PM060M00 Installation Guide for Users

Transcription

1 BenQ Solar Photovoltaic Modules (ETL) PM060M00 Installation Guide for Users Note: The content of this specification is subject to change AU Optronics All Rights Reserved, Do Not Copy.

2 BenQ Solar Photovoltaic Modules (ET ETL) Installation Guide for Users Table of Contents Chapter 1 General Information Limited Warranty... 1 Disclaimer of Liability... 1 General Safety... 2 Handling safety... 2 Installation safety... 3 Chapter 2 Electrical Characteristics of PV Module Chapter 3 Packing and Unpacking Information Chapter 4 Mechanical Installation Suitable location General installation Installation Method Mounting with Zep Systems: Screwing: Clamping: Zep Component Zep Component Installation Chapter 5 Installation-grounding, wiring, limitation of connection Grounding (Negative) Wiring Limitation of connection Installation Warnings Chapter 6 Maintenance Chapter 7 Certification

3 Chapter 1 General Information Important Please read this instruction sheet in its entirety before installing, wiring, or using this product in any way. Failure to comply with these instructions will invalidate the BenQ Solar Limited Warranty for PV Modules. Limited Warranty Module limited warranties are described in the BenQ Solar warranty certificates. Warranties do not apply to any of the following: PV modules which in BenQ Solar s absolute judgment have been subjected to: misuse, abuse, neglect or accident; alteration, improper installation, application or removal (including but not limited to installation, application or removal by any party other than a qualified personnel; non-observance of BenQ Solar s installation, Zep Solar s Installation, users and/or maintenance instructions; repair or modifications by someone other than an approved service technician; power failure surges, lightning, flood, fire, accidental breakage or other events outside BenQ Solar s control. WARRANTY VOID IF NON-ZEP CERTIFIED HARDWARE IS ATTACHED TO GROOVE IN MODULE FRAME Disclaimer of Liability The installation techniques, handling and use of this product are beyond company control. Therefore, BenQ Solar does not assume responsibility for loss, damage or expense resulting from improper installation, handling or use. Last revised: Oct. 14,

4 General Safety Modules interconnect pass direct current (DC) and are sources of voltage when the module is under load and when it is exposed to light. Direct current can arc across gaps and may cause injury or death if improper connection or disconnection is made, or if contact is made with module leads that are frayed or torn. Do not connect or disconnect modules when current from the modules or an external source is present. Cover all modules in the PV array with an opaque material before making or breaking. It is imperative to use the supplied locking connectors and safety clips in order to defend against untrained personnel disconnecting the modules once they have been installed. All installations must be performed in compliance with all applicable regional and local codes. There are no user serviceable parts within the module. Do not attempt to repair any part of the module. Installation should be performed only by qualified personnel. Remove all metallic jewelry prior to installing this product to reduce the chance of accidental exposure to live circuits. Use insulated tools to reduce your risk of electric shock. Do not stand on, drop, scratch or allow objects to fall on modules. Damaged modules (broken glass, torn back sheet, broken j-boxes, broken connectors, etc) can be electrical hazards as well as laceration hazards. Contact with damaged module surfaces or module frame can cause electric shock. The dealer or installers should remove the module from array and contact the supplier for disposal instructions. Do not install or handle the modules when they are wet or during periods of high wind. Contact your module supplier if maintenance is necessary. Save these instructions. Handling safety Do not transport and installation modules by using inappropriate methods to avoid break modules or cause functional influence Do not stand or step on, drop, scratch or allow objects to fall on modules. Do not carry the module by grabbing module junction box or electrical cable. Do not drill holes in the frame or scratch the anodized coating of the frame that may compromise the frame strength and cause corrosion of the frame. Do not scratch or hit the backsheet to avoid damage of the backsheet. Do not put any heavy objects on the module to avoid glass breakage. Always work or handle under dry conditions, both for the modules and tools. Last revised: Oct. 14,

5 When storing uninstalled panels outdoors for any period of time, always cover the panels and ensure that the glass faces down to stop water from collecting inside the panel and causing damage to exposed connectors. Installation safety Do not install or handle the modules when they are wet or during periods of high wind. Do not open electrical connections or unplug connectors while the circuit is under load. The electrical installation should be in accordance with local electrical regulations. To avoid the risk of burns and electric shock, do not touch the modules when installation. Damaged modules (broken glass, torn back sheet, broken j-boxes, broken connectors, etc) can be electrical hazards as well as laceration hazards. Contact with damaged module surfaces or module frame can cause electric shock. The dealer or installers should remove the module from array and contact the supplier for disposal instructions. Only use connectors to connect modules to form a string, or connect to another device. Removing the connectors will make the warranty void. Contact your module supplier if maintenance is necessary. Use tools duly coated with insulating material while working with the modules. Do not install the modules where there may be flammable gases or vapors, since sparks may be produced. Do not touch the terminals while the module is exposing to light. Provide the installation with suitable protection devices to prevent a discharge of 30 or more direct current volts from any person When storing uninstalled panels outdoors for any period of time, always cover the panels and ensure that the glass faces down to stop water from collecting inside the panel and causing damage to exposed connectors. Last revised: Oct. 14,

