Installation Instructions - Unbound Solar

Installation Instructions

Monocrystalline Solar Module Multicrystalline Solar ModuleMonocrystalline Solar Module

2

Contents

Safety 3

8noitallatsnI erofeB

01noitallatsnI retfA

Component 11Front 11Back 11

21noitallatsnI lacirtcelE31snoitcennoC lacirtcelE

G 31gniriW larene31gniriW dnuorG htraE41 noitcennoC seireS51noitcennoC lellaraP

61noitallatsnI lacinahceMM 61gnitnuoM eludo

61noitaredisnoC etiSM 71snoitarugifnoC gnitnuoM 91 scitsiretcarahC lacinahce

12 ytilibaiL fo remialcsiD

22noitacificepS tcudorPM 22enillatsyrc-onoM 32enillatsyrc-itlu

42dohteM dnuorG

52noitcepsnI dna ecnanetniaMDisposal 25

3

Safety

1. Safety

The instructions relate to the safety indi-cated in the following are for preventingunexpected danger or damage in advanceby safely and exactly using the product.

Non-compliance of the instructions may

immediately cause serious injury or death.

DANGER

CAUTIONNon-compliance of the instructions may

cause injury or property damage to the

user.

WARNINGNon-compliance of the instructions may

cause death or serious injury to the user.

This is the sign for calling attention

to the matters and operations that

may cause danger. Please carefully

read and follow the instructions for

preventing danger.

This is the sign for indicating the

method of use that must be avoid-

ed for preventing danger.

4

Safety

DANGER

Do not contact with electrically activeparts of the panel, such as terminals,regardless of connection of the module.

It may result in spark or lethal electric shock.

Please don’t use the module with thebroken window or the torn backside.

There is a danger of electric shock.

5

Safety

WARNING

It may result in safety accident.

Do not approach the damaged or bro-ken module unless you are an expert.

It may result in serious injury.

Please perform works in the dry condi-tion and use only dry tools.Do not handle the wet panels withoutprotection equipment.

Damaged module must be treatedwith safety protection equipment.

It may result in injury.

6

Safety

CAUTION

It may result in damage or failure of theproduct.

Please use proper equipment, connec-tor, wire and buttress for system con-figuration of the module.

It may result in injury.

Do not touch the glass surface orframe of the solar module after instal-lation of the module.

It may result in safety accident.

Do not perform installation in rainy,heavily windy or snowy days.

It may decrease the strength of the frameor glass.

Do not make the holes in the frameor glass of the module.

It may decrease the strength due to corro-sion of the frame.

Do not scratch the coating surface ofthe frame.

The cells organized in the module may bebroken.

Do not locate a heavy object ontothe module. Do not stand on or stepon the module. Do not drop or sudden-ly lay down the module.

7

Safety

CAUTION

It may result in damage of the product.

Do not concentrate sunlight on themodule surface.

It may result in damage of the product.* The installing structure must be in the bent type.

The straight type may cause deformation of the product as shown in the following pictureor decrease the strength of structure due to a space between the frame and the structure.

If the installing structure has a curved surface (ex. arch type) as shown in the belowpicture, do not forcefully modify the module in installation when connecting it withthe structure.Please install the module in the place where the structure has been completely setup because deformation of the structure may cause deformation of the productwhen performing exterior installation by using a crane, etc after assembling themodule to the installing structure.

It may result in damage of the product.

Do not apply a shock to the junctionbox of the module or pull the cable.Do not remove the labels attached tothe module.

Module

Installing structure(bent type)

ModuleInstalling structure(Straight type)

Product Deformation Occurrence of space

8

Before Installation

2. Before Installation

Please carefully read this manual beforeinstallation.

• Solar module installation should be per-formed by an authorized installer for thesafety and maintenance of the system.

• All installation instructions should beclearly understood before attemptinginstallation.

• Do not twist, pull, or scratch the cableattached to the solar module.

• Do not touch the glass or rear surface ofthe solar module with bare hands.

• Do not stand on and put weight on thesolar module.

• Do not drop the solar module and causean excessive load on solar module.

• Do not disassemble the solar module.

• After installation or repair, check whethersolar module operates properly or not.

• In case the currently used solar module orthe parts applied to the solar module havebeen replaced, check whether thechanged solar module is properly operat-ed or not.

The newly replaced solar module andits parts must be the same solar mod-ule (model name) and parts with thecurrent solar module.

• Please contact the local office to con-firm the regulations and to obtain per-mission.

• Follow all safety precautions of allother used components.

