SILVANTIS ® PHOTOVOLTAIC MODULES F-SERIES and R-SERIES 60-Cell High Wattage Modules
INSTALLATION GUIDE
F-SERIES and R-SERIES 60-Cell Installation Guide 1.0 Introduction 1.0 Introduction 2 1.1 Models Covered by Installation Guide 2
Thank you for choosing SunEdison’s Silvantis modules. This guide provides information regarding the proper installation and handling of Silvantis modules.
2.0 Safety 2.1 General Safety 2.2 Mechanical Safety 2.3 Electrical Safety
3 3 3 4
3.0 Mechanical Installation 3.1 Planning and Design 3.2 Module Mounting Options 3.3 Additional Mounting Methods
4 4 5 5
Silvantis modules consist of a series of electrically interconnected monocrystalline solar cells that are sealed within a laminated sheet of tempered, low glare antireflective coating (ARC) glass superstrate, and EVA back sheet substrate. These laminates are secured inside an aluminum frame to provide rigidness and a mounting mechanism to affix to sub-structures.
4.0 Electrical Installation 8 4.1 Planning and Design 8 4.2 Module Wiring 8 4.3 Module Grounding 9 4.3 Option A: Metal Lug 9 4.3 Option B: Racking Manufacturer Integrated Grounding Methods 10 4.3 Option C: Bolt Wire Assembly 10 4.3 Option D: Alternative Grounding 10 4.4 String Grounding 11 5.0 Maintenance
11
6.0 Disclaimer of Liability
12
7.0 Appendix 13 7.1 Module Illustrations 13 7.2 Physical Parameters 13 7.3 Pre-mounted Cables and Connectors 14
2
Please review all the sections that pertain to proper installation of modules listed in this guide. The instructions detailed in this guide must be followed throughout the module’s lifetime deployment. If you need additional information about the safe, proper use and handling of SunEdison photovoltaic module products, please contact SunEdison.
1.1 Models Covered by Installation Guide Silvantis Monocrystalline Modules Silvantis F-Series F255CzC
F260CzC
F265CzC
F270CzC
F275CzC
F255KzC
F260KzC
F265KzC
F270KzC
F275KzC
Silvantis F-Series U.S. Tariff-Free F255CzD
F260CzD
F265CzD
F270CzD
F275CzD
F255KzD
F260KzD
F265KzD
F270KzD
F275KzD
Silvantis R-Series R270CzC
R275CzC
R280CzC
R285CzC
R290CzC
R270KzC
R275KzC
R280KzC
R285KzC
R290KzC
CzC = White back sheet; KzC = Black back sheet CzD = White back sheet U.S. tariff-free; KzD = Black back sheet U.S. tariff-free z indicates manufacturing location: M = Malaysia, X = Mexico, K = Korea, P = China, T = Taiwan For product parameters and specifications see Section 7.0.
© 2015 SunEdison
2.0 Safety Ensure to follow all safety guidelines stated below. Failure to do so can cause severe injury, damages, or a void in the module warranty.
2.1 General Safety
••To safely keep modules stored, they must remain packaged on the provided pallets, and must not be stacked more than two pallets high. ••Upon unpacking, only carry a module by its frame with two or more people. Do not carry a module by the wires or junction box. ••Ensure that frame weep holes are not obstructed by the mechanical installation.
••Modules are intended for outdoor use. ••Do not submerge modules in water at any time. ••The front and back of each module is labeled with a product bar code. Do not cover, remove or deface labels as they are necessary for product identification. ••Troubleshooting should include planning, checking, disconnecting, cause seeking, replacement and record keeping. ••Do not allow unauthorized persons near the installation site or module storage area. ••Do not wear rings, jewelry, watches or other metallic items while working with photovoltaic modules.
2.2 Mechanical Safety ••Packaged modules must be stored indoors; in a dry and ventilated area. Modules should never be stored in a wet or outdoor environment. ••Once opened, continue to store modules in a dry and ventilated room. ••Damage to the glass surface or its anti-reflective coating will impact the power output and overall efficiency of the system. Scratches, handling marks or any other damage to the glass surface must be avoided. ••To avoid these and other performance prohibitive issues, keep the front side of the module clean and free of obstructions including covers, tape, adhesives, paint and debris.
