evergreensolar ES-C-70-fa5 Setup guide

ELECTRICAL EQUIPMENT — CHECK WITH YOUR INSTALLER
Evergreen Solar ES-C Series photovoltaic (PV, solar electric) panels are designed to produce DC electrical energy from light. This manual
contains important safety, installation and operating information with which you should be familiar before using Evergreen Solar panels.
General Information
• All installation and safety instructions should be understood before attempting to
install, wire, operate and maintain the panel.
• When installing, observe all local, regional, national and international statutory
regulations, guidelines, norms and code requirements.
• Installation or maintenance should only be performed by qualied professionals.
• Panels produce voltage even when not connected to an electrical circuit or load.
Panels produce nearly full voltage when exposed to as little as 5% of full sunlight,
and both electrical current and power increase with light intensity.
• Panels can produce higher output than the rated specications.
• Industry standard rated specications are made at conditions of 1000W/m2
irradiance and 25°C (77ºF) solar cell temperature. Colder temperatures can
substantially increase voltage and power.
• Ensure that panels are only subjected to ambient temperatures in the range -40 to
+80°C (-40 to +176°F).
• Reection from snow, water or other surfaces can increase light and therefore
increase both the current and power generated by the panel.
• Do not articially concentrate light on the panel.
• Panels are intended for outdoors, land-based applications only. Panels are not
intended for indoor use.
• Excluded applications also include, but are not limited to, installations where panels
come into contact with salt water or where likely to become partially or wholly
submerged in fresh or salt water, examples of which include boats, docks and buoys.
• Use only equipment, connectors, wiring and support frames suitable for use in a
solar electric system.
• Follow all safety precautions of other used components.
• Each panel is marked with a serial number, including the date of manufacture and
the manufacturing location. Example: XXxxYYYYMMDDzzzzzzz
- XX = country code (49 for Germany, 01 for US, 86 for China)
- xx = manufacturing building code, can be 01 or higher
- YYYY = year, MM = month, DD = day
- zzzzzzz = serial number
Handling Safety
• Do not use the junction box to hold or transport the panel.
• Do not stand or step on the panel.
• Do not drop panel or allow objects to fall on panel.
• Do not damage or scratch the rear surface of the panel.
• Avoid setting the panel down hard on any surface, particularly when placing
it on a corner.
• Do not disassemble, modify or adapt the panel or remove any part or labeling
installed by Evergreen Solar. Doing so will void the warranty.
• Do not drill holes in the frame or glass of the panel. Doing so will void the
warranty.
• Do not apply paint or adhesive to the rear surface of the panel.
• Never leave a panel unsupported or unsecured.
• Panels are constructed with tempered glass, but must still be handled with care.
• A panel with broken glass or torn back-skin cannot be repaired and must not be used
since contact with any panel surface or the frame can produce electrical shock.
• Broken or damaged panels must be handled carefully and disposed of properly.
Broken glass can be sharp and cause injury if not handled with the appropriate
protective equipment.
• Work only under dry conditions, and use only dry tools. Do not handle panels
when they are wet unless wearing the appropriate protective equipment.
• When storing un-connected panels outside for any length of time, always
cover panels which have the glass facing down to stop water collecting inside
the panel and causing damage to exposed connectors.
Installation Safety
• Keep children away from the system and panels when installing.
• Do not carry out installation work when there are strong winds.
• When installing panels above ground, avoid any possible falling or other
safety hazards by following appropriate safety practices and using required
safety equipment.
• Solar electric panels have no on/off switch. Panels can be rendered
inoperative only be removing them from light, or by fully covering their front
surface with an opaque material, or by working with panels face down on a
smooth, flat surface.
• When working with panels in light, follow all applicable regulation regarding
working with live electrical equipment.
• Do not touch electrical terminals or the ends of any wire while the panel is
exposed to light or while installing the panel.
• Do not wear metallic jewelry while performing mechanical or electrical
installation.
• Never open electrical connections or unplug connectors while the circuit is
under load.
• Contact with electrically active parts of the panels, such as terminals, can
result in burns, sparks and lethal shock whether the panel is connected or
disconnected.
• Always use insulated tools and rubber gloves that are approved for working on
electrical installations.
Fire Safety
• Refer to your local authority for guidelines and requirements for building or
structural re safety.
