Aleo S_16 User manual
installation instructions Ed. 01/2012 en-GB-Intl (120508b)
DasverknüpfteBildk ann nichtangezeigtwerden.Möglicherweisewurdedie Dateiverschoben, umbenanntoder gelöscht.StellenSie sicher, dass d ie Verkn üpfun g auf die k orrek te Datei und den k orrek ten Speic heror t zeigt.
installation instructions
for aleo solar modules
S_16, S_17, S_18, S_19
S_24
S_77, S_79
aleo
Page 2/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
© 2012 aleo solar Deutschland GmbH
This manual is protected by copyright law. All rights reserved.
Copying, distributing, translating, and transferring into any
kind of electronic medium or any kind of machine-readable
form in whole or in part is not authorised. The production of a
single backup copy for personal use is permitted.
This document was created by aleo solar according to the
best of its knowledge. However, aleo solar does not accept
explicit nor implicit liability for the completeness or accuracy
of the information provided.
The performance characteristics indicated are only binding if
they have been explicitly agreed upon within the contract.
aleo® and aleo solar® are registered, protected trademarks
of aleo solar AG.
Distribution and Customer Services:
aleo solar Deutschland GmbH
Osterstrasse 15
26122 Oldenburg
Germany
T +49 (0) 441 21988-123
F +49 (0) 441 21988-122
www.aleo-solar.com
Manufacturer Address:
aleo solar AG
Marius-Eriksen-Strasse 1
Gewerbegebiet Nord
17291 Prenzlau
Germany
T+49 (0) 3984 8328-0
F+49 (0) 3984 8328-115
info@aleo-solar.com
www.aleo-solar.com
Printed in Germany
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 3/60
Contents
1.Safety Information .................................................... 4
1.1.Warnings......................................................................4
1.2.Notices ........................................................................4
1.3.Other system components...........................................4
2.About this Manual..................................................... 5
2.1.Audience......................................................................5
2.2.Chapters for planners ..................................................5
2.3.Chapters for installers..................................................5
2.4.Chapters for operators.................................................5
2.5.Key...............................................................................5
2.6.Safekeeping of this document .....................................5
3.Introduction............................................................... 6
3.1.Normal use ..................................................................6
3.2.Product support...........................................................7
4.Handling of aleo Modules......................................... 8
4.1.Mechanical precautionary measures ...........................8
4.2.Electrical precautionary measures...............................9
5.Planning ...................................................................10
5.1.Selecting a location ...................................................10
5.2.Alignment (azimuth)...................................................10
5.3.Inclination (elevation)................................................. 11
5.4.Avoidance of shadowing ............................................ 11
5.5.Visual precautionary measures..................................12
5.6.Selection of aleo modules..........................................12
5.7.General installation options .......................................13
5.8.Visually appealing installation....................................14
5.9.Defined Installation Options.......................................15
5.10.Anti-theft protection ..................................................18
5.11.Matching of solar modules and inverters...................19
5.12.Electrical installation..................................................19
5.13.Precautionary measures ............................................23
6.Preparing for Installation .......................................25
6.1.Storing, transporting and unpacking modules ...........25
6.2.Precautionary measures ............................................25
7.Mechanical Installation ..........................................28
7.1. Visually attractive roof installation.............................28
7.2 .Types of installation ...................................................28
7.3 .Support area..............................................................28
7.4 .Spacing and clearances.............................................28
8.Electrical Installation..............................................30
8.1.Order of work steps ...................................................30
8.2.Series connection......................................................30
8.3.Wiring ........................................................................30
8.4.Parallel switching, special requirements.................... 31
8.5.String diodes.............................................................. 31
8.6.Installation of direct current string fuses ................... 31
8.7.Inverter connection.................................................... 31
8.8.Protective potential equalisation (earthing)................32
8.9.Lightning protection...................................................33
9.Mechanical Mounting Details ................................ 34
9.1.Position of mounting rails..........................................34
9.2.Configuration of the clamps for clamp mounting.......34
9.3.Mounting with clamps ...............................................34
9.4.Mounting with bolts...................................................35
9.5.Lay-in mounting.........................................................36
9.6.Load levels.................................................................36
9.7.Diagram key...............................................................36
9.8.Diagrams ...................................................................38
10.Maintenance............................................................ 44
10.1.Inspection..................................................................44
10.2.Check-up ...................................................................44
10.3.Inspections................................................................44
10.4.Cleaning ....................................................................45
10.5.Repairs ......................................................................46
10.6.Potential Induced Degradation (PID)..........................46
11.Decommissioning ................................................... 47
11.1.Disposal..................................................................... 47
11.2 .Taking Back Scheme.................................................. 47
11.3 .PV Cycle .................................................................... 47
A.Parameters of aleo Modules.................................. 48
B.Creation and Avoidance of Shadowing................. 49
B.1Deepest shadow and half shadow .............................49
B.2Shadows from cylindrical objects..............................49
B.3Shadows from edges .................................................50
C.Optimisation of Wiring for Lightning Protection. 52
C.1.Keep loops small .......................................................52
C.2.Current direction in loops..........................................53
C.3.Laying the return circuit.............................................53
D.Explanations............................................................ 55
D.1.Abbreviations.............................................................55
D.2.Glossary ....................................................................56
E.Index......................................................................... 57
F.Bibliography ............................................................ 59
aleo
Page 4/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
1. Safety Information
Solar modules may only be installed or serviced by properly
trained professionals.
Solar modules can create high direct voltages that can be life-
threatening if handled improperly. Therefore, this installation
manual contains important hazard notices, warnings, and
other precautionary information. For your own safety, please
observe these guidelines.
Please carefully read through the safety information and
familiarise yourself with the proper handling of the modules
before attempting to install, operate, service or dispose of any
modules.
