Installation and Safety Manual for the c
Contents
1. 4 BOSCH Installation and Safety Manual for the c Si M60 S NA 30117 and NA 42117 Families of Crystalline Photovoltaic Modules Copyright Bosch Solar Energy Corp version 1 1 Page 1 of 23 TABLE OF CONTENTS 1 INTRODUCTION roeit iuret neei aiii diia aid aaa iaa dadas 4 Disclaimercof Liability io AA A a A ds 4 SAFETY INFORMATION cui ea 4 General Considerations Lois o ii di tas 4 Installation Precautions incida A iio 5 Electrical and Optical Safety ias dd iaa 6 Fire Safety socio leaks kas edt a a sae aes ees ele ede 7 MODULE PERFORMANCE AND SAFETY STANDARDS scceseceseceseceseceseeeeeeeeneseneeeaeeeaeeeaaeeaaeeaaees 7 Standard Test Conditions ii ai tone aia eana 7 Underwriters Laboratories and Canadian Standards Association Information 7 National Electrical Code NEC and Canadian Electrical COJE cocoocccnononcccnononccnnnnannnnnonananoos 7 LOCATION OF SOLAR MODULES cc cocoa td diaria datada dad 8 Orientation Tilt Angle Shading amp Performance ocoocccccccnononinononnnononnnnnananononnnnnnanonnnnnnnonnnnnononnnns 8 BOSCH SOLAR ENERGY MODULE CHARACTERISTICS cescesseceseceeceeeeeeeceeeeeeeeseneeeaeeeaeeeaaeeaeeaaees 9 Electrical Characteristics a 9 Thermal Characteristies cai ai e A AA A AA an 9 Bypass IS A ee ere 9 Mechanical SpecificatiONS cccoconoooononnnnnnnnanonannnnonncnnnanononnnnnnnnnnnnno nono iiaa Aaka iiA iaaa 10 MECHANICAL INSTALLATION 0 eecc2. and plastic module corner protectors are the main components of the packaging assembly that bare the Copyright Bosch Solar Energy Corp version 1 1 Page 20 of 23 vertical load Pallet Specifications Quanti Dimensions Lx Wx Weight 176 x 110 x 180 cm 645 kg 30 modules 69 29 x 43 13 x 70 87 in 1 422 lbs Figure 8A Shipping Pallet Assembly Whenever the Bosch Solar Energy modules are stored or transported care must be exercised to ensure that they are stood upright in the packing units and that there is sufficient area to support each solar module B Safety Considerations Bosch recommends that the solar modules be stored indoors in their original packaging until ready for final installation Dry storage conditions are important for protecting the integrity of the assembly components Loose solar modules should be stored horizontally on the wedge shaped corner protectors with suitable padding Adequate padding must be placed between the individual solar modules as well The solar modules should be secured against falling over A CAUTION Always adhere to the following pallet assembly handling precautions 1 The module contains glass and is fragile Handle the transportation box as well as the PV module with care Copyright Bosch Solar Energy Corp version 1 1 Page 21 of 23 2 Wear gloves to avoid injury by sharp edges 3 DONOT stack 2 pallets on top of one another 4 Always maintain the pallet assembly
3. angle required Since applications vary widely be sure to consult a PV system integrator or use a commercially available software program to determine the expected system energy output The following chart may serve as a rule of thumb Site Latitude Horizontal Tilt Angle 0 10 10 Degrees 11 20 Latitude 21 30 Latitude 5 31 40 Latitude 10 41 Latitude 15 In order to minimize module soiling it is not recommended to set the tilt angle below 10 degrees Dirt tends to accumulate on modules installed at lower angles and does not wash off as readily during rainfall Dirt accumulation debris and even snowfall on the module will reduce its energy output Select a location with the best possible solar radiation for the photovoltaic system you want to install Your choice of location should take into account the seasonal changes in light conditions Modules should be located in areas with an unobstructed view of the sun where they will receive maximum exposure of sunlight for the longest possible time during the day Shadowing caused by buildings roof pipes and vents trees utility poles and other obstructions may significantly reduce the module energy output In systems that are configured with multiple rows of modules the rows must be spaced far enough apart to minimize the impact of shading on other rows This distance is dependent on the latitude and tilt angle at which the system is installed The
4. 00 Pa and a maximum suction wind loading of 50 Ibs ft 2 400 Pa in accordance with IEC Standard 61215 C Mounting Methods Bosch Solar Energy modules may be secured via a variety of mounting methods including the clamp style Contact Bosch Solar Energy if alternate methods of mounting are required Regardless of mounting method employed always thoroughly review and follow the instructions of the mounting structure manufacturer The modules must be properly secured to the support structure so that they can withstand live load conditions including wind uplift It is the installer s responsibility to insure that the clamps used to secure the modules are strong enough Also for greater longevity Bosch Solar Energy recommends that all fixings are made of 316 grade A4 stainless steel not supplied Prevention of the corrosive effects of dissimilar metals must be considered when mounting the aluminum solar module frame against other materials D Clamp Mounting Method Example Many installations utilize a clamp mounting method in which end and mid clamps are used along the module frame for securing modules to the mounting structure The recommended installation method is as follows 1 Select clamps designed for a module with frame height of 50mm Examples include Schletter end clamp model numbers 130001 050 or 130001 950 and middle clamp model numbers 130002 001 and 130002 901 A minimum of quantity 4 should be used Refer to Fi
