solar module is shown in Fig 3.

Bypass Diode
Blocking Diode
-ve +ve
Fig 3: Solar Module

5. Solar Panel
A Solar panel consists of a number of solar modules,

which are connected in series and parallel
configuration to provide specific voltage and current
to charge a battery. A diode is connected on the +ve
terminal of such string in forward bias. This is called
Blocking diode. This diode is provided so that in
daytime current can flow from module to battery, but
at night or in cloudy day current should not flow
back from battery to module or from one string to
another string Drawing shown in Fig 4 below
illustrates a Solar panel:
Blocking
Diode
+ + + +
- - - -
+ + + +
Charge Controller
Battery set
- - - -
+ + + +
- - - -
+ + + +
Bypass
Diode
- - - -
Fig 4: Solar Panel

5.1 Fabrication of Module
In a Solar module cells are joined by tinned copper

strips. 36 cells are connected in series to charge 12
Volts battery. Now this string is sandwitched
between Ethyl Vinyle Acetate (EVA) sheets, a kind
of thermo-plastic material. It serves as an
encapsulant and it is provided to protect the cells
from weather conditions. After this a Polyester
Tedelar Polyester sheet (built in three layers) is kept
at the bottom and a toughened glass at the top.
Toughened glass of high transmittance is used which
has less iron content. Also its refractive index
matches with that of EVA hence deviation of
sunlight is less. This whole unit is laminated in
special equipment at 140 deg. C by which all the
moisture and air is drawn out and the EVA sheets are
coated uniformly all over the cells and become
transparent. To prevent damage to the glass the
laminate is further fitted inside an anodized
Aluminium channel frame. Terminals are provided
inside a junction box for external connections at the
backside of this frame. This completes the
fabrication of solar panel. The solar modules
supplied to Railways are of the rating 70 Watts, 35
Watts, 20 Watts and 10 Watts. 80-Watt module is
under certification of Railways. The module cross-
section comprising of glass and encapsulating
material such as EVA, Toughened glass and Tedlar
are shown in Fig No.5.

Toughened Glass
EVA sheet
Solar cell string
EVA sheet
Polyester Tedlar Polyester
Aluminum Frame
Fig 5: Cross section of a Solar Module
5.2 Types of Solar Panels :
Solar panels are classified on the basis of the following

points :
1) Crystalline Silicon (Mono/Poly/Amorphous)

2) Different Size or Area of cells
3) Type of cells & nos. (Rectangular/Circular/
Square/ Pseudo-square/Semi-circular etc.)
4) Power (High/Mid/Low range)
5) Connection of cells (Series/Parallel)
6) Specified use
6. Testing before installation:
Before installation the solar panels are tested at the

manufacturing unit to check for the following
parameters:
• Voc-Open circuit voltage

• Isc-Short circuit current
• Vmax- Maximum Voltage
• Imax- Maximum Current
• Pmax- Maximum power at Standard Test

Conditions or Peak Power Output
The following table shows typical user’s

specifications of different modules:
TABLE A
Peak Nom Open Short Max. Max.

Power inal Circuit Circuit Voltage Current
Output Volt Voltage Current (Vmax) (Imax)
(Pmax) age (Voc) (Isc) at Pmax at Pmax
4W 6V >11.5V >0.63A 8.5 V 0.47 A
4W 12V >21V >0.3A 16.7 V 0.23 A
8W 12V >21V >0.56A 16.7 V 0.47 A
10W 12V >21V >0.70A 16.7 V 0.59 A
12W 12V >21V >0.84A 16.7 V 0.71 A
18W 12V >21V >1.26A 16.7 V 1.07 A
35W 12V >21V >2.4A 16.7 V 2.09 A
40W 12V >21V >2.7A 16.7 V 2.39 A
50W 12V >21V >3.3A 16.7 V 2.99 A
65W 12V >21V >4.0A 16.7 V 3.89 A
70W 12V >21V >4.5A 16.7 V 4.19A
75W 12V >21V >5.0A 16.7 V 4.49 A
90W 12V >21V >6.0A 16.7 V 5.38 A
The above values are at standard testing conditions

