Plug-In Solar Sheet Metal/Flat Roof Mount Kit User manual

Plug-In Solar Installation Instructions
Sheet Metal/Flat Roof Mount Kit
Plug-In Solar – Power Your Future
www.pluginsolar.co.uk
These installation instructions contain important information on safety matters and the installation
of the Plug-In Solar kit. Please read this guide carefully to ensure safe installation and operation.
*Installations are undertaken at the customer’s own risk. This Installation manual is to be used as a guide only, and your discretion
must be used when installing the Plug-In Solar kit.You MUST follow the IET Wiring Regulations and consult a professional
electrician if you are in any doubt on how to install the system. Plug-In Solar takes no responsibility for incorrect installation of our
kits.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 2
TABLE OF CONTENTS
Tool Requirements
3
Component Guide
4
Safety Instructions
5
Warnings
6
Step by Step Plug-In Solar Installation Guide
Metal Roof Mount Installation
7
Micro-Inverter Installation
10
Wiring The Solar To The Existing Mains Circuit
14
Isolation/Isolator Requirements
16
Placing Warning Labels
17
Inspecting, Testing and Commissioning
Inspecting and Testing your Plug-In Solar Installation
18
Commissioning your Plug-In Solar Installation
19
Completing your Warranty Card
21
Appendix
Appendix 1. Plug-In Solar Connection Unit – Wiring Diagram
22
Appendix 2. Example G83/2 SSEG Installation Commissioning Confirmation Form
23
Appendix 3. Example Electrical Schematic Diagram
24
Appendix 4. Troubleshooting APS Dual Micro-Inverters
25
Appendix 5. APS Warranty Document
26
Appendix 6. APS Warranty Card
29
Appendix 7. APS G83/2 SSEG Test Report Certificate
30
Appendix 8. Solar Panel Warranty Document
31
Appendix 9. Solar Panel MCS Certificate
35
Appendix 10. Roof Mount Warranty
37

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 3
TOOL REQUIREMENTS
8mm Socket Tool
6mm Hex (Allen) Key
13mm Spanner
Drill with S8 Masonry Bit
Voltage Tester
Wire Strippers
Flathead Screwdriver
Phillips Screwdriver

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 4
COMPONENT GUIDE
The number of components you receive will depend on the type of kit you have purchased. Please
unpack all your items, and check you have all the correct components based on your Dispatch Note.
Solar Panel
Metal Roof Mounting System
Micro Inverter (Dual Input)
AC Bus (Trunk) Cable
Trunk Cable Sealing Cap
End Cap
MC4 Sealing Caps (for kits with odd number of Solar Panels)
Plug-In Solar Connection Unit

