SOLAR PHOTOVOLTAIC - JewsonPlastic Enclosures, Protection IP66/67, insulated, knock-out entries, Red handle and contrasting yellow escutcheon plate, OFF-position lockable with padlocks,

INSTALLATIONAND SERVICINGSOLAR PHOTOVOLTAIC

When replacing any part on this appliance, use only spare parts that you can beassured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.

For the very latest copy of literature for specification and maintenance practices visit our website www.idealheating.com where you can download the relevant information in PDF format.

INSTALLATIONAND SERVICINGSOLAR PHOTOVOLTAIC

When replacing any part on this appliance, use only spare parts that you can beassured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.

For the very latest copy of literature for specification and maintenance practices visit our website www.idealheating.com where you can download the relevant information in PDF format.

February 2011UIN 207941 A01

2 Solar Photovoltaics - Installation and Servicing

general

Solar PhotovoltaicDestination Country: GB, IE

ContentS

Commissioning & Handover ..................................... 31

De-Commissioning ...................................................... 33

Fault Finding ............................................................... 32

Installation .............................................................. 11-31

Installing the on roof Solar Panels ............................11

list of Parts ................................................................. 34

optional extras .............................................................. 9

Safety Info .................................................................... 10

Servicing & Maintenance ........................................... 31

technical Info .............................................................. 3-7

Wiring ...................................................................... 28-29

3Solar Photovoltaics - Installation and Servicing

general

Power Classes

PV Collector type Maximum Power Pmpp

Maximum Power Voltage Umpp

Maximum Power Current Impp

open Circuit Voltage Uoc

Short Circuit Current Isc

area per kW

GD Solar 195 Wp 38.30 V 5.09 A 45.1 V 5.50 A 6.54m2

TSPV 200N 200 Wp 26.34 V 7.63 A 32.91 V 8.30 A 7.45 m2

TSPV 205N 205 Wp 26.39 V 7.80 A 33.08 V 8.33 A 7.26 m2

technical Data:

gD Solar tSPV 200n, 205n

PV Cell configuration: 72 monocrystalline 125 x 125mm 54 monocrystalline 156 x 156mm

Type of connector: MC4 (Type II or IV) Tyco-solarlok, plug in connector 4mm2

Max. System Voltage: 1000 V DC 1000 V DC

Power Tolerance: + / - 3% + 3% / - 0%

Temperature coefficients: PMpp = -0.45%/K, Uoc = -0.35%/K, lsc = +0.05/K PMpp = -0.405%/K Uoc = 102.6mV/K lsc = +4.1mA/K

Standard test conditions (STC): AM1,5 / 1000W per m2 / 25ºC AM1,5 / 1000W per m2 / 25ºC

Ambient Temperature +85ºC to -40ºC +85ºC to -40ºC

Cable length: 900mm (+ve) 900mm (-ve) 2000mm

Bypass diodes: 3 pcs 3 pcs

Panel Dimensions 1580mm x 808mm x 45mm 1507mm x 992mm x 33mm

Certification BABT 8519 02 MCS PV0026

808mm

1580

mm

404mm

Junctionbox

(+)Positive

(-)Negative

45mm

900m

m

FRONT VIEW

992mm

1507

mm

FRONT VIEW

496mm

REAR VIEWREAR VIEW SIDE VIEW

33mm

SIDE VIEW

GD SOLAR TSPV

Panel DIMenSIonS


general

InVerter teCHnICal InFo

DC/aC Inverter

A solar inverter or PV inverter is a critical component in a solar energy system. It performs the conversion of the variable DC output of the Photovoltaic (PV) modules into a utility frequency AC current that can be fed into the commercial electrical grid or used by a local, off-grid electrical network. Solar inverters have special functions adapted for use with PV arrays, including maximum power point tracking and anti-islanding protection.

Inverter SB1200 SB1700 aurora IP21 SB2500 SB3000 SB4000 tlMax DC Power 1320W 1850W 2200W 2700W 3200W 4200WMax DC Voltage 400V 400V 600V 600V 600V 550V

MPPT 100V-320V 139V-320V 90V-580V 224V-480V 268V-480V 125V-440VWeight 23kg 25kg 6kg 28kg 32kg 25kg

DC Connectors MC3 MC3 MC3 MC3 MC3 MC3Nominal AC

output1200W 1550W 2000W 2300W 2750W 4000W

Max power AC 1200W 1700W 2000W 2500W 3000W 4000WOperating

temperature-28…+60 -25…+60 -25…+55 -25…+60 -25…+60 -25…+60

Max output current

6.1A 8.6A 11A 12.5A 15A 22A

Frequency 50Hz-60Hz 50Hz-60Hz 45Hz/550Hz 50Hz/60Hz 50Hz/60Hz 50Hz/60HzTransformerless No No Yes No No Yes

Full technical specifications and installation instructions can be found in the respective inverter manual.

Due to the inverter dissipating heat it should be installed with sufficient space as to prevent any heat transfer to its surroundings. It is recommended that a label be placed next to the inverter to warn of the temperature of the heat sink and also a note not to block it.


general

ISolatorS teCHnICal InFo

AC and DC isolators are available to suit all system sizes. The isolators we supply have an IP66/67 rating which means it’s one of the safest devices on the market. The isolators are supplied in insulated enclosures with the operational currents ranging from 16 to 64 amps and voltages ranging from 450 to 800.

DC Disconnectors for Solar Photovoltaic (PV) Power Supply Systemacc. to IEC 60364-7-712:2002

Data valid only, if the pre-assembled jumpers have not been modified.

