Installation Guide for Imerys Large Format PVt 60 Photovoltaic Panel

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Meryl Hall
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1 Installation Guide for Imerys Large Format PVt 60 Photovoltaic Panel Innovation for sustainable homes

2 CONTENTS 1 INTRODUCTION AND PRODUCT DESCRIPTION 3 2 FIXING RECOMMENDATIONS AND CONSIDERATIONS 4 3 TECHNICAL CHARACTERISTICS OF THE PHOTOVOLTAIC PANEL 5 OVERALL DIMENSIONS 5 MECHANICAL SPECIFICATION 5 ELECTRICAL SPECIFICATION 5 ELECTRICAL BACKBOARD 6 4 PRECAUTIONS AND CONSIGNMENT CHECK 7 5 SAFETY INSTRUCTIONS AND PREPARATION 8 6 INSTALLING WITH IMERYS LARGE FORMAT TILES 9 ROOF TILE BATTEN GAUGE 9 7 POSITIONING THE CABLES 10 WHAT S INCLUDED 10 8 INSTALLING PHOTOVOLTAIC PANELS 11 9 SECURING PV PANELS TO EACH BATTEN CONNECTING EACH PV PANEL 14 ELECTRICAL CONTINUITY TEST JOINING EACH PANEL (MECHANICALLY) FIXING AROUND PV PANELS TOP ROW INSTALLATION COMPATIBILITY PV / ROOF TILES 19 COLOUR AVAILABLITY WIRING DIAGRAMS GUARANTEE COMPLETED INSTALLATION EXAMPLES 27 2

3 1 INTRODUCTION This document is intended as a guide only. Training courses are available on request. Installation work must be undertaken only by installers accredited by the Microgeneration Certification Scheme (MCS). All roofing work must be undertaken by trained operatives in accordance with Health and Safety regulations. Photovoltaic modules are live when exposed to daylight.anyone handling or installing them should be aware of and follow the safety procedures laid down under the guide for PV in Buildings. This guide gives you advice and tips on how best to install them. It is designed to complement a package of services which also includes technical assistance, feasibility studies, PV design and layout plans, wiring diagrams etc. Installation training is available on-site or at our designated training centres. PRODUCT DESCRIPTION Polycrystalline PV panels complete with aluminium frames The clever one-piece interlocking design makes the PVt quick and easy to install on the roof. To facilitate electrical connection each photovoltaic panel is equipped with colour-coded cables, and male and female MC connectors. 3

2 FIXING RECOMMENDATIONS AND CONSIDERATIONS The fitting of the roof tiles can be done as each panel is fixed in place. Every tile that adjoins the PVt panels should be nailed and clipped.

4 2 FIXING RECOMMENDATIONS AND CONSIDERATIONS The fitting of the roof tiles can be done as each panel is fixed in place. Every tile that adjoins the PVt panels should be nailed and clipped. Please remember that different levels of mechanical fixing may be required throughout the roof area dependent upon exposure, building height and roof pitch. This should be determined by submitting drawings and details prior to installation as full NBS fixing specifications are provided for H65 and H60 building clauses in accordance with BS5534:2003 (code of practice for slating and tiling). MINIMUM ROOF PITCH Although the minimum pitch of our large format clay interlocking roof tiles is 17.5 the PV panels are subject to a 22.5 minimum roof pitch. However for optimum performance a pitch of is recommended. SHADING Please check the site to ensure that no obstructions (such as trees or dormers) are shading the PV area of roof. DRY FIXING When installing our PV systems we recommend the Dry Fixing of all ridges and hips wherever possible due to mortar run off. Generally, dry fix systems are faster and cleaner and bring the added benefit of being able to continue installation during difficult weather. 4

