installation instructions

Transcription

1 Das verknüpfte Bild kann nicht angezeigt werden. Möglicherweise wurde die Datei verschoben, umbenannt oder gelöscht. Stellen Sie sicher, dass die Verknüpfung auf die korrekte Datei und den korrekten Speicherort zeigt. installation instructions for aleo solar modules S_16, S_17, S_18, S_19 S_24 S_77, S_79 installation instructions Ed. 01/2012 en-gb-intl (120508b)

2 2012 aleo solar Deutschland GmbH This manual is protected by copyright law. All rights reserved. Copying, distributing, translating, and transferring into any kind of electronic medium or any kind of machine-readable form in whole or in part is not authorised. The production of a single backup copy for personal use is permitted. This document was created by aleo solar according to the best of its knowledge. However, aleo solar does not accept explicit nor implicit liability for the completeness or accuracy of the information provided. The performance characteristics indicated are only binding if they have been explicitly agreed upon within the contract. aleo and aleo solar are registered, protected trademarks of aleo solar AG. Distribution and Customer Services: aleo solar Deutschland GmbH Osterstrasse Oldenburg Germany T +49 (0) F +49 (0) service@aleo-solar.com Manufacturer Address: aleo solar AG Marius-Eriksen-Strasse 1 Gewerbegebiet Nord Prenzlau Germany T +49 (0) F +49 (0) info@aleo-solar.com Printed in Germany Page 2/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

3 Contents 1. Safety Information Warnings Notices Other system components About this Manual Audience Chapters for planners Chapters for installers Chapters for operators Key Safekeeping of this document Introduction Normal use Product support Handling of aleo Modules Mechanical precautionary measures Electrical precautionary measures Planning Selecting a location Alignment (azimuth) Inclination (elevation) Avoidance of shadowing Visual precautionary measures Selection of aleo modules General installation options Visually appealing installation Defined Installation Options Anti-theft protection Matching of solar modules and inverters Electrical installation Precautionary measures Preparing for Installation Storing, transporting and unpacking modules Precautionary measures Mechanical Installation Visually attractive roof installation Types of installation Support area Spacing and clearances Electrical Installation Order of work steps Series connection Wiring Parallel switching, special requirements String diodes Installation of direct current string fuses Inverter connection Protective potential equalisation (earthing) Lightning protection aleo 9. Mechanical Mounting Details Position of mounting rails Configuration of the clamps for clamp mounting Mounting with clamps Mounting with bolts Lay-in mounting Load levels Diagram key Diagrams Maintenance Inspection Check-up Inspections Cleaning Repairs Potential Induced Degradation (PID) Decommissioning Disposal Taking Back Scheme PV Cycle A. Parameters of aleo Modules B. Creation and Avoidance of Shadowing B.1 Deepest shadow and half shadow B.2 Shadows from cylindrical objects B.3 Shadows from edges C. Optimisation of Wiring for Lightning Protection. 52 C.1. Keep loops small C.2. Current direction in loops C.3. Laying the return circuit D. Explanations D.1. Abbreviations D.2. Glossary E. Index F. Bibliography installation instructions Edition 01/2012 en-gb-intl (120508b) Page 3/60

4 1. Safety Information Solar modules may only be installed or serviced by properly trained professionals. Solar modules can create high direct voltages that can be lifethreatening if handled improperly. Therefore, this installation manual contains important hazard notices, warnings, and other precautionary information. For your own safety, please observe these guidelines. Please carefully read through the safety information and familiarise yourself with the proper handling of the modules before attempting to install, operate, service or dispose of any modules. If you act with caution and care during installation and operation then you will already be following a large part of these rules Warnings Warning notices on modules The following symbols can be found on the modules: CAUTION When this symbol appears additionally on a danger or warning product label, it warns against dangerous electric current which can lead to personal injuries if the instructions are not followed Warning notices in the manual GID AS039c CAUTION CAUTION indicates a potentially dangerous situation that, if not avoided, can lead to slight or moderate injury Notices Notices on modules GID AS061a i Read Manual If this symbol also appears on the product label, then it is instructing you to read this installation instructions Notices in the manual in the manual indicates a potentially dangerous situation that, if not avoided, can lead to material damage. RECOMMENDATION RECOMMENDATION in the manual indicates an important fact or a useful piece of information. GID AS033c This is the danger notice symbol. It is used in various forms in this manual as a warning against possible danger of personal injury. Follow all safety instructions following this symbol in order to prevent injury or death Other system components Please follow the instructions and heed the safety information in the manuals for other components of your photovoltaic system such as inverters, combiner boxes, or fire prevention switches. The following notices appear throughout this manual in order to warn against potential dangers or to provide information that clarifies or simplifies a process. GID AS044c DANGER DANGER indicates an immediately dangerous situation that, if not avoided, will inevitably lead to death or serious injury. GID AS033c WARNING WARNING indicates a potentially dangerous situation that, if not avoided, can lead to death or serious injury. Page 4/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

5 2. About this Manual This installation instructions contain the information needed to plan, install, operate, and service framed aleo modules. aleo If you either sell or transfer your aleo modules, please ensure that the buyer or recipient is given this documentation. Please verify the receipt of this document in writing and retain a copy thereof for your records Audience This installation instructions are directed at the following readers: planners installers operators Chapters for planners Ch. 1, Safety Information Ch. 2, About this Manual Ch. 3, Introduction Ch. 4, Handling of aleo Modules Ch. 5, Planning Ch. 6, Preparing for Installation Ch. 7, Mechanical Installation Ch. 8, Electrical Installation Ch. 10, Maintenance 2.3. Chapters for installers Ch. 1, Safety Information Ch. 2, About this Manual Ch. 3, Introduction Ch. 4, Handling of aleo Modules Ch. 5, Planning Ch. 6, Preparing for Installation Ch. 7, Mechanical Installation Ch. 8, Electrical Installation Ch. 9, Mechanical Mounting Details Ch. 10, Maintenance 2.4. Chapters for operators Ch. 1, Safety Information Ch. 2, About this Manual Ch. 3, Introduction Ch. 4, Handling of aleo Modules Ch. 10, Maintenance Ch. 11, Decommissioning 2.5. Key The symbols used in this manual have the following meanings: Listing Chapter 4th order [1] Literature references, see Appendix F, 'Bibliography' 2.6. Safekeeping of this document Operators must keep this installation instructions in a safe place. It contains information necessary for the maintenance, care, and potential resale of your aleo modules. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 5/60