5. 50 255 260 Open Circuit Voltage Voc Volts 37 80 37 90 38 00 38 10 Short Circuit Current Isc Amps 8 72 8 82 8 92 9 02 Maximum Power Voltage Vmpp Volts 30 11 30 31 30 51 30 71 Maximum Power Current Impp Amps 8 14 8 25 8 36 8 47 Maximum System Voltage Volts 600V for UL and 1000V for IEC applications Reverse current load capacity Amps 17 Please note the following the rated electrical characteristics are within 10 percent of the indicated values of Isc Voc and Pmax under Standard Test Conditions i e irradiance of 1000W m AM 1 5 spectrum and a cell temperature of 25 C 77 F B Thermal Characteristics Thermal Characteristic Measure c Si M60 NA 30117 and c Si M60S NA 30117 Model Designator Part No Suffix Se 225Wp 230Wp 235Wp 240Wp 245Wp Operating Temperature Range C 40 to 85 Temp Coefficient of Maximum Power K 0 46 Temp Coefficient of Open Circuit Voltage K 0 32 Temp Coefficient of Short Circuit Current K 0 032 Thermal Characteristic Measure c Si M60 NA 42117 and c Si M60S NA 42117 Model Designator Part No Suffix gt 245Wp 250Wp 255Wp 260Wp Operating Temperature Range C 40 to 85 Temp Coefficient of Maximum Power K 0 44 Temp Coefficient of Open Circuit Voltage K 0 31 Temp Coefficient of Short Circuit Current K 0 031 C Bypass diodes All modules are equipped with factory inst
6. UTION When cleaning solar modules please take the following precautions e Clean the module surface with a soft cloth or sponge using clean and neutral water base non ammonia To remove stubborn dirt you can use a mild non abrasive cleaning agent such as dishwashing soap or alcohol e Only clean modules in the early morning or in the late afternoon when there is low solar radiation and cells are producing less energy e DONOT use either high pressurized water a steam cleaner or any kind of aggressive tool or material that could scratch the surface of the modules e DO NOT clean the modules with hot water when the ambient temperature is low or with cold water when the modules are hot e DO NOT attempt to remove snow or ice from the modules by means of scraping Use a soft brush to avoid creating micro scratches in the module glass B Inspection and Repair When carrying out an inspection please check that the electrical and mechanical connections are Copyright Bosch Solar Energy Corp version 1 1 Page 22 of 23 clean secure and undamaged Be sure to take precautions against electric shock in the event of any defects Any faults must be rectified promptly Should any repairs become necessary to a Bosch Solar Energy module it is essential that you contact Bosch Solar Energy Never under any circumstances attempt to repair the solar module yourself Bosch Solar Energy modules must only be serviced by specialist firms authorized by Bosc
7. alled bypass diodes in the IP65 rated junction box see table Copyright Bosch Solar Energy Corp version 1 1 Page 9 of 23 below The use of bypass diodes reduces the risk of heating of the shaded cells limiting the current that can pass through them and thereby avoiding damage to the cells Maximum Reverse Average Rectified No Diodes per Total No of Cells Voltage Forward Current Module per Diode 40V 12A 3 20 A caution DO NOT attempt to open the diode housing or junction box located on the back side of the module There are no user serviceable parts inside Opening the junction box may expose the individual to an electrical shock hazard and will void the warranty D Mechanical Specifications The mechanical specifications for and weight of the Bosch Solar Energy c Si M60 NA 30117 and c Si M60 NA 42117 module families are summarized in the table below Mechanical Characteristic Dimensions Tolerance Dimensions in inches L x W x H 65 35 x 38 98 x 1 97 0 08 Dimensions in mm L x W x H 1 660 0 x 990 0 x 50 0 2 0 Weight in pounds 46 30 1 1 Weight in kilograms 21 0 0 5 Figures 5A 5B and 5C provide illustrations of the module mounting and grounding holes frame design cable lengths and general dimensions follow below Figure 5A Cutaway profile of module frame long side Copyright Bosch Solar Energy Corp version 1 1 Page 10 of 23 Te Figure 5B Cutawa