such as 25-degree cell temperature and 100-mW/Sq.
cm solar radiation. The output will be reduced as
temperature rises and intensity of sunlight reduces.
Although accurate power is measured with the help

of Module Tester at supplier’s end, however to check
working of module Voc and Isc can be measured at
site as shown in Fig.7 (a) & (b) by simple multimeter
in two different modes i.e. Current mode and Voltage
mode when module is placed in sunlight.
A V
+ _ + _
Solar M odule Solar M odule
Measurement of:
(a) Isc (b)Voc
Fig 7:Testing before installation
The solar panel is kept in such a position that it

receives maximum sunlight.
The typical I-V curve of a 35-Watt module with 36

series connected cells is illustrated in Fig 8.

MODULE PERFORMANCE AT 25 DEG. C & 100 MW/Sq cm.

3000.0
2400.0
1800.0
Amps.
1200.0
Isc : 2.44 Amp.

Voc : 21.38 volts
600.0
FF : 70.31%
I load : 2.21 Amp.
V load : 16.00 volts
P load : 35.43 watts
0.0000
0.0000 6.0000 12.0000 18.0000 24.0000 30.0000
Volts
Fig 8 : IV curve of a 35 watt Solar module
7. Installation
Solar modules are to be installed firmly and

permanently on metallic structures. The structures
depend on the application and size of the system. For
smaller systems like solar home systems, simple
module mounting structures are used. For systems
like solar streetlights, solar powered signal lighting,
solar pumps etc. pole mounting module frames are
used. For bigger systems like solar power plants and
Solar powered Railway signalling installations,
bigger array mounting structures are used.

The installation of Solar Power System involves the
following major steps:
 Civil Foundation Job

 Assembly and fixing of
support structure.
 Mounting of Solar Modules on
the Support Structure.
 Installation of Battery Bank.
 Interconnection of SPV panel,
Charge Control Unit, Battery Bank and Load
(explained in para 9 of page 22).
 Earthing of Lightning
Protection Unit.
The Solar panels are generally installed in such a

way that they can receive maximum direct sunlight
without shade from any building/trees nearby falling
on them at any part of the day.
As we know that the Sun rises in the East and sets in the
West as a result of Earth’s rotation around its own axis.
Also the Earth revolves around the Sun. Due to these two
movements there is variation in the angle at which the
Sun’s rays fall on Earth’s surface over a year. At any
particular place on Earth this variation in angle in one
year may be upto 45 degrees. Considering these facts the
following guidelines are to be kept in mind while
installing solar panels:
a. Solar panels should be installed at an angle of

‘(LATITUDE of the place + 10) degree’ from
horizontal. For example, New Delhi has a Latitude of
26 degree, hence any solar panel in New Delhi is to
be installed at an angle of 26 + 10=36 degree
inclined to horizontal.
b. Solar panels should be installed South facing in the

Northern hemisphere and North facing in the
Southern hemisphere. Since India is in the Northern
hemisphere, Solar panels will be installed always-
South facing in our country. The directions North-
South may be found with the help of Magnetic
Compass. The photograph given in Fig .9 illustrates
this.
Fig. 9 : A Solar Panel installation
c. Any obstruction (such as tree or building) should be

avoided in East, West or South of the place of
installation. The following is the criteria:
i. East or West: The distance between
solar panel and obstruction should be more than
double the height of obstruction.

ii. South: The distance should be more
than half the height of obstruction.
d. The support for the Solar panel need to be a robust

one and should not be accessible to general public. It
should be so installed that rainwater, bird dropping,
leaves etc. do not accumulate and the top surface can
be cleaned easily.
8. Main Components of Solar Photo Voltaic

System:
The solar power system consists of the following

components:
8.1. Solar array.

8.2. Battery Bank
8.3. Solar Charge Controller
8.4. Inverter (DC to AC)
8.5. Converter (DC to DC)
8.6. Solar Module Mounting Structure
8.7. Cables.

du r
le
Mo ola
S
DC Loads
(Relays, Blocks
Points etc.)
Solar Charge
Controller
Inverter AC Loads
(DC to AC)
(Signals, Tracks
Panel indications)
Battery
Fig.10: Block diagram of Solar Photo Voltaic System

8.1 Solar Array:
Consists of series/parallel combination of modules,

which are mounted on the metallic structure in sunny
and shadow free area at a fixed angle as
recommended by designer. All the modules will face
the South in Northern hemisphere. Cables from the
array area will come to the control and battery room
through junction boxes from panels of modules.
8.2 Battery Bank:
The Sun is not always available and it is not regular.