If you act with caution and care during installation and
operation then you will already be following a large part of
these rules.
1.1. Warnings
1.1.1. Warning notices on modules
The following symbols can be found on the modules:
CAUTION
When this symbol appears additionally on a danger or
warning product label, it warns against dangerous
electric current which can lead to personal injuries if
the instructions are not followed.
1.1.2. Warning notices in the manual
This is the danger notice symbol. It is used
in various forms in this manual as a warning against
possible danger of personal injury. Follow all safety
instructions following this symbol in order to prevent
injury or death.
The following notices appear throughout this manual in order
to warn against potential dangers or to provide information
that clarifies or simplifies a process.
DANGER
DANGER indicates an immediately dangerous
situation that, if not avoided, will inevitably lead to
death or serious injury.
WARNING
WARNING indicates a potentially dangerous situation
that, if not avoided, can lead to death or serious injury.
CAUTION
CAUTION indicates a potentially dangerous situation
that, if not avoided, can lead to slight or moderate
injury.
1.2. Notices
1.2.1. Notices on modules
Read Manual
If this symbol also appears on the product label, then it
is instructing you to read this installation instructions.
1.2.2. Notices in the manual
NOTICE
NOTICE in the manual indicates a potentially dangerous
situation that, if not avoided, can lead to material
damage.
RECOMMENDATION
RECOMMENDATION in the manual indicates an
important fact or a useful piece of information.
1.3. Other system components
Please follow the instructions and heed the safety information
in the manuals for other components of your photovoltaic
system such as inverters, combiner boxes, or fire prevention
switches.
G
ID A
S
033
c
G
ID A
S
044
c
G
ID A
S
033
c
G
ID A
S
039
c
i
G
ID A
S
061
a
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 5/60
2. About this Manual
This installation instructions contain the information needed
to plan, install, operate, and service framed aleo modules.
2.1. Audience
This installation instructions are directed at the following
readers:
planners
installers
operators.
2.2. Chapters for planners
Ch. 1, „Safety Information“
Ch. 2, „About this Manual“
Ch. 3, „Introduction“
Ch. 4, „Handling of aleo Modules“
Ch. 5, „Planning“
Ch. 6, „Preparing for Installation“
Ch. 7, „Mechanical Installation“
Ch. 8, „Electrical Installation“
Ch. 10, „Maintenance“
2.3. Chapters for installers
Ch. 1, „Safety Information“
Ch. 2, „About this Manual“
Ch. 3, „Introduction“
Ch. 4, „Handling of aleo Modules“
Ch. 5, „Planning“
Ch. 6, „Preparing for Installation“
Ch. 7, „Mechanical Installation“
Ch. 8, „Electrical Installation“
Ch. 9, „Mechanical Mounting Details“
Ch. 10, „Maintenance“
2.4. Chapters for operators
Ch. 1, „Safety Information“
Ch. 2, „About this Manual“
Ch. 3, „Introduction“
Ch. 4, „Handling of aleo Modules“
Ch. 10, „Maintenance“
Ch. 11, „Decommissioning“
2.5. Key
The symbols used in this manual have the following meanings:
• Listing
Chapter 4th order
[1] Literature references, see Appendix F, 'Bibliography'
2.6. Safekeeping of this document
Operators must keep this installation instructions in a safe
place. It contains information necessary for the maintenance,
care, and potential resale of your aleo modules.
If you either sell or transfer your aleo modules, please ensure
that the buyer or recipient is given this documentation. Please
verify the receipt of this document in writing and retain a copy
thereof for your records.
aleo
Page 6/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
3. Introduction
Thank you for choosing aleo modules. aleo solar manufac-
tures high-quality, state-of-the-art solar modules that will
supply environmentally-friendly energy generated by sunlight
for many years when correctly installed and properly
operated.
This manual contains important information for planning a
photovoltaic system and about the installation and mainten-
ance of aleo modules.
Please read the following installation and operation infor-
mation thoroughly before installing, operating, or servicing
aleo modules and be sure to follow the instructions in this
document. First and foremost, please take careful note of the
safety information!
WARNING
The danger, warning, and caution notices, as well as
the information and procedural instructions in this
manual are obligatory. Follow these instructions in
order to avoid endangering life and limb. Doing so will
also prevent damage to your photovoltaic system or
building.
NOTICE
The recommendations in this manual help ensure that
your photovoltaic system achieves optimum energy
yields and a long service life under the given con-
ditions. These recommendations are not obligatory.
You may deviate from these recommendations in order
to take into account local circumstances. In this
manual, recommendations are identified by the words
'recommendation', 'recommend', etc.
3.1. Normal use
aleo solar offers a wide range of solar modules.
NOTICE
aleo modules are designed to be used for the
production of electrical energy in grid-connected
photovoltaic systems. If you would like to use them
for another purpose, e.g. to directly charge a
battery, then please pay attention to the notices in
this document.
aleo modules were developed for stationary use. Do
not install aleo modules on vehicles and do not use
them in air, space, or sea travel applications.
aleo modules are suitable for installation in coastal
areas. More detailed information can be found in
Ch. 5.1.5, 'Coastal areas'.
aleo modules are suitable for installation near
facilities where animals are kept. More detailed
information can be found in Ch. 5.1.6, 'Proximity to
facilities where animals are kept'.
Do not use aleo modules if they are exposed to
concentrated sunlight or strong artificial light, nor if
they could be submerged in water or other liquids
or are exposed to vapours.
Product-specific information (e.g. the datasheet) for a certain
module type may contain more specific or, in some cases,
differing information. aleo modules should only be used for
the purpose for which they were intended as described in the
product-specific information.
