This manual contains information regarding the safe installation and
Contents
1. Picture6 Grounding Holes and Grounding Bolt 12 a fC sunhappy Happy with the sun 4 Maintenance 4 1 General maintenance SUNHAPPY POWER recommends the following maintenance in order to ensure optimum performance of the module rd 7 EMited AA M 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 replaced 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 batteries etc If any problem arises have them investigated by a competent specialist Do not touch live parts of cables and 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 4 9 sunhappy X 4 2 Clea2. is sunhappy a fy sunhappy Happy with the sun This manual contains information regarding the safe installation and handling of photovoltaic modules produced by Sunhappy Power GmbH SUNHAPPY POWER All the instructions provided in this manual should be read carefully and understood before attempting to install the modules Please contact SUNHAPPY POWER 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 SUNHAPPY POWER They are meant to provide you with valuable information to ensure a smooth and correct installation of SUNHAPPY POWER modules SUNHAPPY POWER modules are made of carefully selected materials They are tested and approved by acknowledged independent certification authorities and may only be installed by qualified professional companies Please observe the standards and regulations applying to photovoltaic systems in the relevant countries as well as the rules of the employers liability insurance associations for accident 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 applicable in Europe Special conditions should always be clarified by an expert so that the roof requirements a
3. SUNHAPPY POWER recommends to use PVC frame protectors in order to prevent damage in the anodized layer of the frame 1 Frame protector 2 PV module 3 Supporting structure Pictured Installation System sunha N Happy with the sun 3 1 4 Module Load Resistance Wind Load 2400 Pa Snow Load 5400 Pa 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 amp The installation requires the execution of electrical connection works for which knowledge of the relevant safety requirements is necessary Having them carried out by unqualified 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 design such a system to comply with the Directives Permits are normally required for installing a PV system and the utility must formally a
4. any potential shading over the modules 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 between the PV module frame and the support structure to prevent corrosion 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 SUNHAPPY Technical Service Contact if module mounting procedure is not clear a fy sunhappy Happy with the sun PV modules by SUNHAPPY POWER can be installed by means of the following processes Installations Using Frame Mounting Holes Q Q Installations Using Pressure Clamps Insertion Systems 3 1 1 Installations Using Frame Mounting Holes Modules must be securely fixed to the mounting structure using the four predrilled Oo mounting holes 10mm 6 5mm placed in the long frame rails at 390 mm from the eage Use M6 stainless steel hardware spring washers and flat washers with a torque of approximately 10 newton metre Nm for normal installation Galvanized or hot dipped zinc plated
5. guide as well as local requirement and regulations by law or authorised organisations Because the use of this manual and the conditions or methods of installation operation use and maintenance of photovoltaic PV product are beyond SUNHAPPY POWER s control SUNHAPPY POWER 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 SUNHAPPY POWER 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 SUNHAPPY POWER 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 warranty expresses or implied SUNHAPPY POWER reserves the right to change the manual the PV modules the specifications or product information sheets without prior notice 8 Contact Information Sunhappy Power GmbH Website www sunhappy de Address Am Gewerbegebiet 12 27243 Gro lppener Germany Tel 49 0 42241419470 Email sales sunhappy de 16 a fy sunhappy Happy with the sun Annex1 Installations Using Frame Mounting Holes Snow 2400 Pa Wind 2400 Pa Snow 5400
6. Pa Wind 2400 Pa Mounting hole Mounting hole Installations Using Pressure Clamps Clamping on the short side Clamping on the long side Snow 2400 Pa Wind 2400 Pa Snow 5400 Pa Wind 2400 Pa 1 4 L 25 L 1 4 L 25 L 0 mm 0 mm g l g L 1 4 L 25 L 1 4 L 25 L 50 mm 50 mm Snow 2400 Pa Wind 2400 Pa Snow 5400 Pa Wind 2400 Pa Insertion Systems
7. ay be generated a fy sunhappy Happy with the sun 3 Installation SUNHAPPY POWER PV 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 SUNHAPPY POWER PV modules connected in series should be installed at same orientation and tilt angle Different orientations or angles may cause a loss of power output due to the change in sunlight exposure The module should not be exposed to unusual chemical loads 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 Protect solar modules from overvoltage e g voltage peaks of battery charges generators etc If the module is connected to a storage battery all precautions of the battery manufacture should be adhered Do not carry out installation in high winds Protects every worker of slipping and falling 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 SUNHAPPY POWER PV modules must be installed and stored in the f
