SolarWorld SunCarport User manual

www.solarworld.com
03/2010
from SolarWorld®
Version: Tilt in crosswise direction
Planning and Implementation.
Translation of the original instruction manual for installers

2
Proven quality – simply clever
Congratulations and thank you for choosing this high-quality from SolarWorld AG. Only the high-
est quality components are used in order to ensure trouble-free operation of your photovoltaic (PV) system as
well as stability and usability of your carport.
The directions below are intended to assist you in properly installing your system and avoiding
problems.
Date: 03/2010

3
Table of Contents
Safety information A1 Types of safety notices 4
A2 Safety 5
A3 Comments regarding system planning 6
A4 Installation 6
System description B1 Technical Overview - Mounting System 7
B2 System arrangement 8
B3 Location conditions 10
Installation C1 Foundations 11
C2 Installing side panels 13
C3 Installing battens/cross braces 18
C4 Aligning and building foundation 21
C5 Module attachment 22
C6 Module wiring 23
C7 Installing trapezoid sheets 24
C8 Installation of cover plate 27
C9 Installing rain gutter 27
C10 Installing inverter 28
C11 Grounding: 28
Maintenance/Cleaning Maintenance and cleaning 29
Liability Liability 29
A
B
C
D
E
Page

4
Safety informationA
A1 Types of safety notices
Read the entire instruction sheet and observe the safety information!
Warning symbol, signal word Warning level
DANGER! Warns of immediate risk of death.
WARNING! Warns of possible risk of death and/or severe injury.
CAUTION! Warns of possible personal injury.
CAUTION Warns of possible property damage without possibility of injury.
Additional notice symbols
Indicates additional important information.
Observe applicable accident prevention regulations during installa-
tion.
Do not stand or walk on modules.
fEnsure that the SunCarport® is used only as intended. Observe local standards, building codes and accident
prevention regulations during installation. Safety information for other system components must also be fol-
lowed.
fNoncompliance with the following instructions may result in electric shock, fire and/or severe injury.
fKeep this instruction manual in a safe place.

5
A2 Safety information
DANGER!
Risk of fatal electric shock
fSolar modules generate electricity as
soon as they are exposed to light. Direct
current voltage of each individual module
is less than 50 V. When several modules
are connected in series, the resulting
total voltage can be dangerously high.
When several modules are connected
in parallel, the currents are cumulative.
Although touch protection is provided in
the form of the fully insulated plug con-
tacts, the following must be observed
when handling the solar modules to
avoid risk of fire, sparking and fatal elec-
tric shock:
fDo not install solar modules and lines
with wet sockets and plugs!
fAll work on the lines must be carried out
with extreme caution!
fHigh contact voltages can occur in invert-
ers even when disconnected!
fCaution is advised in all work on the
inverter and lines!
DANGER!
Risk of fatal arcing
fModules generate direct current (DC)
when exposed to light. When break-
ing a connected string of modules (e.g.,
when disconnecting the DC line from the
inverter under load), a dangerous arc can
occur. Observe the following:
fNever remove the solar generator from
the inverter while it is still connected to
the power grid.
fEnsure that cable connections are in
perfect condition (no cracking or soiling
between socket and plug)!
WARNING!
Risk of falling
fRisk of falling when working on the roof
of the SunCarport and when climbing up
and down. Observe accident prevention
regulations and use suitable fall protec-
tion equipment.
CAUTION!
Risk of hand injury
fHands may be crushed during frame and
module installation.
fWork must be carried out by trained per-
sonnel only.
fWear protective gloves!
WARNING!
Flammable materials warning
fModules must not be operated in the
vicinity of equipment or spaces where
flammable gases or dust may occur or
collect.
CAUTION!
Beware of falling objects
fDuring installation, there is a risk of tools,
mounting materials or modules falling
from the roof and injuring persons below.
fBlock o the area at risk on the ground
before starting installation work and
warn persons in the vicinity.

