Installation Manual
Contents
1. Installation Manual Monocrystalline Modules and Polycrystalline Modules Version May 2014 A fE NHANCE PHOTOVOLTAIC S This manual contains information regarding the safe installation and handling of photovoltaic modules produced by Enhance Photovoltaics Ltd Enhance Photovoltaics All the instructions provided in this manual should be read carefully and understood before attempting to install the modules Please contact Enhance Photovoltaics Customer Service for further explanation These instructions are intended for dealers and installers involved in the planning installation and commissioning of photovoltaic systems with polycrystalline or monocrystalline solar modules by Enhance Photovoltaics They are meant to provide you with valuable information to ensure a smooth and correct installation of Enhance Photovoltaics modules Enhance Photovoltaics modules are made of carefully selected materials They are tested and approved by acknowleged independent certification authorities and may only be installed by qualified professional companies Please ovserve the standards and regulations applying to photovoltaic systems in the relevant countries as well as the rules of the employers liability insurance associations for accifent protection Failure to comply with these can result in major injuries and damage Specifications and assembly instructions from this installation guide are based on the standards ap2. Il 1000Vdc Maximum System Voltage Refer to respective National Electrical Code requirements and standards for safety related grounding of racking system and or module frames In case of executing the grounding of the module frames Enhance Photovoltaics recommends taking into account the following considerations 11 fE NHANCE PHOTOVOLTAIC S B The long frame rails are equipped with pre drilled grounding holes in their centre These holes shall be used only for grounding purposes and must not be used for mounting purposes B Proper grounding is achieved by connecting the module frame s and structural members contiguously using a suitable grounding conductor The grounding wire must be properly fastened to the module frame to assure good electrical contact Use copper copper alloy or any other conductive material accepted by the applicab le National Electrical Regulation B Make electrical contact by penetrating the anodized coating of the aluminium frame To break the anodized layer Enhance Photovoltaics suggests a stainless steel toothed washer to be inserted between the nut and the frame B When carrying out the grounding of the modules the aluminium frame must not enter in permanent direct contact with dissimilar metals which contact could result in a galvanic corrosion Stainless steel flat washers can be inserted between frame and grounding lug B Enhance Photovoltaics recommends the use of stainless steel grounding bol
3. in places where flammable gases may be ge nerated fE NHANCE PHOTOVOLTAIC S 3 Installation Enhance Photovoltaics modules should be installed in a location where they will receive the maximum amount of sunlight throughout the year In the Northern Hemisphere modules should face south while in the Southern Hemisphere modules should face north Enhance Photovoltaics modules connected in series should be installed at same orienta tion and tilt angle Different orientations or angles may cause a loss of power output due to the change in sunlight exposure Do not immerse the module in liquid IP 65 The installation of the modules to sea water lakes and seas should be about 500 meters The module should not be exposed to unusual chemical loads Protect solar modules from overvoltage e g voltage peaks of battery charges gene rators etc If the module is connected to a storage battery all precautions of the battery manu facture should be adhered Do not carry out installation in high winds Protects every worker of slipping and fal ling from the roof Prevent possible fallings from objects Secure the work area so that nobody on the roof and beneath the roof can be injured When designing the final layout of the modules in the photovoltaic system on the ground or on a roof we recommend the designer to keep suitable access space to allow easy maintenance and inspection works Enhance Photovoltaic modules must be installe
4. the drawings on the Annex 1 to get more information about the proper use of mounting ho les and load resistance of all module types Enhance Photovoltaics recommends to use all eight mounting holes if excessive wind or snow loads are expected for the PV installation Drainage 4 8 8 o _ Junction box 16 8 3 Additional mounting holes 4 14 9 Label Mounting holes 4 14 9 AG Connector Grounding holes 2 4 Picture 1 top Mounting Holes Picture 2 bottom Installation with Frame Mounting Holes pe M8 Nut 4S ti truct 2 Washer upporting structure 3 Module frame M8 Bolt 6 L 5 Lock washers fS NHANCE PHOTOVOLTAIC S 3 1 2 Installations Using Pressure Clamps Installation using pressure clamps may be executed along both sides of the module frame according to instructions on Annex 1 The obligatory position of the clips along the frame depends on which side of the module is used for the installation as follows Fixing on the long side the clamps must be mounted along the frame at the posi tion of the mounting hole The clamps must be fixed at a distance 25 of the total side length from the frame edge with a tolerance of 50 mm B Fixing on the short side The clamps must be mounted along the frame at the ed ge
