Sunrise Solartech PV Modules User manual

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Installation Guide of Sunrise Solartech PV Modules
Term 2011
Contents
Purpose of this guide
General
Safety precaution for installing a solar
Photovoltaic system
Product Identification
Mechanical Installation
Selecting the location
Selecting the proper support frame
Ground mount
Roof mount
Pole mount
General installation
Electrical Installation
Grid-connected electrical system
Grounding
General installation
Commission and Maintenance
Blocking diodes and bypass diodes
Testing, commissioning and troubleshooting
Maintenance
Disclaimer of Liability

Purpose of this guide
This guide contains information regarding the installation and safe handling of Sunrise Solartech
Co., Ltd photovoltaic module (hereafter is referred to as “module”). Sunrise Solartech Co., Ltd
hereafter is referred to as “Sunrise”.
Installers must read and understand the guide before installation. Any questions, please contact our
sales department for further explanations. The installer should conform to all safety precautions in
the guide and local codes when installing a module.
Before installing a solar photovoltaic system, installers should become familiar with the
mechanical and electrical requirement for such a system. Keep this guide in a safe place for future
reference (care and maintenance) and in case of sale or disposal of the modules.
General
Installing solar photovoltaic systems may require specialized skills and knowledge. Installation
should be performed only by qualified persons.
Each module comes with a permanently attached junction. Sunrise can provide customers with
fitted cables for ease of installation if desired.
Installers should assume the risk of all injury that might occur during installation, including,
without limitation, the risk of electric shock.
One individual module may generate DC voltages greater than 30 volts when exposed to direct
sunlight. Contact with a DC voltage of 30V or more is potentially hazardous.
Do not disconnect under load.
Photovoltaic solar modules change light energy to direct-current electrical energy. They are
designed for outdoor use. Modules may be ground mounted, mounted on rooftops, vehicles or
boats. Proper design of support structures is responsibility of the system designers and installers.
Use of mounting holes is suggested in a following paragraph.
Do not attempt to disassemble the modules, and do not remove any attached nameplates or
components from the modules.
Do not apply paint or adhesive to module top surface.
Do not use mirrors or other magnifiers to artificially concentrate sunlight on the modules. Do not
expose back sheet foils directly to sunlight.
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When installing the system, abide with all local, regional and national statutory regulations.
Obtain a building permit where necessary.
Safety precaution for installing a solar photovoltaic system
Solar modules produce electrical energy when light shines on their front surface. The DC voltage
may exceed 30V. If modules are connected in series, the total voltage is equal to the sum of the
individual module voltages. If modules are connected in parallel, the total current is equal to the
sum of individual module currents.
Keep children well away from the system while transporting and installing mechanical and
electrical components.
Completely cover the module with an opaque material during installation to keep electricity from
being generated.
Do not wear metallic rings, watchbands, ear, nose, lip rings or other metallic devices while
installing or troubleshooting photovoltaic systems.
Use only insulated tools that are approved for working on electrical installations.
Abide with the safety regulations for all other components used in the system, including wiring
and cables, connectors, charging regulators, inverters, storage batteries and rechargeable batteries,
etc.
Use only equipment, connectors, wiring and support frames suitable for a solar electric system.
Always use the same type of module within a particular photovoltaic system.
The electrical characteristics are within ±10 percent of the indicated values of Isc, Voc, and
Pmax under standard test conditions (irradiance of 100mW/cm2, AM 1.5 spectrums, and a cell
temperature of 25°C (77°F))
Under normal outdoor conditions the module will produce current and voltages that are different
than those listed in the date sheet. Data sheet values are values expected at standard test conditions.
Accordingly, during system design, values of short-circuit current and open-circuit voltage should
be multiplied by a factor of 1.25 when determining component voltage ratings, conductor
ampacity, fuse ratings and size of controls connected to the modules or system output.