6 Chapter 2 Electrical Characteristics of PV Module The module electrical ratings are measured under Standard Test Conditions (STC) of 1000W/m 2 irradiance with AM 1.5G spectrum and a cell temperature of 25ºC. Electrical characteristics of BenQ Solar modules are listed in the table below. Module Type Pmax Voc Isa Vmp Imp (W) (V) (A) (V) (A) PM060M PM060M PM060M A PV module may produce more current and/or voltage than reported at STC. Sunny, cool weather and reflection from snow or water can increase current and power output. Therefore, the values of Isc and Voc marked on module should be multiplied by a factor of 1.25 when determining component voltage ratings, conductor capacities, fuse sizes, and size of controls connected to PV output. An additional 1.25 multiplier may be required by the NEC (National Electric Code) for sizing fuses and conductors as described in the NEC section Performance of PV Modules A PV module generates current which is proportional to the intensity of solar radiation, while the voltage varies with cell temperatures. Note that the cell temperature is usually higher than the environmental temperature. The increase in the temperature of cell compared to the air temperature depends on the thermal characteristics of the module. In summary, depending on solar radiation, the temperature of the cells and the equipment to which they are connected, a PV module will generate a different current and voltage levels, which result in a different power output. Last revised: Oct. 14,

7 Chapter 3 Packing and Unpacking Information Packing configuration Packing configuration Container 20' DC 40' DC 40' HQ Pieces per pallet Pallets per container Pieces per container Pallet packing diagram 1. One pallet packing Last revised: Oct. 14,

8 2. Double pallet packing Container schematic drawing 1. 40' HQ container Last revised: Oct. 14,

9 2. 40' DC container 3. 20' DC container Last revised: Oct. 14,

10 Unpacking Notice Due to the long side vertical module packing design, please refer to the unpacking procedure as below illustration: 1. To remove the PE film in the outmost layer 2. Pull down the fixation of PP/PET bands between pallet and package 3. To remove the top cardboard 4. To take up the top paper spacer 5. Do not move the pallets or package by hand pallet truck or any tool when remove the packing box before/after to avoid the module dumping due to lose balanced. 6. To remove the top slot 7. To take the modules from outside to inside seriatim (Please refer to the direction of red arrow on the bottom paper slot) to avoid the module dumping due to lose balanced. Last revised: Oct. 14,

11 Last revised: Oct. 14,

12 Chapter 4 Mechanical Installation Suitable location Modules may be installed at any angle from horizontal to vertical. Select the appropriate orientation to maximize sunlight exposure. The gap between the module and system structure and ground is required to prevent wiring damage and allows air to circulate behind the module. Gap between two modules has a minimum 20mm for common use, except Zep installation method. Make sure that the module installation shall obey local fire-resistant regulations. Do not remove or alter the module frame. Additional mounting holes may damage the module and reduce the strength of the frame. The module should not be shaded at any time. General installation Do not remove or alter the module frame, or drill additional holes in the module frame as this will void the warranty. Additional mounting holes may damage the module and reduce the strength of the frame. Modules may be mounted at any angle from horizontal to vertical. Select the appropriate orientation to maximize sunlight exposure. The gap between the module and system structure and ground is required to prevent wiring damage and allows air to circulate behind the module. Make sure that the module installation shall obey local fire-resistant regulations. The back of the module avoid direct exposure to sunlight. Do not install the modules where there may be flammable gases or vapors, since sparks may be produced. Last revised: Oct. 14,

