IBC SOLAR PolySol TX Series User manual

Installation instructions IBC PolySol xxx TX photovoltaic modules.
Safety, installation and operating manual
Meets the safety requirements according to IEC 61730; no UL approval
ELECTRICAL INSTALLATION – PLEASE CONSULT YOUR INSTALLATION ENGINEER
IBC PolySol TX series photovoltaic modules (PV/solar power modules) generate direct current
when exposed to light irradiation. This manual contains important information on the safety,
installation, and operation of the modules that you should know before using the modules.
General information
•The solar modules must be assembled and operated according to the latest available
procedures. When assembling, it is vital to observe and to adhere to the respective national
health and safety at work. Special attention should be paid to regulations relating to working
on a roof.
•Before trying to install, wire, commission, and maintain the modules, first make sure that
you have read and understood all installation and safety instructions.
•Observe all the local, regional, national, and international legal regulations, directives,
standards, and ordinances during installation.
•Installation and maintenance work may only be carried out by licensed and qualified
professionals.
•The modules also generate voltage when they are not connected to a circuit or load
resistor. The modules generate nearly full voltage when exposed to light irradiation totaling
as little as 5% of full sunlight . The current and power output increase with the light intensity.
•The output power generated by the modules may exceed the specified rated power.
•The rated values are determined at a radiation intensity of 1000 W/m² and a solar cell
temperature of 25°C according to the industry stand ard. Colder temperatures may lead to a
significant increase in voltage and output.
•Make sure that modules are only exposed to ambient temperatures ranging from -40°C and
+80°C.
•Do not use light concentrators (e.g. mirrors or lenses) in attempting to increase the capacity
of the module. The module may be damaged.
•Avoid bundling rays of lights and directing them onto the module.
•The modules are only intended for operation outdoors and on firm ground. The modules are
not suitable for mobile usage or for indoor installations.
•In addition, they are not intended for operation or use in hazardous areas. In particular, this
includes installations in which the modules come into contact with salt water or could be
immersed, in part or in whole, in freshwater or salt water – e.g. on boats or buoys.
•Only use devices, plugs, cables, and mounting frames that are suitable for use in a
photovoltaic system.
•Observe all safety measures for the other components used.
•Modules that are temporarily stored outdoors and not interconnected must be covered, with
the glass side facing down. This serves to prevent water from accumulating on the module
and protects the exposed plugs against damage.
•Always store the solar modules securely in a dry place. The packaging is not weatherproof!

Safety precautions when handling modules
•Do not use the junction box and/or cables to hold or transport the module.
•Do not subject the module surfaces to mechanical stress. Do not stand on the modules. Do
not drop or place objects on the modules.
•Do not drop the module and protect it against falling objects.
•Make sure that the rear and front side of the module is not damaged or scratched.
•Never place the module down on a surface using excessive force. Exercise particular
caution when the module is set down on its side.
•Avoid disassembling, modifying, or adapting the module or removing any part or label
attached by IBC SOLAR AG. Otherwise, the warranty will become void.
•Do not drill holes in the module's frame or glass surface. Otherwise, the warranty will
become void.
•Do not apply any paint or adhesive on the module rear.
•Never leave the module unsupported or unsecured.
•The modules are made from tempered glass. However, they must still be handled carefully.
•Modules with broken glass surfaces or a crack in the rear film are irreparably damaged and
must never be used, since touching the module surface or mounting frame can result in an
electrical shock.
•Broken or damaged modules must be handled carefully and disposed of properly. Broken
glass can have sharp edges and result in injuries if it is not handled with suitable protective
equipment.
•Only work in a dry environment and use dry tools. Only work with the modules if they are
completely dry unless you are using suitable protective equipment.
Safety precautions during installation
•Make sure that no children or other persons are near the systems or modules during
installation.
•Do not perform installation work under severe windy conditions.
•If the modules are not installed at ground-level, take suitable precautionary measures, and
use suitable protective equipment to prevent damages caused by the modules falling down
as well as other safety risks.
•Photovoltaic modules are not equipped with an on/off switch. They can only be switched off
by removing them from the light irradiation. To do this, their front surface must be either
covered with a cloth, cardboard box, or another completely opaque material, or they must
be placed on a smooth, even surface with their front surface facing down.
•If you work with modules when they are exposed to light, observe all regulations and
ordinances for working with electrical installations carrying current.
•Avoid touching the electrical connection terminals or cable ends during installation or while
the module is exposed to light.
•Do not wear jewelry or any accessories made of metal when performing mechanical or
electrical installation work.
•Never disconnect electrical connections and do not unplug any plugs when the circuit is
carrying current. Physically disconnecting contacts in a live electrical circuit can cause
arching, resulting in grave or mortal injury.
•Touching electrically charged module parts such as terminal connections can result in
burns, sparks, and electrical shocks with fatal consequences. This also applies even if the
module is not connected.
•Only use insulated tools and wear rubber gloves that are approved for electrical installation
work.

