CSUN Crystalline Silicon PV Module Products Installation Manual
Contents
1. Use suitable equipment connectors wiring and mounting system for a PV system It is better to use the same type modules in one system Do not install or handle the modules when they are wet or during strong wind Keep the junction box cover closed Modules are constructed with tempered glass which shall be handled with care Improper operations may cause the tempered glass breakage If the front glass is broken or if the backsheet is burned out contact with any module surface or the aluminum frame can produce electrical shock particularly when the module is wet Broken or damaged modules must be disposed properly When exposed to direct sunlight one individual solar module may generate DC voltages greater than 30 volts it is extremely dangerous to contact it Completely cover the module with an opaque material during installation to keep electricity from being generated Do not wear metallic rings watchbands ear nose lip rings or other metallic devices while installing or troubleshooting photovoltaic systems Use insulated tools that are approved for working on electrical installations and always keep them dry The triangle hole punched on the backside frame of the module is the drain hole which cannot be blocked The maximum system voltage indicated in the nameplate is 1000 V Attention During the system Installation the maximum open circuit voltage in series cannot exceed the maximum system voltage During modules2. interconnection guarantee to fix the connecting cables to the mounting system so as to restrict the amplitude of swing of the slack part of the wire Conform to the allowable minimum bending radius of the wire Always protect the wire with conduit where animals or children can touch it Please use the connector which is specially designed for photovoltaic system and assemble it with the tools recommended or specified by the manufacturer In case that the connector applicable to the solar photovoltaic system is required please contact the local supplier CSUN energy for the future Make sure that the polarity is correct when connecting the module with inverter storage battery or combiner box to avoid the damage of bypass diodes in the modules due to incorrect polarity 4 Product Identification and Current Sorting A Product Identification Each module has labels providing the following information Nameplate Describes the product type rated power rated current rated voltage open circuit voltage short circuit current all are measured at STC weight dimension maximum system voltage and the fuse rating are all shown on the nameplate Barcode Each module has a unique serial number It contains the relevant production information of the module B Current Sorting Each module has a specific label on either side of long aluminum frame as shown in FIG 1 with the following information Modules are sorted by Imp
3. CSUN energy for the future CSUN Crystalline Silicon PV Module Products Installation Manual IEC Version ADD No 123 Focheng West Road Jiangning Development Zone Nanjing China Code 211100 TEL 86 25 52766666 6530 6728 FAX 86 25 52766767 EMAIL info chinasunergy com WEB www chinasunergy com CSUN energy for the future Table of Contents L General Information prsi ceseslees sevsness cess dacs sobs vess cake deus oxi aaa aaa aa a a saian 1 2 Disclaimer of Liability irnia iaai an A REA AREE AAA EAE AAA 1 3 palety Precaution aane a a O A 2 DW GCGE LAL SAL GLY ee a a a a a a teevscnatetenec eteeteneters 2 SD Handling Sateey cies cc ciersdevanesscavdvessdavanehscavdtnescavanehscdcdhessdevencbacduddenscavanesscdcdbeesdavancsscdvddseacavanasscavdheesdavanessel 2 3 3 Installation Safety ic 4chsesisecics tailed fein ealeadehn dienes it acide sha ainda a iS 3 4 Product Identification and Current Sorting cscecceesesseceseceeeeseceseceaeeeaeceaeceseceaeceaeceaeceaeceaeeeaeeeaeeeaeeeaeeeaeeeaeen 4 5 Electrical Property Parameters of Modules 0 eccecceesecesseeseeesecesecesecenecsnecnecnecsnecsecnecueceneceneceneceeneceneceeeeeneees 5 6 Installation Instructions 5 sssedecdscs5icsocescdecs sassdibances igspansetavauesedesnuvas igeeseesiesdugapsgeesevsiespeeyssosedsevesstesoeeapioes sansbesbuesiues 5 6 1 Installation Environment eee eseeseesecsseeseesecseceseesesseceeeeseesecsessaceseesececeseesesseseeeeseese