••All modules are manufactured with a sealed junction box, pre-attached cables and locking connectors. These components should not be modified or tampered with in any way. If connectors are not hooked up right away, SunEdison recommends attaching protective caps to prevent damage to the connectors. ••Do not install or handle the modules or their components when they are wet or during periods of high wind. ••Do not attempt to disassemble, repair or open any part of the module; including the junction box or sub-components. ••Do not install or handle broken modules. If a module is broken, or the back sheet is torn, contact with the surface or frame can cause an electrical shock. ••Do not place or drop objects on the modules, including other modules. ••Do not twist the module frame. ••Do not stand, step, walk or jump on the module. ••Do not mark the modules with sharp instruments. ••Do not leave a module unsupported or unsecured. ••Do not modify the module in any way, which includes the frame, glass, eva, etc.
••Photovoltaic modules produce DC electrical energy from light. When illuminated, each module can have a DC potential of greater than 45 V and should be handled with care.
WARNING: Precautions should be taken to avoid damage to the glass surface when unpacking, handling or storing the modules since any damage to the glass surface may impact the power output of the modules.
© 2015 SunEdison
3
F-SERIES and R-SERIES 60-Cell Installation Guide 2.3 Electrical Safety
3.0 Mechanical Installation
The following safety guidelines and best practices should be followed at all times:
3.1 Planning and Design
••All installations must be performed in compliance with all applicable regional and local electrical codes or other applicable national and international electrical standards. ••Use only insulated tools during installation, troubleshooting and maintenance of the modules. ••Wear suitable protection to prevent direct contact with module’s electrical output and mechanical sharp edges. ••Cover the front of the modules with an opaque material to stop production of electricity when installing or working with a module or wiring. ••Always use a wire management system that keeps wires and cables out of direct contact with edged surfaces, which could cut or damage the insulation. Do not allow wires to rest on the ground or roof surface. ••Modules connected in a series should not be disconnected under illumination. Disconnecting modules under illumination may cause electrical arcing, which may result in burns, fires or other injuries and damages.
••Before installation, check to ensure the sub-structure will accommodate expected system loads. This includes and is not limited to roof, foundations, mechanical structure and mechanical connections. ••All Silvantis solar modules have a module fire resistance rating of Class C. According to the UL1703 test protocol, revised in 2014, all Silvantis solar modules also have a module fire resistance rating of Class A for spread of flame, and fire performance of either Type 1 or Type 2 classification as specified on the module label. Per UL, the fire rating of this module is valid only when mounted in the manner specified in the mechanical mounting instructions. The system fire rating is determined by the module, rack and roofing materials. SunEdison recommends not mixing module fire performance type within a system. ••Consider the following factors during system design, which will influence performance:
a. SunEdison solar modules produce the most power when they are pointed directly at the sun, and should be tilted for optimum system performance.
b. Proximity to obstructions have the potential to shade or damage the modules (examples below): • walls • buildings • trees • groundcover • snow cover • dust and debris
c. Designs should allow adequate airflow across the back of the module because elevated temperatures will decrease energy yield.
d. Allow a minimum spacing of 10 mm between modules for thermal expansion.
e. It is recommended that you mount the modules at least 5 degrees from the horizontal.
••Do not artificially concentrate sunlight on a module.
4
© 2015 SunEdison
3.2 Module Mounting Options
3.3 Additional Mounting Methods
For clamp or bolt mounting locations, please refer to the table on pages 6-7.
Use of the PanelClaw system (Part Number 500000501) is recommended with SunEdison Solar PV modules. Structures manufactured by PanelClaw Inc. use a special clamp, or "claw" designed to attach to the flange of the module at all four corners, on the two short frame ends. For proper placement, attach a claw over the module frame flange at each of the four designated locations and tighten the screw so that the claws are flush with the long and short ends of the module flange (see Figure 1). This mounting method has been tested to a maximum rating of 50 psf in the negative and positive direction. Refer to the mounting configurations on pages 6-7, as well as the PanelClaw installation guide for information on the installation of the clamps.