5 5 1 TECHNICAL CHARACTERISTICS OF THE PHOTOVOLTAIC PANEL OVERALL DIMENSIONS AND WEIGHT 1377mm Weight: 7.0kg Working width: variable between mm Gauge: variable between mm 475mm 2 MECHANICAL SPECIFICATIONS Functional Temperature Range: -40 C to +85 C Anti-corrosion aluminium watertight casing Photovoltaic cell encapsulated in glass with Tedlar backing Double ventilation under the casing and between casing frame and laminate 3 ELECTRICAL SPECIFICATIONS Electrical Data Imerys PVt Tile Type of Cells (Black) Polycrystalline Brand Modules Suntech Maximum Power 60 Wp Open circuit voltage (Voc) 10V Short-circuit (Isc) 8.04 A Maximum Power Voltage (Vmp) 8V Current at Maximum Power (Imp) 7.51 A Module Performance (%) 12.83% Number of Cells per Module 16 Cell Dimensions 156 mm x 156 mm Panel Dimensions (overall) 1377mm x 475mm Working Width (variable) 1340mm-1360mm Panel Gauge (variable) 375mm-350mm Panel Weight 7kg Accuracy of performance data -3% / +5% Thermal coefficients for = 0.055% / C = -0.34% / C = -0.47% / C 5

6 5 IMERYS PVt ELECTRICAL BACKBOARD (OPTIONAL) All photovoltaic installations should be as easy and straightforward as possible. With our new all in Electrical Backboard, we aim to reduce time and costs on site during an installation. Once the PV modules have been connected in sequence on the roof, the DC cables will be run down and connected to the In-Port. From here, the wires are safely stored in our Cable Management System, from where they run through all photovoltaic components. From the In-Port, the electricity is run through a DC Isolator, and then passed into the Electrical Inverter. The Electrical Inverter takes the electricity generated and changes it from DC to AC, so that it can be safely passed through the building electrical network. The electricity then passes through an AC Isolator and an Ofgem Approved Meter, so the total power generated can be read. From here the electricity will enter the building via the Out-Port Backboard (material may vary) Out port In Port DC isolators Total Generation Meter (Ofgem approved) AC isolators Installation warning labels Electrical Inverter ALSO INCLUDES: Cable management for the items Wired and tested (NICEIC pat test certification for fixed equipment) G83-1 electrical conformity 6

Open the boxes carefully on site and check nothing is missing. Box of 20 photovoltaic panels: H: 0.70m L: 1.5m W: 0.

7 4 CONSIGNMENT CHECK Check for damage to the packaging, if it has been damaged during transit report the damage immediately to the courier. Handle the packages with care and store under cover so that the contents do not deteriorate or get lost. Open the boxes carefully on site and check nothing is missing. Box of 20 photovoltaic panels: H: 0.70m L: 1.5m W: 0.90m (overall) Weight: 140kg-150kg Before installing a panel, check it is in perfect condition and that the seals of the grommets are watertight. Check connectors. 7

8 5 SAFETY INSTRUCTIONS Installation work should be undertaken only by Microgeneration Certification Scheme (MCS) accredited installers. All roofing work should only be undertaken by trained operatives in accordance with Health and Safety regulations. Photovoltaic modules are live when exposed to daylight. Anyone handling installing them should be aware of and follow the safety procedures laid down under the guide for PV in Buildings. PREPARATION TOOLS REQUIRED Tape measure and pencil Power screwdriver with Pozi driver Angle grinder with stone disc Multimeter (electrical tester) Allen key 6 (to remove photovoltaic brackets) Our Tip: Allow four hours for two people to install 20x PVt tiles It is recommended that insulated gloves are worn for protection during all preparation, installation and testing work. PREPARING THE PANELS FOR INSTALLATION For their protection, PVt panels should be stored in a secure weatherproof environment prior to installation. Only place as many PVt panels onto the roof as you expect to install and be sure to remove or secure any uninstalled units before leaving the roof. PVt panels should only be carried by the frame with both hands, to avoid scratching the glass. Gloves should be worn for protection. The area above the installation should be kept free of tools and other unsecured items. The glass used on Imerys PVt panels is toughened for strength, but should still be treated with care. Under no circumstances should you step onto the panels, and avoid applying extreme pressure to them as this may cause the glass to break. 8

