Korax Solar KS-90 User manual

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KORAX SOLAR
General installation guide for Korax Solar photovoltaic modules
INTRODUCTION
This guide contains application and safety information with which you should be familiar before using your Korax Solar photovoltaic module. Your
authorized Korax Solar distributor or dealer can provide additional sizing and system design information if necessary.
The information in this guide is based on Korax solar knowledge and experience and is believed to be reliable, but such information including product
specifications and suggestions do not constitute a warranty, expressed or implied. Korax solar reserves the right to make changes to the product
specifications, or guide without prior notice.
G N RAL INFORMATION
The installation of modules re uires a great degree of skills and should (if DC voltage exceeds 100 V then must) only be performed by ualified licensed
professional, including licensed contractors and licensed electricians. The installer assumes the risk of all injury that might occur during installation,
including the risk of electrical shock.
Korax Solar photovoltaic modules do not re uire the use of special cable assemblies. All modules come with a permanently attached junction box that
will accept a variety of wiring applications or with a special cable assembly for ease of installation.
It is recommended to utilize ualified installer or reseller for service.
WARNING
All instructions should be read and understood before attempting to install, wire, operate, and maintain the module. Contact with electrically active parts
of the module such as terminals can result in burns, sparks, and lethal shock whether the module is connected or disconnected.
Modules produce electricity when sunlight or other sources illuminate the module is not considered a shock hazard. When modules are connected in
series, voltages are additive. When modules are connected in parallel, current is additive. Conse uently, a multi module system can produce high
voltages and current, which constitute an increased hazard and could cause serious injury or death.
T CHNICAL INFORMATION
The Korax Solar photovoltaic modules use high efficiency pseudo-s uare monocrystalline (or s uare polycrystalline) silicon cells to turn solar radiation
energy into direct current electric current. The cell circuit is laminated using ethylene-vinyl acetate (EVA) as a capsulant, in an assembly formed by a
tempered glass at its front and plastic polymer (Tedlar) at the rear, which provides resistance against environmental agents and electric insulation.
The laminate fits into an anodised aluminium structure. The IP-65 protected terminal boxes are made from temperature resistant plastic and contains
terminals, connection terminals and protection diodes (by-pass diodes). The frame has several fasting holes for securing the module to the support
structure and its earthing, if necessary.
Section of a photovoltaic module.
The electrical values are obtained under standard testing conditions (STC) which correspond to a 1000 W/m
2
irradiance, 1,5 AM (air-mass) spectrum
and 25
o
C cell temperature. However, the actual working conditions of the modules, once they are installed may be different from the laboratory
conditions. Therefore it is advisable to check out the actual local conditions in order to carry out the pertinent corrections in calculation.
Under actual conditions, a photovoltaic module may experience higher than standard illumination and produce more current and voltage than reported at
STC conditions. Accordingly the values of Isc and Voc should be multiplied by a factor of 1.25 when determining the voltage ratings, conductor
capacities, fuse sizes, and sizes of controls connected to the module output.

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Protection diodes
The shading of a cell may give rise to a reverse voltage in the cell. This cell would, therefore consume power generated by the other cells in series and
an unwanted heating of the shaded cell may occur. This effect, called hot point effect, will be highest at highest incident radiation on the rest of the cells,
and in an extreme case the cell could break up due to over-heating.
The use of protection or by-pass diodes reduces the risk of the shaded cells heating up by limiting the current, which can run through them and in this
way preventing their breakage.
In general, modules made by Korax Solar with 24 or more cells in series are supplied with protection diodes, which are located in the connection boxes.
Connection Boxes
The connection boxes of the modules are located at the rear side of the modules. As specified earlier, they are made of a durable (polycarbonate) plastic,
having a leak tight cover, providing IP-65 safety. The polarity of cable connection marked on the top of the boxes. Normally the modules come without
cabling. The standard Korax Solars cabling system (on re uest) includes a 400 mm long positive and a 700 mm (for KS-75 family) or 1000 mm (for KS-
150 family) negative cable. The Korax Solar standard cable is double insulated, flexible, the upper layer is UV resistant. The standard cross section of
the cables are 4 mm
2
. The sealing in the cable glands can host of maximum 6.5 mm OD cable. The polarity of connections must be respected during the
assembly.
CAUTIONS
 Avoid electrical hazards when installing,
wiring, operating and maintaining the
module.
 A modules generates DC electricity when
exposed to sunlight or other light sources.
 It is recommended that the module
remains packed in the box until time of
installation.
 Do not touch the terminals while module is
exposed to light or during installation.
Provide suitable guards to prevent contact
with 30 VDC or greater. Use properly
insulated tools only.
 When installing or working with module or
wiring, cover module face completely with
opa ue material to halt production of
electricity.
 Work only under dry conditions, with a dry
module and tools.
 Do not stand or step the
module.
 Do not drop the module
or allow objects to fall on
module.
 Never leave a module
unsupported or
unsecured. If a module
should fall, the glass can
break. A module with
broken glass cannot be
repaired and must not be
used.
 Do not drill holes into module frame as it
will void warranty.
 Avoid sharp edges.
 Do not artificially concentrate sunlight on
the module.

