Grape Solar Photovoltaic Modules Safety and Installation Manual

PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
Grape Solar Photovoltaic Modules
Safety and Installation Manual
This document applies to Grape Solar photovoltaic modules with model number CS-S-160-DJ CS-S-165-DJ
CS-S-170-DJ CS-S-175-DJ CS-S-180-DJ, CS-P-200-DJ, CS-P-210-DJ, CS-P-220-DJ, CS-P-230-DJ, CS-P-240-DJ,
CS-P-250-DJ, CS-P-260-DJ, CS-P-270-DJ and CS-P-280-DJ. Carefully read through this manual in its entirety before
installing, operating or servicing the photovoltaic (PV) system. Failure to comply with the instructions described in this
manual may cause bodily injury or damage to property, and invalidate Grape Solar’s limited warranty for photovoltaic
modules!
©Copyright 2010, Grape Solar, Inc. All Rights Reserved
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Tel: 1-877-264-1014 (toll free), 1-541-349-9000, Fax: 1-541-343-9000
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
Table of Contents
I.
General Information ............................................................................................3
II. Safety Precautions ……………………………………...........................................4
III. Module Installation ..............................................................................................7
IV. Maintenance ......................................................................................................11
V. Disclaimer of Liability ………..............................................................................12
VI. Appendix ……….................................................................................................13
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Tel: 1-877-264-1014 (toll free), 1-541-349-9000, Fax: 1-541-343-9000
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
I. GENERAL INFORMATION
1. Grape Solar photovoltaic (PV) modules are designed to produce DC electrical energy from sunlight.
2. This manual contains important safety and installation information of Grape Solar PV modules. All
safety and installation instructions described in this manual should be thoroughly understood before
installing, operating and maintaining the PV system.
3. Working on a PV system requires specialized knowledge, and must be performed by appropriately
qualified and authorized personnel only.
4. Grape Solar PV modules are subject to operate at ambient temperatures within the range -40°C to
+80°C (-40°F to +176°F).
5. PV modules are intended for outdoor, land-based applications only.
6. Rated power output specification of Grape Solar PV modules are made at the Standard Test Condition
(STC), which is 1000W/m2 irradiance, 1.5 Air Mass (AM), and 25°C (77ºF) cell temperature. However,
PV modules can produce voltage at as little as 5% of full sunlight, either connected or not connected to
an electrical circuit or load.
7. Electrical current and power generated by PV module increases with light intensity and higher power
output than the rated specifications can be achieved at colder temperatures.
8. Reflection from snow, water or other surfaces can increase light intensity, and therefore increase the
current and power generated by the module.
9. Do not artificially concentrate light on the module. Concentrating light on the module may result in
damage to the module and malfunction of the whole PV system.
10. Follow all safety precautions of other components used in the PV system.
11. Retain this manual for future reference.
12. Grape Solar recommends that the customer makes a note of the serial numbers of modules in order to
keep a record of the system.
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
II. SAFETY PRECAUTIONS
1. General Safety
1.1
Ensure that the modules are used for the intended purpose only.
1.2
When installing, operating and maintaining the PV system, observe all local, regional, national
and international statutory regulations, guidelines, norms and code requirements.
1.3
The safety information for other system components must also be followed.
1.4
Keep children away from the module and PV system.
2. Handling Safety
2.1
The utmost care is required when unpacking, transporting, and storing the modules. Leave
modules in packaging until they are to be installed.
2.2
Always store the modules in a dry, ventilated in-door space if possible. If the un-connected
modules have to be stored outside for any length of time, always have the glass surface facing
down and cover modules with water-proof material to prevent water collecting inside the panel
and causing damage to exposed connectors.
2.3
Carry modules with both hands. Do not use the junction box as a handle to hold or transport the
module.
2.4
Do not stand or step on the module.
2.5
Do not drop module or allow objects to fall on module.
2.6
Do not mark or scratch the front or rear surface of the module with sharp objects.
2.7
Do not disassemble, modify or adapt the module such as drilling holes in the frame or glass. Do
not apply paint or adhesive to the module rear surface.
2.8
Do not remove any part or labeling installed by Grape Solar from the module. Doing so will
void the module warranty.
2.9
Keep all electrical contacts of module clean and dry. Do not handle modules when they are wet
unless wearing the appropriate protective equipment.