6 3. Introduction Thank you for choosing aleo modules. aleo solar manufactures high-quality, state-of-the-art solar modules that will supply environmentally-friendly energy generated by sunlight for many years when correctly installed and properly operated. This manual contains important information for planning a photovoltaic system and about the installation and maintenance of aleo modules. Please read the following installation and operation information thoroughly before installing, operating, or servicing aleo modules and be sure to follow the instructions in this document. First and foremost, please take careful note of the safety information! GID AS033c WARNING The danger, warning, and caution notices, as well as the information and procedural instructions in this manual are obligatory. Follow these instructions in order to avoid endangering life and limb. Doing so will also prevent damage to your photovoltaic system or building. The recommendations in this manual help ensure that your photovoltaic system achieves optimum energy yields and a long service life under the given conditions. These recommendations are not obligatory. You may deviate from these recommendations in order to take into account local circumstances. In this manual, recommendations are identified by the words 'recommendation', 'recommend', etc Normal use aleo solar offers a wide range of solar modules. aleo modules are designed to be used for the production of electrical energy in grid-connected photovoltaic systems. If you would like to use them for another purpose, e.g. to directly charge a battery, then please pay attention to the notices in this document. aleo modules were developed for stationary use. Do not install aleo modules on vehicles and do not use them in air, space, or sea travel applications. aleo modules are suitable for installation in coastal areas. More detailed information can be found in Ch , 'Coastal areas'. aleo modules are suitable for installation near facilities where animals are kept. More detailed information can be found in Ch , 'Proximity to facilities where animals are kept'. Do not use aleo modules if they are exposed to concentrated sunlight or strong artificial light, nor if they could be submerged in water or other liquids or are exposed to vapours. Product-specific information (e.g. the datasheet) for a certain module type may contain more specific or, in some cases, differing information. aleo modules should only be used for the purpose for which they were intended as described in the product-specific information. Page 6/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

7 3.2. Product support aleo solar is continuously working on the further development of its products in order to be able to provide you with consistently high-quality, safe, and state-of-the-art products. We also make use of information and ideas from planners, installers, and operators to monitor and improve the quality of aleo modules. For questions about: system design and monitoring system components services please contact aleo solar Customer Services: Distribution and Customer Services: aleo solar Deutschland GmbH Customer Services Osterstrasse Oldenburg Germany T +49 (0) F +49 (0) service@aleo-solar.com installation instructions Edition 01/2012 en-gb-intl (120508b) Page 7/60

8 4. Handling of aleo Modules The information and warnings in this chapter apply to solar modules even if they have not yet been installed. DANGER aleo modules may only be installed by properly trained professionals with a high level of experience as the modules can generate dangerous DC voltages in storage as well as during installation, operation, and maintenance. Abide by all relevant laws, regulations, guidelines, safety measures and standards (recognised state-of-the-art), etc. when handling solar modules. GID AS044c Proceed with caution when installing, operating, maintaining and disposing of solar modules in order to prevent accidents (e.g. electric shocks or injuries). Keep unauthorised persons (e.g. children) and animals away from photovoltaic systems. For work on rooftops, ensure that sufficient safety precautions have been taken for all persons involved, e.g. to prevent falls. Take particular note of the relevant provisions regarding work safety and accident prevention for the respective activities ([1], [2], [3], [4], [5]). Take note of the packaging instructions on the module box. Do not alter aleo modules, their parts, and any labels applied by aleo. Do not attempt to modify or disassemble aleo modules. Do not apply paint, pen or adhesives to the front or rear side of an aleo module, but, if necessary, these may be applied exclusively on the frames. aleo modules are generally combined with further components to create a photovoltaic system. Please also follow the installation and operational guidelines for these additional components Mechanical precautionary measures GID AS033c GID AS033c WARNING Do not, under any circumstances, stand or sit on solar modules. This prevents injuries through possible cracking, breaking or splitting of the glass. This will also prevent: micro-cracks in the cells and resulting yield losses other, potentially serious damage to the cells Avoid knocks or blows to the surface, the edges, and the corners of the glass panes as this could break or split the glass. WARNING If the glass of a module is broken, cracked or split, live electrical parts may be exposed, creating a danger of electric shock. Only use modules with flawless insulation. GID AS039c CAUTION Wear suitable protective gear (e.g. gloves and protective goggles) in order to avoid injury that could occur from broken glass in the form of flying glass shards or sharp glass edges. Be especially careful while handling the edges and corners of the glass panes in unframed modules. Avoid breaking or splitting the glass panes as this could cause personal injury. Always wear work gloves when handling aleo modules. This prevents injury resulting from contact with module corners or edges. Always safely set down aleo modules. Never allow modules to stand freely or unsecured. Handle aleo modules with care. Do not drop the modules, avoid knocks, and do not let any objects fall onto the modules ([29], [30]). Do not place any tools on the glass surfaces. Page 8/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

9 Insulating back sheet The insulating back sheet in some aleo modules protects against the effects of weather and helps the electrical insulation. GID AS033c WARNING A damaged rear-side insulating foil can cause electric shock. A damaged insulating back sheet can also cause short-circuits or ground faults which may in turn cause fires. GID AS039c CAUTION The voltages of modules add up when modules are connected in series. Such a series connection can create very high voltages. In a parallel connection the module currents add up. Even a single module can generate a significant current. Ensure that this back sheet remains undamaged. Prevent the module rear side from coming into contact with sharp or pointed objects. A damaged insulating back sheet can cause permanent damage to the solar module (e.g. delamination). Any damages should be immediately repaired by aleo solar or authorised specialists Electrical precautionary measures Always heed the following warnings when handling solar modules: GID AS044c DANGER Do not touch the electrical connections or other live parts of a solar module directly or with a conductive object (e.g. an uninsulated tool)! There is a risk of suffering a dangerous electric shock. This particularly applies if the module has already been electrically connected. If numerous modules are connected in a row, the voltages add up. This can still occur even if the current of the photovoltaic generator has been switched off. GID AS033c WARNING Solar modules create electrical voltage even with low exposure to light. In very unfavourable situations, the voltage of a single solar module can be enough to cause an electric shock ([31]). installation instructions Edition 01/2012 en-gb-intl (120508b) Page 9/60

