Grid Connected PV Systems Installation & User Instructions PV_Technical Manuals... · 3 Solar PV Systems 10 3.1 Solar PV modules 10 3.2 DC circuit 10 3.3 Sunclix DC cable connectors

Grant Solar PhotovoltaicGrid Connected PV Systems

Installation & User Instructions

Part No. DOC.86 Rev.02 October 2010

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ContentsInstallation Instructions1 Introduction 31.1 Principle of operation 31.2 Safety 31.3 Installation requirements 41.4 Labelling 41.5 Start up and shut down

procedure 4

2 Technical Information 52.1 Solar PV kits – contents 52.2 PV modules – technical

specification 62.3 PV modules – dimensions 72.4 DC/AC inverters – technical

specification 82.5 DC cable and connectors 92.6 DC isolators – technical

specification 9

3 Solar PV Systems 103.1 Solar PV modules 103.2 DC circuit 103.3 Sunclix DC cable connectors 133.4 DC isolators 133.5 DC/AC inverters 143.6 AC output from inverter 143.7 Generation (or export) meter 143.8 Consumer unit connection 143.9 Bonding of modules 143.10 Lightning protection 15

4 On-roof Module Installation 164.1 Dimensions 174.2 Installation summary 184.3 Profile tile 204.4 Flat tile 214.5 Slate tile 224.6 Alignment and fixing of

mounting rails 234.7 Joining mounting rails 234.8 Preparations for installation

of PV modules on horizontal mounting rails 24

4.9 Fixing the first PV module 254.10 Fixing the second and

additional PV modules 264.11 Preparations for installation

of PV modules on vertical mounting rails 28

4.12 Fixing the first PV module 294.13 Fixing the second and

additional PV modules 30

5 Flat Roof Module Installation 325.1 Dimensions 335.2 Installation Summary 345.3 Flat roof system installation 355.4 Joining mounting rails 36

6 In-roof Module Installation 386.1 Dimensions 396.2 Installation summary 406.3 Substructure 446.4 Installation of In-roof Kit 446.5 Installation of modules 496.6 Installation of side cover

flashings 516.7 Fitting top cover flashing 526.8 Roof penetration 52

7 Electrical Connection – AC Circuit 54

8 Installation Procedure 608.1 Risk assessment 608.2 DC cable installation 608.3 PV module installation 608.4 Interconnect the modules 608.5 DC/AC inverter installation 608.6 Install the AC wiring 618.7 Connection of kWh meter 61

9 System Commissioning 629.1 Commissioning procedure 629.2 Inspection 629.3 Testing 629.4 Module testing 629.5 Insulation resistance testing 629.6 Array testing 639.7 AC testing and

commissioning documentation required 64

9.8 DC documents required 649.9 DNO notification 64

10 Servicing & Maintenance 6510.1 PV modules 6510.2 Inverters 6510.3 DC cables and connectors 6510.4 Labelling 6510.5 Electrical installation 65

11 Spare Parts 66

12 Fault Finding 68

13 Decommissioning 6913.1 Shut down procedure 6913.2 DC cables 6913.3 PV modules 6913.4 Inverters 6913.5 AC circuit from consumer unit 6913.5 Consumer unit 69

14 Warranty 70

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The AC output from the inverter isconnected into the Consumer unit forthat property – usually via a 16A circuitbreaker. Refer to Section 7 –wiring/connection diagrams.

A kWh electricity meter (usually referredto and an ‘Export’ or ‘Generationmeter’) is fitted between the Inverterand Consumer unit to record theamount of electricity produced by thesolar PV installation. Refer to Section3.7.

Important: A grid-connected system,such as a Grant Solar PV system, willbe automatically disconnected from the

mains supply within 0.5 second in theevent of a power failure on the supplygrid and will not thus provide protectionagainst power cuts.

Grant Solar PV systems utiliseMonocrystalline PV modules. Refer toSection 2 for technical details on themodules.

1.2 SafetySolar PV cells produce electricitywhenever exposed to daylight.Therefore care must be taken whenworking on any solar PV installationduring daylight hours.

1 Introduction

Figure 1-1: Solar PV system diagram

Appliances

DC isolator

Consumer unit

‘Export’ or‘Generation’kWh meter

DC cableSolar PV modules

DC cable

AC connection

AC isolator

DC/AC inverter

Mains electricity supply

AC power

Electricity meter

1.1 Principle of operationSolar photovoltaic (or Solar PV) systemsproduce electricity from silicon cells inthe presence of daylight. The amount ofelectricity produced depends on anumber of factors including the intensityof the solar irradiation (sunlight), theorientation/angle of the PV modules,and the number of PV modules used.

Grant Solar PV systems are designedto be used as a ‘Grid-connected’installations and as such the electricityproduced by the PV modules is DC(Direct Current) and is converted to AC(Alternating Current) by a DC/ACInverter for use in domestic propertiesand other buildings.

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1.3 Installation requirementsAll electrical installation work mustcomply with the requirements of theElectricity at Work Regulations 1989and BS.7671:2008 – IEE WiringRegulations 17th Edition (including anyamendments). All installations must alsocomply with all applicable parts of TheBuilding Regulations - Part P inparticular.

All ‘grid-connected’ Solar PVinstallations must conform to therequirements of the ‘EngineeringRecommendations for the connectionof a small scale embedded generator(SSEG) in parallel with public lowvoltage distribution networks’ publishedby the Energy Networks Association, asfollows:

G83/1-1 – for systems up to 16A perphase

G59/1 – for systems exceeding 16A perphase

To comply with G83/1-1, for singleinstallations up to 16A per phase, thelocal Distribution Network Operator(DNO) has to be notified of theinstallation on or before thecommissioning and a commissioningpro-forma (refer to G83/1-1 Appendix3) has to be submitted within 30 daysof commissioning.

For planned/multiple installations in thesame geographic area the DNO mustbe notified on or before commissioningand an application pro-forma (refer toG83/1 - Appendix 2) must besubmitted for the DNO to assess theimpact of the proposed connection.

To comply with G59/1, the local DNOmust be contacted and the installationdiscussed prior to starting theinstallation.

Further guidance on the design andinstallation of solar PV systems can befound in the DTI publication URN06/1972: Photovoltaics in Buildings –Guide to the installation of PV systems2nd edition.

1.4 LabellingLabels indicating the presence of anSSEG (in this case a Solar PV system)should be displayed at the followinglocations on the electrical installation forthe property – at all meters, consumerunit, all isolators and at the supplyterminals (suppliers fused cut-out). Thislabelling is to warn that there are TWOsources of electrical supply present inthe installation.

Warning labels used should besufficiently robust and fixed in placesuch that it remains legible and securefor the lifetime of the installation. Refer to BS7671:2008 (IEE WiringRegulations 17th Edition) and G83/1-1for further details.

A sheet of suitable labels for DC cables,isolators, inverters, meters, consumerunits, etc. Is supplied with every GrantSolar PV system.

A typical label format and content is asfollows:

1.5 Start up and shut downprocedureCare should be taken in the way thesystem is started up, i.e. switched on,and also how it is shut down.

1 Introduction

Figure 1-2: Warning label

Important:NEVER disconnect a DCconnection (i.e. between the PVmodules and DC/AC Inverter)whilst the system is under load(i.e. with the AC output connectedto the inverter).

ALWAYS isolate the AC side ofthe system (AC supply to inverter)BEFORE isolating the DC outputfrom the PV modules.

ALWAYS isolate the DC outputfrom modules beforedisconnecting or connecting anyDC connections.

The DC output from the PV modulesshould not be shut down ordisconnected whilst the AC side of theinstallation is operational.

The DC isolator switch – whether fittedin the inverter or a separate isolator –must be in the OFF position throughoutthe entire installation process.

DC cables for PV module strings shouldbe connected to the isolator first andthen the individual modules connectedtogether. Refer to Section 3 for furtherdetails on the installation procedure.

Isolate on-site generator atIsolate mains supply at

WARNINGdual supply

Do not work on this equipment until it isisolated from both mains and on-site

generation supplies

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2 Technical Information2.1 Solar PV kits – contents: On-roof kits for portrait modules

Type MPE180 MS05 Monocrystalline PV module (Pack of 2) 1 3 4 5 6 7 8 9 10Type MPE180 MS05 Monocrystalline PV module (Pack of 1) 1 - - - - - - - -Type GPV 180M Monocrystalline PV module (Pack of 2) 1* 3* 4* 5* 6* 7* 8* 9* 10*Type GPV 180M Monocrystalline PV module (Pack of 1) 1* - - - - - - - -Mastervolt Soladin 600 Inverter 1 2 - - - - - - -Mastervolt Sunmaster XS2000 - - 1** 1** - - - - -Mastervolt Sunmaster XS3200 - - - - 1** 1** 1** - -SMA Sunny Boy SB1200 Inverter c/w DC Isolator - 1** - - - - - - -SMA Sunny Boy SB1700 Inverter c/w DC isolator - - 1** 1** - - - - -SMA Sunny Boy SB2500 Inverter c/w DC isolator - - - - 1** 1** - - -Grant AS 1.0 Inverter - 1 - - - - - 1 1Grant AS 1.5 Inverter - - 1 - - - - - -Grant AS 2.0 Inverter - - - 1 1 - - 1 1Grant AS 3.0 Inverter - - - - - 1 1 - -DC Isolator – single string (600V 25A) 1 2(1) 1 2 2 2 2 2 2Solar DC cable 4mm! c/w MC type 4 plugs (10 metres) 2 4(2) 2 4 4 4 4 4 4

Aluminium mounting rails (2.1metres) PV module stop bracketModule retaining end clip – type 9-1 Refer to packing list supplied with kit forModule retaining mid clip – type 9-2 quantities of fixing componentsFixing screw (M8 x 14)Anchor blockRoof Anchors – one option selected to suit roof coveringProfile concrete tile (pack of 2)Flat concrete tile (pack of 2)Slate tile (pack of 2)*Alternative Monocrystalline PV modules **SMA Sunny Boy, Mastervolt Sunmaster XS or Grant AS inverters may be supplied as alternatives

GP

VKIT

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VKIT

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GP

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GP

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1.80

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10 m

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GP

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2.10

kWp

12 m

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GP

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2.52

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14 m

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GP

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16 m

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2 Technical Information2.2 PV modules – technical specification

180Wp Monocrystalline 180Wp MonocrystallineModule Module

Electrical DataModule type reference MPE180 MS05 GPV 180MCell type Monocrystalline MonocrystallineRated output @ STC* - Pmpp 180 Wp 180 WpPower tolerance - !Pmpp +0.5%/-0% ± 3%Open circuit voltage – Voc (nominal) 45V 44.2VShort circuit current – Isc (nominal) 5.2A 5.13AMaximum power voltage – Vmpp (nominal) 36V 36.4VMaximum power current – Impp (nominal) 5A 4.95ACell efficiency 17.2% 16.2%Module efficiency 14.1% 14.3%Temperature Coefficient " (Pmpp) -0.4%/°C -0.55%/°CTemperature Coefficient # (Isc) +0.04%/°C +0.3%/°CTemperature Coefficient $ (Voc) -0.38%/°C -0.22mV/°CTemperature Coefficient % (Impp) +0.04%/°C +0.03%/°CTemperature Coefficient & (Vmpp) -0.38%/°C -0.53%/°CMaximum permissible system voltage 1000V DC 1000V DCNormal operating cell temperature (NOCT)** 45°C ± 3% 45°C ± 3%Number of cells 72 72 Cell size 125 x 125 mm 125 x 125 mm

Physical DataDimensions 1581 x 809 x 42 mm 1580 x 808 x 45 mmWeight 15kg 15.5kgFrame material Anodised Aluminium HD Anodised AluminiumFrame Colour Silver (similar to RAL 7035) SilverGlass Toughened Safety Glass 3.2mm tempered GlassConnector - positive MC type 4 - Male plug MC type 4 - Male plugConnector – negative MC type 4 - Female plug MC type 4 - Female plugConnection cable type 4mm! 1000V 4mm! 1000VConnection lead length – positive 800 mm 900 mm Connection lead length – negative 800 mm 900 mm

Warranty DataElectrical Safety Classification Safety Class 2 Safety Class 2Maximum snow and wind load (EN61215) 3.6 kN/m! 5.4 kN/m!Output Guarantee to 90% Pmpp min 12 years 10 yearsOutput Guarantee to 80% Pmpp min 25 years 25 yearsProduct Standards IEC61215 & EN61730 IEC61215 & EN61730

* Module output is measured at STC of 1000W/m! and 25°C ambient temperature**With Solar radiation 800W/m!, ambient temperature 20°C & Wind speed 1 m/s

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2.3 PV modules – dimensions180Wp Monocrystalline modules

Dimensions (mm) A B C

Height Width ThickModule Type MPE180 MS05 1581 809 42Module Type GPV 180M 1580 808 45

Figure 1-2: 180Wp Monocrystalline module dimensions

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2 Technical Information2.4 DC/AC inverters – technical specification

Solar Input (DC)Max open circuit string voltage Voc (V DC) 155 450 600 400 600 400 400 400 400

Max PV power (Wp) 700 2100 3500 1850 2700 1250 1875 2500 3500Mpp Voltage (V DC) 45-125 145-360 180-480 139-320 224-480 165-300 165-300 165-300 165-300Ambient temperature -20 to -20 to -20 to -25 to -25 to -25 to -25 to -25 to -25 torange (°C) +50 +60 +60 +60 +60 +50 +50 +50 +50Protection class Indoor only IP44 IP44 IP65 IP65 IP65 IP65 IP65 IP65Weight (kg) 1.5 10.0 10.0 25.0 30.0 22.5 27.0 36.5 42.5DC connectors 1 pair 2 pairs 2 pairs 2 pairs 2 pairs 1 pair 1 pair 2 pairs 2 pairs

MC MC MC MC MC MC MC MC MCtype 4 type 4 type 4 type 4 type 4 type 4 type 4 type 4 type 4

Grid Output (AC)Voltage* (V AC 1ph) 230 230 230 230 230 230 230 230 230Frequency* (Hz) 50 50 50 50 50 50 50 50 50Nominal output power * (W) 540 1500 2500 1550 2300 1000 1500 2000 3000Maximum power (W) 600 1575 2625 1700 2500 1100 1650 2200 3300Rated output current (A) 2.4 7.0 11.0 6.7 10.0 4.3 6.5 8.7 13.0Maximum output current (A) 3.0 9.0 15.0 8.6 12.5 5.0 7.0 10.0 15.0AC connection Pre-wired PG-13.5 PG-13.5 Plug Plug Plug Plug Plug Plug

cable Gland & Gland & with with with with with with3-way 3-way PG- PG- PG- PG- PG- PG-

terminal terminal 13.5 13.5 13.5 13.5 13.5 13.5block block gland gland gland gland gland gland

*Dependant on country of use – refer to manufacturers information supplied with the Inverter

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SB

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.0Important:Refer to the manufacturers’Installation and User instructionssupplied with each respectiveinverter for full technicalspecification, details ofInstallation, connection, operationand fault diagnosis/rectification.