13 Installation Method Modules can be installed on the frame using Zep system, mounting holes and clamps as following introduction. Not mounting the modules according to these instructions may void the warranty. Module can be installed in landscape modes. To insure that the screw or clamps used to secure the modules are strong enough. Modules should be mounted using the following methods only Mounting with Zep Systems: While installing modules using Zep mounting hardware, PM060M00 modules must be installed in accordance with either ZS Comp or ZS Span Installation Manual. For in-depth information, please download the latest Manual form the website of Zep Solar. ( PM060M00 modules installed with hardware for ZS Comp and ZS Span are rated for design loads of 50 psf (2400 Pa) on the back surface (e.g., wind load) and on the front surface (e.g., wind and snow load) when installed according to the following diagrams and with all applicable installation instructions. Screwing: Secure the module to the structure using the factory mounting holes. The torque wrench must be used for assembly. In the examples shown, the tightening torque must be 20N.m. Use the existing holes for securing the module; do not drill any additional holes (doing so would void the warranty). Use corrosion-proof fastening materials. For PM060M00 modules, four stainless steel bolts, with nuts, washers, and lock washers are recommended per module. Only the existing mounting holes (Diameter: 6.6mm) that can be used for module to meet 2400Pa design strength under UL 1703 Clamping: Note that the clamping clips on the side frame should be in parallel. Back rail which dimension is over 40mm*80mm is necessary. When Clamping on longer side frame, the side frames are attached to the longer sides of the module. Figure 3 shows effective mounting area. The centerline of the clips should be between D1-281mm~D2-375mm from the short end of the module for 2400Pa design strength under UL Last revised: Oct. 14,

14 Figure 1-1: ZS Comp Layout Dimensions (50 psf Design Load) Figure 1-2: ZS Span Layout Dimensions (50 psf Design Load) Last revised: Oct. 14,

15 Figure 2: Installation of Module (Screwing) Figure 3: Effective Mounting Area (Clamping) Last revised: Oct. 14,

16 Zep Component Zep Groove and Rockit: The Rockit is a hardware feature which used to secure PV modules to the roof attachments. The Rockit fits into the Zep Groove on both sides: The Key side insets, while the Tongue side receives. Figure 4: Zep Groove and Rockit Key and Tongue The Key and Tongue concept informs all Zep Compatible designs. The Key side inserts into the Zep Groove, similar to inserting a key into a lock. On the other side, the Zep Groove allows PV modules to drop in easily onto the Tongue side. Figure 5: Module Drop-In Example Last revised: Oct. 14,

17 Key and Tongue: Interlock Key and Tongue in a Zep Compatible design is also seen with the Interlock, a component that couples and bonds two modules together. Here, the Key and Tongue are differently shaped, but they still fit into the Zep Groove in the same manner as the Rockit. Figure 6: Interlock, Key and Tongue Side Views Zep Component Installation Interlock Installation The Interlock provides module-to-module frame bonding through the interface with the Zep Groove. The Interlock is UL Listed to UL2703 and ETL Listed to UL2703. Alignment marks along the top edge of the Interlock aid in module positioning and tightening of the fasteners. Figure 7: Interlock Alignment Marks Last revised: Oct. 14,

18 Interlock is used to connect modules together. First, insert and push the Key side of the Interlock firmly into the Zep Groove. Second, place Zep Tool over the fastener with the 1 aligned with Interlock reference mark (Please refer the figure below). Last, rotate Zep Tool clockwise to exactly Position #3 (Do not over or under- tighten) Figure 8: Interlock Insertion and Installation Uses Zep Tool Last revised: Oct. 14,

19 Chapter 5 Installation-grounding, wiring, limitation of connection Grounding (Negative) Two grounding methods can be used to provide a path to ground, that is, (1) Using Zep certified component Ground Zep and/or (2) Grounding holes BenQ Solar PV modules have a clearly marked grounding hole on each side of the frame for inserting the ground contact. The grounding screw and bolt are separately used from the mounting parts of the module. The Ground Zep is UL and ETL Listed to UL467 and is UL Listed to Ul2703. First, insert a Ground Zep in the Zep Groove of any module around the array perimeter. Start with the set screw at 9 o clock position (pointing left). Second, using either the Zep Tool or the Flat Tool (shown below), lock the Ground Zep into place by turning 1/4 turn clockwise. After the Ground Zep is turned 90 Degrees, the set screw should be pointing straight up. (This locks the Ground Zep into the Zep Groove and creats a solid ground bond with the module frame.) Figure 9: Ground Zep Installation Insert solid cooper ground wire into the ground wire retention slot and turn the set screw with a flat-bladed screw driver until the ground wire is captured by the set screw. To fully secure, torque the set screw as follows: Wire Size (AWG) Torque (in-lbs) Last revised: Oct. 14,

