Perlight Solar PLM Series User manual

Perlight Solar
PLM Series Module
Installation Manual

Perlight Solar PLM Series Installation Manual 2www.perlight.com
V.01.2019 A1.5
Table of Contents
1. Introduction .....................................................................3
2. Class Application.........................................................3
3. Applicable Modules....................................................4
4. Warning and Notes.....................................................5
5. Permit ................................................................................6
6. Climate Condition........................................................6
7. Module Structure..........................................................6
8. Site Selection.................................................................7
9. Module Tilt Angle.........................................................7
10. Mounting and Notes.......................................... 8-10
11. Grounding......................................................................11
12. Module Wiring...........................................................12
13. Maintenance...............................................................13
14. Recycling......................................................................14

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1. Introduction
Perlight Solar modules consist of a series of electrically interconnected crystalline silicon
solar cells, which are permanently encapsulated between a tempered glass superstrate and
substrate. The entire laminate is secured within an anodized aluminium frame for structural
strength; ease of installation and to protect the cells from the most severe environmental
conditions.
Perlight Solar modules are a highly reliable, virtually maintenance-free direct current (DC)
power source, designed to operate eiciently in sunlight. Perlight Solar modules are ideal for
all applications, Residential, Commercial and Utility-Scale. Perlight Solar modules may also
be used to power remote homes, recreational vehicles, water pumps, telecommunication
systems and many other applications either with or without the use of storage batteries.
Please read this manual carefully prior to handling and installation.
Installation and maintenance of Perlight Solar modules may only be carried out by trained and
qualified personnel.
If you require further information, contact your supplier or local Perlight Service Centre.
Please provide a copy of this manual to the owner and operator of the PV system for
reference.
Thank you for choosing Perlight Solar PV modules.
2. Class Application
The modules are qualified for application class A: Hazardous voltage (IEC 61730: higher than
50V DC; EN 61730: higher than 120V), hazardous power applications (higher than 240W)
where general contact access is anticipated (Modules qualified for safety through EN IEC
61730-1 and -2 within this application class are considered to meet the requirements for
Safety Class II).

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PV Modules with
6” Mono-crystalline Cells:
PV Modules with
6” Poly-crystalline Cells:
PV Modules with
5” Mono-crystalline Cells:
72 cells: PLM-***M-72 (*** = 245-385) 72 cells: PLM-***P-72 (*** = 235-355) 96 cells: PLM-***M-96 (***= 230-280)
72 cells: PLM-***MA-72 (*** = 245-385) 72 cells: PLM-***PA-72 (*** = 235-355) 96 cells: PLM-***MA-96 (***= 230-280)
72 cells: PLM-***MB-72 (*** = 245-385) 72 cells: PLM-***PB-72 (*** = 235-355) 96 cells: PLM-***MB-96 (***= 230-280)
66 cells: PLM-***M-66 (*** = 215-350) 66 cells: PLM-***P-66 (*** = 225-325) 72 cells: PLM-***M-72 (***= 160-210)
66 cells: PLM-***MA-66 (*** = 215-350) 66 cells: PLM-***PA-66 (*** = 225-325) 72 cells: PLM-***MA-72 (***= 160-210)
66 cells: PLM-***MB-66 (*** = 215-350) 66 cells: PLM-***PB-66 (*** = 225-325) 72 cells: PLM-***MB-72 (***= 160-210)
60 cells: PLM-***MA-60 (*** = 220-320) 60 cells: PLM-***P-60 (*** = 195-295) 66 cells: PLM-***M-66 (***= 145-190)
60 cells: PLM-***MA-60 (*** = 220-320) 60 cells: PLM-***PA-60 (*** = 195-295) 66 cells: PLM-***MA-66 (***= 145-190)
60 cells: PLM-***MB-60(*** = 220-320) 60 cells: PLM-***PB-60 (*** = 195-295) 66 cells: PLM-***MB-66 (***= 145-190)
54 cells: PLM-***M-54 (*** = 185-285) 54 cells: PLM-***P-54 (*** = 180-265) 60 cells: PLM-***M-60 (***= 130-175)
54 cells: PLM-***MA-54 (*** = 185-285) 54 cells: PLM-***PA-54 (*** = 180-265) 60 cells: PLM-***MA-60 (***= 130-175)
54 cells: PLM-***MB-54 (*** = 185-285) 54 cells: PLM-***PB-54 (*** = 180-265) 60 cells: PLM-***MB-60 (***= 130-175)
48 cells: PLM-***M-48 (*** = 155-255) 48 cells: PLM-***P-48 (*** = 165-235) 54 cells: PLM-***M-54 (***= 120-155)
48 cells: PLM-***MA-48 (*** = 155-255) 48 cells: PLM-***PA-48 (*** = 165-235) 54 cells: PLM-***MA-54 (***= 120-155)
48 cells: PLM-***MB-48 (*** = 155-255) 48 cells: PLM-***PB-48 (*** = 165-235) 54 cells: PLM-***MB-54 (***= 120-155)
36 cells: PLM-***M-36 (*** = 125-190) 36 cells: PLM-***P-36 (*** = 125-175) 48 cells: PLM-***M-48 (***= 105-140)
36 cells: PLM-***MA-36 (*** = 125-190) 36 cells: PLM-***PA-36 (*** = 125-175) 48 cells: PLM-***MA-48 (***= 105-140)
36 cells: PLM-***MB-36 (*** = 125-190) 36 cells: PLM-***PB-36 (*** = 125-175) 48 cells: PLM-***MB-48 (***= 105-140)
24 cells: PLM-***M-24 (*** = 80-125) 24 cells: PLM-***P-24 (*** = 80-115) 36 cells: PLM-***M-36 (*** = 80-105)
24 cells: PLM-***MA-24 (*** = 80-125) 24 cells: PLM-***PA-24 (*** = 80-115) 36 cells: PLM-***MA-36 (*** = 80-105)
24 cells: PLM-***MB-24 (*** = 80-125) 24 cells: PLM-***PB-24 (*** = 80-115) 36 cells: PLM-***MB-36 (*** = 80-105)
24 cells: PLM-***M-24 (*** = 55-70)
24 cells: PLM-***MA-24 (*** = 55-70)
Mini Panels with
Sliced 6” Mono-crystalline Cells:
Mini Panels with
Sliced 5” Mono-crystalline Cells:
Mini Panels with
Sliced 6” Poly-crystalline Cells:
36 cells: PLM-***M-36 (*** = 5, 10, 20, 30,
40, 50, 60, 70, 80, 100, 120)
36 cells: PLM-***M-36 (*** = 5,10, 50) 36 cells: PLM-***P-36 (*** = 5, 10, 20, 30,
40, 50, 60, 70, 80, 100, 120)
36 cells: PLM-***MA-36 (*** = 5, 10, 20,
30, 40, 50, 60, 70, 80, 100, 120)
36 cells: PLM-***MA-36 (*** = 5,10, 50) 36 cells: PLM-***PA-36 (*** = 5, 10, 20, 30,
40, 50, 60, 70, 80, 100, 120)
3. Applicable Modules
This installation manual is applicable to the following modules:
For the modules listed above *** represents module Wp in increments of 5W of figures shown.
For Mini Panels listed above *** represents Wp stated.

