Renogy Solar Panel 1200W for Off-Grid On-Grid Installation Manual

Renogy Solar Panel 1200W for Off-Grid On-Grid Installation Manual
INSTALLATION GUIDE FOR
PHOTOVOLTAIC (PV) MODULES
Contents
1.
Purpose of this Guide ......................................................................................................... 3
1.1. Disclaimer of Liability ....................................................................................................... 3
1.2 General Safety.................................................................................................................. 3
1.3 Safety Precaution Measures ............................................................................................. 3
2.
Product Identification .......................................................................................................... 4
3.
Installation Considerations .................................................................................................. 4
3.1 Unpacking and Storing ..................................................................................................... 4
3.2 Pre-Installation Requirements........................................................................................... 4
3.3 Site Considerations .......................................................................................................... 5
3.4 System Fire Rating ........................................................................................................... 5
4.
Module Mounting ................................................................................................................ 5
4.1 Bolting .............................................................................................................................. 5
4.2 Top Down Clamps ............................................................................................................ 6
4.3 Grounding......................................................................................................................... 6
4.4 Module Dimensions .......................................................................................................... 6
5. Electrical Installation .............................................................................................................. 8
5.1 Electrical Specifications .................................................................................................... 8
5.2 Cables and Wiring ............................................................................................................ 9
5.3 Bypass Diodes.................................................................................................................. 9
5.4
General Installation .....................................................................................................10
5.5 Grid Connected Electrical System ...................................................................................10
6. Commission and Maintenance ..............................................................................................10
6.1 Testing, Commissioning, and Troubleshooting ................................................................10
6.2 Maintenance ....................................................................................................................11
6.3 Replacing Bypass Diodes ................................................................................................11
2
photovoltaic module that is exposed to sunlight, an electric arc may result.
1. Purpose of this Guide
Such arcs may cause burns, may start fires and may otherwise create
problems. Therefore, be extremely careful!
This guide contains information regarding the installation for solar
modules. All instructions should be read and understood before attempting
Solar modules change light energy to direct-current electrical energy. They
to install. If there are any questions, please contact us for further
are designed for outdoor use. Modules may be ground mounted, mounted
explanation. The installer should conform to all the safety precautions
on roof, vehicles or boats. Proper design of support structures is the
listed in this guide when installing the module. Local codes should also be
responsibility of the system designer and installer.
followed in such installations. Before installing a solar photovoltaic system,
the installer 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 incase of sale or disposal of the
module at the end of its useful life.
This document is applicable to the series of solar modules listed below:

Do not attempt to disassemble the module, and do not remove any
attached nameplates or components.

Do not apply paint or adhesive to module top surface.

Do not use artificially concentrated sunlight directly on the module.
When installing the system, abide with all local, regional and national
statutory regulations. Obtain a building permit where necessary. Abide


RNG260D; RNG250D; RNG150D; RNG100D; RNG50D; RNG30D;
with any local and national regulations when mounting on vehicles or
RNG20D; RNG10D
boats. Safety precaution for installing a solar photovoltaic system
RNG300P; RNG270P; RNG260P; RNG250P; RNG100P; RNG50P
1.3 Safety Precaution Measures
1.1. 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 Renogy’s control, Renogy does not accept
Solar modules produce electrical energy when light shines on their front
responsibility and expressly disclaims liability for loss, damage, or
surface. The DC voltage may exceed 30V. If modules are connected in
expense arising out of or in any way connected with such
series, the total voltage is equal to the sum of the individual module
installation, operation, use or maintenance.
voltages. If modules are connected in parallel, the total current is equal to
No responsibility is assumed by Renogy for any infringement of
the sum of individual module currents.
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
installing mechanical and electrical components.

based on Renogy’s knowledge and experience and is believed to
be reliable; but such information including product specification

systems.

sheets without prior notice.
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,
Installing solar photovoltaic systems may require specialized skills and
knowledge. Installation should be performed only by qualified personnel.
Do not wear metallic rings, watchbands, ear, nose, lip rings or other
metallic devices while installing or troubleshooting photovoltaic
expresses or implied. Renogy reserve the right to change the
1.2 General Safety
Completely cover the module with an opaque material during
installation to keep electricity from being generated.
(without limitations) and suggestions do not constitute a warranty,
manual, the PV produce, the specifications, or product information
Keep children well away from the system while transporting and
inverters, storage batteries and rechargeable batteries, etc.

