Helios 6T Series User manual

PHOTOVOLTAIC SOLAR MODULE MANUAL
Operation/Maintenance and Installation
2 12

INSTALLATION MANUAL – 2 12
1
INDEX
INDEX..1
TECHNICAL CHARACTERISTICS..2
6T S ERIES .4
7T2 S ERIES ......5
9T6 S ERIES ..6
E LECTRICAL V ALUES ..7
A MPS /V OLTAGE C URVES V ARIATION DUE TO S OLAR R ADIANCE & T EMPERATURE ...8
P OTENTIAL P OWER C URVE .....9
JUNCTION BOX 10
D IODE C HARACTERISTICS 11
WARNINGS AND ELECTRICAL RISKS ...12
CONNECTION LIMIT OF THE MODULES 14
M ODULE W IRINGS .14
RECOMMENDATIONS FOR INSTALLATION ....15
I NSTALLATION R EQUIREMENTS ....18
G ROUNDING ...19
MOUNTING INSTRUCTIONS ..22
MAINTENANCE ..2
DIAGNOSTICS AND TROUBLESHOOTING ..24
CERTIFICATES ....25

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TECHNICAL CHARACTERISTICS
Helios Solar Works solar modules belong to the latest generation of mono-crystalline and multi-crystalline 6
in. (156mm) cells. heir contoured surface and triple conduction band systems provide higher generating
power and homogeneous aesthetics.
Each module consists of 60, 72, or 96 high-quality cells in serial configuration to achieve optimal power and
voltage for photovoltaic systems, either connected to the grid or not.
Before designing, assembling, operating, or proceeding with the maintenance of the 6 , 7 2 and 9 6
Series photovoltaic module, please carefully read all of the instructions and recommendations in this
manual.
Helios Solar Works disclaims any liability for breakage, deterioration or the loss of performance of any of
our modules resulting from the incorrect installation, use, and/or maintenance.
he junction box has a level of protection of IP65 against infiltration of dust and water and houses the
connection of the metallic output bands of the module to the cables (positive and negative). he bypass
diodes are connected inside the junction box ensuring the thermal stability of the cells in case of shading
during the hours of irradiation.
wo isolated copper cables, 4mm
2
(see annex A for AWG mm
2
sizing) and 1.2 m long emerge from the
junction box. Each cable is connected at its end with MC compatible plugs, one male, and one female,
which facilitate the connection of the modules by forming serial connections to reach the adequate voltage
for the system.

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In order to protect the module against electrical shorting, fast acting fuses of 15 amps are to be used when
connecting in series.
Figur 1. Cross-s ction of a modul id ntifying diff r nt compon nts.
ALUMINIUM FRAME
ENCAPSULANT
TABS
PHOTOVOLTAIC CELL
TEMPERED GLASS
CELLS CONNECTION
BACKSHEET
BY-PASS DIODE
JUNCTION BO
GROUNDING TERMINAL
WATER EVACUATION

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6T Series

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7T2 Series

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9T6 Series

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he maximum power value, open circuit voltage and short circuit current of any individual module will be
-0% to +3% of these values. Specifications are subject to change.
Electrical Values
In actual conditions, the variation of the parameters of operation for the cells will be related to the variation
of irradiation received and the actual temperature. hese parameters show the indicated values in the
previous charts.
he variations of the working point of the model according to the modification of different operation
parameters are shown in the next page.

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Amps/Voltage Curves Variation due to Solar Radiance & Temperature
Figur 2. Variation of th work curv Amps-Voltag according to th incid ntal
solar radianc to a c ll t mp ratur of 25 ºC
Figur 3. Variation of th work curv Amps-Voltag according to th t mp ratur
of th c ll

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Potential Power Curve
Figur 4. Curv of th pot ntial produc d by a photovoltaic modul in r f r nc
to th working point.
In the above figure, it can be observed that there is a point for which the product (I x V) reaches its
maximum. his point, called the maximum power point, determines the expressed peak power using the
units (Wp).
he ability of the system to trace this point in relation to the variation of working conditions of the module is
called, "tracing of the point of maximum potential (MPP )".

