Installation Manual
Contents
1. System voltage X Voc 1 Ta voc x 25 Tmin WHERE X Number of modules which are connected in series Voc Open circuit voltage of each module refer to the data sheet Ta voc Thermal coefficient of open circuit voltage for the module as a percentage refer to Vikram Solar spec sheet Tmin Minimum ambient temperature of the location of the plant The minimum and maximum outer diameters of the cable are 5mm and 7mm For field connections please use 4mm cables insulated for a minimum of 900C and designated as PV wire The minimum bending radius of our junction box cables is 42mm an yY Lo Fig 8 Bend radius Fig 9 Incorrect cable routing Fig 10 Correct cable routing COY EO IM ONA 1dSA ON 900 lt TVANVW NOLLVTIVLSNI lt YV10S WVU amp MIA 07 ELECTRICAL CONFIGURATION A solar array generates DC electricity when sunlight falls on the modules and the inverter is in active mode Once the minimum voltage and current requirements are met this is converted into AC power accordingly CAUTION The modules are rated to operate at potentially lethal DC voltages which have the potential to cause severe electric hazards in the form of shock arcing and other fire hazards Hence only trained professionals are permitted to work with the modules the DC solar array and the DC com biner box The PV modules are certified to operate at 1000V2. DC A rated isolator DC switch must always be used to interrupt the current flow when disconnecting the connectors Even after disconnecting the DC power may be active for some time hence only expert operators are recommended to work with the modules string combiner box etc Vikram So lar will not be held responsible for any electrical accidents occurring in power plants with Vikram Solar modules FUSING Please rate the fuses for maximum V DC and connect them in each non grounded pole of the solar array If the system is a floating system fuses should be connected in both positive and negative poles The maximum fuse rating connected in series with the array string is usually 15 A but the actual module specific rating can be found on the module data sheet The fuse rating also corresponds to the maximum reverse current that a module will be able to withstand INVERTER SELECTION AND COMPATIBILITY When installed as per the IEC standards and regulations Vikram Solar modules do not normally need to be electrically connected to earth and can operate with either galvanically isolated with transformer or transformerless inverters If galvanically isolated inverters with transformers are used the negative pole of the array must be connected to earth If a transformerless inverter is used the installer should ensure that the right active negative earthing kit is installed by consult ing with the inverter supplier Both methods are requi
3. an external protective cover should be placed over them and the stack height should not be more than 1 pallet high PV modules should always be unpacked vertically by two people as shown in the diagram Care should also be taken to prevent one module falling over and knocking another inside the packaging box PV module surfaces may become damaged scratched if not handled carefully No paint or adhesive should be applied to any of the surfaces including frames Do NOT connect the male amp female connectors of the junction box to the cable of the module Fig 1 Correct way to unpack modules 03 1 MODULE IDENTIFICATION Each module has a unique serial number which is laminated behind the glass Please do not tam per with the serial number of the module and always record all serial numbers in an installation for your future records ZO ASY EO IM ONA 1dSA ON 900 lt TVANVW NOLLVTIVISNI lt YV10S WVU amp MIA U3 04 INSTALLATION ENVIRONMENT 04 1 CLIMATE CONDITIONS Vikram Solar modules are certified to IEC 61701 IEC 62716 IEC 62804 Draft 1 IEC 61215 IEC 61730 II The modules are qualified for application Class A Modules qualified for safety through IEC 61730 within this application class are considered to meet the requirements of Safety Class Il In addition to the IEC certification required to meet European standards Vikram Solar products have also been tested and certified for resistance to ammonia fumes that may
4. need to be grounded according to the respective national electric codes NEC The module frame must be properly grounded refer to NEC clause 250 The grounding wire must be properly fastened to the module frame to ensure good electrical contact Use the recommended connector type or an equivalent for this wire f the support frame is made of metal the surface of the frame must be electroplated and have excellent conductivity First carefully strip 16mm of the insulating jacket from the end of grounding wire to avoid nicking or cutting conductors insert the wire into the slot of the lug see picture and screw down the slotted screw For grounding and bonding requirements please refer to regional and national safety and electrici ty standards If grounding is required use a recommended connector type or an equivalent for the grounding wire If grounding is required the grounding wire must be properly fastened to the module frame to ensure adequate electrical connection The grounding conductor must then make a connection to earth using a Suitable ground electrode Fig 7 Grounding assembly of PV module Vikram Solar modules can be installed with the grounding devices manufactured by third parties and listed for the grounding of metal PV module frames The devices must be installed in accor dance with instructions specified by the grounding device manufacturer ZO ASY EO IM ONA 1dSA ON 900 lt TVANVW NOLLVTI
