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Installation Guide for Suntech Power Reliathon Module

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Table of Contents

1 Purpose of This Guide General safety Handling safety Installation safety Fire safety 5 Product Identification 6 Mechanical Installation Selecting the location General installation Installation method

10 Electrical Installation General installation Grounding 11 Maintenance 12 Appendix 12 Disclaimer of Liability

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Purpose of This Guide

General safety Modules rated for use in this application class may be used in systems operation at greater than 50V DC or 240W, where general contact access is anticipated. Modules qualified for safety through this part of IEC61730-2 & UL1073 and within this application class are considered to meet the requirements for safety class II. Installing solar photovoltaic systems may require specialized skills and knowledge. Installation should be performed only by qualified persons.

Purpose of this guide

This guide contains information regarding the installation and safe handling of Suntech Power Holdings Co., Ltd photovoltaic module (hereafter is referred to as module). Suntech Power Holdings Co., Ltd hereafter is referred to as Suntech. Installers must read and understand the guide before installation. Any questions, please contact our sales department for further explanations. The installer should conform to all safety precautions in the guide and local codes when installing a module. Before installing a solar photovoltaic system, installers should become familiar with the mechanical and electrical requirement for such a system. Keep this guide in a safe place for future reference (care and maintenance) and in case of sale or disposal of the modules.

Installers should assume the risk of all injury that might occur during installation, including, without limitation, the risk of electric shock. One individual module may generate DC voltages greater than 30 volts when exposed to direct sunlight. Contact with a DC voltage of 30V or more is potentially hazardous. Do not disconnect under load. Photovoltaic solar modules convert light energy to direct-current electrical energy. They are designed for outdoor use. Modules may be ground mounted, either on a fixed tilt mount or horizontal single axis tracker. Proper design of support structures is responsibility of the system designers and installers. Do not use mirrors or other magnifiers to artificially concentrate sunlight on the modules. When installing the system, abide with all local, regional and national statutory regulations. Obtain a building permit where necessary. The electrical characteristics are within 10 percent of the indicated values of Isc, Voc, and Pmax under standard test conditions (irradiance of 100mW/cm2, AM 1.5 spectrums, and a cell temperature of 25C (77F)). Use only equipment, connectors, wiring and support frames suitable for a solar electric system. Handling safety Do not lift the module by grasping the modules junction box or electrical leads. Do not stand or step on the module. Do not drop the module or allow objects to fall on module. To avoid glass breakage, do not place any heavy objects on the module. Do not set the module down hard on any surface. Inappropriate transport and installation may break the module.

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Purpose of This Guide

Purpose of This Guide

Do not attempt to disassemble the modules, and do not remove any attached nameplates or components from the modules. Do not apply paint or adhesive to module top surface. To avoid damage to the back sheet, do not scratch or hit the backsheet. Do not drill holes in the frame. It may compromise the frame strength and cause corrosion of the frame. Do not scratch the anodized coating of the frame (except for grounding connection). It may cause corrosion of the frame or compromise the frame strength. Avoid setting the panel down hard on any surface, particularly when placing it on a corner. A panel with broken glass or torn back-skin cannot be repaired and must not be used since contact with any panel surface or the frame can produce electrical shock. Do not knock off or treat harshly the grounding plates. Work only under dry conditions, and use only dry tools. Do not handle panels when they are wet unless wearing the appropriate protective equipment. When storing un-connected panels outside for any length of time, always cover the panels. Storing the glass facing down will cause water to collect inside the panel, causing damage to exposed connectors. Installation safety Never open electrical connections or unplug connectors while the circuit is under load. Contact with electrically active parts of the panels, such as terminals, can result in burns, sparks and lethal shock whether the panel is connected or disconnected. Dont touch the PV module unnecessary during installation. The glass surface and the frame may be hot; there is a risk of burns and electric shock. Dont work in rain, snow or windy conditions. Cables shall be located so that they will not be exposed to direct sunlight in order to prevent degradation of cables. Keep children well away from the system while transporting and installing mechanical and electrical components. Completely cover the module with an opaque material during installation to keep electricity from being generated. Do not wear metallic rings, watchbands, ear, nose, lip rings or other metallic devices while installing or troubleshooting photovoltaic systems. Use only insulated tools that are approved for working on electrical installations.

Abide with the safety regulations for all other components used in the system, including wiring and cables, connectors, charging regulators, inverters, storage batteries and rechargeable batteries, etc. Under normal outdoor conditions the module will produce current and voltages that are different than those listed in the datasheet. Datasheet values are values expected at standard test conditions. Accordingly, during system design, values of short-circuit current and open-circuit voltage should be multiplied by a certain factor when determining component voltage ratings, conductor ampacity, fuse ratings and size of controls connected to the modules or system output. Refer to Section 690-8 of the National Electrical Code for an additional multiplying factor which may be applicable.