Use only equipment, connectors, wiring and support frames suitable
All modules come with a permanently attached junction box and #12 AWG
for use in solar electric systems. Always use the same type of module
wire terminated in connectors. Renogy can provide customers with fitted
within a particular photovoltaic system.
cables for ease of installation, if desired. The installer should assume the
risk of all injury that might occur during installation, including, without
limitation, the risk of electric shock.
Under normal outdoor conditions the module will produce current and
voltages that are different than those listed in the data sheet. Data sheet
values are values expected at standard test conditions.
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. When disconnecting wires connected to a
3
2. Product Identification

Renogy modules have been qualified for Application Class A.
Before installing, obtain information about any requirements and preapprovals for the site, installation, and inspection from the relevant
authorities.
Modules qualified for safety through IEC 61140 and within this
application class are considered to meet the requirements for Safety

Check applicable building codes and ensure that the structure can
bear the module system load
Class II. Modules rated under this class should be used in systems
operating at a voltage above 50 VDC or power above 240 W, where

Ensure the supporting roof has fire resistant roof covering
general contact access is anticipated.

Renogy modules are listed as Class C under the UL790 Standard.
3.1 Unpacking and Storing
A photovoltaic system composed of UL1703 certified modules
mounted on a UL2703 certified mounting system should be evaluated
in combination with roof coverings in accordance with UL1703
standard, with respect to meeting the same fire classification as the
roof assembly. UL-1703, includes revisions through October 12,
2015, Section 16 and 31.1.2; UL790-2014

Module Fire Performance Type 1
o
Mounting systems with a System Fire Class Rating (Class
Unpack module pallets carefully, making sure to follow all directions on the
pallet.

A, B, or C), tested in conjunction with fire rated “Type 1”
loads may cause variances of micro-cracks on the cells which will
modules, are considered to be acceptable for use by
Renogy.
Each module has three labels on its rear side providing the following
information:
Do not step, walk, stand, or jump on any modules. Localized heavy
ultimately compromise module reliability

Do not carry modules on your head or carry modules through the
wires or junction box

Do not use sharp instruments on the modules, especially the
sensitive backsheet

Nameplate: describes the product type; rated power, rated current,

Do not leave modules unsupported or unsecured
rated voltage, open circuit voltage, short circuit current, all as

Keep all electrical contacts clean and dry
measured under standard test conditions; weight, dimension etc.
3.2 Pre-Installation Requirements

Ensure that the modules meet the general technical system
requirements.

Ensure other system components do not damage the modules
mechanically or electrically

Modules can be wired in series to increase voltage or in parallel to
increase current. Series connections have the modules go from
positive of one module to negative of the second module. Parallel
connections connect the positive cables of one module and the
second module.

Bypass diodes in the modules depends on the model itself.

Modules must not be connected together to create a voltage that is
higher than the maximum system voltage.

A maximum of two strings can be connected in parallel without
needing to incorporate an over-current protection device.

Bar code: each individual module has a unique serial number.

Do not remove any label. If the label is removed the product warranty
will no longer be honored by Renogy.

Only modules with similar electrical output should be connected in
the same string to avoid mismatch effects.

The small drainage holes on the undersize of the module must not
be blocked.
3. Installation Considerations

Avoid shading—even minor partial shading reduces yields. Sunlight
should be able to reach the module even on the shortest day of the
year. Shading can affect module service life.
4


The module should be facing true south in northern latitudes and true
for more details. Note that the holes in the center (blue) are for
north in southern latitudes for best power production.
grounding.
For detailed information on the best elevation tilt angle for the

Modules should be safely fixed to bear all expected loads, including
installation, refer to standard solar photovoltaic installation guides or
wind and snow loads. A minimum clearance of 0.25 in (6.5mm) or
a reputable solar installer or systems integrator.
more between modules is required to allow for thermal expansion of
the frames.
3.3 Site Considerations
Renogy modules should be installed in locations that meet the following
requirements:

Operating Temperature within -40°F to 194°F

Relative humidity within 45% to 95%

Avoid trees, buildings, or obstructions
Renogy modules are designed with a mechanical load strength of 2400Pa
3.4 System Fire Rating
The fire rating of Renogy modules is only valid when mounted in the
manner specified in the mechanical mounting instructions. When
installing modules on rooftops, please ensure the assembly is mounted
over a fire resistant roof covering rated for the application.