5. warranty expresses or implied Enhance Photovoltaics reserves the right to change the manual the PV modules the specifications or product infomations sheets without prior notice Contact Information Enhance Photovoltaics Ltd SOLFEX energy systems Website www enhance photovoltaics com Website www solfex co uk Email sales enhance photovoltaics com Address Units 3 5 Charnley Fold Industrial Estate Bamber Bridge Preston PR5 6PS Tel 44 1772 312847 Email photovoltaicsales solfex co uk 16 fE NHANCE PHOTOVOLTAIC S Annex 1 Installation Using Mounting Holes Snow 2400 Pa Wind 2400 Pa ony hole Mounting hole Mounting hole Mounting hole Installation Using Pressure Clamps Clamping on the short side Snow 2400 Pa Wind 2400 Pa Insertion System Snow 2400 Pa Wind 2400 Pa a v l a v l Snow 5400 Pa Wind 2400 Pa Mounting hole Mounting hole Mounting hole 2 Mounting hole Mounting hole Mounting hole Mounting hole Mounting hole Clamping on the long side Snow 5400 Pa Wind 2400 Pa 1 4 L 25 L 1 4 L 25 L 50 mm 50 mm 1 4 L 25 L 1 4 L 25 L 50 mm 50 mm Snow 5400 Pa Wind 2400 Pa
6. 4 Insertion System Note When using insertion systems where the modules are installed sliding through the inner side of the rails Enhance Photovoltaics recommends the use of PVC frame protectors in order to prevent damage in the anodized layer of the frame 1 Frame protector 2 PV module 3 Supporting structure Picture 5 Insertion System fE NHANCE PHOTOVOLTAIC S 3 1 4 Module Load Resistance Wind Load 2400 Pa Snow Load 5400Pa According to IEC 61215 clause 10 16 2400 Pa corresponds to a wind pressure of 130 km h approximately 800 Pa with a safety factor of 3 for gusty winds Please note that information provided above could vary according to the different mounting systems and configurations as described in the Annex 1 3 2 Electrical Installation The installation requires the execution of electrical connection works for which knowled ge of the relevant safety requirements is necessary Having them carried out by unquali fied personnel would be a risk Modules electrically connected together in a series parallel configuration generate DC electrical energy which may be converted to AC by mean of a solar inverter The resulting PV System may be therefore connected to the local utility grid system As local utilities policies and technical rules on connecting a renewable energy system to their power grids vary from region to region consult a qualified system designers or integrators to de sign such a sy
7. B Galvanic corrosion can occur between the aluminium frame of the PV module and mounting hardware if such hardware is composed of dissimilar metals especially in harsh environments such as environments with high humidity In those cases it is recommended to place neoprene tape PVC washers or stainless steel washers bet ween the PV module frame and the support structure to prevent corrosion B Additionally all module support structures used to support PV modules at correct tilt angles should be wind and snow load rated by appropriate local and civil Directives prior to installation It is not allowed to dismount drill or modify the frame or any other part of the PV module Please contact Enhance Technical Service Contact if module mounting procedure is not clear PV modules by Enhance Photovoltaics can be installed by means of the following processes B Installations Using Frame Mounting Holes B Installations Using Pressure Clamps B Insertion Systems fE NHANCE PHOTOVOLTAIC S 3 1 1 Installations Using Frame Mounting Holes Modules must be securely fixed to the mounting structure using the four pre drilled mounting holes 14mm 9mm placed in the long frame rails at 400 mm from the middle Use M8 stainless steel hardware spring washers and flat washers with a torque of appro ximately 10 newton metre Nm for normal installation Galvanized or hot dipped zinc plated hardware is also acceptable Please refer to
8. aics standard PV modules shown as below Drainage 4 8 8 16 8 3 Additional mounting holes Label Mounting holes 4 14 9 Ame Connector Grounding holes 2 4 A 1300 1 15 fE NHANCE PHOTOVOLTAIC S Disclaimer of Liability Installers must follow all safety precautions as described in this guide as well as local requirement and re gulations by law or authorised organisations Because the use of this manual and the conditions or methods of installation operation use and main tenance of photovoltaic PV product are beyond Enhance Photovoltaics s control Enhance Photovoltaies will not accept any responsibility and expressly disclaims any liability for loss damage or expense arising out of or in any way connected with such installation operation use or maintenance No responsibility will be assumed by Enhance Photovoltaics for any infringement of patents or other rights of third parties which may result from use of the PV module No license is granted by implication or otherwise under any patent or patent rights The information in this manual is based on Enhance Photovoltaics s knowledge and experience and it is believed to be reliable Nevertheless such information including product specification without limitations and suggestions do not constitute a