Fire Safety Refer to your local authority for guidelines and requirements for building or structural fire safety. The roof construction and installation may affect the fire safety of a building; improper installation may contribute to hazards in the event of fire. It may be necessary to use components such as earth ground fault circuit breakers, fuses and circuit breakers. Do not use panels near equipment or locations where flammable gases can be generated or collected. The modules are rated fire Class C, and are suitable for mounting over a class A roof. Do not install modules on a roof or building during strong winds in case of accidents. The National Electric Code requires the use of a properly sized GFDI on photovoltaic arrays installed on dwellings. Refer to the NEC for further information on earth ground fault breakers.

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Product Identification

Mechanical Installation

Each module has three labels on its rear side providing the following information: 1) Nameplate: describes the product type; rated power, rated current, rated voltage, open circuit voltage, short circuit current, all as measured under standard test conditions; weight, dimension, etc. The maximum system voltage is shown on the nameplate. Maximum fuse rating is also shown. 2) Pass: describes inspection date and security class. 3) Bar code: each individual module has a unique serial number. The serial number has 18 digits. The 15th and the 16th digit are the week code, and the 17th and the 18th digit are the year code. For example, xxxxxxxxxxxxxx0106 means the module was made in the first week of 2006. There is only one bar code on module. It is permanently attached to the interior of the module visible when viewing from the front of the module. This bar code is inserted at the beginning of laminating.

Selecting the location Select a suitable location for installing the modules. The modules should be facing south in northern latitudes and north in southern latitudes. For detailed information on the best elevation tilt angle for the installation, refer to standard solar photovoltaic installation guides or a reputable solar installer or systems integrator. The module should not be shaded at any time of the day. Do not use module near equipment or in locations where flammable gases can be generated or collected. General installation The Suntech Reliathon Module is designed to be mounted on a 100mm [4.00inch] square tube. The module mounting support structure must be made of durable, corrosion-resistant and UV-resistant material. Select the height of the mounting system to prevent the lowest edge of the module from being covered by snow for a long time in winter in areas that experience heavy snowfalls. In addition, assure the lowest portion of the module is placed high enough so that it is not shaded by plants or trees or damaged by sand and stone driven by wind.

1 1 2 3 1234567 1 2 3 0 1 0 6
Typical serial number barcode label

Provide adequate ventilation under a module for cooling. Always observe the instructions and safety precautions included with the support frames to be used with the modules. Do not attempt to drill holes in the glass surface of the modules. To do so will void the warranty. Do not drill additional mounting holes in the frame of the modules. Doing so will void the warranty. Modules must be securely attached to the mounting structure. Care must be taken to avoid low tilt angles which may cause dirt to build-up on the glass against the frame edge. Dirt build-up on the surface of the panel can cause active solar cells to be shaded and electrical performance to be impaired. Always keep the back sheet of the panel free from any foreign objects or structural elements which could come into contact with the panel, especially when the panel is under mechanical load. Ensure panels are not subjected to wind or snow loads in excess of the maximum permissible loads and are not subject to excessive forces due to the thermal expansion of the support structure, see the following paragraph for more detailed information.

Do not remove any label. If the label is removed, the product warranty will no longer be honored by Suntech.

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Mechanical Installation

Mechanical Installation

For installation in Northern America and in accordance with UL standard, the installed number of modules is suggested not to exceed 10 on one structure, with the system voltage not exceeding 600V. The actual installed number shall be determined by the EPC company according to the local conditions. For installation out of Northern America, the installed number of modules is suggested not to exceed 17 on one structure, with the system voltage not exceeding 1000V. The actual installed number shall be determined by the EPC company according to the local conditions.

Nut Spring Washer

Module Washer

Installation method The modules must be installed with the mounting holes provided on the frame.

Square Tube

Grounding Plates

Mounting Holes

U-Bolt

Module Installation

Installation tools: 17mm socket wrench (electric wrench optional), torque wrench 20-100Nm [14.8ft-73.8lb]. Tightening torque for U- bolts: 20Nm [15.4 ft-lb]. U-bolt fastener assembly includes 1 U-bolt, 1 Module washer, 2 Nuts, spring washers. Installation procedure: Front and Rear view of the Reliathon module

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Mechanical Installation

Electrical Installation

Reliathon modules have interlocking frames. When installing the first module, secure the end with the smaller channel. The smaller channel should be placed at the beginning of the square tube away from the direction from which the modules are being installed. 1. Place the first module on the square tube and align the mounting holes on the small channel to the width of the square tube. Install the U-bolt fastener assembly, ensuring that the module is aligned to the square tube before tightening the fasteners. 2. Install the next module by placing the small channel into the larger channel of the previously installed module. This interlocks the frames between the two modules. Install the U-bolt fastener assembly securing both the larger channel of the previously installed modules and the small channel of the module being installed. Tighten the fasteners. 3. Repeat step 2 when installing the next module. 4. After installing the last module, install the U-bolt fastener assembly on the large channel of the last module and tighten fasteners. This completes the installation of the row of modules. Note:The modules should be installed from the left to the right while facing the glass of the module,with junction boxes positioned on the upper side of the modules. The following pictures show the details of the interlocking module frames.
Nut Spring Washer Module Washer Module