6
A3 System planning
fBuilding a secure and statically flawless foundation
in the ground must be ensured for the subsequent
construction of the support structure (Please see
item C1, Foundation).
fIn case of doubt, consult an expert (e.g., a struc-
tural engineer, expert).
fProtect cables installed out of doors from weather,
UV light and mechanical damage using suitable
precautions (such as use of UV-resistant plastic or
metal conduits).
fObserving the instruction sheet and exclusive use
of provided materials and components is manda-
tory.
A4 Comments regarding installation
fEnsure that all work on the PV system (installation,
start-up, maintenance, repair) is carried out exclu-
sively by appropriately qualified and authorized
personnel.
fObserve applicable accident prevention regula-
tions during mounting.
fUse safety equipment to protect persons on the
ground below from falling debris.
fCompliance with all applicable VDE and DIN direc-
tives and standards is mandatory during the
installation and start-up process.
fPrior to installation, the inverter location must be
determined (left or right side of the carport or in a
dierent location of your choice).
fIn addition, please ensure compliance with the
safety instructions for all other system compo-
nents. Observe the instruction sheets for modules
and inverters included with the products.
fThe installation can also be carried out as a DIY
project. In this case we recommend that 4 persons
are present.
fComply with the stated torque values to ensure
safe seating of all threaded connections.

7
System description B
Proper use
The Carport serves as a shelter for vehicles. Whether
attached to a building or free-standing, the structure
is able to accommodate a photovoltaic system on its
roof, which has a 10° tilt. Proper connection to the
foundations is achieved using foundation adapters.
Solar modules convert light into electricity as a result
of the photovoltaic eect. Solar modules are primarily
designed to be connected to an inverter for the pur-
pose of generating electricity to be fed into the public
power grid. Solar modules must not be connected
directly to electricity consumers. Do not concentrate
sunlight onto the modules using mirrors or lenses.
Proper use includes observing the instruction manual
and following the guidelines for maintenance and
cleaning. The manufacturer does not assume any
liability for damages resulting from failure to follow
the instruction manual.
Improper use
This list does not contain all conceivable types of
improper use and thus does not make any claim
of completeness. It is intended merely to provide
examples of improper use, such as the following:
fThe comments in this installation manual were
disregarded.
fUser information for SolarWorld® solar modules
was disregarded.
fThe system was
-not properly used to generate electricity,
-improperly connected,
-improperly mounted,
-improperly started up,
-improperly operated,
-improperly maintained or not maintained,
-overloaded.
fThe system was altered.
fRepairs were improperly carried out.
fThe system was operated in combination with
components from other manufacturers.
B1 Technical Overview - Mounting System
Technical Description:
fStructural analysis according to Eurocode 1/DIN
1055
fDocumentation for building permit (structural
engineering, construction drawings) upon request
fLight aluminum profile construction, aluminum
and stainless steel connecting elements
fTransport friendly and pre-assembled kit, complete
installation on site
fTrapezoid sheet with rain gutter to catch and
divert water.
fArrangement suitable only for vertical positioning
of supports (compensation for height dierences
in grade via foundations)
fWeather-resistant and low-maintenance structure
consisting of aluminum and stainless steel compo-
nents
Eective loads are transferred to the subsoil via
concrete foundations or screw-in ground anchors. The
foundations are not part of the kit.
Roof pitch 10°
PV system generator power approx. 2.30 kWp
with SW230
Total weight approx. 750 kg
Footprint ca. 19.70 m²
Width 5241 mm
Length 3757 mm
Clearance height* 2.00 m*
Dimensions concrete foun-
dation a x b x h
60x60x60 frost-
protected
*may deviate depending on terrain.

8
B2 System arrangement
h
a
w
17
14
10
22
33
24
19
D
C
Fig. B 2-1
A
B
25 2 6
28
29
8
9
32
31
3
26
E
34
22a

9
No. Designation Pieces
Ver-
sion:
N
Ver-
sion:
SL
1Foundation ─ ─
2Support frame short 02 02
3Support frame long 02 02
4Schnorr washer D=8mm 51 67
5Zylinder head bolt M8x16 A4 51 67
6Gusset plate 03 03
7Reinforcement bracket 100° 02 02
8Reinforcement bracket 80° 02 02
9Supporting profile left 01 01
10 Supporting profile right 01 01
11 Head bolt M8X25
(support)
16 16
12 Head bolt M8x17
(Cross bracing, inverter, rain gutter)
25 25
13 Flange nut M8 A2 92 104
14 Battening/Cross brace 5061mm 06 08
15 Slot nut M8 32 48
16 Corner bracket 70mm 08 12
17 Head bolt M8X49 A2 24 36
18 Connection disc D=36mm 24 36
19 Cover plate 5241mm 01 01
20 Schnorr washer D=6mm V2A 20 20
21 Self-tapping screw JT3-2-6.5x65 20 20
22 Trapezoid sheet TP20/125 long 05 05
22aTrapezoid sheet TP20/125 short 05 05
23 Screw Ejot JT4-6-5,5x22-E16 86 128
24 Rain gutter 5241mm 01 01
25 Foundation adapter 04 04
26 Gusset plate WR crosswise 01 01
27 Head bolt M8x22 (Reinforcement
bracket/supporting profile connec-
tion)
26 29
28 Conduit 25x4000mm 01 01
29 Conduit 38x300mm 01 01
30 PE tape 2x40mm 20m 01 02
31 Inverter plate 01 01
32 Logo plate 01 01
33 Module 1675x1001mm 10 10
34 Inverter 01 01
35 Gutter stabilizer 01 01
36 Drill support 01 01
4
Fig. B 2-2 Support connection
5
A
Fig. B 2-3 Connection aluminum frame beam
15
16 4
5
30
B
18
17
Fig. B 2-4 Module clamp
13
C
Fig. B 2-5 Cover plate connection
21
20
D
Fig. B 2-6
E