KG41B2 x Ø 25

F K

BE H 17

Output + -

+ - Input Input

KG20B/KG32B2 x Ø 25

B

KF

General DataSwitch Disconnector according to EN 60947-3 respectively VDE 0660 Part 107Utilization Category: DC-22 A for Photovoltaic Application with rapid handle operationAmbient Temperature: 50 ˚C during 24 hours with peaks up to 55 ˚C ( KG32B from 26 A: 35 ˚C during 24 hours with peaks up to 40 ˚C )Terminals finger-proof according to VDE 0660-514 and BGV A3, IP 20Maximum permissible wire size (use copper wire only)single core wire or stranded wireflexible wire

KG20B / KG32B: 6 mm² KG41B: 16 mm²KG20B / KG32B: 4 mm² KG41B: 10 mm²

MountingPlastic Enclosures, Protection IP66/67, totally insulated, knock-out entries,Black handle and contrasting grey escutcheon plate, OFF-position lockable with padlocks, cover coupling with interlock

Rated Value / Order NumberOperational Current 16 AOperational Voltage 650 V DCMax. Off load voltage of the PV inverter 750 V DCInsulation Voltage 1000 V

Operational Current 12 AOperational Voltage 800 V DCMax. Off load voltage of the PV inverter 920 V DCInsulation Voltage 1000 V

Connecting diagram

2T3

2L1

1T1

1L3

Input

Output

+ -

+ -

Contact development: 2 pole, 6 contacts per circuit (2 x 3 in series)

KG20B /KG32B

B 100

E —

F 178

H 93

K 190

2 x Ø 25

Ø 25Ø 25 Ø 25

2 x Ø 25

Optional Red/Yellow handle available for use as Main/Emergency-Off DC Disconnector


general

Optional Black/Grey handle available for use as Main Switch.

Main/Emergency - Off AC Disconnectors for Solar Photovoltaic (PV) Power Supply Systemacc. to IEC 60947

Switch - Disconnector

• IP66/67 Protection

• Red/Yellow Padlockable Handle

• Grey Insulated Enclosure

• Switch Interlocked with lid to preventopening in “ON” position

• Earth Terminal

Connecting diagram

KG20 /KG32

B 85

D1 4 x Ø 20

D2 2 x Ø 20

F 150

H 82

K 160

D1

B

KF

H 17

General DataSwitch Disconnector according to EN 60947-3 respectively VDE 0660 Part 107

Ambient Temperature : 35˚C average during 24 hours with peaks up to 40 ˚CTerminals finger-proof according to VDE 0660-514 and BGV A3, IP 20Maximum permissible wire size (use copper wire only)single core / stranded wireflexible wire

KG20 / KG32: 6 mm ² KG41: 16 mm²KG20 / KG32: 4 mm ² KG41: 10 mm²

MountingPlastic Enclosures, Protection IP66/67, insulated, knock-out entries,Red handle and contrasting yellow escutcheon plate, OFF-position lockable with padlocks, cover coupling with interlock

Rated Value / Order NumberOperational Current AC-21A, Ie 25 AInsulation Voltage, Ui 690VEnclosed Thermal Rating Ithe 25A

Operational AC-23A 220-240V 1ph 2.2kW Power AC-23A 380-415V 3ph 7.5kW

D2 D2

B

D1


general

a100BS generatIon MeterThe generation meter is a small device which measures power transferred back to the grid and therefore determining the amount of money the system is generating per month. The DNO will also check these readings like they would check a normal meter. The meter should be fitted between the AC isolator and the consumer unit.

Features • Accuracy Class 1 or 2• KWh import or kWh import/export• 20 years certified life• Large digit multilingual display with chevron information indication.• Extensive security data• Communications as standard• 12Kv impulse withstand• High security, compact design (130mm x 97mm x 47mm)• BS double insulated, glass filled polycarbonate case• Permanently fixed main cover• Rate select for two rate meters, switch to neutral• IP53 in accordance with IEC 60529:1989

options • One or two rates controlled by external device• IrDA communications or IEC 62056-21• IEC –62056 – 21 for infrared only optical probes• Auxiliary terminals configured for: SO Pulse output (IEC 62053-31) Serial data output (IrDA meter)• A102C – kWh and kvarh energy measurement• A103C – Maximum demand, voltage and current instrumentation values• Extended terminal cover

technical Data

Current RangeVoltage RangeFrequency System Connection

10-100A, 20-100A 220-250V, 110-127V 50 or 60Hz1phase 2 wire

Burden (230V) 0.66W, 8.5VA (capacitive burden) InsulationImpulse Withstand

4kV RMS 50Hz 12kV 1.2/50μS 40 ohm source

Display 9.8mm x 3.5mm characters High contrast, wide angle

IrDA Baud RatesIEC 62056 - 21Rate Serial Baud Rates

2400, 4800 or (9600 without serial port) 2400 or 4800 2400 or 4800

Certified Product Life 20 years (OFGEM model)Temperature

Humidity

-20° to + 55° C (operational range)-25° to + 85° C (storage)Annual Mean 75% (for 30 days spread over one year, 95%)

Pulse Output 100ms pulse 100 p /kWh (=10Wh/pulse)(other pulse rates, durations, available)

Weight 349 gramsSpecifications

Case

kWh Class 1 or 2 EN 62053-21:2003 kvarh Class 2 or Class 3 EN 62053-23IP 53 to IEC 60529 : 1989


general

IntroDUCtIon Solar Photovoltaic panels, or Solar PV panels, is a technology in which daylight is converted into electricity which is then used to power homes and businesses. It uses energy from the sun to create electricity that will operate electrical appliances and lighting.

The system allows for excess electricity generated to be sold back to the electricity grid or stored in batteries for off the grid areas. Solar PV panels work well in both urban and rural areas. They are also capable of generating electricity on cloudy days as they only need daylight to work, not necessarily direct sunlight.

Solar PV reduces usage of fossil fuels and housing carbon emissions. The panels produce green energy that will significantly reduce the cost of energy bills.

The use of photovoltaic power can generate revenue as power that is generated and not used can be sold back to the electricity grid through the UK Feed in Tariff.

A range of packs are available which include all the necessary equipment to build a full system to meet the generation requirements.