10 5. Planning The following sections contain important information on the planning of a photovoltaic system with aleo modules. The information and warnings in this chapter are valid even for the planning phase of a photovoltaic system. Please contact the relevant authorities and, in the case of a grid-connected PV generator, the local grid operator in order to arrange for authorisation, as well as to clarify the installation and operational requirements. Also make sure that all your information is up to date Selecting a location Precautionary measures GID AS044c DANGER Sparks or electric arcs can be formed as a result of short-circuits or switching operations in photovoltaic systems. Therefore, make sure to avoid the installation of solar modules near easily flammable solid, liquid, or gaseous materials Solar irradiation Select a location with the best possible solar irradiation for the photovoltaic system that is going to be set up. Take into account changes in light conditions over the course of the entire year. Try to select an installation location where solar modules will receive sunlight without any shadowing from 9 am to 3 pm local time, even on the shortest day of the year. Avoid locations in which, over the course of the day or year, there is systematic shadowing due to neighbouring objects or buildings (see Ch. 5.4, Avoidance of shadowing) Planning Resources The following sources of information can be useful for the general assessment of a location: tables, e.g. about meteorological data for the region of the location and/or software applications, e.g. for snow load and wind force zones etc. These planning resources can help produce more accurate yield predictions. For a defined site, mobile measuring devices can also be useful for assessing shadowing and measuring inclination. For example, these are equipped with: a GPS receiver an electronic spirit level an electronic compass a fisheye camera a display for measured values or, respectively, the visible section of the sky including the sun's orbit over the course of the day and year Snow and wind loads The necessary substructure and the installation details for aleo modules are dependent on the highest expected load levels (see Ch. 7, 'Mechanical Installation'). Therefore, expected snow loads and wind forces at the location should be taken into consideration during the planning phase. The expected pressure load level at a location is dependent on the snow load/wind zone, the elevation, and the inclination of the building s roof, etc. Always take local regulations into consideration. In Europe, for example, these are DIN EN or DIN 1055, parts 4 and Coastal areas aleo modules are suitable for installation in coastal areas. However, it should be avoided as much as possible that modules come into any contact with seawater. For example, this can be caused by: splashing water spray water dripping from cliffs with salt deposits saline particle deposits carried by the wind Choose the distance from the coast depending on the defined conditions at the planned installation site. As the selection of a location is dependent on a variety of factors, aleo solar can only provide general recommendations. The extent to which a photovoltaic system comes into contact with salt spray or salt water is dependent on the salinity of the sea water, the prevailing wind and precipitation conditions, and a number of other local circumstances such as neighbouring buildings or cliffs Proximity to facilities where animals are kept aleo modules are suitable for installation near facilities where animals are kept (ammonia resistance). If you have any questions regarding test certificates, please contact aleo solar Customer Services (see Ch. 3.2, 'Product support') Alignment (azimuth) Set up the solar modules facing south in the northern hemisphere facing north in the southern hemisphere These alignments generally result in the greatest yield. Page 10/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

11 Special requirements If you have any special requirements for your system (e.g. an island system) or if there are any special circumstances at the intended location, a different alignment may merit consideration. These special requirements may include: a specific desired main usage phase an especially clear view of the sun's path at the location For example: if the desired daily main usage phase of a system in the northern hemisphere is during the evening and if the location has a particularly clear view of the sun's path to the south-west, then a southwest alignment may be more advantageous Inclination (elevation) Minimum inclination Incline the surfaces of the solar modules at an angle at least 10 from horizontal so that precipitation can run off and therefore facilitates the self-cleaning of the modules. For optimal self-cleaning, we recommend an inclination angle of at least 15 from horizontal Optimum inclination The optimum inclination angle for power output is particularly dependent on the latitude at the location and the desired main usage phase for the photovoltaic system. Typical inclination angle values for Europe are around 20 in Southern Europe, around 30 in Central Europe, and around 40 in Northern Europe. The following formula can be used to estimate the optimum inclination: Horizontal angle = latitude at the location - 20 More exact values for a chosen location can be taken from corresponding tables or a suitable calculation programme Tracking installation If you would like to use an automatic tracking system, please observe the guidelines and requirements of the tracking system manufacturer. An automatic tracking system can ensure higher yields, particularly in summer, but it also entails substantially higher installation and maintenance costs Avoidance of shadowing aleo Avoid shadowing of the solar modules. In particular, this also applies to small-scale shadowing from small nearby objects such as antennas or lightning protection systems. If there is systematic shadowing over the course of the day or year at the location due to neighbouring objects and there is no way of changing this shadowing then consider a different location OR only plan to use the non-shadowed area at the location for your photovoltaic generator Effects of shadowing Even the shadowing of a single module or a single solar cell can have a noticeable effect on the performance of the entire photovoltaic system. If shadows fall on individual solar modules of a photovoltaic generator or on individual solar cells of a solar module, the shadowed parts generate less or even no further electrical output. This can have an effect on the yield of an entire module string and, subsequently, the whole generator. Shadowing also often means that a portion of the electrical output created in the module no longer contributes toward the yield because it is consumed by the solar cells in the shadowed area instead. This can cause a rise in the temperature of the shadowed cells compared to the normally lit cells. In extreme cases, this can create a fire risk. Extended or systematic shadowing can cause significant yield losses. Furthermore, over the long run, this can lead to accelerated aging and therefore output losses or even failure of the photovoltaic generator. Consequently, such shadowing dependent on the time of day or year (particularly in winter) caused by parts of buildings, for example, should be avoided in order to optimise the yield and service life of your system. More details regarding avoidance of shadowing can be found in Appendix B, 'Creation and Avoidance of Shadowing' Protective devices within the modules aleo modules are equipped with bypass elements that, in the case of shadowing, ensure that increased temperatures caused by internal power consumption remain at uncritical levels, thereby protecting the module. Systematic shadowing should also be avoided as these bypass elements should not be subjected to regular, longer-lasting loads. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 11/60