8. and expressively disclaims liability for loss damage injury or expense arising out of or in any way connected with such installation operation use or maintenance of the module Bosch Solar Energy assumes no responsibility for infringement of patents or other rights of third parties which may result from use of the module No license is granted by implication or otherwise under any patent or patent rights The information in this Manual is based on Bosch Solar Energy s knowledge and experience and is believed to be reliable but such information including product specifications without limitations and suggestions do not constitute a warranty expressed or implied Bosch Solar Energy reserves the right to make changes to the product specification or this Manual without prior notice 2 SAFETY INFORMATION A General Considerations Bosch Solar Energy modules should only be installed by qualified installers with adequate solar PVinstallation experience Take note of all relevant laws regulations guidelines and safety measures when handling solar photovoltaic modules Prevent accidents such as electric shocks during the installation operation maintenance and disposal of solar modules by taking the appropriate precautions Copyright Bosch Solar Energy Corp version 1 1 Page 4 of 23 Keep unauthorized persons and animals away from solar energy systems Pay particular attention to children Take special note of occupational safety an
9. clamp screw with star lock washer PV module PV module channel spring nut module mounting system Figure 6A Illustration of Middle and End Clamps N N Figure 6B Illustration of Unirac Solar Mount Evolution Middle Clamp Copyright Bosch Solar Energy Corp version 1 1 Page 15 of 23 pressure load rating lt 5400 Pa without central support with central support screw fasten ing to assem bly holes fastener clamp system on long sides 500 500 fastener 200 200 clamp system SSS SSI on short sides 1 22 1111170 Y 2222111777 slide in or lay in system slide in or 7 table 2 vertical fastening area ee y r Basa CC SS central support Ms clamp section E junction box Figure 6C Illustration of Acceptable Mounting Methods When Module is in a Portrait Orientation Copyright Bosch Solar Energy Corp version 1 1 Page 16 of 23 pressure load ratir g lt 2400 Pa pressure load rating lt 5400 Pa without central support with central support screw fasten ing to assem bly holes fastener clamp system on long sides 200 fastener clamp system on short sides 300 300 slide in or lay in system slide in or lay in system 37 central support ss clamp section La junction box Figure 6D Illustration of Acceptable Mounting Methods When Module is in a Landscape Orientation table 3 horizontal fa
10. closer to the equator requires a lower tilt angle and therefore the shorter this distance The further from the equator higher tilt angle and therefore the greater this distance needs to be If there are questions regarding the optimum configuration in which to arrange mount or wire the modules obtain assistance from your Bosch Solar Energy dealer or distributor or retain the services of an engineer familiar with proper PV system design Copyright Bosch Solar Energy Corp version 1 1 Page 8 of 23 5 BOSCH SOLAR ENERGY MODULE CHARACTERISTICS A Electrical Characteristics The following electrical characteristics were measured under Standard Test Condition STC Electrical Characteristic Measure c Si M60 NA 30117 and c Si M60S NA 30117 Model Designator Part No Suffix ES 225Wp 230Wp 235Wp 240Wp 245Wp Maximum Power Pmax Watts 225 230 235 240 245 Open Circuit Voltage Voc Volts 36 90 37 00 37 10 37 40 37 70 Short Circuit Current Isc Amps 8 30 8 40 8 50 8 60 8 70 Maximum Power Voltage Vmpp Volts 29 40 29 70 29 90 30 00 30 10 Maximum Power Current Impp Amps 7 80 7 90 8 00 8 10 8 20 Maximum System Voltage Volts 600V for UL and 1000V for IEC applications Reverse current load capacity Amps 17 Electrical Characteristic Measure c Si M60 NA 42117 and c Si M60S NA 42117 Model Designator Part No Suffix 245Wp 250Wp 255Wp 260Wp Maximum Power Pmax Watts 245 2
11. d accident prevention regulations applicable to the work in question Bosch Solar modules can be combined with other components to form a photovoltaic system In this case you must also follow the installation and operation instructions issued for these additional components You must comply with the standards and regulations applicable to PV installations such as the National Electrical Code NEC and local safety and building codes the utility grid operator s technical connection requirements and trade association rules concerning accident prevention Failure to comply can lead to significant personal injury and equipment damage B Installation Precautions Use appropriate protective safety equipment as recommended by local safety codes and practices e g hard hat scaffolding steel toe shoes gloves and restraining harness and exercise caution particularly when installing modules at height e g on a roof Solar modules are heavy and should always be handled by two people A CAUTION Always adhere to the following installation precautions e ALWAYS handle solar modules by their long sides and keep sharp objects away from the module surface when handling e DO NOT place heavy loads or drop objects on the module e DO NOT install a solar module in which the backsheet has been damaged e DO NOT walk on bend or drop the solar module e DO NOT attempt any installation in adverse weather conditions high winds rain or when ice or sno