• Do not let anyone approach the solarmodule who has little knowledge ofsolar modules or on the measures totake when solar modules are damagedin order to avoid the risk of injury orelectrical shock.

• Do not locate the solar module hori-zontally, as this may cause dirt or whiteefflorescence (glass deformation)

• Panels produce voltage even when notconnected to an electrical circuit orload.Panels produce nearly full voltagewhen exposed to as little as 5% of fullsunlight, and both electrical currentand power increase with light intensity.

9

Before Installation

• Panels are intended for outdoors, land-based applications only. Panels are notintended for use indoor use or applica-tion on moving vehicles of any kind.

• Reflection from snow, water or othersurfaces can increase light and there-fore increase both the current andpower generated by the panel.

• Industry standard rated specificationsare made at conditions of 1000W/m2

irradiance and 25°C (77ºF) solar celltemperature. Colder temperatures cansubstantially increase voltage andpower.

• Keep the solar module and systemaway from children when installing.

• Keep the module packed in the cartonuntil the time of installation.

• Make sure the flammable gases are notgenerated near the installation site.

• Do not work alone. Please work as partof a team of two or more people.

• Wear a safety belt if working highabove the ground.

• When working with panels in light, fol-low all applicable regulation regardingworking with live electrical equipment.

• Contact with electrically active parts ofthe panels, such as terminals, canresult in burns, sparks and lethal shockwhether the panel is connected or dis-connected.

• Even partial shadowing can substantial-ly reduce panel and system output.

• Care must be taken to avoid low tiltangles which may cause dirt to build-up on the glass against the frameedge.

• Dirt build-up on the surface of thepanel can cause active solar cells to beshaded and electrical performance tobe impaired.

• Always keep the back surface of thepanel free from any foreign objects orstructural elements which could comeinto contact with the panel, especiallywhen the panel is under mechanicalload.

• For permission to use mounting meth-ods not described in the MountingGuide. Please consult LG Solar. Failureto do so will void the warranty andpanel certification.

10

After Installation

3. After Installation

• Plug the connector in tightly andensure that the wiring properly works.Failure of electricity generation may becaused by failure of inverter operationdue to the non-connection of +/- con-nectors (ex. only 12 units out of 15units connected)

• It is advisable to conduct periodicinspection of the panels for damage tofront glass, back skin, frame, junctionbox, or external electrical connections.

• Check electrical connections for looseconnections and corrosion.

• PV panels can operate effectively with-out ever being washed, althoughremoval of dirt from the front glass canincrease output.

• Water can be used for regular washingor rinsing of the treated front glass toremove dust, dirt or other deposits.

• To remove ingrained dirt, the treatedglass can be washed with a micro-fibercloth and ethanol or a conventionalglass cleanser.

• No aggressive and abrasive cleansersor chemicals should ever be used onthe treated front glass. No alkali basedchemicals should be used, includingammonia based solutions.

• Always wear rubber gloves for electricalinsulation whilst maintaining, washingor cleaning panels.

• Deposits of foreign material on theframe surface can be cleaned using awet sponge or cloth and dried in air orby using a clean chamois.

• Alternatively, a mild detergent or glasscleaner may be used. Never useaggressive alkaline or acid cleaners toclean any part of the panel.

• Foreign material on the frame may insome instances look like small scratch-es, but in most cases can be removedby cleaning.

• Perform the wiring work by connectingthe connector and wires to the standaway from the roof or ground.

11

Component

Junction Box

Backsheet

Frame

<Figure 1>

4. Component

Glass Solar Cell (Mono) Glass Solar Cell (Multi)

LGxxxM1W(C)-G2 / LGxxxS1W(C)-G2 LGxxxP1W(C)-G2 / LGxxxR1W(C)-G2

Front

Back

12

Electrical Installation

5. Electrical Installation

• Avoid all electrical hazards wheninstalling, wiring, operating and main-taining a panel.

• Do not use panels of different electri-cal or physical configurations in thesame system.

• Match the polarities of cables and ter-minals when making the connections;failure to do so may result in damageto the panel.

• When reverse currents can exceed thevalue of the maximum protective fusemarked on the back of the panel, aproperly rated and certified over-cur-rent device (fuse or circuit breaker)must be connected in series with eachpanel or string of panels.

• The rating of the over-current deviceshall not exceed the value of the maxi-mum protective fuse marked on theback of the panel.

• The panel contains factory installedbypass diodes located inside the junc-tion box.

• When installing the system, it is rec-ommended to install the lightening rodto protect the system.