Renogy non-BIPV modules are certified through Intertek as Type 1
for fire performance
The System Fire Class Rating of the module or panel in a mounting
system combination with a fire resistant roof rating is the only way
to achieve this rating.
Any system limitations on inclination or accessories required to
maintain a specific Fire Class Rating should be clearly specified in
the installation instructions and UL2703 Certification of the
mounting system supplier
The modules are intended for use in general open-air climate, as
defined in IEC 60721-2-1: Classification of environment condition
Part-2-1: environmental conditions appearing in nature temperature
and humidity.
To preserve individual module fire class rating, PV modules must be
mounted on a non-combustible surface standoff height of at least 5
inches with 0° inclinations.
Mounting Holes
(Length * Width):
14mm x 9mm
RNG100D Example
4.1 Bolting
Modules must be mounted using the mounting holes located on the rear
side of the long frame parts using M6 or M8 bolt stainless steel bolts,
nuts, and washers. Refer to the racking manufacturer for specific torque
requirements.
The mounting design must be certified by a registered professional
engineer and comply with local code requirements from relevant
authorities.
4. Module Mounting


All installation methods herein are only for reference and Renogy will
not provide their own mounting components. Instead, the system
stainless steel

installer is responsible for making sure installation is abided by all
codes.



Each module must be securely fastened at a minimum of 4 points
on two opposite sides. *Actual bolt depends on railing and
required to maintain a specific System Fire Class Rating should be
certification of the mounting system supplier.
Do NOT drill holes or modify the module frame as it will void
warranty.
Any mounting system limitations on inclination or accessories
clearly specified in the installation instructions and UL2703
Use appropriate corrosion-proof fastening materials—should be
professional installer.

Design load and safety factors will be determined by racking
suppliers or professional engineers.
In order to maintain the fire class rating, the distance between the PV
modules (front glass) and the roof surface should be at least 5 in.

Module mounting must use the pre-drilled mounting holes (Length *
Width: 14mm x 9mm) 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 frame. Refer to the following picture
5

Note that the stainless steel washer is used between the grounding
wire and the module frame. This is for avoiding corrosion due to
dissimilar metals.

The module frame must be properly grounded (refer to NEC clause
250). 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.

4.2 Top Down Clamps
Clamps are an approved method of mounting for Renogy modules. A
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; rated for
clamp holds two modules in a row. The centerline of the clamps must be
600Volts;
company:
ILSCO;
UL
number
is
E34440)when
in-line with the module mounting holes and installed according to code.
grounding. First strip 16mm insulating jacket from the end of the
ground wire (4-14 STR.) carefully to avoid nicking or cutting
conductors, insert the wire into the slot of the lug (see the picture),
and screw down the slotted screw.

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
4.3 Grounding
The frame of the PV module, as well as any exposed non-current carrying
metal parts of fixed equipment that can be energized must be grounded to
avoid electrical shock. Renogy recommends grounding all PV module
frames to ensure the voltage between the conductive equipment and the
earth ground is zero in all circumstances.
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.
4.4 Module Dimensions
The modules will be mounted using the mounting holes (on the short
Appropriate grounding consists of using an appropriately sized EGC or
side of the aluminum frame), closest to the edges.
racking system that can be used for integrated grounding. Renogy panels
implement a coated aluminum frame for corrosion resistance. The frame
rails have pre-drilled holes marked with the grounding sign. Do not drill
additional holes into the frame rails.
6
260 D | 250D
150D
RNG100D
RNG50D
RNG30D
RNG20D
7
RNG10D
RNG100P
RNG300P
RNG50P
5. Electrical Installation
RNG270P | RNG260P | RNG250P
5.1 Electrical Specifications

The electrical characteristics are within ±10 percent of the indicated
values of Isc, Voc, and Pmax under Standard Test Conditions (STC
Irradiance of 100mW/cm2, AM 1.5 spectrum, and a cell temperature
of 25°C (77°F))

