Installation & User Manual - Unconquered Sun Solar Technologies
Contents
1. used at all times to avoid injury 1 4 SITE SELECTION PV modules are intended for outdoor use only and not intended for use on any moving vehicles In most applications UNCONQUERED SUN modules should be installed in a location where they receive the maximum sunlight throughout the year In the Northern Hemisphere the modules will normally face south In the Southern Hemisphere the modules will face North Avoid trees buildings or other obstacles that can cast shadows on the modules Take proper steps in order to maintain reliability and safety in case the PV modules are installed in areas that have heavy snow extreme cold strong winds Installations over or near water and areas where installations are prone to salt water exposure If you are planning to use the PV modules where salt water damage may occur please consult with UNCONQUERED SUN to determine an appropriate installation method if installation is possible 1 5 TILT ANGLE SELECTION UNCONQUERED SUN modules produce the most power when the sun s rays strike the module perpendicular to the module surface To avoid performance losses in series circuits ensure that all modules have the same tilt and orientation Your solar professional will be able to determine the best tilt angle for your location 1 6 MOUNTING AND INSTALLATION There are several approved ways to mount the UNCONQUERED SUN modules to a support structure They may be mounted in either portrait or landscape orientation usin2. UNC NQUERED SUN SOLAR TECHNOLOGIES INSTALLATION AND USER MANUAL UNCONQUERED SUN WINDSOR SERIES PHOTOVOLTAIC MODULES For further information Unconquered Sun Solar Technologies Inc WWW unconqueredsun com Canadian Production Facility 11600 County Rd 42 Tecumseh On N8N 2M1 1 PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING OR USING THE MODULES This manual contains important safety instructions for the PV module that must be followed during the installation and the maintenance of PV modules Failure to follow these instructions may result in bodily injury or damage to property Working on a photovoltaic system requires specialized knowledge and should only be attempted by qualified professionals Introduction Thank you for choosing the UNCONQUERED SUN PHOTOVOLTAIC WINDSOR SERIES PV module UNCONQUERED SUN is a world leader in the production of photovoltaic products Our prime commitment is to produce quality products that will last for many years Please familiarize yourselves with this manual before beginning to install the photovoltaic modules These modules are listed to UL 1703 This manual contains safety information you need to be familiar with This manual does not constitute a warranty expressed or implied Unconquered sun does not assume responsibility and expressly disclaims liability for loss damage or expense arising out of or in any way connected with installation operation use or maintenance of PV mo
3. at 20 in Ibs 4 Grounding Clip at Grounding Hole Module frame Module frame X 10 32 In lbs Thread cutting 10 Select a grounding lug listed for direct burial and outdoor use tin plated solid copper lay in lug with a stainless steel set screw capable of accepting a 4 14 AWG copper conductor e g ILSCO GBL4 DBT Burndy CL50 1TN Use and emery cloth sandpaper or a steel brush to clean the frame The area cleaned should be the same size as the lug mating face Apply an anti oxidation coating e g Burndy Penetrox Ideal Noalox e Tothe grounding hole secure the lug with stainless steel hardware consisting of a thread forming thread cutting screw of at least 32 threads per inch and an external serrated washer Tighten the screw until serrated washer has penetrated frame approximately 20 in Ibs e Select a grounding clip listed and designed to ground photovoltaic modules e To the grounding hole secure the clip per manufacturer s instructions and tighten the screw to 20 in Ibs e Insert copper wire into the wire slot per manufacturer s instructions 3 MAINTENANCE UCONQUERED SUN PV modules are designed for a long life and require very little maintenance If the angle of the PV module is 5 degrees or more normal rainfall is usually sufficient to keep the module glass surface clean under most weather conditions If dirt build up becomes excessive clean the glass surface only with a soft cloth using wate
