TEJAS BORJA Roof&Plug SOLAR FLAT-5XL User guide

INSTALLATION AND SAFETY
MANUAL
SOLAR FLAT-5XL ceramic roof tile

ceramic roof tile
IMPORTANT
Before beginning to install SOLAR Flat-5XL ceramic tiles, make sure you know and understand the product’s
technical characteristics and installation features. Keep this manual for future reference.
To ensure the safety of the installer, equipment and property, this manual must be read carefully
before beginning the installation. The instructions in this manual must be followed during transport,
installation, testing and maintenance.
Version 1 – February 2021
All the specifications and descriptions in this document are correct at the time of publication. However,
and because continuous improvement is one of Tejas Borja’s objectives, we reserve the right to make
changes to these data at any time. To notify us of any possible inaccuracies or omissions in this document,
please send an email to the following address: [email protected].
The data added to the latest versions of our product data sheets may not be in this document. If any
information provided in this document conflicts with the information in a data sheet for a product described
herein, the latest version of the data sheet takes precedence and prevails over this document.
The illustrations, drawings, diagrams and other images in this document are for illustrative
purposes only. The products depicted in this document may be slightly different to the real
products.
Unless expressly authorized, the total or partial reproduction of this document is forbidden, as is the
commercial exploitation and communication of its content.
© All rights reserved. TEJAS BORJA S.A.U.
SOLAR FLAT-5XL
INSTALLATION
and safety manual
2

CONTENTS
1 INTRODUCTION....................................................................................................... 4
2 LIABILITY NOTICE ................................................................................................... 4
3 GENERAL PROVISIONS AND OVERVIEW ............................................................... 4
3.1 SOLAR Flat-5XL ceramic roof tile ........................................................................ 5
3.1.1 Identification of the product........................................................................ 6
3.1.2 Characteristics and specifications .............................................................. 6
3.1.3 Voltage curve............................................................................................ 10
3.1.4 Packaging................................................................................................. 11
4 RECEIPT AND STORAGE....................................................................................... 11
5 SAFETY .................................................................................................................. 12
5.1 General safety ................................................................................................... 12
5.2 Warnings ........................................................................................................... 12
5.3 Precautions ....................................................................................................... 12
5.4 Manual handling safety...................................................................................... 12
5.5 Electrical safety ................................................................................................. 12
5.6 Installation safety............................................................................................... 13
5.7 Fire safety.......................................................................................................... 14
6 GENERAL INSTALLATION INFORMATION ............................................................ 14
6.1 Installation design ............................................................................................. 14
6.2 Location selection ............................................................................................. 14
6.3 Climatic conditions............................................................................................ 15
6.4 Compatibility ..................................................................................................... 15
6.4.1 Ceramic tile – roof covering ...................................................................... 15
6.4.2 Inverters ................................................................................................... 17
6.4.3 Cables and Connectors ............................................................................ 17
6.4.4 Obligatory safety features......................................................................... 17
6.4.5 Optimizers ................................................................................................ 17
6.4.6 DC isolator switch breakers ...................................................................... 17
6.4.7 Battery...................................................................................................... 17
6.4.8 Inverter/charger ........................................................................................ 18
6.4.9 Meter ........................................................................................................ 18
6.4.10 Load regulator ........................................................................................ 18
6.4.11 Electrical switchboard............................................................................. 18
6.4.12 Monitoring systems................................................................................. 18
6.5 Installation requirements.................................................................................... 18
6.6 Pre-installation preparation and precautions...................................................... 19
6.6.1 Accessories and tools for the installation.................................................. 19
6.6.2 Batten installation ..................................................................................... 20
6.7 Installation instructions...................................................................................... 21
6.8 Electrical installation.......................................................................................... 28
6.9 Connection to the inverter ................................................................................. 30
6.10 System wiring diagram .................................................................................... 30
6.11 Commissioning................................................................................................ 31
7 INSTALLATION EXAMPLE...................................................................................... 31
7.1 SOLAR Flat-5XL ceramic roof tile - MONOCRYSTALLINE.................................. 31
7.2 SOLAR Flat-5XL ceramic roof tile - CIGS........................................................... 31
8 MAINTENANCE ...................................................................................................... 32
9 PRECAUTIONS FOR SYSTEM SHUTDOWN .......................................................... 32
10 WARRANTY ............................................................................................................ 32
11 GLOSSARY............................................................................................................. 33
3

