MOUNTING SYSTEM FOR SOLAR POWER SYSTEMS PLANNING AND DESIGN

Transcription

1 Instruction sheet MOUNTING SYSTEM FOR SOLAR POWER SYSTEMS PLANNING AND DESIGN Original instruction sheet for installers

2 Proven quality simply clever With the for solar power systems, you have purchased a high-quality product from the SolarWorld AG product range. To ensure that the solar power system runs smoothly, all components selected and used in the mounting system are of the highest quality. The following instructions describe the correct installation of the based on an example. This should help you to easily install the mounting system. The appearance of special structural features must be documented so that the unique features of the roof can be considered in the system planning. 2

3 Contents A B C D E Page Notes on safety A1 Classification of the safety instructions 4 A2 Safety instructions 5 A3 Notes on system planning 6 A4 Notes on installation 7 System description B1 Intended and improper use 8 B2 Technical overview 9 B3 System construction 10 Installation example C1 Defining the system position 13 C2 Roof area measurement 14 C3 Placing supports 15 C4 Module installation 16 C5 Installation second row 17 C6 Heavy load rail 18 C7 Placing ballast stones 19 C8 Connecting modules 20 C9 Grounding/electric bonding 21 Maintenance/cleaning Maintenance and cleaning 22 Liability Liability 22 3

4 A Notes on safety A1 Classification of the safety instructions Read all installation instructions and observe the safety instructions! Warning signs, signal word DANGER! Warning levels Warns of imminent death. WARNING! Warns of possible death and/or serious injury. CAUTION! Warns of possible personal injury. ATTENTION Warns of damage without the possibility of personal injury. Use of additional information symbols Provides additional important information. Consider applicable accident prevention guidelines during installation. Walking on modules is prohibited. Ensure that the Sunfix Bisun is only used where suitable. During installation, ensure compliance with applicable local ordinances, building standards and accident prevention guidelines. The safety instructions for other system components must also be followed. Failure to follow all instructions listed below may result in electric shock, fire and/or serious injury. Carefully store instruction sheet! 4

5 A2 Safety instructions DANGER! Danger of death from electric shock Solar modules generate electricity as soon as they are exposed to light. The voltage of a single module is lower than 50 V direct current (DC). When several modules are connected in series, the total voltages are cumulative and dangerous. When several modules are connected in parallel, the currents are cumulative. Although touch protection is provided in the form of the fully insulated plug contacts, the following points must be observed when handling the solar modules to avoid the risk of fire, sparking and dangerous electric shock: Do not install solar modules and wiring using wet plugs and sockets! Utmost caution must be exercised during all work on the wiring! The inverter can produce high touch voltages, even when not connected! Exercise caution during all work on the inverter and wiring! WARNING! Danger of falling There is a risk of falling when working on the roof and when climbing up and down. You must observe the accident prevention guidelines and use suitable fall protection equipment. WARNING! Flammable materials Modules must not be operated near equipment or in locations where flammable gases or dusts are emitted or can collect. CAUTION! Hand injuries Hands can be crushed during the installation of support frames and modules. Work may only be carried out by trained sta. Use protective gloves! DANGER! Danger of death from arcing Modules generate direct current (DC) when light strikes them. When breaking a connected string of modules (e.g. when disconnecting the DC line from the inverter under load), a dangerously strong arc can occur. Note the following: Never remove the solar generator from the inverter while it is still connected to the grid. Ensure that the cable connections are in perfect condition (no gap, soiling)! CAUTION! Falling objects f f When mounting on the roof, there is a risk of tools, mounting materials or modules falling from the roof and injuring persons who are present below. f f Cordon o the danger area on the ground before starting installation work, and warn persons in the vicinity. 5

6 A3 Notes on system planning Make sure that the substructure is suitable in terms of load-carrying capacity (dimensioning, state of maintenance, appropriate material specifications), support structure and other aected layers (e.g., insulation layer). Make sure that precipitation run-o is not impeded. Pay attention to the physical construction aspects. The flatness of the roof substructure must be checked and, when necessary, repaired according to professional practice. If you have any doubts consult a specialist (e.g. stress analyst, technical expert). Protect outdoor cables against weathering, UV light and mechanical damage with suitable measures (for example, by laying them in UV resistant plastic tubes or cable ducts). CAUTION! The horizontal forces acting on the PV system from wind loads are transmitted through non-slip mats to the roof structure through static friction. For a correct system design, it is therefore necessary during planing to determine the static friction value between mounting system and roof membrane. ATTENTION! During installation of the mounting system, escape, rescue and maintenance routes must be observed and kept clear! 6