5. 0 4 TVANVW NOLLVTIVISNI lt YV10S WVU amp MIA
6. VISNI lt YV10S WVU amp MIA U8 06 3 MODULE WIRING Module wiring should be performed by professional expert installers in accordance with local regu lations and national codes PV modules can be connected in series to obtain an increase in the operating voltage The positive connector plug of the module is pushed into the negative connector plug of another module until a click is heard Only assume the modules are connected if a click is heard Irreparable damage can be done if the array strings are connected in reverse polarity i e if the positive end is connected to negative input of the string combiner box and vice versa Proper con nection in the right polarity is therefore recommended and if any reverse polarity is seen or any difference of more than 10V is observed the string configuration connection needs to be checked and connected appropriately Vikram Solar modules are provided with standard copper cables with a 4mm cross sectional area and are rated at 1000V TUV 600V UL for maximum system voltage 900C and are UV resistant Ensure the cables are not exposed to water logged areas The maximum voltage of the system should be less than the certified system voltage typically 1000V or the maximum input voltage of the inverter Since Voc a 1 T the open circuit voltage of the array needs to be calculated at the lowest ambient temperature for the location of power plant This can be done using the formula below
7. Y EO IM ONA 1dSA ON 900 lt TVANVW NOLLVTIVISNI lt YV10S WVU amp MIA U6 Type of mounting method Bolt type mounting system Clamp system attachment to the long side of the frame Clamp system attachment to the short side of the frame Dimensions depending on module type mm 2400 Pa load condition Hotima HOLES USE FOUR HOVRTING HOLES Mounting rails should run parallel to the short side of the frame If the expected load is greater than 1600 Pa a support bar should be inserted Cell amp Model name cell size 60 Cell Eldora VSP 60 AAA 03 amp 6 Cell Module Length Eldora VSPB 60 AAA 03 amp Eldora VSPBB 60 AAA 03 16a 247 Ste 1878 alee where AAA 240 260 5400 Pa load condition PUTING HOLES ee L USE EIGHT MOUNTING HOLES MS FEL WT D Mounting rails should run parallel to the short side of the frame An additional sup port bar should be used below the module Width x y A Different mounting configurations can be tried as per the installer s calculations however failure to comply with the above instructions will result in a lowering of load handling capa bilities and may lead to failure in overload situations which may not be covered under the product warranty B c 05 237 25 COM Y EO IM ONA 1dSA ON 900 lt IVANVW NOILVTTIVISNI lt YV10S WVU amp MIA 07 06 2 GROUNDING All module mounting frames and mounting racks
8. be present in barns housing cattle or pigs as well as for their suitability for installation in humid coastal areas that experience extreme sand storms Although Vikram Solar s PV modules have passed IEC 61701 salt mist corrosion tests with a salt concentration of 5 by weight galvanic corrosion can occur between the aluminum frame and mounting or ground materials if such materials are made of dissimilar metals Direct contact between stainless steel and aluminum is therefore not recom mended for seaside installations to avoid metal corrosion NOTE IEC 61215 and IEC 61730 II are completed The other certifications are in progress ENVIRONMENT Ambient temperature 40 C to 50 C Operating temperature 40 C to 85 C Storage temperature 20 C to 50 C Humidity lt 85 RH Mechanical load pressure 5400 Pa on the front and 2400 Pa on the rear o NOTE The mechanical load bearing capacity depends upon the installer s mounting methods and failure to follow the instructions in this manual may result in different capabilities to withstand snow and wind loads The system installer should ensure that the installation methods used meet these requirements as well as any local codes and regulations OS SITE SELECTION PV modules should be installed in a place where no shading occurs throughout the year Shading can be minimized by ensuring that the distance between an obstruction and the solar array is more
9. ck sheet When removing dirt from the back sheet avoid using any sharp objects which can damage the substrate material and cause slits 09 END OF LIFE PRODUCT RECYCLING After the end of their useful life products should be recycled in a useful renewable way Vikram Solar is a member of the PV Cycle organization which manages a collection and recycling scheme for end of life Solar PV modules throughout Europe and can offer help and support provided that you submit the serial numbers of the modules a If recycling less than 40 modules contact PV Cycle directly at http www pvcycle org to locate the nearest recycling collection point b To recycle more than 40 modules contact sales vikramsolar com and we will provide support on how to proceed 10 WARNING PV modules contain no serviceable parts If you have any doubts that your installation is not working properly or may not work properly please contact your installer immediately 1 Contact the Vikram Solar sales service team at sales a vikramsolar com 2 Submit the customer feedback form to sales vikramsolar com and our technical service repre sentative will get in touch with you shortly WARNING While performing any electrical maintenance the system must be completely shut down and such maintenance should be performed by experts Failure to comply with standards may result in lethal shocks burns and sometimes even death ZO ASY EO IM ONA 1dSA ON 90