Under normal conditions, a photovoltaic module is likely to
experience more current and/or voltage than its Standard Test
Condition’s rated output. Accordingly, the values of Isc and Voc
marked on this module should be multiplied by a factor of 1.25 when
determining component voltage ratings, conductor ampacities, fuse
sizes, and size of controls connected to the PV output. (Additional
multiplier of 1.56 may be applicable when sizing conductors and
fuses)
8
Electrical characteristics are displayed below:
Voltage
Module
Rated
at Rated
Power
Power,
(W)
Vmpp
(V)
Current
Open
Short
at Rated
Circuit
Circuit
Power,
Voltage
Current,
Impp (A)
(V)
Isc (A)
Maximum
System
Voltage
UL Vmax
(V)
RNG260D
260
30.40
8.56
37.60
9.09
1000
RNG250D
250
30.10
8.32
37.50
8.87
1000
RNG150D
150
17.90
8.38
22.5
9.05
1000
RNG100D
100
18.9
5.29
22.5
5.75
1000
RNG50D
50
18.5
2.70
22.7
2.84
1000
RNG30D
30
17.5
1.71
21.6
1.85
1000
RNG20D
20
17.5
1.14
21.6
1.23
1000
RNG10D
10
17.5
0.57
21.6
0.62
1000
RNG300P
300
37.46
8.01
46.12
9.56
1000
RNG270P
270
30.80
8.77
37.90
9.26
1000
RNG260P
260
30.40
8.56
37.60
9.09
1000
RNG250P
250
30.20
8.26
37.30
9.84
1000
RNG100P
100
17.8
5.62
22.4
5.92
1000
RNG50P
50
17.8
2.84
22.4
2.95
1000
Portrait Orientation

Landscape Orientation
Series Connections are just plug and play with the male and female
MC4 connectors
Max
Rated
10A
Current
Rated electrical characteristics are within 10% of measured values at STC

Conditions of 1000W/m2, 25°C cell temperature, and spectral irradiation of
Parallel connections will utilize MC4 branch connectors for
centralizing all positive and all negative connections.
AM 1.5 spectrum.
5.2 Cables and Wiring
Renogy modules are equipped with two (2) stranded, PV-rated, output
MC4 cables. The positive connector is a male connector and the negative
connector is a female connector. These wires by themselves are rated for
series connections, but could be adapted to hold parallel connections with
an extra component such as a combiner box or an MC4 adaptor for parallel
strings. Renogy recommends that only sunlight resistant cables be used
with the minimum wire size being 4mm2 in diameter.
Wiring
PV Wire
Type
PV1-F1x4.0mm2
MC4 Connectors
LJQ-1
Junction Box
PV-JM801
5.3 Bypass Diodes
Ratings
Rated Voltage: 1800VDC
The junction boxes used with the Renogy modules contain bypass
-40ׄ°C Up to 120°C
diodes that are wired in parallel with the PV string cells. In the event the
Rated Voltage:1800VDC
modules experience partial shading, the diodes are activated to bypass
Rated Current: 16A
the current generated by the non-shaded cells, therefore limiting module
-40°C Up to 120°C
heating and performance losses. However, they do not protect the panel
Rated Voltage: 1000VDC
from over-current. Over-current protections devices must be used when
Up to 15A
connecting more than 2 modules in series.
If the bypass diodes are suspected of failure, installers or maintenance

Keep connectors dry and clean and ensure that caps are tightly
personnel should contact the company (Renogy).
sealed before connecting modules

Faulty connections can result in electrical shock so make sure to
fasten all connections securely.

Renogy modules can be installed in landscape or portrait orientation.

Model
Rating
SPA2040
Tj Max = 200°C, if 20A
In systems with more than two modules in series, high reverse
Make sure that the proper distance between the panels and the
current can flow through cells that are shaded partially or outright
surface to allow for air circulation.
when part of a module is shaded and the rest is exposed to the sun.
9
These currents can cause the affected cells to get very hot and
6.1 Testing, Commissioning, and
could even damage the module. To protect module from such high
Troubleshooting
reverse currents

All modules rated greater than 55 Watt have bypass diode already

integrated in the junction box.

commissioning it. Follow the instructions in the guides supplied with
In the unlikely event of diode failure Renogy recommends a
qualified service technician be employed to determine if diodes
the components and equipment.

have failed and to make replacement.
5.4

General Installation

personal safety when making these measurements.