However, loads are to be fed any time of the day.
Therefore power should be stored in a battery bank.
Stationary Lead acid battery as per IRS: S 88/93 or
latest of specified capacity will be provided. The
capacity of this battery bank is given in Ampere-
Hour (AH) and bus bar voltage. The bus-bar voltage
is decided by the voltage requirement of the load.
8.3 Solar Charge Controller
Charge controller is the interface between Array and

battery bank. It protects the battery from
overcharging and moderate charging at finishing end
of charge of battery bank. Therefore it enhances the
life of the battery bank. Also, it indicates the
charging status of batteries like battery under-
charged, overcharged or deep discharged by using
LEDs. Some switches and MCBs are also provided
for manual or accidental cut-off of charging. In some
charge controllers load terminals are also provided
through a low battery charge cut-off device so that it
can protect the battery bank from deep discharge.
Solar Charge Controller units for Indian Railways are
manufactured as per RDSO Specification
No.RDSO/SPN/187/2004.
The front view of a typical CEL make Charge

Controller is shown in Fig.11
Fig 11: Front view of a Charge Controller
8.4 Inverter (DC to AC)
Sometimes, some of the equipments require AC

power supply, and then we have to use an Inverter,
which can give AC output of the required voltage,
current and frequency. For this purpose Railways
specify the input/output specification of the inverter
to the manufacturer. Inverter may be a separate unit
as per IRS: S 82/92 with amendment 2 or latest or it
may be integrated with IPS system as per
RDSO/SPN/165/2004 with amendment 4 or latest.

8.5 Converter (DC to DC)
Sometimes, if different DC voltage levels are required

to operate some equipment, then a DC-to-DC
Converter is required. For this purpose railway will
specify the voltage of the battery bank and output
voltage of the converter so that equipment of different
voltage may be operated.
This is applicable for signalling loads where different
DC supplies are required such as 12 Volts, 24 Volts,
60 Volts etc.
8.6 Solar Module Mounting Structure
This is made up of galvanized iron frames and

angles. In this structure flexibility is provided to
change the module-mounting angle seasonally. This
structure is grouted by small civil work and modules
are mounted subsequently. Also, this mounting
structure should be earthed suitably at several places
if voltage of the array is more than 50 Volts.
Provision of earthing shall be done as follows:
The installation shall have proper earth terminals and
shall be properly earthed.
Zonal Railways shall provide earthing arrangement
as per IS:S 3043 and directions issued by RDSO for
Lighting and Surge protection for signalling
equipment vide letter No. STS/E/SPD dated
22.06.2004. The earth resistance shall not be more
than 2 ohm. Earth provided shall preferably be
maintenance free using earth resistance improvement
material.

8.7 Cables:
We require different types of cables to connect

module to module, modules to charge controller,
charge controller to battery, battery bank to inverter
and inverter to load or connect battery to load as
required. The cable size used for interconnection of
SPV module, Charge Controller and battery shall be
minimum 2 X 25 sq. mm Cu. Cable.
As far as some hardware is concerned the screws and
bolts/nuts are of Chrome plated, stainless steel and
brass so that rusting should not be take place.
9. Electrical Interconnections
The connections to the charge control unit are to be

made in the FOLLOWING SEQUENCE ONLY:
Connect at FIRST one end of the 2 core cable supplied

with the unit, to the charge controller at the terminal
marked ‘B’ +ve with ‘Red Wire’ and the terminal
marked ‘B’ –ve with ‘Black Wire’ then connect the
other end of the cable to the respective terminal of the
Battery Bank. Check the glow of LED marked ‘BATT
REV’, if it is glowing reverse the connection.
Connect the SPV array output to the terminals at

‘SPV-IN’ position marked on Charge controller unit.
LED marked ‘CHG ON’ should glow.
Switch off the MCB provided in front face. Connect
the load to the terminals at ‘LOAD’ position marked
on the unit. Then switch ON the MCB.