G
ID A
S
033
c
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 7/60
3.2. Product support
aleo solar is continuously working on the further development
of its products in order to be able to provide you with consis-
tently high-quality, safe, and state-of-the-art products. We also
make use of information and ideas from planners, installers,
and operators to monitor and improve the quality of aleo
modules.
For questions about:
system design and monitoring
system components
services
please contact aleo solar Customer Services:
Distribution and Customer Services:
aleo solar Deutschland GmbH
Customer Services
Osterstrasse 15
26122 Oldenburg
Germany
T +49 (0) 441 21988-123
F +49 (0) 441 21988-122
www.aleo-solar.com
aleo
Page 8/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
4. Handling of aleo Modules
The information and warnings in this chapter apply to solar
modules even if they have not yet been installed.
DANGER
aleo modules may only be installed by properly
trained professionals with a high level of experience
as the modules can generate dangerous DC voltages
in storage as well as during installation, operation,
and maintenance.
Abide by all relevant laws, regulations, guidelines, safety
measures and standards (recognised state-of-the-art), etc.
when handling solar modules.
Proceed with caution when installing, operating,
maintaining and disposing of solar modules in order
to prevent accidents (e.g. electric shocks or
injuries).
Keep unauthorised persons (e.g. children) and
animals away from photovoltaic systems.
For work on rooftops, ensure that sufficient safety
precautions have been taken for all persons in-
volved, e.g. to prevent falls.
Take particular note of the relevant provisions
regarding work safety and accident prevention for
the respective activities ([1], [2], [3], [4], [5]).
Take note of the packaging instructions on the
module box.
Do not alter aleo modules, their parts, and any
labels applied by aleo. Do not attempt to modify or
disassemble aleo modules.
Do not apply paint, pen or adhesives to the front or
rear side of an aleo module, but, if necessary, these
may be applied exclusively on the frames.
aleo modules are generally combined with further compo-
nents to create a photovoltaic system. Please also follow the
installation and operational guidelines for these additional
components.
4.1. Mechanical precautionary measures
WARNING
Do not, under any circumstances, stand or
sit on solar modules. This prevents injuries
through possible cracking, breaking or
splitting of the glass.
This will also prevent:
micro-cracks in the cells and resulting
yield losses
other, potentially serious damage to the
cells
Avoid knocks or blows to the surface, the
edges, and the corners of the glass panes as
this could break or split the glass.
WARNING
If the glass of a module is broken, cracked or split, live
electrical parts may be exposed, creating a danger of
electric shock. Only use modules with flawless
insulation.
CAUTION
Wear suitable protective gear (e.g. gloves
and protective goggles) in order to avoid
injury that could occur from broken glass in
the form of flying glass shards or sharp glass
edges.
Be especially careful while handling the
edges and corners of the glass panes in un-
framed modules. Avoid breaking or splitting
the glass panes as this could cause personal
injury.
Always wear work gloves when handling aleo
modules. This prevents injury resulting from
contact with module corners or edges.
NOTICE
Always safely set down aleo modules. Never allow
modules to stand freely or unsecured.
Handle aleo modules with care. Do not drop the
modules, avoid knocks, and do not let any objects
fall onto the modules ([29], [30]).
Do not place any tools on the glass surfaces.
G
ID A
S
044
c
G
ID A
S
033
c
G
ID A
S
033
c
G
ID A
S
039
c
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 9/60
4.1.1. Insulating back sheet
The insulating back sheet in some aleo modules protects
against the effects of weather and helps the electrical
insulation.
WARNING
A damaged rear-side insulating foil can cause
electric shock.
A damaged insulating back sheet can also
cause short-circuits or ground faults which
may in turn cause fires.
NOTICE
Ensure that this back sheet remains undamaged.
Prevent the module rear side from coming into
contact with sharp or pointed objects.
A damaged insulating back sheet can cause
permanent damage to the solar module (e.g.
delamination).
Any damages should be immediately repaired by aleo solar or
authorised specialists.
4.2. Electrical precautionary measures
Always heed the following warnings when handling solar
modules:
DANGER
Do not touch the electrical connections or other
live parts of a solar module directly or with a
conductive object (e.g. an uninsulated tool)! There
is a risk of suffering a dangerous electric shock.
This particularly applies if the module has already
been electrically connected. If numerous modules
are connected in a row, the voltages add up.
This can still occur even if the current of the
photovoltaic generator has been switched off.
WARNING
Solar modules create electrical voltage even with low
exposure to light. In very unfavourable situations, the
voltage of a single solar module can be enough to
cause an electric shock ([31]).
CAUTION
The voltages of modules add up when
modules are connected in series. Such a
series connection can create very high
voltages.
In a parallel connection the module currents
add up. Even a single module can generate a
significant current.
G
ID A
S
033
c
G
ID A
S
044
c
G
ID A
S
033
c
G
ID A
S
039
c
aleo
Page 10/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
5. Planning
The following sections contain important information on the
planning of a photovoltaic system with aleo modules.
The information and warnings in this chapter are valid even for
the planning phase of a photovoltaic system.
Please contact the relevant authorities and, in the case of a
grid-connected PV generator, the local grid operator in order
to arrange for authorisation, as well as to clarify the installa-
tion and operational requirements. Also make sure that all
your information is up to date.
5.1. Selecting a location
5.1.1. Precautionary measures
DANGER
Sparks or electric arcs can be formed as a result of
short-circuits or switching operations in photo-
voltaic systems. Therefore, make sure to avoid the
installation of solar modules near easily flammable
solid, liquid, or gaseous materials.
5.1.2. Solar irradiation
Select a location with the best possible solar irradiation for
the photovoltaic system that is going to be set up. Take into
account changes in light conditions over the course of the
entire year.
Try to select an installation location where solar modules will
receive sunlight without any shadowing from 9 am to 3 pm
local time, even on the shortest day of the year.