2.10 Do not leave a module unsupported or unsecured.
2.11 There are no user serviceable parts within the module. Do not attempt to repair any part of the
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
module. Broken or damaged modules must not be used and must be handled carefully and
disposed properly since the broken glass can be sharp and cause bodily injury if not handled
with the appropriate protective equipment, and contact with any surface or the frame of the
broken module can result in electrical shock.
3. Installation Safety
3.1
All installations must be performed in compliance with the National Electrical Code (NEC) and
any applicable local codes by authorized personnel. If the module is installed in Canada,
installation shall be in accordance with CSA C22.1, Safety Standard for Electrical Installations,
Canadian Electrical Code, Part 1.
3.2
Keep children away from module and the system when installing.
3.3
Do not wear metallic jewelry while performing mechanical or electrical installation of modules
to avoid accidental exposure to live circuits.
3.4
When working with modules exposed to light, follow all applicable regulations regarding
working with live electrical equipment.
3.5
Do not install or handle the modules when they are wet or during periods of high wind.
3.6
Do not install modules where contact with salt water is likely or where modules are likely to
become partially or wholly submerged in fresh or salt water, examples of which include boats,
docks and buoys.
3.7
Always use insulated tools and rubber gloves that are approved for working on electrical
installations to reduce the risk of electric shock.
3.8
Always use equipment, connectors, wiring and support frames suitable for PV electric system.
3.9
When installing modules on elevated locations, such as a rooftop, use caution to avoid falling or
other safety hazards by following appropriate safety practices and using required safety
equipment.
3.10 PV modules do not have a power ON/OFF switch. The only way to make modules inoperative
is removing them from light, or fully covering their front surface with an opaque material, or
placing modules face down on a smooth, flat surface.
3.11 Avoid setting the module down with any type of force on any surface, particularly when placing
it on a corner.
3.12 To prevent untrained personnel from disconnecting the modules after installed, locking
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
connectors and safety clips must be used in the installation.
3.13 Do not touch electrical terminals or the ends of any wire while installing the module. Do not
open electrical connections or unplug connectors while the PV system circuit is under load.
Contact with electrically active parts of the modules, such as terminals, can result in burns,
sparks and lethal shock whether the module is connected or disconnected.
3.14 Cover all modules in the PV array with an opaque cloth or material before making or breaking
electrical connections.
3.15 Broken junction boxes or broken connectors are electrical and laceration hazardous and cannot
be repaired. Please contact the installers to remove the broken module from the array and
contact the supplier for disposal instructions.
4. Fire Safety
4.1
4.2
4.3
4.4
4.5
Grape Solar’s PV modules are non-explosion-protected equipment and fire rated Class C.
Building fire safety may be affected by installing PV system. Improper installation may lead to
hazards in the event of fire. Refer to local authority for guidelines and requirements for building
or structural fire safety.
For roof installation, PV modules should be mounted over a fire resistant covering which is
rated for the application.
Do not install modules near equipment or locations where flammable gases can be generated or
collected.
Grape Solar recommends using components such as earth ground fault circuit breakers, fuses
and circuit breakers in the PV system for fire prevention.
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
III.
1.
2.
MODULE INSTALLATION
Installation Site Selection
1.1
The site for PV module installation shall have environment temperature within Grape Solar’s
PV module operating temperature range -40°C to +80°C (-40°F to +176°F).
1.2
The site shall allow all modules to be exposed to sunlight without obstruction all year round
(shadows generated by trees or buildings, even partial shading, on the module array will result
in reduction of PV system yield).
1.3
The site shall have adequate ventilation of the module backside to avoid heat build-up, which
can cause module performance degradation and system yield reduction. For roof mounted
systems, at least a 2 inch clearance is required between the module back surface and roof for
rear ventilation and module cooling.
1.4
The modules are designed to have maximum mechanical load at 2400 Pascal (50 lbs/ft2). To
avoid exceeding the maximum load, site specific loads such as wind and snow should be taken
into account.
1.5
The site should not have exposure to extremely corrosive chemicals (e.g. emissions from
manufacturing facilities).
Module Orientation & Tilt Angle
2.1
2.2
3.
