Solar Array Testing Flowchart
Step
Description
Decision/Outcome
1
Start
Begin Process
2
Connect USB Key & Launch SAS 1000
Software must detect USB Key
3
Scan USB ID & Authenticate
Successful authentication required
4
Open ITECH SAS Software
Software must open without errors
5
Set Warm-up Time & Shift Seconds
Set warm-up: 3s, Shift: 1000s
6
Select PV Curve & Profile
Choose HP, Mono, Poly as per controller
7
Set VMP & PMP, Save Settings
Ensure correct voltage & power settings
8
Set Irradiance/Temperature Profile
Choose profile (Hot, Cold, Cloudy)
9
Click Play to Start MPPT
MPPT execution begins
10
Ensure MCB is OFF, Click ON/OFF
Verify values before turning ON
11
Observe & Adjust VMP & PMP
Use Increase/Decrease Keys
12
Click Pause to Stabilize Peak
Peak values remain stable
13
Fill Testing Report
Record test values
14
Is MPPT Efficiency OK?
If YES → Proceed to STOP, If NO → Adjust and Retry
15
Click Stop & Shutdown System
End Process
Standard Operating Procedure (SOP) for Testing Controllers and Motors
Using Solar Array
1. Purpose
This SOP establishes a detailed and standardized procedure for testing controllers and
motors using the solar array setup, ensuring accuracy, consistency, and compliance with
testing requirements.
2. Scope
This procedure applies to all personnel responsible for testing controllers and motors in the
organization's solar array testing facility using ITECH SAS 1000 software.
3. Required Equipment & Materials
- Laptop with SAS 1000 software and ITECH SAS software installed.
- USB drive (key) for software authentication.
- Controller and motor to be tested.
- Solar array setup (including necessary connections and power sources).
- Multimeter (for additional verification of voltage, current, and resistance if required).
- Testing report format (printed or digital form for documentation).
- Personal Protective Equipment (PPE) including gloves and safety goggles.
4. Safety Precautions
1. Ensure Proper Grounding: Verify that all equipment is properly grounded before
initiating the test to prevent electrical hazards.
2. Use PPE: Always wear insulated gloves and safety goggles while working with electrical
equipment.
3. MCB (Miniature Circuit Breaker) MUST be OFF: Ensure the MCB is in the OFF position
before starting the test to avoid power surges.
4. Check Voltage Ratings: Do not proceed with testing if voltage, current, or power levels
exceed the controller’s specifications.
5. Do Not Bypass Safety Features: Ensure all safety interlocks and emergency shutoff
mechanisms are functional before proceeding.
5. Procedure
Step 1: Initial System Setup
1. Connect the USB drive (key) to the laptop.
2. Launch the SAS 1000 software.
3. Click on Scan to detect the USB ID.
4. Click Enter to authenticate.
5. Click OK to confirm information.
6. The ITECH SAS software interface will now be visible.
Step 2: Software Configuration
7. Set the Warm-Up Time to 3 seconds.
8. Set Shift Seconds to approximately 1000 seconds.
9. Select the PV Curve Type based on controller requirements:
- HP (High Power)
- Poly (Polycrystalline)
- Mono (Monocrystalline)
10. Select the HP profile based on the controller's specifications.
11. Double-click the selected PV curve to open settings.
12. Configure the following values:
- VMP (Voltage at Maximum Power)
- PMP (Power at Maximum Power)
13. Click Save to store settings.
14. Set the Irradiance/Temperature Profile:
- Choose a pre-defined profile (Hot, Cold, Cloudy, etc.).
- The software will adjust the graph accordingly.
Step 3: Execution of MPPT Testing
15. Click Play to start the MPPT (Maximum Power Point Tracking) execution.
16. Ensure that the MCB remains OFF before proceeding further.
17. Click ON/OFF to activate the system ONLY AFTER verifying the following:
- Voltage is within the expected range.
- Current is stable and within acceptable limits.
- Efficiency percentage is consistent with requirements.
18. If the system powers ON successfully, the status indicator will turn Green.
Step 4: Monitoring & Performance Adjustments
19. Use the Increase/Decrease keys to fine-tune VMP & PMP values.
20. Observe the corresponding changes in the Shift Seconds value.
21. Gradually increase the shift seconds to maximize VMP & PMP.
22. Observe the peak values in the Irradiance/Temperature curve.
23. Click Pause to stabilize the peak irradiance.
24. Verify that the MPPT efficiency, voltage, current, and power factor meet the required
specifications.
Step 5: Data Recording & Test Completion
25. Document the test results in the testing report format, ensuring that the following
parameters are recorded:
- Controller ID
- Motor specifications
- Test Date & Time
- Voltage, Current, and Power Readings
- MPPT Efficiency Percentage
- PV Curve Type Used
- Observations/Anomalies (if any)
26. Click Stop on the Execute MPPT interface to shut down the system.
27. Disconnect the USB key from the laptop and close the software.
28. Power off the laptop and testing setup if no further tests are required.
6. Troubleshooting Guide
Issue
Possible Cause
Solution
USB Key Not Detected
Faulty USB port or key
Try reconnecting or use a
different port
MPPT Not Activating
Incorrect curve selection
Verify and select the correct
PV curve
Efficiency Too Low
Poor irradiance conditions
Adjust the
temperature/irradiance
profile
Controller Not Turning On
MCB not switched
Ensure MCB is OFF before
proceeding
7. Record Keeping & Report Submission
- Each test must be recorded in the designated test logbook.
- Reports should be digitally stored in the assigned database.
- Any discrepancies must be reported to the supervising engineer for further analysis.