• The junction box is not designed orcertified to be field accessible or main-tainable and should under no circum-stances be opened. Opening the junc-tion box may void the warranty.

• Panels with a suspected electricalproblem should be returned to LGSolar for inspection and possible repairor replacement as per the warrantyconditions provided by LG Solar.

13


Electrical Connections

Modules may be connected in seriesand/or parallel to achieve the desiredelectrical output as long as certainrequirements are met. Please use only thesame type of modules in a combinedsource circuit.

Never direct artificially concentratedlight on to the module.Do not disconnect the module underload.Shock hazard shall be applied near themeans of connection to the modules.

General Wiring

LG Electronics recommends that allwiring be double insulated with a mini-mum rating of 90°C (194°F). All wiringshould use a flexible copper (Cu) conduc-tor.The minimum size should be determinedby the applicable codes.We recommend a size not smaller than4mm2.

Earth Ground Wiring

To prevent electric shock and fire, anearth ground must be done on the framesof Photovoltaic(solar modules) modulesand arrays. There is an earth hole in thecenter of the module frame. Using thishole, an earth conductor and the solarmodule frame must be connected andearthed.

I. The installation instructions shallinclude:

1. Details for wiring in accordance withthe NEC, Article 690 and that thegrounding method of the frame ofarrays shall comply with the NEC,Article 250.

2. CNL model instruction manuals shallalso include a statement that installa-tion shall be in accordance with CSAC22.1, Safety Standard for ElectricalInstallations, Canadian Electrical Code,Part 1.

14


* Maximum Module configuration(recom-mand) : refer to the ‘8. ProductSpecification’ in this manual.(this value is calculated under the con-dition of Voc at -40°C)

Series Connection

The solar modules may be wired in seriesto produce the desired voltage output.The current of each module connected inseries should be same.Do not exceed the 80% of maximum sys-tem voltage.

- SERIES for more voltage -<Figure 2>

15


Parallel Connection

The solar modules may be combined inparallel to produce the desired currentoutput.The voltage of each module connected inparallel should be same.Every series string or solar module mustbe fused prior to combining with otherstrings. By pass diodes are factory instal-lated in the solar modules. Please refer tothe applicable regional and local codesfor additional fusing requirements andlimitations on the maximum number ofsolar modules in parallel.

* Maximum parallel strings without prop-er measures [e.g. fuse 20A and/orblocking diode] : 1 string[Parallel configuration is not limited ifproper measures are taken to block thereverse current flow, e.g. fuses for theprotection of the module and cablesfrom over-current and/or blockingdiodes for prevention of unbalancedstring voltage].

* A multiplying factor is required forincreased output of the PV modules.Under normal conditions, a PV moduleis likely to experience conditions thatproduce more current and/or voltagethan reported at standard test condi-tions.

Accordingly, the values of Isc and Vocmarked on this PV module should bemultiplied by a factor of 1.25 whendetermining component voltage ratings,conductor ampacities, fuse sizes, andsize of controls to the PV output.Refer to Section 690.8 of the NationalElectrical Code for an additional multi-plying factor of 125 percent (80 per-cent derating) which may be applicable.

- PARALLEL for more current -<Figure 3>

16

Mechanical Installation

6. Mechanical Installation

Module Mounting

The LG Electronics (LGE) LimitedWarranty for solar modules is contingentupon modules being mounted in accor-dance with the requirements described inthis section.* Application class A

(Panels rated for use in ApplicationClass A may be used in systems oper-ating at greater than 50 V DC or 240W, where general contact access isanticipated)

Site Consideration

LGE solar modules should be mounted ina location that meets the followingrequirements.

Operating TemperatureAll LGE solar modules must be mountedin an environment that ensures that theLGE solar module will operate within thefollowing maximum and minimum operat-ing temperatures.

Care should be taken to provide adequateventilation behind the solar modules,especially in hot environments.

Design StrengthLGE solar modules are certified to basicloads 30lb/ft2 (about 1440 Pa).When mounting solar modules in snowprone or high wind environments, specialcare should be taken to mount the solarmodules in a manner that provides suffi-cient design strength while meeting thelocal code requirements.

Excluded Operating Environments Certain operating environments are notrecommended for specific LGE solarmodules and are excluded from the LGELimited Warranty for these modules. NoLGE solar module should be mounted ata site where it may be subject to directcontact with salt water.