4. be installed in the place where the sunshine is adequate The module should not be shaded at any time during its operation During installation the module surface shall not be partly shaded by clothes tools packaging materials etc Install the module in well ventilated place and guarantee that adequate natural air heat dissipation channels are provided at the back and sides of the module to ensure that the heat generated during operation is radiated in time Never place the module in locations where flammable gases may be easily generated or collected CSUN suggests installing the module in dry areas where the climate is moderate In case of the special installation environments such as the seaside farm high humidity environment and sandstorm environment contact the local dealer for professional support and confirmation Modules connected in series should be at the same tilt and azimuth Differing orientations or angles may cause a loss of power output due to differing amount of sunlight exposure for each module Typically the optimal tilt for a module is roughly the same as the installation location 6 2 Selection of Mounting Structure Always conform to the instruction manual and safety rules attached to the mounting system CSUN energy for the future The entire PV system consisting of modules must be able to withstand anticipated mechanical pressure which comes from local wind force snow etc Drilling holes on the su
5. cal laws and regulations It is need to obtain the required certificates in advance when necessary such as the building permit 3 2 Handling Safety Store modules in a dry and ventilated environment Keep children and unauthorized persons away from the modules while transporting and installing them Improper transportation and placing may lead to glass breakage or power loss of the modules resulting in the loss of the use value of modules Handle modules with care Lift and put down modules gently It is forbidden to pull the junction box or cables when carry or lift the modules Carry a module by its edges with two or more persons Do not place excessive loads on the module or twist the module frame Do not stack the modules for transportation Pay special attention not to collide scratch or press the module backside when transporting and installing the modules To avoid module damage do not stand or step on the module Do not drop or place objects on the modules such as tools Do not set the module down on any hard surface which maybe cause the cells broken CSUN energy for the future Inappropriate transport and installation may damage the module Control the vehicle speed when the road condition is relatively poor 3 3 Installation Safety Abide by the safety regulations for all other components used in the system including wiring and cables connectors solar charge controller inverters storage batteries etc
6. ed by connecting the module frame s and structural members contiguously using a suitable grounding conductor The grounding conductor must then make a connection to earth using a suitable earth ground electrode Recommend to use the ground wire accessories lugs connected to ground Cable Welding ground cable to the jack of lugs and then with the M4 screws inserted into the wiring nose ring and t the grounding hole of the module frame fastening with nuts Star spring washers should be used to prevent the screws from loosening and lead to poor grounding If the module is used in high temperature and high humidity environment CSUN suggests the customer provide the inverter which allows negative grounding and contains isolation transformer as shown in FIG9 ns ne o 3 D S 2 T D 2 gt D 5 o D G gt 4 FIG 9 Schematic diagram for grounding potential of the inverter 12 CSUN energy for the future M4 Nut a Cup Washer FIG 10 a Grounding hole FIG 10 b Grounding method 8 Maintenance and Care Clean the glass surface on a regular basis In general use water and a soft sponge or cloth for cleaning A mild non abrasive cleaning agent can be used to remove stubborn dirt Avoid pressing part of the module hard during cleaning Pressing hard on part of the module may cause glass deformation cell damage and service life reduction of the module Remove
7. f the mounting system to prevent the lowest edge of the module from being covered by snow for a long time in winter in areas that experience heavy snowfalls The module shall be installed on the mounting system with appropriate height instead of being directly laid on the ground In addition assure the lowest portion of the module is placed high enough 900 mm so that it is not shaded by plants or trees and the module is not damaged by sand and stone driven by wind or the module surface is not shaded by the mud 7 CSUN energy for the future splashed by rain water 6 4 Two Installation Methods Modules can be installed on the frame using mounting holes or clamps Modules must be installed according to the following examples Not mounting the modules according to these instructions may void the warranty The modules have been evaluated by UL for a maximum positive or negative design loading of 2 400 Pa and for standard installation the four symmetry holes close to the inner side on module frames or pressure clamp shall be used to fix the module to the support frame CUSN modules can sustain 2400 Pa wind pressure and 5400 Pa snow load System designer and installer are responsible for load calculations The mounting system and other various goods amp materials required suchas screw shall be made of durable corrosion resistant and UV resistant materials 1 Screw fitting Using corrosion proof screws M8 in the existing ins