12. eeceeeeeeeeeececacecsaeceaecsaeceaecaeceeeeeeeseneeeaeeeaeecaaecaaecsaeseaeeeaeeeaeeees 12 Module Orientation and Handling Safety ccccccccccccesssssssssecececessesssnsseeeeecesseseeaeeeeseeseeseaaaes 13 Wind and Snow LOadS 3 minesinin a saad uvaaedoh a i Na 13 Mounting Methods esc ias ada i dada cd dida iaa 13 Clamp Mounting Method Example ccccscscccccscsssessssececeeseessesseaeeeeeesseesssaeaeeeeseeseeseaeaeeeesensees 13 Copyright Bosch Solar Energy Corp version 1 1 Page 2 of 23 Ze SELECTRICAL INTERCONNECTIONS SS viii 18 A Module To Module Interconnection eeecceeeceeeseeeeseeeeaceceeeeeceaeeeeaaeeeeaeeceeeeeaeeseaaeeeeaeeeneeeee 18 B PV System Design Considerations ccccccccccccsssssssssecececessessceeseseescesseseeaeeeeeessesseaeaeeeesesseeseaaeas 18 E GTO UNI E A A A E 19 8 STORING TRANSPORTING AND UNPACKING SOLAR MODULES 0ccocococccocccoccconncnocanannnnnccanccanacinnnos 20 Ais SPACKA SING it A A A AA dean baka Pet dasha dan esa td 20 B Safety Considerations ii aaa 21 9 PRODUCT SUPPORT aid td RR idad 22 10 CARE AND MAINTENANCE cisien enoii aa a Ea AiE Tiia 22 As Module Cleanmin gis hdi de it a a oa danas a E a aaa hos htc 22 B Insp ctio and Repa a ea a a aaa ha ie ee eR A e ee 22 11 END OF UPE nindaite aeai ee eaea ata dais 23 Copyright Bosch Solar Energy Corp version 1 1 Page 3 of 23 1 INTRODUCTION Thank you for purchasing this Bosch Solar Energy product In 2011 t
13. gure 6A for more information 2 Affix the clamps to the mounting structure using stainless steel bolts and nuts For a mounting rail such as the Schletter Profile GP1 rail model no 124201 XXX it is recommended to use M8 x 35 allen head bolts reference model no 943308 135 bolt with serration at the bottom side of the screw head and M8 self locking nuts reference model no 943911 008 3 Figures 6C and 6D shows the recommended areas for placement of the clamps Bosch Solar Energy allows the fastener clamps to be installed on the long or short sides of the module frame Please contact Bosch Solar Energy for guidelines on alternate mounting methods Copyright Bosch Solar Energy Corp version 1 1 Page 13 of 23 4 5 6 7 8 Please refer to Figure 5C for the module dimensions and mounting hole locations Maintain a gap of least 1 8 3 mm between neighboring modules When mounting multiple rows of PV modules be sure to maintain enough distance to prevent shading by adjacent rows Make sure to face the glass side of the module to the sun DO NOT remove or alter the module frame Creating additional mounting holes may damage the module and reduce the strength of the frame and will invalidate the warranty Another popular clamp type mounting method is the Unirac Solar Mount Evolution system The recommended installation method is as follows 1 2 3 4 5 6 7 8 Select clamps designed for a module w
14. h otherwise the product and performance warranties may be voided 11 END OF LIFE When solar modules reach the end of their service life they must be disposed of in accordance with all relevant local state and national laws and regulations They must never be disposed of as household waste It is the responsibility of the user to ensure that this product is disposed of properly Please contact your local waste disposal center or Bosch Solar Energy if you have any questions concerning the proper disposal of this product Copyright Bosch Solar Energy Corp version 1 1 Page 23 of 23
15. hazard may be present in photovoltaic modules and arrays during sunlight hours and even at low light levels This hazard increases when multiple modules are connected together to provide higher system voltage or current levels Dangerous voltages may also be present at night from connections to batteries and feedback from inverters or other system components Cover the front surface of the modules with an opaque material to prevent the modules from generating electricity Ensure that both the front and back surfaces of the module and the sheaths of the connecting cables are undamaged Improper electrical connections can result in electrical arcing which can ignite any flammable material located in close proximity When flammable material is within 30 cm 12 in of either the solar module or any of the electrical connections then install an appropriate flame barrier to prevent potential risks of fire A CAUTION Always adhere to the following installation precautions e DO NOT damage pull bend or place heavy loads on the cables e DO NOT connect the cables if the terminals are wet e DONOT disconnect module cables under electrical load e DO NOT attempt to open the diode housing or junction box located on the back side of any Bosch Solar Energy module There are no user serviceable parts inside Opening the junction box may expose the individual to an electrical shock hazard and will void the warranty e Remove any jewellery or other metallic ado