To obtain maximum yield from the PV system, the direction and tilt angle for the modules shall
be set to receive the incident sunlight perpendicularly to the module surface. To avoid
performance degradation in serial connected module strings, all modules shall have the same
orientation and tilt angle.
To avoid dirt build-up on the glass against the frame edge, low module tilt angle is not
recommended. Dirt build-up on the module surface can cause partial shading and degrade
module and system electrical performance.
Electrical Connection
3.1
All installations must be performed in compliance with the National Electrical Code (NEC) and
any applicable local codes by authorized personnel. If the module is installed in Canada,
installation shall be in accordance with CSA C22.1, Safety Standard for Electrical Installations,
Canadian Electrical Code, Part 1.
3.2
Modules may be connected in series and/or in parallel to achieve the desired electrical output.
When serial connected, all modules must have the same amperage, but the maximum open
circuit voltage of the system must not exceed the specified maximum system voltage of the
modules. When parallel connected, all modules must have the same voltage.
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
3.3
3.4
3.5
3.6
3.7
3.8
4.
Do not use modules with different electrical performance or physical property in the same
system.
To prevent untrained personnel from disconnecting the modules when under load, which may
cause serious bodily injury or death, all Grape Solar PV modules are equipped with
factory-installed wires and Multi-Contact® Type-3 or Type-4 quick connectors with locking
safety clip. Once connected, the connector requires the use of a special tool to disconnect
module-to-module connections.
When making module-to-module connections, the polarities of cables and terminals must be
matched. Failure to do so may result in damage to the module and void the module warranty.
Use cables and wires with adequate cross-sectional areas (min. of 12AWG) and suitable
connectors (Multi-Contact interlockable connectors, such as MC4 type) which are approved for
use at the maximum short-circuit current of the module.
Over-current device (e.g. fuse or circuit breaker) whose rating is not greater than the value of the
protective fuse marked on the back of the module must be serial connected with each module or
string of modules when reverse current is anticipated to exceed the value of the module
protective fuse.
The junction box contains factory installed 3 bypass diodes and is not designed to be field
accessible or maintainable, and should not be opened under any circumstances. Opening the
junction box will void the warranty.
Grounding
4.1
To reduce the possibility of electrical shock and protect the PV system from lightning, all
module frames and mounting racks must be properly earth grounded by using grounding
hardware that has been UL certified and in accordance with the National Electrical Code before
wiring the circuit.
4.2
If the building at which the PV system is installed is already equipped with exterior lightning
protection system, the PV system installation must be integrated in the lightning protection
system.
4.3
Each PV module has a hole on the each side with a grounding sign
. Grape Solar
recommends the following two methods of grounding the module frame.
4.3.1 Use the listed grounding and bonding equipment (KDER), e.g. SOLKlip type 1954381-1,
by Tyco Electronics Corp (E69905), to provide a reliable grounding connection to the
module frame.
4.3.2 Use a set of stainless steel grounding and bonding equipment including bolt/nut/cupped
washer/flat washer/serrated washer) to provide a reliable grounding connection to the
module frame (refer to Figure-1). A flat washer is required between serrated washer and
Φ2.5mm grounding wire. A cupped washer is required between grounding wire and the
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
nut (with torque less than 4N•m). Grounding wire should be directly connected with the
screw.
4.4
The rack must also be grounded unless they are mechanically connected by nuts and bolts to the
grounded PV modules. The array frame shall be grounded in accordance with NEC Article 250.
1
2
3
4
5
6
Stainless steel M5 nut
Stainless steel cupped M5 washer
Stainless steel flat M5 washer
Stainless steel M5 serrated washer
Grounding lead
Stainless steel M5 bolt
Figure-1 Grounding panel frame with stainless steel grounding & bonding equipment
5.
Mounting
5.1
The modules have been evaluated by UL for a maximum positive or negative design loading of
30 lbs/ft2. The maximum load on the module must not exceed 2400 Pascal (50 lbs/ft2).
5.2
Each module must be securely fastened at a minimum of 4 points using support frames or
mounting kits specialized for PV applications.
5.3
Panels may be mounted at any angle from vertical to horizontal orientation. However, to obtain
maximum yield from the PV system, the direction and tilt angle for the modules shall be set to
receive the incident sunlight perpendicularly to the module surface.