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4. Warning and Notes
Perlight Solar modules generate electricity when exposed to light. An array
of modules can cause lethal shock and burn hazards. Only authorized and
trained personnel should have access to the PV modules. To reduce the risk
of electrical shock or burns, modules may be covered with an opaque material
during installation. Do not touch live terminals with bare hands. Use insulated
tools for electrical connections.
Each Perlight Solar module has a pair of male and female waterproof connectors. For a series
electrical connection, connect positive (+) connector of first solar module to negative (-)
connector of the following module.
Do not short the positive and the negative. Do not disconnect under load. Ensure each
connection is sound with no gap between the insulators. Poor connections may cause arcing
and pose a fire and/or an electrical shock hazard.
Artificially concentrated sunlight shall not be directed on the Perlight Solar module. The
electrical characteristics are the indicated value of Pmax under standard test conditions
(Irradiance of 1000W/m², AM 1.5 spectrum, and cell temperature of 25°C).
Under normal conditions, a solar PV module is likely to experience conditions that produce
more current and/or voltage than reported at standard test conditions. Accordingly the
value of Isc and Voc marked on this module should be multiplied by a factor of 1.25 when
determining component voltage ratings, conductor current ratings, fuse sizes, and sizes
of controls connected to the Perlight Solar PV module output. Refer to local and national
Electrical Code for any additional multiplying factors, which may also be applicable.
Handle with care
Unpack and handle the PV modules with care. For safety always avoid installing PV modules
during wet and windy conditions or during electrical storms.
• Do not place heavy objects on to the PV modules.
• Do not step or walk on the module, although Perlight Solar modules are rugged, flexing
caused by bodyweight on the module face can create micro-cracks in the solar cells,
which may not be visible but will eect cell performance as the module ages. Take care
not to impact the module during installation, module glass can be broken (and the module
will no longer work properly) if it is dropped or hit by tools or other objects.
• Take care not to allow the front glass or backsheet of the module come into contact with
hard or sharp surfaces such as scaold during the installation process to avoid scratching
or damaging the PV module.
• Do not scratch the PV module backsheet.
• Do not drill or cut the PV module frame.
• Do not apply paint or glue to the PV module.

