General Installation Manual for Powercom Photovoltaic Modules
Contents
1. follow the applicable codes for outdoor installation of wires in conduits Minimum diameter of wire conduit is 4 0 mm Verify that all fittings are properly installed to protect wires against damage and prevent moisture intrusion 6 0 Module Mounting The POWERCOM Limited Warranty for PV Modules is contingent upon modules being mounted in accordance with the requirements described in this section 6 1 Site Considerations POWERCOM modules should be mounted in locations that meet the following requirements Operating Temperature All POWERCOM modules must be mounted in environments that ensure POWERCOM modules will operate within the following maximum and minimum operating temperatures Max Operating Temp 85 C 185 F Min Operating Temp 40C 40 F Care should be taken to provide adequate ventilation behind the modules especially in hot environments Design Strength POWERCOM modules are designed to meet a maximum positive or upward e g wind design pressure of 2400 Pa and negative or downward e g static load design pressure of 5400 Pa when mounted in one of the mounting configurations specified in Section 6 2 A design strength of 2400 Pa corresponds approximately to a wind speed of 125 mph When mounting modules in snow prone or high wind environments special care should be taken to mount the modules in a manner that provides sufficient design strength while meeting local code requirements Excluded Operating Enviro2. hot dipped zinc plated fasteners are acceptable J Module frame Plain washers 7 Stainless steel Grounding hole Diameter 0 149 3 8mm 1 e Terminal washers Stainless steel or bra Fs ES ire NO 1IG A r 2 3mr Plain washers S t a nl ess st ee Spring lock washers Stainless steel a m I Thread forming tapping screws 8 18 Stainless steel Figure 2 Panel Grounding 5 3 Module Wiring The modules may be wired in series to produce the desired voltage output Do not exceed the maximum system voltage indicated in Table 1 The modules may be combined in parallel to produce the desired current output Each series string or module may be required to be fused prior to combining with other strings Table 1 describes the maximum fuse size allowed Please refer to the NEC Article 690 for additional fusing requirements Modules shall not be wired in parallel without maximum over current protection These modules contain factory installed bypass diodes If these modules are incorrectly connected to each other the bypass diodes cable or junction box may be damaged In order to minimize voltage surges which could be induced by indirect lightning strikes DC cables of the same string should be bundled together so that loops are kept as small as possible String configurations should be checked before system commissioning If the open circuit voltage Voc and the sho
3. Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 WwWww pcmups com tw BEJ Complete Power Solution Ver 1 3 Jan 2014 Module interconnects pass direct current DC and are sources of voltage when the module is under load and when it is exposed to light Direct current can arc across gaps and may cause injury or death if improper connection or disconnection is made or if contact is made with module leads that are frayed or torn Do not connect or disconnect modules when current from the modules or an external source is present Before installing modules contact the appropriate authorities to determine permissions installation and inspection requirements which should be followed All installations must be performed in compliance with the National Electrical Code NEC and any applicable local codes and also be performed only by authorized personnel To avoid the hazard of electric shock and injury cover the entire front surface of the PV modules with a dense opaque material such as a cardboard box during installation and handling of the modules or making breaking electrical connections To avoid the hazard of electric shock work only in dry conditions with dry modules and adequate dry insulated tools To avoid the hazard of electric shock and injury be sure to completely ground all modules Do not install or handle the modules when they
4. BEJ Complete Power Solution Ver 1 3 Jan 2014 General Installation Manual for POWERCOM Photovoltaic Modules Important Please complete reading this instruction before installing wiring connecting or using the product in any way Failure to comply with these instructions will invalidate the POWERCOM Limited Warranty for PV Modules 1 0 Introduction Thank you for choosing POWERCOM photovoltaic modules With proper operation and maintenance POWERCOM PV modules will provide you with clean renewable solar electricity for many years This manual contains important installation maintenance and safety information The word module as used in this manual refers to one or more PV modules Retain this manual for future reference 1 1 Disclaimer of Liability The installation techniques handling and use of this product are beyond company control Therefore POWERCOM 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 by using this manual POWERCOM assumes no responsibility for any infringement of patents or other rights of third parties which may result from use of modules No license is granted by implication or under any patent or patent rights The information in this manual is believed to be reliable but does not constitute an expressed and or implied warranty POWERCOM reserves the right to make chan