16. he Bosch Group proudly celebrated its 125 year anniversary symbolizing the company s long term viability and continued commitment to bringing Invented for Life solutions to market Bosch Solar Energy is the photovoltaic business operation within the Bosch Group and manufactures high quality solar modules Our solar modules utilize advanced technology components to supply environmentally friendly solar energy for many years when correctly installed and operated This document provides recommendations for the installation and maintenance of Bosch Solar Energy s crystalline silicon photovoltaic PV modules and also identifies the hazards associated with the handling and installation of these products Before installing wiring and using a Bosch Solar Energy module it is important to thoroughly read this manual and understand the instructions Installers must understand the basic principles of electricity and electrical apparatuses as well as article 690 of the National Electrical Code for installations in the United States or Part 1 of the Canadian Electrical Code Please pay special attention to any safety instructions designated with the following caution symbol CAUTION A Disclaimer of Liability Since the use of this Installation and Safety Manual and the conditions or methods of installation operation use and maintenance of the module are beyond the control of Bosch Solar Energy Bosch Solar Energy does not assume responsibility
17. hey should be installed in metallic cable conduits A CAUTION DO NOT connect or disconnect a Bosch Solar Energy module unless the array string is open circuited or all of the modules in the array string are covered Take appropriate steps to black out the top cell side of the solar modules as much as possible The connectors are not designed to make or break the full system current Do not direct concentrated artificial lighting sources on the modules or panels B PV System Design Considerations Series and Parallel Wiring The modules may be wired in series to produce the desired voltage output in the range of maximum system voltage and input voltage of the required inverter Connect the modules in series electrically by connecting the positive connector of one module to the negative connector of another Only use modules of the same type for series connections An arrangement of several solar modules which are connected in series is often referred to as a module string To determine the maximum number of modules that may be connected in series divide the maximum system voltage as stated on the module label or the maximum allowed by local standards or codes whichever is less by the module open circuit voltage Voc printed on the label after correcting for temperature as required by local codes or standards The number of module strings connected in parallel without protective fuses should be limited to two If more than t
18. in flat position Stacking on uneven ground may cause module breakage 5 DO NOT cut the polyethylene straps until installation commences 9 PRODUCT SUPPORT Bosch Solar Energy is committed to offering high quality products which are safe and reflect the state of the art in technology today and in the future We value feedback and ideas from our installers and users to help make our solar products better For information or for service and technical support on Bosch Solar Energy products please contact Bosch Solar Energy via one of the methods listed below E mail solarenergy us bosch com Telephone 1 650 356 3100 Website www bosch solarenergy com 10 CARE AND MAINTENANCE Bosch Solar Energy modules require minimal care and maintenance in order to provide high performance Bosch Solar Energy recommends that system maintenance is carried out by qualified personnel on a regular basis This maintenance may include such tasks as verification of the integrity of the electrical and mechanical connections checking that any system alarms are operating correctly and cleaning of the solar modules as required A Module Cleaning Solar modules may become soiled to varying degrees depending upon surrounding conditions and this may reduce their performance Periodic cleaning of the modules will ensure maximum output However if modules are installed at height e g on a roof then cleaning should only be performed by qualified personnel A CA