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JUNCTION BOX
he junction box can be found on the backside of the module. he module’s cells are soldered in a series
and terminate at four points within the junction box where the current passes through two bypass diodes,
the circuit board, and +/- outputs before entering two isolated copper cables with multi-type connectors.
he junction box does not require any extra field wiring at the terminals.
NO E: Changing wires or modifying any piece of the junction box will void the module’s warranty.
9 6
Figur 5. El ctrical outlin of th conn ction b tw n th c lls and th
diod s, that int racts in th photovoltaic solar modul .
6
7 2

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Any shadowing of cells resulting from the projection of any object or from the accumulation of dirt or debris
can result in reverse voltage. he junction box contains three bypass diodes to avoid this problem.
he reverse polarization of a cell can lead to consuming the energy produced by the rest of the system.
he dissipation of this energy can lead to dangerous overheating and affect the cell. Damage can include,
but is not limited to, the release of its anti-reflection cap, the perforation of the P-N union or the breakage of
the soldering.
Bypass diodes have the capacity to run a current larger than the maximum produced by the module and
block the reverse current generated by the system itself to avoid overheating.
Diode Characteristics
he 6 and 7 2 Series contain three by-pass diodes each, the 9 6 contain four by-pass diodes, with the
following characteristics:
Model ype UL RAFAS REC IFIERS
Maximum Average Forward Current 15 A

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WARNINGS AND ELECTRICAL RISKS
• Each Module produces a direct current (DC) when it is exposed to sunlight or other light sources. Contact
with any of the electrically active parts of the module, such as terminals, can result in injury or death,
regardless of whether or not the module is connected.
• he modules must be handled and installed only by certified electricians.
• he modules are packed and protected to avoid shipping/handling damage. his packaging must not be
removed until installation to avoid damage.
• he modules should be stored in a dry and temperature controlled place prior to their installation, always
in a well-balanced position. Please note that dropping can result in glass breakage. A module with a
broken glass must not be installed. Broken glass can produce fragments that may cause injury to
personnel handling it.
• he module’s glass is tempered and therefore has higher resistance to impact. However, impact of a tool
can cause serious damage to it. Modules should be handled with extreme caution to avoid impact from
any tool or other heavy objects. Walking on the modules should also be avoided. (Maximum load rating is
146.5 Kg/m
2
)
• DO NO disassemble the module or remove any of its parts. Improper handling of the junction box may
produce loss of the waterproof rating and electrical protection, which may lead to deterioration and/or
corrosion of the unit. DO NO handle the bypass diodes or bypass connections.
• he module already contains all the necessary wiring for its connection, so the junction box must not be
interfered with in its installation.

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• he photovoltaic solar module has been designed to work with levels of incidental irradiance normally
found on the Earth´s surface. DO NO concentrate the radiation without the express consent of Helios
Solar Works as this concentration without rigorous and uniform control can produce malfunctions and can
affect some cells of the module.
• he photovoltaic module produces a voltage in the form of current that always continues as long as the
unit is illuminated. As a precaution, it is recommended that the module should be covered for its handling
and/or connection or otherwise the connection should be done in hours of low irradiance intensity.
• he tools used to connect the modules must comply with provincial electrical safety regulations. hey
must be dry and have the correct level of insulation.
• he connection and disconnection of the photovoltaic modules can produce sparks. DO NO attempt to
connect or disconnect the modules in the presence of flammable substances.
• 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 capacities, fuse sizes, and size of controls connected to the PV output. Please refer to
the local electrical safety code for additional information.

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CONNECTION LIMIT OF THE MODULES
he thickness and composition of the back sheet provides Helios Solar Works modules with electrical
insulation of 600 V DC subject as per UL regulation. As a result, when installing within North America:
6 series module can be connected to each other in groups of up to 13.*
7 2 series module can be connected to each other in groups of up to 11.*
9 6 series module can be connected to each other in groups of up to 8.*
* values were calculated using standard test conditions (S C).
Back sheet thickness and composition are also IEC certified, providing Helios Solar Works modules with
electrical insulation of 1000 V DC. herefore, when installing modules where IEC standards hold precedence
6 series module can be connected to each other in groups of up to 21.*
7 2 series module can be connected to each other in groups of up to 17.*
9 6 series module can be connected to each other in groups of up to 13.*
* values were calculated using standard test conditions (S C).
here is no limit to the connection of modules in parallel, as the operation of one does not affect the others,
however, they must all work at the same voltage level. herefore, all the modules connected in parallel
must have an equal number of cells, in order to avoid the recirculation of current between rows of modules.
In case of a parallel connection, the new maximum intensity allowable to the inverter is the limit of the
number of modules to be installed.