6 1 INSTALLING WITH IMERYS LARGE FORMAT TILES PREPARATION OF THE ROOF Load out roof in the usual way using 25x50 battens, centrally position the panels leaving a minimum of two courses of roof tiles

9 6 1 INSTALLING WITH IMERYS LARGE FORMAT TILES PREPARATION OF THE ROOF Load out roof in the usual way using 25x50 battens, centrally position the panels leaving a minimum of two courses of roof tiles between the PV panels and any perimeter or abutment. 2 ROOF TILE BATTEN GAUGE Check the vertical batten gauge FAG 10 PV Gauge Mini (350) Maxi (375) HP10 350mm 375mm Alpha mm 370mm PV10 350mm 375mm Panne H2 360mm 360mm *Fixed H10 350mm 375mm Rhona mm 375mm 9

7 POSITIONING THE CABLES Make sure you have positioned the cables. Our tip: Connect the cables as you go along. Use the extensions (black cable) to join each row of panels.

10 7 POSITIONING THE CABLES Make sure you have positioned the cables. Our tip: Connect the cables as you go along. Use the extensions (black cable) to join each row of panels. MC4 Cables Our tip: Connect the cables at the top and bottom of the connected panels before passing them between the roof membrane layers into the roof space. Make sure you identify the positive and negative leads and be sure you can reach the cables from inside (eg, if access at the eaves is restricted inside the roof space, thread the lower lead back under the battens to a more accessible point higher up the roof. This should be done before the remaining PV tiles are put into place. Take care not to damage the membrane. Installation kit includes the following fixing components: Item 2.9x19mm Pozipan self tap stainless steel screw MFW19 Bonded washer Interlocking tile stainless steel eave clip 4.2x4.5mm Pozipan self tap stainless steel screw Mono16 Tension clip 409 Tile clip 65x48 MC4 Cables Function Fix PV to batten Must be used with 2.9x19mm screw Fix leading bottom of PV Roof tile/pv bottom bracket clip Used to secure top row of roof tiles Secure all roof tiles around PV array To connect and join banks of PV together 10

8 INSTALLING PHOTOVOLTAIC PANELS Two batten nibs are located at the

Starting at the bottom of the roof, line the first panel up with the

PV clips (two per panel) must be fixed along the bottom row.

Mark a line where bottom of clip will lay, this is determined by your

11 8 INSTALLING PHOTOVOLTAIC PANELS Two batten nibs are located at the rear of each panel to help position each panel correctly. Starting at the bottom of the roof, line the first panel up with the roof tiles. PV clips (two per panel) must be fixed along the bottom row. Mark up and position clip as shown. Mark a line where bottom of clip will lay, this is determined by your batten gauge. Your marked position should be below the tile nail hole as shown. The clips must be screwed not nailed using 4.2x45 Pozipan self-tap stainless steel screws provided. 11

12 8 INSTALLING PHOTOVOLTAIC PANELS Each PV clip has a slot to allow for vertical adjustment. Slide the panel down into each clip as shown. First panel shown in position using bottom PV clip. This is essential to avoid possible wind uplift. 12

9 SECURING PV PANELS TO EACH BATTEN Using specified 2.

Within the top recess of each panel you will see three pre-punched

Screw the self tapping screws with the sealed bonded washers,

13 9 SECURING PV PANELS TO EACH BATTEN Using specified 2.9x19 Pozipan stainless steel screw and bonded washer. Within the top recess of each panel you will see three pre-punched hole locations. Screw the self tapping screws with the sealed bonded washers, securing the panel to the 25 x 50mm tiling batten (three screws per panel). Three pre-punched hole locations are clearly visible along each panel. 13

10 CONNECTING EACH PV PANEL As you install each panel, remember to connect each panel with the MC4 cables provided as you

ELECTRICAL CONTINUITY TEST Before testing the fitting of the tiles, we advise you to check the wiring.

Connect a multimeter to the positive and negative terminals of the PV panels.