••Each module should be mounted using four bolts through the mounting holes on the rear side of the module, or with four clamps over the front side within the region specified as shown in the mounting diagram below. ••Depending on the desired load capability of the array, modules may be mounted either perpendicular or parallel to the structure rails. Clamps can be mounted anywhere inside of the safe mounting range for each case illustrated in the table on pages 6-7. ••If using bolts, use a bolt stack no smaller than ¼"-20 or M6, with two flat washers and a locking washer as shown in Appendix 7.1.
Figure 1: Illustrations of the Panel Claw
••To ensure an adequate clamping area, all clamps must be able to clamp within the range specified in the table on pages 6-7. All fasteners used to fix the modules with clamps should be no smaller than ¼”-20 or M6. ••To provide adequate fixing or clamping force, torque the fasteners to the manufacturers torque specifications. ••For all cases, the area of the supporting structure in contact with rear side of the module must comply with the dimensions specified in Appendix 7.2. ••All other structural dimensions, such as clamp and rail thickness, should be sized appropriately for the intended site load.
© 2015 SunEdison
5
F-SERIES and R-SERIES 60-Cell Installation Guide MOUNTING CONFIGURATIONS
LOAD PARAMETERS
CLAMP MOUNT LOCATIONS
BOLT MOUNT LOCATIONS
RAIL MOUNT (PORTRAIT & LANDSCAPE) Structural rails running perpendicular to the length of the module should be fixed via bolts or clamps at the mounting holes between each long side frame.
PORTRAIT
B
A
Maximum Rear Load: Clamp mount allowable range
2400 Pa (50 psf) Maximum Front Load: 5400 Pa (113 psf)
LANDSCAPE
REAR VIEW
FRONT VIEW
Maximum Rear Load:
D
2400 Pa (50 psf)
Clamp mount allowable range
CLAMP MOUNT ONLY
Maximum Front Load:
FRONT VIEW
5400 Pa (113 psf) END MOUNT F
PORTRAIT
Structural rails running parallel to the length of the module should be fixed ONLY via bolts at the mounting holes or clamps within the allowable clamp range on each long side frame.
Maximum Rear Load: Clamp mount allowable range
2400 Pa (50 psf) CLAMP MOUNT ONLY
Maximum Front Load: 2400 Pa (50 psf)
LANDSCAPE
E
FRONT VIEW
Maximum Rear Load:
H
5400 Pa (113 psf) Maximum Front Load: 5400 Pa (113 psf)
Module Color Code:
G Clamp mount allowable range
REAR VIEW
Mounting Hole Location
FRONT VIEW
Module Rail
Clamp Mount Range
Clamp mount allowable range: A: 0 – 382 mm B: 0 – 207 mm C: 0 – 248 mm D: 0 – 124 mm E: 0 – 248 mm F: 0 – 50 mm G: 0 – 382mm H: 0 – 50 mm
6
© 2015 SunEdison
C
MOUNTING CONFIGURATIONS
CLAMP MOUNT LOCATIONS
BOLT MOUNT LOCATIONS
LOAD PARAMETERS
This mounting configuration is specific to flat rooftops. Mounting should only be done via clamps. The alpine configuration (not shown) is also allowed.
LANDSCAPE
CORNER MOUNT Maximum Rear Load: 2400 Pa (50 psf) Maximum Front Load:
FRONT VIEW
CORNER MOUNT WITH CENTER MOUNTS Attach module clamps at four corners and at center of module. Applicable to S:Flex East-West and Alpine mounting system; refer to S:Flex installation manual.
Maximum Rear Load: Clamp mount allowable range
Clamp mount allowable range
FRONT VIEW
FRONT VIEW
S:Flex East-West
Alpine Configuration
2400 Pa (50 psf) Maximum Front Load: 5400 Pa (113 psf)
CASE 1
Maximum Rear Load:
Clamp mount allowable range
2400 Pa (50 psf) Maximum Front Load: 2400 Pa (50 psf)
FRONT VIEW
Maximum Rear Load:
CASE 2
FULL LENGTH CLAMPING (CASES 1&2) When clamping the module full width across the ends it is unsupported along the unclamped edge.