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Module Wirings
• he wiring must ensure that the loss of nominal potential is ~1% and no more greater than 2%
• he recommended rating for wiring connections is 6mm
2
and never less than 4mm
2
, (10 AWG
recommended and never less than 12 AWG). Use only cable listed by UL 4703 PV Wire, 90ºC/194ºF
thermal insulated in accordance with local fire, building and electrical code.
RECOMMENDATIONS FOR INSTALLATION
he modules must be secured to structures that can support them using anchors that take into account the
constraints imposed by the resulting movements of the processes of thermal expansion and contraction.
o achieve the maximum annual yield the installer shall determine the optimum orientation and tilt of the
PV modules. Generation of maximum power occurs when sunlight shines perpendicularly onto the front
surface PV modules.
Avoid Shading
Even the slightest partial shading (e.g., from dirt deposits) will cause a reduction in yield. A module is
considered "shadow-free" if it is unobstructed across its entire surface regardless of the time of year. Even
on the shortest day of the year unobstructed sunlight should reach the module’s front surface.

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Reliable Ventilation
Sufficient clearance between the module frame and the mounting surface is required to allow cooling air to
circulate around the back of the module. he clearance should also allow any resulting condensation or
moisture to dissipate.
he solar module should be assembled in the best possible orientation (South) and kept free from
shadows, including partial shadows, to be able to obtain a good performance. Calculate the best
inclination of the system depending on the latitude. In order to achieve a good self-cleaning effect through
precipitation, the modules should be installed on at least a 20° angle.
• Each module should be situated with at least 15cm or 6in. of open space behind it to ensure that the
ventilation dissipates the heat produced by the cells, and that the losses from this effect are minimal.
• If the modules are installed one beside the other, the height of the hardware should be levelled to avoid
the projection of shadows.
• he anchors that connect the module frame to the structure and the structure to the building must comply
with the standards for wind resistance outlined by the local building code.
• Prior to the installation of modules, contact the appropriate authorities to determine installation permits
and inspections.
• Check applicable building codes to ensure that the construction or structure (roof, facade, support, etc.)
where the modules are being installed has appropriate strength.

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• When installing the modules, please ensure the assembly is mounted over a fire resistant roof covering
rated for the application and required a slope less than 5in/ft (127 mm/305 mm) to maintain a fire class
rating.
• he modules must not be installed in the proximity of highly flammable substances (e.g., filling stations,
gas containers, paint equipment) since the connection and disconnection process may produce sparks.
• he modules must not be installed near open flames or flammable materials.
• Do not expose modules to artificially concentrated light sources.
• he modules must not be immersed or continuously exposed to water
• here is a risk of corrosion when modules are exposed to salt (i.e., marine environments) or sulphur (i.e.,
sulphur sources, volcanoes).

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Installation Requirements
• Ensure that the modules meet technical requirements of the PV system as designed.
• Ensure that other system components do not exert damaging mechanical or electrical influence on the
modules.
• Modules can be wired in series to increase voltage or in parallel to increase current. o connect in series,
connect cables from the positive terminal of one module to the negative terminal of the following one. o
connect in parallel, connect cables from the positive terminal of one module to the positive terminal on the
following.
• Connect the quantity of modules that match the voltage specifications of the inverters used in the system.
he modules must not be connected together to create a voltage higher than the permitted system voltage.
• In order to avoid (or minimize) mismatch effects in arrays, it is recommended that identical electrical
performance of modules should be connected within the same series.
• Modules should be firmly fixed in place in a manner suitable to withstand all expected loads, including
wind and snow loads.
• he small openings on the underside of the modules allow rain to run out. Make sure that these openings
are not obstructed after mounting.

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Grounding
he modules are certified double insulated, however it is recommended that they be grounded. In U.S.
and Canada only: all PV modules must be grounded by electrical connection from the module frames to the
ground. A UL-listed grounding lug should be used.
Ensure compliance with all local electrical codes and regulations.
Several different methods of grounding can be used to provide the required connection through the
anodized frame; the following methods of performing this task are acceptable.
A UL-listed grounding lug may be used. he existing grounding holes in the module frames should be
used as the point of attachment to the module frame (the diameter M8 –5/16”- groundings holes on the
module frame, identified with a yellow label). o ensure a conductive connection, i.e. to penetrate the non-
conductive coating on the frame, a combination of screw, spring washer and lock nut must be used to
mount the grounding lug onto the frame. he spring washer must be placed between the frame and the
grounding lug. Use all stainless steel hardware to mount the lug to the module frame.
he grounding lug has to be capable of accepting a 4-14 AWG (see
annex A for AWG mm
2
sizing) copper conductor. Modules can be
grounded using clip systems provided they have been tested and
certified to local regulation on anodized aluminum frame and are
installed according to the manufacture’s specified instructions.
Connect module frames to each other using cables with cable lugs.
All the connections on the conductive connection must be fixed.