Grape Solar CS-S-175-DJ Instruction Manual

INSTALLATION
MANUAL
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Solar Module
Installation User Manual
For Module Model Number:
CS-S-175-DJ, CS-S-180-DJ
CS-P-220-DJ, CS-P-230-DJ, CS-P-270-P, CS-P-280-DJ
Rev. 04
©Copyright 2009, Grape Solar Inc. All Right Reserved

INSTALLATION
MANUAL
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Table of Contents
Thank you for selecting solar modules from Grape Solar. In order to use the modules
properly, please read this Installation Manual carefully and completely before beginning
work or installing the panels.
About Solar Modules .................................................................................. 3
Characteristics and Names of Components ........................................... 4-6
Safety Warnings .................................................................................. 6-10
Installation ........................................................................................... 11-18
Maintenance & Inspection ........................................................................ 19
After-Sale Services ................................................................................... 19

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About Solar Modules
What is a solar module?
A solar module is a big semiconductor (PN diode) which can transfer sun energy into
electrical energy without any help from mechanical energy. Solar modules produce
“quiet” and “clean” energy generators which can create “direct current” (DC)
electricity continuously under the sunlight.
Theory
Grape Solar can supply monocrystalline solar modules. Under the sunlight, the cells in
mono modules will produce electrons and cavities by photo-emission which is
influenced by an internal electrical field. The electrons will go towards and assemble
at Negative-silicon and cavities will go towards and assemble at Positive-silicon. As a
result, an electromotive force will occur. If they are connected with an exterior load,
the DC electricity will be created.

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Cell Function Diagram
Internal electrode
solar energy
Exterior electrical polarity
Anti-reflectance coating
N-silicon
PN
P-silicon
DC

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Characteristics and Names of Components
Key Factors
•The module is highly efficient due to adopting a high-efficency cell
•The module is highly reliable due to adopting highly transparent tempered glass
•The structure of module is wind-resistant.
Component Names
(Front of Solar Module Example)

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(Back of Solar Module Example)

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Characteristics
Table 1
Model
Open Circuit
Voltage at
STC,
(V dc)
Rated
Voltage at
STC,
(V dc)
Maximum
System
Voltage, (V
dc)
Rated
Current at
STC,
(A dc)
Short
Circuit
Current at
STC,
(A dc)
Rated
Maximum
Power at
STC,
(Watts)
Maximum
Series
Fuse,
(A)
CS-S-180-DJ 44.2 36.2 600 4.97 5.36 180 10
CS-S-175-DJ 44.2 35.8 600 4.89 5.25 175 10
CS-P-220-DJ 35.87 29.40 600 7.48 8.40 220 15
CS-P-230-DJ 36.23 29.70 600 7.74 8.70 230 15
CS-P-270-DJ 43.65 35.20 600 7.67 8.59 270 15
CS-P-280-DJ 43.77 35.30 600 7.93 8.76 280 15
*Note : Rated electrical characteristics are within ±10 percent of the indicated values of I
sc
, V
oc
, P
max
under Standard Test Conditions. (Irradiance of 100 W/cm, Am 1.5 spectrum and a cell emperature of
25°C (77°F)

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Safety Warning
In order to use the modules properly, avoid property losses, and avoid injury to the operater or anyone
else, warnings and some other caution signss are printed on the solar modules and Manuals.
Sign Introduction
Sign Introduction
Warning
Means “Misoperation will cause a risk of lethal or personal serious injury ”
Caution
Means “Misoperation will cause a risk of injuring or porperty loss”
Graph introduction
Graph Introduction
Prohibited (proceeding not permitted )
The details will be described in the signs, graphs and texts
Compulsion (proceeding is compulsory )
The details will be described in the signs ,graphs and texts
Caution (Warning included)
The details will be described in the signs or graphs and texts

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General warnings
Warning
！
！！
！ Solar module installation, maintenance, removal
and resetting shall only be done by
distributor or professionals
•If there were defects, there is a risk of electrical shock or fire.
When installing, wiring, operating, removing and maintaining modules, pay attention to the risk
of electrical shock
•If module is shined by sunlight or other illuminator, the DC electricity will be
produced.
•Artificially concentrated sunlight shall not be directed on the module.
•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 multipied by a factor of 1.25 when determining component voltage
ratings, conductor ampacities, fuse sizes, and size of controls connected to the
PV output. Please 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.
•If modules are connected in series or parallel, the voltage and current will increase,
the danger will be increased respectively
•When installing, wiring, or maitaining modules, in order to prevent
producing the DC electricity, please cover the module surface with sufficiently
opaque material
•When installing, wiring, or maitaining modules, please use protective instruments
such as rubber gloves

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Installation Warnings
Warning
Installing, maintaining, removing and
resetting modules shall only be done by
distributor or professionals.
Don’t stand or step on the solar
modules Because glass
face of the module will be
damaged and it is slippery
which may injure
someone.
Don’t touch the terminals
•There is a risk of
electrical shock
Don’t wear steel material
like rings
•There is a risk of
electrical shock
Sharp objects prohibited
They may puncture the back of
Module There are risks of electrical
shock ,electricity leakage and solar module’s
service life may be shortened
Don’t put wires between
Frame and prop.
•The wire may be damaged and cause
electrical shock and fire
•
•When connecting modules with other
controlling devices please entrust
distributors or professionals
Don’t damage or process wiring
Material.
•It may cause a risk
of electrical shock.