Maximum Operating Temperature: +90°C (194°F)

Minimum Operating Temperature: -40°C (-40°F)

17


Mounting Configurations

Mounting using frame bolt holes

Solar modules may be mounted at anyangle from horizontal to vertical. Selectthe appropriate orientation to maximizesunlight exposure. Specific informationon the solar module dimensions and loca-tion of mounting and grounding holes isprovided below.In order to prevent water from enteringthe junction box, which could present asafety hazard, module should not bemounted such that the front/top glassfaces downward.Clearance between the solar moduleframes and structure or ground isrequired to prevent wiring damage and toallow air to circulate behind the solarmodule.

When installed on a roof, the solar mod-ule must be mounted over a fire-resistantroof covering rated for the application.(Fire rating of LGE PV module is C)The solar module is only IEC listed foruse when its factory frame is fully intact. Do not remove or alter the solar moduleframe. Creating additional mountingholes may damage the solar module andreduce the strength of the frame.The solar module may be mounted usingonly the following methods: (*Torque:2.5kgf-m )

Step 1 Step 2 Step 3 Step 4

<Figure 4>

18


Frame Hole

Junction Box

‘A’

<Figure 5>

Frame HolesSecure the solar module to the structureusing the factory mounting holes. Four M6 stainless steel bolts, four nuts,four spring washers, and eight plain wash-ers are recommended per solar module.Refer to Figure 6 for the solar moduledimensions and mounting hole locations.The module may be fastened to a supportusing the bolt holes in the bottom of theframe at location ‘A’ (refer to Figure 5). The module should be fastened with M6bolts, plain washers, spring washers, andnuts for support.

* Roof mount : A gap between the solarmodule and mounting surface is nec-essary for cooling air circulation. Donot seal this gap. The recommendedstandoff height is a minimum of 4inches.

19


Mechanical characteristics

Description LGxxxM1W(C)-G2 & LGxxxS1W(C)-G2

Length

Width

Depth

Weight

1632mm

986mm

42mm

18.5kg

24.7/0.97

42/1.655/0.20

12/0

.47

8/0.31

14/0

.55

R4/0.16

6/0.

24

5.5/0.22

R3/0.12

DETAIL X DETAIL Y

SCALE 20:1

DETAIL Z

926/36.46

1000

/39.

37

14*8 (Z View) Mounting Holes(8ea)

6*5.5 (X View) Drain Holes(4ea)

12*5 (Y View) Drain Holes(8ea)

4- 4.3Grounding Holes(4ea)

986/38.82

(Mounting Hole Distance between centers)

(Grounding Hole Distance between centers)

(Size of cross-section)

(Mou

ntin

g H

ole

Dis

tanc

e be

twee

n ce

nter

s)

(Mou

ntin

g H

ole

Dis

tanc

e be

twee

n ce

nter

s)

1632

/64.

25

(Siz

e of

long

sid

e)

940/37.00

950/37.40

1432

/56.

38

1132

/44.

57

100/3.94

Juntion Box(-) (+)

250/

9.84

60/2

.36

157/

6.18

176/

6.93

<Figure 6>

20


24.7

425

12

8

14

R4

6

5.5

R3

DETAIL X DETAIL Y

SCALE 20:1

DETAIL Z

926

1000

14*8 (Z View) Mounting Holes(8ea)

6*5.5 (X View) Drain Holes(4ea)

12*5 (Y View) Drain Holes(8ea)

4- 4.3Grounding Holes(4ea)

986

(Mounting Hole Distance between centers)

(Grounding Hole Distance between centers)

(Size of cross-section)

(Mou

ntin

g H

ole

Dis

tanc

e be

twee

n ce

nter

s)

(Mou

ntin

g H

ole

Dis

tanc

e be

twee

n ce

nter

s)

1632

(Siz

e of

long

sid

e)

940

950

1432

1132

100

Juntion Box(-) (+)

250

60

157

176

<Figure 6>

Mechanical characteristics

Description LGxxxP1W(C)-G2 & LGxxxR1W(C)-G2

Length

Width

Depth

Weight

1632mm

986mm

42mm

18.5kg

21

Disclaimer of Liability

7. Disclaimer of Liability

Since the use of this Safety, Installationand Operation Manual and the conditionsor methods of installation, operation, useand maintenance of the panel are beyondLG Solar control, LG Solar does notassume responsibility and expressly dis-claims liability for loss, damage, injury orexpense arising out of or in any connect-ed with such installation, operation, use ormaintenance of the panel.

LG Solar assumes no responsibility forany infringement of patents or otherrights of third parties that may resultfrom use of the panel. No license isgranted by implication or otherwise underany patent or patent rights.