10. itting method PV Laminaria Aluminum Fr a Hut avenuar Supe Slruchae ZO ASY EO IM ONA 1dSA ON 900 4 TVANVW NOLLVTIVLSNI lt YV10S WVU amp MIA Ud gt B MOUNTING WITH CLAMP FIXING Vikram Solar has tested modules with a number of clamps and suggests using clamps which have an EPDM or any other insulating washer To fix the modules on the mounting rail a minimum of 4 clamps must be used The clamps should never touch the glass and cause any breakage and clamps should also not cause any shading effects on the module The customer should not modify the frame under any circumstances When modules are mounted using the clamp mounting method at least 4 clamps need to be used 2 clamps on each long side of the module and 2 clamps on each short side of the module Vikram Solar modules are certified to bear 2400 Pa Wind Load and 5400 Pa Snow Load on the front side Additional clamps can be used to ensure that modules are able to bear the load Fringe position module installation and middle module installation diagrams are given below FRINGE MODULE INSTALLATION mar PY Laminate Screw IT Alurninum Frame xB ii Backing Nul Mul Washer A Supper Slruchure Fig 5 PV modules installed using fringe clamping method MIDDLE MODULE INSTALLATION ae j PY Laminate SEEN n Aluminum Frama Backing Mui Nut Washer Supponi Structure Fig 6 Middle modules installed using clamping method CO
11. red in order to prevent the modules from potential induced degradation in the field COY EO IM ONA 1dSA ON 900 lt TVANVW NOLLVTIVLISNI lt YV10S WVU amp MIA 08 MAINTENANCE AND CARE Well designed PV plants require minimum maintenance however with further maintenance the performance and reliability of the system can be improved Yearly maintenance by a trained professional is usually advised Check that the mounting structures are properly laid and the modules are held tightly in accor dance with the mounting instructions given above Ensure that no part of the light collecting area of the module is shaded any leaves trees or any object which causes shading must be removed accordingly Ensure all cable assemblies are tight and no part of any cable assembly is exposed to water log ging Check that the string fuses in each non earthed pole are in operation In order to clean PV modules use a soft module cleaning kit A soft cloth with mild soft detergent can be used as an alternative Only use water with the same temperature as that of the module otherwise thermal shocks can be created and can damage the module Ensure the module is cleaned without causing any damage such as micro cracks etc to the module Always keep the module clean to ensure maximum power generation from the solar PV module The rear surface of the solar module does not require specific cleaning unless any dirt or debris is stuck on the ba
12. ssly or implicitly nor under any patent rights All information given in this manual is based on Vikram Solar s knowledge and experience Vikram Solar reserves the right to change this manual and module specification without prior notice 02 SAFETY PRECAUTIONS PV modules generate electricity upon direct exposure to light which can result in electric shock Use of insulated tools and gloves is recommended while working with modules in sunlight No metallic contact points should be on the human body No one should stand on the front and or rear surfaces of the PV module as non uniform localized pressure might cause damage to the solar cells inside the module The front surface of the module is constructed with tempered glass and hence it should be handled with the utmost care If the glass breaks human contact with the surface can lead to electric shock particularly when the ambient conditions are wet Broken modules cannot be repaired and should be disposed of properly All electrical connectors should be well protected against corrosion and soiling Ensure that con nectors are corrosion free and clean with absolutely no gaps between the contacts Gaps can result in electrical arcing causing a fire hazard For your personal safety do not install handle PV modules in adverse environmental conditions such as gusty winds or wet frosted roof surfaces Ensure the polarity of the modules or strings is not reversed in rela