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Warning
Grounding
If not connected properly, it will cause a
risk of electrical shock. Please don’t connect the cable
with any other pipes such as gas pipe, water pipe,
thunder-avoiding rod etc. Each PV module has a hole
on the each side with a grounding sign . 。 The use
of the listed grounding and bonding equipment
(KDER), type 1954381-1, by Tyco Electronics Corp
(E69905), is to provide a reliable grounding connection
to the module frame.(Details: see Appendix A )
•
•Don’t install solar modules on movable
objects such as doors or vehicles.
• The glass may be damaged and cause
injury due to libration.
Operation Warning Warning for operating
Warning
Do not open cover of junction
box, it may result in electric
shock.
Don’t let children approach modules
There is risk of electric
shock or injury.
Do not damage or
process wiring material,
which may cause electric shock.
Do not prick back of
solar module with
sharp objects as this may
result in electric shock,
electricity leakage, or damage the
solar module
Don’t stand on or step on the solar modules because the solar module may
be damaged and/or people can slip resulting in injury

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Caution
don’t touch solar modules
The module will reach high temperatures under sunshine, and may cause a risk of scalding
Maintenance Warning
warning
Don’t open cover of junction box and
clean inside with liquid, it may result in
electrical shock.
Don’t immerse the solar modules in
liquid, it may result in electrical shock
Do not use damaged
or abnormal solar modules which
may cause risk of an electric
shock.
If module is damaged/abnormal
please contact distributor
or GRAPESOLAR.
Don’t deform or
bend solar
module, it may result in
electric shock or injury.
Don’t stand or step on solar module.
The module may be damaged due to its glass surface and it may cause injury if slipping occurs.

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Don’t touch the cable of the solar module (cont’d)
since DC electricity will be produced when solar module is under
sunlight, please pay attention to this to avoid electrical shock.
Specification for bypass diode
Rated current 10A
Max reversing voltage 40V
Installation
warning
Installing, repairing, removing and resetting solar modules shall only be done by distributor and professionals
Caution: •Don’t put heavy objects on solar module
•Don’t let optical lens and other spotlight objects to shine the
modules directly.
•Don’t toss or drop the solar modules
Installation shall be in accordance with CSA C22.1, Safety Standard for Electrical Installations, Canadian Electrical Code,
Part 1.
Attention for installation:
The modules shall be mounted so that the junction box shall be in the uppermost position to minimize
water damage.
Site Selection
Please select a site without shadows from trees or buildings, enabling the module to be shined by sun frequently. Especially
in very hot weather, make sure modules are not shaded. Remember! Shadow positions change with the season. Please take
this into account

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If you want to know the design for tilt angle of a support structure in a heavy snow area
or littoral area please contact distributor
Installation direction
The module should face south to get sufficient sunlight and to optimize the output of the power generation.
Tilt angle
Irradiation each day will be different according to different latitudes all over the country. The optimum angle is equal to
latitude but is also subject to the design conditions such as site and design angle etc.
Tilt Angle
Sunlight
PV module will get maximum output of power generation when sunlight irradiates on their surfaces vertically. But
if operating time and operating purpose are limited, the above-mentioned design may not be optimum. You also
can contact distributor about this.
Support Structure
In order to make PV modules have a long service life outside please pay attention the following items:
•Choosing a strong and safe structure
•Choosing appropriate materiel for solar modules
•Adopting appropriate method for anticorrosion
•Following all regulations concerned
•Don’t damage any parts of modules for power generation.
•The site shall be in compliance with ambient and climate
•Site should be easily accessible
•The foundation shall be done by a professional designer or construction company
Contact distributor for details

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PV module installation
Caution!
Use the long side of module frame as the top. Use the side with 4 installation holes as the bottom. The modules
shall be mounted so that the junction box is in the uppermost position to minimize the ingress of water.
If PV modules are blow away, it will be very dangerous.
The clamping area (Example A) of the washer must cover at least 135 mm2 or 0.21 in2. A torque wrench must
be used for assembly. In the examples shown, the tightening torque (using stainless steel M8 or 5/16 inch bolts)
must be 20 Nm or 11.8 ft-lbf. Use the existing holes for securing the module; do not drill any additional holes
(doing so would void the warranty). Use appropriate corrosion proof fastening materials.
In salty area please take appropriate methods to prevent solar modules from corrosion
Each module must be securely fastened at a minimum of 4 points. The frame has been stress tested for
mounting by the long sides. The module should not be secured by its short sides. PV modules can be mounted
to the substructure by clamping on (Example A) at the front side or by screwing (Example B) at the back side.