Product identification
Each module has three labels on its rear side providing the following information:
Nameplate: describes the product type; rated power, rated current, rated voltage, open circuit
voltage, short circuit current, all as measured under standard test conditions; weight, dimension
etc.; the maximum system voltage 1000 volts DC and is shown on the nameplate. Maximum fuse
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rating is also shown.
“Pass”: describe inspection date and security class.
Bar code: each individual module has a unique serial number. The serial number has 17 digits.
There is only one bar code on module. It is permanently attached to the interior of the module
visible when viewing from the front of the module. This bar code is inserted at the beginning of
laminating.
Typical serial number barcode label
Do not remove any label.
If the label is removed, the product warranty will no longer be honored by Sunrise.
Mechanical Installation
Selecting the location
Select a suitable location for installing the modules.
The modules should be facing south in northern latitudes and north in southern latitudes.
For detailed information on the best elevation tilt angle for the installation, refer to standard solar
photovoltaic installation guides or a reputable solar installer or systems integrator.
The module should not be shaded at any time of the day.
Do not use module near equipment or in locations where flammable gases can be generated or
collected.
Selecting the proper support frame
Always observe the instructions and safety precautions included with the support frames to be
used with the modules.
Do not attempt to drill holes in the glass surface of the modules. To do so will void the warranty.
Do not drill additional mounting holes in the frame of the modules. Doing so will void the
warranty.
Modules must be securely attached to the mounting structure using four mounting points for
normal installation. If additional wind or snowloads are anticipated for this installation, additional
mounting points are also used. The details please see the below drawing. Load calculations are left
to the system designers or installers.
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Mechanical Installation
The support module mounting structure must be made of durable, corrosion-resistant and
UV-resistant material.
Ground mount
Select the height of the mounting system to prevent the lowest edge of the module from being
covered by snow for a long time in winter in areas that experience heavy snowfalls. In addition,
assure the lowest portion of the module is placed high enough so that it is not shaded by plants or
trees or damaged by sand and stone driven by wind.
Roof mount
When installing a module on a roof or building, ensure that it is securely fastened and cannot fall
as a result of wind or snow loads.
Provide adequate ventilation under a module for cooling (10cm minimum air space between
module and mounting surface).
When installing module on a roof, ensure that the roof construction is suitable. In addition, any
roof penetration required to mount the module must be properly sealed to prevent leaks.
In some cases, a special support frame may be necessary.
The roof installation of solar modules may affect the fireproofing of the house construction.
The modules are rated fire Class C, and are suitable for mounting over a class A roof. Do not
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install modules on a roof or building during strong winds in case of accidents.
Mechanical Installation
Pole mount
When installing a module on a pole, choose a pole and module mounting structure that will
withstand anticipated winds for the area.
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General installation
Module mounting must use the pre-drilled mounting holes in the frame.
The most common mounting is achieved by mounting the module using the four symmetry points
close to the inner side on module frames.
If excessive wind or snow loads are expected, all eight mounting holes must be used
Do not lift the module by grasping the module’s junction box or electrical leads.
Do not stand or step on module.
Do not drop module or allow objects to fall on module.
To avoid glass breakage, do not place any heavy objects on the module.
Do not set the module down hard on any surface.
Inappropriate transport and installation may break module.

Electrical Installation
This guide describes some of the most important typical uses as representative examples.
Grid-connected electrical system
The DC electrical energy generated by photovoltaic systems may also be converted to AC and
connected to a utility grid system. As local utilities’ policies on connecting renewable energy
systems to their grids vary from region to region.
Consult a qualified system designer or integrator to design such a system. Permits are normally
required for installing such a system and the utility must formally approve and inspect such a
system before it can be accepted.
Grounding
The module frame must be properly grounded. The grounding wire must be properly fastened to
the module frame to assure good electrical contact. Use the recommended type, or an equivalent,
connector for this wire.
If the support frame is made of metal, the surface of the frame must be electroplated and have
excellent conductivity.
We recommend the lay-in lug (Cat. No. GBL4-DBT is recommended by Sunrise) when grounding.
