SolarWorld Sunfix Bisun User manual

Instruction sheet
www.solarworld.com
MOUNTING SYSTEM FOR SOLAR POWER
SYSTEMS
PLANNING AND DESIGN
Original instruction sheet for installers

22
Proven quality – simply clever
With the for solar power systems, you have purchased a high-quality product from the SolarWorld
AG product range.
To ensure that the solar power system runs smoothly, all components selected and used in the mounting system
are of the highest quality. The following instructions describe the correct installation of the based
on an example. This should help you to easily install the mounting system. The appearance of special structural
features must be documented so that the unique features of the roof can be considered in the system planning.

33
Contents
Page
Notes on safety A1 Classification of the safety instructions 4
A2 Safety instructions 5
A3 Notes on system planning 6
A4 Notes on installation 7
System description B1 Intended and improper use 8
B2 Technical overview 9
B3 System construction 10
Installation example C1 Defining the system position 13
C2 Roof area measurement 14
C3 Placing supports 15
C4 Module installation 16
C5 Installation second row 17
C6 Heavy load rail 18
C7 Placing ballast stones 19
C8 Connecting modules 20
C9 Grounding/electric bonding 21
Maintenance/cleaning Maintenance and cleaning 22
Liability Liability 22
A
B
C
D
E

44
Notes on safety
fEnsure that the Sunfix Bisun is only used where suitable. During installation, ensure compliance with appli-
cable local ordinances, building standards and accident prevention guidelines. The safety instructions for
other system components must also be followed.
fFailure to follow all instructions listed below may result in electric shock, fire and/or serious injury.
fCarefully store instruction sheet!
Warning signs, signal word Warning levels
DANGER! Warns of imminent death.
WARNING! Warns of possible death and/or serious injury.
CAUTION! Warns of possible personal injury.
ATTENTION Warns of damage without the possibility of personal injury.
Read all installation instructions and observe the safety instructions!
Use of additional information symbols
Provides additional important information.
Consider applicable accident prevention guidelines during installation.
Walking on modules is prohibited.
A1 Classification of the safety instructions
A

55
A2 Safety instructions
DANGER!
Danger of death from electric shock
fSolar modules generate electricity as soon as they
are exposed to light. The voltage of a single modu-
le is lower than 50 V direct current (DC). When
several modules are connected in series, the total
voltages are cumulative and dangerous. When
several modules are connected in parallel, the cur-
rents are cumulative. Although touch protection
is provided in the form of the fully insulated plug
contacts, the following points must be observed
when handling the solar modules to avoid the risk
of fire, sparking and dangerous electric shock:
fDo not install solar modules and wiring using wet
plugs and sockets!
fUtmost caution must be exercised during all work
on the wiring!
fThe inverter can produce high touch voltages,
even when not connected!
fExercise caution during all work on the inverter
and wiring!
DANGER!
Danger of death from arcing
fModules generate direct current (DC) when light
strikes them. When breaking a connected string
of modules (e.g. when disconnecting the DC line
from the inverter under load), a dangerously
strong arc can occur. Note the following:
fNever remove the solar generator from the inver-
ter while it is still connected to the grid.
fEnsure that the cable connections are in perfect
condition (no gap, soiling)!
WARNING!
Danger of falling
fThere is a risk of falling when working on the roof
and when climbing up and down. You must obser-
ve the accident prevention guidelines and use
suitable fall protection equipment.
WARNING!
Flammable materials
fModules must not be operated near equipment or
in locations where flammable gases or dusts are
emitted or can collect.
CAUTION!
Hand injuries
fHands can be crushed during the installation of
support frames and modules.
fWork may only be carried out by trained sta.
fUse protective gloves!
CAUTION!
Falling objects
fWhen mounting on the roof, there is a risk of tools,
mounting materials or modules falling from the
roof and injuring persons who are present below.
fCordon o the danger area on the ground before
starting installation work, and warn persons in the
vicinity.

66
A3 Notes on system planning
fMake sure that the substructure is suitable in
terms of load-carrying capacity (dimensioning,
state of maintenance, appropriate material spe-
cifications), support structure and other aected
layers (e.g., insulation layer).
fMake sure that precipitation run-o is not impe-
ded.
fPay attention to the physical construction aspects.
fThe flatness of the roof substructure must be
checked and, when necessary, repaired according
to professional practice.
fIf you have any doubts consult a specialist
(e.g. stress analyst, technical expert).
fProtect outdoor cables against weathering, UV
light and mechanical damage with suitable measu-
res (for example, by laying them in UV resistant
plastic tubes or cable ducts).
ATTENTION!
fDuring installation of the mounting system,
escape, rescue and maintenance routes must be
observed and kept clear!
CAUTION!
fThe horizontal forces acting on the PV system
from wind loads are transmitted through non-slip
mats to the roof structure through static friction.
For a correct system design, it is therefore neces-
sary during planing to determine the static friction
value between mounting system and roof mem-
brane.