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Mounting on the short side is NOT allowed as this would void the warranty
Wiring and Connection
Wiring
Grape Solar modules come with pre-wired and terminated connectors ready for most grid-tie and off-grid
wiring connection applications. Each module has two #10 AWG type of sunlight resistant output cables
each terminated with Multi-Contact locking connectors. The positive connector has (+) for male terminal
and the negative connector has (-) for female terminal. The module wiring is solely for series connections
only, i.e. male (+) to female (-) interconnect. When making connections with Multi-Contact connectors,
make sure the array is disabled. DO NOT MAKE CONNECTIONS WHILE UNDER LOAD.
Bypass Diodes and Blocking Diodes
Partial shading of an individual module can cause a reverse voltage across the shaded SPV module.
Current is then forced through the shaded area by the other modules. When a bypass diode is wired in
parallel with the series string, the forced current will flow through the diode and bypass the shaded SPV
module, thereby minimizing module heating and array current losses.
In system utilizing a battery, blocking diodes are typically placed between the battery and the SPV
module output to prevent battery discharge at night.
Diodes that are used as blocking diodes must: Have a Rated Average Forward Current [I
F(AV)
] above
maximum system current at highest module operating temperature. Have a Rated Repetitive Peak
Reverse Voltage [V
RRM
] above maximum system voltage at lowest module operating temperature.
Modification or tampering of diodes by unqualified personnel is not permitted.

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Grounding
All module frames and mounting racks must be properly grounded in accordance with the National
Electrical Code. Proper grounding is achieved by connecting the module frame(s) and structural members
contiguously one to another using a suitable grounding conductor. The grounding conductor or strap may
be copper, copper alloy, or other material acceptable for use as an electrical conductor per NEC. The
grounding conductor must then make a connection to earth using a suitable earth ground electrode.
Attach a separate conductor to one of the 4mm diameter grounding holes marked 'GR' on the module
frame with a bolt and nut that incorporates an external tooth washer. This is to ensure positive electrical
contact with the frame. The rack must also be grounded unless they are mechanically connected by nuts
and bolts to the grounded PV modules. The array frame shall be grounded in accordance with NEC
Art250.
Underwriters Laboratories Information (U.S. and Canada)
The solar module electrical characteristics are within +/-10% of the label indicated values electrical
values under STC (Standard Test Conditions: irradiance of 100 mW/cm2, AM 1.5 spectrum, and a cell
temperature of 25°C/77°F).
Under normal conditions, a photovoltaic module is likely to experience conditions that produce more
current and/or voltage than reported at STC. 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
capacities, fuse sizes, and size of controls connected to the PV output.
Refer to section 690-8 of the National Electric Code (NEC) for an additional multiplying factor of 125%
(80% de-rating) which may be applicable.
Over-current protection shall be in accordance with the requirements of Article 240 of the NEC
Conductor recommendations: 8-12 AWG USE-2 (non-conduit)/ THWN-2 (conduit ), 90°C wet rated.
Cable conduits should be used in locations where the wiring is accessible to children or small animals
Connection
PV modules can be wired in series to increase voltage as shown in figure 1. In this case, the maximum
open circuit voltage must not be greater than the specified maximum system voltage (as shown on the
back label of each module), also in Table 1, or per specified inverter input voltage range.

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PV modules can be wired in parallel to in increase the current as shown in figure 2. In the case of parallel
connection, please take proper measure to block the reverse current flow, not to exceed maximum series
fuse rating per specified on the back label of each module (also indicated in Table 1)

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Removal
Only professionals can disassemble or reinstall the solar modules.
Maintenance and Inspection
Routine Inspection
It is unnecessary to do inspection everyday; our suggestion is one time per year.
If the dirt is built-up please clean the surface with soft sponge with water.
Inspection for Wind and Rain Hazard or Earthquake
If wind and rain hazard or earthquake occurs, please check to make sure the modules were not damaged.
Inspection for Salt or Snow Hazard
Schedule an inspection to determine whether PV modules were corroded
After heavy snow, please check the condition of solar modules.
Disclaimer of liability
Since compliance with this guide and the conditions and methods of installation, operation, use and
maintenance of the modules are not checked or monitored by Grape Solar Inc. Grape Solar accepts no
liability for damage arising through improper use or incorrect installation, operation, use or maintenance.
Furthermore, liability for infringements of patent law or of other third party rights arising from the use of
the modules is excluded unless we are automatically liable by law.

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After-Sale Services
Warranty Issues
After filling the form, please contact the concerned distributor.
Name: _______________________________________________________
Address: _____________________________________________________
Model/ series number (printed in label): ____________________________
Date of purchase: ______________________________________________
Telephone Number:_____________________________________________
Description of abnormal module:__________________________________
Grape Solar reserves the right to revise the models/ contents without notice. Please see
product warranty documentation for more details.
Website: www.GrapeSolar.com
If there was anything you want to know more please contact distributor.
GRAPE SOLAR reserve the right to revise the models/contents without
notice.