9. d and stored in the following conditions below 85 RH fE NHANCE PHOTOVOLTAIC S B When installing a module on a roof or building ensure that it is securely fastened and prevented from falling because of wind snow or other mechanical loads B Provide adequate ventilation under a module for cooling Enhance Photovoltaics recommends 10 cm minimum air space between module and mounting surface g Modules should not to be shaded at any time of trees antennas cables houses etc If a module is shaded or even partially shaded it will fail to perform at ideal conditions and results in lower power output 3 1 Mechanical Installation B Always use structures and materials specifically developed and certified for photo voltaic modules installation B The minimum distance between two fixed modules for linear thermal expansion of the module frames should be 5 mm Nevertheless the recommended distance bet ween two solar modules is 20 mm to allow wind circulation in order to reduce pres sure loads and improve module ventilation The PV module should not be mounted in such a way that the drain holes of PV module can incur blockage B The PV modules are suitable for mechanical mounting both with a horizontal or ver tical orientation In choosing the orientation please keep in mind the internal PV mo dule by pass diode configuration to ensure the optimum electrical behaviour from any potential shading over the modules
10. d connectors Use appropriate safety equipment insulated tools insulating gloves etc when handling modules Do not disconnect the grounding when doing system maintenance For any electrical maintenance the PV system must first be shut down Improper maintenance can cause lethal electric shock and or burns 13 fE NHANCE PHOTOVOLTAIC S 4 2 Cleaning Dirt and dust can accumulate on the glass surface of the PV module over time particularly in low inclination installations This can cause a general decrease of power output and also sedimentation on the lower edge of the modules due to dirt accumulation Enhance Photovoltaics recommends a periodic cleaning of PV modules to ensure maximum power output especially in regions with high quantity of dust in the air or low precipitations as follows BR Under most weather conditions normal rainfall is enough to keep the PV module glass surface clean Clean the glass surface of the module as necessary and consider that lower inclination requires more cleaning frequency B Always use water and a soft sponge or cloth for cleaning A mild non abrasive clea ning agent can be used to remove stubborn dirt High mineral content water is not recommended as it may leave residual deposits on the module B Enhance Photovoltaic modules may be equipt with antireflective coating glass This technology provides Enhance Photovoltaic modules with high transmittance and low re reflectivity f
11. eatures which improves the module power output reduces the dust and dirt deposition and produces very low glare To avoid any damage to this layer do not clean the modules with high pressure washers steam or corrosive chemicals Do not use abrasive sponges or aggressive tools that could scratch the module surface under no circumstance should the dirt be dry removed as this would cause micro scratches which could have a negative impact on the module s performances gy To avoid a possible thermal shock clean the modules during early morning when the module is still cold This is especially recommended in regions with hotter tem peratures B In cold environments with snow do not try to remove the frozen snow or ice from the module scratching on the front glass Only soft snow can be removed gently with a soft brush in order to improve the production Don t clean modules having broken glass or exposed wiring This can cause a gene ral electrical failure of the module or electrical shock hazard 5 Modules End of Life Enhance Photovoltaics is a member of the PV cycle association a European non profit a association managing a fully operational collection and recycling scheme for end of life PV CYCLE photovoltaic modules throughout Europe Please visit the website of PV CYCLE Associ ation for further information www pvcycle org 14 fE NHANCE PHOTOVOLTAIC S 6 Module Specifications Drawing for Enhance Photovolt
12. ing with modules without any cover the safety re gulations for live electrical equipment need to be followed Do not wear metallic rings watchbands ear nose or lip rings or other metallic de vices while installing or troubleshooting photovoltaic systems in order to avoid elec tric shock Use only insulated tools that are approved for working on electrical installations Abi de with the safety regulations for all other components used in the PV system inclu ding wiring and cables connectors charging regulators inverters storage batteries and rechargeable batteries etc D Use only equipment connectors wiring and support frames suitable for a solar elec tric system Always use the same type of module within a particular photovoltaic system E Do not attempt to repair any part of the PV module 2 4 Fire Safety Enhance Photovoltaic modules have passed all the required safety tests according to the IEC EN 61730 Directives with Application Class A and fire safety has been rated as Class C The devices of on roof systems can affect the fire safety of a building Improper installations can result in a hazard in case of fire In the case of on roof applications the modules must be mounted above a fire resistant surface Rooftop installations should be placed over fire resistant roofs only fire class A is recommended For rooftop installations only fire resistant components should be used Do not use panels near equipment or