1 INTRODUCTION
2 LIABILITY NOTICE
3 GENERAL PROVISIONS AND OVERVIEW
This manual contains information about the installation
and correct handling of the SOLAR FLAT-5XL
ceramic roof tile model photovoltaic modules made
by Tejas Borja S.A.U.
Installers must read and understand the contents of
this manual before beginning installation.
If in any doubt, please send a message to Tejas Borja
Technical Support by emailing [email protected]
to ask for more information.
When installing the SOLAR FLAT-5XL ceramic
roof tile, installers must use all the safety measures
detailed in this manual as well as complying with
all local rules and regulations whether mandated by
law or official bodies.
Before installing a solar photovoltaic system,
installers must be familiar with its mechanical and
electrical requirements. Keep this manual in a safe
place for future reference.
The specifications in this manual are subject to
change without notice. Always consult the latest
version on the Tejas Borja website at tejasborja.com.
The real images included in this document represent
the product and give the closest reflection of its
real physical appearance. However, Tejas Borja
recommends in-person viewing of product samples
through its distributors and sales network.
Tejas Borja’s solar photovoltaic energy solutions can
be adapted to meet the specific energy generation
requirements of each project and cut electricity
bills while helping to reduce our carbon footprint
by providing an alternative, environmentally-friendly
way to generate electricity.
The choice of material for the roof tiles is crucial
to guarantee the durability, protection and energy
efficiency of the property, and nor should the importance
of the roof’s aesthetic appearance be overlooked.
To combine efficiency and style, Tejas Borja’s solar
solutions are integrated into the ceramic roofing
tiles so they impact the original project design as
little as possible.
The products in our SOLAR range and our ceramic
tiles must always be installed using dry installation
systems and connectors which meet international
standards to guarantee optimal safety and the maximum
watertightness and durability of the roof.
This manual provides basic information about
the SOLAR FLAT-5XL ceramic roof tile.
Tejas Borja will not be liable for any damages, losses,
costs or legal liability arising from the use of other
equipment or components, incorrect installation,
mounting, operation, application and maintenance
which is not under the control of Tejas Borja.
Tejas Borja will not be liable for breaches of patent
laws or third party rights caused by installation
methods or the use of the product.
If the method of installation used deviates from
the instructions in this manual, ensure the installation
method and the application of the product are viable.
The user does not have the right to sub-licence any
of the intellectual property rights or patents associated
with the SOLAR FLAT-5XL ceramic roof tile.
Tejas Borja reserves the right to modify this manual,
technical specifications and all information about
the SOLAR FLAT-5XL ceramic roof tile at any
time.
The installation must always and only be carried out
by a qualified installer.
Before beginning the installation, the installer must
know all the electrical requirements of the photovoltaic
system.
This manual must be read together with the product
data sheet and the specifications for the FLAT-5XL
ceramic tile and its installation guidelines.
4

3.1 SOLAR FLAT-5XL ceramic roof tile
The SOLAR FLAT-5XL ceramic roof tile has
been designed to integrate perfectly into the roof.
SOLAR SOLAR FLAT-5XL ceramic roof tile tiles
are the only large ceramic tiles with an integrated
solar energy system. They are ideal for providing
a reliable supply of solar energy. Thanks to the
integration of the solar panel into the tile, the
tiles provide all the benefits of a roof made from
ceramic tiles in terms of watertightness, without
any risk of deterioration or oxidation.
The photovoltaic panel is perfectly integrated into
the tile, this being the best way to achieve a roof
which captures clean energy without affecting
its aesthetic appearance, preserving the line
and usual thickness of the covering. This perfect
integration is completed with the installation of
the roof or facade using FLAT-5XL tiles and other
ceramic accessories.
All the electrical components included i n t h e SOLAR
FLAT-5XL ceramic roof tile have been
carefully selected to guarantee the highest
quality of the product. The junction box is
compact and extremely reliable in harsh
environments, its IP67 certificationmeansit provides
protection against moisture and its bypass diode
means it also protects against the flow of
inverse currents in darkness, when it is cloudy
or when the roof is in shade or covered by
leaves or other objects.
The SOLAR FLAT-5XL ceramic roof
tile has an entirely black (FULL-
BLACK), anti-reflective finish,
with none of the typically visible
connections.
The SOLAR FLAT-5XL ceramic roof
tile is designed for a roof or facade
made from FLAT-5XL flat ceramic
tiles and their complementary
special ceramic pieces.
Photovoltaic energy is a clean and environmentally-
friendly form of energy, ideal for self-consumption
and to reduce monthly electricity bills, both for
homes and company premises.
A technology which is widely used around the world,
photovoltaic panels convert solar energy into electricity.
Photovoltaic electrical energy systems are the only ones
which, using a renewable source, can produce electricity
in the place it is consumed.
The importance of self-consumption: save while protecting the environment.
5

3.1.1 Identification of the product
Each SOLAR FLAT-5XL ceramic roof tile carries a unique serial number. Do not remove any labels.
The information on them is important for the traceability of the product.
3.1.2 Characteristics and specifications
6

1 - FLAT-5XL ceramic support
2 - Photovoltaic panel
3 - Junction box ceramic housing
4 - Connection cables
5 - MC4 connector (+) positive terminal
6 - MC4 connector (-) negative terminal
7 - Holes for fixing to the batten*
* Requires 2 screws for fixing to the batten (per solar tile unit): diameter from 3,5 to 4,2 / thread length 45 - 55 mm,
depending on the batten type.
Key:
7