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 5
SAFETY INSTRUCTIONS
Before installing or using a Plug-In Solar kit, please read all instructions and cautionary markings in
this document and on the Micro-Inverters and Solar Panels.
The installation of a Plug-In Solar kit shall be carried out by a competent person with sufficient skills
and training to apply safe methods of work, in compliance with G83/2 Engineering
Recommendations.
The installation of a Plug-In Solar kit will be carried out to no lower a standard than that required in
the Manufacturer’s installation instructions, as provided here.
No parameter relating to the electrical connection and subject to type verification certification will
be modified unless previously agreed in writing between the DNO (Distribution Network Operator)
and the Customer.
All electrical installations shall be performed in accordance with local electrical codes.
All appropriate health and safety regulations must be observed and required safety precautions
taken.
Be aware that installation of this equipment includes the risk of electric shock.
Be aware that the body of the Micro-Inverter is the heat sink and can reach a temperature of 80°C.
To reduce risk of burns, do not touch the body of the Micro-Inverter.
DO NOT disconnect the PV module from the Micro-Inverter without first disconnecting the AC
power. !In no circumstances, connect a DC input when an AC connector is unplugged.
DO NOT attempt to repair a Micro-Inverter. If it fails, contact APS Customer Support to obtain an
RMA number and start the replacement process. Damaging or opening a Micro-Inverter will void
the warranty.
CAUTION! !The external protective earthing conductor is connected to the micro-inverter
protective earthing terminal via an AC connector. !When connecting; connect the AC connectors
first to ensure the micro-inverter earthing then undertake the DC connections. When
disconnecting; disconnect the AC by opening the branch circuit breaker. Whilst maintaining the
protective earthing conductor in the branch circuit breaker, connect to the micro-inverter, then
disconnect the DC inputs. !
You MUST follow the IET Wiring Regulations at all times and consult a professional
electrician if you are in any doubt.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 6
WARNINGS
Never disconnect the DC wire connectors under load. Ensure that no current is
flowing in the DC wires prior to disconnecting. An opaque covering may be used to
cover the module prior to disconnecting the module.
Do not touch any live parts in the system, including the Solar array, when the
system has been connected to the electrical grid.
Prior to installing any of the Micro-Inverters, verify that the utility voltage at the
point of common connection matches the voltage rating on Micro-Inverter label.
Do not mount the Micro-Inverter in a location that allows exposure to direct
sunlight. Allow a minimum of 3/4’’(1.5cm.) between the roof and the bottom of the
Micro-Inverter to allow proper airflow.
Always disconnect AC power before disconnecting the PV module wires from the
Micro-Inverter. The AC connector of the first Micro-Inverter in a branch circuit is
suitable, as a disconnecting means, once the AC branch circuit breaker in the load
center has been opened.
The Micro-Inverter is powered by PV module DC power. Make sure you disconnect
and reconnect the DC connections to watch for the three short flashes.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 7
METAL ROOF MOUNT SYSTEM INSTALLATION
Roof Mounting System Components
1. Before fitting the roof mounting system, please check that:
a) The roof structure is !able to support the Solar Panel array
b) The installation is able to take the wind loadings based on your location
c) You comply with all building codes, including any that may supersede this manual.
d) You maintain the waterproof integrity of the roof.
The roof mount system, when installed in accordance with this guide will be structurally adequate
and will meet the DIN 1055 standards. When installing this product please observe the appropriate
health and safety regulations and take required safety precautions.
Plug-In Solar takes no responsibility for the method by which you choose to install your mounting
system. This is a guide only. Please consult a roofing expert if you are in any doubt on how to
safely and correctly install your system. It is your responsibility to ensure the roof is watertight.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 8
Installing the Roof Mounting System
2. The distance between the two U-Profiles will depend upon the trapezoidal sheet profile but
should be as near as possible half the Solar Panel length apart. On the short side of the module
always leave an expansion gap, ideally 17mm.
3. Start on the lower elevation of the roof, ensuring your U-Profiles are in the same line. Use a
marker pen to indicate the correct location of each U-Profile. You will need your 8mm socket
set. Please make sure the screws are tightened correctly.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 9
4. Mount the second row of U-Profiles. The distance between the two rows will be:
D= Module width + 18 mm. Continue to mount the rest of the U-Profiles in the same way.
5. Mount the solar panels starting on the lower elevation of the roof. Locate the panels
according!to step 1 at the 1/4 points of the modules. Next attach the end clamps to the U-
profiles as you work along the first row, and tighten the clamps with a 6mm allen key. The solar
panels must be placed in the middle of the U-Profile as the diagram below shows. The
recommended torque to the screws of the clamps: 20 Nm.
6. Continue this process until you have installed all the solar panels. Ensure all screws and
clamps are sufficiently tightened, and your mains cable is accessible for wiring to the mains.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 10
MICRO-INVERTER INSTALLATION
1. Once you have completed installing the roof mount system, attach the Micro-Inverters to Solar
Panel Frames, or railing system using nuts, bolts or Z-Modules provided. You will need your
Hex key and Spanner. Ensure the bolts are tightened securely.
NOTE: If you are unable to bolt the inverter to the solar panel frame, use the additional U-
Supports and Z-Module clamps provided to secure the Micro-Inverter to the railing system. See
images below. (Please refer to the ‘Roof Mount Installation’ section of this manual for information
on how to fix U-Supports)
Each Micro-Inverter has serial number labels affixed. Once the micro-inverters are installed, please
peel one label off each micro-inverter and stick them to the warranty card (please refer to the
‘Completing Your Warranty Card’ section of this installation manual for more information).