While disconnecting the Charge Controller, the reverse
sequence is to be followed.
The SPV array and battery bank are to be connected to

the Charge Control Unit using minimum 2 X 25 sq.
mm. size Cu. cable. The thimbles, required for
crimping at the cable ends after cutting the required
lengths are being supplied separately.
A typical diagram showing interconnections among
SPV array, Lightening protection unit, SPV Charge
Controller, Battery and Load is given in Fig. 12 below:
PU 360
SPV in SPV out Gnd
+ - + - SC-351 CI
A L B B L A
+ + + - - -
SPV Panel
Battery
To load
LIGHTNING PROTECTION UNIT

Fig 12: Interconnection diagram
10. Operation
Operation of the Solar power source is very simple.

Once the system is installed, CHG. ON (Green) LED
will glow during daytime and will indicate that the
power is available for charging Battery Bank from
SPV panel. Connect the equipment to be operated on

solar power to the SPV Charge Control Unit at
terminals marked ‘LOAD’ position.
11. Maintenance
 Solar panels require virtually no maintenance.

However once a fortnight the surface of the panels
should be wiped clean with wet rag to remove
dust, fallen leaves, bird dropping etc. Only water to
be used and no other cleaning agent.
 With Solar Panel Secondary battery maintenance
becomes minimum. Still general periodical
maintenance of battery should be carried out in
usual manner and as per maintenance manual.
12. Solar Panel Requirement for IPS System at

PI Station in Non-RE Area
RDSO has standardized the Solar Panel requirements

for IPS System at Panel Interlocked Station in Non-
RE area based on the assumption that all three
sources of supply i.e. solar power, AC commercial
supply and DG set supply will be utilized everyday
for running signalling system at a station. Battery
capacity has already been specified as 300 AH for
IPS system in non-RE area. These requirements are
separately worked out for up to 3 line station, 4 line
station, 6 line station and 4 line station with DC LED
Signals, and are tabulated in Table B below:

TABLE B
Sr Description Up to Up to 4 Up to 6 Up to 4
3 line line line line
station station station station
with DC
LED
signal
1. Approximate 13A 22A 28A 16A
Signalling load
(AC + DC)
except track
circuit at 110 V
2. Required from solar power (in AH)

a. for 12 hrs. load 12x13= 12x22= 12x28= 12x16=
per day 156 AH 264 AH 336 AH 192 AH
b. for 10 hrs. load 10x13= 10x22= 10x28= 10x16=
c. for 08 hrs. load 08x13= 08x22= 08x28= 08x16=
d. for 06 hrs. load 06x13= 78 06x22= 06x28= 06x16=
per day AH 132 AH 168 AH 96 AH
3. SPV requirement for 110 V system
i) Derating factor 10% (0.9) 10% 10% 10% (0.9)
of Solar Panel (0.9) (0.9)
ii) Derating factor 10% (0.9) 10% 10% 10% (0.9)
of Battery (0.9) (0.9)
efficiency
iii) Sun availability 5 Hrs. 5 Hrs. 5 Hrs. 5 Hrs.
assumed
iv) Charging current 4.2 A 4.2 A 4.2 A 4.2 A
of Solar panel
v) No. of 12 V, 70 W Solar Panels required in parallel
a. for 12 hrs. load 156/ 264/ 336/ 192/
per day (0.9X0.9X (0.9X0. (0.9X0.9 (0.9X0.9
5X4.2)=1 9X5X4. X5X4.2) X5X4.2)
0 Nos. 2)=16 =20 Nos =12 Nos
Nos