19. ith frame height of 50mm Examples include Unirac Solar Mount Evolution end clamp model number 002011M and middle clamp model number 002106M Unirac Solar Mount clamp size E or Sun Frame cap strip size E A minimum of 4 should be used Affix the clamps to the mounting structure using stainless steel bolts and nuts Refer to Figure 6B for one possible example Figures 6C and 6D shows the recommended areas for placement of the clamps Bosch Solar Energy allows the fastener clamps to be installed on the long or short sides of the module frame Please contact Bosch Solar Energy for guidelines on alternate mounting methods Please refer to Figure 5C for the module dimensions and mounting hole locations Maintain a gap of least 1 8 3 mm between neighboring modules When mounting multiple rows of PV modules be sure to maintain enough distance to prevent shading by adjacent rows Make sure to face the glass side of the module to the sun DO NOT remove or alter the module frame Creating additional mounting holes may damage the module and reduce the strength of the frame and will invalidate the warranty A caution Contact Bosch Solar Energy if additional mounting methods are required Copyright Bosch Solar Energy Corp version 1 1 Page 14 of 23 detail 1 end clamp end clamp screw with star lock washer PV module channel spring nut module mounting system detail 2 middle clamp middle
20. listing may not apply if the modules are mounted integral to the roof or wall of a building and does not cover marine or vehicle applications Refer to your local authority for guidelines and requirements of building or structural fire safety 3 MODULE PERFORMANCE AND SAFETY STANDARDS A Standard Test Conditions The module electrical ratings at Standard Test Conditions appear on the label on the back of each module Standard Test Conditions are defined as an irradiance level of 1000W m AM 1 5 spectrum and a cell temperature of 25 C 77 F It is important to note that under normal operating conditions a photovoltaic module is likely to experience conditions that produce more current and or voltage than reported at Standard Test Conditions B Underwriters Laboratories and Canadian Standards Association Information These Bosch Solar Energy modules have been tested and certified in accordance with ULC ORD C1703 UL 1703 and IEC 61730 Safety standards as well as the IEC 61215 and IEC 61646 performance standards UL 1703 the Standard for Safety for Flat Plate Photovoltaic Modules and Panels covers solar PV modules intended for installation on or integral with buildings or to be freestanding not attached to buildings in accordance with the National Electrical Code NFPA 70 appropriate building codes and any other applicable local codes C National Electrical Code NEC and Canadian Electrical Code The in United States the Natio
21. nal Electrical Code NEC covers the installation of photovoltaic systems and must be adhered to when systems are designed and installed Article 690 Solar Photovoltaic Systems of the NEC applies to solar photovoltaic energy systems including the array circuit s power conditioning unit s and controller s for such systems For photovoltaic system projects in Canada the installation must be accordance with CSA C22 1 Canadian Electrical CE Code Part 1 the Safety Standard for Electrical Installations Under normal conditions a photovoltaic module is likely to experience conditions that produce more current and or voltage than reported at Standard Test Conditions As previously mentioned the values of Isc and Voc marked on the modules must be sized according to section 690 8 of the National Electrical Code All wiring shall be in accordance with the NEC and grounding method of the module arrays shall comply with the NEC Article 250 Copyright Bosch Solar Energy Corp version 1 1 Page 7 of 23 4 LOCATION OF SOLAR MODULES A Orientation Tilt Angle Shading amp Performance Photovoltaic modules generate maximum power when facing directly towards the sun PV systems can track the sun or remain in a fixed tilt position Tracking systems will produce more energy on an annual basis but are more costly and may require more maintenance Most PV systems are designed with a fixed tilt The further North from the equator the greater the tilt
22. of 1 25 when determining component voltage ratings conductor ampacities fuse sizes and size of controls connected to the PV output Refer to Section 690 8 of the National Electrical Code for an additional multiplying factor of 125 percent 80 percent derating which may be applicable Please note the following the Isc and Voc ratings are printed on the product data sheet as well as the label adhered to the rear side of the solar module C Grounding In order to ensure a code compliant installation requirements for earth grounding and lightning protection must be followed In the United States the grounding methods must comply with Articles 250 and 690 of the National Electric Code NEC In Canada grounding methods must comply with the Canadian Electrical code Part 1 CSA C22 1 entitled Safety Standard for Electrical Installations According to the National Electric Code the installer must ground the module frame Figure 7A illustrates a method of creating a reliable ground connection to the PV module frame using a grounding clip An example of a ground clip which is intended and designed for grounding of photovoltaic modules is the Tyco Electronics SolKlip assembly catalog numbers 1954381 1 with self tapping and 10 32 thread cutting screw 1954381 2 8 32 screw and hex nut or 1954381 3 8 32 screw lock washer and hex nut Refer to figure 7A Secure the grounding clip to the module grounding hole and torque the mounting screw pe