Non-standard Grant solar PVsystems may use other invertersnot shown in the above table.Refer to manufacturers’Installation and User instructionssupplied with the inverter for fulltechnical specification, details ofInstallation, connection, operationand fault diagnosis/rectification.

Important:Short-circuiting or connectionwith reversed polarity on the DCside can damage the inverter.

All the above mentioned invertersincorporate an ’Anti-Islanding’ safetyfeature – to comply with requirementsof G/83 -1. This ensures that theinverter is shut down within 0.5seconds of the mains electrical supplyto the inverter being interrupted, eitherdeliberately or due to a mains powerfailure.

These Inverters are only suitable foruse as part of a ‘Grid connected’solar PV installation and should notbe used for any other type ofsystem.

The Mastervolt Sunmaster XS and SMASunny Boy inverters listed above allincorporate an integral DC isolationdevice. However, local regulations mayrequire an external DC isolator to befitted when using one of these Inverters.If this is the case please contact GrantUK for details of an appropriate DCisolator to be used.

The Mastervolt Soladin 600 and GrantAS inverters are NOT fitted with anintegral isolator and thus must beinstalled with a suitable DC isolator – assupplied in the Grant Solar PV kitsusing these inverters.

All the above inverters have a maximumpower point tracker (MPP) fitted andconfigured to suit the kit. This ensuresthat the system is configured tooptimise the efficiency of the PVinstallation.

CAUTION!Polarity must be observed correctly.Connections made to the inverter arepolarity sensitive and damage to theinverter may result if the connectionsare incorrect.

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2.5 DC cable & connectorsThe cable supplied for connection ofthe PV modules to the Inverter, andalso that used for the connection leadson the PV modules, is 4mm! doubleinsulated cable – rated at 1000V. Cableresistance is 5.09m'/metre.

The 10 metre lengths of DC cablesupplied in the Grant Solar PV kitscome fitted with Multi Connector (MC)Type 4 DC connectors – one maleconnector and one female connectorpre-fitted on either end.

These connectors are rated at 20A and1000V. The degree of protection is IP2Xwhen separated and IP67 whencorrectly connected together. Operatingtemperature range is -40°C to 90°C.

Note: Once fitted, the MC Type 4connectors cannot be removed and re-fitted to the DC cable.

2.6 DC isolators – technicalspecificationThe DC isolators supplied in the GrantSolar PV kits have the followingspecification:

Operational current: 32A

Operational voltage: 690V

Operational power (1ph): 3kW

Class II insulation (double insulated)

Lockable in OFF position

Switch interlocked with cover – covercannot be removed when in ONposition

IP66/67 protection

Operating temperature 35°C (averageover 24 hour period with peaks of40°C)

Screw down terminals - Maximum wiregauge 6mm! (stranded wire).

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3.1 Solar PV modulesThe Solar PV modules are connected together in series, with the positive output connector of one module connected to the negativeoutput connector of the next, to form a ‘STRING’.

The total peak output of such a string = module peak output x number of modules in the string

e.g. For a string comprising 8 x 180Wp modules:

Total peak power output = 180 x 8 = 1440Wp or 1.44kWp for the string

The total Open Circuit voltage (Voc) of a string = module Voc x number of modules

For a module Voc of 44.2V: Total Voc = 44.2 x 8 = 353.6V DC for the string

The total Short Circuit current (Isc) of a string = module Isc (as it is a series connection)

For a module Isc of 5.13A: Total Isc = 5.13A for the string

Depending on the total number of PV modules and the rating of the inverter used, modules may be connected as PARALLEL strings - each consisting of an equal number of modules.

e.g. For 2 strings each comprising 4 x 180wp modules:

Total peak power output = 180 x 8 = 1440Wp or 1.44kWp for the string

The total Open Circuit voltage (Voc) across both strings = string Voc = module Voc x number of modules

For a module Voc of 44.2V: Total Voc = string Voc = 44.2 x 4 = 176.8V DC for the 2 parallel strings

The total Short Circuit current (Isc) of both strings = 2 x string Isc = module Isc (it is a series connection)

For a module Isc of 5.13A: Total Isc = 2 x 5.13A = 10.26A for the 2 parallel strings

Thus, depending on the number of PVmodules involved and the rating of theInverter rating used in a Grant Solar PVsystem, the modules may beconnected as a single string OR asparallel strings. Refer to Section 3.2 forconnection details and Section 2.1 forfurther details on the standard Grantsolar PV kits.

3.2 DC circuitThe Solar PV modules are connectedtogether in series to form a string (orstrings), with the positive outputconnector of one module connected tothe negative output connector of thenext. Refer to Figure 3-1.

3 Solar PV Systems

Figure 3-1: Male and Female MC Type 4 plugs

Female MC Type Plug Male MC Type Plug

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For two parallel strings, four DCextension cables are supplied forconnection to both pairs of connectorson the inverter. Refer to Figure 3-3.

These DC extension cables aresupplied with MC Type 4 connectorsalready fitted - with male connector atone end and a female connector at theother.

Note: These connectors cannot be removedand re-fitted to the DC cable.

One end of each DC cable isconnected to the correspondingconnectors on the positive and negativeconnection leads at either end of themodule string. The remaining ends ofthe two DC cables are connected tothe corresponding MC Type 4connectors on the Inverter. Refer toFigures 3-2 and 3-3.

Figure 3-3: Two parallel strings of PV modules connected to one Inverter

DC/AC inverter

DC inputconnections

AC output

DC isolatorDC extension

cable

DC extensioncable

The positive connection (maleconnector) and negative connection(female connector) from the PV modulestring are connected to the DC/ACinverter using the DC extension cablessupplied in the system kit. For a singlestring of modules, two DC extensioncables are supplied for connection toone pair of connections on the inverter.Refer to Figure 3-2.

Figure 3-2: Single string of PV modules connected to InverterDC/AC inverter

DC inputconnections

AC output

DC isolatorDC isolator

DC extensioncable

DC extensioncable

DC extensioncable

DC extensioncable

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The smaller Grant AS 1.0, AS 1.5 and Soladin 600 Inverters are fitted with only one pair of MC Type 4 connectors. They are thereforesuitable for connection of a single module string only. Refer to Figures 3-4 and 3-5.

The larger Grant AS, SMA and Mastervolt Inverters are fitted with two pairs of MC Type 4 connectors and can be used for theconnection of two module strings in parallel with each other. It is therefore important that the correct ‘matching’ pair of connectors isused when connecting the DC cables from the module string.

Please refer to the manufacturers’ Installation and User instructions supplied with each Inverter to determine which pairs ofconnectors should be used for connection of each module string. Refer to figures 3-6, 3-7 and 3-8.

3 Solar PV Systems

Figure 3-4: Mastervolt Soladin 600 Inverter with one pair ofMC Type 4 connectors

Figure 3-5: Grant AS 1.0 and AS 1.5 Inverters with one pair ofMC Type 4 connectors

Figure 3-8: Grant AS 2.0 and AS 3.0 Inverters with two pairsof MC Type 4 connectors

Figure 3-6: SMA Sunny Boy Inverter with two pairs of MCType 4 connectors

Figure 3-7: Mastervolt Sunmaster Inverter with two pairs ofMC Type 4 connectors

2 pairs of MCtype 4 plugs

2 pairs of MCtype 4 plugs

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The MastervoltSoladin 600 is NOTfitted with an integralIsolator and thus mustbe installed with asuitable DC isolator –as supplied in theGrant Solar PV kitsusing this Inverter.

The Grant ASInverters are NOTfitted with an integralIsolator and thus mustbe installed with asuitable DC isolator –as supplied in theGrant Solar PV kitsusing this Inverter.

Figure 3-9: Table of modules, inverters and strings

Grant Number of OutputKit Ref Modules kWp Inverter Strings

GPVKIT0 3 0.54 1 x Soladin 600 1 x 3 modules1 x SMA SB1200 1 x 6 modules

n/a 6 1.08 2 x Soladin 600 2 x 3 modules1 x Grant AS 1.0 1 x 6 modules1 x SMA SB1700 1 x 8 modules

GPVKIT1 8 1.44 1 x Mastervolt XS2000 1 x 8 modules1 x Grant AS 1.5 1 x 8 modules1 x SMA SB1700 2 x 5 modules



GPVKIT4 14 2.52 1 x Mastervolt XS3200 2 x 7 modules1 x Grant AS 3.0 2 x 7 modules

GPVKIT5 16 2.881 x Mastervolt XS3200 2 x 8 modules1 x Grant AS 3.0 2 x 8 modules

GPVKIT6 18 3.241 x Grant AS 1.0 1 x 6 modules1 x Grant AS 2.0 2 x 6 modules

GPVKIT7 20 3.601 x Grant AS 1.0 1 x 8 modules1 x Grant AS 2.0 2 x 6 modules

Figure 3-11: DC isolator fitted to Mastervolt SunmasterInverter

Integral DCisolator

Note: Depending on the number of PVmodules involved and the rating of theInverter rating used in a Grant Solar PVsystem, the modules may have to beconnected as a single string OR asparallel strings. Refer to Figure 3-9 forfurther details on the standard Grantsolar PV kits.

3.3 Sunclix DC cableconnectorsSome SMA Sunnyboy inverters arenot supplied with the MC Type 4connectors, but are fitted with analternative type of connector. Theseinverters use the SMA ‘Sunclix’connectors and these are NOTcompatible with the MC Type 4connectors. Hence, an MC Type 4 maleconnector on a DC cable will not fit intoa Sunclix female connector and viceversa.

In order to overcome this mismatchbetween the connectors, all SMASunnyboy inverters fitted with Sunclixconnectors, supplied as part of a GrantSolar PV system, will come with a packof loose Sunclix connectors for fitting tothe DC cables. The MC Type 4connectors on the end of the DCcables can be removed (cutting thecable just before the connector) and thecorresponding male or female Sunclixconnector fitted in its place. NB. Ensurethat a Female MC Type 4 connector isreplaced with a Sunclix femaleconnector and the same for maleconnectors.

Sunclix connectors are easy to fit,require no special tools and can beeasily removed from a cable and re-fitted, if necessary. Refer to theillustrated fitting instructions providedwith each pack of Sunclix connectors.

3.4 DC IsolatorsThe Mastervolt Sunmaster XS andSMA Sunny Boy Inverters used in theGrant Solar PV kits all incorporate anintegral DC isolation device. Refer toFigures 3-10 and 3-11 for details of theIsolators fitted to these Inverters.

However, local regulations may requirean external DC Isolator to be fittedwhen using on of these Inverters. If thisis the case please contact Grant UK fordetails of an appropriate DC Isolator tobe used.

Figure 3-10: DC isolator fitted to SMA Sunny Boy Inverter

Integral DC isolator

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3.5 DC/AC inverters

Grant Solar PV kits (and the Invertersincluded in them) are NOT suitable for a‘stand alone’ or ‘off-grid’ Solar PVinstallations. For advice on suchinstallations please contact the GrantTechnical department.

FunctionThe main functions of a ‘grid-connected’ inverter are:

1. To convert the DC power generatedby the Solar PV modules to AC thatcan either used in the propertyconcerned or fed back into theelectricity supply grid.

2. To monitor the supply grid and, inthe event of power failure, shutdown the Solar PV installation.

To comply with the requirements of theENA Engineering RecommendationsG38/1-1 this disconnection must bewithin 0.5 seconds of the power failureoccurring. All inverters used in theGrant Solar PV kits satisfy thisrequirement.

It must be understood that a grid-connected system will NOT operatewhilst there is a failure of the mainssupply to prevent ‘Islanding’ – where itwould be dangerous for the Solar PVsystem to feed power into thedistribution grid (e.g. when the grid isshut down for maintenance work).

Full installation, connection andoperating instructions for the Invertersused with Grant Solar PV systems isgiven in the manufacturers informationsupplied with each inverter. Please referto this information BEFOREcommencing the installation of the SolarPV system.

3.6 AC output from inverterThe AC power output from the Invertermust be connected to the electricalsystem in the property concerned via adedicated circuit in the Consumer Unit.