8. ays in a symmetric position with respect to the middle line for a proper load distribution Refer to the drawings on the Annex 1 Clamps must be installed according to the manufacturer s specific instructions Do not apply excessive pressure on the frame such that the frame deforms SUNHAPPY POWER recommends a torque of approximately 10 newton metre Nm however please refer to the clamp manufacturer for specific hardware and torque requirements gt 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 Pressure clamps should not be mounted outside the specified areas otherwise the module mechanical resistance could be affected O s MAN IGA R S E D oe n a NNN LLLI VELL LLL 2 SOS ILLU SMO OY e __ MSS gp YZ A h 2 Picture3 Installation with Pressure Clamps a fy sunhappy lt 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 Picture4 Installation System Note When using insertion systems where the modules are installed sliding through the inner side of the rails
9. ch the PV module surfaces Do not stand or step on module gt Do not drop module or allow objects to fall on module Do not use the junction boxes and the cables as a grip To avoid glass breakage do not place any heavy objects on the module gt Do not set the module down hard on any surface Inappropriate transport and installation may break module 2 le e 2 FRAGLE HANDLE DO NOT STEP STACKING WITH CARE LIMITATION Installing solar photovoltaic systems requires specialized skills and knowledge One individual 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 gt Do not disconnect modules under load to avoid electrical arcs Keep connectors dry and clean gt Do not insert electrically conductive parts into the plugs and sockets Do not install solar modules and wiring with wet plugs and sockets a fy sunhappy Happy with the sun 2 4 Fire Safety 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 generators etc At installation modules should be kept entirely away from light or covered with a dark opaque material When work
10. fetyrelated grounding of racking system and or module frames In case of executing the grounding of the module frames SUNHAPPY POWER recommends taking into account the following considerations 11 a fC sunhappy Happy with the sun gt The long frame rails are equipped with predrilled grounding holes in their centre These holes shall be used only for grounding purposes and must not be used for mounting purposes gt 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 applicable National Electrical Regulation Make electrical contact by penetrating the anodized coating of the aluminum frame To break the anodized layer SUNHAPPY POWER suggests a stainless steel toothed washer to be inserted between the nut and the frame When carrying out the grounding of the modules the aluminum 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 gt SUNHAPPY POWER recommends the use of stainless steel grounding bolts or grounding lugs specifically designed for photovoltaic applications 2 06 5mm
11. hardware is also acceptable Please refer to the drawings on the Annex 1 to get more information about the proper use of mounting holes and load resistance of all module types SUNHAPPY POWER recommends to use all eight mounting holes if excessive wind or snow loads are expected for the PV installation S Junction box Additional mounting hole 4 10x6 5 Mounting holes ve 5 Module frame Z memme a 4 Supporting structure Ground holes Jo 2places 2 06 5mm 5 Lock Washers 6 M6 Bolt Picture2 Installation with Frame Mounting Holes Picture1 Mounting Holes a fy sunhappy Happy with the sun 3 1 2 Installations Using Pressure Clamps oO 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 gt Fixing on the long side the clamps must be mounted along the frame at the position 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 gt Fixing on the short side The clamps must be mounted along the frame at the edges 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 alw
12. ing with modules without any cover the safety regulations for live electrical equipment need to be followed Do not wear metallic rings watchbands ear nose or lip rings or other metallic devices while installing or troubleshooting photovoltaic systems in order to avoid electric shock Use only insulated tools that are approved for working on electrical installations Abide with the safety regulations for all other components used in the PV system including wiring and cables connectors charging regulators inverters storage batteries and rechargeable batteries etc Use only equipment connectors wiring and support frames suitable for a solar electric system Always use the same type of module within a particular photovoltaic system Do not attempt to repair any part of the PV module SUNHAPPY POWER PV 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 onroof systems can affect the fire safety of a building Improper installations can result in a hazard in case of fire In the case of onroof applications the modules must be mounted above a fireresistant surface gt 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 in places where flammable gases m
13. mum 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 viewing 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 regulations Installation should be performed only by qualified persons The installer 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 gt 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 gt Do not use mirrors or other magnifiers to artificially concentrate sunlight on the modules gt Do not expose back sheet foils directly to sunlight sunha N Happy with the sun 2 2 Handling Safety 2 3 Installation Safety Do not exceed the maximum height of pallets stacked on top of each other Maximum height is 2 pallets standard packaging for shipment Do not damage or scrat