Check the open-circuit voltage (Voc) of every series module using a
a PV array, especially for application with a high operation voltage. If
digital multimeter (Fluke 170 series are recommended). The
modules are connected in series, the total voltage is equal to the sum
measured system Voc should correspond to the sum of the Vocs of
of individual voltages. For applications requiring high currents,
the individual module. You will find the rated voltage in the technical
several photovoltaic modules can be connected in parallel; the total
specifications of the type of the module used and in the tables at the
current is equal to the sum of individual currents.
end of this Installation Guide. If the measured value is significantly
Module is supplied with Multicontact connectors (PV-KBT4 and PV-
lower than the expected value, proceed as described under
Electric Code to determine system wiring size (refer to NEC clause

To determine Voc and Isc in the following tests, the module(s) must
be exposed to the sun and not connected to a load. Observe
“Troubleshooting an excessively low voltage”.
KST4) to use for system electrical connections. Use the National

Testing modules connected in series before they are connected to
system.

Do not use modules of different configurations in the same system.
Several modules are connected in series and then in parallel to form
Test all electrical and electronic components of your system before

Determine the short-circuit current (Isc) of every series circuit. It can
310), type and temperature rating of conductors to be connected to
be measured directly by connecting the digital multimeter connected
the module’s connectors. Wiring connected to the module’s wiring
in the two terminals of series circuit or module, Attention, the rated
should be #12 AWG (minimum) and must be temperature rated at
scale of the ammeter or the rated current of load should more than
90°C (minimum).
1.25 times than the rated short-circuit current of series module. You
In Canada installation shall be in accordance with CSA C22.1, Safety
will find the rated current in the technical specifications of the type
Standard for Electrical Installations, Canadian Electrical Code, Part
of module used. The measured value can vary significantly,
1.
depending on weather conditions, the time of day and shading of
The cross section area of cable and the capacity of connector must
the module.
be selected to suit the maximum system short circuit current,
otherwise the cable and connector will be overheated under large
current. Refer to NEC for details.

Module overcurrent protection, rated for DC use fuses
To identify the commonly low voltage and excessively low voltage, the
commonly how voltage mentioned here is the decrease of open-circuit
voltage of the module, which is caused by the temperature rising of solar
cells or lower irradiance. Excessively low voltage is typically caused by
5.5 Grid Connected Electrical System

The DC electrical energy generated by photovoltaic systems may
improper connections at the terminals or defective bypass diodes.

also be converted to AC and connected to a utility grid system. As
First, check all wiring connections to make sure it is not open-circuit
or is not connection well.
local utilities’ policies on connecting renewable energy systems to

Check the open-circuit voltage of each module:
their grids vary from region to region, consult a qualified system

Fully cover the modules with an opaque material.
designer or integrator to design such a system. Permits are

Disconnect the wiring at both terminals of the modules.
normally required to install such a system and the utility must

Remove the opaque material from the module to be checked and
formally approve and inspect such a system before it can be
connected to the grid.
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
6. Commission and Maintenance
Renogy recommends that all work in commissioning and maintenance of
a system must be performed by a qualified solar PV technician!
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.
10
6.2 Maintenance
Renogy 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. Observe the maintenance instructions for all components
used in the system, such as support frames, charging regulators,
inverters, batteries, etc.
6.3 Replacing Bypass Diodes
Removing the bypass diodes should be done only by a competent PV
technician and after the module has been disconnected from the system.

Place module face down on a soft, flat surface Insert a 3mm flat
screwdriver into the slot on the junction box cover. (The cover has a
sign of screwdriver). Gently pull up the four slots until the cover been
opened.

Insert the 3mm flat screwdriver into a hole alongside of diode and
near one mounting hole of the diode, pry the screwdriver in the
opposite direction of diode and gently pull the diode up until the lead
comes free. Do the same in the other mounting hole of the diode, and
repeat until the diode is free.

Note the orientations of the polarity markings on the diodes.

Check the resistance of the diodes by using the digital multimeter’s
ohms scale. Resistance should be low in one direction, then when
leads are reversed on the diode’s terminals the resistance should be
high, as illustrated in the two pictures below. If a diode has a low
resistance in both directions, it is probably shorted. If it has high
resistance in both directions it is probably open. In either case it
should be replaced.

Replace a defective diode with a diode of the same type, and ensure
that its polarity making is oriented the same way as the original diode.

Finally, check the open-circuit voltage (Voc) of the module, as
described previously, and replace both covers.
11
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