HoW a MoDUle ProDUCeS eleCtrICItyA solar photovoltaic panel is made up of a number of cells wired together (PV module) which convert energy gathered from sunlight into direct current (DC) electricity.

A PV cell consists of two thin layers of semi-conducting materials (generally silicon). When sunlight shines on the PV cell it knocks electrons from the orbits of the semi-conductor in sufficient numbers to generate direct current electricity.

With the aid of an Inverter, direct current electricity is converted into alternating current (AC) power. Alternating current is the type of electricity required to run electrical appliances in the home.

HoW It WorkSOn the grid solar PV systems are the most common type of installation. In the case of on the grid installations the electricity produced during the day is used by the property with the excess being sold back to the utility provider. At night, electricity is supplied via the normal utility grid system.

DC Circuit

AC Circuit

DC Isolator

Mains ACIsolator

PV Generation MeterMainsElectric Meter

Mains Electricity Circuits

To National Grid

Fuse Box

AC Isolator

DC/AC Inverter


general

PaCkage lISt/oPtIonal extraS

All packages consist of;

• Modules

• Inverter

• Isolators (both AC and DC)

• A generation meter

• Full on roof mounting kit

• Appropriate cables and connections (including rail earth components if required)

Ideal solar PV is available in a choice of various kW output packs to suit your individual requirements. Components are also available to order separately if needed.

A typical 2kW pack consists of the following:

1. Modules (200W) x 10

2. Single Phase Inverter x 1

3. Single Phase Kw meter x 1

4. DC Isolator x 1

5. AC Isolator x 1

6. Cable and connections x 1

7. Mounting System to fix 10 modules

+ + + +

+ + + +

1

2

3

4 56

7


general

lISt oF all aPProPrIate StanDarDS

BS7671:2011 IEE Wiring RegulationsBS EN61558 Isolating TransformersG83/1 – 2003 Network Connection <16AG59/1 – 2003 Network connection >16ABS EN 61730-1:2007 Photovoltaic Module SafetyBS 7671:2008 Guidance Note 7, Sections 10 & 15

SaFety InFoSolar PV modules produce electricity when ever they are exposed to light so care must be taken at all times during the installation process, as they are always live.

The DC isolator must always be in the OFF position while installing the system or connecting/disconnecting any wires or modules.

DC cables should be connected to the isolator before the individual modules are connected together.

The DC output from the PV array should not be shut down or disconnected while the AC side of the installation is operational.

All grid connected installations must conform to the engineering recommendations for the connection of a small scale embedded generator (SSEG) in parallel with public low voltage distribution networks.

G83/1.1 for systems up to 16A per phaseG59/1 for systems exceeding 16A per phase

To indicate the presence of an SSEG labels should be displayed at the following important locations on the system; all meters, consumer unit, all isolators and at the supply terminals.

When moving and lifting the PV modules, never use the junction box on the back of the panel to lift it up.

The area below any work being done should be adequately secure to prevent any access or injury from falling parts.

A risk assessment should be carried out prior to any work starting, the risks associated with PV installation are;

• Working at heights

• PPE

• Manual handling

• Risk of electrocution (working with live DC)

• Working in confined spaces

eartHIng arrangeMentSThere shall be no direct connection between the DC side of the PV array and the supply PE/PEN connection. Where the DC to AC inverter is of the transformer type and is isolated from the AC supply, protective equipotential bonding may be omitted.An RCD may be fitted after the AC isolation switch if required.

11

InStallatIon

Solar Photovoltaics - Installation and Servicing

InStallIng tHe on rooF Solar PanelS

SySteM oVerVIeWAll components of the system are listed below. The version and quantities of the parts can vary, depending on

- Type of roof,

- Type of module,

- Number of modules,

- Site specifics

CoMPonent PartSComponents to mount the PV modules are listed below. The inclusion and amount is supplied is dependent upon the particular requirements of each kit

1 Roof hook 170 - tiled roof.2 Roof hook with L bracket -

slate roof3 Hanger bolt and L bracket -

corrugated roof4 Base Rail 7/49 (provided in 2.4

and 3 m lengths)5 Splice for joining 7/49 base rail6 Module mid clamp7 Module end clamp 33mm8 Module end clamp 45mm

key1 Base rail2 Joiner piece3 Module mid clamp4 Roof hook5 Module end clamp

(1) (2) (3) (4)

(5) (6) (8)(7)

4

3

51

2

12

InStallatIon


2

1

5

4

3

x

x

x

x

DeSIgnIng tHe MoDUle FIelDBelow, the distances between roof connections for a portrait installation are specified. Clamp-on roof hooks, roof hooks and hanger bolts need to be installed in specific distances, depending on the distance of rafters and other constraints.

1. Height of the module field: module height x number of modules vertically

2. Width of the module field: number of modules horizontally x (width of module + 19mm) +

31mm

3. Distance between roof connections vertically (according to the clamping points predefined by the module producer): Quarter-points of the modules, about 1/2 of module height.

4. Distance between roof connections horizontally: Depending on the distance between rafters and on the static

requirements*

5. Distance between modules: 17mm When positioning the modules, please take into consideration

- That the values above are.

- That dimensions of tiles or other roof covering and the position of the rafters define the precise actual horizontal distance between roof connections.

- That the distance between roof laths defines the precise actual vertical distance between roof connections.

* TheconfigurationmustbeinaccordancewiththelocalconditionsandwithDIN1055parts4and5/Eurocode9DINVENV

IMPortant InStallatIon InStrUCtIonSoperating ConditionsThe various components of the on-roof system can withstand different maximum charges. Therefore, the exact components for a project need to be checked as to their compliance with the local standards and regulations for each project.