5. are during periods of high wind Do not touch the junction box terminals to avoid the hazard of electric shock and injury Remove all metallic jewelry prior to installing this product to reduce the chance of accidental exposure to live circuits The shock hazard increases as modules with nominal open circuit voltage Voc in excess of 50 V and or modules rated for maximum system voltage in excess of 50 V The installer assumes the risk of all injury that might occur during installation including without limitation the risk of electric shock Since sparks may occur do not install the module where flammable gases or vapors are present Be sure that the construction or structure roof fa ade etc has enough strength where the modules are being installed For modules mounted on roofs special construction or structures may be required to help provide proper installation support Both roof construction and module installation design have an effect on the fire resistance of a building Improper installation may contribute to fire hazards Additional devices such as ground fault fuses and disconnects may be required Do not treat the back sheet or front surface with paint or adhesives to avoid reducing its functionality damage inoperable conditions and other unknown troubles Do not stand on drop scratch or allow objects to fall on modules If the front glass is broken or the back sheet is torn contact wi
6. ding wind and snow loads We recommend installation methods shown in Figure 1 In some areas local electrical codes may govern the installation and use of PV modules 5 0 Electrical Connections e Modules may be connected in series and or parallel to achieve the desired electrical output as long as certain conditions are met Please use only the same type of modules in a combined source circuit All connections should be secure tight and electrically and mechanically sound UV resistant cables and connectors approved for outside use should be used Ensure that they are electrically and mechanically sound Conductor gauge should be chosen so as to ensure that DC power losses voltage drop are kept to a minimum less than 1 is preferred Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 WwWww pcmups com tw BEM Complete Power Solution Ver 1 3 Jan 2014 Solar Module Mounting Structure Rail Solar Module A rad M8 Nut _ Spring washer Flat washer Mounting Structure Rail a Flat washer a Spring washer M8 Bolt Figure 1 Installation 5 1 Equipment Grounding To avoid electrical shock ground the frame of the module or array before wiring the circuit using a grounding method that meets NEC requirements for grounding solar electrical systems POWERCOM recommends the follow
7. elow Table 2 and Figure 3 In order to prevent water from entering the junction box which could present a safety hazard modules should not be mounted such that the front top glass faces downward e g on a tracking structure that positions the modules with the junction box facing skyward during sleep mode Clearance between the module frames and structure or ground is required to prevent wiring damage and allows air to circulate behind the module The module is only UL Listed for use when its factory frame is fully intact Do not remove or alter the module frame Creating additional mounting holes may damage the module and reduce the strength of the frame For roof mounting the assembly is to be mounted over a fire resistant roof covering rate for the application and any slope less than 5 in ft 127 305 mm required to maintain a fire class rating pPv i40M6 bos bos fos 945 PPV 220M6 PPV245M6 1632 PPV255M6 1632 PPV 300M6 1948 Table 2 Structure configuration Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 www pcmups com tw BEJ Complete Power Solution p Ver 1 3 Jan 2014 Tem peres glass Rubber nA Solar cell Ve m ioiii S N Tedlar B F EVA Tedlar B B section PV Alu