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5. Permit
Before installing your system, contact local authorities to determine the necessary permit,
installation and inspection requirements.
6. Climate Conditions
Install the Perlight Solar PV modules in the following conditions:
• Ambient temperature: -20°C to +40°C.
• Operating temperature: -40°C to +85°C.
• Storage temperature: -40°C to +40°C
• Humidity: below 85RH%
• Wind pressure: below 50.12lb / ft² (2400Pa)
• Corrosion resistant: Except for corrosive salt areas and sulphurous areas.
7. Module Structure
Fig.1: Module Structure

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8. Site Selection
In most applications, Perlight Solar modules should be installed in a location where they
will receive maximum sunlight throughout the year. In the Northern Hemisphere, the
module should typically face south, and in the Southern Hemisphere, the modules should
typically face north. Modules facing 30 degrees away from true South (or North) will lose
approximately 10 to 15 per cent of their power output. If the module faces 60 degrees away
from true South (or North), the power loss will be 20 to 30 percent.
When choosing a site, avoid trees, buildings or obstructions, which could cast shadows on
the solar photovoltaic modules especially during the winter months when the arc of the sun is
lowest over the horizon. Shading causes loss of output, even though the factory fitted bypass
diodes of the Perlight Solar module will minimize any such loss.
Do not install the Perlight Solar module near naked flame or flammable materials. Do not
install the Perlight Solar module in a location where it would be immersed in water or
continually exposed to water from a sprinkler or fountain etc.
9. Module Tilt Angle
Perlight Solar modules connected in series should be installed at same orientation and angle.
Dierent orientation or angle may cause loss of output power due to dierence in amount of
sunlight exposed to the module.
Perlight Solar modules produce the most power when they are pointed directly at the sun.
For installations where the Perlight Solar modules are attached to a permanent structure,
the modules should be tilted for optimum winter performance. As a rule, if the system power
production is adequate in winter, it will be satisfactory during the rest of the year. The module
tilt angle is measured between the solar modules and the ground (Figure 2). Optimal tilting of
Perlight Solar module is almost the same as the latitude of installation location.
Fig.2: Installation angle
Degrees of
Latitude Tilt Angle
0⁰ ~ 15⁰ 15⁰
15⁰ ~ 25⁰ Equal to Latitude
25⁰ ~ 30⁰ Latitude + 5⁰
30⁰ ~ 35⁰ Latitude + 10⁰
35⁰ ~ 40⁰ Latitude + 15⁰
40⁰ + Latitude + 20⁰

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10. Mounting and Notes
The PV module frame is made of anodized aluminium, and therefore corrosion can occur if
the module is subjected to a salt water environment with contact to a rack of another type
of metal (Electrolysis Corrosion). If required, PVC, EPDM or stainless steel washers can be
placed between the PV module frame and support structure to prevent this type of corrosion.
Module support structures that are to be used to support Perlight Solar modules at the
correct tilt angles should be wind and snow load rated for use by the appropriate local and
civil codes prior to installation.
Perlight Solar modules can be mounted using the following methods:
• Direct fixing to mounting structure
• Suitable module clamps as part of solar mounting system
• Insertion systems
• Roof integrated systems
Direct Fixing to Mounting Structure
2400Pa Wind Load
2400Pa Snow Load
5400Pa Wind Load
3800Pa Snow Load
Use Four Mounting Holes Use Eight Mounting Holes
Direct Fixing to Mounting Structure
The frame of each module has 8 mounting holes
(14mm*9mm), which can be used to secure the
modules to a supporting structure. The module frame
must be attached to a supporting structure using
corrosion-proof M8 stainless steel nuts and bolts with
spring washers and flat washers in at least four points
symmetrical on the PV module. Applied torque is
approx. 8 Newton-meters.

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Solar Mounting Systems
2400Pa Wind Load
2400Pa Snow Load
5400Pa Wind Load
3800Pa Snow Load
Fig.:3 Use Four Clamps
Fig.: 4 Use Four Clamps on Short Side and Two
Clamps on Long Side
Fig.: 5 Use Four Clamps Fig.:6 Use Six Clamps
Module mounting clamps must not come into contact with the front glass and must not
deform the frame. Module clamps should not cause shadowing eects. It is not permitted to
modify the module frame under any circumstances. Recommended distance between two
modules is 5mm considering linear thermal expansion of the module frames.
Clearance between the module frame and mounting surface may be required to prevent the
junction box from touching the surface, and to circulate cooling air around the back of the
module.

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Insertion Mounting Systems
2400Pa Wind Load
2400Pa Snow Load
5400Pa Wind Load
3800Pa Snow Load
Fig.: 7 Insertion System Short Side
Fig.: 8 Insertion System Short Side and Two Clamps
on Long Side.
Insertion Systems must not cause shadowing eects.
It is not permitted to modify the module frame under
any circumstances. Recommended distance between
two modules is 5mm considering linear thermal
expansion of the module frames.
Clearance between the module frame and mounting
surface may be required to prevent the junction box
from touching the surface, and to circulate cooling air
around the back of the module.
Fig.: 9 Insertion System Long Side
Mounting design may have an impact on fire resistance. If the modules are to be installed on
the roof or wall of a building, using an integrated mounting system, the fire resistance of roof
covering or wall should be rated for the application and certified for use to local and national
standards. Here the stand-o method or the rack method is recommended. The modules are
supported parallel to the surface of the building wall or roof. Clearance between the module
frames and surface of the wall or roof is required to prevent wiring damage and to allow air
to circulate behind the module. The recommended stand-o height is 115mm. Any slope less
than 5in/ft (127mm/305mm) is required to maintain a fire class rating. Do not mount Perlight
Solar module in such way that the drain holes of the module are intended to block up.
Roof-integrated (in-roof) systems must comply with local and national regulations, including
fire test certification where necessary.