Fire precautions
•Please contact the local authorities to determine the fire prevention regulations and
requirements for homes and buildings.
•Roof constructions and installations can affect a building's fire resistance. Defects in these
areas can pose fire hazards.
•When installing modules on the roof, they should be mounted on a fire resistant covering (or
surface) that is approved for this purpose.
•Components such as ground fault switches, fuses, and circuit breakers may be required.
•Do not place the modules near equipment or areas where gas is produced or can
accumulate.
Electrical installation
•When installing, wiring, operating, and maintaining the module, take all required
precautionary measures to prevent electrical hazards.
•In the case of module or phase voltages of more than 120 V, the extra-low voltage range is
left. Undertake the necessary protection and cautionary measures. Installation, handover,
and maintenance must be performed by a licensed electrician unless the local ordinances
require any other measures for handling electrical systems.
•Contact with DC voltage of 30 V or more is potentially dangerous.
•Do not install modules with different electrical parameters or physical specifications within
the same system.
•The system's maximum open-circuit voltage must not exceed the module's maximum rated
system voltage.
•All IBC SOLAR AG modules are equipped with factory installed connecting cables and
plugs. Their design allows them to be easily installed in series.
•IBC SOLAR AG modules of series PolySol TX are equipped with Multi-Contact® type 4
snap-in connectors. The PV module's plug connection can also be protected using the
pluggable PV-SSH4 safety lock clip available from Multi-Contact®.
•The PV-SSH4 clip is not supplied by IBC SOLAR AG and must be purchased separately. If
the lock clip is installed, the PV module's plug connection can only be unlocked using the
PV-MS tool, which is also available from Multi-Contact®.
•Make sure to use suitable cross-sections and connections that are approved for the
module's maximum short-circuit current when wiring the system.
•When establishing the connections, make sure the polarities of the cables and connection
terminals are correct. Otherwise, there is a risk of damaging the module.
•If the reverse current can exceed the maximum fuse rating specified on the module rear, a
properly approved and certified over current blocking device (fuse or circuit breaker) must
be installed in series with each module or each module string both in the positive as well as
the negative pole of the generator.
•The rated power of the over current blocking device must not exceed the maximum fuse
rating specified on the module rear.
•The module is equipped with factory installed bypass diodes that are located inside the
junction box.
•The junction box is not suitable for modification during installation and must never be
opened. If the junction box is opened, the module warranty will become void.
•Modules suspected of having electrical problems should be returned to IBC SOLAR AG for
inspection and if necessary, repair according to the warranty conditions of IBC SOLAR AG.
•Warning: Connecting modules in reverse polarity to a high current source, such as a
battery, will destroy the bypass diodes. This will render the complete module inoperative.
Bypass diodes cannot be replaced by the user.

Important!
The reverse current rating of the modules depends on the type and is 20 A for IBC
PolySol TX modules. If the reverse current can exceed the maximum fuse rating
specified on the module rear, a properly approved and certified over current blocking
device (fuse or circuit breaker) must be installed in series with each module or each
module string. The fuse rating of the IBC PolySol TX module types is 15 A.
Grounding
System Bonding
•The module frames do not require grounding according to the regulations of IBC SOLAR
AG. Regional or national regulations, however, may require that the module frames be
grounded. In addition, the module frames may require grounding for lighting/overvoltage
protection.
Functional Grounding
•In case modules are installed within 500 m of the coastline, a functional grounding of the
photovoltaic generator has to be installed.
DANGER! Incorrect grounding causes risk of fire hazard!
The direct grounding of the positive or negative conductor is only permitted if any hazards
for persons can be excluded. Comply to all valid regulations for personal safety and fire
prevention.
For the installation of a functional grounding:
•Only use galvanic isolated inverters (inverters with transformers).
•Only ground the negative conductor of the PV-generator.
•Only unse grounding kits which are compliant with the inverter.
•Meet all earthing instructions of the inverter manufacturer.
Mechanical installation
•The modules should be mounted so that they are exposed as directly to sunlight as
possible and to as little shading as possible.
•Even partial shading can significantly reduce the output power of the modules and system.
•The modules must be securely fastened. To do this, use special mounting frames or
mounting kits designed for photovoltaic applications.
•The tilt angle of the PV modules measured between the PV modules and the horizontal
must be 5°at minimum. Ensure that the drainage openings of the frame are left open
following installation to allow water runoff. This prevents frost damage.
•Make sure to avoid an insufficient inclination angle (i.e. <15°), since otherwise, dirt can
accumulate on the glass surface and be retained by the frame.
•Dirt accumulations on the module surface can cause shading on active solar cells, thus
reducing the electrical output.
•For roof-mounted systems, make sure that there is sufficient room for ventilation below the
module in order to cool the rear (at least 100 mm).
•Always make sure that the module rear does not come into contact with foreign objects or
building elements, especially if the module is subjected to a mechanical load.
•The modules may be installed in landscape or portrait format. Install the module in such a
way that the junction box is positioned in the upper area of the module.
•IBC SOLAR AG allows several mounting methods. You can obtain detailed information on
the permissible mounting methods along with the permissible clamping areas in the drawing
found in the appendix.