Characteristics SOLAR FLAT-5XL ceramic roof tile - MONOCRYSTALLINE
All measurements are approximate.
Note: The SOLAR FLAT-5XL roof tile has an entirely black (FULL-BLACK), anti-reflective finish, with none of the typically visible connections. It is entirely
compatible with the FLAT-5XL ceramic tile (see available finishes on the Tejas Borja website).
* SOLAR FLAT-5XL ceramic roof tile must always be installed on ventilated roofs using a double batten system or equivalent.
** Depending on batten spacing.
*** The certification process is pending.
STC standard conditions: irradiance = 1.000 W/sq. m.; cell temperature = 25ºC; AM = 1,5.
Dimensions: 457 x 510 mm
Individual weight: 7,50 kg.
Finish: LEON MATTE / CRISTAL FULL-BLACK
Cell type: Monocrystalline
Base: Flat-5XL ceramic roof tile
Fixing system: 3 pre-drilled holes (batten xing – min. 2 places)
Panel dimensions: 410 x 360 mm (320 x 360 mm useful area)
Equivalence to ceramic tiles: 1 Flat-5XL roof tile
Placing: Depending on the Flat-5XL roof tile *
Connection: Mixed (series – parallel)
Maximum power (Pmax): 24 Wp
Maximum power tolerance: -5% / +5 %
Maximum power current (Impp): 1,9 A
Maximum power voltage (Vmpp): 12,75 V
Short circuit current (Isc): 2,05 A
Open circuit voltage (Voc): 15,16 V
Temperature coefficient of Pmax (δ): -0,38 %/K
Temperature coefficient Voc (β): -0,30 %/K
Temperature coefficient Isc (α): 0,043 %/K
Maximum system voltage: 600 V ( IEC)
Maximum series fuse rating (Isf): 5 A
Operating temperature: -40 °C a 85 °C.
Standard**: IEC 61646 - IEC 61730
Front glass panel: 4 mm. tempered glass
Backsheet: Combination of polymers
Junction box: IP 67
Connectors: MC4 or compatible connectors
DC cable: 4,0 sq. mm., (12 AWG)
DC cable length: 2 x 470 mm
Units /sq. m.: 5,85 – 5,50 units
Maximum power/sq. m.***: 143,26 Wp/sq. m.
sq. m. – 1 kWp: 6,98 sq. m.
Units/kWp: 41,32 units
The SOLAR FLAT-5XL ceramic roof tile comes in two versions to adapt to each project’s energy generation needs
and available space.:
· SOLAR FLAT-5XL ceramic roof tile – MONOCRYSTALLINE
· SOLAR FLAT-5XL ceramic roof tile – CIGS
8

Characteristics SOLAR FLAT-5XL ceramic roof tile - CIGS
Dimensions: 457 x 510 mm
Individual weight: 7,50 kg.
Finish: LEON MATTE / CRISTAL FULL-BLACK
Cell type: CIGS (free from Cd and Pb) (1)
Base: Flat-5XL ceramic roof tile
Fixing system: 3 pre-drilled holes (batten xing – min. 2 places)
Panel dimensions: 410 x 360 mm (320 x 360 mm useful area)
Equivalence to ceramic tiles: 1 Flat-5XL roof tile
Placing: Depending on the Flat-5XL roof tile *
Connection: Mixed (series – parallel)
Maximum power (Pmax): 17 Wp
Maximum power tolerance: -3% / +5 %
Maximum power current (Impp): 0,54 A
Maximum power voltage (Vmpp): 31,7 V
Short circuit current (Isc): 0,61 A
Open circuit voltage (Voc): 40,2 V
Temperature coefficient of Pmax (δ): -0,34 %/K
Temperature coefficient Voc (β): -0,24 %/K
Temperature coefficient Isc (α): +0,01 %/K
Maximum system voltage: 1.000 V ( IEC)
Maximum series fuse rating (Isf): 5 A
Operating temperature: -40 °C a 85 °C.
Standard**: IEC 61646 - IEC 61730
Front glass panel: 3,2 mm. tempered glass
Backsheet: 1,8 mm. tempered glass
Junction box: IP 67
Connectors: MC4 or compatible connectors
DC cable: 4,0 sq. mm., (12 AWG)
DC cable length: 2 x 600 mm
Units /sq. m.: 5,85 – 5,50 uds
Maximum power/sq. m.***: 102 Wp/sq. m.
sq. m. – 1 kWp: 9,8 sq. m.
Units/kWp: 58,82 units
All measurements are approximate.
Note: The SOLAR FLAT-5XL roof tile has an entirely black (FULL-BLACK), anti-reflective finish, with none of the typically visible connections. It is entirely
compatible with the FLAT-5XL ceramic tile (see available finishes on the Tejas Borja website).
* SOLAR FLAT-5XL ceramic roof tile must always be installed on ventilated roofs using a double batten system or equivalent.
** Depending on batten spacing.
*** The certification process is pending.
STC standard conditions: irradiance = 1.000 W/sq. m.; cell temperature = 25ºC; AM = 1,5.
(1) CIGS (copper, indium, gallium and selenium) is an acronym which describes the latest development in high efficiency solar cell technology (this tech-
nology is the most effective in shady conditions) providing high performance while free from cadmium and lead. 9

In each case the graph shows two curves. The first
is the I-V curve, represented by a dotted line. This
shows the relationship between current and voltage
at different irradiance levels. Each irradiance level is
shown in a different colour.
The other is the P-V curve, represented by a
continuous line. This shows the relationship between
power and voltage at different irradiance levels.
3.1.3 Voltage curve
(I-V and P-V curves different irradiance levels)
I-V and P-V curves - SOLAR FLAT-5XL ceramic roof tile MONOCRYSTALLINE
I-V and P-V curves - SOLAR FLAT-5XL ceramic roof tile CIGS
10