• The roof construction and installation may affect the re safety of a building;
improper installation may contribute to hazards in the event of re.
• For roof application, the panels should be mounted over a re resistant covering
rated for the application.
• It may be necessary to use components such as earth ground fault circuit
breakers, fuses and circuit breakers.
• Do not use panels near equipment or locations where ammable gases can be
generated or can collect.
Electrical Installation –General Recommendations
• Avoid all electrical hazards when installing, wiring, operating and maintaining
a panel.
• If the total DC system voltage exceeds 100V, the system must be installed,
commissioned and maintained by a qualied professional.
• Contact with a DC voltage 30V or more is potentially hazardous.
• Do not use panels of different electrical or physical congurations in the same
system.
• The maximum open circuit voltage of the system must not be greater than the
specied maximum system voltage for the panel.
• When reverse currents can exceed the value of the maximum protective fuse
marked on the back of the panel, a properly rated and certied over-current
device (fuse or circuit breaker) must be connected in series with each panel
or string of panels.
• The rating of the over-current device shall not exceed the value of the maximum
protective fuse marked on the back of the panel.
• Panels with a suspected electrical problem should be returned to Evergreen
Solar for inspection and possible repair or replacement as per the warranty
conditions provided by Evergreen Solar.
1 of 4 Valid from 1st December 2009 / 2009-DEC_IM_ES-C_EN_IEC_revA © 2009 Evergreen Solar, Inc.
This Manual is valid outside North America only (IEC 61730 compliant; Not UL 1703 compliant)
ES-C Series Photovoltaic Panels
Safety, Installation and Operation Manual

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Panel Wiring – Cable and Bypass Diodes Installation
• ES-C panels come with a conduit ready junction box designed to be used with
standard wiring, watertight strain relief ttings and conduit connections.
• To open the junction box, loosen the two captive screws in the cover. The cover is
designed to remain open during wiring and cannot be removed from the panel.
• The junction box has a gasket that ensures the waterproof integrity. Check that
the gasket is in the right position before securing the junction box. Do not over-
tighten the cover screws.
• The junction box has four (4) 22mm Ø knockouts; two (2) on the bottom
and one on each side. Use a tool such as a at screwdriver to remove the
knockouts. Remove only the required knockouts by hitting the perimeter and
not the center as shown in Figure 1.
• Before running wires through the knockouts, it is required to install a watertight
strain relief or conduit.
• Use the appropriate (M20 x 1.5) or (PG 13.5) watertight cable strain relief
depending on your installation and the cable diameter. Table 2 shows some of
the (M20 x 1.5) or (PG 13.5) options.
• Knockouts are designed to attach to any standard M20 or PG 13.5 rigid or
exible conduit.
• Steel or nylon lock nuts can be used. Make sure lock nuts are properly tightened
to avoid ingress of humidity or water inside the junction box.
• Cables used to wire ES-C panels may be single or two conductors, from 14 AWG
(2.5mm
2
) up to 10 AWG (6mm
2
) gauge.
• For cables exposed outdoors, use only sunlight resistant cables rated for 90ºC
and wet locations. Table 1 shows the outdoor sunlight resistant cable options.
• For cables installed in conduit, types THWN-2, RHW-2 and XHHW-2 are
recommended.
Wire Type Insulation (Jacket) Character-
istics
Watertight Strain
Relief
USE-2 XLP/XLPE cross-linked
polyethylene
Underground
service
entrance
(M20 x 1.5) or (PG
13.5)
with 1 or 2 round
holes.
Steel or nylon lock nut.
TC (Tray) Thermoplastic (PVC,
Nylon). XLP/XLPE for
conductors.
2-conductor,
direct burial
(M20 x 1.5) or (PG
13.5)
with 1 oval hole.
Steel or nylon lock nut.
PV WIRE XLP/XLPE cross-linked
polyethylene
Thicker jacket per
UL4703
Ungrounded
arrays,
Transformer-
less inverters.
(M20 x 1.5) or (PG
13.5)
with 1 round hole.
Steel or nylon lock nut.
Table 1. Sunlight 90ºC Wet Resistant Cables.