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 11
2. Connect the Micro-Inverters to the AC Bus Trunk Cable
Connect the AC connector of the Micro-Inverter to the AC Bus Trunk Cable. Do this for each
Micro-Inverter in your system. Ensure a click is heard as connectors engage. Ensure that all
connections are properly closed.
WARNIING: Do NOT exceed a maximum of (5) five Micro-Inverters in an AC branch circuit when
using the Plug-In Solar System.
Cover any unused connectors on the AC Bus Trunk Cable to protect the connectors. Ensure a
click is heard as connectors engage. Ensure that all connections are properly closed.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 12
3. Install Protective End Cap onto the AC Bus Trunk Cable
a. Strip AC Bus Trunk Cable
b. Insert the cable end into the seal. !
c. Insert the wires into the cable clamps.
d. Rotate the nut with 3.3N·m until the
latching mechanism meets the base.
4. Connect Micro Inverters to Solar Panels (PV Modules)
Connect each Solar Panel to the Micro-Inverter DC cables to feed PV power into the Micro
inverter, following the polarity direction marked on each Micro inverter. Ensure a click is heard as
connectors engage.
When plugging in the DC cables, the Micro-Inverter should immediately blink green three times.
This will happen as soon as the cables are plugged in and will show that the Micro-Inverter is
functioning correctly. This entire check function will start and end within 5 seconds of plugging in
the unit, so pay careful attention to these lights when connecting the DC cables.
WARNING: Ensure that all AC and DC wiring is correct. Ensure that none of the AC and DC wires
are pinched or damaged. Ensure that all connections are properly closed.
WARNING: If you are installing an odd number of Solar panels, ensure you use the MC4 sealing
caps provided with your kit to seal the exposed MC4 connectors on the Micro-Inverter.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 13
5. If you need to extend the length of AC Bus Trunk Cable, we can supply extra lengths on
request. If you provide your own cable please be sure to use the correct cable wire size (AWG)
depending on distance of the last Micro-Inverter to the connection point and the number of
Micro-Inverters in the branch, as shown in the table below. Please be aware, the longer the
cable run, the greater the power loss.
Follow the instructions outlined below to connect the APS AC Bus Trunk Cable to your extension
cable, using a connection box, or similar (supplied upon request).

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 14
WIRING THE SOLAR TO THE EXISITING MAINS CIRCUIT
IMPORTANT SAFETY INFORMATION – FOR YOUR PROTECTION
Before installation please read these instructions carefully and use the Plug-In Solar Connection Unit in
accordance with these safety wiring instructions.
In older houses, you may find a variety of old fuse boxes where the mains supply comes in. You may also
have wiring and fittings of an older style. These may not be up to the standard required today. If this is the
case, have it all checked and tested by a professional electrician BEFORE carrying out any work on it.
Some old installations may now be dangerous.
Electricity is dangerous. Always disconnect from mains supply before any inspection or repair to equipment.
Safety must always be given top priority. Do not allow children to tamper with electrical devices.
ALWAYS FOLLOW THE IET WIRING REGULATIONS.
You must NOT install the Plug-In Solar Connection Unit in the following locations as set out by Part P:
(a) within a room containing a bath or shower, the space surrounding a bath tap or shower head,
where the space extends —
(i) vertically from the finished floor level to —
(aa) a height of 2.25 metres; or
(bb) the position of the shower head where it is attached to a wall or ceiling at a point
higher than 2.25 metres from that level; and
(ii) horizontally —
(aa) where there is a bath tub or shower tray, from the edge of the bathtub or shower
tray to a distance of 0.6 metres; or
(bb) where there is no bath tub or shower tray, from the centre point of the shower
head where it is attached to the wall or ceiling to a distance of 1.2 metres; or
(b) a room containing a swimming pool or sauna heater.
As an additional precaution, wear rubber-soled shoes. This will provide a measure of insulation between you
and the ground!
IF YOU ARE NOT ABSOLUTELY CERTAIN ABOUT ANY ASPECT OF ELECTRICAL WORK, SEEK PROFESSIONAL ADVICE
1.1. Switch off the power and remove the fuse for the relevant circuit before carrying out any
work, or inspecting, either it, or the appliances connected to it. Never inspect, or carry out work
on, any part of the system with the power on. Make sure that power cannot be inadvertently
restored by someone else.
1.2. Use a voltage tester to check the power to the wires or connections are off before touching
them.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 15
1.3. Once the power is disconnected, wire the Plug-In Solar Connection Unit using the following
instructions.
Wire Identification (if in doubt consult a qualified electrician)
EARTH – Green and Yellow Sleeving
LIVE – Red or Brown
NEUTRAL – Blue or Black
a) If using the Plug-In Solar Connection Unit to replace an old socket (or similar), note the cable
connections and wire up the Plug-In Solar Connection Unit the same way as the replaced item, with
earthing as stated in these instructions.
b) Route the cable through the appropriate entry point of the mounting box (this is usually at the rear).
c) Cables should be prepared so sufficient conductor length reaches the terminals. Strip the ends of
the individual conductors so that an adequate length enters the terminals.
d) Carefully arrange the wiring to lie along the edges of the product or box, keeping the central area
clear.
e) Wire the Plug-In Solar Connection Unit using the following diagram (a larger version can be found in
Appendix 1):
f) When connecting the Plug-In Solar Connection Unit ensure that only the bare end of the wire enters
the terminal, and no bare wires are visible. Always tighten the terminal screws, but don’t over
tighten. An earth connection should always be made between the mounting box earth terminal and
the fused connection unit terminal. If the earth wire is bare, it must be sleeved with appropriate
green/yellow sleeving.
g) If you are in any doubt about connecting this product consult a qualified electrician.
1.4. Wiring insulation tests should be completed to avoid misleading instrument readings and
possible internal damage to the unit. Check your work thoroughly before restoring power to the
circuit. If you are not certain, seek professional advice.
1.5. Once power has been restored, your Plug-In Solar kit will be feeding FREE electricity into
your mains circuit.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 16
ISOLATION/ISOLATOR REQUIREMENTS
Under G83/2 requirements, it must be possible to isolate a Plug-In Solar kit from the from the
DNO’s Distribution System, using a Double Pole Isolator. This is the function of the Plug-In Solar
Connection Unit.
The Plug-In Solar Connection Unit, is a double pole Switched Fused Connection Unit, that adheres
to British Standard BS1363-4, and offers on load isolation from the grid.
G83/2 regulations also state that the Plug-In Solar Connection Unit is lockable in the OFF position
only. This ensures isolation under maintenance. The Fuse carrier of the Plug-In Solar Connection
Unit can be locked open (the OFF position), as per the image below, in order to meet this
requirement (padlock not provided).