Refer to Section 7 for further details onelectrical connection. This AC circuit willinvariably include an ‘Export’ or‘Generation’ meter (refer to Section 3.7below) and an isolator – locatedbetween this meter and the Inverter, toallow isolation of the AC supply fromthe Solar PV system.

A further Isolator may be required undersome installation conditions . Forexample, if the Inverter is located in theloft of the property and the consumerunit is on the ground floor, to allow localisolation of the Solar PV system at ornear the AC output of the inverter anadditional AC isolator should beinstalled.

The inverter should be earthed as anyother electrical apparatus in accordancewith the requirements of BS.7671:2008– IEE Wiring Regulations 17th Edition,including any amendments.

3.7 Generation (or Export)meterAn electric kWh meter should beconnected in the AC circuit betweenthe output of the inverter and theconsumer unit. This meter records theamount of electricity generated by theSolar PV system.

A ‘generation’ (or ‘export’) meter will berequired in any installation subject tothe Government’s ‘Feed-in Tariff’ (FiT)scheme, where the consumer is paidfor all the electricity generated(irrespective of whether it is used by theconsumer or not). Some electricitysuppliers feed-in tariff schemes alsorequire a ‘generation’ meter as a basisfor the payment of the tariff.

To meet the conditions of these ‘Feed-in Tariff’ schemes, an ‘OFGEM’approved export meter must be used.

Check with the power supplierconcerned for further details regardingthe selection and installation of theexport meter they require for their ownrespective feed-in tariff schemes.

3.8 Consumer unit connectionGenerally, smaller domestic Solar PVinstallations up to 16A per phase willrequire the use of a dedicatedprotective device (circuit breaker/fuse) inthe consumer unit for connection of theAC output from the Inverter to thedomestic electrical installation of theproperty. This will apply to installationsusing one of the Grant Solar PV kits, asdetailed in Section 2.1 of theseInstallation Instructions.

For larger installations the circuitbreaker rating and method ofconnection will have to be determineddepending on the output of the systemand after consultation with the localDistribution Network Operator (DNO).Refer to Section 1.3 of these InstallationInstructions.

Refer to Section 7 for typical consumerunit connection diagrams.

3.9 Bonding of module framesBonding of the PV module frames canreduce the risk of electric shock toanyone coming into contact with thearray. Such bonding of module framesalso provides some protection fromlightning strikes.

Bonding will only typically be required if the modules, DC cables andconnectors are not Class II and theframes are considered to be anextraneous conductive part, as definedin BS.7671:2008 – IEE WiringRegulations.

However, bonding of the array frames isnot always required. Refer to Figure 3-12 for the flow chart (taken from the DTIGuide to the installation of PV systems– URN 06/1972) to determine whetheror not bonding is required for aparticular installation.

3 Solar PV Systems

Important:The Inverters supplied in theGrant Solar PV kits are intendedfor ‘Grid-connected’ installationsonly, i.e. those installations wherethe output from the PV installationis connected to the electricitysupply grid via the electricalinstallation in the propertyconcerned.

Sol

ar P

V S

yste

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15

Following the guidance given in the flowchart in Figure 3-12, bonding of the PVmodules would NOT be required aslong as ALL three of the followingconditions exist:

1. The modules are Class II. All GrantModules meet this requirement.

2. The cables, connectors, junctionboxes are Class II. All cables,connectors and DC isolatorssupplied by Grant meet thisrequirement.

3. The inverter has an isolatingtransformer between the DC andAC parts. All Inverters supplied byGrant meet this requirement as theyhave the necessary GalvanicIsolation, as required by G83/1–1.

3.10 Lightning protectionThe risk of a direct lightning strike on atypical roof mounted Solar PVinstallation is generally considered to below, but where the building in questionis either tall or in an exposed open area,making it the highest structure in thatarea, there may be a greater risk. Insuch a case advice should be soughtfrom a lightning protection specialistand, where necessary, a lightningprotection system installed conformingto BS 6651: Code of Practice forProtection of Structures againstLightneng.

If not at risk from a direct lightningstrike, a solar PV system can also be

damaged from induced surges in thepower supply, particularly where this isvia overhead power lines. Power surgesdue to lightning can occur in either theDC or AC parts of the system.

To protect against surges the DC cableruns should be kept as short aspossible and the positive and negativecables from a string or main DC supplycables should be bundled together.Long runs of DC cable (e.g. over 50m)should be installed in earthed metaltrunking or conduit to shield them frominduced surges.

Figure 3-12: Array frame bonding flow chart

Class II Modules? and

Class II Cables, Connectors/ions & Junction Boxesand

Isolation Transformer in Inverter?(Note: to BS 3535 between a.c. & d.c.)

In Equipotential Zone?(Note: freestanding ground mounted, or building roofmounted arrays (away from building metalwork) will

normally not be within the equipotential zone. However, asolar thermal system, or other building linked metalwork,installed within reach may extend the equipotential zone

outside the normal building envelope

Leave Floating

(Note: If an earth spike is already installed for Lightning Protection, bond to this braid)(Note: Use 10mm2 braid or equivalent)

No

PME Earthing?

Yes

Install & bond to earth spike(Note: do not take PME out ofequipotential zone) (Note: Use

10mm2 braid or equivalent)

Bond direct to ConsumerEarthing Terminal

(Note: Use 10mm2 braid orequivalent)

No

Yes

Yes

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4 On-roof Module Installation

Figure 4-1: On-roof installation of modules

Number Module Modules: Portrait Modules: Portrait Modules: Landscape Modules: Landscapeof Dimensions Rails: Horizontal Rails: Vertical Rails: Vertical Rails: HorizontalModules A B C D Emax C D Emax C D Emax C D Emax

3 1580 808 2515 2471 1400 4831 4787 1800 2515 2471 1400 4831 4787 18004 1580 808 3346 3302 1400 6434 6390 1800 3346 3302 1400 6434 6390 18005 1580 808 4177 4133 1400 8037 7993 1800 4177 4133 1400 8037 7993 18006 1580 808 5008 4964 1400 9640 9596 1800 5008 4964 1400 9640 9596 18007 1580 808 5839 5795 1400 11243 11199 1800 5839 5795 1400 11243 11199 18008 1580 808 6670 6626 1400 12846 12802 1800 6670 6626 1400 12846 12802 18009 1580 808 7501 7457 1400 14449 14405 1800 7501 7457 1400 14449 14405 180010 1580 808 8332 8288 1400 16052 16008 1800 8332 8288 1400 16052 16008 180011 1580 808 9163 9119 1400 17655 17611 1800 9163 9119 1400 17655 17611 180012 1580 808 9994 9950 1400 19258 19214 1800 9994 9950 1400 19258 19214 180013 1580 808 10825 10781 1400 20861 20817 1800 10825 10781 1400 20861 20817 180014 1580 808 11656 11612 1400 22464 22420 1800 11656 11612 1400 22464 22420 180015 1580 808 12487 12443 1400 24067 24023 1800 12487 12443 1400 24067 24023 180016 1580 808 13318 13274 1400 25670 25626 1800 13318 13274 1400 25670 25626 180017 1580 808 14149 14105 1400 27273 27229 1800 14149 14105 1400 27273 27229 180018 1580 808 14980 14936 1400 28876 28832 1800 14980 14936 1400 28876 28832 180019 1580 808 15811 15767 1400 30479 30435 1800 15811 15767 1400 30479 30435 180020 1580 808 16642 16598 1400 32082 32038 1800 16642 16598 1400 32082 32038 180021 1580 808 17473 17429 1400 33685 33641 1800 17473 17429 1400 33685 33641 180022 1580 808 18304 18260 1400 35288 35244 1800 18304 18260 1400 35288 35244 1800

Grant Solar PV – On-roof installation dimensions

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4.1 Dimensions

Figure 4-2: PV modules arranged in landscape position

Figure 4-3: PV modules arranged in portrait position

a) Landscape/one above the otherMounting rails: vertical

b) Landscape/adjacentMounting rails: horizontal

A - Length of moduleB - Width of moduleC - Length of mounting railD - Overall width/height of modules(Refer to table on opposite page)

A - Length of moduleB - Width of moduleC - Length of mounting railD - Overall width/height of modules(Refer to table on opposite page)

c) Portrait/one above the other Mounting rails: vertical

d) Portrait/adjacentMounting rails: horizontal

A

D

B

CD

400mmmax.

22m

m

400mmmax.

500mmmax. Rail

overhang

500mmmax. Rail

overhang Roof anchor positions

B

A

DC

D

C

E

F

200mmmax.

22m

m

50m

m

400m

mm

ax. 200mm

max.

500mm max. Rail overhang

Roof anchorpositions

Roof anchorpositions


B

E

A

E A

C

D

50m

m

Roof anchor positions

B

Max200mm



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4.2 Installation summary

4 On-roof Module Installation

Figure 4-4: Modules installed in portrait format

Item Description

01 PV Module

02 Mounting rail

03 Roof anchor – type selected to suit roof covering (slates, profile tile or flat tile)

04 Module retaining end clip

05 Module retaining mid clip

06 Fixing screw - M8 x 14

07 Anchor block

08 T-bolt

09 Module s top bracket

01

04

07

08

02

09

06

05

03

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Figure 4-4: Modules installed in landscape format

Item Description

01 PV Module

02 Mounting rail

03 Roof anchor – type selected to suit roof covering (slates, profile tile or flat tile)



06 Fixing screw - M8 x 14

07 Anchor block

08 T-bolt

09 Module s top bracket

10 End stop

11 Fixing bolt

06

04

01

05

07

11

10

0802

03

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4 On-roof Module Installation4.2 Profile tileRoof Anchors fixed to Rafters1. For profile concrete tiles, these roof

anchors are attached directly to theroof rafters (rafter-mountedinstallation).

Caution:Never attach safety harness to theinstallation system!

2. Expose the installation area abovethe rafters. For roof anchorintervals, see Page 17, Section 4.1On-Roof System installation.

Note:As a rule, pushing up the roof tilesis sufficient. Horizontal positioningof roof anchors is dependent on therafters and the tile valleys.

3. Place roof anchor (03-A) in line withthe top edge of the roof tile in thetile valley. Fix the base plate of theroof anchor to the rafter withscrews (16).

4. Fix all further roof anchors in thesame way. For roof anchor intervals,see Page 17, Section 4.1 On-RoofSystem installation.

Note:Roof anchors must be horizontallyand vertically aligned (follow roof tilevalleys).

65mm

70mm

40mm

150mm

120m

m60

mm

Figure 4-6: Dimensions of roof anchor A

Figure 4-7: Horizontal and vertical alignment

Horizontal-Distance

Horizontal-alignment

Vertical-alignment

Vertical-Distance

Figure 4-8: Installation of roof anchors A

16

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Horizontal-Distance


Vertical-alignment

Vertical-Distance

4.4 Flat tileRoof Anchors fixed to Rafters1. For flat concrete tiles, these roof

anchors are attached directly to theroof rafters (rafter-mountedinstallation).


2. Expose the area above the rafters.For roof anchor intervals, see Page17, Section 4.1 On-Roof System.

Note:As a rule, pushing up the roof tilesis sufficient. Horizontal positioningof roof anchors is dependent on therafters and the tile valleys.

3. Place roof anchor (03-B) in line withthe top edge of the roof tile. Fix theroof anchor to the rafter with screws(16).

4. Fix all further roof anchors in the sameway. For roof anchor intervals, seePage 17, Section 4.1 On-RoofSystem installation.

Note:Roof anchors must be horizontallyand vertically aligned (follow roof tilevalleys).

65mm

100mm

200mm

30mm

125m

m40

mm

75m

m


Figure 4-11: Fixing mounting battens and roof anchors

Figure 4-9: Dimensions of roof anchor B

Horizontal-Distance


Vertical-alignmentVertical-Distance

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4 On-roof Module Installation4.5 Slate tileRoof Anchors fixed to Rafters1. On slate roofs, additional mounting

battens are fixed to the roofsubstructure. Roof anchors ‘C’ arefixed through the slate tiles to themounting batten (batten-mountedinstallation).


2. Expose the area required forinstallation (length of mountingbatten). For roof anchor intervals,see Page 17, Section 4.1 On-RoofSystem installation.

Note:As a rule, pushing up the roof slatesis sufficient. Horizontal positioningof roof anchors is dependenton the rafters and the tile valleys.

3. Mounting battens (18) are fixed withscrews to the rafters at a distance of185mm from the roof batten below.

Note:The distance of 185mm isdependent on the roof anchor andtype of roofing and must be modifiedif necessary.

4. Place the roof anchor (17) on to theslate tile and mounting battens andfix with screws (16).

5. Fix all further roof anchors in the sameway. For roof anchor intervals, seePage 17, Section 4.1 On-RoofSystem installation.

Note:Roof anchors must be horizontallyand vertically aligned.


Figure 4-14: Fixing mounting battensand roof anchors

Figure 4-15: Fixing mounting battensand roof anchors through sarking

Note:If roof is fully sarked (timber boards)then mounting anchors should bescrewed through sarking into therafters below.

65mm

250mm

30mm

50m

m

1617

Figure 4-12:Horizontal andvertical alignment

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4.7 Joining mounting railsOn many installations it will be necessaryto join two or more sections of mountingrail to create a longer length of rail. Thesections of rail are butted together andjoined using the connector kit(s)provided. Each kit comprises twoconnector plates and eight fixing screws.

Join the rails, using the fixing kit(s), asfollows:

1. Fit four of the fixing screws providedinto one of the connector platesprovided, ignoring the middle hole.Ensure that the ends of the screwthreads DO NOT protrude throughthe connection plate at this time.Refer to Figure 4-19A.

2. Fit one end of the connector plateinto the end of the one mounting

rails to be joined – locating the plateinto the lower section of the railprofile. Refer to Figure 4-19B.