• Units / pallet: 36 SOLAR FLAT-5XL ceramic roof tiles
• Pallet weight: 320 kg
• Dimensions: 75 x 112 x 70 (mm)
• Stackable: up to 3 tiers
3.1.4 Packaging
4 RECEIPT AND STORAGE
Upon receipt, check that the product delivered
matches that ordered.
Upon receiving the product and before sending it
on to its final destination, the packaging must
be checked for any damage. If the packaging
is damaged, a photograph must be taken of
the packaging and all the solar tiles inside it
must be checked for any damage.
Due to the special characteristics of the product,
SOLAR FLAT-5XL ceramic roof tile must be
handled carefully.
Store the packing boxes in a clean, dry place with
a relative humidity below 85% and at an ambient
temperature between -20°C and 50°C.
DO NOT stack more than the maximum permissible
quantity of pallets (up to 3 pallets).
Keep the product in its original packing box until
ready to install it.
When they are at the installation site and before
beginning the installation, make sure to keep
SOLAR FLAT-5XL ceramic roof tiles clean and dry,
particularly their electrical contacts. The contacts
may corrode if their cables are exposed to humid
conditions. Any SOLAR FLAT-5XL ceramic roof
tile with contacts affected by corrosion must not
be used.
To ensure the safety of personnel and the product
when handling SOLAR FLAT-5XL ceramic roof
tiles, two people must work together to unpack
the modules from their packing boxes.
Do not remove the edges of the modules if the modules
are to be temporarily stored off the pallet.
Never use a blade cutting tool (such as a box cutter,
knife or similar) to cut the straps; use scissors or pliers.
Never place a SOLAR FLAT-5XL ceramic roof tile
directly on top of another.
11

5 SAFETY
5.1 General safety
Specialized skills and knowledge are required to install
solar photovoltaic systems. Installation must only be
carried out by qualified, trained personnel.
Installers must follow all security precautions when
installing SOLAR FLAT-5XL ceramic roof tiles.
Never install solar tiles which are physically damaged
and/or present defects in any of their parts or elements.
Only use equipment, tools, connectors, cables, etc.
which are appropriate for solar electrical systems.
Follow the laws regarding health and safety at work
and local safety regulations regarding fall prevention.
5.2 Warnings
When exposed to direct sunlight, one module
alone can generate more than 30 V of DC. Safety
measures must be used during installation because
contact with a voltage of 30 V or more of DC is
dangerous. Avoid contact with electrically charged
components and make sure live circuits are isolated
before making or breaking any connections.
Installers must assume the risk of injuries which may
occur during installation including, but not limited
to, electric shock.
When installing the system, you must follow all local,
regional and national regulations. When necessary,
obtain a building permit.
5.3 Precautions
Do not attempt to remove SOLAR FLAT-5XL
ceramic roof tiles once they have been installed. Do
not remove any label or component from the tiles.
Do not apply paints or adhesives to the upper surface
of SOLAR FLAT-5XL ceramic roof tiles.
Do not use mirrors or magnifying lenses to concentrate
the light onto the solar tiles. Never use artificial means
to concentrate sunlight onto the solar modules.
Store on a flat surface in a place which is well ventilated
and dry.
5.4 Manual handling safety
Do not disconnect SOLAR FLAT-5XL ceramic
roof tiles when they are charging.
When handling SOLAR FLAT-5XL ceramic roof
tiles, always wear appropriate safety footwear and
Class 0 insulating gloves which meet the requirements
of UNE standard EN 60903:2005 to protect
the handler against electric shocks and to
prevent the product from falling.
Only work in dry conditions and use dry tools. Unless
you have the appropriate protective equipment, do
not handle SOLAR FLAT-5XL ceramic roof tiles or
electric components if they are wet.
Do not pick up a SOLAR FLAT-5XL ceramic roof
tile by the junction box or the electric cables.
Do not sit, step or walk on a SOLAR FLAT-5XL
ceramic roof tile. Do not step on the front or rear
surface of SOLAR FLAT-5XL ceramic roof tiles
either before or after installation.
Do not scratch the surface of the glass or panel.
Do not drop SOLAR FLAT-5XL ceramic roof tiles,
do not drop objects on top of them or subject them
to heavy blows.
Do not place any heavy object on top of SOLAR
FLAT-5XL ceramic roof tiles or on top of any of its
components, cables or connectors.
Take care when positioning SOLAR FLAT-5XL
ceramic roof tiles on the roof surface, particularly
when working at a corner.
Do not damage the cables. Do not pinch, twist or
stretch them using excessive force.
Improper transport or installation may break
the SOLAR FLAT-5XL ceramic roof tiles and
void the warranty.
SOLAR FLAT-5XL ceramic roof tiles with
damaged glass (whether it is broken or scratched)
cannot be repaired.
Contact with any damaged surface of a SOLAR
FLAT-5XL ceramic roof tile may cause an electric
discharge. Never use a SOLAR FLAT-5XL ceramic
roof tile which has broken glass or a damaged
backsheet.
Be sure to protect the connector contacts against
corrosion and dirt. Check that all the connectors
are free of corrosion and clean before connecting
them.
Keep the SOLAR FLAT-5XL ceramic roof tiles out
of the reach of children at all times.
5.5 Electrical safety
You must comply with safety regulations for electrical
installations and the electrical code in accordance
and national and/or local legislation depending on
the location of the installation.
Under normal conditions, the current and/or voltage
produced by a SOLAR FLAT-5XL ceramic roof tile
will probably be superior to those recorded under
standard measurement conditions. Consequently,
the values for Isc and Voc given for the SOLAR
FLAT-5XL ceramic roof tile should be multiplied by
1.25 to determine the voltage of the components,
the fuse sizes and the size of the controls connected
to the photovoltaic output.
Under no circumstances should the open circuit
voltage of the installation exceed the maximum
voltage of the system (IEC 1.000V / UL 1.000V).
12