LANDSCAPE S:FLEX
2400 Pa (50 psf)
Clamp mount allowable range
2400 Pa (50 psf) Maximum Front Load: 2400 Pa (50 psf)
Module Color Code:
FRONT VIEW
Module Rail
© 2015 SunEdison
S:Flex Snow Sheet
Clamp Mount Range
7
F-SERIES and R-SERIES 60-Cell Installation Guide 4.0 Electrical Installation
4.2 Module Wiring
4.1 Planning and Design All modules are manufactured with a sealed junction box, pre-attached cables and locking connectors. These components should not be modified or tampered with in any way. Note: Installers shall ensure that the polarized locking connectors are from the same supplier. Do not mix polarized interlocking connectors from different manufacturers—including connections at the inverter, combiner boxes and modules. Doing so will void the warranty. Refer to the corresponding data sheet for connector types. ••Ensure connectors are clean and dry before establishing connection. ••Ensure that all wire, fusing and disconnects are appropriately sized for the system design according to national, regional, and local codes. ••Electrical characteristics are within plus or minus 5% of rated values for Isc, Voc, Impp and Vmp. Pmax ranges between 0 W to +5 W at standard test conditions (STC). However, modules will operate under conditions that may be significantly different than STC. SunEdison suggests multiplying specified ratings by a minimum of 1.25 or more when designing the system and balance of system components. Refer to local codes before planning and designing the system. ••Determine the maximum number of modules that may be connected in series using the following formula:
••The module includes wires and polarized locking connectors from the junction box on the back of the module. Field replacement of connectors or cables must be avoided and will void the product warranty. Polarized locking connectors of the same type, make and manufacturer are required for all series string wiring. The maximum operating temperature of the wires and connectors should not exceed 85 C. ••Always wire modules so that proper polarity is maintained. Avoid placing excessive tension on the cables. ••There is no limit to the maximum number of series strings that can be combined in parallel. However, when doing so, each string must include overcurrent protection with a maximum rating of 15 A. SunEdison recommends the use of DC rated fuses or overcurrent protection devices with the appropriate maximum voltage rating. ••Do not connect modules of three or more strings directly to a parallel bus. ••The cross-sectional area of cable and the connector type must be selected to align with the overall system design, and should include the maximum short circuit current of the system, maximum operating temperatures and cable run lengths. ••For field connections, use at a minimum #12 AWG/4 mm2 wires insulated for a minimum of 85 C. Use copper wire only.
Ns = Vmaxs/Vocm Where: Ns equals the maximum modules in series. Vmaxs equals the maximum system voltage and is either 600 V or 1000 V for installations that are subject to UL certification for the module and with having approval from the local AHJ. Vocm equals the module open circuit voltage at coldest conditions for the site (refer to local codes). WARNING: Installers should adhere to all applicable local, regional, and national codes and regulations when designing and constructing the photovoltaic system. Note: In colder climates, it may be necessary to further reduce the maximum number of modules in a series by using Vocm at the minimum expected operating temperature.
8
© 2015 SunEdison
4.3 Module Grounding
Metric set
Module frames and structures grounding must be compliant with all national and local regulations.
- Stainless Steel Bolt M4
SunEdison recommends grounding all module frames and associated structures in order to maintain a zerovoltage potential between the electrically conductive equipment and the earth in all scenarios.
- Stainless Steel Flat Washer M4
- Stainless Steel Nut M4
See below for approved grounding methods: ••Lug Method: A copper, stainless steel, or tin plated grounding lug that is rated for outdoor use and uses no smaller than a #12 wire is acceptable. The use of a copper split bolt connector is authorized for use as well. ••Alternative Methods: Other code compliant frame grounding methods that are certified to UL 1703/2703 standards are acceptable. ••The frame has predrilled holes marked with a grounding sign as illustrated in Figure 2. These holes should be used exclusively for grounding. Do not drill additional holes or modify existing holes in the frame.
- Stainless Steel Spring Washer M4 - Stainless Steel Lock-Toothed Washer M4 - Stainless Steel Slotted Washer M4 English set - Stainless Steel Bolt #8-32 - Stainless Steel Nut #8-32 - Stainless Steel Flat Washer #8-32 - Stainless Steel Spring Washer #8-32 - Stainless Steel Lock-Toothed Washer #8-32 - Stainless Steel Slotted Washer #8-32 Step 1: Place the grounding lug over the grounding hole on the exterior of the module frame. Step 2: Place a star washer directly between the bottom of the grounding lug and the exterior surface of the frame.