23. osition on flat or sloped roofs or surfaces and at flat or tilted angles Always use caution when mounting a module on tilted angles or sloped roofs so the module does not slide out of position while attaching it to the module mounting system It is also recommended that modules are mounted so that the junction box shall be in the uppermost position to minimize the ingress of water A clearance of 6mm 0 25 between modules is sufficient in most installations to accommodate thermal expansion of the material However the appropriate clearance is dependent upon installation specific factors including the module mounting system ambient temperature at the site and the maximum operating temperature of the module Also it is important to note that the maximum distance between modules should not exceed 12 based on using standard wiring The minimum recommended standoff distance between Bosch Solar Energy modules and the roof is 1 57 inches 40mm B Wind and Snow Loads All solar installations should also be in accordance with local building codes and regulations For proper structural design it is recommended to retain the services of a structural engineer experienced with the installations of PV systems It is important to reference the most current revision of ASCE 7 for determining the proper wind and snow load calculations for the project site Bosch Solar Energy modules have been evaluated for a maximum pressure snow loading of 112 lbs ft 5 4
24. r the installation instructions of Tyco Electronics Figure 7B shows the diameter and location of the grounding hole on the module frame The ground wire should be a minimum of 12 AWG and be sized in accordance with the requirements of the application and the National Electric Code Other means of module grounding may be required Contact Bosch Solar Energy for guidelines regarding the use of alternative grounding techniques Copyright Bosch Solar Energy Corp version 1 1 Page 19 of 23 Screw Head Flush with Base Base Flush with Frame PV MATA RS d c YI Screw Head Flush with Base Base Flush with Frame Frame Hex Nut is Tight Frame Figure 7A Grounding of Module Frame Using Ground Clip 4 36 mm 11 64 Inches for 10 32 thread cutting screw Grounding Symbol 2 sl G a 100 130 Figure 7B Size and location of module grounding hole 8 STORING TRANSPORTING AND UNPACKING SOLAR MODULES A Packaging Bosch Solar Energy modules are shipped on a pallet assembly that is designed to provide the proper protection during shipment Please refer to picture 8A for more information The pallet box consists of the following components 1 Wooden pallet 2 Plastic module corner protectors 3 Shrink wrap The modules are packaged horizontally on the pallet It is important to note that the wooden pallet
25. rnments to avoid accidental electrical contact and use insulated tools e A two person team is to be used while performing field work on all energized equipment where the system open circuit voltage is 30 volts or greater e Wear electrical insulating gloves rated at 1000 volts and suitable eye protection when working on systems where the system open circuit voltage is 30 volts or greater e DO NOT touch terminals while the module is exposed to light without wearing electrical insulating gloves e DO NOT connect or disconnect a module unless the array string is open circuited or all of the modules in the string are covered e DO NOT install or operate a module in which the rear surface insulation film backsheet has been damaged A damaged backsheet can create serious reliability and safety issues such as delamination of module and danger to life and health e Prevent sunlight from being concentrated or reflected artificially onto a solar module In particular do not use any concentrating lenses or mirrors Copyright Bosch Solar Energy Corp version 1 1 Page 6 of 23 D Fire Safety The Bosch Solar Energy c Si M60 NA 30117 modules have been certified by Intertek Testing Services NA to comply with the UL1703 Class C fire rating To satisfy the conditions of this rating when installing on a building you must mount the modules using standoff or rack methods over a fire resistant roof covering rated for the application The module