14 10 CONNECTING EACH PV PANEL As you install each panel, remember to connect each panel with the MC4 cables provided as you work along or up the roof. Male and female MC4 connectors. ELECTRICAL CONTINUITY TEST Before testing the fitting of the tiles, we advise you to check the wiring. This test allows you to check the electrical connections and the correct functioning of the installation. Connect a multimeter to the positive and negative terminals of the PV panels. In the roof space checking the wiring of the PV panels Our Tip: Each time you fit a new PV panel you are advised to check the connection. The voltage must be measured. This voltage depends on the sunlight. If there is no voltage, check that each connector is properly attached. 14

11 JOINING EACH PANEL (MECHANICALLY) When

Ensure that you mechanically secure each

15 11 JOINING EACH PANEL (MECHANICALLY) When the first panel is secured slide the other panel into the location brackets. Close-up of location bracket (two per panel) being slotted into position. 12 FIXING ROOF TILES AROUND PV ARRAY Ensure that you mechanically secure each tile with nails and clips as shown. Imerys x48 tile clip. 15

16 12 FIXING ROOF TILES AROUND PV ARRAY Secure clip into batten, hooking onto interlock. Side view 409 clip. With two panels secured, the process is repeated until the top row is reached. 16

allen key after laying the final top row

17 13 TOP ROW ROOF TILE INSTALLATION There are two PV connection brackets located at the top of each PV panel. These should be removed using a size 6 allen key after laying the final top row of panels as shown, to allow roof tiles to be laid evenly along the top. Remove top row brackets. Take a mono 16 tile clip. Place on underside of batten. 17

18 13 TOP ROW ROOF TILE INSTALLATION Pull clip up and clip onto the interlock this must be repeated along the top row. It is essential to nail and clip the top row. The finished result, with PVt panels and roof tiles securely integrated. 18

19 14 ROOF TILE/PVT 60 PANEL COMPATIBILITY CHART IMERYS CLAY ROOF TILES Overall PVt Frame Size 1377x475mm Covering Width mm Headlap (max-min) mm Gauge (max-min) mm Min Pitch 22.5 ROOF TILES AND COLOUR AVAILABILITY HP10 ALPHA 10 PV10 PANNE H2 H10 RHONA10 Argentique Natural Red Burnt Red Slate Serac Chevreuse Old Red Brown Slate Natural Red Dark Brown Natural Red Burnt Red Slate Rustic Red Burnt Red Natural Red Dark Brown Slate Red Flammé Rustique Vieilli Masse Slate Brilliant Black Old Red Red Burnt Red Slate 19

15 PVT 60 SYSTEM SIZES p/a* CO 2 offset p/a (kg)** *** 8 0.48 408 232 4 10 0.60 510 290 5 16 0.96 816 463 8 18 1.08 918 521 9 20 1.20 1020 579 10 24 1.44 1224 695 12 32 1.92 1632 927 16 36 2.

20 15 PVT 60 SYSTEM SIZES p/a* CO 2 offset p/a (kg)** *** * Based on a unshaded south facing roof in the UK, generating 850 units per kwp. Please note, the performance of solar PV systems is impossible to predict with any certainty due to the variability in the amount of solar radiation (sunlight) from location to location, season to season and from year to year. ** Using SAP calculations, the C02 savings per kwh is taken at 0.568kg *** Roof space is based on 350mm batten gauge. Numbers have been rounded to the nearest m 2. WIRING DIAGRAMS 8 PANEL LAYOUT

21 15 WIRING DIAGRAMS 10 PANEL LAYOUT PANEL LAYOUT (HORIZONTAL) PANEL LAYOUT (VERTICAL)

22 15 WIRING DIAGRAMS 18 PANEL LAYOUT (HORIZIONTAL) PANEL LAYOUT (VERTICAL) PANEL LAYOUT (HORIZONTAL)

15 WIRING DIAGRAMS 20 PANEL LAYOUT (VERTICAL) 20 1.

23 15 WIRING DIAGRAMS 20 PANEL LAYOUT (VERTICAL) PANEL LAYOUT PANEL LAYOUT

15 WIRING DIAGRAMS 36 PANEL LAYOUT 36 2.

24 15 WIRING DIAGRAMS 36 PANEL LAYOUT PANEL LAYOUT PANEL LAYOUT

25 15 WIRING DIAGRAMS 52 PANEL LAYOUT PANEL LAYOUT ,

I M E RYS M A R K E T L E A D I N G D UA L WA R R A N T Y AA GUARANTEE

a minimum of 80% of designed output for 25 years.

