3.3 Complete PV Laboratory for less than $50,000
The starter laboratory discussed above consisted of a 2,000 watt PV array that includes crystalline silicon modules, a mock roof and hardware for instruction on mounting the array, one inverter for direct grid-tied applications, electrical balance-of-system components, and sufficient instrumentation to measure component and system performance. A much more complete and versatile laboratory is described below. However, it costs approximately $40,000 more, with the total cost being less than $50,000. What do those additional dollars buy, and what added capabilities and value do they provide?
Shading analysis and site assessment are critical skills when designing PV arrays. Practice with shading analysis tools is important for giving students the necessary experience in performing these vital tasks. Programs should provide additional tools for this when possible.
For the inverter lab, four (rather than one) grid-tied inverters and associated electrical BOS are used, adding approximately $4,500 to the cost compared to the starter laboratory. The added equipment will allow small student teams of 4 or 5 members per station for the inverter lab demonstrations and experiments.
Because a fair percentage of grid-tied PV systems in hurricane-prone areas along the Atlantic and Gulf coasts use batteries for backup power, laboratory experiments and student practice with bimodal inverters and systems is appropriate. The added cost for a bimodal inverter, batteries, and ancillary equipment is approximately $3,600.
For the array mounting and I-V measurements lab, four arrays, four roof mockups, and four mounting systems are used (rather than one). The added cost compared to the starter lab is approximately $15,000.
Finally, approximately $9,000 in added costs is associated with multiple numbers of measuring instruments, meters, safety equipment, tools and installation materials. In summary, the laboratory presented below can provide student learners with hands-on experience using the equipment and procedures associated with PV systems design, installation, operation and maintenance.
| PV Training Equipment for a Complete Laboratory That Costs Less Than $50,000 | |||||
| Assumes a class of 20 students | |||||
| # of Items | Item | Vendor | Unit Cost | Total Cost | LaboratoryUse |
| 2 | Pathfinder | Solar Pathfinder | $270 | $540 | Shading and Site Survey Lab |
| 1 | Pathfinder Assistant Program | Solar Pathfinder | $160 | $160 | |
| 2 | Solmetrics Sun Eye 110 | Solmetric | $1,500 | $3,000 | |
| 2 | Solmetrics Sun Eye 210 | Solmetric | $2,000 | $4,000 | |
| Subtotal | $7,700 | ||||
| 4 | Inverter, PV Powered 2000SD | Affordable Solar | $1,500 | $6,000 | Inverter Lab |
| 4 | Meter, AC kWh | Hialeah Meter | $50 | $200 | |
| 4 | Meter, AC can | Home Depot | $30 | $120 | |
| 4 | Disconnect, AC | Home Depot | $30 | $120 | |
| 4 | Breakers (x2), AC, 15 amp, SP | Home Depot | $30 | $120 | |
| 4 | Disconnect, DC, 30 amp, HU361 | Affordable Solar | $175 | $700 | |
| 4 | Box, DC, Combiner outback | Outback Power Sys | $150 | $600 | |
| 4 | Fuses (x2), DC,KLKD-15 | Outback Power Sys | $25 | $100 | |
| 4 | Fuse holder (x2), DC, 30 amp, DIN mount | Outback Power Sys | $40 | $160 | |
| 4 | Load panel, 100 amp, 240 V | Various | $100 | $400 | |
| Subtotal | $8,520 | ||||
| 1 | Inverter, Battery, 48 V | Various | $1,800 | $1,800 | Battery and Inverter Lab |
| 1 | Charge Controller/ MPPT | Various | $575 | $575 | |
| 1 | Meter, AC kWh | Hialeah Meter | $50 | $50 | |
| 1 | Meter, AC can | Home Depot | $30 | $30 | |
| 1 | Disconnect, AC | Home Depot | $30 | $30 | |
| 1 | Breakers , AC, 60 amp, SP | Home Depot | $30 | $30 | |
| 1 | Disconnect, DC, 30 amp, HU361 | Affordable Solar | $175 | $175 | |
| 1 | Box, DC, Combiner outback | Outback Power Sys | $150 | $150 | |
| 2 | Fuses, DC, KLKD-15 | Outback Power Sys | $25 | $50 | |
| 2 | Fuse holder, DC, 30 amp, DIN mount | Outback Power Sys | $50 | $100 | |
| 4 | Batteries, 12V | Outback Power Sys | $150 | $600 | |
| 1 | Load panel, 100 amp, 240 V | Various | $100 | $100 | |
| Subtotal | $3,690 | ||||
| 4 | Roof mockup | FSEC constructed | $600 | $2,400 | Inverter, I-V Curve and Array Mounting Lab |
| 4 | Mounting systems (racks, etc.) for PV | Affordable Solar | $750 | $3,000 | |
| 4 | 2,000 Watt PV array ($1.30/watt) | Affordable Solar | 2,675 | $10,700 | |
| Subtotal | $16,100 | ||||
| 1 | Solmetric PVA 600 IV Curve String Analyzer | Solmetric | $3,200 | $3,200 | Inverter and I-V Curve Lab |
| 5 | Clamp, DC current, AEMC DC | Newark Electronics | $200 | $1,000 | |
| 10 | VOM meter, Fluke (x2) 115 | Newark Electronics | $300 | $3,000 | |
| 5 | Meter, Solar, Daystar | Daystar, Inc. | $150 | $750 | |
| 5 | IR Temp Gun, Fluke | Newark Electronics | $100 | $500 | |
| 5 | Wire wound resistor 25 Ohm, 1000W | Various | $150 | $750 | |
| Subtotal | $9,200 | ||||
| 1 | Load tester | Autometer | $350 | $350 | Battery Demonstration Lab |
| 1 | Starting battery, lead acid | Various | $100 | $100 | |
| 1 | Deep cycle battery | Various | $200 | $200 | |
| 1 | Face shield | Various | $40 | $40 | |
| 1 | Rubber gloves | Various | $25 | $25 | |
| 1 | Safety apron | Various | $50 | $50 | |
| 2 | Charge controllers | Various | $110 | $220 | |
| Subtotal | $975 | ||||
| 4 | Safety material and equipment (harness, life line, leash, eye protection, roof mounting bracket, safety video) | Various | $100 | $400 | |
| Subtotal | $400 | ||||
| Work tools and materials (drill, screw drivers, torque wrench, bonding equipment, gloves, drill bits, socket sets, hammers, sealants) | Various | $2,000 | $2,000 | ||
| Subtotal | $2,000 | ||||
| GRAND TOTALS | $20,325 | $48,595 |