20 Figure 10: Connect Ground Zep to Building Ground/Earth The Grounding Hole on each side of the frame. Please make sure the grounding screw removes the anodizing from the surface of the grounding holes, or scratch off the anodizing before the grounding connection is made since the frame is fully insulated by anodizing. If the material of support structure is different with the material of frame (aluminum), the Insulation between them is required. Should the support structure be a non conductor, a cable must be connected by means of a suitable fastening system. The fastening system will be joined to a cable with a minimum 2.5mm 2 cross section, together with all the grounding conductors from each module. Please make sure that each module is grounding properly. The recommended assembly is shown below in Figure 11. Figure 11 Recommended grounding connection Per NEC , electrical equipment secured to and in electrical contact with a metal rack or structure provided for its support and grounded by one of the means indicated in shall be considered effectively grounded. Notice: Please follow your local electrical code when you Installation and grounding. Last revised: Oct. 14,

21 Wiring DO NOT do any change or adjustment on the cable of Junction Box. DO NOT disconnect cable by yourself! Important The cable must not be bent or crushed on the direct exit of the cable screw joint. A minimum bending radius r 4x (static steady), r 5x (dynamic) cable diameter must be maintained. The cable must be routed in a way that tensile stress on the conductor or connections is prevented. Radius 4x cable diameter (static steady) 5x cable diameter (dynamic) r Radius 4x cable diameter (static steady) r Figure 12 Minimum bending radius of cable For the wiring, please pay attention to: 1. Correct wiring scheme Check that the wiring is correct before commissioning the system. If the measured open circuit voltage differs from the specifications, then there is a wiring fault. Ensure that the polarity is correct. 2. Correct plug connections c Make connections only in dry conditions. Ensure that connections are secure and tight. 3. Use of suitable materials Use special solar cable and suitable connectors only. Ensure that they are in perfect Last revised: Oct. 14,

22 electrical and mechanical condition. Use only single wire cables. Select a suitable conductor diameter to minimize voltage drop. 4. Cable protection We recommend securing the cables to the mounting system using UV-resistant cable ties. Protect exposed cables from damage using suitable precautions. Avoid direct exposure to sunlight. Limitation of connection ETL The UL 1703 certificate of these modules guarantees their insulation up to a DC voltage of 1000 V. (UL 1703 Standard). However, a cable with a suitable cross section must be used for conducting the sum of the currents as generated by the modules. A series protection fuse of 15A is recommended for each string when module strings are parallel connected. In any event, BenQ Solar recommend the PV conductor, which cross section is 4 mm 2. External connection boxes will be used to enable greater cable cross section area for long distance transmission. The modules are qualified for the application class A: Hazardous voltage (IEC 61730: higher than 50V; EN 61730: higher than 120V), hazardous power applications (higher than 240W) where general contact access is anticipated. Shadow effect The shadow or hot spot effect is caused by an isolated shadow on one or several module cells while the rest are receiving high radiation. This situation must be solved by removing the cause of the shadows. The three protection diodes described in the junction box are provided to prevent damage to the cells. Last revised: Oct. 14,

23 Installation Please note the following instructions: To ensure the correct orientation of the module, the module should face southwards in the northern hemisphere and northwards in the southern hemisphere. The module must be installed so that air can freely circulate around it. The cells working temperature will thus be reduced and, consequently, the module s performance will be enhanced. The cross section for the conductors must be ensured that the voltage drop during the installation does not exceed 2% of its nominal voltage. BenQ Solar PV modules are supplied with or without cables, according to where they are ordered. Should they be supplied without cables, it is recommended that cables with cross sections between 4 and 10 mm 2 be used. The cables, which allowed easy handling while providing high protection against overloads and short-circuits, are formed by flexible Cu conductors, cross linked insulated polyethylene and coated with polyvinyl chloride or similar. They must be kept with low corrosive gas surrounded and with acid and alkali resistance and must not be flamed nor fire propagated during operating. The back of the module avoid direct exposure to sunlight. Warnings The modules should be installed and handled by qualified persons only. Do not climb up or walk on the module. Do not drop the module or throw objects onto it. Use the module only for the purpose to which it is designed for. Do not dismantle the module or remove any part, label, or piece installed by the manufacturer and protection diodes without the manufacturer s authorization. Do not concentrate sunlight or other artificial light sources onto the module. Use tools duly coated with insulating material while working with the modules. Always work under dry conditions, both for the modules and tools. Do not install the modules where there may be flammable gases or vapors, since sparks may be produced. Avoid electric discharges when installing, wiring, starting up or carrying out maintenance work on the modules. Do not touch the terminals while the module is exposing to light. Provide the installation with suitable protection devices to prevent a discharge of 30 or more direct current volts from any person. Please prevent adherent of oil such as paraffin liquid, animal oil and vegetable oil form molding parts. It may be cracked or broken and loose the performance of Junction Box and connectors. Last revised: Oct. 14,