4. d 0 2 min wer Washer catch width 0 12 min EIL 0 4 m AL i _ thickness EEE spring washer support widht di SED pec E ee Rail 5 16 M8 nut L upp Figure 3 Attachment Guidelines Permissible Clamping Zones Both Portrait and Landscape Options lt 331b Ft lt 1600 Pa 54lb Ft 2600Pa lt 75 Ib Ft 3600 Pa Clamping Long Side permissible clamp zone Clamping Short Side permissible clamp zone Eg Ze 2g N Ma E E gs eo 52 a EE ew gc 2 PV MODULE ELECTRICAL INSTALLATION All Unconquered Sun modules are pre wired with 2 4mm PV1 F 90 C UL listed wire and terminated with MCA connectors This wire intended for interconnection wiring of grounded and ungrounded photovoltaic power systems as described in 690 31 A Negative is indicated on connector Positive is indicated on other connector Make sure that all connections are not under load while being connected Care must be taken to arrange the system ground so that the removal of one module will not interrupt the grounding of the other modules Under no circumstances should the junction box be opened Series and parallel connections shall be made by use of 10 or 4mm AWG 90 C type sunlight resistant output cables or equivalent with Male and Female MCA locking connectors To comply with NEC 2008 locking ring may be required Select a suitable conductor diameter to minimize voltage dro
5. devices follow the instructions of the Grounding and Bonding Equipment manufacturer s installation instructions e Use the holes milled in the frame for grounding e When using grounding wire select ground wire of copper copper alloy or other suitable material no smaller than 14 AWG 2 1mm sized accordingly for the photovoltaic system per NEC and sized compatibly with the Grounding and Bonding Equipment manufacturer s installation instructions 2 2 Grounding Methods 1 Grounding Lug with Machine Screw at Grounding Hole Module frame SS 8 32 K Lock Nut e g Fastenal 70922 i CU Lug 20 X i SS 8 Flat Washer In Ibs e g Fastenal 71008 SS 8 32x1 Machine Screw Copper wire e g Fastenal 0170682 44 6 at 35 in Ibs 8 at 25 in Ibs 10 14 at 20 in Ibs e Select a grounding lug listed for direct burial and outdoor use tin plated solid copper lay in lug with a stainless steel set screw capable of accepting a 4 14 AWG copper conductor e g ILSCO GBL4 DBT Burndy CL50 1TN e Use and emery cloth sandpaper or a steel brush to clean the frame The area cleaned should be the same size as the lug mating face Apply an anti oxidation coating e g Burndy Penetrox Ideal Noalox e To the grounding hole secure the lug with stainless steel hardware consisting of a machine screw min 8 a flat washer and a lock nut as shown in the figure Tighten the nut to approximately 20 in Ibs e Tighten the l
6. dules No responsibility is assumed by UNCONQUERED SUN for any infringement of patents or other rights of third parties that may result from use of PV modules UNCONQUERED SUN reserves the right to make changes to the product specifications or installation manual without prior notice Manufacturer Unconquered Sun Solar Technologies Inc 11600 County Rd 42 Tecumseh On N8N 2M1 We reserve the right to make amendments 2010 Unconquered Sun Solar Technologies Inc Installation and User Manual UNCONQUERED SUN Photovoltaic Modules UNCONQUERED SUN 220 230 and 240 Watt Windsor Series Panels CONTENTS 1 WARNING NOTICES 1 1 General Safety 1 2 Handling Safety 1 3 Installation Safety 1 4 Site Selection 1 5 Tilt Angle Selection 1 6 Mounting Installation 2 PV MODULE ELECTRICAL INSTALLATION 1 7 Grounding 1 8 Grounding Methods 3 MAINTENANCE 1 9 Specifications ooon anA co 11 11 1 WARNING NOTICES Danger of Death from Electric Shock Photovoltaic modules can generate electricity when exposed to light The voltage of single modules is less than 50 VDC but when connected together in series the total voltage can be dangerously high When connected together in parallel the current is added together When handling the module the following must be followed to avoid the risk of arcing fire and electric shock The installation of PV should only be performed by qualified personnel Do not wear metallic jewellery when install