12 5.5. Visual precautionary measures Do not artificially concentrate or directly reflect sunlight on an aleo module. Do not use any lenses or mirrors. If your photovoltaic generator is located in an area with strong reflections (e.g. due to snow or areas of water) then the maximum performance of the photovoltaic generator may be increased. This is non-critical for aleo modules. However, please take this situation in consideration when dimensioning and selecting your inverter (see Ch Matching of solar modules and inverters ). 1 a b 5.6. Selection of aleo modules Select the aleo module type that is best-suited to your concrete system. A main distinguishing feature among modules is whether they are made from mono or poly-crystalline cells. Which cell type is best-suited to your needs depends on your goals and expectations. The following general rules can make this decision easier: Mono-crystalline cells have: an octagonal shape (square with bevelled corners) a black base colour. - this base colour can vary depending on the actual cell being used. Poly-crystalline cells have: a square shape a bluish base colour - this base colour can also vary depending on the actual cell being used. 2 3 Fig. 1 Mono-crystalline and poly-crystalline cells with white, grey and black back sheet (diagram) a: mono-crystalline cells, b: poly-crystalline cells; 1: white, 2: grey, 3: black back sheet. Only use modules of the same type, the same cell type, and the same output class within a module string. Doing so will optimise your energy yield. If you connect numerous module strings to an MPP tracker in parallel, make absolutely sure that you use the same number of modules for every one of the module strings connected in parallel. Deviating from this procedure can have a significant effect on the output of a photovoltaic system, increase the risk of damage, and reduce the service life of the modules. Information on how to match aleo modules and inverters can be found in Ch. 5.11, 'Matching of solar modules and inverters'. Page 12/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

13 5.7. General installation options WARNING Mount the aleo modules in such a way that they can withstand expected loads and weather-related influences. The supporting structure should be laid out to support all locally expected snow and ice loads, as well as wind forces (and suction forces). In regions with especially high snow loads, supporting measures on the rear side of the module are necessary. Details on the mounting options for different loads can be found in Ch. 9, 'Mechanical Mounting Details'. If you have any doubts, please contact aleo solar Customer Services (see Ch. 3.2, 'Product support') Roof installation WARNING Only install solar modules on roofs that have a so-called fire-resistant surface according to DIN [15], e.g. on roofs made of tiles, metal, or shingle. Do not, under any circumstances, install solar modules on a thatch roof or on any other kind of roof that has a so-called soft surface, such as roofs made from straw or wood shingles. For rooftop installation, the following options apply: On a flat roof: Installation on supporting stands. GID AS033c GID AS033c On a pitched roof, the above, plus: on-roof installation aleo in-roof installation More information on installation options can be found in Ch. 7, 'Mechanical Installation'. WARNING Installation on roofs requires special sub-structures in order to properly mount the solar modules. Ensure that the sub-structure used, including all individual components, adheres to the relevant laws, regulations, guidelines, etc. Evenness of the substructure GID AS033c Construct the substructure in such a way that the mounting surface is flat (even) for the modules. This will make mounting the modules easier and increase the durability of the mounted modules against mechanical loads. It will also help prolong the service life of the modules. Avoid an arched or warped mounting surface at all costs. Even out height differences in the roof construction with suitable additional components. More details about mounting options for aleo modules can be found in Ch. 9, 'Mechanical Mounting Details' Free-field installation In a free-field installation situation, ensure that the lower edges of the modules have sufficient clearance from the ground. This serves to prevent soiling through spray water or through blown/accumulated snow, as well as possible shadowing by vegetation. 1 Hard roofing includes: roofing that is listed as resistant against flying sparks and radiant heat according to DIN roofing made from natural and artificial stones according to the DIN 4102-A building material class metal roofs according to the DIN 4102-B and DIN 4102-B1 building material classes various types of bitumen sheeting according to DIN 52128, DIN 52130, DIN and DIN in at least double-ply roofing covered completely with gravel filling (at least 5 cm thick, 16/32 graining, specific surface weight of at least 80 kg/m²)) roofing that is completely covered with mineral panels roofing with a test certificate according to DIN installation instructions Edition 01/2012 en-gb-intl (120508b) Page 13/60

14 5.8. Visually appealing installation In order to install the modules on a roof in a visually appealing way, please observe the following guidelines: Substructure Right-angled Construct the substructure in such a way that mounting surface is at a right-angle. A parallelogram or trapezoid shape can create an optimal surface for module installation, but it may make the module field appear inaesthetic, which may not be desirable for the operator. The necessary width of the mounting rails is also determined by the intervals between the rafters. A horizontal displacement of the modules may result in an undesirable protruding of rail ends in some rows. When laying out modules in a parallelogram or trapezoid shape, offsetting the rows by a half or a whole module width between neighbouring rows may create the most attractive effect. If necessary, plan an alternative module orientation (e.g. horizontal) or plan with modules that have different external dimensions. Orientation of the rails Lay rails that run parallel to the ridge horizontally. Check the orientation of the rails, e.g. with a spirit level and a masonry cord. Lay rails that run vertically to the ridge so that their upper edge is horizontal. Check the orientation of the rails, e.g. with the help of a square, a spirit level and a masonry cord Modules Horizontal orientation Always mount the modules so that one module side has a horizontal orientation. For vertical installation, this is the short side, in horizontal installation, the long side. Check the orientation of the modules, e.g. with a spirit level and a masonry cord. Avoid a slanted orientation of the modules in which none of the module sides are horizontal. Such an orientation may, in some situations, optimise the roof surface for mounting the modules, but, the module field may be far less aesthetically pleasing ('saw-tooth pattern') which is almost always undesirable for the operator. GID AS055a Fig. 2 Module alignment in a parallelogram shape (offset at a half-module interval) GID AS056a Fig. 4 Module orientation to be avoided (no horizontal edge) Interval between frames Leave a gap of at least 3 mm between individual frames (see also Ch , 'Spacing between the module frames'). GID AS057a Fig. 3 Module alignment in a trapezoid shape (offset at a halfmodule interval) Page 14/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