Figure 2: Image of the grounding holes
Step 3: Place a bolt through the lug, star washer and frame grounding hole. Step 4: Secure the lug to the frame using a flat washer, split washer and nut. Step 5: Torque the bolt stack to approximately 1.5–2.3 N·m (1.1–1.7 ft·lbs) to ensure the star washer penetrates the anodized frame. Figure 3: Option A Grounding Lug Assembly
4.3 Option A: Metal Lug SunEdison recommends copper or tin plated grounding lugs rated for outdoor use and used with a #12 or larger wire. The use of a copper split bolt connector is authorized for well. Attach the grounding lug to the frame by referring to Figure 3 and the following steps: Use stainless steel metric or English sets only. Please refer to the following list for the minimum hardware requirements for each set.
© 2015 SunEdison
9
F-SERIES and R-SERIES 60-Cell Installation Guide 4.3 Option B: Racking Manufacturer Integrated Grounding Methods
4.3 Option C: Bolt Wire Assembly1
Integrated grounding methods must be appropriately certified to UL standards and must be in accordance with the specified instructions of the respective manufacturer. SunEdison modules can be grounded by bonding modules to a grounded racking system. SunEdison recommends using its internally developed integrated grounding clip, PN: 720256 with its piloted bolt, PN: 720230. The grounding clip utilizes a 304 stainless steel KEP nut to make the ground connection, and the geomet finished bolt carries the current to the grounded structure. The torque specification for the bolt and clip is 14.9 N·m (11 ft·lbs).
Step 1: Attach grounding lug at one of the designated aforementioned grounding hole locations. Using only stainless steel hardware, insert a stainless steel bolt first through the stainless steel cup washer, and then through the grounding hole. Step 2: Loosely add a stainless steel backing nut and a toothed lock washer to the bolt. Step 3: Bend the EGC into an Omega (Ω) shape to tightly fit between the partially installed bolt head and cup washer. The EGC will be exclusively in contact with the steel. Step 4: Tighten the bolt to approximately 4 N·m (35 in·lbs) of torque. The toothed washer must penetrate the coated aluminum.
Figure 4: Option B Grounding Lug Assembly
Step 5: Route the correctly sized ECG wire without bringing the wire into contact with the module frame. Figure 5: Option C Bolt Wire Assembly
Mounting Rail Here
If the clip is not available, SunEdison also recommends using the BURNDY WEEBs integrated rack grounding, part numbers WEEB-ADC, WEEB-ADR, WEEB-WMR1 and WEEB-WMR2. These devices are made of 304 stainless steel that properly ground the modules with specialized teeth that penetrate both module and structure. Should you choose a rack integrated method that is not approved by UL please contact SunEdison before proceeding to determine compatibility.
10
4.3 Option D: Alternative Grounding To use other code compliant frame grounding methods that are UL certified contact SunEdison for approval.
1
If the omega configuration is not possible and a full loop is required, please add another cup washer between the screw head and the copper wire loop.
© 2015 SunEdison
5.0 Maintenance
4.4 String Grounding Silvantis F-series modules come in two types, PID-free and PID-resistant. PID-free panels have a “PID-free” designation on the nameplate label (Figure 6a) as well as a “P” on the right side of the bar code label (Figure 6b). String grounding requirements for the two types of modules are: ••PID-free modules do not require string grounding and are fully compatible with floating ground transformerless and micro-inverters, as well as with galvanically isolated inverters. ••PID-resistant modules: For string voltages greater than 100 V PID-resistant modules must be used with galvanically isolated inverters with the negative end of the string held at ground potential. Floating ground transformerless string inverters may not be used with PID-resistant modules. PID-resistant modules are fully compatible with microinverters where string voltage is less than 100 V, in which case string grounding is not required. Figure 6: PID-free module designations
(a)
Check the modules for any damages to the glass surfaces and frames on a regular basis. Routinely inspect all modules for safe electrical connections, sound mechanical connections, and for any shading or corrosion issues. If dirt or debris becomes built-up clean the glass using only a soft cloth, with a mild, non-abrasive detergent and water. SunEdison recommends using mild cleaning liquids; a neutral pH in the range of 6.0 to 8.0 is recommended. Chemicals with pH less than 6.0 or greater than 8.0 should be avoided as it may damage the glass surface and/or the anti-reflective coating. Please consult with the system designer to determine the best cleaning and inspection schedule based on local environmental conditions. Do not power wash, use harsh cleaning materials or coarse objects such as scouring powder, steel wool, scrapers, blades or other sharp instruments to clean the module. Use of any such methods and materials will void the product warranty. Do not wash modules with water that is more than 20 C cooler than the surface of the module. Doing so can cause the glass to crack. WARNING: Use caution when cleaning the back surface of the module to avoid scratching the substrate materials.