8. ges to the product specifications or manual without prior notice 1 2 Limited of Warranty The limited warranty set forth herein is expressly in lieu of and excludes all other express or implied warranties including but not limited to the warranties of merchantability and fitness for a particular purpose and all other obligations or liabilities on the part of POWERCOM unless such other warranties obligations or liabilities are expressly agreed to in writing by POWERCOM PV modules which in POWERCOM s absolute judgment have been subjected to misuse abuse neglect or accident alteration improper installation application or removal by any party other than a POWERCOM authorized dealer non observance of the applicable POWERCOM installation users and or maintenance instructions repair or modifications by someone other than an approved service technician of POWERCOM power failure surges lightning flood fire accidental breakage or other events outside POWERCOM s control POWERCOM shall have no responsibility or liability whatsoever for damages or injury to persons or property or for other loss or injury resulting from any cause whatsoever arising out of relating to the PV modules s including without limitation any defects and or failures in the PV module s or from use or installation 2 0 Safety Precautions Before installing this device read all safety instructions in this document Danger Powercom Co Ltd Address 9F No 246
9. he maximum design pressure of the module Verify this capacity with the mounting system vendor before installation 7 0 Maintenance Inspect all modules annually for safe electrical connections sound mechanical connection and freedom from corrosion Periodically clean the module surface with water and a soft cloth or sponge Fingerprints may be removed with standard glass cleaner Do not use harsh cleaning materials such as scouring powder steel wool scrapers blades or other sharp instruments to clean the glass surface of the module Use of such materials will invalidate the product warranty Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 WwWww pcmups com tw
10. ing two methods of grounding the module frame Figure 2 is for customer reference 1 Using an equipment ground conductor with stainless steel hardware at one of the two designated 3 8 grounding holes on the module frame If a equipment ground conductor larger in diameter than 10 AWG is necessary a grounding lay in lug is required A thread forming 8 18 stainless steel screw is required when using a Self drilling type screw to make the frame ground connection Please refer to NEC Article 690 on grounding PV arrays for specific requirements 2 _POWERCOM modules can be grounded using third party grounding washer or clip systems provided they have been tested and certified to meet UL 467 and UL 1703 requirement for bonding grounding systems and are installed according to the manufacturer s specified instructions 5 2 System Grounding A wiring terminal or bonding location of module intended to accommodate a field installed equipment grounding conductor shall be identified with the appropriate symbol IEC 60417 5019 DB 2002 10 or shall have a Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 WwWww pcmups com tw BEJ Complete Power Solution green colored part Ver 1 3 Jan 2014 eTo avoid galvanic corrosion use of stainless steel fastening materials are the preferred choice but galvanized or
11. minium frame extrusion single key cross section g mark AO lum ame A Junction box Elactrical cable J t j OO C j ZO i E ki j f e A ta L A Smmx4mm 16 Fi ith drai ij Pa mmx mm rame wi rainage A A section a m PP 8 0mm 8 Mounting Places A A N a l ee _ SCALE 31 44 Ja a 7 i Aluminium frame component C D mmxmm 4 Frame wi th draina g SCALE 4 1 Figure 3 Structure Design Modules may be mounted using the following methods only 1 Frame Holes Secure the module to the structure using the factory mounting holes Four 8mm stainless steel bolts with nuts washers and lock washers are recommended per module Refer to Table 2 for the module dimensions and hole locations This method has been certified by a third party organization according to UL 1703 2 Pressure Clamps or Clips Mount the module with the clips on the side frame of the module The side frames are attached to the longer sides of the module The centerline of the clips should be 6 15 from the end of the side frame Installers should ensure the clamps are of sufficient strength to allow for the maximum design pressure of the module Clips and clamps are not provided by POWERCOM 3 End Mount End mounting is the capture mounting of the length of the module s end frame to a supporting rail The end frames are on the shorter dimensions of the module The end mounting rail and clips or clamps must be of sufficient strength to allow for t