7. g either the bolt holes provided or using frame clamps not provided For all mounting methods a minimum gap of 4 7 mm between modules is required to allow for thermal expansion For roof mounted systems a minimum gap of 1 between the module and the roof surface is required to allow for ventilation The modules may be fastened to a support using the bolt holes in the bottom of the frame shown in Figure 1 The module should be fastened at four points with a 5 16 M8 bolt washers and a nut not provided Inter module type or end type clamps must be designed for PV modules and have minimum dimensions shown in Figure 2 and installed in accordance with the instructions below and drawings provided The mounting clamps should be at least 1 5 38 mm long at least 0 12 3 mm thick and have a catch width of at least 0 2 bmm When installing the clamp must overlap the support rail by at least 0 4 10 mm and be placed within the permissible clamping zones shown in Figure 3 For the high load situations shown in Figure 3 an additional center support rail should be used Note that UNCONQUERED SUN does not warranty frame clamps The UNCONQUERED SUN module warranty may be void if customer selected frame clamps are improper or inadequate with respect to properties including strength or material or installation Figure 1 Attachment Using Mounting Holes Figure 2 Attachment Using Clamps 1 5 min 5 16 MB bolt catch length SO P sa m
8. ing Do not install PV modules when wet Tools must be dry Do not use damaged or defective modules Place all damaged or defective modules in a carton to avoid exposure to light Even damaged or defective modules can produce electricity 5 Contact with electrically active parts of a PV module such as terminal can result in burns sparks and lethal shock whether the PV modules are connected or not 6 PV systems can produce high voltage and current which could present an increased hazard and may cause serious injury or death 7 Artificial sunlight should not be concentrated upon the PV module Do not expose PV modules to sunlight concentrated with mirrors lenses or other means 8 Use appropriate safety equipment insulated tools insulated gloves etc when working on any wiring Qu NES Danger of death from electric shock The inverter can produce dangerous high voltage 1 Besure to follow all manufacturers instructions before installing any PV modules 2 Use extreme caution when wiring or installing an inverter 3 Be sure to shut down inverter before installing or removing PV modules Danger of death from electric shock When exposed to light PV modules produce direct current When disconnecting any PV modules from a string a deadly arc can occur 1 Never remove a PV module without disconnecting the inverter from the grid 2 Never remove the PV module without disconnecting the PV system from the inverter Make sure that
9. le gloves such as leather gloves with padding in the palm and finger areas Do not drop the PV module or allow objects to fall on the PV Module 1 3 INSTALLATION SAFETY 10 11 Always wear protective head gear insulating gloves and safety shoes with rubber soles Due to the risk of electrical shock do not perform any work if the terminals of the PV module are wet Do not install PV modules in the rain snow or windy conditions Insert Interconnect connectors fully and correctly Check all connections Cables should be secured to the PV module frames support structure or raceway to prevent movement Keep connectors out of direct sunlight Do not touch the terminal box and the end of the interconnect cables with bare hands during installation or under sunlight regardless of whether the PV module is connected to or disconnected from the system Do not unplug a connector if the system circuit is connected to an operating load Do not damage the back sheet of PV modules when mounting the PV modules Do not damage the surrounding PV modules or mounting structure when replacing the PV module Keep children away from the system when installing Use UV resistant cable ties or other wire management hardware to secure the interconnect cables Drooping cable may cause various problems such as leading to electrical shorts When installing PV modules on roof or other structures the appropriate safety practices and safety equipment should be
10. p Conductors should be between 8 14 AWG 1 5 10mm USE 2 non conduit THWN 2 conduit or check with your solar professional to determine correct conductor sizing or wire Over current protection shall be in accordance to NEC 240 NOTE MAXIMUM SYSTEM VOLTAGE IS 600 VDC All installations string sizing and electrical connections should be designed to meet the relevant NEC codes A qualified solar professional should refer to NEC 690 7 a to determine the maximum number of UNCONQUERED SUN modules that can be placed in series Under normal conditions a photovoltaic module is likely to experience conditions that produce more current and or voltage than reported at standard test conditions Accordingly the values of Is and Vo marked on this module should be multiplied by a factor of 1 25 when determining component voltage ratings conductor ampacities fuses and the size of controls connected to the PV output Refer to section 690 8 of the National Electrical Code for an additional multiplying factor of 125 percent 8096 de rating which may be applicable 2 1 GROUNDING Several different methods of grounding can be used to provide the required connection through the frame Before installation contact the local code Authority Having Jurisdiction AHJ to determine the proper grounding requirements Attach all module frames to an earth ground in accordance with applicable articles of the National Electrical Code NEC 250 and 690 e For listed