8. ith each others and the same requirements shall go to the connection terminals of module end and system end for the connectors of the different manufacturers may not be compatible with each others which easily leads to mismatch risk Never perform pretreatment to modules including connector junction box and cable with lubricating oil or cleaning agent made of alkane materials during installation The cross section area and connector capacity of the cable selected must satisfy the maximum short circuit current of the system It is recommended that the cross section area of the cable used for the single module is 11 CSUN energy for the future 4mm and the rated current of the connector is greater than 10A Please note that the upper temperature limit of the cable and connector is 85 C and 105 C respectively When installing the module place the end with the junction box up and try to avoid the rain Do not carry out installation in rainy weather for humidity will void the insulation protection thus causing safety accidents 7 2 Grounding All module frames and mounting racks must be properly grounded The grounding wire must be properly fastened to the module frame to assure good electrical contact Use the recommended type or an equivalent connector for this wire Ifthe mount system is made of metal the surface of the structure must be electroplated and have excellent conductivity Proper grounding is achiev
9. le frame by the clamp of this type of module F Clamped length of the module frame by the clamp of this type of module NOTES CSUN s limited warranty will be void in cases where improper clamps or installation methods deviating from this manual are used When installing inter modules or end type clamps take measures so as A Not to bend the module frame B The clips must only fix the modules by the contact with the frame Do not allow contact between clip and glass C Not to damage the surface of the frame D When mounting be sure that the module s drain holes are not blocked For matters concerning installation not mentioned in this section contact the local dealer for professional support 7 Electrical Installation 7 1 General With Regard to Electrical Installation Try to use the modules with the same configuration in the same photovoltaic system If the modules are connected in series the total voltage is the sum of voltages of all the modules and the maximum number of the series modules N Vmax System Voc at STC Ifthe system requires the installation of high current several photovoltaic modules can be connected in parallel and total current is the sum of current of all the modules The maximum number of the parallel module strings N Imax fuse rating Isc When connecting modules make sure that the connectors of the same series module shall come from the same manufacturer or totally be compatible w
10. manual before installation Any questions please contact the sales or customer service personnel of CSUN for further explanations The installer should conform to all safety precautions in the manual and local laws amp regulations when installing module before installing a solar photovoltaic system installers should become familiar with the mechanical and electrical requirement for such a system CSUN has the right to refuse to compensate for the product damage due to construction or design defects of the solar photovoltaic system Keep this manual in a safe place for future reference care and maintenance and in case of sale or disposal of the modules 2 Disclaimer of Liability Customers shall strictly abide by the requirements of this manual when installing the modules of CSUN If the conditions or methods of the installation handling use and maintenance of the customer are beyond the range specified in this manual and cause damage CSUN does not assume responsibility for any loss damage or expense thus caused No responsibility is assumed by CSUN for any infringement of patent right or other rights of third parties which may result from the customer s use of the CSUN s modules No patent license or patent rights is granted to customer express or implied due to its use of CSUN s modules The information in this manual is based on CSUN s best knowledge and experience and is believed to be reliable but such information including p