PreparationIt is recommended to familiarise yourself with the conditions on site before installation, especially regarding.- The roof construction (including isolation)- Dimensions and quality of roof laths and rafters- Type, shape and material of the roof covering

toolsThe following tools are required for the installation:- 6 mm Allen key- Cordless drill- Open-end spanner (13mm)- Torx-30 (AW 30) Bit- Angle grinder with stone disk- Cord- Spirit level- Rule- If necessary, timber to shim the roof hooks- Hoisting gear- Vacuum lifting pads- Power drill (as necessary)

Note.distance“x”mustbebetween250mmand300mm

13

InStallatIon


InStallatIon oF on rooF MoDUle MoUntIng HarDWare

WarnIngWorking on the roofWhen working on the roof care must be taken to ensure parts or tools do not fall.

Great care must be taken when working on the roof and all local health and safety guidelines must be adhered to.

- Secure yourself against falling.- Do not remain in the danger area.- Wear a hard hat.- After completing the installation, check that the system and the

PV modules are securely fastened.

CAUTIONDamage to tiles through stepping on roof hooksDo not use fitted roof hooks as a ladder, as this extreme point load could damage the tile below.

CAUTIONobserve minimum edge distancesScrews fixed too close to the edges of rafters can rip out.

- Do not fix any screws closer than 30mm to the edge of rafters.- Predrill holes when using screws with a diameter >6mm.

Depending on the type of roof covering different roof connections must be used. The type of roof connection included in your delivery depends on your order.

12

3

4

InStallIng tHe tIleD rooF Hook 170Key:

1. 3 x wood screw (6 x 80mm)

2. Rafter

3. Tiled roof hook 170

4. Wood plates to shim roof hooks, if necessary

CAUTIONMaterial damage through faulty installationThe roof hook must not press against the tiles to avoid damaging the tiles. If necessary:- Shim roof hook with wooden plates, so that the roof hook does not touch the underlying tile.- If necessary, use an angle grinder or hammer to cut a recess in the tile that covers the roof hook so that the tile lies flat on the

surface.

Installation:- Remove the roof tiles at the marked positions or, if possible, simply push them up.- Position the roof hooks above the low parts of the tiles- Fix the roof hooks to the rafter using three 6 x 80mm wood screws.

InStallIng tHe Slate rooF Hook WItH l BraCketThe installation of the slate roof hook is a variation of the above. Noching slates will be needed to make room for the hook. Following this without the appropriate flashing the slate roof hook can be subject to leakage. To prevent leakage install zinc metal flashing underneath the roof hook, providing sufficient overlap to ensure rain water drains over the top of the slates.

14

InStallatIon


InStallIng Hanger BoltS - CorrUgateD rooF InStallatIon - oPtIonal extra

1

Key:

1. Hanger bolt with L-bracket

2. Sealing washer

3. Nut

CAUTION

Damage to the building through leakageInappropriately fixed hanger bolts can cause leakage.

- Never position hanger bolts on the low parts of the corrugated sheets.

CAUTION

observe minimum edge distancesHanger bolts fixed too close to the edges of purlins can rip out.

- Observe a minimum distance of 5xd to the edge of the purlin when installing hanger bolts

- Pre-drill holes when using bolts with a diameter > 6mm.

Installation- Drill through the roof cladding at the planned location.

- Screw the hanger bolts into the purlins

- Press the sealing washer onto the drill hole and fix it with the nut without further damaging the sheeting. The tightening torque depends on the type of roof sheeting.

2

3

15

InStallatIon


InStall tHe SySteM

Installation ProcedureThe following pages list the individual steps for installing the parts in the correct sequence.

The pages feature three rows. Each row represents a complete sequence of actions. The sequence of actions consists of an illustration, the corresponding steps and additional information and safety instructions.

Quickstone and x-StoneDuring the installation, Quickstones are used. The Quickstone is a special nut used to connect several parts of the Alpha. The only tool needed for installation is a 6mm Allen key.

The Quickstone can be sued on both channels of the base rail.

For a cross-installation of two layers of base rails, X-Stones are used. These consist of an aluminium block with two pre-assembled Quickstones.

3

3

4

InStallIng tHe QUICkStone InStallIng tHe x-Stone

Key:

1. Element to be fixed (e.g. module clamp)

2. Allen bolt

3. Quickstone

4. Base rail

RAIL FACE RAIL FACE

Key:

1. Horizontal base rail

2. X-Stone with 2 Quickstones

3. Vertical base rail

11

2

2

CAUTION

Material damage through faulty installationIncorrectly installed Quickstone connections can rip out the profile.

- Install all Quickstone connections as described below.

Installation- If necessary, adjust the bolt so that it does not protrude

the Quickstone.

- Fit the Quickstone from above into the profile channel so that it wedges underneath the protruding rail hooks. When fitted correctly, the Quickstone matches the form of the profile exactly.

- Tighten the bolt with a torque of 8 Nm.

Installation- Install both Quickstones as described above.

- Make sure the upper rail lays flat on the lower one.

- Completely tighten both Quickstones only when you have put the rails in their final position.

16

InStallatIon


InStallIng tHe BaSe raIlS

DANGER

Working on the roofWhen working on the roof care must be taken to ensure parts or tools do not fall.


- Secure yourself against falling.

- Do not remain in the danger area.

- Wear a hard hat

- After completing the installation, check that the system and the PV modules are securely fastened.

CAUTION

Damage to the tiles through stepping on roof hooksdo not use fitted roof hooks as a ladder, as this extreme point load could damage the tile below.

Base railsDepending on the number of modules in one row, the base rails can be of one or of several pieces. The length of the base rail corresponds with the width of the module field. The parts of base rail are inter-connected with joiner pieces. If the end of the base rail overhangs the modules, trim to the required length.

12

Key:

1. Joining splice

2. Base rail

17

InStallatIon


FIxIng tHe BaSe raIlS

alIgnIng raIlS

Inter-ConneCtIng BaSe raIlS

Key:

1. Roof connection

2. Quickstone

3. Base rail

Key:

1. Base rail

2. String or spirit level

Key:

1. Base rail

2. Joiner piece

Installation- The installation is shown with the base rail 13/58.