1. General installation Do not use modules of different configurations in the same system. The max. number (connected in series) of module (N) = Vmax system / [Voc(at STC)]. Under normal outdoor conditions the module will produce current and voltages that are different than those listed in the data sheet. Data sheet values are values expected at standard test conditions. Accordingly, during system design, values of short-circuit current (Isc) and open-circuit voltage (Voc) marked on UL series modules should be multiplied by a factor of 1.25 when determining component voltage ratings, conductor ampacity, fuse sizes and size of controls connected to the module or system output. The factor may vary according to the local standards of different regions. The max. number (connected in parallel) of module is not limited, which is determined by system design such as current, power output. Several modules are connected in series and then in parallel to form a PV array, especially for application with a high operation voltage. If modules are connected in series, the total voltage is equal to the sum of individual voltages. For applications requiring high currents, several photovoltaic modules can be connected in parallel; the total current is equal to the sum of individual currents. Module is supplied with connectors to use for system electrical connections. Consult rated local wiring regulations to determine system wire size, type, and temperature. The cross section area of cable and the capacity of connector must be selected to suit the maximum system short circuit current (Recommended cross section area of cable is 4mm2 for a single module and rated current of a connector is larger than 10A), otherwise the cable and connector will be overheated under large current. Please note that the upper limit temperature of cable is 90C, and the connector is 105C. In Canada, installation shall be in accordance with CSA C22.1, Safety Standard for Electrical Installations, Canadian Electrical Code, and Part 1. The DC electrical energy generated by photovoltaic systems may also be converted to AC and connected to a utility grid system. As local utilities policies on connecting renewable energy systems to their grids vary from region to region, consult a qualified system designer or integrator to design such a system. Permits are normally required for installing such a system and the utility must formally approve and inspect such a system before it can be accepted. Reliathon modules come with integrated wire slots. Route the wires through the wire slot to secure the wires.
Connector Plugs Integrated Wire Slot

Module

Smaller Channel

Larger Channel Square Tube

U-Bolt

Details of the installation

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Electrical Installation

Appendix

Grounding The Reliathon module frames are electrically connected to the mounting structure (100mm/4.00in square tube) through the grounding plates installed at the factory. The modules and mounting structure are grounded by connecting the grounding conductor to the mounting structure via a lay-in lug. We recommend the lay-in lug (Cat. No. GBL-4DBT (Supplier: ILSCO) or SolKip (Supplier: TYCO). The following picture shows the grounding details.

Lay in Lug Integrated Module Grouding Plate Square Tube

The following table shows the electrical parameter of modules. Open-Circuit Model STP295-VRM-1 STP290-VRM-1
Grounding Conductor

Rated Voltage(Vmax) at STV(Vdc) 36.8 36.5 35.8 35.2 35.1 35.0 34.8 34.6 34.4

Maximum System 1000 1000 1000 1000 1000 1000 1000 1000 1000

Maximum System 600 600 600 600 600 600 600 600 600

Rated Current (Imax) at STC(Adc) 8.02 7.95 7.95 7.95 7.84 7.71 7.47 7.23 6.98

Short - Circuit Current (Isc) atSTC (Adc) 8.53 8.40 8.37 8.33 8.26 8.20 8.09 7.87 7.65

Rated Maxinum Power (Pmax) atSTC(Watts) 295 290 285 280 275 270 260 250 240

Maximum Model Series Fuse (A) 20 20 20 20 20 20 20 20 20

Voltage (Voc) atSTC(Vdc) 44.9 44.8 44.8 44.8 44.7 44.5 44.0 43.8 43.6

Voltage(Vdc)-IEC Voltage(Vdc)-UL

STP285-VRM-1 STP280-VRM-1 STP275-VRM-1 STP270-VRM-1 STP260-VRM-1 STP250-VRM-1 STP240-VRM-1

Grounding Detail

Maintenance Disclaimer of liability

Suntech recommends the following maintenance in order to ensure optimum performance of the module: Clean the glass surface of the module as necessary. Always use water and a soft sponge or cloth for cleaning. A mild, non-abrasive cleaning agent can be used to remove stubborn dirt. Check the electrical and mechanical connections every six months to verify that they are clean, secure and undamaged. If any problem arises, have them investigated by a competent specialist. Attention: observe the maintenance instructions for all components used in the system, such as support frames, charging regulators, inverters, batteries etc.
Because the use of this manual and the conditions or methods of installation, operation, use and maintenance of photovoltaic (PV) product are beyond Suntechs control, Suntech does not accept responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected with such installation, operation, use or maintenance. No responsibility is assumed by Suntech for any infringement of patents or other rights of third parties, which may result from use of the PV product. No license is granted by implication or otherwise under any patent or patent rights. The information in this manual is based on Suntechs knowledge and experience and is believed to be reliable; but such information including product specification (without limitations) and suggestions do not constitute a warranty, expresses or implied. Suntech reserve the right to change the manual, the PV product, the specifications, or product information sheets without prior notice.

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