15 Avoid flush installation. This is an option (see also Ch , 'Spacing between the module frames'), but, aleo solar recommends mounting at intervals. This applies particularly to bolt or lay-in mounting systems. Uniform configuration In a sequence of modules, ensure uniform configuration within a row. Doing so for module fields with numerous rows makes it easier to achieve an aesthetic appearance. Measure the intervals between the modules when laying a row. If, for example, you start mounting a module row from the left, measure the gap to the upper-left corners of the neighbouring modules. Use this same interval for all the modules in the row. aleo Avoid measuring the module intervals only with a gauge (e.g. a spacer). As module frames may vary slightly in terms of width, this may lead to the rows below ending up with a slightly different overall width. This, together with the row above, can create an inaesthetic effect as the edges of the modules on the sides are no longer properly aligned. In the case of numerous rows on top of one another, this effect may become more pronounced ('V pattern'). Also, only use a well-orientated first row as a reference point for the orientation of the rows below it. Always measure the intervals between modules for the following rows. b b b The following illustration shows a uniform configuration allowing for tolerances in the width of the module frame (the diagram of the differences is exaggerated): a a a b b b GID AS059b Fig. 6 Configuration to be avoided with equal space between modules (diagram exaggerated) GID AS058b Fig. 5 Uniform offsetting of the same module corners (diagram exaggerated) 5.9. Defined Installation Options Installation location On-roof installation Attach aleo modules with clamps or bolts to at least four support points. If there is a pressure load > 2,400 Pa, only clamp the modules symmetrically. Symmetrically means: all clamps are an equal distance from the nearest module corner. Bolt fastening is also symmetrical fastening. For symmetrical fastening, a dual-layer mounting system may be necessary, depending on the installation conditions (e.g. the distances from existing tile rows); see also Ch , 'Identical mounting rail intervals in rows/columns'. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 15/60

16 More information on possible substructure variations can be found in: Ch , 'Asymmetrical and symmetrical clamping' Ch , 'Differing mounting rail intervals in rows/columns' Ch , 'Identical mounting rail intervals in rows/columns' When using a lay-in system, only mount the modules in a line on the long side. Also, please observe the guidelines provided by the mounting system manufacturer. Details can be taken from the diagrams in Ch. 9, 'Mechanical Mounting Details'. In-roof installation Only mount aleo modules with the long side supported along its entire length. Also, please observe the guidelines provided by the mounting system manufacturer. Details can be taken from the diagrams in Ch. 9, 'Mechanical Mounting Details'. Free-field installation Attach the aleo modules to at least four support points as per an on-roof installation. When using a lay-in system, modules may be lined up on both the long and short sides. Also, please observe the guidelines provided by the mounting system manufacturer. Details can be taken from the diagrams in Ch. 9, 'Mechanical Mounting Details' Installation orientation of the modules Vertical installation (portrait orientation) When using vertical installation, mount the modules in such a way that the outlets for the cables on the module or its junction box point towards the ground. This prevents water penetration. This also applies to modules without their own connecting cables. GID AS008b Fig. 7 Correct position of the junction boxes when mounted vertically Horizontal installation (landscape orientation) In horizontal installation, try to mount the modules in such a way that the outlets for the cables on the modules or their junction boxes are on the inside of the photovoltaic generator. Avoid the area along the edge of the photovoltaic generator. Doing so will help minimise the influence of the local environmental conditions such as wind or rain. This recommendation correspondingly also applies to modules without their own connecting cables. GID AS009b Fig. 8 Recommended position of the junction boxes when mounted horizontally Clamp installation Ensure that there are: sufficient clamp and support areas so that the aleo modules remain firmly fastened to the substructure, even under high loads; open drainage holes for the drainage of water from the hollow frame. Clamping on the long sides Clamp aleo modules preferably on the long sides. Clamping to the short sides Clamping aleo modules by their short sides is also an option. Make sure that the modules are only clamped symmetrically Asymmetrical and symmetrical clamping The actual pressure load expected at the installation site determines the correct way to clamp the modules. In most cases, there is a degree of freedom during planning regarding how to select the spacing of the mounting rails, e.g. in order to be able to adapt the orientation to existing tile rows. This can simplify the installation process and reduce costs. Asymmetrical clamping provides the greatest number of options because even within a module row (or column, see below) the clamp interval to the nearest corner on a module side can vary. There are also some variations for symmetrical clamping. Within a module row (or column), the clamp interval to the nearest corner of a module side is always the same. This interval can, however, be varied for each module row (column). Page 16/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

17 c GID AS054a r aleo Symmetrical clamping Symmetrical clamping means that all clamps on both (long or short) module sides are the same distance from the nearest corner. Modules should always be clamped symmetrically in these cases: the pressure loads at the installation site exceed 2400 Pa modules are clamped on the short side The interval of the rails for a particular module row or column can be different for each module row or column. This allows for a certain degree of freedom with respect to the spacing of the mounting rail pairs. Fig. 9 Definition of module columns and module rows c: module column, r: module row Asymmetrical clamping Asymmetrical clamping means that the clamps on one and the same long module side can have differing distances from the nearest corner (see below). Make sure, however, that the opposing clamps maintain the same interval from the respective corner. Asymmetrical clamping is possible under the following conditions: the expected pressure loads at the installation site are a max. of 2400 Pa modules are clamped on the long side. This allows for the most freedom in planning the substructure. For example, in vertical module on-roof installations, the mounting rail pairs of the module rows can be arranged in such a way that the mounting rails are spaced at differing intervals, thereby making use of the mounting options to best fit the height of the tile rows. Fig. 11 Symmetrical clamping, example 1 GID AS011b b1 b1 a5 a5 a6 a6 a1 b2 b2 a2 a3 GID AS012b Fig. 12 Symmetrical clamping, example 2 a4 GID AS010b Fig. 10 Asymmetrical clamping, example installation instructions Edition 01/2012 en-gb-intl (120508b) Page 17/60