12. nments Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 WwWww pcmups com tw BEJ Complete Power Solution Ver 1 3 Jan 2014 Certain operating environments are not recommended for POWERCOM modules and are excluded from the POWERCOM Limited Warranty for these modules No POWERCOM module should be mounted at a site where it may be subject to direct contact with salt water Recommended distance from the sea 1600 feet POWERCOM modules with an anti reflective coating on the glass should not be mounted in basic environments those which have a PH balance equal to or greater than 7 Basic environments degrade the coating reduce module energy gain and may cause a non uniform appearance This is not a concern in most areas because most outdoor environments are acidic and therefore do not pose a problem but POWERCOM recommends that the site be checked before mounting the modules especially in coastal settings Where POWERCOM module could be exposed to sulfur or other corrosive chemicals such as near sulfur springs or volcanoes because of the danger of corrosion 6 2 Mounting Configurations Modules may be mounted at any angle from horizontal to vertical Select the appropriate orientation to maximize sunlight exposure Specific information on module dimensions and the location of mounting and grounding holes is provided b
13. rt circuit current Isc deviates from the specifications this could indicate a configuration fault Correct DC polarity should be observed at all times Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 WwWww pcmups com tw BEJ Complete Power Solution Ver 1 3 Jan 2014 5 4 Array Wiring The term array is used to describe the assembly of several modules on a support structure with associated wiring National electrical codes and regulations need to be followed when selecting cables For field connections recommend using minimum 4 mm or 12 AWG copper wires insulated for a minimum of 90 C Cables should use UV resistant cable ties or other sunlight resistant device and are insulated to withstand the maximum possible system open circuit voltage Loose and unsecured cables should be protected from mechanical damage Avoid as far as possible exposing the cables to direct sunlight eCheck your local codes for requirements 5 5 Module Terminations A junction box as a terminal enclosure is equipped for electrical connections on POWERCOM modules If two or more separable connectors are provided they shall be configured or arranged so that the other and vice versa will not accept the mating connector for one if it will result in an improper connection 5 6 Conduit For applications where wire conduits are used
14. tage ratings conductor ampacities fuse sizes and size of controls connected to PV output An additional 1 25 multiplier may be required by the NEC for sizing fuses and conductors as described in the NEC Section 690 8 Rated Power W Power Tol Open circuit voltage Voc V Short circuit current Isc A b Module weight kg Dimensions mm x mm x mm 6 Maximum fuse rating A Total number of cells Powercom Co Ltd 140 190 220 C C 40 190 20 18 2 995 995 40 1316 995 40 1474 995 40 1632 995 40 1632 995 40 eo e po eo po poo Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 www pcmups com tw BEJ Complete Power Solution Ver 1 3 Jan 2014 Values at Standard Test Conditions STC of Irradiance 1000 W m2 Air Mass AM1 5 Cell Temperature 25 C Nominal Operating Cell Temperature NOCT is 44 8 C 2 C Temperature Coefficient of Current is 3 214 mA C Temperature Coefficient of Voltage is 149 mV C Temperature Coefficient of Power is 0 37 C Maximum System Voltage is 1000V Table 1 Electrical Characteristics at STC 3 1 Fire Rating The module is Class C fire rated 3 2 Bypass Diode Rating The bypass diode of Junction Box is Tyco SL1110 40V 15A rated 4 0 Installation Modules should be firmly fixed in place in a manner suitable to withstand all expected loads inclu
15. th any module surface or module frame can cause Powercom Co Ltd Address 9F No 246 Lien Chen Road Jhonghe Dist New Taipei City Taiwan R O C TEL 886 2 2225 8552 FAX 886 2 2225 1776 886 2 2226 0537 www pcmups com tw BEJ Complete Power Solution electric shock Ver 1 3 Jan 2014 There are no user serviceable parts within the module Do not attempt to repair any part of the module Do not artificially concentrate sunlight on a module to avoid the hazard of fire or damage Do not use modules of different specifications in the same system Do not disconnect terminals while PV modules generate electricity and connect electrical load to avoid the hazard of electrical shock Follow all safety precautions of other system components used Use a module for its intended purpose only Contact your module supplier if maintenance is necessary 3 0 Electrical Characteristics The module electrical ratings are measured under Standard Test Conditions STC of 1 kW m irradiance with AM 1 5G spectrum and a cell temperature of 25 C POWERCOM modules deliver specific electrical characteristics Table 1 A photovoltaic module may produce more current and or voltage than reported at STC Sunny cool weather and reflection from snow or water can increase current and power output Therefore the values of Isc and Voc marked on the module should be multiplied by a factor of 1 25 when determining component vol
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