with DC
LED
signal
b. for 10 hrs. load 130/ 220/ 280/ 160/
per day (0.9X0.9X (0.9X0. (0.9X0.9 (0.9X0.9
5X4.2)=0 9X5X4. X5X4.2) X5X4.2)
8 Nos. 2)=13 =17 Nos =10 Nos
Nos
c. for 08 hrs. load 104/ 176/ 224/ 128/
per day (0.9X0.9X (0.9X0. (0.9X0.9 (0.9X0.9
5X4.2)=0 9X5X4. X5X4.2) X5X4.2)
7 Nos. 2)=11 =14 Nos =08 Nos
Nos
d. for 06 hrs. load 78/ 132/ 168/ 96/
per day (0.9X0.9X (0.9X0. (0.9X0.9 (0.9X0.9
5X4.2)=0 9X5X4. X5X4.2) X5X4.2)
5 Nos. 2)=08 =10 Nos =06 Nos
Nos
vi) No. of 12V, 70W 9 9 9 9
Solar panel
required
vii) Total solar panel required (nos.)
a. for 12 hrs. load 90 144 180 108
per day
b. for 10 hrs. load 72 117 153 90
per day
c. for 08 hrs. load 63 99 126 72
per day
d. for 06 hrs. load 45 72 90 54
per day
4. Area requirement for fixing solar panels (size approx. 1.2
mx0.55m per panel) in square meter
a. for 12 hrs. load 60 95 119 72
per day
b. for 10 hrs. load 48 78 101 60
per day
with DC
LED
signal
c. for 08 hrs. load 42 66 84 48
per day
d. for 06 hrs. load 30 48 60 36
per day
5. Approximate cost of solar panels (@ Rs. 15400/-)

a. for 12 hrs. load 14 lakhs 23 lakhs 28 lakhs 17 lakhs
per day
b. for 10 hrs. load 11 lakhs 18 lakhs 24 lakhs 14 lakhs
per day
c. for 08 hrs. load 10 lakhs 16 lakhs 20 lakhs 11 lakhs
per day
d. for 06 hrs. load 07 lakhs 11 lakhs 14 lakhs 9 lakhs
per day
Note: Actual solar panel requirement shall be carried out by

the Railway as per the guidelines given above in the
table B based on actual signalling load at a station
with IPS system.
13. Troubleshooting
The SPV Power Source is reliable Source of Electrical

energy. However, there may be rare instances, when
the SPV Power Source is not able to drive the
connected equipment.

Charge Controller
Inverter
Battery
Load
SPV Panel
Fig. No. 13 - SPV Power Source

The diagnosis of the problem in such situations starts
with the battery. Check the voltage of the battery bank.
If the voltage of the battery bank is correct as indicated
in Charge controller, there may be problem in the
inverter or switch between load and inverter i.e. either
inverter is tripped or switch/load MCB is tripped or
load fuse is blown off.
If none of the above fault is observed then check the
specific gravity of the electrolyte in the secondary cells
of the battery. There may be two cases:
a.If the specific gravity is above the level 1.2

(Hydrometer reading 1200) value or as specified in the
maintenance manual, it implies that the battery is in
order and the problem would be either with the Charge
Controller or Load. Disconnect the load (S & T
Equipment) from Charge Controller and connect it
directly to Battery Bank. If the equipment operates, the
defect may be with the Charge Controller. Disconnect
the Charge Controller and check as per troubleshooting
instructions given in the manual supplied with it or
inform the manufacturer/supplier.
b. If the specific gravity of the electrolyte is below the

specified level and BATT/LOW (Red)) LED is

glowing, the problem may be with any of the
following:
i. Load: This may be drawing more current from

the battery than required. In such case, battery
is bound to get discharged, even if SPV Panel is
functioning properly. This would result in
frequent tripping of the load. To avoid this, get
the load equipment checked and replace any
defective components.
ii. SPV Panel: The SPV Panel may not be

producing required power for which the Power
Source has been designed. In that case, check
the SPV Panel as given below:
 Check for any loose

connection/breakage of wire in SPV module
interconnections.
 If there is no such loose
connection, clean the SPV Modules with soft
cloth. Whenever there is bright sunshine,
measure the voltage and current of each
module after disconnecting the wire. Open
circuit voltage of each module should be
around 21 volts and short circuit current
should be as per table given under Para 6
depending upon the wattage of the module, at
100 mW/Sq.cm AM 1.5 Solar radiation.
 If any of the SPV modules
gives low voltage/current output during bright
sunlight (Sun intensity 90 mW/Sq. cm)
inform the manufacturer/Supplier with
module serial number along with the
measurement taken, for necessary
investigations.
iii. Failure of blocking diode: Blocking

diode fails in short circuit and open circuit mode. If
it is failed in short circuit mode, voltage across its
terminal will be zero in place of 0.7 V while
charging current flows through it. When it fails in
open circuit mode, the current will not flow
through the diode.
The diode may be checked as per standard method
of checking of diode by removing from the circuit.
Apart from these some possible complaints and trouble

shooting methods for Solar modules are listed below :
S. No. Symptom Failure Cause Action