18 Differing mounting rail intervals in rows/columns The interval of the mounting rails for a particular module row or column can be different for each module row or column. This allows for a certain degree of freedom with respect to the intervals of the mounting rail pairs. This applies particularly to asymmetrical clamping and, in certain cases, also to symmetrical clamping Identical mounting rail intervals in rows/columns If the installation situation requires identical intervals for the mounting rails in all module rows or columns, e.g. due to aesthetic requirements, the requirements for symmetrical clamping areas for very high loads, or bolt installations, aleo solar recommends a dual-layer substructure. This makes it possible to align the top layer of profiles independently, for example, from the tile rows. The free space under the modules is also thereby increased, often by more than 45 mm. This means: at high pressure loads, there is a greater degree of freedom regarding clamping and less additional effort required (e.g. omission of additional clamps or supports), the modules are better ventilated from the back and are cooler, which may bring yield advantages Bolt installation aleo modules have mounting holes with a diameter of 9 mm. This makes it possible to also attach the modules with M8 (5/16 inch) size bolts (see Ch. 9.4, 'Mounting with bolts'). A bolt installation requires an appropriate interval between mounting rails. Avoid flush fitting in a bolt installation situation. This is an option (see also Ch , 'Spacing between the module frames'), but aleo solar recommends mounting at intervals Lay-in installation Avoid flush fitting. This is an option (see also Ch , 'Spacing between the module frames') but, aleo solar recommends mounting at intervals. On-roof installation Modules can be lined up on both the long and the short side. In-roof installation Line up the modules exclusively on the long side. Free-field installation Modules can be lined up on both the long and the short side. Also, please observe the guidelines provided by the mounting system manufacturer Anti-theft protection The following list contains a number of anti-theft options (it is not exhaustive): Fill the internal hexagon of the bolt heads with cast resin. Use bolts with a head that separates with a defined torque during installation. Use specially shaped cross slot bolts that can be screwed in, but not out. Engrave a self-explanatory code in the frame, e.g. the Owner Identification Number (acronym: 'OIN') which is made up of five components: city or area code from the vehicle number plate, municipality key, street name, house number, and the initials of the operator. Use a substructure with locking technology that requires special tools for removal. Put a fence around an free-field system. Install CCTV. Install an electronic monitoring system. Avoid driving steel balls into the bolt head internal hexagons. The strong vibration can cause microcracks and yield losses, and lead to a loss of warranty. Also avoid boring the internal hexagons of the bolts. The vibration can also cause micro-cracks and yield losses, and lead to a loss of warranty. Avoid driving in (stamping) identification marks in the frame. The strong vibration can cause microcracks and yield losses, and lead to a loss of warranty. Avoid engraving identification marks into the module glass. This could irreparably damage the module. Page 18/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

19 5.11. Matching of solar modules and inverters Orientate all aleo modules connected to a particular MPP tracker of an inverter in the same direction (same azimuth) and with the same inclination from horizontal (same elevation). If the photovoltaic generator is located in an area with strong reflections (e.g. due to snow or areas of water), the maximum electricity and therefore the maximum performance of the photovoltaic generator may be increased. Please take this into consideration when arranging the inverter. Make sure the aleo modules and the inverters to be used are compatible with one another ([18], [19], [23]). To optimise output, aleo solar recommends always operating photovoltaic generators with at least one MPP tracker. MPP trackers are integrated into most inverters. Details on the MPP tracker can be found in the inverter manual. Some of the literature recommends a slight underdimensioning of the inverter, e.g. to 90% of the expected maximum output of the photovoltaic generator. Other literature recommends that the inverter arrangement should be 100% or a little higher. These arrangement options have the following effects that should be considered during the planning phase: A slightly under-dimensioned inverter has the following consequences: it can be slightly cheaper to purchase it generally leads to smaller yields it can age a little more quickly. A slightly over-dimensioned inverter has the following consequences: it can be slightly more expensive to purchase it generally leads to larger yields it can age a little more slowly. If a single inverter is not sufficient for your situation, then you have the following options: use several MPP trackers or inverters -OR- use an inverter that features several independent MPP tracker inputs. aleo Parallel connection of module strings Parallel connection of module strings can reduce the number of required inverter inputs. Please observe the following information when using parallel connection: Parallel connection of module strings most likely costs less than the use of numerous inverters or MPP trackers. Several inverters or an inverter with several independent inputs for module strings entails higher acquisition costs in most cases. Such a system can, however, achieve higher yields during its planned lifetime that offset or even exceed the additional costs. Only parallel connect those module strings with identically orientated modules 2 the same number of modules modules of the same type and the same output class. Please note the information on the parallel connection of module strings in Ch , 'String diodes' and Ch , 'Direct current string fuses'. Deviating from these recommendations can significantly affect the output of a photovoltaic system, increase the risk of damages, and reduce the service life of the modules Electrical installation GID AS033c WARNING All electrically relevant components of a photovoltaic system (modules, cables, connectors, string fuses, fire prevention switches, DC isolators, inverters, etc.) must be approved for the voltages and currents that can occur in the photovoltaic system under consideration ([20], [22], [24]). GID AS039c CAUTION Only use connecting cables without softeners. This ensures the reliable and safe operation of the system. Information on cable properties can be obtained from the cable manufacturers. 2 Same orientation (same azimuth) and same inclination (same elevation). installation instructions Edition 01/2012 en-gb-intl (120508b) Page 19/60

20 GID AS039c Wiring CAUTION aleo modules are suitable for a maximum system voltage of 1000 V. Details on the maximum system voltage for a certain module type can be found on the product label or on the corresponding data sheet. Local regulations may stipulate a lower voltage. Other components of the system may also require a lower maximum voltage. Design the system in such a way that the maximum system voltage is not exceeded, even in the worst case scenario, e.g. a photovoltaic generator with the current switched off, low outdoor temperatures, and strong irradiation. As a rule of thumb, multiply the open circuit voltage under standard test conditions (STC) by a safety factor of 1.25 (see Appendix A, 'Parameters of aleo Modules'). Regional regulations may stipulate multiplying by a different factor. Avoid cross connection 3 of the modules. A cross connection is, in practice, a frequent source of faults as it leads to more complex wiring Wiring and lightning protection Plan the laying of the cables so that the cables of a circuit span as small an area as possible. This minimises the likelihood of damages in the event of a lightning strike in the area. More careful wiring can pay off in a lower potential for damage. More details on this kind of wiring can be found in Appendix C, 'Optimisation of Wiring for Lightning Protection' Connection and system voltage As a rule, keep the system voltage low. This reduces the voltage load of the electrical components and can lead to a longer service life. If necessary, divide a long module string into numerous strings with the same number of modules and connect these shorter module strings in parallel Cable properties Only use cables that have been approved for use in photovoltaics. This means, for example, that: the insulation of the cable is approved for the maximum open circuit voltage the cable material is compatible with the modules as well as their connectors and cables (forgoing use of softeners) the cable casing can withstand the expected stress loads: temperatures temperature changes moisture (above all humidity) mechanical loads UV-radiation ozone ([17]). aleo recommends using only halogen-free cables. Locally valid regulations may also stipulate their use, for example in interior spaces. Information about cable properties can be obtained from the cable manufacturers. The smaller the area that the wiring takes up, the smaller the voltage that the magnetic field of a lightning current (e.g. through a nearby lightning conductor) induces in the conductor loop (of the module string circuit). Lay all the cables of the module string as follows: form as small loops as possible lay loops next to one another with alternating current directions lay the return circuit of the string as close to the outgoing circuit as possible. 3 In a cross connection, the modules of a string, e.g. made up of 8 modules, are connected in a 1, 3, 5, 7, 8, 6, 4, 2 order. Or, more simply: on the 'way there', every second module is connected (1, 3, 5, 7), on the 'way back' the modules not yet connected are then connected (8, 6, 4, 2). Page 20/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