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 Module installation and operation should be performed by ualified personnel only. Children should not be allowed near the solar electric
installation.
 If not otherwise specified, it is recommended that re uirements of the local, national or regional electrical codes be followed.
 Use module for its intended function only.
 Do not disassemble the module, or remove any part or label installed by manufacturer.
INSTALLATION
Series and parallel wiring
Modules can be wired in series to increase voltage. Connect wire from the positive terminal of one module to the negative terminal of the next module.
The first illustration shows four modules connected in series. Installer should consider the maximum allowed system voltage in case of connecting
modules in series. Take also care of connecting in series strictly only modules of the same type (the current at the maximum power point must be the
same).
Connect modules in parallel to increase current. Connect wires from the positive terminal of one module to the positive terminal of the next module. The
second illustration shows four modules connected in parallel.
It is recommended that paralleling modules be performed using an external junction box. Installer should also keep in its mind that the current values are
additive in parallel connection and the common wire cross section must be chosen according to local regulations and standards. When cabling a system
of several modules installer should ensure that the voltage drop on the main conductor does not exceed 2 % of the nominal voltage.
There are many types of mounting system used to install Korax Solar modules. The mounting structure must withstand all snow and wind forces. Module
mounting holes are provided for easy installation and proper mechanical loading. Contact your local dealer for information regarding mounting structures
and special mounting profiles for modules. This illustration shows one possibility to mounting some modules.
Grounding
Module frames should be connected to an earth for safety and protection from lighting. Korax Solar modules have a hole on the frame marked with
symbol for connecting the earthing cable. If the support structure is a conductor, the metallic contact between the frame and the structure must be
ensured during the assembly of the modules. In that case the supporting structure must earthed according to the local regulations. Should the support
structure made of non-conducting material it is recommended that the earth conductors from the individual modules connected to a common earthing
terminal (bus conductor) so that removal of any module does not interrupt the earth connection of the remaining modules.
Air Circulation
Sufficient clearance between the module frame and the mounting surface is re uired to allow cooling air to circulate around the back of the module. This
also allows any condensation or moisture to dissipate.

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MAINT NANC OF TH PHOTOVOLTAIC MODUL S
Photovoltaic modules re uiring very little maintenance due to their own design, with no moving parts and with an interior cell circuit soldering isolated
from the environment by protecting materials. At the same time the uality control performed by Korax Solar is very strict.
Maintenance may include one or several of the following steps:
 Regular cleaning of the module
 Visual inspection of possible internal degradation of the module sealing
 Check out of the condition of electric connectors and wiring
 Occasionally, checking out the electrical characteristics of the module
Regular cleaning of the modules
Dirt piled up on the transparent surface of the module reduces its performance and may cause reversal effects similar to those caused by shadows. The
layers of dust that reduce evenly the sun intensity are not dangerous and power reduction is not usually significant. In many cases the rainfall can
reduce or remove the dirt to an acceptable level.
The spot dirt is advisable to remove by occasional cleaning by washing the modules with water or some nonabrasive detergent.
Visual inspection of the module
The aim of the visual inspection of the modules is to detect the possible faults, like broken glass and/or corrosion of the circuits elements, mostly due to
humidity leakage at the damaged insulation spots or glass breakage. Consult your area dealer or Korax Solar in case of serious damage.
Check out the connections and cabling
The regular check-out of connections tightness and cable conditions considered as a preventive maintenance step.
SP CIFICATIONS/PRODUCT OV RVI W
PHYSICAL AND ELECTRICAL CHARACTERISTICS
KS-90 KS-180 KS-180L KS-240
PHYSICAL
Dimensions 1224 x 545 x 39.5 mm 1224 x 1047 x 39.5 mm 1600 x 800 x 39.5 mm 1657 x 977 x 39.5 mm
Weight 9 kg 15 kg 15 kg 19 kg
Number of cells 36 72 72 60
Size of cells 5” 5” 5” 6”
ELECTRICAL (1000 W/m
2
, 25
o
C cell, AM 1.5)
Nominal voltage (Vn) 12 V 24 V 24 V 24 V
Maximum power (Pmax) 90 Wp 180 Wp 180 Wp 240 Wp
Short-circuit current (Isc) 5,23 A 5,23 A 5,23 A 8,39 A
Open circuit voltage (Voc) 21,7 V 43,42 V 43,42 V 37,44 V
Maximum power current (Imax) 4,90 A 4,90 A 4,90 A 7,88 A
Maximum power voltage (Vmax) 18,61 V 37,25 V 37,25 V 31,2 V
DESIGN
Cells Monocrystalline Si, textured and covered with antireflection layer
Contacts Redundant contacts on each cell for circuit reliability
Laminate EVA (Ethylene-vinyl acetate)
Front face Tempered glass with improved light transmission
Rear face Tough multilayered backsheet Tedlar
Frame Anodised aluminium
Connection boxes IP 65 with built-in bypass diode
Cable cross section 4 mm
2
Connection box Pression screw with possibility of soldering, MC optional
PHYSICAL AND ELECTRICAL CHARACTERISTICS