Avoid locations in which, over the course of the day or year,
there is systematic shadowing due to neighbouring objects or
buildings (see Ch. 5.4, Avoidance of shadowing).
5.1.3. Planning Resources
The following sources of information can be useful for the
general assessment of a location:
tables, e.g. about meteorological data for the
region of the location and/or
software applications, e.g. for snow load and wind
force zones etc.
These planning resources can help produce more accurate
yield predictions.
For a defined site, mobile measuring devices can also be
useful for assessing shadowing and measuring inclination. For
example, these are equipped with:
a GPS receiver
an electronic spirit level
an electronic compass
a fisheye camera
a display for measured values or, respectively, the
visible section of the sky including the sun's orbit
over the course of the day and year.
5.1.4. Snow and wind loads
The necessary substructure and the installation details for
aleo modules are dependent on the highest expected load
levels (see Ch. 7, 'Mechanical Installation'). Therefore, ex-
pected snow loads and wind forces at the location should be
taken into consideration during the planning phase.
The expected pressure load level at a location is dependent
on the snow load/wind zone, the elevation, and the inclination
of the building’s roof, etc.
Always take local regulations into consideration. In Europe, for
example, these are DIN EN 1991-1-4 or DIN 1055, parts 4
and 5.
5.1.5. Coastal areas
aleo modules are suitable for installation in coastal areas.
However, it should be avoided as much as possible that
modules come into any contact with seawater. For example,
this can be caused by:
splashing water
spray
water dripping from cliffs with salt deposits
saline particle deposits carried by the wind
Choose the distance from the coast depending on the defined
conditions at the planned installation site. As the selection of
a location is dependent on a variety of factors, aleo solar can
only provide general recommendations.
The extent to which a photovoltaic system comes into contact
with salt spray or salt water is dependent on the salinity of the
sea water, the prevailing wind and precipitation conditions,
and a number of other local circumstances such as neigh-
bouring buildings or cliffs.
5.1.6. Proximity to facilities where animals are kept
aleo modules are suitable for installation near facilities where
animals are kept (ammonia resistance). If you have any
questions regarding test certificates, please contact aleo solar
Customer Services (see Ch. 3.2, 'Product support').
5.2. Alignment (azimuth)
Set up the solar modules
facing south in the northern hemisphere
facing north in the southern hemisphere
These alignments generally result in the greatest yield.
G
ID A
S
044
c
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 11/60
5.2.1. Special requirements
If you have any special requirements for your system (e.g. an
island system) or if there are any special circumstances at
the intended location, a different alignment may merit
consideration.
These special requirements may include:
a specific desired main usage phase
an especially clear view of the sun's path at the
location
For example: if the desired daily main usage phase of a
system in the northern hemisphere is during the evening and
if the location has a particularly clear view of the sun's path to
the south-west, then a southwest alignment may be more
advantageous.
5.3. Inclination (elevation)
5.3.1. Minimum inclination
Incline the surfaces of the solar modules at an angle at
least 10° from horizontal so that precipitation can run off and
therefore facilitates the self-cleaning of the modules.
For optimal self-cleaning, we recommend an inclination angle
of at least 15° from horizontal.
5.3.2. Optimum inclination
The optimum inclination angle for power output is particularly
dependent on the latitude at the location and the desired
main usage phase for the photovoltaic system.
Typical inclination angle values for Europe are around 20° in
Southern Europe, around 30° in Central Europe, and
around 40° in Northern Europe.
The following formula can be used to estimate the optimum
inclination:
Horizontal angle = latitude at the location - 20°
More exact values for a chosen location can be taken from
corresponding tables or a suitable calculation programme.
5.3.3. Tracking installation
If you would like to use an automatic tracking system, please
observe the guidelines and requirements of the tracking
system manufacturer.
An automatic tracking system can ensure higher yields,
particularly in summer, but it also entails substantially higher
installation and maintenance costs.
5.4. Avoidance of shadowing
NOTICE
Avoid shadowing of the solar modules. In particular,
this also applies to small-scale shadowing from
small nearby objects such as antennas or lightning
protection systems.
If there is systematic shadowing over the course of
the day or year at the location due to neighbouring
objects and there is no way of changing this
shadowing then
consider a different location
–OR–
only plan to use the non-shadowed area at the
location for your photovoltaic generator.
5.4.1. Effects of shadowing
Even the shadowing of a single module or a single solar cell
can have a noticeable effect on the performance of the entire
photovoltaic system.
If shadows fall on individual solar modules of a photovoltaic
generator or on individual solar cells of a solar module, the
shadowed parts generate less or even no further electrical
output. This can have an effect on the yield of an entire
module string and, subsequently, the whole generator.
Shadowing also often means that a portion of the electrical
output created in the module no longer contributes toward
the yield because it is consumed by the solar cells in the
shadowed area instead. This can cause a rise in the tempe-
rature of the shadowed cells compared to the normally lit
cells. In extreme cases, this can create a fire risk.
Extended or systematic shadowing can cause significant yield
losses. Furthermore, over the long run, this can lead to
accelerated aging and therefore output losses or even failure
of the photovoltaic generator. Consequently, such shadowing
dependent on the time of day or year (particularly in winter)
caused by parts of buildings, for example, should be avoided
in order to optimise the yield and service life of your system.
More details regarding avoidance of shadowing can be found
in Appendix B, 'Creation and Avoidance of Shadowing'.
5.4.2. Protective devices within the modules
aleo modules are equipped with bypass elements that, in the
case of shadowing, ensure that increased temperatures
caused by internal power consumption remain at uncritical
levels, thereby protecting the module. Systematic shadowing
should also be avoided as these bypass elements should not
be subjected to regular, longer-lasting loads.
aleo
Page 12/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
5.5. Visual precautionary measures
NOTICE
Do not artificially concentrate or directly reflect
sunlight on an aleo module. Do not use any lenses or
mirrors.