Manufac-
turer
Part Number
(Black & Gray)
Opening
(Cable range)
Cable Type Fit
Hummel CD16NS-01 &
CD16NS-02
One oval, 6.1mm x
14mm
(0.24” x 0.55”)
TC (Tray) 2.5mm2/2
(AWG #14/2),
4mm2/2 & 6mm2/2
(12/2 &10/2)
Hummel CD13NR-BK &
CD13NR-GY
One round, 5.1mm to
8.9 mm
(0.2” to 0.35”) Ø
PV WIRE 2.5, 4, 6mm2
(AWG #14,12 &10)
USE-2 2.5, 4, 6mm2
(AWG #14,12 & 10)
Hummel CD13N4-BK &
CD13N4-GY
Two round, 5.1mm
(0.2”) Ø
USE-2 2.5, 4, 6mm2
(AWG #14,12 & 10)
Heyco 4340 & 4341
3216 & 3217
One round, 4.3mm
to 11.4mm
(0.17” to 0.45”) Ø
PV WIRE 2.5, 4, 6mm2
(AWG #14,12 &10)
USE-2 2.5, 4, 6mm2
(AWG #14,12 & 10)
Table 2. Watertight Strain Reliefs
• The panel contains factory installed bypass diodes located inside the junction
box. These diodes are designed to protect the panel against partial shading
conditions and should not be removed.
• Diodes can be easy replaced in the eld if necessary. Use only Super Barrier
type diodes, Diodes Inc SBR10U45SD1, 45V, 10A or Diotec SB1240. Diodes
should be installed as shown in Figure 2.
Figure 2. Junction Box Components
• ES-C series panels are factory wired for 12V nominal operation and are not
intended to be recongured for other voltages.
• The electrical connection block has three (3) double screw terminals; positive (+),
negative (-) and spare. It is recommended that the top screws of the terminals be
reserved for the bypass diodes, and the output wiring be connected only to the
bottom screws. Junction box components are described in Figure 2.
• Match the polarities of cables and terminals when making the connections;
failure to do so may result in damage to the panel.
• The Spare terminal can be used to wire arrays at different voltage congurations.
Figure 3. Shows examples of the standard 12, 24 and 48V congurations.
Figure 3. Wiring Examples
Grounding
• Evergreen Solar does not require the grounding of panel frames, however local
or national regulations may require frame grounding. Frame grounding may also
be required for lightening (over voltage) protection purposes.
• The panels can be grounded using the 4mm diameter holes provided in the
frame. The grounding wire can be attached to the panels using a stainless steel
bolt (size M4) with stainless steel washers, as shown in the following diagram.
The grounding wire size and earthing method must be in accordance with local
requirements.
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
12 V (2 PARALLEL)
24 V (2 SERIES)
48 V (4 SERIES)
ES-C Series Photovoltaic Panels
Safety, Installation and Operation Manual
Valid from 1st December 2009 / 2009-DEC_IM_ES-C_EN_IEC_revA © 2009 Evergreen Solar, Inc.
M4 stainless steel bolt
Stainless steel washer
Stainless steel washer
Grounding wire inserted here,
wrapped around bolt
Stainless steel star washer
Stainless steel bolt
Aluminium frame

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Mechanical Installation
• Panels should be mounted to maximize direct exposure to sunlight and to
eliminate or minimize shadowing.
• Even partial shadowing can substantially reduce panel and system output.
• Panels must be securely fastened using support frames or mounting kits
specialized for PV applications.
• Panels may be mounted at any angle from vertical to horizontal orientation.
• Care must be taken to avoid low tilt angles which may cause dirt to build-up
on the glass against the frame edge.
• Dirt build-up on the surface of the panel can cause active solar cells to be
shaded and electrical performance to be impaired.
• Contact Evergreen Solar for more information regarding minimum recommended
tilt angles for specic panel products.
• For roof mounted systems, provide adequate rear ventilation under a panel
for cooling (100mm: 4 in. gap minimum).
• Clearance of 7mm:¼ in or more between panels is required to allow for
thermal expansion of the frames.
• Always keep the back surface of the panel free from any foreign objects or
structural elements which could come into contact with the panel, especially
when the panel is under mechanical load.
• Ensure panels are not subjected to wind or snow loads in excess of the
maximum permissible loads and are not subjected to excessive forces due to
thermal expansion of the support structure.
• Evergreen Solar permits several different mounting methods. The permissible
mounting methods and maximum permissible wind and snow loads are
detailed in the Mounting Guide available from Evergreen Solar (IEC 61730
compliant version).