26. stening area Copyright Bosch Solar Energy Corp version 1 1 Page 17 of 23 7 ELECTRICAL INTERCONNECTIONS A Module To Module Interconnection Bosch Solar Energy modules have been designed to be easily interconnected Each module comes with one positive cable with a plug on one end and one negative cable with a receptacle on one end Both wires are connected inside of the junction box diode housing Modules are interconnected by inserting the plug from one module into the receptacle of the next module in the array string Secure the mated connector pair to the inside flange of the module frame to protect it from damage For added safety Bosch Solar Energy modules feature Multi Contact MC4 locking connectors that require a tool for disconnection such as the Multi Contact PV MS open end spanner model no 32 6024 Wiring Considerations Always use cables and connection techniques consistent with the anticipated environmental conditions and applicable codes related to the installation For wiring that is exposed to weather select conductor cable that is sunlight UV resistance and that offers a minimum rating of 90 C 194 F Bosch recommends that all wiring be double insulated use flexible copper Cu conductors at least 3mm in diameter AWG 12 and rated as PV Wire USE 2 or equivalent The module cables should also be attached and supported to ensure adequate strain relief If cables are installed within a building then t
27. w is present e NEVER leave a module unsupported or unsecured If a module falls the glass could break A module with broken glass cannot be repaired and must not be used e NEVER attempt to modify a solar module or take it apart Never remove any markings or labels applied or parts fitted by the manufacturer Do not apply any paint or adhesive to a solar module e DO NOT attempt to install or service any portion of the PV system unless you understand the electrical operation and are fully qualified to do so e DO NOT drill holes in the frame or glass of the module Doing so will void the warranty e Have a fire extinguisher and first aid kit when performing field work on all energized equipment where the system open circuit voltage is 30 volts or greater e Since sparks may be produced do not install module where flammable gases or vapors are present e DO NOT work on modules when they are wet If a wet module is cracked or broken the full system voltage may be present e Mount the solar module so that the junction box is at the upper edge of the module to minimize the ingress of water Copyright Bosch Solar Energy Corp version 1 1 Page 5 of 23 e Ensure that all electrical connections are properly connected and protect them from interference from unauthorized personnel or animals C Electrical and Optical Safety Photovoltaic PV modules generate electricity whenever they are exposed to light Lethal voltages and or a shock
28. wo strings are to be connected in parallel then a series fuse is required for each string in each non earthed pole Only DC fuses rated at the maximum system voltage should be used Maximum fuse rating should not exceed the maximum system voltage rating stated on the module label Copyright Bosch Solar Energy Corp version 1 1 Page 18 of 23 DC Fuse Ratings To calculate the minimum fuse size multiply the short circuit current Isc rating of the module by a factor of 1 56 The Isc value must take into consideration the maximum irradiation and temperature of the installation site If the loss of a fuse connection occurs verify that the maximum current rating was considered when calculating the fuse rating caution When selecting the minimum current carrying capacity of the cable please refer to the typical short circuit current Isc rating and multiply this by 1 56 times the number of solar modules connected in parallel Note that further safety factors may be required depending upon the ambient temperature of the installation and the means of installation of the cables e g conduit installation Refer to the local standards to ensure full compliance with legislation A caution Under normal conditions a photovoltaic module is likely to experience conditions that produce more current and or voltage than reported at Standard Test Conditions Accordingly the values of Isc and Voc marked on this module should be multiplied by a factor
29. y profile of module frame short side Copyright Bosch Solar Energy Corp version 1 1 Page 11 of 23 99022 38 98 0 08 1 A mm Inches 50 1 97 99022 38 98 0 08 4 36 0 17 10 sr a 5 o o v4 19 0 358 T Mounting hole a typical of 4 o Ss 3 30 1 187 3 A Q _ F 3 3 0 z E B ii 3 3 o eN A ES ite rm 15 0 59 i 430 16 93 Figure 5C Detailed Module Dimensions 6 MECHANICAL INSTALLATION A photovoltaic system must be installed so that it can withstand environmental influences such as wind rain hail and snow If solar modules are to be installed on a roof or fa ade a suitable mounting system will be required to enable the solar modules to be properly fastened Make sure that the mounting system structure and all components used for fastening the solar modules in place comply with all relevant local building codes and regulations A caution The information in this section only suggests possible methods of securing the PV modules to a module mounting system It is the sole responsibility of the user and or installer to verify that the module mounting system and mounting method are properly engineered and in accordance with local building codes and regulations Copyright Bosch Solar Energy Corp version 1 1 Page 12 of 23 A Module Orientation and Handling Safety Bosch Solar Energy PV modules can be arranged in either landscape or portrait p
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