Astronergy CHSM5409M User manual

THE POWER OF ASTRONERGY
CRYSTALLINE SILICON PV MODULE
INSTALLATION GUIDE

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CRYSTALLINE SILICON PV MODULE
INSTALLATION GUIDE
1. Introduction
2. Safety
3. Mechanical Installation
4. Electrical Installation
5. Maintenance and Disposal
1.1 Purpose
1.2 Limitation of Liability
2.1 General Safety
2.2 Installation Safety
3.1 Installation Condition
3.2 Installation Methods
4.1 Installation Condition
4.2 Grounding

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1. Introduction
1.1 Purpose
This document provides detailed instructions and valuable safety information regarding the installation, electrical connection,
and maintenance of the following ASTRONERGY Crystalline Photovoltaic modules:
CHSM5409M CHSM5611M CHSM5612M CHSM6609M CHSM6610M CHSM6612M
CHSM6606P CHSM6609P CHSM6610P CHSM6611P CHSM6612P
All instructions and mechanical and electrical requirements should be read and understood before attempting installation.
The installer should conform to all safety precautions in this guide when installing the module. Keep this guide in a safe place
for further reference.
1.2 Limitation of Liability
Because the use of this manual and the conditions or methods of installation, operation, use and maintenance of photovoltaic
(PV) products are beyond Astronergy’s control, Astronergy does not accept responsibility and expressly disclaims liability
for loss, damage, or expense arising out of or in any way connected with such installation, operation, use or maintenance.
Astronergy reserves the right to change the manual without prior notice.
2. Safety
2.1 General Safety
2.1.1 Consult and follow local codes and other applicable laws concerning required permitting as well as installation &
inspection requirements, rules, and regulations.
2.1.2 PV modules should be installed and maintained by qualied personnel.
2.1.3 Use the same performance modules within a given series.
2.1.4 Follow all safety precautions of all components used in the system.
2.1.5 Do not shade portions of the PV module surface from the sun for a long period of time. The shaded cell may become
hot (hot spot phenomenon), which can result in solder joints peeling o.
2.1.6 Do not clean the glass surface with chemicals.
2.1.7 Do not drop the PV module or drop objects onto the PV module.
2.1.8 Do not concentrate sunlight on the modules or panels.
2.1.9 Do not attempt to disassemble the modules, and do not remove any attached components from the modules.
2.1.10 Do not scratch or hit at the back sheet, the glass, the terminal box. Do not pull the cables or touch them with
bare hands.
2.1.11 Do not drill holes in the frame or scratch the insulating coating of the frame.

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2.1.12 Keep the PV module packed in the carton until installation.
2.1.13 Do not use modules near equipment or in places where ammable gases may be generated.
2.2 Installation Safety
2.2.1 Wear protective head gear, insulating gloves, safety shoes, and insulated tools when installing the modules.
2.2.2 Do not install the modules in rain, snow, or otherwise wet or windy conditions.
2.2.3 Completely cover the PV module surface with an opaque material during PV module installation and wiring to
prevent accidental charge buildup.
2.2.4 Plug in connectors tightly when working on wiring.
2.2.5 Due to the risk of electrical shock, do not perform any work if the terminals of PV module are wet.
2.2.6 Do not touch the terminal box and the end of output cables (connectors) with bare hands.
2.2.7 Do not unplug the connector under load.
2.2.8 Do not work alone.
2.2.9 Wear a safety belt if working far above the ground.
2.2.10 Do not wear metallic jewelry, which can cause electric shock, while installing or troubleshooting the PV system.
2.2.11 Follow the safety regulations for any and all other system components, including wires, connectors, charging
regulators, batteries, inverters, etc.
2.2.12 Do not expose wires to direct sunlight. Use UV-resistant cabling.
2.2.13 Do not damage the surrounding PV modules or mounting structure when replacing a PV module.
2.2.14 Do not change any PV module components (diode, junction box, plug connectors, etc.).
3. Mechanical Installation
3.1 Installation Conditions
3.1.1 Environment temperature: -40 to 85 °C
3.1.2 Operating temperature: -40 to 85 °C
3.1.3 Mechanical load on panels (e.g., from wind or snow): less than 5400 Pa
3.1.4 Tilt Angle selection: The installation should be facing north in the southern hemisphere and facing south in the
northern hemisphere.
3.1.5 To maintain the modules’ Class C re rating, the re class of the roof and building materials should higher than Class C.
3.2 Installation Methods
3.2.1 Bolts
All modules must be securely fastened with at least 4 bolts. For maximum security against strong winds or heavy snow falls, all
6 mounting holes (modules CHSM5409M, CHSM6609M/P, and CHSM6610M/P; see gure 1a) or 8 mounting holes (CHSM6611P
and CHSM6612P; gure 1b) should be used.