years an output is achieved of less than 80% of the minimum specified at the

to a defect in material or manufacture, Suntech will compensate for the power

make good the output deficiency up to a sum deemed pro-rata to the time the

or b repairing or replacement of a module, a decision to be taken solely by

Aluminium Anti-corrosion of Framework & Water tightness 30 year anti-corrosion

individually and between PV panels within an array provided that the panels have

This Guarantee is reduced to a period of 10 years if the PV panels are not

appropriate Imerys TC installation kit and clips which ensure peripheral

accordance with BS 5534 2003 (Code of Practice for Slating and Tiling) taking

recommendations based on NBS H60 and H65 fixing specifications, wind loading and

Any deviation from this British Standard code of practice including workmanship

In the event of a fault occurring at any time during the first 30 years due to a

26 I M E RYS M A R K E T L E A D I N G D UA L WA R R A N T Y AA GUARANTEE PHOTOVOLTAIC PANELS Solar Panels (Performance) Guaranteed by Suntech to generate a minimum of 80% of designed output for 25 years. (subject to general terms and conditions of manufacture) If, during the first 25 years an output is achieved of less than 80% of the minimum specified at the date of discovery, and in the opinion of Suntech (sole arbiter) the loss is due to a defect in material or manufacture, Suntech will compensate for the power loss by: Either a supplying the purchaser with sufficient replacement modules to make good the output deficiency up to a sum deemed pro-rata to the time the defective modules have been in service. or b repairing or replacement of a module, a decision to be taken solely by Suntech. Aluminium Anti-corrosion of Framework & Water tightness 30 year anti-corrosion Guarantee of the aluminium framework and watertightness of the PV panels individually and between PV panels within an array provided that the panels have been installed in accordance with the manufacturer's recommendations. This Guarantee is reduced to a period of 10 years if the PV panels are not correctly integrated with compatible Imerys TC clay roofing tiles using the appropriate Imerys TC installation kit and clips which ensure peripheral watertightness between the array of panels and the surrounding Imerys clay roof tiles. This Guarantee is also subject to the surrounding tiling being installed in accordance with BS (Code of Practice for Slating and Tiling) taking into account minimum roof pitch, tile suitability and the manufacturer's fixing recommendations based on NBS H60 and H65 fixing specifications, wind loading and zonal fixing calculations. Any deviation from this British Standard code of practice including workmanship could invalidate the Guarantee. In the event of a fault occurring at any time during the first 30 years due to a manufacturing defect (with the exception of incorrect installation or excessive tightening etc) this Guarantee will cover the replacement of the defective items. Similarly, in the event of substandard quality, the supplier will be obliged, without delay and at his expense, to remedy any defects, and if necessary, replace any materials or items deemed not fit for purpose. BS EN ISO 14001:2004 Environmental management system ASSOCIATE MEMBER Innovation for Sustainable Homes 26

EXAMPLES TECHNICAL ASSISTANCE Tel 0161 928

Toekomststraat 18 B-9800 Deinze, Belgium

specification clauses H65 and H60 for each

27 EXAMPLES TECHNICAL ASSISTANCE Tel Facsimile Website Imerys Roof Tiles, Toekomststraat 18 B-9800 Deinze, Belgium NBS Specification Service Detailed roof specification clauses H65 and H60 for each Imerys Clay roof tile are available free of charge from our technical department ASSOCIATE MEMBER BS EN ISO 14001:2004 Environmental management system MCS Approval Pending

IMERYS Environmental Statement

Uniclass IMERYS Environmental Statement L5211 The Imerys Huguenot HP10 Clay Tile Our commitment to sustainable development Cl/SfB (47) Ng2 Large format interlocking clay roof tiles IMERYS has a corporate