First strip 16mm insulating jacket from the end of the ground wire carefully to avoid nicking or
cutting conductors, insert the wire to the feet of the lug (see the picture), and screw down the
slotted screw. Be careful not to damage the wire core. And then tighten up the screw.
Electrical Installation
Next, assemble the recommended ILSCO grounding lug to the aluminum frame using stainless
steel M3 or M5 screw and hardware as shown below. Note: there are two different size grounding
holes, the smaller of which is being phased out.
Further, buildup of hardware for mounting the grounding lug are the same—except for the M3
screw, an added flat washer is mounted directly under the M3 screw head. The star washer is fitted
directly under the grounding lug and makes electrical contact by penetrating the anodized coating
of the aluminum frame; the screw assembly is further fitted with a flat washer, then a split lock
washer and finally a nut to secure the entire assembly, as shown. Recommended torque of M3 or
M5 screw assembly is 0.8NM or 1.5 NM.
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Electrical Installation
General installation
Do not use modules of different configurations in the same system. The max. number of module
(N) = Vmax system / [Voc(at STC)].
Several modules are connected in series and then in parallel to form a PV array, especially for
application with a high operation voltage. If modules are connected in series, the total voltage is
equal to the sum of individual voltages.
For applications requiring high currents, several photovoltaic modules can be connected in parallel;
the total current is equal to the sum of individual currents.
Module is supplied with connectors to use for system electrical connections.
Consult rated local wiring regulations to determine system wire size, type, and temperature.
The cross section area of cable and the capacity of connector must be selected to suit the
maximum system short circuit current (Recommended cross section area of cable is 4mm2 for a
single module and rated current of a connector is larger than 10A), otherwise the cable and
connector will be overheated under large current. Please note that the upper limit temperature of
cable is ≥85℃, and the connector is ≥105℃.
The junction box has a breather port. The breather port must be mounted facing down and can not
be exposed to rain. Therefore, the junction box must be on the higher side of the module when it is
mounted.
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Commission and Maintenance
First, check all wiring connections to make sure it is not open-circuit or is not connection well.
Check the open-circuit voltage of each module:
Fully cover the modules with an opaque material.
Disconnect the wiring at both terminals of the modules.
Remove the opaque material from the module to be checked and measure the open-circuit voltage
at its terminals.
If the measured voltage is only half of the rated, this indicates a defective bypass diode. Refer to
‘Testing and replacing bypass diodes’.
In the case of not very low irradiance, if the voltage across the terminals differs from the rated
value by more than 5 percent, this indicates a bad electrical connection.
Maintenance
Sunrise recommends the following maintenance in order to ensure optimum performance of the
module:
Clean the glass surface of the module as necessary. Always use water and a soft sponge or cloth
for cleaning. A mild, non-abrasive cleaning agent can be used to remove stubborn dirt.
Check the electrical and mechanical connections every six months to verify that they are clean,
secure and undamaged.
If any problem arises, have them investigated by a competent specialist. Attention, observe the
maintenance instructions for all components used in the system, such as support frames, charging
regulators, inverters, batteries etc.
Disclaimer of liability
Because the use of this manual and the conditions or methods of installation, operation, use and
maintenance of photovoltaic (PV) product are beyond Sunrise’s control, Sunrise does not accept
responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any
way connected with such installation, operation, use or maintenance.
No responsibility is assumed by Sunrise for any infringement of patents or other rights of third
parties, which may result from use of the PV product. No license is granted by implication or
otherwise under any patent or patent rights.
The information in this manual is based on Sunrise’s knowledge and experience and is believed to
be reliable; but such information including product specification (without limitations) and
suggestions do not constitute a warranty, expresses or implied. Sunrise reserve the right to change
the manual, the PV produce, the specifications, or product information sheets without prior notice.
SUNRISE SOLARTECH CO., Ltd
Add: No.65-22 Xinggang Road Zhonglou Development Zone Changzhou 213023 China
Phone: [phone]
Fax: [phone]
Email: [email protected]