SolarWorld Suntub User manual

SolarWorld. And EveryDay is a SunDay. www.solarworld.de
July 2009
Flat roof assembly system
esign and installation

ate: July 2009
Proven quality – simply clever
Congratulations and thank you for choosing the high-quality Suntub® Assembly System from
SolarWorld AG.
The Suntub® Assembly System is weighted with ballast (gravel, blocks, etc.) in order to resist
wind loads. The required ballast load can be customized – based on tested dimension tables –
to fit the situation and provide an optimized, safe installation.
Only the highest quality components are used in order to ensure trouble-free operation of your
PV system.
The directions contained here are intended to assist you in properly installing your Suntub®
Assembly System.
Since individual circumstances may vary, you are advised to seek expert assistance in adapting
these recommendations to your particular roof situation.
The information provided in these installation instructions is based on the relevant standards
and regulations valid in Germany. If you are installing the Suntub® Assembly system outside of
Germany, please be sure you know and understand the relevant standards and regulations for
your area.

Contents
Page 4 A 1 Safety warnings
Page
5 A 2 System design
Page
6 A 3 Installation
Page
8 B 1 Dimensions
Page 8 B 2 Required ballast load
Page 10 B 3 Shading table
Page
12 C 1 Setup
Page
15 C 2 Module connection
Page
16 C 3 rounding
Page
17 Maintenance/Cleaning/Liability
A Safety instructions
B Technical overview
C Assembly
Maintenance/Cleaning/
Liability

4
Please read all safety instructions and information carefully!
The Suntub® is intended for mounting SolarWorld Sunmodules on flat roofs only. Other uses are considered
unsafe. Observe local ordinances, building standards and accident prevention regulations during installation.
Any safety information and/or requirements for other system components must also be followed.
Keep this manual for future reference!
Risk of death by electric shock
Solar modules generate electricity whenever they are exposed to light. The voltage of a single module is less
than 50 V C. When several modules are connected in series, the total voltage can be dangerously high. When
the modules are connected in parallel, the currents are cumulative. Although touch protection is provided in the
form of the fully insulated plug contacts, the following points must be observed when handling solar modules
to avoid the risk of fire, sparking and fatal electric shock:
o not install solar modules and cables while plugs and sockets are wet!
Perform any work on cables with utmost care!
High contact voltage in the grid connected inverter is possible even in the isolated condition!
Care should be taken when performing any work on the grid connected inverter and the cables!
Risk of death by electric arc
Modules generate direct current ( C) when any amount of light shines on them. When breaking a connected
string of modules (e.g., when disconnecting the C line from the inverter under load), a lethally strong arc can
occur:
Never remove the solar generator from the inverter while it is still connected to the main grid!
Ensure that the cable connections are in perfect condition (no cracking, soiling or other contamination)!
Safety instructions
A
A1 Safety warnings

5
eneral safety instructions
Ensure adequate load capacity (based on dimensions, condition and material properties) of the substructure,
support structure and other affected layers of the roof (such as an insulation layer).
Materials suitable for the ballast include concrete slabs, gravel or similar. If gravel is used, it must be secured
against rolling away.
When using ballast for position stability, make sure the substructure has sufficient reserve load capacity.
Check whether protective mats are needed.
• If so, be sure that they are of suitable materials.
• If you are uncertain as to the compatibility of the protective mat and roof flashing materials, we recommend
putting in a separating mat layer.
Make sure that the runoff of rainwater is not impeded.
Consider any physical or structural issues.
Any assessment of structural or functional suitability of the roof to support the PV array should be conducted
by a qualified professional such as a structural engineer.
Protect cables from weather, UV light and mechanical damage using suitable precautions (such as UV-resis-
tant plastic or metal conduits).
The distance between the module rows is calculated individually from the angle of inclination of the modules
(28°) and the minimum angle of insolation at your location.
Safety information for the edge areas
The Suntub may not be installed within the edge or corner areas of the roof. These areas are subject to air turbulence
and considerably elevated wind loads (see EC1, Wind loads).
A2 System design
a1
a2
h
w
d
Recommended edge distances a:
a1≥ 0,2 × h a2≥ 0,2 × h
h Building height
w Building width
d Building depth
Fig. A2.1

6
A3 Assembly
eneral safety instructions
Ensure that any work on the PV system (installation, commissioning, maintenance, repair, etc.) is performed
by qualified professionals.
Observe all local and national code requirements for the prevention of accidents, including those that may
supersede this installation guide.
Ensure that fall protection is used on buildings that are greater than 3 m tall.
Protect persons on the ground against falling objects with appropriate barriers.
Observe any safety instructions provided with other system components.
Comply with any local codes and standards applicable in the relevant country for installation and commis-
sioning.
The system connection to the public grid may only be performed by a qualified electrician who may be
required to provide a certificate from the respective utility (Regulations in the relevant country must be
observed.)
For installation in roof areas, observe the applicable rules and standards for the respective country.
Special safety instructions
Observe installation instructions for modules and grid connected inverters as well as the installation and
wiring diagram enclosed with the delivered system.
The work should be performed by a qualified professional.
Ensure that all bolted connections are tightened to a torque of 20 Nm.