The maximum voltage of the system should not be
exceeded under any circumstances. If the voltage
of the SOLAR FLAT-5XL ceramic roof tile were
expected to surpass the values detailed in the data
sheet under operating temperatures lower than 25°C,
this must be taken into account when designing the
photovoltaic system.
Only personnel qualified to work with photovoltaic
capture systems should access or work with SOLAR
FLAT-5XL ceramic roof tiles or on the solar system.
Before connecting the SOLAR FLAT-5XL ceramic
roof tiles to the inverter, open the circuit breakers and
turn off the inverter.
To prevent electrical discharges, do not carry out
the installation when the SOLAR FLAT-
5XL ceramic roof tiles, installation tools or
installation area are exposed to water.
Before switching on the system, make sure all
the SOLAR FLAT-5XL ceramic roof tiles are
connected and use a multimeter to check the total
voltage of the entire solar tile installation.
Make sure that all connections have been made safely,
without any space between the contacts. Any space
between contacts may cause an electric arc which is
capable of causing a fire and/or electric discharges.
To prevent the appearance of electric arcs and
discharges, NEVER disconnect a solar tile when it
is charging. If this were ever necessary, cover
the surface of the tile with an opaque covering before
disconnecting it.
Make sure that the polarity of each SOLAR FLAT-5XL
ceramic roof tile or string is not inverted in relation to
the rest of the tiles or the strings.
For all connections with inverters, regulators,
batteries or to the general control panel, take into
account the manufacturer’s specifications in each case.
The rated electrical characteristics are within a
range of +5% to -3% of the values measured under
standard test conditions (STC): 1,000 W/sq. m., with
a cell temperature of 25°C and a solar spectrum
corresponding to an air mass of 1.5.
5.6 Installation safety
Solar photovoltaic tiles convert light energy from
sunlight into direct current electricity. They are designed
to be installed outdoors on sloping roofs or facades.
The proper design of the structures which support
the tiles is the responsibility of the system designers
and the installers.
Always use tools and PPE which comply with standards
for electrical installations and working at height.
All electronic components used in the photovoltaic
system (including cables, connectors, charge
regulators, inverters, batteries, etc.) must comply with
safety regulations.
Never unplug connectors or open the electrical circuit
at any point while the circuit is charging or receiving
electric current.
To prevent electrical discharges while handling
the SOLAR FLAT-5XL ceramic roof tiles, we
recommend you cover the surface of the solar tiles with
an opaque material both while installing and removing
them to stop them from generating electricity.
Contact with the electrically charged parts of a SOLAR
FLAT-5XL ceramic roof tile, such as the terminals, may
cause burns, sparks and even lethal shocks, either if
the tile is connected or if it is not.
During the installation, do not touch the photovoltaic
modules unless necessary. The glass surface and
the frame may heat up excessively and there is a
risk of burns or electric shock.
Never install or handle SOLAR FLAT-5XL ceramic roof
tiles if they are wet. Do not carry out the installation
in adverse or severe weather conditions such as high
winds, heavy rain, snow or hail.
To prevent damage to the cables, keep them out of
direct sunlight as much as possible and do not let
them be stained by any product used in assembling
the roof (foam, adhesives, mortar, asphalt, etc.) before
installation.
Only use insulated tools which are authorized for use
in electrical installations.
Duringtheinstallation, repairorremoval of photovoltaic
systems, metallic accessories (bracelets, watches,
rings, earrings or metal piercings anywhere on
the body) must not be worn.
Respect safety regulations (e.g. regulations
concerning working in power plant stations) for all
the other components of the system such as wires
and cables, connectors, load regulators, inverters,
storage batteries, rechargeable batteries, etc.
13