13. kaging for shipment Do not damage or scratch the PV module surfaces Do not use the junction boxes and the cables as a grip Do not stand or step on module Do not drop module or allow objects to fall on module To avoid glass breakage do not place any heavy objects on the module Do not set the module down hard on any surface Inappropriate transport and installation may break module FRAGILE HANDLE STACKING WITH CARE Ae LUMITATION 2 3 Installation Safety Installing solar photovoltaic systems requires specialized skills and knowledge One in dividual module may generate DC voltages greater than 30 V when exposed to light of any intensity Contact with a DC voltage of 30 V or more is potentially hazardous Series or parallel connection of the modules increases the voltage or electric current respectively B Do not disconnect modules under load to avoid electrical arcs Keep connectors dry and clean D Do not insert electrically conductive parts into the plugs and sockets B Do not install solar modules and wiring with wet plugs and sockets fE NHANCE PHOTOVOLTAIC S Exercise extreme caution when carrying out and work on the wiring High contact voltage can occur in the inverter when it is isolated Protect solar modules from overvoltage e g voltage peaks of battery charges gene rators etc At installation modules should be kept entirely away from light or covered with a dark opaque material When work
14. ltage Short Circuit Current all as measured under Standard Test Conditions weight dimensions Maximum System Voltage Maximum series fuse etc Serial number each individual module is identified by a unique serial number coupled with a barcode They are permanently inserted inside the laminate under the front glass of the module visible when vie wing from the front of the module There is only one serial number coupled with one barcode on the module 2 1 General Safety All PV modules shall be installed according to all local and national applicable standards codes and re gulations Installation should be performed only by qualified persons The installators bear the risk of all injury that might occur during installation including without limitation the risk of electric shock Check and follow all safety precautions specified even for the other components of the system B Rooftop installations should be placed over fire resistant roofs only Do not attempt to disassemble the modules and do not remove any attached nameplates or components from the modules Do not apply paint or adhesive to module top surface Do not use mirrors or other magnifiers to artificially concentrate sunlight on the modules Do not expose back sheet foils directly to sunlight fE NHANCE PHOTOVOLTAIC S 2 2 Handling Safety B Do not exceed the maximum height of pallets stacked on top of each other Maxi mum height is 2 pallets standard pac
15. plica ble in Europe Special conditions should always be clarified by an expert so that the roof requirements as well as other individual requirements are duly taken into account Keep these installation instructions in a safe place Overview 1 Product Identifcation canes pag 2 2 Safety L aeeeeraen pag 2 2 1 General Safety 2 2 Handling Safety 2 3 Installation Safety 2 4 Fire Safety 3 Installation 3 1 Mechanical Installation nana pag 6 3 1 1 Installations Using Frame Mounting Holes 3 1 2 Installations Using Pressure Clamps 3 1 3 Insertion Systems 3 1 4 Module Resistance 3 2 Electrical Installation 0 aes pag 10 3 2 1 General Considerations 3 2 2 System Grounding 4 Maintenance 2 p aeren pag 13 4 1 General Maintenance 4 2 Cleaning ATT pag 14 5 Module End of Life 1 6 Module Specification netennian pag 15 fE NHANCE PHOTOVOLTAIC S 7 Disclaimer of Liability 2 nettnnne pag 16 8 Contact Information pag 16 Annex ppa oean pag 17 Installations Using Frame Mounting Holes Installations Using Pressure Clamps Insertion Systems Product Identification Each module can be identified by means of the following embedded information Nameplate it is to be found on the module backside According to EN 50380 Directives it provides infor mation about the main parameters of the module Product Type Maximum Power Current at Maximum Power Voltage at Maximum power Open Circuit Vo