The information in this Manual is basedon LG Solar knowledge and experienceand is believed to be reliable; but suchinformation including product specifica-tions (without limitations) and sugges-tions do not constitute a warranty,expressed or implied. LG Solar reservesthe right to make changes to the product,specifications or this Manual without priornotice.

22

Product Specification

8. Product Specification

Mono-crystalline

Standard Test Condition (STC): Irradiation1,000W/m2, Cell temp. 25°C, 1.5AM

)xamP:xxx( 2G-)C(W1MxxxGLledoM

230

36.6

29.5

7.81

8.37

235

36.8

29.6

7.94

8.49

240

36.9

29.7

8.10

8.58

245

37.0

29.8

8.23

8.67

250

37.1

29.9

8.37

8.76

255

37.2

30.0

8.50

8.85+3% / -0%

600V

20A

60each

3/ 320A/each

-0.434%/K

0.052%/K

-0.335%/K

Pmax(W)

Voc(V)

Vmp(V)

Imp(A)

Isc(A)

Output Tolerance

Maximum System Voltage

Maximum Series Fuse

Total Number of Cells

Total Number of StringsDiodes / Rating

Temperature coefficientof power (TkPmax)

Temperature coefficientof current (TkImp)

Temperature coefficientof voltage (TkVmp)

)xamP : xxx( 2G-)C(W1SxxxGLledoM

230

36.6

29.5

7.81

8.37

235

36.8

29.6

7.94

8.49

240

36.9

29.7

8.10

8.58

245

37.0

29.8

8.23

8.67

250

37.1

29.9

8.37

8.76

255

37.2

30.0

8.50

8.85

260

37.3

30.1

8.64

8.94

+3%/ -0%

600V

20A

60 each3/ 3

20A/each

-0.420 %K

0.042 %K

-0.306 %K

Pmax(W)

Voc(V)

Vmp(V)

Imp(A)

Isc(A)

Output Tolerance


Maximum Series Fuse






23

Product Specification

)xamP:xxx( 2G-)C(W1PxxxGLledoM

220

36.1

28.9

7.62

8.21

225

36.3

29.0

7.76

8.30

230

36.4

29.1

7.91

8.39

235

36.6

29.2

8.05

8.48

240

36.7

29.3

8.20

8.57

+3% / -0%

600V

20A

60each

3/ 320A/each

-0.456%/K

0.059%/K

-0.334%/K

Pmax(W)

Voc(V)

Vmp(V)

Imp(A)

Isc(A)

Output Tolerance


Maximum Series Fuse






)xamP : xxx( 2G-)C(W1RxxxGLledoM

220

36.0

28.7

7.69

8.06

225

36.4

28.9

7.80

8.21

230

36.6

29.1

7.93

8.35

235

36.9

29.5

7.97

8.48

240

37.2

30.0

8.02

8.61

+3%/ -0%

600V

20A

60 each

3/ 320A/each

-0.409 %K

0.04 %K

-0.319 %K

Pmax(W)

Voc(V)

Vmp(V)

Imp(A)

Isc(A)

Output Tolerance


Maximum Series Fuse






Multi-crystalline

Standard Test Condition (STC): Irradiation1,000W/m2, Cell temp. 25°C, 1.5AM

24

Ground method

9. Ground method

To prevent electric shock or fire, an earthmust be done on the frames of solarmodules.(*Torque: 2.5kgf-m )

F

B

E

D

ABC

B

Grounding Bolt (screw)A

Plain WasherB

Toothed Lock WasherC

Grounding WireD

Cupped WasherE

NutF<Figure 7>

Grounding hardware Dimension & material Remark

Hexagon nut & bolt

Plain washer

Toothed lock washer

Screw washer

Ground wire

M4 stainless

M4 stainless

M4 stainless

M4 stainless

12 AWG copper

The length of the bolt: 15 mm

25

Maintenance and Inspection

10. Maintenance and Inspection

Disposal

Please contact us at the address givenoverleaf if you have any queries related tothe disposal or recycling of solar modulesfrom LG Electronics.

26

Notices

LG Electronics U.S.A Inc.1000 Sylvan Ave, Englewood Cliffs, NJ 07632Contact : [email protected] http://www.lgsolarusa.com

Product specifications are subject to change without notice.LG, LG logo and Life's Good are trademarks of LG Electronics, Inc. worldwide. Trademarks andintellectual properties of LG Electronics, Inc. are protected by international copyright laws.

Document Ver : U_V1_201201

Documents

Installation Instructions - Unbound Solar