•If you want to employ mounting methods that are not described in the drawing, please
contact IBC SOLAR AG for permission to do so. Otherwise, the warranty and the module
certification are no longer valid.
•In addition to the instructions contained in the installation manual, always observe the
installation instructions of the mounting frame manufacturer. In case the instructions of the
mounting frame manufacturer are stricter as those contained in the installation manual, the
manufacturer instructions take precedence.
•In case the maximum permissible load specified by the mounting frame manufacturer is less
than the value specified in the installation manual, the maximum load specification of the
mounting frame manufacturer is binding.
•Make sure that the modules are not subjected to loads exceeding the maximum load
caused by wind and snow and that they are not exposed to excessive forces due to the
thermal expansion of the supporting structure.
•The maximum loads apply to uniformly distributed loads caused by wind or snow. Avoid
mounting the modules in areas prone to drifting snow or icicle and glacier formation.
Possibly occurring drifting snow loads forces have to be identified separately. If necessary,
steps should be taken to avoid damages. Please refer to the IBC reference sheet
"Instructions for increased snow loads."
•In order to take into account the thermal linear expansion of the module frame the distance
between 2 modules should be 20 mm. However, it has to be at least 10 mm.
•For mounting with clamps the surface pressure shall be 8.5 – 9.5 N/mm². The Clamp area
surface (clamp depth x clamp width) should be ≥400 mm². We recommend using clamps
with 80mm x 8mm bearing surface (IBC mounting clamp). The screw for the clamps (M8
A2-70) should be fixed with 15 Nm. Any damages of the modules have to be avoided and it
must be secured that the connection between clamp and module is sufficient.
Operation and maintenance
•The modules do not require regular maintenance. However, we recommend regularly
checking the modules for damage to the glass surface, the rear film, the frame, the junction
box, and the outer electrical connections.
•The electrical connections should be checked for loose connections and rusting.
•PV modules operate efficiently even when they are never cleaned. Nevertheless, removing
contamination on the glass surface increases the output power.
•Dust, dirt, or other residues on the coated glass surface can be regularly washed off or
rinsed off using water.
•Persistent dirt deposits on the coated glass can be removed using a microfiber cloth and
ethanol or using a standard glass cleaner.
•The coated glass surface must never be treated with aggressive and abrasive cleaning
agents or chemicals. Only use pH-neutral cleaning agents.
•Always wear rubber gloves when maintaining, washing, or cleaning the modules to insulate
and protect yourself against electrical shocks.

Required specifications according to IEC 61730
•IBC SOLAR AG modules of series PolySol TX are qualified for application class A.
•Modules certified for application class A can be installed in systems operated with more
than 50 V of direct current or 240 W in publicly accessible environments.
•Modules of application class A that meet the standard IEC 61730 also meet the
requirements of safety class II.
•During normal operation, it is likely that the voltage and/or current generated by the
photovoltaic modules will, under certain circumstances, exceed the values determined
under standard test conditions. Therefore, the short-circuit current (Isc) and open-circuit
current (Voc) values specified on the modules should be multiplied by a factor of 1.25 to
determine the component voltage ratings, the conductor capacities, the fuse sizes, and the
size of the controllers connected to the module output.
•Maximum number of module configurations connected in series or parallel: a maximum of 3
strings can be operated in parallel without an over current protection device connected in
series for each string. If a certified and properly rated over current protection device is
connected in series with each string, 4 or more strings can be operated in parallel.
Recycling
Do not decommission the module on your own. Commission a specialist company for
this purpose. IBC SOLAR AG is a member of the European PV Cycle Association and accepts
our product responsibility. You can give back modules of IBC SOLAR AG and allow them to be
processed within the PV Cycle member states.
Disclaimer
IBC SOLAR AG has no influence over the use of this safety, installation, and operating manual
and the conditions and methods employed during installation, operation, use, and maintenance
of the module. IBC SOLAR AG therefore assumes no responsibility and expressly disclaims
liability for loss, damage, injury, or expense arising out of or in conjunction with the installation,
operation, usage, and maintenance of the module. IBC SOLAR AG assumes no responsibility
for patent infringements or other infringements to the rights of third parties that may result from
using the module. No license is granted by implication or otherwise under any patent or patent
rights. The information contained in this manual is based on knowledge and experience of IBC
SOLAR AG and is deemed reliable. Information, product specifications (without any limitations),
and suggestions, however, do not represent an expressed or implied warranty. IBC SOLAR AG
reserves the right to make changes to the product, specifications, or this manual without prior
notice. Note: This document may be written in several languages. In case there are any
discrepancies between the different versions, the English document takes precedence.
Bad Staffelstein - Germany, February 17th, 2012

Appendix 1 Clamping range long side

Appendix 2 Clamping range short side
Attention:
For using clamps at the short side the max load must not exceed 2400 Pa!