10
Vd
Hd
Building the foundations
The subsoil must have sucient load bearing capacity
to absorb eective loads safely. The eective loads are
summarized in the following table:
Version N
Maximum bearing strength
Vp[KN] Hp[KN]
LCC 1
(snow+wind pressure)
-9.90 (pressure) 0.70
LCC 2
(wind suction)
7.40(suction) 1.20
Remarks:
LCC = Load case combination according to DIN 1055/
Eurocode
Vp= Vertical pressure design according to DIN 1055/
Eurocode
Hp= Horizontal pressure design according to DIN 1055/
Eurocode
Version SL
Maximum bearing strength
Vp[KN] Hp[KN]
LCC 1
(snow+wind pressure)
-16.70 (pressure) 0.90
LCC 2
(wind suction)
7.40(suction) 1.20
B3 Location conditions
SunCarport can be used in areas with the following
wind and snow loads according to Eurocode
.
[KN/m²] Version N Version SL
Permissible
Snow Load sk
1.21 2.58
Permissible
Wind Load w
0.65 0.65
Fig. B 3-1 Foundation adapter with foundation and loads
Foundation adapter

11
Installation C
Essentially, the SunCarport® consists of aluminum
frames bolted together using angle brackets and gus-
set plates. PV modules are installed onto the roofing
battening; the trapezoid sheet for roof drainage is
screwed to battening from below.
All necessary materials and mounting components
CAUTION!
Risk of hand injury
fHands may be crushed during frame and module
installation.
fWork must be carried out by trained personnel
only.
fWear protective gloves!
are part of the kit and included in the delivery. The
foundations are built on site with reinforced concrete
or screw-in ground anchors.
The arrangement of the SunCarport® is described
below. It is secured with standard foundation adapt-
ers axed to the cured foundations.
C1 Foundations
To be able to absorb wind suction loads securely, the
foundation must be built with reinforced concrete, be
frost-protected, and measure a x b x b 60x60x60cm.
Ordinary soil conditions do not require reinforcement.
When in doubt, a structural engineer should be con-
sulted. In the alternative, the foundation can be built
using screw-in ground anchors. The foundations must
correspond to the dimensions given.
Fig. C 1-1 Foundation dimensions [mm]
Front viewSide view
GradeGrade
Fig. C 1-2 Foundation dimensions [mm]
600 600
3070 5151

12
Connection of supports:
fFoundation adapters to be bolted to cured founda-
tion (e.g. with connection anchors, see Fig. C 1-3)
The PV system cables are routed into the ground
through one of the two long supports. To accom-
plish this, conduit ø 50mm must be embedded into
the concrete
(see Fig. C 1-3).
Fig. C 1-4 Foundation adapter on foundation
Fig. C 1-3 Conduit placement
Conduit
Foundation
Roof structure
Inverter plate
(mounting optional)
Cable
Anchoring provided by the
customer

13
4
5
C2 Installing side panels
The first step is to install the side panels.
Installing foundation adapters
fPush foundation adapters into the support frames
and bolt together using cylinder head bolts M8x16.
Torque MA= 20 Nm
Fig. C 2-1 Side view mounted side panel
Fig. C 2-3 Foundation adapter
with mounted support frame
Fig. C 2-2 Foundation adapter/
support frame

14
Fig. C 2-7
45
Fig. C 2-7a
7
6 2
Fig. C 2-4 Fig. C 2-5
11
Installation of 100° reinforcement brackets and gus-
set plates (short supports).
fInsert head bolts M8x25 (4 pcs./support) into the
support frames (see Fig. C2-4 and C2-5).
fPlace pre-drilled gusset plates and reinforcement
brackets onto head bolts and tighten with nuts.
Make sure the reinforcement brackets and gusset
plates of each support are facing the interior of the
carport. (see Fig. C3).
Torque MA= 20Nm
Fig. C 2-6 Mounting angle 105° and gusset plate
Reinforcement
bracket
Gusset plate Supporting
head