1. No output Cable Conductor Replace cable
break
Connector Defective Replace
connector connector
Corrosion Replace
connector
Junction Mechanical Return to
box damage factory for
servicing
Connection Connect
problem properly
None of the Internal Return to
above problem factory, if
within
warranty
2. Output Cell/interco Internal Return to
voltage nnections damage factory, if
S. No. Symptom Failure Cause Action

OK, but within
no output warranty
current
3. Front Breakage Mishandling/ Unserviceable
glass transportatio , Replace
broken n
4. No Diode Random Replace the
voltage failed in failure diode
across short circuit
blocking mode
diode
5. Voltage Diode Random Replace the
high failed in failure diode
across open circuit
blocking mode
diode

SPV power
source not
driving the
load
Check
SPV
Panel
Is Disconnect
battery C/C Connect
voltage load directly
OK? to battery
Any
loose
Yes
Connection/
Breakage?
Check
inverter and Is load
switch working?
No
between
load & C/C
Clean
SPV Yes
Module
Is Problem in
inverter No charge
or controller
switch
Check OK? Rectify
Voc &
Isc Yes
Check or
Check
inform
Specific
supplier
Gravity
of each
Is Voc cell
and Isc
OK?
Is Sp.
No No Gravity No
OK?
Inform Check load
supplier/ Replace
manufacturer defective
Yes
components
Fig. No. 14 - Troubleshooting flowchart for SPV Panel

14. Precautions and Preventive Steps
Please ensure that:
a.SPV Modules are connected in parallel and SPV Panel

output voltage is less than 25 Volts under normal
sunshine condition (for 12 V System/Module)
b. All connections are properly made tight and neat using

the crimped Red (for +ve) and Black (for –ve) wires
supplied by the manufacturer in order to avoid reverse
connection.
c.The rating of the fuse in the charge controller is not

changed.
d. The SPV Panel is installed facing SOUTH and with

the correct ‘Angle of tilt’.
e.There is no shadow on any part of the SPV Panel at

any time of the day, to get maximum power.
f. SPV Modules are protected against any act of

vandalism and accidental strike or hit by heavy objects,
like stone, hammer etc. If the SPV Panel is installed on
ground, it must be fenced properly to protect it from
cattle and to prevent from any damage/theft. Fencing
should be made in such a way that no shadow should
fall on SPV Panel at any time of the day.
g. Battery Bank is placed on a rack or platform insulated

from ground and located in a well-ventilated room and
also sufficient clearance is there over the battery.

h. FIRST the Battery Bank, then SPV Panel and then
Load is connected to SPV Charge Control Unit and for
disconnection reverse sequence is adopted.
i. Battery terminals are never shorted even momentarily

as shorting will result in HEAVY SPARK AND FIRE.
(To avoid the same connect the cable at Charge
Controller end ‘First’ and then Battery end.)
j. Never connect the Load directly to the SPV Panel as
SPV Panel may give higher/lower voltage than
required by the Load Equipment and hence the
equipment may be DAMAGED permanently.
k. Blocking diode is provided at the array output for
protection against reverse polarity.
15. Utilization of Solar Power Supply System in

the Indian Railways:
The efficient running and control of Railway traffic

in the country is some times seriously hampered by
the irregular grid supply (by State Electricity Board)
resulting in traffic congestion and other operational
equipment failures also. The alternate D.G. sets pose
considerable problem as it has a high maintenance
cost and necessitates the use of additional D.G. sets
as stand by. Again diesel oil is prone to pilferage,
and moreover transportation and storage costs are
involved. It also causes atmospheric pollution.
Hence by harnessing the abundantly available and

non-polluting by nature solar energy source for
power requirements came into action after decades of
research and field experience.