3. Position the connector plate so thatapproximately half the length of theplate is within the rail. Tighten thetwo fixing screws at that end (usinga suitable Allen key – not suppliedin the kit). Refer to Figure 4-19B.

4. Fit the next section of mounting railonto the protruding half of theconnector plate, Ensure that thetwo sections of rail correctly alignedand then tighten the remaining twofixing screws. Refer to Figure 4-19C.

5. Repeat the process to join furthermounting rails as necessary.

4.6 Alignment and fixing ofmounting rails1. Close the roof covering at the top

and bottom.

2. Fix top mounting rail (04) to the roofanchor (03).

Position the heads of interlocking T-bolts (10) parallel to the mountingrail (04) and place them on themounting rail, push the interlocking

T-bolts to the top in the roof anchor(03) and secure with a 90° turn.Tighten the nuts of the interlockingT-bolts (hand tight). Use serratedwashers to secure the nuts.

Install all further mounting rails inthe same way.

3. Align the mounting rails horizontallyand vertically so that the rails andthe roof tiles are parallel. Diagonaldimensions between mounting railsmust be equal: D1 = D2

Tighten the nuts on the interlockingT-bolts.

Installation of solar collectors:See pages 33 to 35.

Figure 4-16: Roof covering with roof anchors

10

04

03

Figure 4-18: Aligning the mounting rail

Figure 4-19A:Connector plate with

screws fitted

Figure 4-19B:Rail with connector

plate fitted

Figure 4-19C:Two rails jointed

together

D1

D2

Figure 4-17: Fixing the mounting rail

Now go to Section 7.

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4 On-roof Module Installation4.8 Preparations forinstallation of PV modules onhorizontal mounting rails1. Insert the anchor blocks (07) with

the bullet side facing inwards - atone end of the mounting rails (02).See section 4.1 for cuttingdimensions.

2. Pre-mount module retaining endclips (04) loosely onto the mountingrail using fixing screws (06).

Tip:The anchor blocks is slotted intothe mounting rail from above.

Figure 4-20: End retaining clip to befitted at one end of mounting rail

Item Description

02 Mounting rail


06 Fixing screw

07 Anchor blockBullet side

06

04

07

02

04

02

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Figure 4-21: Location of module stop bracket

Figure 4-22: Location of module on rail

4.9 Fixing the first PV moduleThe PV modules should be positionedso that the connecting boxes are in thesame position. The modules are fittedwith pre-fabricated solar cables. Werecommend that the modules beconnected together electrically as theyare mounted on the roof. Refer toSection 3.2.

Ensure connectors are correctlyconnected together to give a durablewatertight connection. See Section 3.2.

Always make the connection in an open circuit, ie.. the cable should beattached to the inverter last.

Never open the connector while underload, ie. first disconnect the inverter.

1. Hook two PV module stop brackets(09) into the lower mounting rail asillustrated in Figure 4-16.

2. Position PV module on themounting rails/PV module stopbrackets and slide into the endfixing clips (04) as illustrated inFigure 4-17.

3. Align PV module and tighten thefixing screws (06).

Item Description

01 PV module

02 Mounting rail


06 Fixing screw

09 Module stop bracket

Item Description

02 Mounting rail


0209

Approx. 100mm up to a max. 1/4 module dimension

0902

06

04

01

26

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4 On-roof Module Installation4.10 Fixing the second andadditional PV modules1. Insert the anchor blocks (07) into

the mounting rails for the secondPV module.

2. Fix intermediate module retainingmid clips (05) using screws (06) asillustrated in Figure 4-23.

3. Push the retaining mid clips ontothe PV module and screw onloosely. Do not tighten at this stage.

4. Insert two module stop brackets(09) into the mounting rail asillustrated in Figure 4-24.

Figure 4-23: Fixing the module retaining mid clips

Figure 4-24: Fixing the module stop brackets

Item Description

01 PV module

02 Mounting rail


06 Fixing screw

07 Anchor block

09 PV stop bracket

05

01

05

01

0902

06

05

07

02

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5. Place the second PV module ontothe mounting rails/PV module stopbrackets and slide into the midretaining clips (05) as illustrated inFigure 4-25.


7. Connect PV modules electrically.Installing additional PV modulesfollowing steps 1 to 7 again.

8. Secure the last PV module on theoutside using two module retainingend clips (04). See Figure 4-20.Insert the anchor blocks into themounting rail with the bullet sidefacing inwards.

9. Position the two retaining end clipson the module and fit the fixingscrews, as shown in Figure 4-20.

10. Tighten the fixing screws to securethe retaining end clips.

Figure 4-25: Installing the second PV module

Figure 4-26: Securing final PV module

Item Description

01 PV module

02 Mounting rail


06 Fixing screw

09 PV stop bracket

09

01

06

06

09

05

02

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4 On-roof Module Installation4.11 Preparations forinstallation of PV modules onvertical mounting rails

1. Drill a hole (Ø8mm) in the mountingrail (dimensions: see Figure 4-27).

2. Push the securing clip (10) into themounting rail as illustrated in 4-27.Drill both parts together (Ø 5mm)using the pre-drilled securing clipsas a drilling template.

3. Insert the bolts from the securing kitinto the drilled holes.

4. Insert the anchor block (07) - withthe bullet side facing inwards - atone end of the mounting rails (02).See Section 4.1 for cuttingdimensions.

5. Pre-mount retaining end clip (04)loosely onto the mounting rail usingfixing screws (06).

Tip:The mounting rails can beprepared prior to mounting ontothe roof as illustrated in Figure 4-27 and 4-28.

The anchor block can be fittedinto the mounting rail from above(this may also be done after thesecuring clip has been fitted).

Figure 4-27: Assembling the securing kits

Figure 4-28: Module retaining end clipto be fitted at the end of mounting rail

Figure 4-29: Fixing of securing clip

Item Description

02 Mounting rail


10 Securing clip

11 Fixing bolt

Item Description

02 Mounting rail


06 Fixing screw

07 Anchor block

Item Description

02 Mounting rail

10 Securing clip

02 11

04

10

10

Drill holeØ 5mm

Drill holeØ 8mm

02

10.5

Approx65mm

(Depending on position of roof anchor)

Bullet side

06

04

07

02

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4.12 Fixing the first PV moduleThe PV modules should be positionedso that the connecting boxes are in thesame position. The modules are fittedwith pre-fabricated solar cables. Werecommend that the modules beconnected together electrically as theyare mounted on the roof. Refer toSection 3.2.

Ensure plugs are correctly connectedtogether to give a durable watertightconnection. See Section 3.2.

Always make the connection in an open circuit, ie. the cable should beattached to the inverter last.

Never open the plug connector whileunder load, ie. first disconnect theinverter.

1. Insert the PV module into themodule retaining end clips (04) asillustrated in Figure 4-30.

Secure PV module duringassembly until at least two retainingend clips are tightly fixed.

2. Align PV module and tighten thescrews (06).

Item Description

01 PV module

02 Mounting rail


06 Fixing screw

10 Securing clip

Figure 4-30: Location of module on rails

01

10

06

02

04

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4 On-roof Module Installation4.13 Fixing the second andadditional PV modules1. Insert the anchor blocks (07) into

the mounting rails for the secondPV module.

2. Fix intermediate module retainingmid clip (05) using screws (06) andanchor blocks as illustrated inFigure 4-31.

3. Push the retaining mid clip onto thePV module and screw on loosely.Do not tighten at this stage.

4. Place the second PV module ontothe mounting rails and slide intoretaining mid clips (05), as illustratedin Figure 4-32.


6. Connect PV modules electrically.

Item Description

01 PV module

02 Mounting rail



06 Fixing screw

07 Anchor block

06

05

Figure 4-32: Installing the second PV module

Figure 4-31: Fixing the retaining mid clip

04

02

01

06

05

07

06

05

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To install additional PV modules followsteps 1 to 6 again.

7. Secure the last PV module on thetop using two module retaining endclips (04). See Figure 4-33. Insertthe anchor blocks into the mountingrails with the bullet side facinginwards.

8. Position the two retaining end clipson the module and fit the fixingscrews, as illustrated in Figure 4-33.

9. Tighten the fixing screws to securethe retaining end clips.

Item Description

01 PV module


Figure 4-33: Fitting final module retaining end clips

04

01

32

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5 Flat-roof Module Installation

Figure 5-1: Flat-roof installation of modules

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Number Module Modules: Portraitof Dimensions Rails: Horizontal

Modules A B C D Emax

3 1580 808 2515 2471 14006 1580 808 5008 4964 14008 1580 808 6670 6626 140010 1580 808 8332 8288 140012 1580 808 9994 9950 140014 1580 808 11656 11612 140016 1580 808 13318 13274 140018 1580 808 14980 14936 140020 1580 808 16642 16598 140022 1580 808 18304 18260 1400

Grant Solar PV – Flat-roof installation dimensions

5.1 Dimensions

Figure 5-2: PV modules arranged in portrait position

Portrait/adjacentMounting rails: horizontal

A - Length of moduleB - Width of moduleC - Length of mounting railD - Overall width/height of modulesE - Distance between frames(Refer to table below)

C

D

50m

m

400m

mm

ax.


Roof framepositions


B

E1320mm1318mm

1316

mm

1334

mm

A

34

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The standard installation kit allows solarcollectors to be fitted vertically ontohorizontal mounting rails.

Mounting rails are supported using thetriangular roof mounting frames.

04

01

07

02 09

0506

12


Figure 5-3: Modules installed in portrait format

Item Description

01 PV Module

02 Mounting rail

03 Roof mounting frame04 Module retaining end clip


06 Fixing screw

07 Anchor block

08 T-bolt


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5.3 Flat roof systeminstallation1. Lay mounting rails on the installation

surface with the wide grooveuppermost. Mounting rail interval = 1470mm.

Diagonal dimensions betweenmounting rails must be equal:D1 = D2

2. Open out a prefabricated flat roofmounting frame and place the longL-profile on the mounting rail sothat the T-profile points backwards.For maximum rail overhang ‘a’, seePage 33.

3. Fix the flat roof mounting frame to the mounting rail using the Tee-bolts (14), serrated washersand nuts provided.

Note:Tee-bolts must be secured to themounting rail using a 90° turn.

4. Place the next flat roof mountingframe on the mounting rail and fixusing the Tee-bolts. Do not tightenthe bolts too tightly, as finaladjustment may be required. Formounting frame interval b, see Page33.

Figure 5-4: Installation of the first flatroof mounting frame

Figure 5-6: Installation of the secondflat roof mounting bracket

Figure 5-5: Fixing using Tee-bolt

D1

D2a

a

b

04

04

1470

SW 13


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7. Place an interlocking nut (23) inmounting rail (02) and secure it inthe mounting rail by turning it 90°.Place a spacer sleeve (17) on theinterlocking nut and fix the stays ofthe securing cruciform (13) usinglocking washer (18) and punchingbolt (15).

Tighten the punch bolt until a clearsnap is heard. Continue to turn andtighten normally.

Caution:Turning the punch bolt fixes thesecuring cruciform into its finalposition; check distances andcorrect seating of the interlockingnuts beforehand.

Figure 5-8: Installation of the second flat roof mounting frame

Figure 5-7: Punch bolt/fixing screw

Figure 5-9: Fixing the securingcruciform and mounting rail

15

A

B

24

15

18

17

16

02

12

13

5. Unscrew securing cruciform (13). Itis fixed to the legs of the flat roofmounting frame and the mountingrail.

Place the angled long ends of thesecuring cruciform between the flatroof mounting frame and fix with bolts(M8x18), washers and nuts provided.

Note:Always fit the stays of the securingcruciform to the right hand side ofthe flat roof mounting angles. Seedetail views (A and B).

6. Tighten the nuts on the Tee-bolts, Ifnecessary, modify the position ofthe second flat roof mountingframe.

Note:Use punch bolt (15) with offsetscrew tip for fixing to the mountingrail. Do not confuse with fixingscrew (06).

8. Fix all further flat roof mountingframes to the mounting rails inaccordance with steps 2-4, and fixthe legs tightly using the Tee-boltsM8x18mm.

For mounting frame intervals seePage 33.

9. Place the flat roof mounting frametogether with theT-profiles, align according to planand make the structure robust.

To prevent damage to the roofcovering, it may be necessary touse protective mats. If the flat roofmounting frame is not bolted to thebuilding structure, it must besecured according to technicalrequirements.

Caution:The complete flat roof mountingframe must be adequately weighteddown or bolted. If the supportingframe is to be secured by deadweight, rather than being screweddown, contact Grant UK for amountof weight required. This will dependon the location and height of thebuilding, and also the number ofmodules used.

Permissible roof load must not beexceeded under any circumstances,and if necessary a structuralengineer must be consultedbeforehand. If the substructure hasbeen penetrated, it must becarefully re-sealed in accordancewith technical standards.

Item Description

02 Mounting rail12 Roof mounting frame13 Cruciform14 Tee bolt15 Punch bolt16 Flat nut17 Spacer sleeve18 Locking washer

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37Figure 5-11: Support frame with dead weighting

5.4 Joining mounting railsOn many installations it will be necessaryto join two or more sections of mountingrail to create a longer length of rail. Thesections of rail are butted together andjoined using the connector kit(s)provided. Each kit comprises twoconnector plates and eight fixing screws.

Join the rails, using the fixing kit(s), asfollows:

1. Fit four of the fixing screws providedinto one of the connector platesprovided, ignoring the middle hole.Ensure that the ends of the screwthreads DO NOT protrude throughthe connection plate at this time.Refer to Figure 4-19A.