- If your set of rails consists of rails of different lengths, then always begin with the shortest piece.

- Install the rails for each row of modules loosely on the roof hooks, using an M 8x25 mm Allen bolt, washer, retaining washer and Quickstone each (2 to 3 turns of the screw are adequate for loose installation).

- Completely tighten the Quickstones only when you have put the rails in their final position.

Installation- Align all rails using a piece of string or a spirit level.

- Tightly fix all Quickstone connections on the rails (tightening torque 8Nm).

IMPORTANT.

The oblong holes in the roof hooks or L-brackets allow for a height adjustment of the rails to level out the PV installation on uneven roofs.

Installation- Slide the joiner pieces halfway onto the rear side of the base rails.

- Fix the according Allen bolt to the base rail (tightening torque 8 Nm)

- Slide the next rails segment into the joiner piece.

- Leave a 1cm gap as an extension joint.

- Fix the second Allen bolt to the base rail (tightening torque 8 Nm)

IMPORTANT.

The connected rails should not be longer than 12 meters

1

1

1

1

1

1

2

1

2

2

3

18

InStallatIon


InStallIng tHe MoDUleS

DANGER

Working on the roofWhen working on the roof care must be taken to ensure parts or tools do not fall.




- Wear a hard hat


The modules are successively mounted onto the base rails. It is recommended to start on one side of the module field.

Add anti-slip protection, consisting of a bolt and nut inserted into the holes on the underside of the module frame, to the lowest row of modules (horizontal rail installation only). This keeps the modules from sliding off and thus facilitates installation. The anti-slip protection does not have any static function in the finished installation.

The modules are fixed with inter-module clamps and end-clamps. An end-clamp will hold one module, an inter-module clamp 2 consecutive ones.

Note.WheninstallingGDSolarPanelsconsideraccessneededtowirepanelsleadsandearthconnections.Seesection-ElectricalInstallations

19

InStallatIon


InStallIng tHe antI-SlIP ProteCtIon

FIxIng tHe oUter MoDUleS oF eaCH roW

FIxIng tHe Inner MoDUleS oF eaCH roW

InStallIng FUrtHer roWS oF MoDUleS

Key:1. Module frame (underside)2. Anti-slip protection3. Base rail

Key:1. Module end-clamp with Quickstone2. Module3. Base rail

Key:1. Inter-module clamp with Quickstone2. Module3. Base rail

Installation- The anti-slip protection is only necessary on the lower most row of

modules.- Fit two bolts M6 x 20 and nuts into the lower holes of each module.- Place the first module of the bottom row so that the anti-slip protection

sits in the rail channel of the lowest row of rails.

Installation- Slide the Quickstone into the rail channel.- Align the module and push the module end-clamp firmly against the side of

the module.- Tighten the Allen bolt and Quickstone (tightening torque 8Nm).

IMPORTANT.

When installing laminates, laminate clamps need to be used instead of module clamps. The installation process is identical. The laminates are set between the rubber lips of the laminate clamps.

Installation- Slide the Quickstone into the rail channel.- Push the inter-module clamp firmly against the already fixed module.- Push the next module against the other side of the module-end clamp.- Tighten the Allen bolt and Quickstone (tightening torque 8Nm).

IMPORTANT.

When installing laminates, laminate clamps need to be used instead of module clamps. The installation process is identical. The laminates are set between the rubber lips of the laminate clamps.

Installation- Set the modules of the next row above the lowest row of modules. For

optical reasons, a gap can be left between module rows.

Note.Useaspareinter-moduleclampasagaugeforthespacebetweenmodulerows.Inthisway,thehorizontalandverticalgapsbetweenmoduleswillbeidentical.

- Fix the modules to the base rails using inter-module clamps and module end-clamps, as described above for the first row of modules.

1

2

1

3

2

1

1

3

2

2

3

3

1

20

InStallatIon


InStallatIon oF Flat rooF MoUntIng HarDWareNote: Flatroofmountinghardwareisofferedasanoptionalextra.

DANGERWorking on the roofWhen working on the roof care must be taken to ensure parts or tools do not fall.




- Wear a hard hat


All components needed to install PV modules on flat roofs are listed below:

1. Support triangle complete with mounting feet.

2. X Stone

3. Base rail 13/58

4. Joining splice 13/58 (not visible)

5. Diagonal strut

6. Module end clamp

7. Module mid clamp

1

5

3

47 6

2

2 31 4

5 76

21

InStallatIon


teCHnICal SPeCIFICatIonS

Support profile, base rails Extruded aluminium (EN AW 6063 T66)

All other profiles Aluminium (EN AW 6060 T6)

Accessories Stainless steel (V2A)

Back plate Aluminium (EN AW 5005)

SolRec base plate PE

oPeratIng ConDItIonSApplication Range Flat roof

Roof pitch 0 — 5°, greater pitch subject to prior verification

PV module Framed, unframed

Roof construction The suitability of the entire roof construction, in particular at the load transfer points of the mounting system, must be examined for static, insulation, leak tightness, and fire protection requirements prior to installation of the PV system.

Permissible roof load Must be specifically checked for each project.

Attachment method Must be specifically checked for each project.

Triangle and support rails Up to 1,900 PA for a 2.5 m2 surface per triangle and a roof pitch up to 5°

Max. row length 12 m

Distance between the triangles Depending on project planning, portrait installation up to approx. 1.5 m

22

InStallatIon


PlannIng oF tHe MoDUle FIelDDimensionsIn the following, the dimensions of the mounting system will be given. The exact spacing between the triangles is project-specific and must be individually defined in the planning phase.

Width of the unit: Number of horizontal modules x (module width + 19) + 31mm; maximum 12m.