21 Conductor cross-sections GID AS033c WARNING Always use conductor cross-sections that have a safe ampacity for the highest shortcircuit current of the module string. Information about this can be found in the technical literature ([36]). With a parallel circuit of module strings, please note the corresponding increased short-circuit current. An environment with strong reflections (e.g. snow, areas of water) can increase the shortcircuit currents. As a rule of thumb, for the assumed maximum current, multiply the short-circuit current under standard test conditions (STC) by a safety factor of 1.25 (see Appendix A, 'Parameters of aleo Modules'). Regional regulations may stipulate multiplying by a different factor. For the cabling of a single module string 4 with an inverter, please use copper cables with the following minimum crosssection: For a simple cable length of under 40 m: conductor cross-section at least 4 mm² (AWG 11); For a simple cable length between 40 m and 75 m: conductor cross-section at least 6 mm² (AWG 9). Special cases In the following cases, please do a project-specific calculation: for a simple cable length of more than 75 m, with the use of string combiner boxes for parallel connections of module strings. Matching additional components After determining the necessary conductor cross-sections, please ensure that the intended additional components (e.g. connectors, jacks, clamps) are suitable for these crosssections. Conductor cross-sections in parallel connections Parallel switching of individual module strings can, in some situations, reduce the number of required inverter inputs. In this case, not only plan sufficient conductor cross-sections for the higher currents, but also for the additional components that may be necessary for parallel connections, such as string diodes and/or direct current string fuses for every module string. Details on this can be found in the following chapters String diodes Reasons for string diodes aleo The installation of string diodes is necessary in the following cases: Numerous module strings are connected in parallel and occasional shadowing of individual module strings is expected: The diodes are necessary because the shadowing of a module string can cause a reverse current in the shadowed string. The internal module bypass elements only work for currents in the operational direction. Therefore, this situation can cause an impermissibly high power loss in a single module. By installing string diodes, possible module over-heating and damage can be prevented. The photovoltaic generator is directly connected to a battery: The diodes are necessary because they prevent discharging of the battery via the photovoltaic generator at night. The photovoltaic generator is connected directly to an inverter without reverse current protection: The diodes are necessary because they prevent possible damage to the modules. If the above points are not observed, there is a danger that operation will damage the modules or their bypass elements. According to aleo solar, the installation of string diodes is: Generally recommended for parallel connections with two module strings, Essential for parallel connections with three or more module strings 4 This information is only valid for the cabling of a single module string, not for parallel connection of module strings. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 21/60

22 Connection The following circuit diagram shows how to install the string diodes: Fig. 13 Connection of string diodes, diagram (schematic) Arrangement Only use string diodes: in which the continuous forward current is suitable for at least the maximum expected short-circuit current of the module string (I SC, max ) -AND- in which the reverse voltage is also suitable for at least double the maximum open circuit voltage of the module string (U OC, max ), so that the diode will not be damaged if a module string is accidentally reverse-poled Direct current string fuses GID AS033c WARNING For string fuses, only use direct current fuses that are approved for photovoltaic systems and which safely extinguish the direct current electric arc when triggered. RECOMMENDATION If an unearthed module string has been installed, both connections of the module string and have a floating voltage to earth. In this case, install a direct current string fuse in both connections of the module string. Some inverters are equipped with fuse holders that can be fitted with fuses where necessary. GID AS013b = Specify the fuses in such a way that they are triggered if the current exceeds the maximum reverse current (I REV ) stated in the corresponding data sheet for the modules. Only a trained professional should carry out the dimensioning of the fuses. Corresponding information materials is available from the fuse manufacturers. If string diodes are required (see Ch , 'String diodes') always install direct current string fuses in addition to the string diodes Inverter connection WARNING Make sure that all necessary safety components have been planned for when connecting the inverter. These include depending on specific local regulations for example, DC isolators, direct current string fuses, and/or short-circuiters. If your inverter allows a one-sided earthing of the photovoltaic generator and you would like to earth your photovoltaic generator, aleo solar recommends earthing the negative connection 5 of the module strings. See also Ch. 10.6, 'Potential Induced Degradation (PID)'. aleo solar recommends installation of the following components: a fire prevention switch in a position located before the cables of the photovoltaic generator enter the building GID AS033c a direct current string fuse in every connection / of a string (2 fuses per string) at every inverter input a double DC isolator between every string of the photovoltaic generator and the corresponding string connection to the inverter. DC isolators, direct current string fuses, or short-circuiters are already integrated in some inverters. National regulations may, however, stipulate the use of external components. aleo solar recommends the installation of direct current string fuses. These protect the modules in the event of faults (e.g. faulty inverter, lightning strike). Direct current string fuses also offer basic protection against stray currents and can help prevent fire. Local regulations may even stipulate the use of direct current string fuses. Page 22/60 5 The recommendation to earth the negative connection applies to all currently manufactured aleo modules that contain cells with p substrate. In the future, aleo solar may also offer modules that contain other cells (with n substrate). A special, alternative earthing recommendation may then apply for these modules. installation instructions Edition 01/2012 en-gb-intl (120508b)