If your photovoltaic generator is located in an area with strong
reflections (e.g. due to snow or areas of water) then the maxi-
mum performance of the photovoltaic generator may be
increased. This is non-critical for aleo modules.
However, please take this situation in consideration when
dimensioning and selecting your inverter (see Ch. 5.11.
‘Matching of solar modules and inverters’).
5.6. Selection of aleo modules
Select the aleo module type that is best-suited to your con-
crete system. A main distinguishing feature among modules is
whether they are made from mono or poly-crystalline cells.
Which cell type is best-suited to your needs depends on your
goals and expectations.
The following general rules can make this decision easier:
Mono-crystalline cells have:
an octagonal shape (square with bevelled
corners)
a black base colour. - this base colour can
vary depending on the actual cell being used.
Poly-crystalline cells have:
a square shape
a bluish base colour - this base colour can
also vary depending on the actual cell being
used.
Fig. 1 Mono-crystalline and poly-crystalline cells with white,
grey and black back sheet (diagram)
a: mono-crystalline cells, b: poly-crystalline cells; 1: white,
2: grey, 3: black back sheet.
NOTICE
Only use modules of the same type, the same cell
type, and the same output class within a module
string. Doing so will optimise your energy yield.
If you connect numerous module strings to an MPP
tracker in parallel, make absolutely sure that you
use the same number of modules for every one of
the module strings connected in parallel.
Deviating from this procedure can have a significant
effect on the output of a photovoltaic system,
increase the risk of damage, and reduce the service
life of the modules.
Information on how to match aleo modules and inverters can
be found in Ch. 5.11, 'Matching of solar modules and
inverters'.
ba
1
2
3
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 13/60
5.7. General installation options
WARNING
Mount the aleo modules in such a way that they can
withstand expected loads and weather-related in-
fluences. The supporting structure should be laid out
to support all locally expected snow and ice loads, as
well as wind forces (and suction forces).
NOTICE
In regions with especially high snow loads, supporting
measures on the rear side of the module are necessary.
Details on the mounting options for different loads can
be found in Ch. 9, 'Mechanical Mounting Details'. If you
have any doubts, please contact aleo solar Customer
Services (see Ch. 3.2, 'Product support').
5.7.1. Roof installation
WARNING
Only install solar modules on roofs that have
a so-called fire-resistant surface according to
DIN 41021[15], e.g. on roofs made of tiles,
metal, or shingle.
Do not, under any circumstances, install
solar modules on a thatch roof or on any
other kind of roof that has a so-called soft
surface, such as roofs made from straw or
wood shingles.
For rooftop installation, the following options apply:
On a flat roof:
Installation on supporting stands.
On a pitched roof, the above, plus:
on-roof installation
1Hard roofing includes:
roofing that is listed as resistant against flying
sparks and radiant heat according to DIN 4102-4
roofing made from natural and artificial stones
according to the DIN 4102-A building material class
metal roofs according to the DIN 4102-B and
DIN 4102-B1 building material classes
various types of bitumen sheeting according to
DIN 52128, DIN 52130, DIN 52131 and DIN 52143
in at least double-ply
roofing covered completely with gravel filling (at
least 5 cm thick, 16/32 graining, specific surface
weight of at least 80 kg/m²))
roofing that is completely covered with mineral
panels
roofing with a test certificate according to
DIN 4102-7.
in-roof installation
More information on installation options can be found in
Ch. 7, 'Mechanical Installation'.
WARNING
Installation on roofs requires special sub-structures in
order to properly mount the solar modules. Ensure that
the sub-structure used, including all individual com-
ponents, adheres to the relevant laws, regulations,
guidelines, etc.
Evenness of the substructure
NOTICE
Construct the substructure in such a way that the
mounting surface is flat (even) for the modules.
This will make mounting the modules easier
and increase the durability of the mounted
modules against mechanical loads. It will also
help prolong the service life of the modules.
Avoid an arched or warped mounting surface at all
costs.
Even out height differences in the roof
construction with suitable additional
components.
More details about mounting options for aleo modules can be
found in Ch. 9, 'Mechanical Mounting Details'.
5.7.2. Free-field installation
In a free-field installation situation, ensure that the lower
edges of the modules have sufficient clearance from the
ground. This serves to prevent soiling through spray water or
through blown/accumulated snow, as well as possible
shadowing by vegetation.
G
ID A
S
033
c
G
ID A
S
033
c
G
ID A
S
033
c
aleo
Page 14/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
5.8. Visually appealing installation
In order to install the modules on a roof in a visually appealing
way, please observe the following guidelines:
5.8.1. Substructure
Right-angled
Construct the substructure in such a way that mounting
surface is at a right-angle.
A parallelogram or trapezoid shape can create an optimal
surface for module installation, but it may make the module
field appear inaesthetic, which may not be desirable for the
operator.
The necessary width of the mounting rails is also
determined by the intervals between the rafters. A
horizontal displacement of the modules may result
in an undesirable protruding of rail ends in some
rows.
When laying out modules in a parallelogram or
trapezoid shape, offsetting the rows by a half or a
whole module width between neighbouring rows
may create the most attractive effect.
If necessary, plan an alternative module orientation
(e.g. horizontal) or plan with modules that have
different external dimensions.
Fig. 2 Module alignment in a parallelogram shape (offset at a
half-module interval)
Fig. 3 Module alignment in a trapezoid shape (offset at a half-
module interval)
Orientation of the rails
Lay rails that run parallel to the ridge horizontally.
Check the orientation of the rails, e.g. with a spirit
level and a masonry cord.
Lay rails that run vertically to the ridge so that their upper
edge is horizontal.
Check the orientation of the rails, e.g. with the help
of a square, a spirit level and a masonry cord.