7 A4 Notes on installation Consider applicable accident prevention guidelines during installation. Observe the applicable engineering guidelines during roof installation. Observe the applicable rules and standards during installation and commissioning. Secure people located on the roof of a building 3 m or higher with fall protection. Use cordons to protect people on the ground from falling objects. Also follow the safety instructions of all other system components (e.g. inverters and modules). Only have the system connected to the public grid by a qualified electrician. Note the mounting instructions delivered with modules and inverters, as well as the mounting and wiring plan Ensure that all screw connections are securely fastened. Required tools / Additional required materials Cordless screwdriver Chalk line Allen key 5 mm and 6 mm Torque wrench Tape measure Ballast elements (e.g. paving slabs) 7

8 B System description B1 Intended and improper use Intended use The mounting system Sunfix Bisun is for the installation of solar power modules on flat roofs of conventional design and height. Intended use includes observing the instruction sheet and compliance with the maintenance and cleaning instructions provided. The manufacturer accepts no liability for damage caused by not following the instruction sheet. Improper use This list does not include all conceivable types of improper use and thus does not claim completeness. The advice provided is only intended to convey a sense of improper use. The advice provided in this installation sheet has been disregarded. The mounting system was: not used properly for the fastening of solar power modules, not installed according to the conditions described in this installation sheet (e.g., for the attachment to walls), incorrectly mounted, incorrectly or not maintained, altered, subjected to improper loads. A repair was performed improperly. 8

9 B2 Technical overview The Sunfix Bisun mounting system is a versatile support structure for the installation of solar modules on flat roofs. It is individually prefabricated as a complete kit. The basis of individual planning consists of data from the existing roof structure and the structural requirements (snow and wind loads, etc.) at the installation site. Every system is provided with an system layouts and DC wiring plan specific to your system. These define the arrangement of the Sunfix Bisun elements, as well as the module cabling to the inverter, all matched to suit your roof construction and module arrangement. Properties of the Sunfix Bisun mounting system Permitted building height H 25 m Permitted roof pitch 5 (flat roof) Module tilt 10 Minimum size per module array 3 x 3 modules Maximum size per module array 10 x 10 modules Standard static friction values: Membrane roof with rubber mats (foil-laminated): µ 0.7 Divergent values are possible and can require more or less ballast. The required ballast is determined as part of the system planning and depends on system size, wind load (location, building height), static friction value between system and roof, and presence of a parapet. Flat roof insulation: We assume that the existing flat roof insulation is at least equivalent to the application type DAA dh according to DIN NOTE The positional security of the system is ensured by the dead weight and ballast. The measurement is done according to Eurocode EN Nevertheless, after extreme wind events, but at least once per year, the condition of the system must be checked, since a shift of a few centimeters can never be completely ruled out. 9

10 B3 System construction 7 A 4 B 5 3 Fig. B 3-1 System construction A B Fig. B 3-1 Detail 1 Fig. B 3-1 Detail 2

11 Sunfix Bisun component list 1 Module 2 Front rack 3 Connecting rack 1 4 End rack 5 Ballast tray (237 cm x 30 cm) 6 Ballast stone (e.g. paving slab 30 cm x 30 cm) 7 Heavy load rail 2 6 C C 2 Fig. B 3-1 Detail 3 11

12 Dimensions system construction (For reference only) Fig. B 3-2 System construction Fig. B 3-3 System construction side view 12