7
System assembly overview B
The Suntub® Assembly System for flat-pitched roofs is a support structure for the lengthwise installation of
PV modules. It consists of a black plastic body (100% recycled H PE) with aluminium and stainless steel mount-
ed parts. The excellent ventilation of the modules optimizes the output of the PV system. The ballast required to
secure the unit against wind loads is provided by the customer in the form of gravel or concrete slabs, etc.
The roof pitch must be between 0° and 6°.
All mandatory framework conditions and technical data are summarized in the following table:
Components
1. Module
2. Clamp
3. Aluminium profile (to be inserted)
4. Suntub, right part
5. Suntub, left part
6. Connectors (optional)
Basic material 100% recycled, UV-resistant H PE
Module tilt 28°
Allowable roof pitch 6°
Net weight approx. 14kg (not including module and ballast)
Required ballast Gravel, concrete blocks (recommended size 40x40cm) or similar materials
Required loads according to table on page 9
Module type SolarWorld 200-230
Check with SolarWorld AG for compatibility with other modules
Operating temperature range -40° to 85°C
Warranty 10 years
Allowable building height 20m
1
3
4
6
5
3
2
Fig. B.1

8
B1 imensions
In order to ensure the stability of the PV system against lifting, tipping and displacement, it must be weighted
down with ballast (gravel, concrete slabs, etc.). The expected wind loads must be calculated individually for each
system, as they depend on the building height and the system location.
The required ballast loads have been calculated based on extensive wind tunnel tests and can be taken from
the tables.
The following tables are applicable only with an available attic height of at least 10 cm.
The tables apply for the terrain categories under the Belgian standard NBN EN 1991-1-4.
B2 Required ballast load
ca. 1570mm
ca. 1570mm
ca. 28°
Fig. B1.1
Area approx. 2.47 m2
Weighted area approx. 1.30 m2
(contact surface for concrete blocks, gravel, etc.)

9
Table 1: Suntub ballast values without connectors
Building height/
PV system area
Class I Class II Class III Class IV
[kg/Module] [kg/Module] [kg/Module] [kg/Module]
5m / Center 182,6 149,0 120,9 114,8
5m / Edge 228,2 186,2 151,1 143,5
8m / Center 203,5 170,7 120,9 114,8
8m / Edge 254,3 213,4 151,1 143,5
12m / Center 222,2 190,5 141,2 114,8
12m / Edge 277,7 238,1 176,5 143,5
16m / Center 235,8 205,3 156,3 114,8
16m / Edge 294,8 256,6 195,4 143,5
20m / Center 246,8 217,0 168,4 126,8
20m / Edge 308,5 271,2 210,5 158,5
The following points must be considered:
1. Table 1 is generally applicable. Load reduction according to Table 2 is possible if the individual Suntubs are
joined together (optional).
2. The load is generally determined for the edge area (= edge area of the system: first and last row plus the last
two units of a row).
The loads can be reduced for interior areas (“Centre ballast” column).
3. The edge area of the roof should be kept clear (spacing 0.2×h). Check with SolarWorld AG before installing
within this area.
4. These tables serve to determine the required ballast loads for the Suntub® Assembly System only.
The ballast loads required for each system are calculated as part of system planning.
Table 2: Suntub ballast values with connectors
Building height/
PV system area
Class I Class II Class III Class IV
[kg/Module] [kg/Module] [kg/Module] [kg/Module]
5m / Center 126,8 103,4 83,9 79,7
5m / Edge 158,5 129,3 104,9 99,6
8m / Center 141,3 118,6 83,9 79,7
8m / Edge 176,6 148,2 104,9 99,6
12m / Center 154,3 132,3 98,1 79,7
12m / Edge 192,9 165,4 122,6 99,6
16m / Center 163,8 142,5 108,6 79,7
16m / Edge 204,7 178,2 135,7 99,6
20m / Center 171,4 150,7 116,9 88,1
20m / Edge 214,2 188,3 146,2 110,1