5.8.2. Modules
Horizontal orientation
Always mount the modules so that one module side
has a horizontal orientation. For vertical installa-
tion, this is the short side, in horizontal installation,
the long side.
Check the orientation of the modules, e.g. with a
spirit level and a masonry cord.
NOTICE
Avoid a slanted orientation of the modules in which
none of the module sides are horizontal. Such an
orientation may, in some situations, optimise the roof
surface for mounting the modules, but, the module field
may be far less aesthetically pleasing ('saw-tooth
pattern') which is almost always undesirable for the
operator.
Fig. 4 Module orientation to be avoided (no horizontal edge)
Interval between frames
Leave a gap of at least 3 mm between individual frames (see
also Ch. 7.4.1, 'Spacing between the module frames').
GID AS055a
GID AS057a
GID AS056a
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 15/60
NOTICE
Avoid flush installation. This is an option (see also
Ch. 7.4.1, 'Spacing between the module frames'),
but, aleo solar recommends mounting at intervals.
This applies particularly to bolt or lay-in mounting
systems.
Uniform configuration
In a sequence of modules, ensure uniform configuration within
a row. Doing so for module fields with numerous rows makes
it easier to achieve an aesthetic appearance.
NOTICE
Measure the intervals between the modules when
laying a row. If, for example, you start mounting a
module row from the left, measure the gap to the
upper-left corners of the neighbouring modules. Use
this same interval for all the modules in the row.
The following illustration shows a uniform configuration
allowing for tolerances in the width of the module frame (the
diagram of the differences is exaggerated):
Fig. 5 Uniform offsetting of the same module corners (diagram
exaggerated)
NOTICE
Avoid measuring the module intervals only with a
gauge (e.g. a spacer).
As module frames may vary slightly in terms of
width, this may lead to the rows below ending
up with a slightly different overall width. This,
together with the row above, can create an
inaesthetic effect as the edges of the modules
on the sides are no longer properly aligned.
In the case of numerous rows on top of one
another, this effect may become more pro-
nounced ('V pattern').
Also, only use a well-orientated first row as a
reference point for the orientation of the rows
below it. Always measure the intervals between
modules for the following rows.
Fig. 6 Configuration to be avoided with equal space between
modules (diagram exaggerated)
5.9. Defined Installation Options
5.9.1. Installation location
On-roof installation
Attach aleo modules with clamps or bolts to at least four
support points.
NOTICE
If there is a pressure load > 2,400 Pa, only clamp
the modules symmetrically. Symmetrically means:
all clamps are an equal distance from the nearest
module corner.
Bolt fastening is also symmetrical fastening.
For symmetrical fastening, a dual-layer mounting
system may be necessary, depending on the
installation conditions (e.g. the distances from
existing tile rows); see also Ch. 5.9.6, 'Identical
mounting rail intervals in rows/columns'.
aaa
GID AS058b
b b b
b b b
GID AS059b
aleo
Page 16/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
More information on possible substructure variations can be
found in:
Ch. 5.9.4, 'Asymmetrical and symmetrical
clamping'
Ch. 5.9.5, 'Differing mounting rail intervals in
rows/columns'
Ch. 5.9.6, 'Identical mounting rail intervals in
rows/columns'
When using a lay-in system, only mount the modules in a line
on the long side. Also, please observe the guidelines provided
by the mounting system manufacturer.
Details can be taken from the diagrams in Ch. 9, 'Mechanical
Mounting Details'.
In-roof installation
Only mount aleo modules with the long side supported along
its entire length. Also, please observe the guidelines provided
by the mounting system manufacturer.
Details can be taken from the diagrams in Ch. 9, 'Mechanical
Mounting Details'.
Free-field installation
Attach the aleo modules to at least four support points as per
an on-roof installation.
When using a lay-in system, modules may be lined up on both
the long and short sides. Also, please observe the guidelines
provided by the mounting system manufacturer.
Details can be taken from the diagrams in Ch. 9, 'Mechanical
Mounting Details'.
5.9.2. Installation orientation of the modules
Vertical installation (portrait orientation)
When using vertical installation, mount the modules in such a
way that the outlets for the cables on the module or its
junction box point towards the ground. This prevents water
penetration. This also applies to modules without their own
connecting cables.
Fig. 7 Correct position of the junction boxes when mounted
vertically
Horizontal installation (landscape orientation)
In horizontal installation, try to mount the modules in such a
way that the outlets for the cables on the modules or their
junction boxes are on the inside of the photovoltaic generator.
Avoid the area along the edge of the photovoltaic generator.
Doing so will help minimise the influence of the local environ-
mental conditions such as wind or rain. This recommendation
correspondingly also applies to modules without their own
connecting cables.
Fig. 8 Recommended position of the junction boxes when
mounted horizontally
5.9.3. Clamp installation
Ensure that there are:
sufficient clamp and support areas so that the aleo
modules remain firmly fastened to the substruc-
ture, even under high loads;
open drainage holes for the drainage of water from
the hollow frame.
Clamping on the long sides
Clamp aleo modules preferably on the long sides.
Clamping to the short sides
Clamping aleo modules by their short sides is also an option.
Make sure that the modules are only clamped symmetrically.
5.9.4. Asymmetrical and symmetrical clamping
The actual pressure load expected at the installation site
determines the correct way to clamp the modules.
In most cases, there is a degree of freedom during planning
regarding how to select the spacing of the mounting rails, e.g.
in order to be able to adapt the orientation to existing tile
rows. This can simplify the installation process and reduce
costs.
Asymmetrical clamping provides the greatest number of
options because even within a module row (or column, see
below) the clamp interval to the nearest corner on a module
side can vary.
There are also some variations for symmetrical clamping.