11. ntilation and heat dissipation behind the module During stacking type installation the module shall be installed on the fire resistant roof The modules Fire Resistance Rated Class of the modules is Class C and the modules are suitable for mounting on an above Class A roof Do not install modules on a roof or building during strong winds For the roof system installed in the area that ever experienced relatively heavy snowfall or snow cover the customer shall reinforce the mounting system at the lower frame of the module in order to prevent the lower frame from being pressed and damaged by the falling snow and avoid the module damage due to melt snow freezing in daytime CSUN suggests to selecting the support reinforcing mechanism shown in Figure 2 CSUN energy for the future ce fel Heo q is ia m ole p sjam ca et elf f el XY ct zm r S r FIG 2 Schematic diagram of reinforcement mounting of module B Pole Mounting When installing a module on a pole choose a pole and module mounting structure that will withstand the anticipated wind power of the local area The support rod must be constructed on a solid foundation FIG 3 Pole mounting FIG 4 Ground mounting C Ground Mounting Select the height o
12. p current at maximum power point Different color labels with distinct alphabetical letters I Iz Is L are used to represent the Impp class CSUN recommends connecting the same Impp class modules in series in order to avoid or minimize power loss due to mismatch FRONT VIET FIG 1 Label of module current CSUN energy for the future 5 Electrical Property Parameters of Modules Under Standard Test Conditions 1 000W m AM 1 5 and 25 C 77 F the electric characteristics including Isc Voc and Pmax the deviation between the measued value and nominal value is within 10 Under normal outdoor conditions a module is likely to produce different current and voltage than the values measured under STC in the specification of CSUN module products Therefore when determining the parameters related to the power output of the module for example nominal voltage conductor capacity fuse capacity and controller capacity etc refer to the values of short circuit current and open circuit voltage of the modules and take 125 of those values during design and installation The maximum nominal voltage for all module series is 1000V according to IEC standards 6 Installation Instructions 6 1 Installation Environment In most applications PV modules should be installed in a location where they will receive maximum sunlight throughout the year The module shall
13. rface of module glass may void the warranty Drilling additional mounting holes on module frames may void the warranty The mounting system structure must be made of durable corrosion resistant and UV resistant materials Forces generated during thermal expansion and contraction of the mounting system structure shall not influence the performance and use of the module The bearing surface of the mounting structure must be smooth without any twist or deformation and the connected support frames shall be at the same height 6 3 Three kinds of Mounting A Roof Mounting Itis necessary to provide a special support frame for the roof mounting When installing a module on a roof or building ensure that it is securely fastened and cannot fall or be damaged as a result of strong winds or heavy snows During roof mounting check the building codes being used to ensure that the building and its structure where the module is installed have adequate bearing capacity The roof needs to be penetrated during module installation and fixing shall be sealed to avoid rainwater seepage To be suitable for operation reduce steam condensation and facilitate the ventilation amp heat dissipation of the module during tile installation the module shall be parallel to the wall or roof surface of the building and the clearance between module and surface of the wall or roof shall be at least 115mm to prevent wiring damage and to allow air circulation ve
14. roduct specification without limitations and suggestions do not specifications or product information without prior notice CSUN energy for the future 3 Safety Precaution 3 1 General Safety Installing solar photovoltaic systems require specialized skills and knowledge Installation should be performed only by qualified persons Installers should assume the risk of all injuries that might occur during installation such as electric shock A single module may produce the direct current hereafter is referred to as DC voltage of above 30V in direct sunlight and it is extremely dangerous to contact it Do not touch or lean on an operating module Photovoltaic modules are designed for outdoor use Modules may be mounted on ground rooftops vehicles or boats Proper design of support structures is the responsibility of the system designers or installers Mounting holes or clamp range and numbers suggested in this manual shall be used Do not disconnect under load or apply paint or adhesive to module surface Do not use mirrors or other magnifiers to artificially concentrate sunlight on the modules Do not expose the backside of modules directly to sunlight for a long time Keep all electrical contacts clean and dry Do not change the wiring of the bypass diodes Do not disassemble the modules or remove any attached nameplates or components from the modules When installing the modules it is should abide by the relevant lo