13. than three times the height of the obstruction PV modules should typically face south in the northern hemisphere and north in the southern hemisphere Vikram Solar modules can be mounted either in landscape or portrait orientation however the impact of dirt shading the solar cells can be minimized by selecting portrait orienta tion For optimum energy production solar modules should normally be mounted facing the equator at an angle to the horizontal plane equivalent to the latitude of the installation If the PV module is placed at a different angle or orientation this could have a direct impact on the power output An inclination of less than 1 2 4 is required to maintain the fire class rating Avoid using mounting methods where drainage holes are blocked PV modules should not be installed in such a way that they will be immersed under water under any circumstances and should also not be installed on moving vehicles vessels ZO ASY EO IM ONA 1dSA ON 900 4 TVANVW NOLLVTIVLSNI lt YV10S WVU amp MIA 06 MOUNTING INSTRUCTIONS 06 1 MOUNTING METHODS Corrosion proof M bolts are to be used in the PV module mounting holes which are on the rear side of the module PV modules can be fixed using either the bolt method or clamp method Re gardless of the mounting method the installer should ensure that 120mm clearance is provided between module frames and the surface of the roof or the wall There is a minim
14. tion to the other modules in the string Concentrating artificial sunlight on solar modules is not allowed as it will degrade their perfor mance and life span Vikram Solar modules are certified for operation in Class A installations at voltages below 1000V DC This value should be taken into consideration when designing the power plant as should the temperature ranges present at the site The mixing of power classes in one string is not allowed and can be harmful Damage to modules due to such mixing can lead to the invalidity of product warranties Under normal conditions a photovoltaic module is likely to produce more current and or voltage than reported under standard test conditions as the environmental conditions are different in each location Reflections from snow and water can increase the sunlight intensity which in turn aug ments current and power The Isc value should be multiplied by 1 25 when determining the conduc tor current ratings fuse sizes and the size of controls connected to SPV output ZO ASY EO IM ONA 1dSA ON 900 4 TVANVW NOLLVTIVISNI lt YV10S WVU amp MIA 02 03 UNPACKING AND STORAGE Upon receipt of the PV modules verify that the product details correspond to those ordered The packing list affixed to the outside of the box contains all details including the serial numbers of the modules Do NOT stack packing boxes pallets more than 2 boxes high If pallets are temporarily stored outside
15. um distance of 10 5mm between 2 modules Drainage holes are not blocked under any circumstances PV modules are not to be subjected to wind or snow loads exceeding the maximum permissible loads and should not be subjected to excessive forces due to the thermal expansion of support structures When modules are ground mounted select the height of the mounting system in sucha way as to prevent the lowest edge of the module from being covered by snow for a long time in win ter in areas that experience severe snow fall If snow settles on the PV modules the regular clear ing of snow and other foreign particles is highly recommended to ensure the long term reliability of the PV modules Failure to comply may result in damage to the module and lead to deformation not covered under warranty gt MOUNTING WITH FRAME BOLT HOLES The frames of each module have 8 6 5mm 10mm mounting holes Vikram Solar strongly recom mends the use of corrosion proof stainless steel fixings The modules are to be secured with an M bolt and a flat washer or spring washer and nut as shown in the figure The assembly should be tightened to a torque of at least 16 25Nm l E j P aan a i i kasimi I i 4 ine ma Wi ma Fig 2 Mechanical drawing of PV module Eldora VSP 60 AAA 03 amp Eldora VSPB 60 AAA 03 amp Eldora VSPBB 60 AAA 0 Se Tera e Bacbrg Mul Fig 3 Sectional view of Al profile Fig 4 Modules installed using screw f
16. vikram vision In action This manual applies exclusively to IEC certified PV modules Table of Contents 01 DISCLAIMER OF LIABILITY a xxx n 2 02 SAFETY PRECAUTIONS a E EELE n n 2 03 UNPACKING AND STORAGE n 3 03 1 MODULE IDENTIFICATION aaaeeeaa aaa aa naaa 3 04 INSTALLATION ENVIRONMENT xiii 4 04 1 CLIMATE CONDITIONS orrara aa 4 05 SITE SELECTION jK K ka E n 4 OG MOUNTING INSTRUCTIONS K k K a nn 5 06 1 MOUNTING METHODS aaaea oaaao Laaa nnan 5 06 2 GROUNDING aircnmee sietada deiade ioina 8 06 3 MODULE WIRING aaaea aE EAEE n an 9 07 ELECTRICAL CONFIGURATION a 10 07 1 FUSING 11d s t L r SS S klk 10 07 2 INVERTER SELECTION AND COMPATIBILITY u ii uun ununi 10 08 MAINTENANCE AND CARE a ici 11 09 END OF LIFE PRODUCT RECYCLING a 11 10 WARNING ELE E 11 G COM Y EO IM ONA 1dSA ON 900 lt TVANVW NOLLVTIVLSNI lt 4V10S WVU amp MIA 01 DISCLAIMER OF LIABILITY The use of this manual the installation and the handling of Vikram Solar modules are beyond Vikram Solar s control Vikram Solar assumes no responsibility for failure to follow instructions resulting in any loss damage injury or expense due to improper installation handling usage or maintenance Vikram Solar assumes no responsibility for the infringement of intellectual property rights or other rights of third parties that may result from use of the module No license is granted in this regard either expre
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