14. ning 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 SUNHAPPY POWER 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 gt 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 Always use water and a soft sponge or cloth for cleaning A mild nonabrasive cleaning agent can be used to remove stubborn dirt High mineral content water is not recommended as it may leave residual deposits on the module gt SUNHAPPY POWER modules may be equipped with antireflective coating glass This technology provides SUNHAPPY POWER modules with high transmittance and low reflectivity features 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 ca
15. odules Do not use different type of modules in the same circuit in order to avoid mismatch power loss or damage to the PV system 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 For electrical design considerations the values given in the module label or datasheet 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 component 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 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 SUNHAPPY modules are certified for Class A applications IEC 61730 Safety Class Il 1000Vdc Maximum System Voltage Refer to respective National Electrical Code requirements and standards for sa
16. ollowing conditions Operating environment temperature Storage temperature Humidity below 85 RH sunha N Happy with the sun 3 1 Mechanical Installation 7 7 gt 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 Provide adequate ventilation under a module for cooling SUNHAPPY POWER recommends 10 cm minimum air space between module and mounting surface 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 Always use structures and materials specifically developed and certified for photovoltaic modules installation The minimum distance between two fixed modules for linear thermal expansion of the module frames should be 5 mm Nevertheless the recommended distance between two solar modules is 20 mm to allow wind circulation in order to reduce pressure 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 The PV modules are suitable for mechanical mounting both with a horizontal or vertical orientation In choosing the orientation please keep in mind the internal PV module bypass diode configuration to ensure the optimum electrical behaviour from
17. pprove and inspect the system before its connection to the grid can be accepted 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 respective National Electrical Code or applicable National Regulations 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 including 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 sunha N Happy with the sun 3 2 1 General Considerations amp gt 3 2 2 System Grounding Modules are fitted with two preassembled 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 Several modules are connected in series and then in parallel to form a PV array especially for applications with high operating voltage When modules are connected in series the total voltage of the resulting sting is the sum of the individual voltages of the m
18. s well as other individual requirements are duly taken into account Keep these installation instructions in a safe place Overview 1 Product identification 2222 te tne pag 2 2 Safety 7 nnn pag 2 2 1 General Safety 2 2 Handling Safety 2 3 Installation Safety 2 4 Fire Safety 3 Installation 2 e pag 5 3 1 Mechanical Installation 2 2 2 2 2 nt tne 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 2 0 tt tins pag 10 3 2 1 General Considerations 3 2 2 System Grounding 4 Maintenance tne pag 13 4 1 General Maintenance 4 2 Cleaning 5 Modules End of Life ttt pag 15 6 Module Specification e pag 15 7 Disclaimer of Liability o nee pag 16 8 Contact Information e pag 16 a fo sunhappy Happy with the sun Annex 4 pnh ee cee pag 1 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 information about the main parameters of the module Product Type Maximum Power Current at Maximum Power Voltage at Maximum power Open Circuit Voltage Short Circuit Current all as measured under Standard Test Conditions weight dimensions Maxi
19. use micro scratches which could have a negative impact on the module s performances gt 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 temperatures gt 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 gt Don t clean modules having broken glass or exposed wiring This can cause a general electrical failure of the module or electrical shock hazard 14 a fy sunhappy Happy with the sun 5 Modules End of Life kerem SUNHAPPY POWER is a member of the PV CYCLE Association a European PVY CYCLE nonprofit as sociation managing a fully operational collection and recycling a scheme for endoflife photovoltaic modules throughout Europe 6 Modules Specifications Drawing for SUNHAPPY POWER standard PV modules shown as below Mounting holes 4 10x6 5 Barcode label Ground holes Jo 2places 2 06 5mm Picture 7 Module Drawing 15 sunhappy 5M96 6M60 6P60 6M72 6P72 1580 1640 1956 1082 992 992 r wo wo E co Weight kg 152 25 195 27 NeofCelis 72 e z Max Fuse Rating 10A 10a 1 1 Disclaimer of Liability Installers must follow all safety precautions as described in this
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