Note. Thematerialexpansionofa12mm-rowcanbeapprox.2cm.Therefore,aminimumdistanceof10cmbetweentherowsisrecommended.Furthermore,forlargesystems,itiswisetoleavemorespaceatregularintervalsasmaintenancepaths.

a

d

b

g

cf

j

e

h

a. Depth of the frame unit: see table A belowb. Height of the frame unit: see table B belowc. Pitch: 20°, 25°, 30°d. Distance between the rows: according to project plane. Distance to ground: at least 8 cm, depending on module positioningf. Distance between the triangles: according to plan, portrait mounting up to approx. 1.5 m, g. Distance between the foot brackets of the triangle: 955 mmh. Drill hole size in the foot brackets: 11 mm or 13 mm, depending on selectionj. Distance between the base rails for portrait installation: marked by the drill holes in the module frame, approx. ½ the module length

DePtH oF tHe UnIt, InClUDIng MoDUle

Pitch Portrait installation20º module length x 0.94; at least 995mm25º module length x 0.91; at least 995mm30º module length x 0.87; at least 995mm

DePtH oF tHe FraMe UnIt, InClUDIng MoDUle

Pitch Portrait installation20º module length x 0.34 + 80mm; at least 534mm25º module length x 0.42 + 80mm; at least 615mm30º module length x 0.50 + 80mm; at least 692mm

23

InStallatIon


IMPortant MoUntIng InForMatIonMounting aids and required toolsYou will need the following tools to install the system:• 6mm Allen key• combination wrenches 13• folding rule / tape measure• 9mm metal drill bit - suitable for metal

Appropriate tools for the respective roof mounting variations, e.g.:

• For riveting onto SolRec floor plates: 6.1mm drill bit, rivet gun• For attachment with fix anchors into concrete: 12.5mm

concrete drill bit, hammer

additionally required materialsDepending on the system plan, the following additional materials may be necessary:• Suitable fixation material for roof• Material for weighting as ballast, for example gravel, concrete

slabs or other• Suitable protective mats to protect the roof surface

InStallatIon

PreParatIon Work

DANGERPotentially mortal danger from falls and falling objects• Protect yourself against falling.• Do no remain in the danger zone.• Wear a hard hat.• After the assembly is complete, ensure secure positioning of

the mounting system and the modules

1. Preparing the fixation points

• Define and mark the fixation points, and/or the planned substructure according to plans, and prepare for installing the triangles.

2. Preparing the triangles

• Unfold the triangles and pre-mount both of the support elements with 2 bolts each (self-locking nut M8, 2 washers and M8 x 20 Allen bolt) at the desired angle (tightening torque 8 Nm).

• Tighten all of the screw connections on the triangle (tightening torque 8 Nm)

CAUTION

Material damage from improper mounting

Improperly fastened triangles can bend or collapse.

• Carry out all new bolted connections using the above mentioned materials (bolts, washers and nuts).

• After installation, ensure that all bolted connections are tight.

3. Mounting the anti-slip protection (only for portrait installation)

• Attach one bolt with M6 nut in each of the lower drill holes of the module frame as an anti-slip protection, and tighten them by hand.

20º 25º 30º

24

InStallatIon


InStallIng tHe SySteM1. Mounting the triangles

• While maintaining the planned spacing, arrange the triangles so they are parallel, and fix them with the designated connecting materials.

3. Install Base Rail

• Mount 2 horizontal base rail sections per row of triangles.

• Align and position the rails according to the selected module dimensions.

• Lay the rails with the smooth side down on the triangles and fasten them loosely to the vertically-mounted x-stones on the side.

• Take care to observe the differing alignment of the rails for portrait or landscape installation (see illustration on the left)

• Align the rails and subsequently tighten the vertical and horizontal X-stone bolts finally (tightening torque 8 Nm)

WARNINGMaterial damage due to inappropriate material selection

Inappropriate fixation material can cause the triangles to rip out, roof damage and leakage.

• Select appropriate fixation material according to the location, roof state, and system design.

WARNING

Material damage from improper mounting

Improperly fixed triangles can rip out and result in leaks.

• All attachments should be of professional quality.• After mounting, ensure that the fixation is correct.

2. Fixing the X-stones

• Fix two X-stones per triangle (see point 4.1 dimensions) to the support rail of the triangle at the specified points. Take care to observe the differing alignment of the X-stones for portrait or landscape installation (see illustration on the right).

• Insert the Quickstone into the profile channel so that the form of the Quickstone fits perfectly into the profile. The bolt may not protrude beyond the lower edge of the Quickstone.

• Fasten the Quickstone loosely with 2 bolt turns.

• Put the X-stone in the desired positing and line it up transversely to the support rail.

• Tighten the bolt just enough so that the X-stone does not slide down. Do not tighten completely.

CAUTION

Material damage due to improper mounting

Improperly fastened X-stones may slip or rip out.

• All Quckstone connections must be mounted according to instructions.• After mounting, check that the bolted connections are tight.

25

InStallatIon


4. Connecting the Individual Rails

• The splice should be slid in half-way from the side, on the back side of the profile rail.

• Slide the next profile rail into the splice.

• Tighten both bolts of the splice (tightening torque 8 Nm).

5. Attaching the diagonal struts

• Mount 2 diagonal struts per unit on the left and right ends of the row.

• Loosely mount one end of the diagonal in the lowest pre-drilled bore hole of the strut to the outside triangle with a self-locking nut M8, 2 washers and an allen bolt.

• Point the strut diagonally to the next triangle in the row and mark the exact position of that triangle’s upper-most bore hole on the diagonal.

• Drill a hole with diameter of 9mm at the marked location.

• Fix the second end of the diagonal.

• Tighten both diagonal connections finally (tightening torque 8 Nm).

• If necessary, shorten any protruding ends of the diagonals (purely for appearance purposes).

26

InStallatIon


InStallIng tHe MoDUleS

InStallatIon1. Module Positioning

• Place the modules on the rails so that the slip-guard bolts are in the lowest rail channel.