Within a module row (or column), the clamp interval to the
nearest corner of a module side is always the same. This
interval can, however, be varied for each module row
(column).
GID AS008b
GID AS009b
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 17/60
Fig. 9 Definition of module columns and module rows
c: module column, r: module row
Asymmetrical clamping
Asymmetrical clamping means that the clamps on one and the
same long module side can have differing distances from the
nearest corner (see below). Make sure, however, that the
opposing clamps maintain the same interval from the
respective corner.
Asymmetrical clamping is possible under the following
conditions:
the expected pressure loads at the installation site
are a max. of 2400 Pa
modules are clamped on the long side.
This allows for the most freedom in planning the substructure.
For example, in vertical module on-roof installations, the
mounting rail pairs of the module rows can be arranged in
such a way that the mounting rails are spaced at differing
intervals, thereby making use of the mounting options to best
fit the height of the tile rows.
Fig. 10 Asymmetrical clamping, example
Symmetrical clamping
Symmetrical clamping means that all clamps on both (long or
short) module sides are the same distance from the nearest
corner.
Modules should always be clamped symmetrically in these
cases:
the pressure loads at the installation site exceed
2400 Pa
modules are clamped on the short side
The interval of the rails for a particular module row or column
can be different for each module row or column. This allows
for a certain degree of freedom with respect to the spacing of
the mounting rail pairs.
Fig. 11 Symmetrical clamping, example 1
Fig. 12 Symmetrical clamping, example 2
GID AS054a
r
c
GID AS010b
a1
a2
a3
a4
GID AS011b
a6
a6
a5
a5
b1
b1
b2
b2
GID AS012b
aleo
Page 18/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
5.9.5. Differing mounting rail intervals in rows/columns
The interval of the mounting rails for a particular module row
or column can be different for each module row or column.
This allows for a certain degree of freedom with respect to the
intervals of the mounting rail pairs.
This applies particularly to asymmetrical clamping and, in
certain cases, also to symmetrical clamping.
5.9.6. Identical mounting rail intervals in rows/columns
If the installation situation requires identical intervals for the
mounting rails in all module rows or columns, e.g. due to
aesthetic requirements, the requirements for symmetrical
clamping areas for very high loads, or bolt installations, aleo
solar recommends a dual-layer substructure.
This makes it possible to align the top layer of profiles
independently, for example, from the tile rows.
The free space under the modules is also thereby increased,
often by more than 45 mm. This means:
at high pressure loads, there is a greater degree of
freedom regarding clamping and less additional
effort required (e.g. omission of additional clamps
or supports),
the modules are better ventilated from the back
and are cooler, which may bring yield advantages.
5.9.7. Bolt installation
aleo modules have mounting holes with a diameter of 9 mm.
This makes it possible to also attach the modules with M8
(5/16 inch) size bolts (see Ch. 9.4, 'Mounting with bolts'). A
bolt installation requires an appropriate interval between
mounting rails. Avoid flush fitting in a bolt installation
situation. This is an option (see also Ch. 7.4.1, 'Spacing
between the module frames'), but aleo solar recommends
mounting at intervals.
5.9.8. Lay-in installation
Avoid flush fitting. This is an option (see also Ch. 7.4.1,
'Spacing between the module frames') but, aleo solar
recommends mounting at intervals.
On-roof installation
Modules can be lined up on both the long and
the short side.
In-roof installation
Line up the modules exclusively on the long
side.
Free-field installation
Modules can be lined up on both the long and
the short side.
Also, please observe the guidelines provided by the mounting
system manufacturer.
5.10. Anti-theft protection
The following list contains a number of anti-theft options (it is
not exhaustive):
Fill the internal hexagon of the bolt heads with cast
resin.
Use bolts with a head that separates with a defined
torque during installation.
Use specially shaped cross slot bolts that can be
screwed in, but not out.
Engrave a self-explanatory code in the frame, e.g.
the Owner Identification Number (acronym: 'OIN')
which is made up of five components: city or area
code from the vehicle number plate, municipality
key, street name, house number, and the initials of
the operator.
Use a substructure with locking technology that
requires special tools for removal.
Put a fence around an free-field system.
Install CCTV.
Install an electronic monitoring system.
NOTICE
Avoid driving steel balls into the bolt head internal
hexagons. The strong vibration can cause micro-
cracks and yield losses, and lead to a loss of
warranty.
Also avoid boring the internal hexagons of the bolts.
The vibration can also cause micro-cracks and yield
losses, and lead to a loss of warranty.
Avoid driving in (stamping) identification marks in
the frame. The strong vibration can cause micro-
cracks and yield losses, and lead to a loss of
warranty.
Avoid engraving identification marks into the
module glass. This could irreparably damage the
module.
aleo
installation instructions Edition 01/2012 en-GB-Intl (120508b) Page 19/60
5.11. Matching of solar modules and inverters
NOTICE
Orientate all aleo modules connected to a particular
MPP tracker of an inverter in the same direction
(same azimuth) and with the same inclination from
horizontal (same elevation).
If the photovoltaic generator is located in an area
with strong reflections (e.g. due to snow or areas of
water), the maximum electricity and therefore the
maximum performance of the photovoltaic genera-
tor may be increased. Please take this into consi-
deration when arranging the inverter.
Make sure the aleo modules and the inverters to be
used are compatible with one another ([18], [19],
[23]).
To optimise output, aleo solar recommends always operating
photovoltaic generators with at least one MPP tracker. MPP
trackers are integrated into most inverters. Details on the
MPP tracker can be found in the inverter manual.
Some of the literature recommends a slight under-
dimensioning of the inverter, e.g. to 90% of the expected
maximum output of the photovoltaic generator. Other litera-
ture recommends that the inverter arrangement should be
100% or a little higher.