• For permission to use mounting methods not described in the Mounting Guide
(IEC 61730 compliant version), please consult Evergreen Solar. Failure to do
so will void the warranty and panel certication.
• Always follow the mounting equipment vendors’ installation instructions in
addition to the instructions found in the Mounting Guide (IEC 61730 compliant
version). In cases where the vendors’ instructions are more stringent than
those detailed in the Mounting Guide (IEC 61730 compliant version), the
vendors’ instructions shall apply.
• In cases where the maximum permissible loading determined by the mounting
equipment vendor is less than the maximum permissible load stated in
the Mounting Guide (IEC 61730 compliant version), the maximum loads
determined by the vendor should always be used.
• The maximum permissible loads apply to uniformly distributed wind or snow
loading. Care should be taken to avoid mounting panels in areas that are prone
to drifting snow, icicle and/or ice dam formation.
Operation and Maintenance
• No routine maintenance is required. However it is advisable to perform periodic
inspection of the panels for damage to glass, back-skin, frame, junction box or
external electrical connections.
• Check electrical connections for loose connections and corrosion.
• PV panels can operate effectively without ever being washed, although removal
of dirt from the front glass can increase output.
• Water can be used for regular washing or rinsing of the front glass to remove
dust, dirt or other deposits.
• To remove ingrained dirt, the glass can be washed with a micro-ber cloth and
ethanol or a conventional glass cleanser.
• No aggressive and abrasive cleansers or chemicals should ever be used on
the front glass. No alkali based chemicals should be used, including ammonia
based solutions.
• Always wear rubber gloves for electrical insulation whilst maintaining, washing
or cleaning panels.
IEC 61730 Required Information
• The Evergreen ES-C series panels have been qualied for Application Class A.
• Panels rated for use in Application Class A may be used in systems operating at
greater than 50V DC or 240 W, where general contact access is anticipated.
• Panels qualied to IEC 61730 within Application Class A are also considered
to meet the requirements for safety class II.
• Under normal conditions, a photovoltaic panel 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 panel should
be multiplied by a factor of 1.25 when determining component voltage ratings,
conductor capacities, fuse sizes, and size of controls connected to the PV
output.
• Conductor recommendations: single conductor cable, type USE-2 (non-
conduit), or PV WIRE 14 AWG minimum (2.5mm2 minimum).
• Maximum number of series/parallel panel congurations: a maximum of 2
strings in parallel may be used without an over-current protection device in
series with each string. 3 or more strings in parallel may be used if a properly
rated and certied over-current protection device is installed in series with
each string.
• To ensure that the string voltage does not exceed 1000V, a maximum of 35
panels may be connected in series at an ambient temperature of -40°C.
ES-C Series Photovoltaic Panels
Safety, Installation and Operation Manual
Valid from 1st December 2009 / 2009-DEC_IM_ES-C_EN_IEC_revA © 2009 Evergreen Solar, Inc.

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www.evergreensolar.com
ES-C Series Photovoltaic Panels
Safety, Installation and Operation Manual
Electrical Specifications at STC*
ES-C-70
-fa5
ES-C-80
-fa5
ES-C-110
-fa2
ES-C-120
-fa2
ES-C-115
-fa4
ES-C-125
-fa4
Pmp (W) 70 80 110 120 115 125
Vmp (V) 17.50 18.23 17.27 17.27 17.92 18.36
Imp (A) 4.00 4.39 6.57 6.95 6.42 6.81
Voc (V) 21.70 22.51 20.92 21.34 22.30 22.63
Isc (A) 4.56 4.78 7.33 7.62 7.15 7.37
Electrical Specifications at NOCT**
ES-C-70
-fa5
ES-C-80
-fa5
ES-C-110
-fa2
ES-C-120
-fa2
ES-C-115
-fa4
ES-C-125
-fa4
Pmp (W) 51.2 58.6 80.5 87.8 84.2 91.5
Vmp (V) 16.01 16.68 15.33 15.80 16.40 16.80
Imp (A) 3.20 3.51 5.26 5.56 5.14 5.45
Voc (V) 19.86 20.60 19.14 19.53 20.40 20.71
Isc (A) 3.65 3.82 5.86 6.10 5.72 5.90
TNOCT (°C) 45.4 45.4 45.4 45.4 45.4 45.4
*At Standard Test Conditions: 1000W/m2, 25°C cell temperature, AM 1.5 spectrum. Minimum specied power rating is
5% below Pmp for all products; other specications are +/-10% of measured values per ASTM E 892. Specications
subject to change without notice. Warranty details available on request.