77
fConsider applicable accident prevention guidelines
during installation.
fObserve the applicable engineering guidelines
during roof installation.
fObserve the applicable rules and standards during
installation and commissioning.
fSecure people located on the roof of a building 3 m
or higher with fall protection.
fUse cordons to protect people on the ground from
falling objects.
fAlso follow the safety instructions of all other
system components (e.g. inverters and modules).
fOnly have the system connected to the public
grid by a qualified electrician. Note the mounting
instructions delivered with modules and inverters,
as well as the mounting and wiring plan
fEnsure that all screw connections are securely
fastened.
A4 Notes on installation
Required tools / Additional required materials
Cordless screwdriver
Allen key
5 mm and 6 mm
Tape measure
Chalk line
Torque wrench
Ballast elements
(e.g. paving slabs)

88
B1 Intended and improper use
System description
B
Intended use
The mounting system Sunfix Bisun is for the installati-
on of solar power modules on flat roofs of conventio-
nal design and height.
Intended use includes observing the instruction sheet
and compliance with the maintenance and cleaning
instructions provided. The manufacturer accepts
no liability for damage caused by not following the
instruction sheet.
Improper use
This list does not include all conceivable types of
improper use and thus does not claim completeness.
The advice provided is only intended to convey a sense
of improper use.
fThe advice provided in this installation sheet has
been disregarded.
fThe mounting system was:
• not used properly for the fastening of solar
power modules,
• not installed according to the conditions
described in this installation sheet (e.g., for the
attachment to walls),
• incorrectly mounted,
• incorrectly or not maintained,
• altered,
• subjected to improper loads.
fA repair was performed improperly.

99
B2 Technical overview
The Sunfix Bisun mounting system is a versatile sup-
port structure for the installation of solar modules on
flat roofs. It is individually prefabricated as a complete
kit. The basis of individual planning consists of data
from the existing roof structure and the structural
requirements (snow and wind loads, etc.) at the
installation site. Every system is provided with an
“system layouts” and “DC wiring plan” specific to your
system. These define the arrangement of the Sunfix
Bisun elements, as well as the module cabling to the
inverter, all matched to suit your roof construction
and module arrangement.
Properties of the Sunfix Bisun mounting system
fPermitted building height H ≤ 25 m
fPermitted roof pitch ≤ 5° (flat roof)
fModule tilt 10°
fMinimum size per module array 3 x 3 modules
fMaximum size per module array 10 x 10 modules
fStandard static friction values:
Membrane roof with rubber mats (foil-laminated): µ ≥ 0.7
Divergent values are possible and can require more or less ballast.
fThe required ballast is determined as part of the system planning and depends on system size, wind load
(location, building height), static friction value between system and roof, and presence of a parapet.
fFlat roof insulation: We assume that the existing flat roof insulation is at least equivalent to the application
type DAA dh according to DIN 1408-10.
NOTE
The positional security of the system is ensured by
the dead weight and ballast. The measurement is
done according to Eurocode EN 1991. Nevertheless,
after extreme wind events, but at least once per
year, the condition of the system must be checked,
since a shift of a few centimeters can never be
completely ruled out.

1010
B3 System construction
Fig. B 3-1 Detail 1 Fig. B 3-1 Detail 2
Fig. B 3-1 System construction
AB
36
4
B
A
5
7
4
3

1111
Fig. B 3-1 Detail 3
Sunfix Bisun component list
1Module
2Front rack
3Connecting rack
4End rack
5Ballast tray (237 cm x 30 cm)
6Ballast stone (e.g. paving slab 30 cm x 30 cm)
7Heavy load rail
C
2
C
1
6
2

1212
Dimensions system construction (For reference only)
Fig. B 3-2 System construction
Fig. B 3-3 System construction side view

1313
Installation example
As an example, the installation of a system with 3 x 3 modules is described.
Fig. C 1-1
C1 Defining the system position
NOTE
Edge clearances:
When installing systems on flat roofs, it should be
noted that in the edge areas of roofs, special load
assumptions must always be made due to possibly
occurring turbulence. Details can be found in EN
1991 (Eurocode 1). Sunfix Bisun systems from Solar-
World can only meet these requirements when a
constant distance of at least 1.5 m is maintained by
the solar power system to the roof edge or parapet.
It is not permitted to go below this minimum
distance.
Securing against slippage:
Due to thermal expansion of the metal compon-
ents of the Sunfix Bisun system from SolarWorld,
in extreme cases, movement of the system on the
roof in the direction of the eaves may occur. This is
relevant for roofs with a tilt angle of 3° or more. In
this case, the system must be secured against long-
As a rule, all work undertaken by the customer on the roof to provide additional fastening of SolarWorld
Sunfix Bisun systems must adhere to the relevant engineering guidelines, in particular in terms of the proper
structural sealing of penetrations of the roof membrane.
term slippage by the customer. There are several
methods available, as shown in the following list:
fFor roofs with a symmetrical arrangement or a
central ridge, protection against slippage can be
achieved by bracing the two system parts (equal
weight) over the ridge.
fIf other points of attachment are present, it must
be checked whether these can also be used.
fFixing using a suitable connection to the parapet
also represents an alternative, however this must
also be checked and implemented by the customer.
C
1,5 m