13 Installation example C As an example, the installation of a system with 3 x 3 modules is described. C1 Defining the system position NOTE Edge clearances: When installing systems on flat roofs, it should be noted that in the edge areas of roofs, special load assumptions must always be made due to possibly occurring turbulence. Details can be found in EN 1991 (Eurocode 1). Sunfix Bisun systems from Solar- World can only meet these requirements when a constant distance of at least 1.5 m is maintained by the solar power system to the roof edge or parapet. It is not permitted to go below this minimum distance. term slippage by the customer. There are several methods available, as shown in the following list: For roofs with a symmetrical arrangement or a central ridge, protection against slippage can be achieved by bracing the two system parts (equal weight) over the ridge. If other points of attachment are present, it must be checked whether these can also be used. Fixing using a suitable connection to the parapet also represents an alternative, however this must also be checked and implemented by the customer. Securing against slippage: Due to thermal expansion of the metal components of the Sunfix Bisun system from SolarWorld, in extreme cases, movement of the system on the roof in the direction of the eaves may occur. This is relevant for roofs with a tilt angle of 3 or more. In this case, the system must be secured against long- As a rule, all work undertaken by the customer on the roof to provide additional fastening of SolarWorld Sunfix Bisun systems must adhere to the relevant engineering guidelines, in particular in terms of the proper structural sealing of penetrations of the roof membrane. 1,5 m Fig. C

14 C2 Roof area measurement 1. Before beginning installation, the roof must be measured according to planning documents and the first point of installation must be determined. It is advisable to mark the front baseline using the chalk line, and then to measure the lateral boundary line at right angles and to mark it accordingly. Fig. C 2-1 NOTE A maximum of 10x10 modules should be installed in a contiguous generator array. Here, a maximum of only 10 transverse modules may be interconnected! Then, a new generator array must be started in each direction! 14

15 C3 Placing supports 1. After determining the total base area of the system, mark the distance to the front supports, position them and connect them with a ballast tray. To protect the roof membrane, four rubber mats must be placed below each ballast tray. 1,5 m 1,5 m 90 Fig. C 3-1 Fig. C 3-2 Remove plastic film Torque value M A = 15 Nm for M8 bolts Driver: Allen key SW6 2. Place the connecting supports and measure the distance to the front supports. The connecting supports can still be repositioned in the course of the module installation. Then position the next connecting supports. ca mm Fig. C 3-3 Fig. C

16 C4 Module installation Place modules on the fastening supports and tighten the module clamps with 10 Nm. Beginning with the second module, before placement, the cables are attached to the plug connections and these are secured to the module frame using cable tie clips. Fig. C 4-1 Torque force M A = 10 Nm Driver for module clamping: 5mm allen key 16

17 C5 Installation second row 1. After completing the first row, the distance to the next module row automatically results, and the installation process is repeated as from Fig. C 3-2. In the final back row, the end supports are placed and ballast is again added according to planning specifications. The number and positioning of the ballast stones may change depending on wind loads. Fig. C 5-1 Fig. C 5-1 Detail 1 Fig. C 5-1 Detail 2 17

18 C6 Heavy load rail 1. Depending on project specific wind and snow loads a heavy load rail may become applicable to support the modules. If your project documentation reflects the application of heavy load rails, two rails per module are to be attached to each long side of the frame. Make sure that the mounting holes of the rails will align with the mounting holes of the frame. The final position of the rail is locked by two bolts (without nuts). Fig. C 6-1 Fig. C 6-1 Detail 1 Fig. C 6-1 Detail 2 18

19 C7 Placing ballast stones Fig. C 7-1 NOTE Ballast should be evenly distributed. Fig. C 7-2 Fig. C 7-3 Fig. C 7-4 Fig. C

20 C7 Connecting modules DANGER! Potentially lethal voltages Connecting modules in series can lead to potentially deadly voltages! Do not connect the inverter for a test. The solar power system may only be connected to the public grid and activated by an authorized electrician. The technical description provided with the equipment is binding with regard to the installation, electrical connection and operation of the inverter. String 2 String 1 1 Grid 2 Inverter 3 Solar power generator Wire the modules using the connection diagram. You must adhere to the specifications of the connection diagram (allocation of strings, possible switches, cable group). Faulty wiring can destroy the inverter and/or the modules. In order to keep the inductive coupling as low as possible in the event of a lightning current, string feed and return lines (+/-) should be run as close together as possible (avoid looping). The bending radius used for the cables may never be less than the minimum bending radius (5x cable diameter). Do not lay or install modules at temperatures below -5 C. Keep plugs and sockets dry during assembly. 2. Lay the cable group. 3. Here, fasten the cable to the supporting profile using UV-resistant cable ties. 4. Mount and wire the subsequent module rows. Ensure the correct polarity. Testing 1. Check the correct generator interconnection of the multi-string solar generator by measuring the open-circuit voltages of the individual strings. 2. Compare the measured values with the specifications. Values deviating from the specifications are an indication of a wiring fault. ATTENTION! f f Be sure to follow the currently valid instruction sheet for the assembly of multi-contact plug connectors. Only use approved tools for the assembly of the cable groups. Do not deviate from the procedures described in the instruction sheet, since otherwise, neither safety nor compliance with the technical data can be ensured during selfassembly. 20