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Figure 1. Bolt positions for the at-minimum four-bolts for a) modules CHSM5409M, CHSM6609M/P, CHSM6610M/P; and b) modules CHSM6611P
and CHSM6612P. Solid red arrows indicate primary bolt positions; dashed blue arrows indicate positions where bolts can be added for additional
support.
Bolts are inserted as described in the process below (see gure 2).
1. Place the module on the frame.
2. Insert four stainless-steel bolts (M6) through the holes (7x11.5mm) in the frame according to gure 1. For maximum
security against strong winds and heavy snow, all available mounting holes should be used.
3. Secure each bolt to the frame with 2 stainless-steel washers, one on each side of the mounting structure; and screw on
either a stainless-steel spring washer or a toothed lock washer. Finally, secure with a stainless steel nut (M6).
4. The torque for tightening the nut and bolts recommended 13Nm when the property class of bolts and screws is Class 8,8.
Figure 2. Securing the module with bolts.
3.2.2 Clamping with clamps (aluminum alloy)
Modules can be laid either across the supporting bars (gure 3a) or parallel to them (gure 3b and gure 3c).
(a) (b)
(a) (b)

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Figure 3. Illustrations of the three dierent methods for clamping modules onto the frame with aluminum clamps.
Each aluminum mounting clamp comes with an M8 bolt, a plain washer, a spring washer, and an M8 nut. To fasten the module:
1. Lay the module on the two supporting bars (not provided). The bars should be made with stainless material or treated
with an anti-corrosion process (e.g., anodic oxidation treatment).
2. The bar’s top surface contacted with module frame should come with grooves compatible with an M8 bolt.
3. Slide bolts through groove on the supporting bars next to the locations where the 4 clamps are to be fastened.
The module may be clamped only in the permitted clamping areas on the long edge of the frame. For exact locations
on the frame refer to gure 6 in conjunction with table 1 below.
4. If the bars do not come with grooves, holes of a suitable diameter may need to be drilled to allow bolts to be attached to
the bars at the same locations as mentioned before.
5. Secure each clamp by attaching plain washer, spring washer, and nut, in that order.
6. The modules may be mounted using clamps designed for solar modules as shown in Figures 3b, the modules must be
supported along the length of the long edge, and should overlap the array rail by 10mm – 14mm as shown in Figures 3d.
7. The modules may be mounted using clamps designed for solar modules as shown in Figures 3c. Note that the clip positions
are important – the clamp centerlines must be between 50mm and 200mm from the end of the module (Note: this method
is not suitable for these two kinds of modules: CHSM6610M/P - 1652*994*35, because their mechanical load could not
pass 5400Pa, but could pass 2400Pa).
8. The torque for tightening the nut and bolts recommended 28Nm when the property class of bolts and screws is Class 8,8.
Figure 4. Placement of middle and side clamps on the modules
(c) (d)
middle
clamps
side
clamps

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Figure 5. Close-ups of middle (a) and side (b) aluminum clamps. The dimensions for the middle clamps are a ≥ 40 mm,
b ≥ 26 mm, c = 8 mm, d ≥ 28 mm, and Ø = 9 mm.
Figure 6. Permitted clamping locations with clamp. For exact dimensions for a given module series, see table 1 (below).
Table 1. Use in conjunction with gure 6 to determine permitted clamping locations for a given module series for clamping
with clamps.
Module Series Dimension A B C
CHSM5409M 1200*554*35 1200 50 250
CHSM5611M 1453*808*35 1453 200 150
CHSM5612M 1580*808*35 1580 200 200
CHSM6610PM/P 1652*994*35 1652 200 210
CHSM6606P 1020*994*45 1020 50 205
CHSM6609M/P 1494*994*45 1494 50 320
CHSM6610M/P 1652*994*45 1652 50 360
CHSM6611P 1798*994*50 1798 60 400
CHSM6612M/P 1956*994*50 1956 60 440
Variable clamping range
(b)
(a)