11. r Do not use high pressure spray or chemicals to clean the modules If cleaning the back of the module is necessary take the utmost care not to damage the backside materials In order to ensure proper operation of the system please check all wiring connections and the condition of the wire insulation periodically 3 1 SPECIFICATIONS WINDSOR WINDSOR WINDSOR 220 230 240 Maximum Power Pmax 220W 230W 240W Open Circuit Voltage Voc 36 6V 37 0V 37 4V Short Circuit Current l 8 33A 8 40A 8 65A Maximum Power Voltage Vom 30 0V 30 0V 30 1V Maximum Power Current lpm 7 66A 7 67A 7 98A Maximum System Voltage 600V 600V 600V Series Fuse Rating A 15A 15A 15A Weight 17 7 kg 39 0lbs 17 7kg 39 0lbs 17 7kg 39 0lbs Length 1644mm 64 72 1644mm 64 72 1644mm 64 72 Width 972mm 38 26 972mm 38 26 972mm 38 26 Depth 50mm 1 96 50mm 1 96 50mm 1 96 Maximum Load 50psf 2400Pa 50psf 2400Pa 50psf 2400Pa Temperature Coefficients P max 0 485 C Voc 0 351 C lee 0 053 C The electrical characteristics are within 10 of the indicated values of lIs Voc and Pmax under Standard Test Conditions irradiance of 100 mW cm AM 1 5 spectrum and a cell temperature of 77 F 25 C 11
12. the connectors are in good working condition and are properly connected to each other 1 1 GENERAL SAFETY OP ND 9 All PV modules should be installed in accordance with applicable codes and regulations Roof mounted PV modules are to be mounted over a fire resistant roof Only PV modules with the same cell type and size should be connected in series Follow all safety precautions of other components used in the system Avoid uneven shade on the PV module surface Shaded cells may be come hot hot spot phenomena which may result in permanent damage to the module Do not use high pressure water spray or chemicals to clean the PV modules Turn off the inverters and circuit breakers immediately should there be a problem 1 2 HANDLING SAFETY gu dw 8 Do not expose the PV module to excessive loads on the surface of the PV module or twist the frame The glass may break Do not stand or step on the PV module The glass may be slippery and there is a risk of injury or electric shock if the glass is broken PV modules are heavy Please handle with care Do not hit or put excessive load on the glass or back sheet PV cells may break Do not twist the interconnect cable excessively Do not drill holes in the frame It may compromise the frame strength and cause corrosion of the frame and will void the warranty Do not touch the PV module with bare hands The frame of the PV module has sharp edges and may cause injury Wear suitab
13. ug set screw to the copper wire at the torque specified by lug manufacturer 2 Grounding Lug with Machine Screw at Mounting Hole Module frame SS 8 32 Nut e g Fastenal 70706 SS 8 Flat Washer e g Fastenal 71008 a ES lug sag SSii8 Flat Washer e g Fastenal 71008 In Ibs hm _ SS8 32x1 Machine Screw Copper wire e g Fastenal 0170682 4 6 at 35 in Ibs 8 at 25 in lbs 10 14 at 20 in Ibs Select a grounding lug listed for direct burial and outdoor use tin plated solid copper lay in lug with a stainless steel set screw capable of accepting a 4 14 AWG copper conductor e g ILSCO GBL DBT Burndy CL50 1TN e Use and emery cloth sandpaper or a steel brush to clean the frame The area cleaned should be the same size as the lug mating face Apply an anti oxidation coating e g Burndy Penetrox Ideal Noalox To the mounting hole secure the lug with stainless steel hardware consisting of a machine screw min 8 two flat washers and a nut as shown in the figure Tighten the nut to approximately 20 in Ibs e Tighten the lug set screw to the copper wire at he torque specified by lug manufacturer 3 Grounding Lug with Thread Cutting Screw at Grounding Hole Module frame SS 10 External Serrated Washer e g McMaster 91120A140 Lug SS 10 32 x Thread Cutting Screw e g Fastenal 11112837 20 N sA In Ibs Copper wire 84 6 at 35 in Ibs 8 at 25 in lbs 10 14
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