21 C8 Grounding/electric bonding Proper grounding is the responsibility of the installing company. XX No external lightning protection installed A functional earth is recommended for PV module frames. Connect all electrically conductive parts with each other by appropriate means and then connect them to the equipotential busbar with at least 6 mm² (copper). X X External lightning protection installed PV module frame must be included in the protection concept against direct lightning strike. If necessary, consult a lightning protection company. 21

22 Maintenance and cleaning D ATTENTION! In case of repair, only use original replacement parts! The use of dierent replacement parts can lead to serious property damage and personal injury! Do not walk on modules. Possibly required module cleaning according to Sunmodule user information. In case of heavy soiling (which will result in output reductions), we recommend cleaning the modules using plenty of water (from a hose) without cleaning agents and using a gentle cleaning implement (a sponge). Dirt must never be scraped or rubbed away when dry, as this may cause micro-scratches that have a negative eect on the module performance. The condition of the generator array should be checked at regular intervals (visual check, check of connections). PV system maintenance The following aspects of the system should be checked once every year: Secure mounting and freedom from corrosion of all fasteners. Secure connection, all cable connections are clean and free of corrosion. Cables and front glass are undamaged. Shifting due to thermal expansion. Liability E Since observance of these installation instructions and the conditions and methods of installation, operation, use and maintenance of the Sunfix Bisun mounting system can not be checked or monitored by SolarWorld, SolarWorld AG assumes no liability for any damage arising from improper use or incorrect installation, operation, use or maintenance. Moreover, SolarWorld assumes no liability when SolarWorld, its representatives or vicarious agents cannot be accused of gross negligence or intent. The previous restrictions do not apply to damage relating to injury to life, body or health, as well as in cases applicable to other laws, such as the liability for assumption of guarantee, liability according to the German Product Liability Act (Produkthaftungsgesetz) or in the case of infringements of important contractual obligations (cardinal obligations). Regardless of the previously described limitations of liability, SolarWorld assumes no liability for infringements of patent law or of third party rights arising from the use of the modules and the mounting system, as far as liability is not present under the regulations previously described. The text and the illustrations of this instruction sheet reflect the state of the art at the time of printing. Subject to change without notice. 22

23 Notes 23

24 THE SITES OF THE SOLARWORLD GROUP Production / Research 1 SolarWorld Industries Sachsen / Freiberg, Germany SolarWorld Innovations / Freiberg, Germany 2 SolarWorld Industries Thüringen / Arnstadt, Germany 3 SolarWorld Industries America / Hillsboro, USA 4 Qatar Solar Technologies / Ras Laan, Qatar Sales 5 SolarWorld headquarters/ Bonn, Germany 6 SolarWorld France / Grenoble, France 7 SolarWorld UK / Salisbury, England 8 SolarWorld Italy / Verona, Italy 9 SolarWorld Africa / Capetown, South Africa 10 SolarWorld Asia Pacific / Singapore, Singapore 11 SolarWorld Japan / Yokohama, Japan SolarWorld AG Martin-Luther-King-Str Bonn Deutschland SolarWorld Industries America NW Evergreen Rd. Hillsboro, OR, USA SolarWorld France S.A.S. ZI Bouchayer-Viallet 31, rue Gustave Eiel Grenoble Frankreich SolarWorld Africa Pty. Ltd. 24th Floor 1 Thibault Square Kapstadt, 8001 Südafrika SolarWorld Asia Pacific Pte. Ltd. 107 Amoy Street #03-01 & Singapur Singapur SolarWorld AG Martin-Luther-King-Str Bonn Germany Phone: Fax: service@solarworld.de EN