16. s of the module the clamp fixing area lies within 25 of the overall length of the short side from the frame edge Note that on both sides of the module the pressure clamps should be mounted always in a symmetric po sition with respect to the middle line for a proper load distribution Refer to the drawings on the Annex 1 B Clamps must be installed according to the manufacturer s specific instructions Do not apply excessive pressure on the frame such that the frame deforms Enhance Photovoltaics recommends a torque of approximately 10 newton metre N m please refer to the clamp manufacturer for specific hardware and torque requirements B The clamps must only fix the modules through the contact with the frame only Do not allow contact between clamp and glass and avoid shadowing effects from the module clamps B Pressure clamps should not be mounted outside the specified areas otherwise the module mechanical resistance could be affected Lock washer 2 a D 3 Washer 4 Clamping plate 5 M8 T bolt Picture 3 Installation with Pressure Clamps fS NHANCE PHOTOVOLTAIC S 3 1 3 Insertion Systems Insertion systems on the short sides of the module are allowed with a limitation on the maximum load resistance of 2400 Pa Insertion systems on the long side of the module are not affected by any limitation and are allowed with a maximum of 5400 Pa for snow load See Annex 1 for more information Picture
17. stem to comply with the Directives Permits are normally required for installing a PV system and the utility must formally approve and inspect the system before its connection to the grid can be ac cepted The connection of the inverter to the grid needs to be done by a competent authorized company The PV system electrical installation must be executed in accordance with the res pective National Electrical Code or applicable National Regulations B Use only insulated tools that are approved for working on electrical installations Abide with the safety regulations for all the components used in the system inclu ding wiring and cables connectors charge regulators inverters storage batteries etc To avoid conductor loops the strings and should be laid together The cable groove on the cross profile can hereby be used If possible roof penetration should only be at one point 10 fE NHANCE PHOTOVOLTAIC S 3 2 1 General Considerations B Modules are fitted with two pre assembled sunlight resistant isolated cable leads which are terminated with PV fast connectors The positive terminal has a female connector while the negative terminal has a male connector These cable leads and connectors must not be removed or cut off B Several modules are connected in series and then in parallel to form a PV array espe cially for applications with high operating voltage When modules are connected in series the to
18. tal voltage of the resulting sting is the sum of the individual voltages of the modules Do not use different type of modules in the same circuit in order to avoid mismatch power loss or damage to the PV system D When selecting the size of the cables that connect the module strings to the solar inverter it is recommended to refer to the nameplate electrical parameters of the related module type When selecting the size of the cables that connect the module strings to the solar inverter it is recommended to refer to the nameplate electrical parameters of the related module type D For electrical design considerations the values given in the module label or data sheet of the related model type should be multiplied by a factor of 1 25 for Short Circuit Current Isc and 1 10 for Open Circuit Voltage Voc when determining com ponent voltage ratings conductor current ratings fuse sizes and the rest of electrical hardware connected to the module strings Nevertheless consult rated local wiring regulations to determine system wire size type and temperature allowed for your installation D Parallel interconnection of more than two strings requires the installation of string fuses The maximum fuse current is stated to be 15 amps If more than 2 strings are interconnected in parallel this value might be exceeded in the event of a fault 3 2 2 System Grounding Enhance modules are certified for Class A applications IEC 61730 Safety Class
19. ts or grounding lugs specifically designed for photovoltaic applications Drainage 4 8 8 H Junction box o 16 8 3 Additional mounting holes 4 14 9 Label Mounting holes 4 14 9 AR Connector 800 1 Grounding holes 2 4 A 1300 1 Picture 6 Grounding Holes and Grouding Bolt fE NHANCE PHOTOVOLTAIC S 4 Maintenance 4 1 General maintenance Enhance Photovoltaics recommends the following maintenance in order to ensure optimum performance of the module Check the electrical and mechanical connections every six months to verify that they are clean secure and undamaged Check that mounting hardware terminal screws and grounding components are tightly secured and are not affected by corrosion Replacement modules must be the same type of those to be repla ced Modules generate high voltage when exposed to sunlight Please cover the front surface of modules with an opaque no scratching material when repairing Repairing works must be performed by Specialized and properly trained personnel only Follow the maintenance instructions for all components used in the system such as support frames charge regulators inverters batte ries etc If any problem arises have them investigated by a competent spe cialist Do not touch live parts of cables an
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