15. seseaseaesaeseeaeegs 5 6 2 Selectrom Of Mounting SUCHE fas snc sacs ee Sbdk na ninaa a AE EAN ra ebb EAE a duds doce N aA AEEA EEANN 5 6 3 Three Kinds of MOunting cccccccssccssseeseeeseeeceseecsseeeseneeseaeeesseeceseecseneceeeeseaeeeeseessseeeneeaeeeneeseeeenseeeees 6 A ROOF MOnnUNE oeaiei 6 CB Pole MOUniDE orianioriinioiiaiin anie vats EAA AAT R ENAA ANN 7 C Ground Mounting cessneneaniennn a aa 7 6 4 Two Installation Methods cccesccescceseeeseceseceseceseceseceaeceaeceaeceaeceseceaeceaeceaeeeaeceaeceseceaeceaeceaeeeaeeeaeeeaeeeaeens 8 PELE CHICA IS tall ath e E A dace inesveec ededace T snccadeesas dace ins cadecenseddcednccadeessesseedacedescudioa 11 7 1 General With Regard to Electrical Installation eee cesceesceseceseeeseceseceseeeseceeeeseceseeeeceeeeeeeeeeseenees 11 T2 GLOUNGING seponeren EE cataahncseasceeecnieguacseasthascngeadiazeacshanste E TE EEEE E e 12 8 Maintenance and Care CSUN energy for the future Crystalline Silicon PV Module Products Installation Manual IEC Version Version May 2013 1 General Information This manual contains information regarding the installation and safe handling of the photovoltaic module hereafter is referred to as module produced by China Sunergy Nanjing Co Ltd CEEG Nanjing Renewable Energy Co Ltd and CEEG Shanghai Solar Science Technology Co Ltd hereinafter referred to as CSUN Installers must read and understand the
16. stallation schemes which are not included in this manual please contact the local dealer for professional support End Clip Middle Clip FIG 7 a Clamping mounting method CSUN energy for the future Use 4 standard mounting holes long side FIG 7 b Long side installation If heavy snowfall relatively large snow load or large wind pressure exist in the module installation area CSUN suggests the customer to selecting the 5400Pa strengthening installation scheme to clamp and fix the module as shown in FIG 8 to improve the bearing capacity of the module for static snow load at front side and dynamic wind pressure at back side and enhance the system capacity a A e _ __ E A A E E _ Ela FIG 8 Module type Mechanical Loading Pa A mm B mm C mm D mm E mm F mm 2400 1580 808 350450 10 gt 80 CSUN200 72M 5400 1580 808 200450 790450 10 gt 80 2400 1640 990 350450 10 gt 80 CSUN250 60M P 5400 1640 990 200450 820 50 10 gt 80 2400 1956 990 400450 10 gt 80 CSUN300 72M P_ I ttt tr 5400 1956 990 250450 978450 10 gt 80 Note A Length of this type of module B Width of this type of module 10 CSUN energy for the future C The distance of clamp center from the edge of this type of module D The distance of clamp center 2 from the edge of this type of module E Clamped width of the modu
17. talling holes in the module frame Do not attempt to drill holes in the glass surface or additional mounting The frame of each module has 4 mounting holes used to secure The module frame must be attached to the mounting system using M8 stainless steel hardware together with spring washers and flat washers in four places symmetrical on the module b 3 A i i i Mounting holes for x normal use For high wind and snow loads these J mounting holes must i l also be used FIG 5 Mounting holes CSUN energy for the future A Flat Washer Supporting Structurer See K Spring Washer M8 Nut T FIG6 Screw fitting method 2 Clamp fitting Using suitable module clamps on the side of the module frame to mount the modules we suggest installer use the long side of the module frame When using clamps to clamp the module frame the area of side A of module frame clamped by each clamp shall be no less than 800 mm The modules should be fixed to the structure using M8 stainless steel hardware together with corrosion proof clamps on the long side The clamps must be mounted at the position of the mounting hole or CSUN suggested clamp range and numbers Note that long sides should always be mounted in a symmetric position respect to the center Recommended torque should be 8 Newton meters Please see details in FIG 7 Ifthe customer has special clamping and in
18. the snow covered on the module in time to avoid the module damage caused by long term accumulation of snow cover and freezing of melted snow Examine the PV module s for signs of deterioration Check all wiring for possible rodent damage weathering and that all connections are tight and corrosion free Check electrical leakage to ground Check fixing screws and mounting brackets adjust and tighten as necessary Never clean the electrical connectors including cable junction box and connector with the cleaning agents that contain organic matters such as alkane If any problem arises have it investigated by a competent specialist Tf the maintenance measures are not included in this manual please contact the local dealer for professional support 13
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