6 GENERAL INSTALLATION INFORMATION
To connect the SOLAR FLAT-5XL ceramic roof
tiles in series or to connect them to another device,
only use identical or compatible connectors.
The warranty will be void if the connectors are
removed.
During the transport and installation of the mechanical
and electrical components, no-one other than
installation personnel should be in the immediate
area.
5.7 Fire safety
Consult the local authorities regarding
the guidelines and requirements for fire safety
in buildings and structures. Always comply with
the regulations in force.
The construction and installation of roofs
(sloping roofs and terraced roofs) may affect
the fire safety of the building; improper installation
may increase fire risks.
Use the components required by local regulations
such as ground fault circuit interrupters and fuses
as required by local regulations.
Do not use SOLAR FLAT-5XL ceramic roof tiles
near to equipment or in places where they could
generate flammable gases.
NEVER use water to extinguish electrical fires.
6.1 Installation design
To create an optimal design for an installation
using SOLAR FLAT-5XL ceramic roof tiles, we
recommend you take the following into account:
• Consider the location of the project (area,
environment, orientation, shade, etc.).
• Draw up an appropriate design for the sloping roof
(gradient, structural load, materials, execution, etc.).
• Ensure compliance with regulations and local rules
before proceeding.
• Define the type of installation (limited self-consumption,
with sale of excess power generated, with storage, or
isolated from the national power grid).
Upon request, Tejas Borja can provide a preliminary
project study, together with an installation proposal
for a solar photovoltaic energy system made using
SOLAR FLAT-5XL ceramic roof tiles. The information
in any such study serves only as a guide for
the design of the photovoltaic installation. Tejas
Borja does not undertake any commitment or assume any
responsibility for the execution of the project. It
will be the accredited installer who must assume
responsibility for fulfilling the design criteria and
the requirements of the installation.
The design of the installation must take into account
local climatic conditions and the characteristics
of the inverter, always complying with current
regulations.
6.2 Location selection
Choose an appropriate place for the installation of
the SOLAR FLAT-5XL ceramic roof tiles.
For the best results, SOLAR FLAT-5XL ceramic roof
tile installations in the northern hemisphere must be
orientated towards the south, and in the southern
hemisphere towards the north.
The minimum recommended gradient for sloping roofs is
30% (*) to maximise energy production. As a general
rule, a tilt angle equal to the latitude facing the equator
may be used. However, the installation must always
be designed according to local conditions to obtain
the best angle.
(*) Minimum recommended gradient for sloping roofs with FLAT-
5XL flat ceramic tiles. In zone 1, a protected location, installed
in a staggered formation with waterproof sheet and a batten
distance of 340 mm on a roof slope of up to 6.5 m. Please consult
the table of minimum slope data depending on the roof length and
geographical area in accordance with standard UNE-136020.
14

For detailed information about the best slope
gradient, please get in touch with us via email:
[email protected].
Although SOLAR FLAT-5XL ceramic roof tiles are
guaranteed to give high performance and produce
the specified energy output, and are highly effective
in the shade, their installation in areas where the tiles
may be shaded at any time is not recommended.
Avoid installing the SOLAR FLAT-5XL ceramic
roof tiles in places which are frequently shaded. If
a SOLAR FLAT-5XL ceramic roof tile is affected
by total or partial shade, its performance will be
impeded, causing a lower power output.
Do not use SOLAR FLAT-5XL ceramic roof tiles
near to equipment or in places where they could
generate flammable gases.
6.3 Climatic conditions
SOLAR FLAT-5XL ceramic roof tiles are
guaranteed to function with a linear output of up
to 80% for 25 years in the following environmental
conditions:
• Operating temperature: -40°C to 85°C.
The system installer must make sure that the installation
methods used comply with the aforementioned
requirements and any other code or regulations in
force.
We can advise you on the design and
specification of a SOLAR FLAT-5XL ceramic
roof tile installation to meet your needs.
Contact us! [email protected]
6.4 Compatibility
6.4.1 Ceramic tile – roof covering
The SOLAR FLAT-5XL ceramic roof tile is entirely
compatible with the FLAT-5XL ceramic tile
https://tejasborja.com/en/roof-tile/at-5xl/
The FLAT-5XL ceramic tile, made from high-quality
stoneware clay, has a water absorption coefficient of
less than 3%, the lowest on the market. This makes it
suitable for installation in any climate. Its dimensions
means it offers all the installation benefits of large
format tiles.
15