These arrangement options have the following effects that
should be considered during the planning phase:
A slightly under-dimensioned inverter has the
following consequences:
it can be slightly cheaper to purchase
it generally leads to smaller yields
it can age a little more quickly.
A slightly over-dimensioned inverter has the
following consequences:
it can be slightly more expensive to purchase
it generally leads to larger yields
it can age a little more slowly.
If a single inverter is not sufficient for your
situation, then you have the following options:
use several MPP trackers or inverters
-OR-
use an inverter that features several
independent MPP tracker inputs.
5.11.1. Parallel connection of module strings
Parallel connection of module strings can reduce the number
of required inverter inputs. Please observe the following
information when using parallel connection:
NOTICE
Parallel connection of module strings most likely
costs less than the use of numerous inverters or
MPP trackers.
Several inverters or an inverter with several
independent inputs for module strings entails
higher acquisition costs in most cases. Such a
system can, however, achieve higher yields during
its planned lifetime that offset or even exceed the
additional costs.
Only parallel connect those module strings with
identically orientated modules2
the same number of modules
modules of the same type and the same
output class.
Please note the information on the parallel
connection of module strings in Ch. 5.12.6, 'String
diodes' and Ch. 5.12.7, 'Direct current string fuses'.
Deviating from these recommendations can significantly
affect the output of a photovoltaic system, increase the risk of
damages, and reduce the service life of the modules.
5.12. Electrical installation
WARNING
All electrically relevant components of a photovoltaic
system (modules, cables, connectors, string fuses, fire
prevention switches, DC isolators, inverters, etc.) must
be approved for the voltages and currents that can
occur in the photovoltaic system under consideration
([20], [22], [24]).
CAUTION
Only use connecting cables without
softeners. This ensures the reliable and safe
operation of the system.
Information on cable properties can be
obtained from the cable manufacturers.
2Same orientation (same azimuth) and same inclination (same
elevation).
G
ID A
S
033
c
G
ID A
S
039
c
aleo
Page 20/60 installation instructions Edition 01/2012 en-GB-Intl (120508b)
CAUTION
aleo modules are suitable for a maximum
system voltage of 1000 V. Details on the
maximum system voltage for a certain
module type can be found on the product
label or on the corresponding data sheet.
Local regulations may stipulate a lower
voltage. Other components of the system
may also require a lower maximum voltage.
Design the system in such a way that the
maximum system voltage is not exceeded,
even in the worst case scenario, e.g. a
photovoltaic generator with the current
switched off, low outdoor temperatures, and
strong irradiation.
As a rule of thumb, multiply the open circuit
voltage under standard test conditions (STC)
by a safety factor of 1.25 (see Appendix A,
'Parameters of aleo Modules'). Regional
regulations may stipulate multiplying by a
different factor.
5.12.1. Wiring
NOTICE
Avoid cross connection3of the modules. A cross con-
nection is, in practice, a frequent source of faults as it
leads to more complex wiring.
5.12.2. Wiring and lightning protection
NOTICE
Plan the laying of the cables so that the cables of a
circuit span as small an area as possible. This mini-
mises the likelihood of damages in the event of a
lightning strike in the area.
The smaller the area that the wiring takes up, the smaller the
voltage that the magnetic field of a lightning current (e.g.
through a nearby lightning conductor) induces in the con-
ductor loop (of the module string circuit).
Lay all the cables of the module string as follows:
form as small loops as possible
lay loops next to one another with alternating
current directions
lay the return circuit of the string as close to the
outgoing circuit as possible.
3In a cross connection, the modules of a string, e.g. made up
of 8 modules, are connected in a 1, 3, 5, 7, 8, 6, 4, 2 order.
Or, more simply: on the 'way there', every second module is
connected (1, 3, 5, 7), on the 'way back' the modules not yet
connected are then connected (8, 6, 4, 2).
More careful wiring can pay off in a lower potential for
damage. More details on this kind of wiring can be found in
Appendix C, 'Optimisation of Wiring for Lightning Protection'.
5.12.3. Connection and system voltage
NOTICE
As a rule, keep the system voltage low. This reduces
the voltage load of the electrical components and
can lead to a longer service life.
If necessary, divide a long module string into
numerous strings with the same number of modules
and connect these shorter module strings in
parallel.
5.12.4. Cable properties
Only use cables that have been approved for use in photo-
voltaics. This means, for example, that:
the insulation of the cable is approved for the
maximum open circuit voltage
the cable material is compatible with the modules
as well as their connectors and cables (forgoing use
of softeners)
the cable casing can withstand the expected stress
loads:
temperatures
temperature changes
moisture (above all humidity)
mechanical loads
UV-radiation
ozone ([17]).
aleo recommends using only halogen-free cables. Locally valid
regulations may also stipulate their use, for example in
interior spaces.
Information about cable properties can be obtained from the
cable manufacturers.
G
ID A
S
039
c
This manual suits for next models
6
Table of contents
Other Aleo Solar Panel manuals
Popular Solar Panel manuals by other brands
Solbian
Solbian ALLINONE installation manual
Erco
Erco ES-650PIA Original Operator's Manual
LDK Solar
LDK Solar LDK-160D-24s installation guide
EDN
EDN RADIASOL 150 D Instructions for installation, use and maintenance manual
Sunna Design
Sunna Design Sol EVERGEN M Series installation guide
V-TAC
V-TAC VT-10100 manual
Leapton
Leapton LP182*182-M-66-MH-560W Installation & maintenance
boviet SOLAR
boviet SOLAR Vega BVM7612M H-HC-BFDG Series Installation and maintenance manual
Schletter
Schletter PvMax3 Mounting instructions
LG
LG LG240M1C installation instructions
Viessmann
Viessmann Vitosol 200-T Service instructions for contractors
Sonnenkraft
Sonnenkraft DBP20 manual