5.4
For roof mounted systems, at least a 2 inch clearance is required between the module back
surface and roof for rear ventilation and module cooling.
5.5
Clearance of a quarter inch or more between modules is required to allow for thermal expansion
of the frames.
5.6
Keep the back surface of the module free from any foreign objects or structural elements which
could come into contact with the module, especially when the module is under mechanical load.
5.7
To prevent water from entering the junction box, which could result in a safety hazard, modules
should not be mounted with the front/top glass facing downward.
5.8
Clearance between the module frames and structure or ground is required to prevent wiring
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
damage and allows air to circulate behind the module.
5.9
PV modules can be mounted to the structure by the following methods:
5.9.1 Frame Holes: Secure the module to the structure using the mounting holes. There are 8
mounting holes in the frame of the module and they have been evaluated by UL for
mounting. At least four stainless steel screws of the Ø 10*22mm, the stainless steel nuts
and washers of Ø 10mm are required to mount the module securely. It is recommended that
the nut be tightened to a torque of 2.5Nm.
5.9.2 Pressure Clamps or Clips: Mount the module with the clips on the side frame of the
module. The side frames are attached to the longer sides of the module. Installers should
ensure the clamps are of sufficient strength to allow for the maximum design pressure of
the module.
5.10 Modules must be securely fastened at a minimum of 4 points on the long sides. Mounting the
module only on the short side is NOT allowed. Doing so will void the warranty.
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PHOTOVOLTAIC MODULES SAFETY
AND INSTALLATION MANUAL Rev. K
VALID IN NORTH AMERICA ONLY
IV. MAINTANIENCE
1. No routine maintenance is required.
2. Grape Solar recommends that periodic inspection of the PV system for tight electrical and mechanical
connection and free of corrosion should be performed.
3. Periodic cleaning of modules is not required, but is recommended, as periodic cleaning can result in
better performance of the PV system, especially in regions with low levels of annual precipitation.
4. Do not remove the dirt by scraping or rubbing away from the module front surface when dry as this
may cause micro-scratches on the glass and lead to module performance degrading.
5. Water can be used for regular washing or rinsing of the module front glass to remove dust, dirt or other
deposits.
6.
To remove ingrained dirt, first rinse off area and let soak for a short period of time (5-minutes). Re-wet
and use a soft sponge or seamless cloth to wipe glass surface in a circular motion. Mild detergent or
glass cleaner may be used to clean the ingrained dirt, but harsh cleaning materials such as scouring
powder, steel wool, scrapers, blades, or other sharp instruments must not be used to clean the module.
Use of such materials will void the product warranty.
7. Always wear rubber gloves for electrical insulation while maintaining, washing or cleaning panels.
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PHOTOVOLTAIC MODULES SAFETY
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VALID IN NORTH AMERICA ONLY
V. DISCLAIMER OF LIABILITY
Since the use of this safety and installation manual and the conditions and methods of installation, operation,
use and maintenance of the modules are not checked or monitored by Grape Solar Inc. Grape Solar assumes
no liability for loss, damage, injury or expense arising through improper use or incorrect installation,
operation or maintenance.
Furthermore, Grape Solar assumes no responsibility for any infringement of patents or other rights of third
parties that may result from use of the module. No license is granted by implication or otherwise under any
patent or patent rights.
The information in this Manual is based on Grape Solar’s knowledge and experience and is believed to be
reliable; but such information including product specifications (without limitations) and suggestions do not
constitute a warranty, expressed or implied. Grape Solar reserves the rights to make changes to the product,
specifications or this Manual without prior notice.
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PHOTOVOLTAIC MODULES SAFETY
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VALID IN NORTH AMERICA ONLY
Appendix
Figure-2 Position of Mounting Holes, Model#: CS-S-160-DJ, CS-S-165-DJ, CS-S-170-DJ, CS-S-175-DJ, and CS-S-180-DJ
Figure-3 Position of Mounting Holes, Model#: CS-P-200-DJ, CS-P-210-DJ, CS-P-220-DJ, CS-P-230-DJ, and CS-P-240-DJ
Figure-4 Position of Mounting Holes, Model#: CS-P-250-DJ, CS-P-260-DJ, CS-P-270-DJ, and CS-P-280-DJ
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Valid from September 2010
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