The largest ceramic tile ever made
High performance in installation (5 units/sq. m.)
Wide range of finishes
(BorjaJET exclusive)
® TRADE MODEL
> Klinker
35 510
395 457
25
Maximum
Surface Flatness
Mountain
climate
Longitudinal Overlap
45 mm
Flexural
Strength
FLAT-5XL®
Dimensions 457 mm x 510 mm
Minimum pitch recommended 30% - 17º (*)
Weight 6,55 Kg./Unit
Units / sq. m. 5,5 Units
Units per LM eave line 2 Units
Useful width 476 mm
Useful length
(Batten distance) VARIABLE 340-385 mm
Pallet data (G1) 152 Units / 990 Kg.
Minimum order 2 Units **
Approximate values: If the roof tiles are installed on battens, the useful length must be calculated
on site. A tolerance of ± 2% is allowed on the dimensions of the roof tiles according to EN 1024.
(*) In zone 1 (protected area), arranged in staggered formation with waterproof membrane and batten
distance of 340 mm on a skirt of up to 6.5 m. Check pitch pannel according to the roof length and
the geographical area according to EN 136020.
** The tiles are subject to minimum order and must be multiples thereof.
Mountain climate
According
D.3 RP34.02
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6.4.2 Inverters
The choice of inverter will be determined by the
project manager in accordance with the project’s
specifications and requirements while always keeping
in mind and complying with local regulations regarding
the generation of electrical energy in isolated systems
or those connected to the public power grid.
The inverter must be located as near as possible
to the property’s main switchboard, or very close
to the meter, while always being kept out of direct
sunlight.
Modifications to the aforementioned system must be
carried out under the supervision of the project manager.
6.4.3 Cables and Connectors
To prevent overheating of cables and connectors,
the choice of the cross section of the cables
and the capacity of the connectors must be
contingent upon the maximum short circuit
current of the system. The recommended
cable to ensure complete safety is a
photovoltaic cable with a cross section of
4 sq. mm.
Tejas Borja supplies SOLAR FLAT-5XL ceramic
roof tiles with connectors used for electrical
connections in the system. The recommended
connectors are Multi-Contact MC4 or equivalent. To
correctly connect the Multi-Contact MC4 connectors,
they must be pushed together until you hear a click.
The cable bend radius must be at least six times the exterior
diameter of the cable.
All the cabling in the installation must be appropriate
for photovoltaic installations in accordance with
current regulations.
To make connections in parallel, Multi-Contact MC4
connectors or equivalents must be used, whether you
are using string connectors or Y connectors.
6.4.4 Obligatory safety features (*)
Fuses - Protection against reverse current. A string
fuse must be installed between the inverter and
SOLAR FLAT-5XL ceramic roof tiles.
Thermal magnetic circuit breaker - Protection
against short circuits and overloads in the system.
It must be installed between the inverter and
the property’s electrical system.
Residual current device (RCD) - Protection
against contact with live parts of the installation or
leakage due to lack of insulation. It must be installed
between the inverter and the property’s electrical
installation.
* According to current regulations in Spain. Please consult local
regulations for each project.
6.4.5 Optimizers
Due to the characteristics of the SOLAR FLAT-5XL
ceramic roof tiles, the use of optimizers in their
installation is unnecessary.
6.4.6 Seccionadores CC
Should it be necessary, the type and specifications
of the DC isolator switch breaker will be determined,
along with its location in the specified string.
In the event an isolator switch breaker is used, check
that the voltage and the current of the isolator switch
breaker meet the requirements of the installation.
You must ensure that the isolator switch breaker is
correctly located and labelled.
6.4.7 Batería
In the case of an autonomous installation with a storage
system, batteries must be correctly connected to each
other and to the property’s electrical circuit through
a regulator or an inverter/charger.
These batteries must also be large enough to supply
sufficient electricity to the property for the desired number
of days the property needs to be powered by the
electricity stored in the batteries in the event of adverse
weather events which impede the proper operating of
the SOLAR FLAT-5XL ceramic roof tile array.
Example of a string connector
Example of a Y connector
The largest ceramic tile ever made
High performance in installation (5 units/sq. m.)
Wide range of finishes
(BorjaJET exclusive)
17

6.5 Installation requirements
The structure to which SOLAR FLAT-5XL ceramic
roof tiles are attached must be made from a durable
material which is resistant to corrosion, ultraviolet
rays and adverse weather conditions.
All the components and materials used in the installation
must be made from durable materials which
are resistant to corrosion, ultraviolet rays and
adverse weather conditions.
In areas which experience heavy snowfalls, take into
account the slope of the roof where the photovoltaic
system is to be located to prevent the lower edge
of the SOLAR FLAT-5XL ceramic roof tiles getting
covered in snow at any time. Moreover, make sure
that the lowest part of the tiles is high enough so
as not to be shaded by nearby plants or trees or
damaged by sand carried by the wind.
SOLAR FLAT-5XL ceramic roof tiles are to be
installed on sloping roofs together with FLAT-5XL
ceramic tiles and their complementary special
ceramic pieces. When installing SOLAR FLAT-5XL
ceramic roof tiles on the roof, always leave a safe
working area between the edge of the roof and
the outer edge of the solar array.
Never place SOLAR FLAT-5XL ceramic roof tiles
in the first row of tiles at the eaves, in the rows next
to the gables, in the rows of tiles below the ridge or
next to other joins or singular points in the roof. It
is particularly important not to install SOLAR FLAT-
5XL ceramic roof tiles near to chimney pieces.
SOLAR FLAT-5XL ceramic roof tiles must be
safely attached to the mounting structure. SOLAR
FLAT-5XL ceramic roof tiles must be attached
using 2 self-drilling, rustproof screws.
SOLAR FLAT-5XL ceramic roof tiles must always
be installed on ventilated roofs using a double batten
system or equivalent. Make sure there is adequate
ventilation under the SOLAR FLAT-5XL ceramic
roof tiles in accordance with current regulations.
In general, we recommend a minimum distance of
45 mm between the roof surface and the solar tile
frame.
Always follow the instructions and safety
precautions which are included with the solar tiles
support structures.
When installing SOLAR FLAT-5XL ceramic roof
tiles onto a roof, make sure that the construction
of the roof is adequate. Moreover, to prevent leaks,
any perforation made in the roof support in order to
install the solar tiles must be properly sealed.
The accumulation of dust on the surface of the solar tiles
may reduce their output. Tejas Borja recommends
that SOLAR FLAT-5XL ceramic roof tiles are
installed at a minimum gradient of 30% to help
the rain to wash dust from the tiles and ensure
the watertightness of the roof.
Make allowances for the linear thermal expansion
of the SOLAR FLAT-5XL ceramic roof tiles frames
(we recommend leaving a minimum distance of 2
mm between one SOLAR Flat-10 tile and another).
Make sure the solar tiles are not subject to wind or
snow loads which exceed the maximum approved
loads or excessive forces due to the thermal
expansion of the support structures.
All SOLAR FLAT-5XL ceramic roof tiles must be
securely attached so they are able to withstand
wind and snow loads lower than the maximum
approved loads.
6.4.8 Inverter/charger
If the installation includes a storage system,
the inverter may be replaced by an inverter/
charger which combines the functions of
the inverter and a regulator in one single
device.
6.4.9 Meter
It is possible to install a meter to precisely measure
the electricity generated or supplied to the grid at
a certain point in the installation through the SOLAR
FLAT-5XL ceramic roof tile array.
6.4.10 Load regulator
If the installation includes a storage system which
uses a conventional inverter, a load regulator
must be installed between the SOLAR FLAT-
5XL ceramic roof tile array and the inverter. This
regulator is the device which connects the batteries
to the electrical circuit and controls the charge level
of the batteries, thereby guaranteeing their optimal
charge and extending the useful life of the batteries.
6.4.11 Electrical switchboard
If the property’s electrical switchboard does not have
enough space to house the necessary protective
components for the photovoltaic generator
circuit, a switchboard will have to be installed outside
the property which can house the necessary protective
components.
6.4.12 Monitoring systems
If the client wishes to monitor all the energy flows,
opt for zero injection into the grid or manage
charging, an energy management device must be
installed in the property’s electrical circuit after
the electric meter.
18