2. Fit one end of the connector plateinto the end of the one mountingrails to be joined – locating the plateinto the lower section of the railprofile. Refer to Figure 4-19B.

3. Position the connector plate so thatapproximately half the length of theplate is within the rail. Tighten thetwo fixing screws at that end (usinga suitable Allen key – not suppliedin the kit). Refer to Figure 4-19B.

4. Fit the next section of mounting rail

onto the protruding half of theconnector plate, Ensure that thetwo sections of rail correctly alignedand then tighten the remaining twofixing screws. Refer to Figure 4-19C.

5. Repeat the process to join furthermounting rails as necessary.

5.5 Module fittingFor details on fitting the modules refer toSection 4.8 to 4.10.

Now go to Section 8.

Figure 5-10: Rotate completesupport frame

03-C

1m

protective mats

38

Flat

-roo

f M

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6 In-roof Module Installation

Figure 6-1: In-roof installation of modules

Number Single Row Two Row Three Row Four Rowof of Modules of Modules of Modules of ModulesModules N A B X Y N A B X Y N A B X Y N A B X Y

mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

3 3 2468 1580 2768 2000 - - - - - - - - - - - - - - -6 6 4958 1580 5258 2000 3 2468 3182 2768 3602 2 1638 4784 1938 5204 - - - - -8 8 6618 1580 6918 2000 4 3298 3182 3598 3602 - - - - - 2 1638 6386 1938 680610 10 8278 1580 8578 2000 5 4128 3182 4428 3602 - - - - - - - - - -12 12 9938 1580 10238 2000 6 4958 3182 5258 3602 4 3298 4784 3598 5204 3 2468 6386 2768 680614 14 11598 1580 11898 2000 7 5788 3182 6088 3602 - - - - - - - - - -16 16 13258 1580 13558 2000 8 6618 3182 6918 3602 - - - - - 4 3298 6386 3598 680618 18 14918 1580 15218 2000 9 7448 3182 7748 3602 6 4958 4784 5258 5204 - - - - -20 20 16578 1580 16878 2000 10 8278 3182 8578 3602 - - - - - 5 4128 6386 4428 6806

N = Number of modules per row. A = Module area width (mm). B = Module area height (mm). X = Overall width (mm). Y = Overall height (mm).Module width = 808mm. Module height = 1580mm.

Solar PV In-roof Kit Dimensions - Portrait Modules

35-A

43

39

43

52

43

44

34-A

36-A 50 50

52

34-B

35-B

39

51

33-B

33-A51

44

53 36-B

33

Item Description

33-A Top cover flashing - left hand33-B Top cover flashing - right hand34-A Side cover flashing - left hand34-B Side cover flashing - right hand35-A Side cover flashing extension -

left hand35-B Side cover flashing extension -

right hand

Item Description

39 Single vertical channel profile43 Gasket44 Double vertical channel profile50 Bottom fixing rail51 Intermediate/top fixing rail52 Side stop plate53 Centre stop plate

Item Description

36-A Bottom apron flashing - left hand

36-B Bottom apron flashing - right hand

37 Bottom apron flashing extension(not shown)

38 Top cover flashing extension (not shown)

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6.1 Dimensions

Figure 6-2: PV modules array dimensions

Solar PV In-roof Kit Dimensions - Landscape Modules

22mm 150mm150mm22

mm

210m

m

100mm 100mm

Mod

ule

area

hei

ght (

B)

Module area width (A)

X

Y

210m

m

Number Single Row Two Row Three Row Four Rowof of Modules of Modules of Modules of ModulesModules N A B X Y N A B X Y N A B X Y N A B X Y

mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

3 3 4784 808 5084 1228 - - - - - - - - - - - - - - -6 6 9590 808 9890 1228 3 4784 1638 5084 2058 2 3182 2468 3482 2888 - - - - -8 8 12794 808 13094 1228 4 6386 1638 6686 2058 - - - - - 2 3182 3298 3482 371810 10 15998 808 16298 1228 5 7988 1638 8288 2058 - - - - - - - - - -12 12 19202 808 19502 1228 6 9590 1638 9890 2058 4 6386 2468 6686 2888 3 4784 3298 5084 371814 14 22406 808 22706 1228 7 11192 1638 11492 2058 - - - - - - - - - -16 16 25610 808 25910 1228 8 12794 1638 13094 2058 - - - - - 4 6386 3298 6686 371818 18 28814 808 29114 1228 9 14396 1638 14696 2058 6 9590 2468 9890 2888 - - - - -20 20 32018 808 32318 1228 10 15998 1638 16298 2058 - - - - - 5 7988 3298 8288 3718

N = Number of modules per row. A = Module area width (mm). B = Module area height (mm). X = Overall width (mm). Y = Overall height (mm).Module width = 1580mm. Module height = 808mm.

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72mm

20mm

147mm

147mm

l Verticalprofiles

Figure 6-3: In-roof Kit Components

Single verticalprofiles

Top cover flashing (LH)

Bottom apron flashing (LH)Bottom apron flashing (RH)

Top cover flashing (RH)

Sideflashing

Sideflashing

Side flashingextension

Side flashingextension

Double verticalprofiles

l Roof batten

l Modulearea

Note:Top/bottom flashing extensionsnot shown.

Gasket

Single verticalprofiles

Gasket

Double verticalprofiles

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Number Single Row Two Row Three Row Four Rowof of Modules of Modules of Modules of ModulesModules Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kitin array 1 2 3 4 5 L 1 2 3 4 5 L 1 2 3 4 5 L 1 2 3 4 5 L

3 1 1 0 2 2 2.0 n/a n/a n/a n/a n/a n/a 1 3 0 0 2 5.8 n/a n/a n/a n/a n/a n/a6 1 1 0 5 2 2.0 1 2 0 2 2 3.5 1 3 0 1 2 5.8 n/a n/a n/a n/a n/a n/a8 1 1 0 7 2 2.0 1 2 0 3 2 3.5 n/a n/a n/a n/a n/a n/a 1 4 0 1 2 6.5*10 1 1 1 9 2 2.0 1 2 0 4 2 3.5 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a12 1 1 1 11 2 2.0 1 2 0 5 2 3.5 1 3 0 3 2 5.8 1 4 0 2 2 6.5*14 1 1 2 13 2 2.0 1 2 0 6 2 3.5 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a16 1 1 2 15 2 2.0 1 2 0 7 2 3.5 n/a n/a n/a n/a n/a n/a 1 4 0 3 2 6.5*18 1 1 3 17 2 2.0 1 2 1 8 2 3.5 1 3 0 5 2 5.8 n/a n/a n/a n/a n/a n/a20 1 1 3 19 2 2.0 1 2 1 9 2 3.5 n/a n/a n/a n/a n/a n/a 1 4 0 4 2 6.5*

Kit 1 (GPV231136) = Number of Basic In-roof kits.Kit 2 (GPV231137) = Number of Side flashing (vertical) extension kits.Kit 3 (GPV231138) = Number of Top/bottom flashing (horizontal) extension kits.Kit 4 (GPV231633) = Number of Double (centre) vertical channel profiles.Kit 5 (GPV231632) = Number of Single (side) vertical channel profiles.L Length of Single (side) and Double (centre) vertical channel profiles (metres).* This length requires joining two lengths - using channel profile joiners.

Grant Solar PV - In-Roof Kits - Portrait Module Configuration

Number Single Row Two Row Three Row Four Rowof of Modules of Modules of Modules of ModulesModules Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kit Kitin array 1 2 3 4 5 L 1 2 3 4 5 L 1 2 3 4 5 L 1 2 3 4 5 L

3 1 0 0 2 2 1.0 n/a n/a n/a n/a n/a n/a 1 1 0 0 2 2.7 n/a n/a n/a n/a n/a n/a6 1 0 1 5 2 1.0 1 1 0 2 2 2.0 1 1 0 1 2 2.7 n/a n/a n/a n/a n/a n/a8 1 0 2 7 2 1.0 1 1 0 3 2 2.0 n/a n/a n/a n/a n/a n/a 1 2 0 1 2 3.510 1 0 3 9 2 1.0 1 1 1 4 2 2.0 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a12 1 0 4 11 2 1.0 1 1 1 5 2 2.0 1 1 0 3 2 2.7 1 2 0 2 2 3.514 1 0 5 13 2 1.0 1 1 2 6 2 2.0 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a16 1 0 6 15 2 1.0 1 1 2 7 2 2.0 n/a n/a n/a n/a n/a n/a 1 2 0 3 2 3.518 1 0 7 17 2 1.0 1 1 3 8 2 2.0 1 1 1 5 2 2.7 n/a n/a n/a n/a n/a n/a20 1 0 8 19 2 1.0 1 1 3 9 2 2.0 n/a n/a n/a n/a n/a n/a 1 2 1 4 2 3.5

Kit 1 (GPV231136) = Number of Basic In-roof kits.Kit 2 (GPV231137) = Number of Side flashing (vertical) extension kits.Kit 3 (GPV231138) = Number of Top/bottom flashing (horizontal) extension kits.Kit 4 (GPV231633) = Number of Double (centre) vertical channel profiles.Kit 5 (GPV231632) = Number of Single (side) vertical channel profiles.L Length of Single (side) and Double (centre) vertical channel profiles (metres).

Grant Solar PV - In-Roof kits - Landscape Module configuration

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Figure 6-4: Calculating of dimensions for fixing brackets, fixing points and butyl tape

Figure 6-5: Calculation of dimensions for metal sheeting

Double fixingbracket

Butyl tape

Double fixingbrackets

Double fixingbrackets

I Bottom cover plate installed

b Module area

I Module area

I Side cover plate installed = I Module area + 2 x 60mm

Side coverplate

45mm

45mm

+60mm

150mm

150mm

I Top cover plate installed

b Module area

Top cover plate

100mm overlap dimension

I Side coverplate installed

100mm (Overlapdimension)

Bottomcover plate

80mm overlap dimension

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6 In-roof Module Installation6.3 Substructure

6.3.1 Installation of bottom apronflashing

1. Remove the roof covering over theinstallation area. The height andwidth of the area must be greaterthan the dimensions given in thetable in Section 6.1.

(29) Rafters(30) Waterproof membrane(31) Cross batten (when fitted)(32) Roof batten

2. Calculate distance between roofbattens. Refer to Figure 6-7.

Note: If its position is appropriate, anexisting available roof batten canalso be used.

6.4 Installation of In-roof kit3. The bottom apron flashing consists

of the left hand (36-A) and righthand (36-B) bottom aprons, plusany bottom apron extensions (37) -if required. When installing bottomapron extensions, check thenumber required by referring to thein-roof kit components table inSection 6.1.

The required width of the finishedbottom apron must be determinedfrom the dimensions table inSection 6.1 for the number andconfiguration of modules to beinstalled and the bottom apronflashings (or bottom apronextensions) cut to lengthaccordingly.

To achieve the required width cutone of the bottom apron flashings(or bottom apron extensions) to therequired length.

Important:When cutting bottom apronextensions only cut the endopposite to the butyl sealing strip.

DO NOT CUT OFF THE ENDWITH THE BUTYL STRIP!

Figure 6-6: Preparation of roof area

Figure 6-7: Distances between roof battens

Figure 6-8: Bottom apron overlap dimensions

Length of module area

Top cover plate

Additionalroof batten

Additionalroof batten

Module area height -28mm

22 270

Bottom coverplate

StopI vert.

22I vert.

80mm (overlap dimension)

Horizontal distance

Verticaldistance

Horizontally flush

Vertically flush32

31 30 29

Note: Butyl tape has strong adhesiveproperties meaning that mistakescannot be corrected afterapplication.

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4. Install the bottom roof batten(supplied by others) at a distance of220mm above the last tile battenbelow. Fix tightly with screws(supplied by others) to each truss.

The horizontal distance from theedge of the roof tile to the roofbatten and to the bottom coverplate (36) is 90mm. See Figure 6-10.

Push the bottom cover plate up tothe roof batten but do not screwtightly.

Note: The additional roof battens musthave the same thickness as theexisting roof battens.

6.4.1 Installation of the left singlevertical channel profile

5. Install the top batten (supplied byothers) at the required distancefrom the bottom roof batten (seeFigure 6-7). Fix tightly with screws(supplied by others) to eachcounter batten. See Figure 6-10.

6. Cut the single vertical profiles (38) tolength in accordance with dimensionsgiven in the in-roof kit componentstable given in Section 6.1.

Install the gasket (43) in the grooveof the single vertical channel profile(next to the wide outer channel)and cut to length flush with theends of the vertical channel profile(39). See figure 6-12.

Figure 6-9: Installation of bottom roof batten and bottom apron flashing

Figure 6-10: Installation of bottom andtop roof battens

Figure 6-11: Installation of gasket onsingle vertical channel profile

Figure 6-12: Installation of gasket on single vertical channel profile

Shorten roof batten

84mm

130mm

Covered at bottom

Facinggasket (43)

Wide channel(outside)

Vertical profile,single (38)

Shortenroof batten

RefertoFigure6-7

36

90mm

220mm

Roof batten (suppliedby customer)

Important:The position of the bottom roofbatten determines the overallposition of the module installation.It is therefore important to ensurethat the layout is fully horizontal(in alignment with the roofcovering).

Important:Do not confuse the single verticalchannel profile (39). With thedouble vertical channel profile(44). Refer to Figure 6-1.

Important:The gasket lip must be facingoutwards - towards the widechannel of the single verticalchannel profile.

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Important:The side stop plate has no cut-out. Do not confuse the Side stopplate (52) with the centre stopplate (53).

Important:Do not confuse double verticalchannel profile (44) with the singlevertical channel profile (39). Referto Figure 6-1.