(b)
© 2015 SunEdison
11
F-SERIES and R-SERIES 60-Cell Installation Guide 6.0 Disclaimer of Liability
International Product Certifications: Certification
The information in this manual is based on SunEdison’s knowledge and experience and is believed to be accurate. However, the information in this manual (without exception) including recommendations and specifications does not constitute a warranty, expressed or implied. SunEdison reserves the right to change the manual, the module, or specifications without prior notice.
••IEC 61215 certified by TÜV SÜD ••IEC 61730 certified by TÜV SÜD to ensure electrical safety ••UL 1703 listed by CSA for US and Canada
Environmental
AB8 (−50 C to +40 C)
The product warranty will be voided if:
Module Fire Performance
Type 1 or Type 2 available1
••Handling and installation does not conform to SunEdison’s written installation instructions.
Fire Resistance Rating
Class C
••The product has been modified in a manner not previously authorized by SunEdison in writing.
1
••The product is installed in an environment for which it was not designed.
IEC 61215, IEC 61730, CE, UL 1703 and Safety Class II certifications ensure that SunEdison solar products operate safely and comply with applicable national and global electrical, performance, reliability and fire safety codes.
SunEdison will not be held liable for special, indirect, consequential, contingent or incidental damages related to or arising from the installation or use of the product by purchaser under any circumstances.
Refer to design package and module label for specific Fire Performance Type.
SunEdison modules are certified by:
SunEdison assumes no responsibility for any product application or use that is beyond SunEdison’s direct control. SunEdison does not accept responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected to such installation, operation or maintenance of the product.
12
© 2015 SunEdison
7.0 Appendix 7.1 Module Illustrations
7.2 Physical Parameters Dimension
mm
inch
Module Dimensions
Bolt Stack Details Dimension
mm
inch
Mounting Hole Spacing
A
990
39.0
E
950
37.4
B
1,658
65.3
F
994
39.1
C
50
2.0
D
30
1.18
Cable Length L
1,000
39.4
Dimension tolerance range for: A ±3 mm, B ±3 mm and C ±0.3 mm
Module Weight
19 kg
Frame Material
Black Anodized Aluminum
Tempered ARC Glass Thickness
3.2 mm
Connector Types
Amphenol Helios H4 (–38, –39) Bizlink S418 (–34)
© 2015 SunEdison
13
F-SERIES and R-SERIES 60-Cell Installation Guide 7.3 Pre-mounted Cables and Connectors Mounting Configuration Type Cross Section Maximum Current Maximum System Voltage Temperature Rating Qualification
14
Pre-mounted Cables TUV – PV1-F & UL – PV wire 4.0 mm² 16 A 1000 VDC / UL 1000 V − 40 C to +90 C TUV 2PFG & UL PV wire
© 2015 SunEdison
Pre-mounted Connectors locking polarized connectors 4 mm diameter 25 A 1000 VDC / UL 1000 V − 40 C to +85 C EN 50521 & UL for PV system
SunEdison Delivers Solar Solutions Around the World Australia Brazil Bulgaria Canada Chile China France Germany Greece India Indonesia Israel Italy Japan Jordan Malaysia Mexico South Africa
South Korea Spain Taiwan Turkey U.A.E United Kingdom U.S.A.
www.sunedison.com
600 Clipper Drive Belmont, CA 94002 Phone: 866-786-3347 or 650-453-5600 ©2015 SunEdison Products Singapore Pte. Ltd.; A SunEdison Company. All rights reserved. SunEdison and the SunEdison logo are registered trademarks or trademarks of SunEdison Products Singapore Pte. Ltd. and/or its affiliates in the United States and certain other countries. All other trademarks mentioned in this document are the property of their respective LWI-19376 TF_F_R60_Vega_45_GD_50mm_v6 06.2015 owners.