15
Fig. C 2-10
Abb. C 2-8
11
12
Fig. C 2-9
27 12 27
x6 x6
x3
12
27 27
Installation of 80° reinforcement brackets and gusset
plates and (optional) inverter plate.
NOTE: If desired, inverter plate must be installed
at this point! Subsequent installation requires
increased time and expenditure!
Variant 1: Inverter installation right
(view of eaves)
fInsert head bolts (4 pcs./angle plate) into long sup-
port frames. If installing inverter plate, 2 additional
head bolts must be inserted into the inner groove
(see Fig. C2-8). Install and bolt together gusset
plates and reinforcement brackets the same as
with short supports.
fInsert head bolts (6 pcs./reinforcement bracket)
into long supporting profiles. If installing inverter
plate, 3 additional head bolts must be inserted
into the inner groove (see Fig. C2-9). Bolt together
supports and supporting profiles (Fig. C2-10); make
sure positioning tabs are inserted into slots.
View of variant 1 - inverter right

16
Fig. C 2-13
Fig. C 2-12
27 12 27
x6 x6
x3
27 12 27
Fig. C 2-11
11
12
Variant 2: Inverter installation left (view of eaves)
fInsert head bolts (4 pcs./angle plate) into long sup-
port frames. If installing inverter plate, 2 additional
head bolts must be inserted into the outer groove
(see Fig. C2-11). Install and bolt together gusset
plates and reinforcement brackets the same as
with short supports.
fInsert head bolts (6 pcs./reinforcement bracket)
into long supporting profiles. If installing inverter
plate, 3 additional head bolts must be inserted
into the outer groove (see Fig. C2-12). Bolt together
supports and supporting profiles (Fig. C2-10); make
sure positioning tabs are inserted into slits.
View of variant 2 - inverter left

17
Overview side panel
Variant 3: Installation without inverter plate
fIf you do not intend to install the inverter plate to
the carport, installation of the inverter plate is not
necessary. Supports and supporting profiles as well
as frame brackets and gusset plates are installed
as in variants 1 and 2.
Fig. C 2-14 Overview side panel after installation
Inverter plate (optional)
Support frame short
Support frame long
Reinforcement bracket 100°
Supporting profile
Reinforcement bracket 80°
2742
2201
3070
3419

18
Fig. C 3-1
Fig. C 3-3
Fig. C 3-2
ca. 30 mm ca. 30 mm
Fig. C 3-4
13
C3 Installing battens/cross braces
At this point, the support grid for the roof is installed.
Installing cross braces
fPlace side panels of carport in upright position.
Attach two cross braces to the four existing gusset
plates and bolt together using head bolts M8x17
(per conn. 4 pcs.).
Attach tape to battening
fOn each of the remaining 4 cross braces (version SL
6 cross braces), attach PE tape to a narrow side.
The taped sides will serve as contact areas for the
trapezoid sheets yet to be installed.
fA clearance of approx. 30 mm must be kept on
both edges.
PE tape

19
Fig. C 3-6
Fig. C 3-5
16 30
14
WARNING!
Risk of falling
fRisk of falling when working on roofs
fUse appropriate fall protection equipment
fObserve accident prevention regulations.
CAUTION!
Beware of falling objects
fDuring installation, there is a risk of tools, mount-
ing materials or modules falling from the roof and
injuring persons below.
fBlock o the area at risk on the ground before
starting installation work and warn persons in the
vicinity.
Installing battening
fInsert slot nuts into the appropriate grooves.
fBolt battening to supporting profiles using corner
brackets. Distance between battening according
to Fig. C3-6 must be observed.
Note: Lateral corner brackets must be installed in
opposing directions.
(see Fig. C3-7)!

20
Fig. C 3-7 View of support grid from below Version N
340 1140 570 1140 265
Corner
bracket
16
Battening
Top
PE tape taped to
underside
Position
modules
Bottom
Gap
(for draining
rain water)
9
99
Top
Bottom
9
Gap
(for draining
rain water)
99
Battening
16
PE tape
taped to
underside
304 570 570 570 570 570 265
Support grid variant N (4x battening)
Support grid variant SL (6x battening)
Fig. C 3-8 View of support grid from below Version SL
Diagonal dimension D
Diagonal dimension D