Figure 6-13: Bottom drill hole in singlevertical channel profile

Figure 6-14: Fitting of side stop plate

Figure 6-15: Installation of gasket for double vertical channel profile

Side stop (40)Sealingscrew

Double verticalprofile (44)

40

Gasket

Facinggasket (43)

06

06

06

Figure 6-16: Horizontal fixing rails used to determine distance between vertical profiles

Important:Do not fix vertical channel profileto bottom batten with screws yet!

Note: IInstall the gasket for all 1-piecevertical profiles (i.e. without a joint)on the floor (i.e. before taking theprofiles on to roof).

7. Lay the single vertical channelprofile on the left side of the in-roofinstallation, on top of the bottomapron with the wide channel onthe outside (and the gasket lipfacing outwards) and align verticallyto the roof construction. See Figure6-13.

Fix the single vertical profile withone sealing screw (40) per roofbatten. See Figure 6-13.

8. Using the side stop plate (52) as adrilling template, drill a single 6mmdiameter hole for the sealing screwin the bottom of the right handchannel of the single verticalchannel profile. See Figure 6-14.

9. Push the side stop plate (52) upbetween the single vertical channelprofile and the bottom apron as faras possible i.e. until the bottom faceis against the profile end. Fix thesingle vertical channel profile andside stop plate tightly in to the roofbatten with a sealing screw throughthe 6mm hole previously drilled inthe profile . See Figure 6-15.

6.4.2 Installation of double verticalchannel profile

10. Install the gasket (43) in the groovenext to the centre channel of theprofile and cut to length flush withthe ends of the double verticalchannel profile (44). See Figure 6-16.

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Figure 6-17: Fitting of centre stop plate

Figure 6-18: Installation of right single vertical channel profile

Figure 6-19: Jointing of single vertical channel profiles – right hand

Covered at bottom

130mm

Shorten roof batten

Note: Install the gasket for all 1-piecevertical profiles (i.e. without a joint)on the floor (i.e. before taking theprofiles on to roof).

11. Use the horizontal bottom fixingrails as a template to determine thehorizontal distance between thevertical channel profiles.

To do this, insert 4 anchor blocks(07) into the top and bottom of thevertical channel profiles. Fit thebottom fixing rail (50) and fixingscrews (06) - two per rail andslightly tighten the screws. SeeFigure 6-17.

Repeat with intermediate/top fixingrail (51) at top of vertical channelprofiles.

Then fix the double vertical profileonto the roof battens with thesealing screws in the right and leftgrooves. See Figure 6-17.

Dismantle and remove the fixingrails; the anchor blocks can remainfitted in the vertical channel profiles.

12. Using the centre stop plate (53) asa drilling template, drill a single6mm diameter hole for the sealingscrew in the bottom of both outerchannels of the double verticalchannel profile.

Push the centre stop plate (53) upbetween the double vertical channelprofile and the bottom apron as faras possible i.e. until the bottom faceis against the profile end.

Important:The lips of the two gaskets mustface towards the centre of thedouble vertical channel profile (i.etowards each other).

Important:Do not fix vertical channel profileto bottom batten with screws yet!

Important:The centre stop plate has acentral cut-out. Do not confusethe centre stop plate (53) with theside stop plate (52).

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Figure 6-20: Jointing of single vertical channel profiles – left hand

Module height +22mm

Figure 6-21: Position of upper anchor block

Figure 6-22: Fitting of bottom fixing rail

50

Fix the double vertical channelprofile and centre stop plate tightlyin to the roof batten with twosealing screws through the 6mmholes previously drilled in the profile.See Figure 6-18.

13. Additional vertical profiles are fixedonto the roof using the sameprocedure as above.

6.4.3 Installation of right singlevertical channel profile

14. Installation of the left single verticalchannel profile is a mirror image ofthe left. See Figure 6-19.

6.4.4 Lengthening of the verticalchannel profiles

15. Where vertical channel profiles areto be joined, they must beconnected using the correct jointplates.

The single vertical channel profilesare joined using either the righthand joint plate (46-B) for right handvertical profiles (see Figure 6-20) orthe left hand joint plate (46-A) forleftt hand vertical profiles (seeFigure 6-21).

To fit the joint plates, push thenarrower end of the joint plate intothe outer (wider) channel of thelower vertical channel profile as faras possible. See either Figure 6-20or 6-21, as applicable. Remove theprotective strips from the butyl tape,lay the single vertical profile flush ontop of upper section of the jointplate from above and fix with thescrews provided.

Note: Butyl tape has strong adhesiveproperties meaning that mistakescannot be corrected after assembly!

Important:The gasket lip must be facingoutwards - towards the widechannel of the single verticalchannel profile.

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Figure 6-25: Alignment of intermediatefixing rail

Figure 6-24: Applying Butyl tape tointermediate/top fixing rails

Figure 6-26: Fitting of central rail fixing

Doublefixing rail

Butyl tape

Figure 6-23: Installation of first PV module

16. Double vertical channel profiles arejoined using the double verticalchannel joint plate (47). To fit thejoint plates, push the narrower endof the joint plate Into the centrechannel of the lower verticalchannel profile as far as possible.See either Figure 6-19 or 6-20, asapplicable. Remove the protectivestrips from the butyl tape, lay thesingle vertical profile flush on top ofupper section of the joint plate fromabove and fix with the screwsprovided.

Note: Butyl tape has strong adhesiveproperties meaning that mistakescannot be corrected after assembly!

6.4.5 Installation of PV modules

17. Position the bottom anchor blocksso they are flush to all bottomedges of the vertical profiles.

The position of the top anchorblocks for the first horizontal row ofmodules must be determinedbased on the vertical height of themodule. See Figure 6-22.

18. Lay the bottom fixing rail (50) on thevertical channel profiles with theedge facing towards the top of theinstallation. Fit using the fixingscrews (06) without tightening atthis stage.

Note: No butyl tape is required herebecause the fixing bracket isinstalled above the bottom coverplate.

Important:The gasket must bridge the gapat the joint.

Important:The gasket must bridge the gapat the joint.

50

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Figure 6-27: Installation of double fixing bracket

Figure 6-29: Fitting of side cover flashing

Figure 6-28: Location of top fixing rail

Figure 6-30: Side cover flashing fitted against module side

6.5 Installation of modules19. The PV modules should be

positioned so that the connectingboxes are all in the same position.

Insert the first PV module behindthe bottom fixing rail (50) alreadymounted on the vertical channelprofiles. See Figure 6-23.

Align the ends of the module to beflush with the ends of the bottomfixing rail and secure by tighteningthe two fixing screws. See Figure 6-24.

20. Apply the butyl tape supplied to theunderside of both side flanges onthe intermediate fixing rails (51). Seefigure 6-25. Cut off flush with theends of the rail. On the top fixingrails only apply the butyl strip to oneof the side flanges – i.e. the flangein contact with the top edge of theuppermost module.

Note: Apply the butyl strip on all fixingrails on the floor (i.e. before takingthem on to roof). Leave protectivestrips in place until you are readyto fit the fixing rails.

The butyl tape can also be cut intopieces joint by joint.

Install the modules in rows workingfrom bottom to top.

21. Fit the first intermediate fixing railadjusting the position of the anchorblocks (in the vertical channelprofiles) to align with the holes inthe fixing rail.

Place the second module in front ofthe installation position and attachthe connector cables. Lay themodule onto the vertical channelprofiles, locate under the upperflange of the fixing rail and alignroughly flush with the lower module.

22. For modules installed in alandscape configuration, where thehorizontal length greater than1000mm, an additional central railfixing must be installed. See Figure6-27.

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Figure 6-31: Roof tile overlapping on cover plate

Figure 6-32: Overlap of top cover flashing with butyl strip

Figure 6-33: Installation of top cover flashing

80mm (0verlappingdimension)

23. Keeping the side flanges of the railAbove the frames of the modules,remove the protective strip from thebutyl tape. Position the intermediatefixing rail above and flush withboth modules and push it downbetween the modules. See Figure6-28. Secure the fixing rail bytightening the two fixing screws (06).

Note: Butyl tape has strong adhesiveproperties meaning that the fixingrail position cannot be correctedafter fitting!

The PV module array should nowbe tested (per string) for correctoperation. Refer to Section 9 ofthese Installation instructions forfurther details of module testing.

24. The top edge of the uppermostmodule is also fixed with a top fixingrail. There is no need for butyl tapeon the underside of top flange ofthe fixing rail as the top cover plateis attached here later. See Figure 6-29.

6.6 Installation of side coverflashings25. The number of side cover flashings

and side cover flashing extensionsrequired are given in the in-roof kitcomponents table in Section 6.1.

Fit the side cover flashing (34-A or34-B) into the gap between theouter edge of the vertical channelprofile and the edge of the module(into the visible groove) of either theright or left single vertical channelprofiles – hooking the flange of theside cover flashing under the edgeof the module. See Figure 6-30.Press down on the side coverflashing until the outer flange is flaton the roof battens.

Where side cover flashing extensions(35-A or 35-B) are used, these mustbe installed working from thebottom to top. The upper sidecover flashing must always overlapover the top of the one below.

26. Fix the side cover flashings ontoeach second roof batten using theclips and nails provided.

27. Lay the roof tiles overlapping on theside cover flashings.

28. If necessary, cut the roof tiles up tothe plate edging.

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Figure 6-34: Visible installation of plate protector

Side plate protector Centre plate protector

Figure 6-35: Penetration of string cables through membrane

6.7 Fitting top cover flashing29. The number of top cover flashings

and top cover flashing extensionsrequired are given in the in-roof kitcomponents table in Section 6.1.

The required width of the finished topcover flashing must be determinedfrom the dimensions table in Section6.1 for the number and configurationof modules to be installed and thetop cover flashings (or top coverextensions) cut to l length accordingly.

Length alignments only on sidewayfrom the butyl tap

To achieve the required width cutone of the top cover flashings (ortop cover extensions) to therequired length.

30. Position the groove (under loweredge of the top cover plate) ontothe upper flange of the top fixing railas far as it will go. See Figure 6-34.

31. Fix the top cover flashing to the roofbatten approximately every 500mm.

The roof tiles above the collectorarray usually have to be cut. Theoverlap of these tiles over the topcover flashing must be as follows, inaccordance with the roof pitch:

– = 35° at least 120mm overlap

– > 35° at least 100mm overlap

– > 50° at least 80mm overlap

32. At the top of each vertical channelprofile fit one of the foam protectorblocks provided. Locate block intoside channel of vertical profile andunder the lower edge of the topcover flashing. See Figure 6-35.

6.8 Roof penetration33. Guide the electric connector cables

through the waterproof membrane.To ensure that the roof covering issealed, place an overlapping strip ofwaterproof membrane over theopening and fix in place with a suitableadhesive tape. See Figure 6-36.

Important:When cutting top cover flashings(or top cover extensions) only cutthe end opposite to the butylsealing strip. DO NOT CUT OFF THE ENDWITH THE BUTYL STRIP!

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Figure 6-36: Complete installation

Centre foam block



Side foam block

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7 Electrical Connection - AC Circuit

Figure 7-1: Schematic diagram of system using - one string of modules connected in series

DC Isolator

DC/AC Inverter

AC Isolator

AC Isolator

Export Meter

Consumer Unit

Utility Meter

DNO Supply

Ele

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AC

Cir

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55Figure 7-2: Schematic diagram of system using - two strings of modules connected in series

DC Isolator

DC/AC Inverter

AC Isolator

AC Isolator

Export Meter

Consumer Unit

Utility Meter

DNO Supply

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AC

Cir

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Figure 7-3: Schematic diagram of system using - two inverters each with single strings of modules connected in series

DC Isolator DC Isolator

DC/AC Inverter DC/AC Inverter

AC IsolatorAC Isolator


Export Meter

Consumer Unit

Utility Meter

DNO Supply

Ele

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onne

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AC

Cir

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57Figure 7-4: Schematic diagram of system using - two inverters with three strings of modules

DC Isolator DC IsolatorDC/AC Inverter DC/AC Inverter



Export Meter

Consumer Unit

Utility Meter

DNO Supply

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Cir

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L N N L

Figure 7-6: Typical connections - split load consumer unit

Supply Meter

230V AC MainsElectrical Supply

230V AC input fromSolar PV Inverter

Consumer Unit

Note: Circuit ProtectiveConductors (CPC’s) not

shown for clarity

Note: Refer to Section8.6 for guidance on

use of RCD protection

Figure 7-5: Typical connections - consumer unit

Supply Meter



Consumer Unit


shown for clarity

Mains switch(isolator)

LN

LN

L N N L


LN

LN

LN

LN

20mARCD

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Cir

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Figure 7-7: Typical connections - garage consumer unit

Figure 7-8: Connections for ‘Export/Generation’ kWh meter

Supply Meter


Export (or Generation) kWh Meter

AC Supply fromPV Inverter

AC Supply fromConsumer Unit


Consumer Unit Garage Consumer Unit


shown for clarity


Henley Block

L N

L N N

L

N

L

N

L

N L

LN

LN

LN

LN

LOADMAIN


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8.1 Risk assessmentPrior to commencing any work, a fullrisk assessment must be made of allactivities and risks involved in theinstallation of the Solar PV system,including:

Any roof working and working atheights - necessary to install the PVmodules.

Manual handling – necessary to get PVmodules on to roof.

Risk of electrocution – Live working onthe DC side is inevitable due to thenature of the work involved.

Risks due to falling objects or brokenglass.

Risks associated with working in loftspaces.