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4. Electrical Installation and Grounding
4.1 Installation
4.1.1 The electrical characteristics are within ±10 percent of the indicated values of Isc. Voc and Pmp under test conditions
(irradiance of 100 mW/cm2,AM1.5 spectrum, and a cell temperature of 25°C).
4.1.2 The maximum system voltage for all module series is 600 V for North American Market and 1000V for European
Market.
4.1.3 Connect quantity of modules that match the voltage specications of the inverters used in system. Modules must
not be connected together to create a voltage higher than the permitted maximum system voltage under the worst
local temperature conditions.
4.1.4 Under normal conditions, a photovoltaic module is likely to experience conditions that produce more current and/
or voltage than reported at standard test conditions. Accordingly, the values of Isc and Voc marked on this module
should be multiplied by a factor of 1.25 when determining component voltage ratings, conductor ampacities,
fuse sizes, and size of controls connected to the PV output.
4.1.5 Refer to Section 690-8 of the National Electrical Code for an additional multiplying factor of 125 percent (80 percent
derating) which may be applicable.
4.1.6 Each module (or series-connected string of modules) shall be provided with the maximum series fuse, specied as 10
A for the 5 inch cell module series and 15 A for the 6 inch cell module series.
4.1.7 Use a special solar cable and plugs for installing the PV system and make sure that all connections are safe and tight.
The cable should be 4 mm2 (12 AWG), and able to withstand the maximum possible system open-circuit voltage.
4.1.8 Bypass diodes are included in module junction boxes to avoid decreased module performance in the event of shade
or shelter. The number of diodes in each module series is given in table 2.
Table 2. Number of junction-box bypass diodes for a given module series.
Module Series Number of diodes
CHSM 5409M 3
CHSM 5612M 3
CHSM 6609M/P 6
CHSM 6610M/P 6
CHSM 6611P 6
CHSM 6612P 6

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4.2 Grounding
Figure 7. Grounding the aluminum frame with copper wire.
4.2.1 Use the marked 5.5 mm grounding holes (5.5mm) to ground the anodized frame. Use an M5 nut, two M5 cut washers,
an M5 plain washer, an M5 spring washer, and an M5 bolt and a copper wire. All nuts, bolts, and washers are type M5
and should be made of stainless steel (as in gure 8).
4.2.2 Put the bolt through the cup washer and wrap the copper wire around the bolt. (Note that the copper wire cannot be
attached directly to the aluminum.)
4.2.3 Put the bolt through the cut washer and then through the hole in the aluminum frame.
4.2.4 Add the spring washer and nut on the other side of the bolt and tighten to secure all parts. The tightening torque
should be 210±20 N•cm.
5. Maintenance
5.1 Regularly carry out a visual inspection for dirt, dust, bird dropping, leaves, and other detritus covering the modules.
5.2 If there is a build-up of dirt or dust on the module surface, wash the module with clean water and a gentle implement
(a sponge). Never use chemicals on the surface of the module.
5.3 If snow is present, a soft-bristled brush with soft bristles may be used to clean the surface of the modules.
5.4 Regular electrical and mechanical inspection by a licensed professional will keep the system safe and operating at
maximum eciency.

WENZHOU,CHINA
HANGZHOU,CHINA
SHANGHAI,CHINA
SEOUL,
KOREA
TOKYO,
JAPAN
BANGKOK,
THAILAND
BARCELONA,
SPAIN
SOUTH
SAN FRANCISCO,
USA
RAVENSBURG,
GERMANY
Japan
KoyoAstro Co., Ltd.
Higashi 1-5-6, Chuo-ku,
Tokyo 103-0004, Japan
Tel: + 03 3866 6113
Fax: + 03 3866 6115
Korea
Astronergy Solar Korea
Misung Bldg 3F,
91-5 Banpo-dong, Seocho-gu,
Seoul, Korea
Tel: + 82 (0)2 2226 3911
Fax: + 82 (0)2 2226 3910
Thailand
Astronergy Solar Korea (Thailand) Co.,
Ltd.
184/88 Forum Tower 18FL
Ratchadapisek Rd., Huay-Kwang,
Bangkok 10320 Thailand
Tel: + 662 645 4155
Fax: + 662 245 3185
BRANCH OFFICES
Spain
Chint Solar Hispania S.L.
Paseo de Gracia, 78, 2-2A
08008 Barcelona, Spain
Tel: + 34 9346 73778
Fax: + 34 9346 73789
Germany
Astronergy GmbH
Karlstr. 8
88212 Ravensburg, Germany
Tel: + 49 (0)751 295096-0
Fax: + 49 (0)751 295096-39
North America
Astronergy Solar Inc
377 Swift Avenue
South San Francisco, CA 94080
USA
Tel: + 1 650 827 9810
Fax: + 1 650 392 2778
CORPORATE HEADQUARTERS
Chint Solar (ZheJiang) Co., Ltd.
1335 Bin’an Road, Binjiang District
Hangzhou, Zhejiang Province, 310053
China
Tel: + 86 571 5603 1888
Fax: + 86 571 5603 2383
MANUFACTURING PLANTS
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