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 17
PLACING WARNING LABELS
When installing a Plug-In Solar kit you must place labelling at the Plug-In Solar Connection Unit,
Existing Consumer Unit and at all points of isolation between the Plug-In Solar Connection Unit
and the Solar Panels within your premises. This is to indicate the presence of a Small Scale
Embedded Generation installation (SSEG). The labelling should fixed in place to ensure that it
remains legible and secure for the lifetime of the installation. The following labels must be used and
have been provided with your Plug-In Solar kit.
Dual supply labelling should be placed at the
Plug-In Solar Connection Unit between the
PV system and Existing Consumer Unit to
indicate the presence of on-site generation
and indicating the position of the main A.C
switch disconnector.
An APS Inverter should be labelled stating
"Inverter - isolate A.C. and D.C. before carrying
out work". The Micro-Inverters also have this
warning label as standard.
An AC isolator Label should be placed next
to the Plug-In Solar Connection Unit and all
other AC switches/disconnects (if
applicable). ON and OFF positions should
be clearly labelled.
To ensure the Fire and Rescue Service are
aware that Solar is installed on the roof the
following sign shall also be fitted next to the
existing consumer unit in the building. You do
not need this label for Ground Mount systems.
In addition to this safety labelling, you must also display an electrical schematic diagram next to the
existing consumer unit in the property. You will have been provided with an electrical schematic
diagram relevant to your kit, but can see an example in Appendix 3. Please note the diagram in
Appendix 3 is non-prescriptive and is for illustrative purposes only.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 18
INSPECTING AND TESTING YOUR PLUG-IN SOLAR INSTALLATION
As part of the G83/2 on-site commissioning tests you shall carry out a functional check of the loss
of mains protection, for example by removing the supply to the Plug-In Solar kit during operation
and checking that the Plug-In Solar Connection Unit operates to disconnect the Plug-In Solar Kit
from the DNO’s Distribution System.
In the UK the installation of a Plug-In Solar Kit is considered non-notifiable electrical work under
Part P of the Building Regulations 2013, as it is an alteration to an existing installation (the mains
grid).
“Regulation 12(6A) sets out electrical installation work that is notifiable. All other electrical
installation work is not notifiable – namely additions and alterations to existing installations outside
special locations, and replacements, repairs and maintenance anywhere.”
Installation of a non-notifiable Plug-In Solar kit should still be designed, installed, inspected, tested
and certificated in accordance with BS 7671.
For more information on how to do this, you can find a copy of Part P building regulations here:
http://www.planningportal.gov.uk/uploads/br/BR_PDF_AD_P_2013.pdf