8.2 DC cable installationDC cabling should be installed andterminated into the DC isolator orinverter prior to installation of PVmodules. Ensure that DC cables are:

Correctly connected with allplugs/spring connectors correctly made.

Correctly routed such that they are notprone to damage.

Adequately fastened in place wherenecessary.

Clearly labelled at each end especiallywhere multiple strings are involved.

Run separately from any AC cabling.

Tested for continuity and insulation.

Checked that double insulation is intactthroughout.

ALWAYS ensure that connections arenot made or disconnected whilst underload, the DC isolator should always bein the off position wheneverconnections are being made ordisconnected and when installing, untilall of the array connections have beenfinalised.

8.3 PV module installationRefer to the information given in theSections 4, 5 or 6 of these Installationinstructions, as appropriate, for themodule mounting method being usedBEFORE commencing installation of themodules, as follows:

Section 4 – On-roof installation.

Section 5 – Flat roof installation.

Section 6 – In-roof installation.

Installation of the modules should onlybe carried out when:

Proper access equipment is used, e.g.correctly erected scaffolding.

The area below any roof work is secureand warning notices displayed.

Any lifting machinery is certified safeand operative trained to use it.

Installer(s) are wearing the appropriatesafety equipment/clothing.

Installer should be qualified orexperienced in both working at heightsand also the hazards associated withworking with PV modules and DCelectrical systems.

Whilst Grant Solar PV modules are rigidin construction, they are fragile and canbe damaged if dropped. Care must betaken when handling them, e.g. liftingthem onto, or carrying on, a roof, asthey can be caught by the wind.

8.4 Interconnect the modulesRefer to information given in Section 3of these instructions for the method ofconnecting modules in series to form astring.

Ensure that DC cables betweenmodules are connected as each one isfitted to the mounting system, leavingthe ‘free’ cable and plug accessible forconnection to the cable of next module,and so on.

The cables must be adequatelysupported and, where applicable,secured (such as with cable ties) to thearray frame, this will avoid damagebeing caused to the cables under windyconditions where, if unsecured, theywould move and chafe against the roofor the array frame.

Finally, if not already done, connect theextension cables from within thebuilding to the remaining male (positive)and female (negative) plugs.

8.5 DC/AC inverter installationIdentify the most convenient location forthe Inverter. This may be in the loftspace (to minimise the length of DCcable runs from roof mounted modules)or at a lower level in the property.Whatever the location, the invertershould be easily and safely accessiblefor the user of the system as well as theinstaller.

Reference MUST be made to themanufacturers instructions suppliedwith the inverter for specific installationrequirements – e.g. clearances aroundthe inverter and the need for anyventilation to allow dissipation of theheat generated by these devices inoperation.

8 Installation Procedure

Important:Grant Solar PV modules will notsupport the weight of an installerand therefore must not be stoodon under any circumstances.

Important:The inverter(s) must not bemounted on a combustiblesurface.

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8.6 Install the AC wiringAll electrical installation work mustcomply with the requirements of theElectricity at Work Regulations 1989and BS.7671:2008 – IEE WiringRegulations 17th Edition, Including anyamendments.

All domestic installations must also complywith all applicable parts of the BuildingRegulations, in particular, Part P.

All ‘grid-connected’ Solar PVinstallations must conform to therequirements of the ‘ENA EngineeringRecommendations for the connectionof a small scale embedded generator(SSEG) in parallel with public lowvoltage distribution networks’ publishedby the Energy Networks Association, asfollows:

G83/1-1 – for systems up to 16A perphase.

G59/1 – for systems exceeding 16A perphase.

The AC output circuit between theInverter and consumer unit will includea double pole isolator and an export (orgeneration) meter. A further Isolator maybe required if, say, the Inverter islocated in the loft of the property andthe consumer unit is on the groundfloor, to allow local isolation of the SolarPV system at or near the AC output ofthe inverter.

AC circuit design : The AC circuitshould be designed in accordance withBS7671 including any amendments aswould be the case for any other type ofAC circuit. For installations less than16A per phase (those falling withinG83/1-1) typically a cable size of2.5mm2 and protective device of 16A orless would be adequate. However thedesigner of the circuit must make surethat they have taken into account anyvoltage drop considerations and theearth fault loop impedance calculationsfor the circuit.

RCD protection for the circuit should beconsidered if required by BS7671. Forexample if the cable is buried in a wallat a depth of less than 50mm and theinstallation is not under the supervisionof a skilled or instructed person then itis likely that RCD protection is requiredfor the cable. If however the AC cable issurface mounted then it is unlikely thatit will require RCD protection.

It should be noted that with modernfully electronic inverters a higherthan expected protective conductorcurrent can be present, in somecases where RCD’s are used this canresult in nuisance tripping of theRCD. The use of RCD’S with thesetypes of inverters should beconsidered carefully by the designerof the AC circuit prior to installation.

Refer to Section 7 of these Instructionsfor electrical connection details.

8.7 Connection of kWh meterAn electric kWh meter should beconnected in the AC circuit betweenthe inverter and consumer unit. Refer toFigure 7.1 for location.

This meter will record the amount ofelectricity produced by the Solar PVinstallation and will be the basis for thepayment under the Feed in Tariffscheme (as well some energy supplier‘export’ tariff schemes that may apply).

Refer to the connection instructionsprovided with the meter. Ensure that themeter is correctly connected,remembering that the supply beingmetered in this instance is that comingfrom the PV system/inverter and NOTthat coming from the power supplygrid.

Thus connections to the meter must beas follows:

MAIN – Connect the supply from thePV system inverter

LOAD – Connect the supply from theConsumer Unit

Refer to Figure 7.8 for furtherconnection details.

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9 System Commissioning9.1 Commissioning procedureAll electrical installation work mustcomply with the requirements of theElectricity at Work Regulations 1989and BS.7671:2008 – IEE WiringRegulations 17th Edition, Including anyamendments.

The following guidance applies mainlyto the DC side of the installation, it isenvisaged that those undertaking theinstallation work will be familiar with therequirements of the AC side of theinstallation.

9.2 InspectionWith all electrical installations there is arequirement under the regulations toinspect and test all new componentsthat make up the installation to verifythat all equipment has been installedand selected in accordance withBS7671 and the appropriate standards.

The inspection and testing process is toconfirm before energisation that thereare no faults on the system and theintegrity of the electrical installation isnot compromised.

The inspection process should alwaysprecede the testing.

A visual inspection of the system andcomponents is required and thefollowing items as a minimum should beinspected:-

• AC wiring and connections

• AC isolators and junction boxes

• Full labelling of the AC and DC supplies

• Earthing, Bonding and lightning protection

• Inverter/s

• DC wiring and connections including PV cabling

• DC isolators and junction boxes

• PV modules

• Over current protective devices

• Array mounting system (secure and properly weather sealed)

The installer should keep a record ofthe inspections as per the scheduleof inspections given in BS7671 andin addition the PV system installationcheck list.

All serial numbers associated withthe modules should be recorded onthe PV array test report.

9.3 TestingThere are a number of tests that needto be carried out before the installationcan be safely put into service and thesecan be broken down into groups oftests.

• Module testing

• Array Testing

• DC testing

• AC testing (outside of the scope of these installation instructions) but seebelow for advice on completion of thedocumentation.

All tests should be carried out bysuitably qualified personnel; some ofthe tests stated may result in a FATALelectric shock risk, especially whenundertaken at height, if not carried outcorrectly. If you are unsure about any ofthe tests please consult a suitablyqualified person.

9.4 Module testingThe testing of a PV system should beginduring the Installation phase. It is mostefficient to verify each module as it isinstalled as if faults are found it will savetime in troubleshooting and the need todismantle the entire array to find a faultymodule. Below is a suggestedsequence for module testing:-

1. Place the module in sunlight andthen measure the open circuitvoltage on the output of themodule. Refer to Section 2.2.

2. Remove the module from the sunlight(preferably by covering it). Thenshort the output of the module andthen once again place it in sunlight.Use a clamp meter (set on DC amp)to then measure the short circuitcurrent. (Not all clamp on meterswill measure DC amps). Refer toSection 2.2.

3. At the same time measure the solarirradiance using a suitableirradiance meter. The moduletemperature should be measured.

4. The measured short circuit currentof the Module (Isc) should becorrected for the measuredirradiance level as shown in thefollowing:

1000 x (Measured value of Isc)(Measured irradiance)

The result should be compared tothe rated module output on thedata plate of the module to verifythat the module output is asdeclared.

5. The Voc is then corrected for thetemperature change (-0.5% changefor each degree of increase from25˚C or + 0.5% for each degreedecrease from 25˚C).

The result should be compared to therated module output on the data plateof the module to verify that the moduleoutput is as declared.

9.5 Insulation resistancetestingNOTES REGARDING TEST METHOD

Two test methods are possible:

Method 1 Test between Earth and Array Negativefollowed by a test between Earth andArray Positive.

Method 2Test between Earth and Array Positive & Negative short circuited together(simplified method).

In either case where the structure/frameis bonded to earth, the earthconnection may be to any suitableearth connection or to the array frame(where the array frame is utilised,ensure there is good contact, and thatthere is continuity over the wholemetallic frame).

For systems where the array frame isnot bonded to earth, for example wherethere is a class II.

Installation, the commonest ofinstallation methods, the following testmay be the most appropriate to verifythere are no shorts between the DCcabling and the array frame.

Procedure for Test Method 1 & 2between Array cables and Frame.

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Test Preparation:Remove any electronic equipment thatmay be vulnerable to a the test or thatmay cause false readings. As aminimum isolate the PV array from theinverter at the array switch disconnector(DC isolator).

Ensure that there are no connectionsbetween the positive or negativeconnections and earth.

Where the test is to be undertakenbetween Earth and short-circuited Arraypositive and Array negative cables anappropriate test box should be used.

The test can be conducted on theentire array at the same time if theconnections are possible, if not theneach string can be tested individually.

Select an appropriate test instrument toconduct the test and select the correcttest voltage (usually 500v DC) as perIEE guidance note Three.

Following the instructions on theinsulation resistance tester connect onelead from the instrument to the arraycable(s).

Connect the other lead from theInsulation resistance device to arrayframe or earth as per above, dependanton which method is being used.

Press the button to apply the test andrecord the readings on the PV array testreport.

Ensure that the test is repeated tocover all required permutations required(dependant on test method selected).

Ensure that any charge has had time todischarge before removing the leads ortouching any parts under test.

9.6 Array testingThe open circuit voltage and shortcircuit current of the array need to bemeasured prior to connection to theA.C supply. Essentially the array test isthe same as that stated above for themodule test. A suggested sequence forarray testing is as follows:

1. Isolate all of the strings by ensuringthat all of the string DC isolatorsand the main DC Array isolators areset to the OFF position.

2. Insulation resistance testing.

3. For each string in turn complete thefollowing:

a Connect a voltmeter across the positive and negative input terminals of the DC isolator or use a suitable test box, and record the voltage displayed. Then correct this valuefor temperature changes from thestandard test conditions. This is the open circuit Voltage (Voc).

b Verify that the open circuit voltagevalue is around ‘n’ multiplied by Voc for a module, from the data plate, where ‘n’ is the number of modules connected in series in the string. This is the string Voc and should be recorded on the PV array test report.

c With the DC isolator set in the OFF position, connect a shorting link across the positive and negative output of the DC isolator, or use a suitable test box.

d Using a clamp meter with DC amps position it around the link or the leads of the test box.

e Switch the DC isolator or test boxto the ON position and record thecurrent displayed. This is the short circuit current (Isc) and should be recorded on the PV array test report.

f Where possible a simultaneous reading of the solar irradiance should be taken.

g As per the module testing under Section 9.4 point 4 above, divide the measured value of Isc by the measured value of the in-plane solar irradiance and multiply the result by 1000 to correct the measured value of Isc to STC radiation (1000 W/m2).

h Verify that the corrected short circuit current value agrees with manufacturer's data for the module. Refer to Section 2.2.

i Switch the DC isolator to the OFFposition before removing the link or test box.

4. Assuming no faults, i.e. the opencircuit voltage for each string has asimilar value, set all of the string DCisolators to the ON position.

5. Repeat 2 steps (a-j) for the wholearray and using the main arrayisolator if provided.

6. Verify that the array voltage isapproximately equal to the lowestmeasured string voltage (n x Voc)and that all string voltages havesimilar values (+/-3V).

7. Verify that the corrected arraycurrent is equal to the sum of thecorrected string currents.

Complete the PV array installationCertificate commissioning reportand Check list with the abovedetails.

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9 System Commissioning9.7 AC tests andcommissioningdocumentation required The AC side of the installation shouldbe inspected and tested as perBS7671 (including any amendments)and the IEE Guidance note Three.

For all installations this will mean thatthe following will need to be completedfor the AC side as a minimum.

• Electrical installation certificate

• Schedule of inspections

• Schedule of test results

NOTE : Great care should be taken oncompleting the above documentationas it when completed it should coverboth the AC and DC side of theinstallation. In some cases this maymean that when software is used tocomplete the documentation it will notallow the user to complete all fields (i.e.when you have to indicate that theinstallation is both AC and DC) wherethis is the case the commissioningengineer should consider using withertwo sets of the electrical installationcertificate or completing thedocumentation by hand.

9.8 DC documents requiredAs detailed in the tests listed above,following DC documentation is required:

• PV array test report

• PV system installation check list

These documents should be completedin full and serial numbers of the installedmodules detailed.

9.9 DNO notification For installations under 16A per phase(falling under G83/1-1) the DNO mustbe informed that a small scaleembedded generator has been installedonto the network at or immediately aftercommissioning, then completion &submission of the followingdocumentation to the DNO must beundertaken.