1414
C2 Roof area measurement
NOTE
A maximum of 10x10 modules should be installed
in a contiguous generator array. Here, a maximum
of only 10 transverse modules may be interconnec-
ted! Then, a new generator array must be started
in each direction!
1. Before beginning installation, the roof must be
measured according to planning documents and
the first point of installation must be determined.
It is advisable to mark the front baseline using the
Fig. C 2-1
chalk line, and then to measure the lateral
boundary line at right angles and to mark it
accordingly.

1515
Fig. C 3-3 Fig. C 3-4
Fig. C 3-1 Fig. C 3-2
90°
1,5 m
1,5 m
C3 Placing supports
1. After determining the total base area of the
system, mark the distance to the front supports,
position them and connect them with a ballast
2. Place the connecting supports and measure the
distance to the front supports. The connecting
supports can still be repositioned in the course of
tray. To protect the roof membrane, four rubber
mats must be placed below each ballast tray.
the module installation. Then position the next
connecting supports.
Torque value MA= 15 Nm for M8 bolts
Driver: Allen key SW6
Remove plastic film
ca. 1131 mm

1616
C4 Module installation
fPlace modules on the fastening supports and tigh-
ten the module clamps with 10 Nm.
fBeginning with the second module, before
placement, the cables are attached to the plug
Torque force MA= 10 Nm
Driver for module clamping: 5mm allen key
connections and these are secured to the module
frame using cable tie clips.
Fig. C 4-1

1717
C5 Installation second row
1. After completing the first row, the distance to the
next module row automatically results, and the
installation process is repeated as from Fig. C 3-2.
In the final back row, the end supports are placed
and ballast is again added according to planning
specifications. The number and positioning of the
ballast stones may change depending on wind
loads.
Fig. C 5-1
Fig. C 5-1 Detail 1 Fig. C 5-1 Detail 2

1818
C6 Heavy load rail
Fig. C 6-1
Fig. C 6-1 Detail 1 Fig. C 6-1 Detail 2
1. Depending on project specific wind and snow loads
a heavy load rail may become applicable to sup-
port the modules. If your project documentation
reflects the application of heavy load rails, two rails
per module are to be attached to each long side of
the frame. Make sure that the mounting holes of
the rails will align with the mounting holes of the
frame. The final position of the rail is locked by two
bolts (without nuts).

1919
C7 Placing ballast stones
Fig. C 7-1
Fig. C 7-2
Fig. C 7-4
Fig. C 7-3
Fig. C 7-5
NOTE
Ballast should be evenly distributed.

2020
C7 Connecting modules
1. Wire the modules using the connection diagram.
fYou must adhere to the specifications of the con-
nection diagram (allocation of strings, possible
switches, cable group). Faulty wiring can destroy
the inverter and/or the modules.
fIn order to keep the inductive coupling as low as
possible in the event of a lightning current, string
feed and return lines (+/-) should be run as close
together as possible (avoid looping).
fThe bending radius used for the cables may never
be less than the minimum bending radius (5x cable
diameter).
fDo not lay or install modules at temperatures
below -5° C.
fKeep plugs and sockets dry during assembly.
2. Lay the cable group.
3. Here, fasten the cable to the supporting profile using
UV-resistant cable ties .
4. Mount and wire the subsequent module rows.
Ensure the correct polarity.
Testing
1. Check the correct generator interconnection of the
multi-string solar generator by measuring the
open-circuit voltages of the individual strings.
2. Comparethemeasuredvalueswiththespecifications.
Values deviating from the specifications are an indica-
tion of a wiring fault.
1 Grid
2 Inverter
3 Solar power generator
String 1
String 2
1
2
3
DANGER!
Potentially lethal voltages
fConnecting modules in series can lead to potenti-
ally deadly voltages!
fDo not connect the inverter for a test.
fThe solar power system may only be connected
to the public grid and activated by an authorized
electrician.
fThe technical description provided with the equip-
ment is binding with regard to the installation,
electrical connection and operation of the inverter.
ATTENTION!
fBe sure to follow the currently valid instruction
sheet for the assembly of multi-contact plug con-
nectors. Only use approved tools for the assembly
of the cable groups. Do not deviate from the pro-
cedures described in the instruction sheet, since
otherwise, neither safety nor compliance with
the technical data can be ensured during self-
assembly.