10
Table 3: Shading intervals, front edge to front edge [mm] depending on the roof pitch and angle of insolation
Angle of insolation 12° 13° 14° 15° 16° 17° 18°
Roof pitch Shading intervals from front edge to front edge [mm]
6° 2331 2249 2175 2109 2047 1991 1940
5° 2421 2331 2249 2175 2109 2047 1991
4° 2523 2421 2331 2249 2175 2109 2047
3° 2638 2523 2421 2331 2249 2175 2109
2° 2769 2638 2523 2421 2331 2249 2175
1° 2920 2769 2638 2523 2421 2331 2249
0° 3095 2920 2769 2638 2523 2421 2331
- 1° 3302 3095 2920 2767 2638 2523 2421
- 2° 3549 3302 3095 2920 2767 2638 2523
- 3° 3851 3549 3302 3095 2920 2767 2638
- 4° 4228 3851 3549 3302 3095 2920 2767
- 5° 4712 4228 3851 3549 3302 3095 2920
- 6° 5355 4712 4228 3851 3549 3302 3095
B3 Shading table
Sample calculation of required ballast
The ballast required for a building with the following data has been calculated as follows:
• Building height h = 8m
• Basic building size 10x20m
• Class III
• Individual Suntubs to be joined (optional)
• Roof pitch 2°
• Angle of insolation 14°
1. PV system distance from edge:
a1=a2=0,2x8,0=1,60m
2. Ballast
Building height h=8m, joined rows → Table 2:
• Centre ballast 83,9 kg and
• Edge ballast 104,9 kg
3. Shading interval
Front edge to front edge: 2.523 mm
Required ballast Centre 83,9 kg/Suntub
Edge: 104,9 kg/Suntub
20
a1
10
a2
8
Fig. B5.1

11
eneral
The available roof surface must be clean and even. It must not be too smooth or slippery; if the surface is
slippery (e.g., PVC, EP M) an anti-slip mat or an appropriate separating mat (friction coefficient ≥ 0.60)
should be used.
Check that the installation surface (e.g., the existing roof structure) is designed to accommodate the additional
roof load.
Long Suntub® rows can impede the runoff of rainwater. If you are uncertain, we recommend having this
checked by a qualified expert.
1. Positioning the Suntub® Assembly System
The plastic body of the Suntub® consists of 2 parts which are fitted together (Fig. B1). Position the Suntub®
with the flat surface facing south so that the modules are tilted to face the incoming sunlight.
The side distance between the modules when fully assembled should be at least 8 mm for the setup without
connector. The distance between the modules for the setup with connector should be approx. 25 mm.
If the individual Suntubs® are to be joined together (to reduce the required ballast), the connecting elements
must be already put in place and fastened during positioning (Fig. C1.1, item 3).
C1 Setup
1 Suntub, right section
2 Suntub, left section
3 Connecting piece (optional)
The connecting piece is fastened to the
Suntub with 2 M8 screws at each end.
The Suntub is first lowered onto the
connecting piece and then the screws
are installed.
Fitting the Suntub and
connecting piece, with screws
3
2
1
Fig. C1.1
Assembly C

12
2. Ballast
After positioning and (optional) connecting, the Suntubs® are now weighted down with the required
ballasted loads according to the system plan. Gravel or concrete blocks may be used, for example.
The ballast must be distributed evenly.
3. Aluminium profile installation
Next, the two aluminium profiles are inserted in the weighted Suntubs® up to the stop.
The groove must be on top to anchor the T-head bolts.
Fig. C1.2
Fig. C1.3

13
4. Securing the modules
Now the bottom clamping connections are
loosely pre-installed.
The module can be inserted from above.
Next, the top clamping connections can be
installed. After the module has been aligned, all
bolts can be tightened (tightening torque 20Nm).
The modules must be centered on the Suntub®.
The distance between the modules when fully
assembled should be at least 8mm.
etail of bottom
clamping connection
Fig. C1.4
Fig. C1.6
Fig. C1.7
Fig. C1.5

14
C2 Module connection
Attention: Connecting modules in series may yield high voltages!
1. Wire the modules according to the wiring diagram.
Make sure to strictly observe the wiring diagram instructions (string distribution, electrical switches,
group cable). Incorrect wiring may damage or destroy the grid connected inverter and/or the modules.
In order to keep inductive coupling as low as possible in the event of a lightning strike, the supply and return
cables (+/-) of the string shall be laid as closely to each other as possible (avoid loops)
The minimum bending radii of cables (5x cable diameter) must be observed in all situations.
Keep plugs and sockets dry during installation.
2. Install the group cable.
3. Attach the cable to the supporting section using UV-resistant cable binders.
4. Install and wire the subsequent module rows. Observe the polarity.
Observe the polarity.
Test
1. Check the correct generator connection of the multi-string solar generator by measuring the open
circuit voltages of the individual strings.
2. Compare the measured values to the specification. eviating values indicate wiring errors!
o not connect the grid connected inverter for test purposes.
The solar system may only be connected to the public grid by an authorized electrician.
The technical instructions enclosed with the unit shall be strictly adhered to for the installation,
electrical connection and operation of the grid connected inverter.
~
II
String 1
String 2
1. Solar array
2. Inverter
3. Utility grid
123
Fig. C2.1