• ENA Engineering recommendation G83/1-1.SSEG installation commissioning confirmation

This documentation must be completedand submitted to the DNO within 30days of the installation beingcommissioned.

For installations in excess of 16A perphase the advice of the DNO must besought during the design stage to gaintheir permission to install such asystem. It is likely that such aninstallation will require compliance withG59/1 and each DNO’s requirementsmay differ so early communication isessential.

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Grant Solar PV systems require littleroutine maintenance. However to keepthem running safely and at optimumoutput some regular attention isrequired, as follows:

10.1 PV modulesRegular cleaning of the glass andframes is not essential. However, alarge build up of dirt can reduce theoutput of the system so, if required,wipe the glass and frames using waterand a soft sponge or cloth. Mild non-abrasive cleaning agent can be used,where necessary to remove stubborndirt.

Check the electrical connections areclean, secure and undamaged and alsocheck that all cables undamaged andsecured (e.g. with cable ties) and notfree to move in the wind.

If any electrical problems are found withthe modules, cables or connectorsisolate and lock off the AC supply to theinverter and isolate the DC input fromthe modules. Any rectification workmust be carried out by a competentSolar PV installer as necessary beforeputting the system back into operation.

10.2 InvertersReference should be made to theInstallation and operating instructionssupplied with each Inverter.

Check the inverter for any signs ofexternal physical damage. Also checkthat the inverter is in operation – usuallyshown by an indicator light on the unit.

If any damage is seen to the unit thatmight compromise safe electricaloperation then isolate and lock off theAC supply to the inverter and isolatethe DC input from the modules. Anyrectification work must be carried outby a competent Solar PV installer asnecessary before putting the systemback into operation.

The Inverter casing and displays, if dirty,can be cleaned by wiping with a dampcloth. Solvents, abrasives or corrosivecleaning agents must not be used.

If necessary any dirt/dust deposits onthe cooling fins of heat sinks should becarefully removed using an appropriatesoft brush or paintbrush.

Caution – Inverter heat sink fins may beHOT! Isolate and lock off the AC supplyto the inverter and isolate the DC input.Then allow the inverter to cool beforeinspecting and/or cleaning.

On SMA Sunny Boy invertersperiodically check the integral DCisolator (Solar switch) for wear. Refer tothe SMA Installation Guide suppliedwith the inverter for details of theprocedure involved.

10.3 DC cables andconnectorsAll DC cables and connectors that areaccessible (e.g. in the loft space) shouldbe periodically inspected. Check theconnections are clean, secure andundamaged and also check that allcables are undamaged, suitablesecured where necessary, and notlocated where they can be easilydamaged.

Any rectification work must be carriedout by a competent Solar PV installeras necessary before putting the systemback into operation.

10.4 LabellingCheck all parts of the system areadequately labelled and that safetylabels fitted at the time of installationhave not been removed in themeantime. If necessary replace anymissing safety labels.

10.5 Electrical installationAs with all electrical installations aperiodic inspection is required, asspecified by the installer on the initialinspection certificate. This should beconducted by a suitably competentelectrical contractor/solar PV installer,and the appropriate inspectioncertificates completed and left with thehouseholder.

10 Servicing & Maintenance

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Part Name Part No.

Solar Cable 4mm! x 10m c/w male & female MC Type 4 connectors (fitted) GPV249640

Adaptor cables MC Type 4 to type 3 (1 pair) GPV231333

Rail connection kit GPV221165

Module retaining end clip c/w anchor block and fixing screw GPV221673

Module retaining mid clip c/w anchor block and fixing screw GPV221674

Anchor block (single) GPV221353/S

Fixing screw – to fit anchor block (single) GPV221227/S

Solar Irradiance meter GPV222020

T-bar Allen key (6mm) – to fit fixing screw GS222001

Module stop bracket GPV221201

AC Isolator (lockable) – 20A GPVAC20

DC isolator (lockable) GPVDC02

MC Type 4 connectors - male & female (1 pair) GPV231333

Crimping tool – for MCType 4 connectors GPV231037

kWh Meter (Elster) GPV5235B/WF

Bolt, nut & washer - for flat-roof frames (box of 100) GS222094

Solar test box GPV221176

Grant Solar PV System Spare Parts

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12.1 GeneralThe investigation and rectification of anyfault with a Grant Solar PV system mustbe conducted by a suitably competentelectrical contractor/Solar PV installer.

All electrical checks and testing mustbe carried out in accordance with therequirements of BS7671:2008 – IEEWiring Regulations 17th Edition(including any amendments).

Any work carried out at high level (e.g.on a roof) must be done so in a safemanner, in compliance with the Work atHeights Regulations 2005 (including anyamendments).

12.2 Fault finding proceduresFor guidance on fault identification andrectification please refer to themanufacturers’ Installation and Userinstructions supplied with the inverter(s).

Each inverter has a display which willindicate the nature of a system fault.Follow the directions given in therelevant section of the inverterinstructions to diagnose and rectify thefault.

Before commencing any work on thesystem ensure that BOTH electricalpresent on site are isolated, as follows:

• Isolate and lock off the AC supplyto the Consumer unit

• Switch off Solar circuit MCB inConsumer unit.

• Isolate the DC input to inverter fromthe PV modules at the DCisolator(s). This may be at the DCisolator integrated into the inverteror at the external DC isolator(s)fitted – depending on the type ofinverter(s) used.

12 Fault FindingImportant:NEVER disconnect a DCconnection between the PVmodules and the inverter whilstthe system is under load, i.e. withthe AC output connected to theinverter.

ALWAYS isolate the AC side ofthe system (AC supply to theinverter) BEFORE isolating the DCoutput from the PV modules.

ALWAYS isolate the DC outputfrom the PV modules beforedisconnecting or connection anyDC connectors.

CAUTIONSolar PV modules will generate anelectrical output wheneverexposed to daylight!

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If required Grant Solar PV systemsshould be de-commissioned as follows:

13.1 Shut down procedureIsolate and lock off the AC supply tothe Consumer unit.

Switch off Solar circuit MCB inConsumer unit.

Isolate the DC input to inverter from thePV modules at the DC isolator(s). Thismay be at the DC isolator integratedinto the inverter or at the external DCisolator(s) fitted – depending on thetype of inverter(s) used.

13.2 DC cables Disconnect the DC cables from theinverter. Refer to Section 3.2 for inverterconnections.

Disconnect the DC string cables fromthe PV module array.

Disconnect the interconnecting DCcables between the modules

Disconnect the string cables from theDC isolator(s).

Disconnect any cables between DCisolator(s) and the inverter(s)

Remove DC isolators.

13.3 PV modules Unscrew the retaining clips and removethe modules from the roof mountingsystem. Refer to sections 4, 5 or 6 asrequired for details of the fixing systemconcerned.

Carefully remove the modules to groundlevel and either store or dispose of asrequired.

If modules are to be re-used: ensurethat DC cables/connectors are tiedaway to avoid any damage or risk ofelectrocution. Store such that noexcessive load is applied to the solarPV cells, e.g. store in an uprightposition.

Important: Solar PV modules produceelectricity whenever exposed todaylight. Therefore care must be takenwhen handling PV modules duringdaylight hours.

Remove all mounting rails and fixingbrackets from roof and keep together.

If the modules are to be disposed ofthen do so in accordance with all localand national regulations for electronicwaste.

Make good any holes to the roofcovering. In the case of an in-roofinstallation the area will need to be re-tiled when the modules and roofinstallation system is removed, to re-weather the roof.

13.4 Inverters Disconnect inverter(s) from the ACsupply (from Consumer unit).

Remove the Inverter and, if it is to beused again, store in a dry location. Ifpossible pack the inverter in the originalpackaging if still available.

If inverter is to be disposed of, do so inaccordance with all local and nationalregulations regarding electronic waste.

13.5 AC circuit from consumerunit With consumer unit isolated from theAC supply, disconnect the ACconnections to the Solar circuit MCB.

Remove cable from between Consumerunit and inverter as required.

13.6 Consumer unitWith Solar circuit MCB set to ‘off’reconnect AC supply to consumer unitand check that other circuitsconnected, e.g. lights, ring mains, etc.work correctly.

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14 WarrantyThe Grant Solar PV SystemWarrantyDear CustomerYou are now the proud owner of aGrant Solar PV System from GrantEngineering (UK) Limited that has beendesigned to give years of reliable,trouble free operation. GrantEngineering (UK) Ltd. guarantees themanufacture of the system, including allelectrical and mechanical components,for a period of twelve months from thedate of purchase provided the systemis installed in full accordance with theinstallation instructions provided. Thiswill be extended to a period of fiveyears* if the system is registered withGrant UK within thirty days ofinstallation and it is serviced at twelvemonth intervals. See Terms andConditions below.

Performance GuaranteeGrant Solar PV Modules have a twentyfive year performance guarantee, i.e.the modules are guaranteed to producethe following minimum output.

Minimum of 90% of original output forup to ten years of operation.

Minimum of 80% of original output forbetween ten to twenty five years ofoperation.

ImportantPlease register your Grant Solar PVsystem with Grant UK within thirty daysof installation, as follows:

Either

a) visit www.grantuk.com and followthe links to the ‘Householder Zone’, or

b) go to www.grantuk.com/solarpvregistration.aspx,

where you can register your Solar PVsystem for a further four years warranty(giving five years* from the date ofpurchase). This does not affect yourstatutory rights.

Breakdown during theManufacturer’s WarrantyIf your Grant Solar PV System shouldfail within the first five years* of the dateof purchase you must contact GrantEngineering (UK) Limited, who willarrange for the repair under the termsof their Warranty, providing that thesystem has been correctly installed andcommissioned, serviced (if older thantwelve months) and the fault is not dueto misuse, or the failure of any systemcomponents not supplied by Grant UK(e.g. circuit breakers, AC cabling, etc.),any fault in the existing electricalinstallation or the incorrect setting of thesystem controls. This extended fiveyear* warranty only applies if thesystem is registered with Grant UKwithin thirty days of installation.

In the first Instance:Contact your installer to ensure that thefault does not lie with any part of theexisting electrical installation in theproperty, any other components notsupplied as part of the Grant Solar PVSystem, or any incorrect setting of thesystem controls.

If a Fault is Found:Ask your installer to contact GrantEngineering (UK) Limited ServiceDepartment on 01380 736920 who willarrange for a qualified service engineerto attend to the fault.

Free of Charge Repairs:During the first five years* no charge forparts or labour will be made providingthat the Solar PV System has beeninstalled and commissioned correctly inaccordance with the manufacturer’sinstructions, serviced at twelve monthintervals and the system wasregistered with Grant UK within thirtydays of installation. Proof of ‘purchase’date must be provided upon request.

Chargeable Repairs:A charge will be made if the causeof the breakdown is due to any ofthe following:

• Faults caused by the existingelectrical system in the property,the AC wiring to the PV systemor any external electricalsystems and components.

• The Grant Solar PV System hasnot been commissioned, orserviced, in accordance with theInstallation & User manualsupplied with the system.

• The system has been installedfor over five years.

Remember before you contactGrant:Please register your Grant Solar PVSystem within thirty days of theinstallation.

Terms of Manufacturer’s Guarantee1. The Grant Solar PV System

guarantee starts from the date ofpurchase.

2. All electrical and mechanicalcomponents supplied with the GrantSolar PV System (including themodules, inverter, etc.) areguaranteed for a period of fiveyears*, subject to them beingsupplied as a kit. The GrantWarranty does not cover any ‘mixed’systems – i.e. where the modules orinverter(s) were not supplied byGrant Engineering UK Ltd.

3. This guarantee does not coverbreakdowns caused by incorrectinstallation, neglect, misuse,accident or failure to operate thesystem in accordance with theInstallation and User Instructionsprovided.

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4. The Grant Solar PV System isregistered within thirty days ofinstallation. Failure to do so doesnot affect your statutory rights.

5. The Grant Solar PV System mustbe installed by a competent installerand in full accordance with therelevant Codes of Practice,Regulations and Legislation in forceat the time of installation.

6. The Grant Solar PV Systemcomponents must not have beenmodified or tampered with.

7. The installation is subject to atwelve month visual inspection – toinclude checking that the modulesare not in shade and are in a cleancondition. Routine cleaning of themodules is not usually required asnormal dirt build up is removed byrain. Any Receipts should be keptas proof.

8. The installation is checked by aqualified electrician every ten years,or sooner, as required by thecurrent BS.7671 (WiringRegulations – 17th Edition).

9. All claims under this guaranteemust be made to Grant Engineering(UK) Ltd prior to any work beingundertaken. Proof of purchase anddate of installation must beprovided on request. Invoices forcall out/repair work by any thirdparty will not be accepted unlesspreviously authorised by GrantEngineering (UK) Ltd.

10. This guarantee is transferableproviding the installation is servicedprior to the dwelling’s new ownerstaking up residence. GrantEngineering (UK) Ltd must beinformed of the new owner’s details.

11. Grant Engineering (UK) Ltd willendeavour to provide promptservice in the unlikely event of aproblem occurring, but cannot beheld responsible for anyconsequence of delay howevercaused.

12. This guarantee applies to GrantSolar PV Systems installed on theUK mainland, Isle of Man andChannel Islands only. Provision ofin-warranty cover elsewhere in theUK is subject to agreement withGrant Engineering (UK) Ltd.

* 2 years warranty for MastervoltSoladin 600 inverter only

GRANT ENGINEERING (UK) LTDHopton House, Hopton Industrial Estate, Devizes, Wiltshire. SN10 2EU

Telephone: 01380 736920 Fax: 01380 736991Email: [email protected] Website: www.grantuk.com

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