15.1 Advantages of Solar Powered System for
Signalling
Along with the advantages mentioned earlier the

following are the additional advantages w.r.t.
Signalling:
1. Totally Solid State design and highly

desirable.
2. Eliminates need for kerosene lamps or other
out dated light sources.
3. Does not use Soda cells or other primary
cells, which need frequent replacement.
4. Power supply cabling from station building to
the signal unit or cabin not needed, since the unit
is a self contained power sources. This saves
cabling cost.
5. Minimum maintenance, which can be easily
done by low skilled worker.
6. Long life of whole system and the system
gives trouble free performance.
7. System design suited to monsoon and low
light condition thus ensuring failure free
operation of the signalling gears throughout the
year.
15.2 Application of Solar Powered System for

Signalling & Telecommunications:
Almost all signalling and Telecommunication gears

can be run by solar power. In Indian Railway
Signalling system is Solar powered in phased
manner. Priorities are given to those locations where
there is no conventional power or power transmission
through cables is cost effective. Some example of
application of solar power for signalling and
telecommunication gears are given below:
1. Semaphore signal lighting at night.

2. Charging battery to power Signal lighting and
Point Machines.
3. Charging battery for Optic Fibre Cable hut.
4. Solar powered Radio warning system/Gate
Signal/HKT/TC.
5. Solar powered RRI/PI/relay operation
(internal and external circuits)/ALR.
6. Charging secondary cells for
Tokenless/Token block instruments.
7. Lighting Outer/Warner Signals and Distant
Signal with motor operation.
8. Solar distillation plants.


Solar System For Railway Signaling

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CAMTECH/S/2006/SP/1.

Environmental pollution like deposition of carbon

Indian Railways is one of the biggest Central

1.1 Advantages and Disadvantages of Solar

 Fuel source for Solar Panel is direct and endless so

 Operation is simple and no electrochemical reaction

 Initial cost is high

Solar Panel March 2006

Electricity can be generated directly from sunlight,

The photo voltaic effect can be observed in almost

Fig 1:Photo Voltaic Effect

Solar Panel March 2006

The basic building block of a photovoltaic system is

The P-N junction of the solar cell gives rise to diode

Two Tinned copper strips work as terminal leads for

The operation of solar cells involves these major

i) Absorption of sunlight into semiconductor

Silver Oxide lines

Fig 2 (a) Sketch showing front view of typical pseudo

Solar Panel March 2006

Tinned Copper Strips

Fig 2 (b) Sketch showing rear view of typical pseudo square

Fig. 2 (c): Solar Cell: Actual view (CEL make)

Solar Panel March 2006

The power generated by a single cell is small and

A terminal box is provided on the backside of the

Generally rating of bypass diode is 1.52 times of the

Solar Panel March 2006

Fig 3: Solar Module

A Solar panel consists of a number of solar modules,

Fig 4: Solar Panel

Solar Panel March 2006

In a Solar module cells are joined by tinned copper

Solar Panel March 2006

Fig 5: Cross section of a Solar Module

5.2 Types of Solar Panels :

Solar panels are classified on the basis of the following

1) Crystalline Silicon (Mono/Poly/Amorphous)

6. Testing before installation:

Before installation the solar panels are tested at the

• Voc-Open circuit voltage

• Pmax- Maximum power at Standard Test

The following table shows typical user’s

Peak Nom Open Short Max. Max.

The above values are at standard testing conditions

Although accurate power is measured with the help

Solar M odule Solar M odule

Fig 7:Testing before installation

The solar panel is kept in such a position that it

The typical I-V curve of a 35-Watt module with 36

Solar Panel March 2006

MODULE PERFORMANCE AT 25 DEG. C & 100 MW/Sq cm.

Isc : 2.44 Amp.

Fig 8 : IV curve of a 35 watt Solar module

Solar modules are to be installed firmly and

Solar Panel March 2006

 Civil Foundation Job

The Solar panels are generally installed in such a

a. Solar panels should be installed at an angle of

b. Solar panels should be installed South facing in the

Fig. 9 : A Solar Panel installation

c. Any obstruction (such as tree or building) should be

Solar Panel March 2006