2. Attaching the outer modules

• Insert the Quickstone of the module end clamps in the top channel of the base rail (the bolt may not protrude on the under side of the Quickstone) and fasten them loosely.

• Before tightening, push the modules under the module clamps and align them.

• Tighten the module end clamps (tightening torque 8 Nm)

3. Attaching the inner Modules

• Insert the Quickstone of the module clamp into the top rail channel of the base rail, slide them onto the previously mounted module and fasten loosely.

• Slide the second module onto the module clamp, align it, and tighten the bolts (tightening torque 8 Nm).

CAUTION

Material damage due to improper mounting

Improperly fastened module (end) clamps may rip out.

• All Quickstone connections must be mounted according to instructions.

• After installation, ensure that the bolted connections are tight.

27

InStallatIon


eleCtrICal InStallatIonSImportant notes when wiring modules:

• Ensure cable specified is suitable for solar PV installation and is of correct cross sectional area. Ensure cable specified is suitable for maximum operating current and maximum short circuit current for each particular installation. The optimum cross section should be determined by the maximum short circuit voltage and the total length of the wiring (line voltage drop).

• The rated voltage of the solar cable must be 1000V minimum.• Use flexible cables to ensure consistency against movements, wind etc.• Keep the length of cable connections as short as possible to optimise the energy yield. • Fix loose solar cables after mounting to avoid damage.• Take care while handling cables to avoid damage, especially at low temperatures. The cables should not be bent or folded in an

extreme way. • Use conduits for laying and fixing of the cables.• To avoid voltage from indirect lightening strikes, lay the feed line and return line very close to each other.• Always consider polarity.• Undertake the grounding system in accordance with national and international standards.• Ensure both AC and DC isolators are fitted.

Connection of the PV module to a grounding system: It is essential that the PV panels are correctly earthed using suitably sized grounding cable.

tSPV Panel grounding Procedure: When fitting TSPV panels a grounding connection must be made to opposing module corners using the grounding lugs provided within the modules frame (see picture one). The grounding cable must be connected with a stainless steel screw M6 x 20mm with two washers located on the inside and outside of the grounding lug and a self locking screw nut. The assembly from the outside to the inside should be: Screw Head – Washer – Grounding Lug – Eyelet – Washer – Self Locking Nut.

gD Solar Panel grounding Procedure: When fitting GD Solar panels a grounding connection must be made to opposing corners using the loose grounding connections provided.

The grounding clip assembly consists of a slider base, and self-captivating thread-cutting screw. The grounding clip accepts solid uninsulated copper wire sizes 10 or 12 AWG.

grounding clip installation procedure:

1. Using a No. 21 drill bit drill a 4.09mm (0.161 inch) diameter hole on the underside corner of the frame.2. Place the grounding clip onto the frame, making sure the screw straddles the drilled hole. Using a No. 2 cross-recessed

screwdriver, thread the screw into the hole until the head is flush with the frame, then tighten the screw with another ¼ to ½ turn. (Recommended torque is between 2.3 and 2.8 Nm (20 and 25 in. – lbs).

3. Insert the wire into the wire slot. Press down on both ends of the wire (the wire slot will cause the wire to form a slight curve).4. Manually, or using channel lock pliers, push the slider over the base until it covers the base. This will terminate the wire.

TSPV Grounding Lug Connection

28

InStallatIon


DC/ACinverter

DC inputconnections

AC output

DC isolatorDC extension

cable

DC extensioncable

eleCtrICal InStallatIonSWhen wiring the modules together, the positive output connector of one module should be connected to the negative output connector of the next module to form a string. The total output of the string is then calculated by;

200Wp x the number of modules connected in the string.

Example;

200Wp x 6 = 1.2kW array which would then require a 1.2kW inverter.

Wiring diagrams for different packs i.e. 1-2 strings

DC Isolator DC/AC Inverter

ACIsolator

OptionalExportMeter

Consumer UnitUtilityMeter

DNO Supply

ACIsolator

DC Isolator

DC Isolator

DC/AC Inverter

ACIsolator

OptionalExportMeter

Consumer Unit

UtilityMeter

DNO Supply

ACIsolator

29

InStallatIon


Wiring for AC side of inverter

From inverter, to export meter, to consumer unit.

L N

Supply Meter

230V AC MainsElectrical Supply

230V AC input fromSolar PV Inverter

via AC isolator and RCD(If required)

Consumer UnitProtective equipotentialbonding as required

N L

N L

Note: circuit ProtectiveConductors (CPC’s) not shown for clarity

Mains switch(isolator)

LN

30

InStallatIon


InStallatIon anD teStIngBefore starting any installation procedures a risk assessment must be carried out for the appropriate safety risks, refer to safety section for more advice.

Before any PV modules are installed the DC cables should be fitted and terminated into the DC isolator and inverter and the DC isolator need to be in the OFF position when the connections are made to the PV modules.

Any cables either on the roof or inside need to be adequately secured to prevent damage.

When installing the inverter you should choose a location which has adequate wall space and is easily accessible. The wall should also have any combustible materials removed such as paper.

Both +ve and -ve DC cables as well as any PE connections must be run close together and away from any other AC power cables.

Clear labelling of all DC and AC isolators must be present as well as any protective devices in accordance with regulations.

Install mounting frames

Install all AC cables and

generation meter

Fit inverter and isolators into their

locations

Fit modules to the mounting frames

Install DC cable into the inverter

and isolator

Connect modules together and to

DC cable

InStallatIon reQUIreMentS

Start UP & SHUt DoWn ProCeDUre

Switch ONat

consumer unit

SwitchOFFat

consumerunit

Turn ACisolator

toON

IsolateAC

SwitchON

Inverter

SwitchOFF

Inverter

Turn DCisolator

toON

IsolateDC

31

InStallatIon


CoMMISSIonIng anD HanDoVer

The commissioning of a PV system is required to ensure that the system is working and that it complies with the current regulations governing the equipment. The following sequence should be followed to test the system. Observe the start up and shut down sequence at all times.