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 19
COMMISSIONING YOUR PLUG-IN SOLAR INSTALLATION
Once you have installed, inspected and tested your Plug-In Solar kit, it is a requirement that you
complete and return a G83/2 SSEG Installation Commissioning Confirmation Form to your District
Network Operator (DNO) within 28 days.
Distribution Network Operators (DNOs) own and operate the distribution network of towers and
cables that bring electricity from the national transmission network to homes and businesses. They
don’t sell electricity to consumers, this is done by the electricity suppliers. Informing the DNO of
your installation allows them to manage the grid more effectively.
There are 9 different DNO’s across the UK, so you must make sure you submit your form to the
correct DNO in your area. You can find your DNO by entering your postcode using this website:
https://www.ssepd.co.uk/Whoismynetworkoperator/
Once you have identified your DNO you must download a G83/2 SSEG Installation Commissioning
Confirmation Form from their website (or request that they e-mail one to you).
Completing G83/2 SSEG Installation Commissioning Confirmation Form
An example G83/2 Commissioning Confirmation Form can be found in Appendix 2 of this
Installation Manual. Please note G83/2 forms differ between DNO’s, this is an example only.
The G83/2 SSEG Installation Commissioning Confirmation Form is relatively self-explanatory,
however there are a number of sections that you must complete correctly:
SSEG Installation Address Details Section
A Meter Point Administration Number, also
(MPAN), is a 21-digit reference used in the
UK to uniquely identify electricity supply
points. You must correctly fill in your own
MPAN in this section of the form.
Your MPAN can be found on your electricity
bill and often looks like the image on the left.
SSEG Details Section
Within the SSEG Details section of the form,
fill in the details of your installation. The
capacity will be the size of the Plug-In Solar
kit you purchased, i.e. 1kW. The Primary
Energy Source must always be filled as ‘Solar
PV’. If you have any existing SSEG’s (e.g.
wind/solar) you must also declare these here.
SSEG Installer Details Section
As Plug-In Solar kits are DIY, self installed
solar systems you should complete this
section as the installer. In the
Accreditation/Qualification section you should
fill this in as ‘N/A (Self-Installed)’, unless you
have an appropriate accreditation. This
section of the form also needs to be signed.

Plug-In Solar
289 London Road | Burgess Hill | West Sussex | RH15 9QU
www.pluginsolar.co.uk | [e-mail] | 01444 672005
Page 20
Along with the completed G83/2 SSEG Installation Commissioning Confirmation Form, you must
also supply the DNO with the following:
1. An electrical schematic diagram for your installation (A relevant electrical schematic diagram will be
provided with your Plug-In Solar Kit). An example can be seen in Appendix 3.
2. A copy of the G83/2 SSEG Test Report Certificate for the Micro-Inverters (These can be found in
Appendix 7)
3. A photograph of your existing electricity meter (be sure to include the make and model of the meter)
Email/Fax/Post the information above to your DNO using the contact supplied on the
Commissioning Form. Do not send it to Plug-In Solar; we cannot apply to the DNO on your behalf.
When the DNO has received your form and it has been processed, you will get a confirmation
email/letter to say it has been accepted.
Notifying the DNO of changes to a Plug-In Solar kit
If during the lifetime of the Plug-In Solar kit it is necessary to replace a major component of the
Plug-In Solar kit, it is only necessary to notify the DNO if the operating characteristics of the Plug-In
Solar kit or the Plug-In Solar Connection Unit have been altered when compared against the unit
that was originally commissioned.
Notifying the DNO of the decommissioning of a Plug-In Solar kit
In the event that a Plug-In Solar kit is to be decommissioned and will no longer operate as a
source of electrical energy in parallel with the DNO’s Distribution System, you must notify the DNO
by completing a G83/2 SSEG Decommissioning Confirmation Form. Please contact your DNO for
a copy of this form.