15
Liability
Since observance of these installation instructions and the conditions and methods of installation, operation,
use and maintenance of the Suntub® mounting system is not checked or monitored by SolarWorld AG,
SolarWorld AG accepts no liability for damage arising through improper use or incorrect installation, operation,
use or maintenance. Moreover, SolarWorld® assumes no liability when SolarWorld®, its representatives or vicar-
ious agents are accused of gross negligence or intent. The previous restrictions do not apply to damage relating
to death, body or health, as well as in cases applicable to other laws, such as the liability for assumption of
guarantee, liability according to the German Product Liability Act (Produkthaftungsgesetz) or in the case of
infringements of important contractual obligations (cardinal obligations).
Regardless of the previously described limitations of liability, SolarWorld® assumes no liability for infringe-
ments of patent law or of third party rights arising from the use of the modules and the mounting system,
as is present under the regulations previously described.
The text and figures in this manual are in compliance with the state of technology at the time of printing
and are subject to change.
The warranty period is based solely on the usability of the Suntub® itself, and only on that component;
no liability is accepted for loss of yield or for assembly and disassembly costs in case of damage.
Maintenance/Cleaning/Liability
The installation company is responsible for ensuring professional grounding of the system and components.
No External lightning protection
A ground is recommended, and often required by local code, for PV-module frames and mounting racks.
Connect all electricity conducting parts with measures suited to this purpose and connect with the earth
(ground) circuit connector (PAS) with at least 6 mm² (copper).
External lightning protection
PV-Module frame and mounting frame must be included in the protection against the direct strike of
lightning. If necessary, consult a lighting protection expert.
C3 Grounding
Maintenance and cleaning
It is generally not necessary to clean the modules (rainfall will have a self-cleaning effect).
In case of heavy contamination (capacity reduction), we recommend cleaning the modules using plenty
of water (from a hose) without cleaning agents, along with a gentle cleaning brush or sponge. irt
must never be scraped or rubbed away when the modules are dry as this may cause micro-scratches,
which have a negative effect on the module performance
The generator field should be inspected at regular intervals for flawless condition (visual inspection).
The modules and the Suntub® must be inspected annually for correct position and secure mounting!

SolarWorld. And EveryDay is a SunDay. www.solarworld.de
SolarWorld AG
Martin-Luther-King-Str. 24
53175 Bonn
Germany
SolarWorld Ibérica, S.L.
C/La Granja 15,
Bloque B-1º B
28108 Alcobendas, Madrid
Spain
SolarWorld California Inc.
4650 Adohr Lane
Camarillo, CA 93012
USA
Production and distribution sites
of the SolarWorld Group
SolarWorld AG
Martin-Luther-King-Str. 24
53175 Bonn
Germany
Telephone: +49 - 228 - 55920 - 0
Fax: +49 - 228 - 55920 - 99
[e-mail]
SolarWorld Africa Pty. Ltd.
20th Floor
1Thibault Square
Cape Town, 8001
South Africa
SolarWorld Asia Pacific Pte. Ltd.
72 Bendemeer Road
#07-01, Luzerne
Singapore 339941
Singapore
SolarWorld Korea Ltd.
Gangnam Finance Center
16F Yeoksam-dong, Gangnam-gu
Seoul, 135 - 925
South Korea
1
2
36
5
47
8
9
10
Production
1
Deutsche Solar/Freiberg, Germany
Deutsche Cell/Freiberg, Germany
Solar Factory/Freiberg, Germany
Sunicon/Freiberg, Germany
SolarWorld Innovations/Freiberg, Germany
2
SolarWorld Industries America/Camarillo, USA
3
SolarWorld Industries America/Vancouver, USA
4
SolarWorld Industries America/Hillsboro, USA
5
SolarWorld Korea Ltd., South Korea
Distribution
6
SolarWorld Head Oce/Bonn, Germany
7
SolarWorld Ibťrica/Madrid, Spain
8
SolarWorld Africa/Cape Town, South Africa
9
SolarWorld Asia Pacific/Singapore, Singapore
10
SolarWorld California/Camarillo, USA
KA 0032