InSPeCtIon

A visual inspection of the system should be completed by a competent person and should include:• PV Array• Corrosion protection measures• PV Array cabling• Junction boxes• DC cables• DC isolator• Inverter• Earthing• Lightning protection• Labelling• AC cabling• AC isolators

PV teStIng

As required by BS7671:2008 PART 6 each string and the whole array need to be tested for open circuit voltage and short circuit current. These tests should be carried out before the system is connected to the grid.

InVerter teStIng

Once the PV array has been tested and the system has been connected to the grid then the inverter will need to be tested. The following steps should be taken to test the inverter.

Turn on the DC isolator then the AC isolator and check the status of the inverter, it should be in stand by mode for 3 mins. (G83/1 Compliant)

Measure the DC array and inverter power with the inverter running and feeding the grid. The DC and AC power values should be compared to the values available from the inverter. When the inverter is operating, the DC input voltage should be less that 80% of the measured open circuit voltage, indicating that the inverter is tracking the maximum power point.

Finally the inverter should be disconnected by switching off the AC isolator then the DC isolator and the response of the inverter should be observed.

g83/1 VerIFICatIon

The final stage of commissioning a PV system is to check if the inverter protection system meets G83/1. Although the manufacturer will state that the product is G83/1 compliant, it still has to be checked. This is done using a computer software which connects to the inverter and allows the installer to check the protection settings, the start up and shut down times and also the anti islanding feature can be checked.

DoCUMentatIon

Once the testing of the system is complete there is certain documentation which should be completed. Copies of the BS7671 forms should be completed along with an array testing sheet. An installation commissioning form must also be completed and used to formally notify the distribution network operator within 30 days of commissioning.

SerVICIng anD MaIntenanCe

The Ideal solar PV system needs very little maintenance throughout its life time however it is beneficial to carry out a few checks which will keep the system in the best condition.

It is recommended to rinse the PV modules approximately every 2 months to wash away dirt and debris which may affect the amount of light the module receives. Also the connections and wiring should be checked to see if it is secured properly, this can be done visually if necessary and should be done at least yearly.

The inverter only needs a visual inspection to check for any damage and check that it is operational.

Where possible the DC cables and connections should be checked for damage and security.

Across the PV system, any components should be labelled for safety therefore these will need to be kept in good condition so they are clear and legible at all times.

32

FaUlt FInDIngFa

Ult

FIn

DIn

g F

aU

lt

FIn

DIn

g F

aU

lt

FIn

DIn

g F

aU

lt

FIn

DIn

g F

aU

lt

FIn

DIn

g


FaUlt FInDIngA PV system is expected to operate for 25 to 30 years. Due to weather exposure, various faults can occur in this time. Depending on the fault, it is always advisable to visually check the system, especially the PV array. Mechanical damage should be looked for and all wiring connections should be checked.

To aid the troubleshooting process it is useful to have the following information available;

• Installation certificate

• Schedule of inspections

• Schedule of test results

• A system layout

• Any alterations made to the system

• The nature of the fault and when it occurs

Inverter does not operate correctly or at all

The array has low or no voltage / current

Switch off the inverterVisually check the modules and cabling - replace and

repair if necessary

Some of the modules in the

series string may be faulty and

need replacing

Could be caused by weather or connections

between parallel strings may be

faulty

Low Voltage Low CurrentRefer to inverter manual for

fault finding

Check earth connections - repair if found

Switch on inverter


general

De-CoMMISSIonIng

If the Ideal solar PV system ever has to be de-commissioned then the following steps should be followed to complete the procedure safely.

To shut down the system you will firstly need to switch off the circuit at the consumer unit and lock it off. Then switch off the DC supply to the inverter by turning the DC isolator to the OFF position.

The next step is to disconnect the DC cables from the inverter and disconnect them from the PV array. You can then disconnect the strings and individual modules ready for removal.

To remove the PV modules you should follow the mounting instructions in reverse and replace any tiles which have had to be modified during the original installation.

The rest of the system can now be safely disconnected and removed and certain parts such as the inverter or isolators may be re used.

Once the full system has been removed or disconnected the AC power can be switched back on at the consumer unit.

34

lISt oF PartS


key no Description Qty Product number1 GD Solar Pv Module 1580 x 808 1 2070662 TSPV PV Module 200WP 1507 x 992 1 2065523 TSPV PV module 205WP 1507 x 992 1 2065514 DC Isolator 1 2065645 AC Isolator 1 2065656 SB1200 Inverter Single Phase 1 2065557 SB1700 Inverter Single Phase 1 2065568 Aurora IP21 Inverter 1 2070019 SB2500 Inverter Single Phase 1 20655710 SB3000 Inverter Single Phase 1 20655811 SB 3300 Inverter Single Phase 1 20655912 SB 3800 Inverter Single Phase 1 20656013 SB4000TL Inverter Single Phase 1 20700014 4mm Solar PV Cable x 30m 1 20656815 Tyco Female 4mm Connector (Blue - Minus) 1 20656916 Tyco Female 4mm Connector (Red - Plus) 1 20657017 MC4 Female Connector 1 20657118 MC4 Male Connector 1 206572

SPareS


general

Ideal Boilers ltd, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

technical training

Ideal Stelrad group pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

The Ideal Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. For details of courses please ring:................ 01482 498 432

CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001: 2000 Quality System accepted by BSI

Ideal Installer/Solar Technical Helpline: 01482 498 307www.idealheating.com

Documents

SOLAR PHOTOVOLTAIC - JewsonPlastic Enclosures, Protection IP66/67, insulated, knock-out entries, Red handle and contrasting yellow escutcheon plate, OFF-position lockable with padlocks,