** At Nominal Operating Cell Temperature Conditions: 800W/m2, 20°C ambient temperature, wind velocity 1m/s, AM
1.5 spectrum.
The relative reduction of panel efciency at 200W/m2 irradiance in relation to 1000W/m2 both at 25°C cell temperature
and spectrum AM 1.5 is 0%.
ES-C-70, 80 -fa5 ES-C-110, 120 -fa2 ES-C-115, 125 -fa4
Individual Cell Size 150 x 50 mm 150 x 80 mm 150 x 77 mm
Number of Cells 76 72 76
Bypass Diodes Use Only Super Barrier type diodes, Diodes Inc SBR10U45SD1,
45V, 10A or Diotec SB1240, 40V, 12A.
Max. Series Fuse/
Max. Reverse Current
8A 15A 15A
TÜV Rated System
Voltage
1000V DC Maximum
Temperature Coefficients
gPmp -0.43 (%/°C)
bVmp -0.40 (%/°C)
a Imp -0.03 (%/°C)
bVoc -0.31 (%/°C)
aIsc +0.05 (%/°C)
ES-C- 110, 120 – fa2, 115, 125 – fa4
All dimensions in millimeters; Weight: 12.3 kg (27 lbs.)
Mechanical Specifications
DRAINAGE HOLES MOUNTING HOLES GROUNDING HOLES
570
611.4
ALL DIMENSIONS IN MILLIMETERS - WEIGHT: 12.3 Kg (27 LBS.)
ES-C_EN_110W - 130W
PA NEL DA T A &
SAFETY LABEL
12x ø 6 FRAME
DRAINAGE HOLES
(NOT TO BE USED
FOR MOUNTING)
10x ø6.6
MOUNTING
HOLES
FOR M6 BOLT S
PA NEL
SERIAL
NUMBER
JUNCTION
BOX
251
41
57
FRAME ID LABEL
2x ø4 ±0.10 GROUNDING HOLES
(1 NEARSIDE, 1 FA RSIDE)
652 ±1.5
57
7.4
40.6 TYP
132
4x ø4
GROUNDING
HOLES
40.6
TYP
137
1585 ±1.5
40.6
17
762
320
70
57
2x ø4 ±0.10
GROUNDING HOLES
(1 NEARSIDE, 1 FA RSIDE)
792.5
ES-C-70, 80 - fa5
All dimensions in millimeters; Weight: 8.6 kg (19 lbs.)
DRAINAGE HOLES MOUNTING HOLES GROUNDING HOLES
570
611.4
ALL DIMENSIONS IN MILLIMETERS - WEIGHT: 8.6 Kg (19 LBS.)
ES-C_EN_70W - 80W
12x ø 6 FRAME
DRAINAGE HOLES
(NOT TO BE USED
FOR MOUNTING)
10x ø6.6
MOUNTING
HOLES
FOR M6 BOLTS
PANEL DATA &
SAFETY LABEL
PANEL
SERIAL
NUMBER
4x ø4
GROUNDING
HOLES
JUNCTION
BOX
132 251
41
57
137
652 ±1.5
FRAME ID LABEL
2x ø4 ±0.10 GROUNDING HOLES
(1 NEARSIDE, 1 FARSIDE)
57
7.4
545
515
320
70
57
1089.6 ±1.5
40.6
17
2x ø4 ±0.10
GROUNDING HOLES
(1 NEARSIDE, 1 FARSIDE)
40.6 TYP
40.6 TYP
Customer Service -
Europe, Middle East and Africa
Evergreen Solar GmbH
Wallstrasse 65, 10719 Berlin, Germany
T: +49 30.850.700.0
F: +49 30.850.700.100
[e-mail]
European Headquarters
Evergreen Solar GmbH
Wallstrasse 65, 10719 Berlin, Germany
T: +49 30.850.700.0
F: +49 30.850.700.100
[e-mail]
Valid from 1st December 2009 / 2009-DEC_IM_ES-C_EN_IEC_revA © 2009 Evergreen Solar, Inc.