24 Chapter 6 Maintenance Inspect all modules annually for safe electrical connections, sound mechanical connection, and freedom from corrosion. BenQ Solar PV module may use anti-reflective coating glass to enhance power output. Strongly recommend not to touch glass surface unless putting on clean gloves in order to prevent fingerprints left. Periodically clean glass and the module surface only with a soft cloth or sponge using mild detergent and water. Fingerprints may be removed with standard glass cleaner. Do not use harsh cleaning materials such as scouring powder, steel wool, scrapers, blades, or other sharp instruments to clean the glass surface of the module. Use of such materials will invalidate the product warranty. 1. Regular cleaning of the module Dirt piled up on the module s transparent surface reduces its performance and may cause reverse hot spot effects. The problem may become serious in the case of industrial waste and bird droppings. The intensity of the effect depends on the waste s opacity. The layers of dust that reduce the sun s intensity evenly are not dangerous and the power reduction is not usually significant. The frequency of cleaning depends, of course, on how quickly dirt accumulates. When the module is mounted over angle of fifteen degree, the module has efficacy of self-cleaning. In many cases, rainfall may reduce or remove the need to clean the modules. BenQ Solar recommends cleaning module during early morning, late afternoon or cloudy day. Do not clean module during high temperature, temperature lower than zero degrees Celsius, or when large temperature difference between module and cleanser. If necessary to clean back side of module, do not damage any components. Please prevent any oily liquids such as paraffin liquid, animal oil, or vegetable oil contacting with junction box, cable and connector. Some BenQ Solar PV module can withstand snow pressure of 2400 Pa.(UL 1703) Please use soft brush lightly removing snow pileup. Do not try to remove frozen snow and solid ice on the module. The cleaning operation must be performed, in general, by the user. It simply consists of washing the modules with solution and tools. The cleaning step as follows: - Solution:clean water, water with low mineral amount, non high-pressure water, non-abrasive/ non-caustic detergent, weak acid/weak alkalescent solution, or solution of PH < Tool:soft brush, non-conductive brush, non-abrasive sponge, non-abrasive cloth, seamless cloth Last revised: Oct. 14,

25 1. Clean module and glass surface with solution and tool described as above. 2. If dirty area on glass surface which is hard to be cleaned such as oily substances, try to use commercial glass detergent, alcohol, isopropanol(ipa), or sodium bicarbonate solution. 3. Use clean water to clean glass again and weeding out water by dry cloth. Do not leave stagnant water on glass surface. 2. Anodic oxide coatings of module frame The cleaning cycle for regular anodic oxide coatings is generally every six months. When cleaning, attention should be paid not only to cleaning surface dirt, but also not to damage the anodic oxide coatings. Dirt can generally be cleaned off using a suitable lubricant or warm, mild soapy water, and a fibre brush may be used to clean any dust that may also stick to the surface. Sandpaper, steel wire brushes or other friction articles, or acid and alkali may not be used to clean anodic oxide coatings, as they may damage the coatings. To prevent the anodic oxide coatings of the anodised profiles from being damaged, special attention should be paid during transportation. When storing the anodised profiles, do not allow the profiles to come into contact with contaminants such as cement or mortar, which will cause damage to the anodic oxide coatings. Reference:GB , Wrought aluminium alloy extruded profiles for architecture 3. Visual inspection of the module The purpose of visual inspection of the module is to detect possible faults, specifically: Possible broken glass. Rust on the circuits and soldering of the PV cells: this is normally due to moisture entering the module through a breakage in the encapsulating layer during installation or transport. 4. Inspection of connections and cabling Perform preventive maintenance every 6 months, carrying out the following operations: Check the tightness and condition of the connection cable junctions. Check the junction box sealing. Should sealing faults be observed, the items which have been affected should be replaced and cleaned. It is important to monitor the junction box sealing by using new sealing methods such as silicon sealing according to the case Last revised: Oct. 14,

26 Chapter 7 Certification ETL This product meets or exceeds the requirements set forth by UL1703 for PV Modules. This UL1703 Standard covers flat-plate PV modules intended for installation on buildings and those intended to be freestanding. To satisfy the listing for this product the modules must be mounted with a rack or standoff structure. It does not include integration into a building surface because additional requirements may apply. This product is not intended for use where artificially concentrated sunlight is applied to the module. BenQ Solar is a division of AU Optronics Copyright AUO Optronics Corp. All rights reserved. Information may change without notice. Last revised: Oct. 14,