Fall protection system for
working at height
C
B
A
Anchorage
Connection
Harness
We can advise you on the design and
specification of a SOLAR FLAT-5XL ceramic
roof tile installation to meet your needs.
Contact us! [email protected]
6.6 Pre-installation preparation and
precautions
Install the components described in the manual
and follow its instructions. Tejas Borja will not be
liable for any damages caused due to an installation
which does not comply with the instructions in this
manual.
Before beginning the installation, the installers
must ensure that the amount of SOLAR FLAT-
5XL ceramic roof tiles and the cabling are
compatible with the installation area and must follow
the instructions for the installation of the inverter and
other system components in accordance with their
respective manuals.
When installing the sloping roof with the SOLAR
FLAT-5XL ceramic roof tile system, the installation
personnel must include a ceramic tile installer and
an electrician to install the solar tiles.
SOLAR FLAT-5XL ceramic roof tiles are installed
in the same way as FLAT-5XL ceramic tiles, the former
having been designed to combine perfectly with the latter.
Due to its dimensions, one SOLAR FLAT-5XL ceramic
roof tile is the same size as 1 FLAT-5XL ceramic tile unit.
Before beginning the installation, we recommend
you mark out the area where the solar array will
be located. Similarly, we recommend having
marked out the location of the other elements
which make up the solar installation (inverter,
fuses, optimizer, etc.) and checked that the solar
tiles operate correctly before installing them.
6.6.1 Accessories and tools for
the installation
Personal Protective Equipment (PPE):
The type of screw used to fix the SOLAR FLAT-
5XL ceramic roof tiles in place will depend on
the type of batten the tiles are to be fixed to
(metal or wood).
Cables to connect the strings in parallel
and connectors (see 6.3.4 Cables and
connectors).
Slip-resistant footwear Insulating gloves
19

6.6.2 Batten installation
The roof must be waterproofed before installing
both the primary and secondary mounting battens.
Insulating the roof when installing SOLAR FLAT-5XL
ceramic roof tiles and completing the roof with
FLAT-5XL ceramic tiles and their associated special
pieces is not an essential requirement. However,
Tejas Borja recommends using the BORJATHERM
insulation system to further improve the property or
project.
Installers must make sure installations comply with
national and/or local regulations to ensure the compatibility
of the mounting battens with the dimensions of the SOLAR
FLAT-5XL ceramic roof tile. If using wooden battens, these
must be at least 40 mm (width) x 30 mm (depth). Primary
and secondary battens must be used to create an air
chamber under the tiles and enable the routing of cables
underneath them.
The SOLAR FLAT-5XL ceramic roof tile is
completely compatible with the FLAT-5XL ceramic
tile. Consequently, the distance between two
horizontal battens is variable, using the same
spacing as that for the ceramic tile (from 340 to
370 mm; a spacing from 355 mm upward is
recommended).
The primary battens are installed in the direction
of the slope. The recommended spacing between
primary battens is from 400 to 600 mm. For other
configurations, please consult the Tejas Borja
Technical Department. When the roof support
structure is protected by a waterproof/breathable
membrane, the underside of the battens must be
protected with under-batten tape, installed before
the primary battens are fixed in place, to prevent
water seeping through the screw holes.
The first batten at the eaves must be at least 2 cm
higher than the rest to preserve the slope on the first
row of tiles. To achieve this, an eaves batten which is
thicker than the rest may be used and/or an additional
batten may be added.
Key:
D - distance between primary battens (400-600 mm)
d1 - distance to first secondary batten
(ensure tile overlap) (345-360 mm)
d2 - distance to secondary batten (355-370 mm)
1 - additional eaves batten
2 - eaves grate
3 - secondary eaves batten
4 - primary batten
5 - secondary batten
6 - under-batten tape
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