23 5.13. Precautionary measures Facade or overhead installation GID AS033c WARNING Structural analysis GID AS033c Only use aleo modules for roof or free-field installation. Do not use aleo modules for facade or overhead installation. WARNING Perform the necessary verifications for the building or property or have the following carried out by professionals: load capacity verification structural integrity verification, usability verification (deflection under load verification). See also the following literature references: [6], [7], [8], [9], [10], [11], [12], [13], [14], [15] and [16] Fire protection GID AS033c WARNING The solar modules as well as the substructure may affect the level of the building s fire resistance. aleo Improper installation may create an additional risk in the event of a fire and when measures are undertaken to extinguish a fire. Determine and follow the relevant requirements of authorities, energy supply companies, insurance companies and fire services as during the planning phase of the photovoltaic system and definitely prior to the start of installation. Install PV system components (e.g. inverters) away from business premises at risk of fire ([45]). Select a different, permitted location. When planning, please also take into account the additional fire prevention components that are recommended, necessary or required, such as fire prevention switches, direct current fuses and/or short-circuit monitoring. GID AS039c CAUTION Take into account the expected snow loads and wind forces at the location. With respect to the structural analysis of the overall building, take into account the additional loads created by the photovoltaic system. Remember, in elevated systems, e.g. on a flat roof, snow or ice may accumulate behind the modules. Fire prevention switch RECOMMENDATION aleo solar recommends the installation of a double fire prevention switch between each string of the PV generator and the corresponding inverter connection. Local, national or international regulations may require a fire prevention switch. Install the fire protection switch so that it is easily accessible and at the point at which cables from the photovoltaic generator enter the building. This allows the current for the direct current devices of the photovoltaic system to be switched off inside the building. Please note that direct current cables directly connected to the inverter may still be live for some time after disconnection from the photovoltaic generator (see also Ch , 'Precautionary measures in inverters'). installation instructions Edition 01/2012 en-gb-intl (120508b) Page 23/60

24 DC Isolator RECOMMENDATION aleo solar recommends the additional installation of a double DC isolator between the photovoltaic generator and the direct current side of the inverter. This makes it possible, if necessary, to switch off the current of the photovoltaic generator and to switch off the DC voltage for the subsequent devices, e.g. for maintenance work to the inverter. Local, national or international regulations may require a DC isolator. Install the DC isolator as close as possible to the inverter. During installation of the DC isolator, also take into account local regulations that may stipulate a specific installation location. Some inverters include integrated DC isolators. Local or national regulations may, however, require the use of an external isolator. Please observe the guidelines in the inverter's manual. Please note that direct current cables that are directly connected to the inverter may still be live for some time after disconnection from the photovoltaic generator (see also Ch , 'Precautionary measures in inverters'). aleo solar principally recommends lightning protection for installation in exposed locations. This includes components such as: lightning rods, lightning protection conductors lightning current arresters. Please also observe the guidelines in Ch , 'Wiring and lightning protection' on minimising damages in the case of a lightning strike close to the system. Existing lightning protection If your building is already equipped with lightning protection, your photovoltaic generator must be integrated into the existing lighting protection system. If the existing lightning protection system is modified, grandfather clauses may become invalid. In the event a grandfather clause becomes invalid, please update your lightning protection system to comply with the latest regulations. Please also observe the regulations that apply for interior lightning protection, e.g. the installation of surge arresters within the building Lightning protection GID AS033c WARNING The planning of lightning protection measures should only be carried out by a professional. Absolutely avoid using the module frame or its earthing as an active part of lightning protection measures. Separate lightning conductors must be used for the connection of the lightning rods with the lightning protection earth in order to ensure the safety and reliability of both the lightning protection measures as well as the photovoltaic system. If the module frame has been earthed, the only purpose of the earthing is to equalise the potential between the module frame and the supporting structure. Page 24/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

25 6. Preparing for Installation 6.1. Storing, transporting and unpacking modules 6.2. Precautionary measures General precautionary measures aleo During storage and transportation, ensure that the aleo modules in the packing units stand vertically and that every module has a sufficient support surface. Secure every module against tipping. Only transport aleo modules standing. Horizontal transportation is not permitted. Only store loose aleo modules so that they are standing on tapered bases with suitable padding. Be sure to use adequate padding also between individual modules. Avoid stacking packing units at all costs. Stacking can cause damage to the modules. Also avoid stacking individual modules and stacking palettes on which there are solar modules. When transporting individual modules, ensure that no pulling or pressure is exerted on the junction box and the cables. Please observe the unpackaging instructions on the module box. Check the mechanical integrity of each aleo module prior to installation. Take particular note of possible damage to glass panes and insulating back sheets, if these components are part of the respective module types. Please check for possible damage to the insulation of cables, connectors and junction boxes. If you find any damages, please bring them immediately to the attention of the supplier or transport company. DANGER Sparks or electric arcs may occur as a result of short-circuits or switching operations in photovoltaic systems. Therefore, make sure to avoid the installation of solar modules near easily flammable solid, liquid, or gaseous materials. During installation on roofs and other elevated locations there is a danger that objects may fall off during the installation process and injure people or animals. Close-off the respective danger area prior to beginning installation work and remove, as much as is possible, all objects from the danger area. WARNING Observe all relevant laws, regulations, guidelines and standards (state-of-the-art) etc. during installation. Take particular note of the provisions regarding work safety and accident prevention. Only allow aleo modules to be installed by authorised professional companies in order to avoid restrictions to the product and service warranty. We strongly recommend that at least two qualified professionals should be involved in the installation of a photovoltaic system. GID AS033c GID AS044c Only install modules in which the glass is undamaged. A module with defective glass is irreparable. If the module has already been installed, it must be replaced. If the module has already been electrically connected, switch off the current of the photovoltaic system before replacing the module, see Ch , 'Precautionary measures in inverters'. During installation and operation of an aleo module, ensure that its glass pane(s) is/are not touching other glass, metal, or any other kind of hard object. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 25/60

26 Electrical precautionary measures DANGER Before working on the electrical components of a module, a module string, or the photovoltaic generator, switch off the current of the photovoltaic generator. This prevents the formation of a dangerous electric arc while creating or disconnecting electrical connections. A photovoltaic generator whose current has been switched off may still be live with high DC voltages. Protect yourself at all costs against possible electric shock. GID AS033c GID AS044c WARNING Only use components that are in perfect condition when installing the photovoltaic system. Do not install any solar modules with visible damage to glass panes, the insulating backsheet, or the insulation of electrical connections. Do not operate damaged solar modules that have already been installed and/or connected. Do not use cables or connectors with visible damages to the wiring. Leave the connecting cables and connectors of the module principally unchanged. Use only approved connection components to connect the modules to other system parts, e.g. inverters or string diodes. GID AS033c WARNING In order to prevent a dangerous generation of electrical energy while handling aleo modules and module wiring, where possible, fully cover the front sides of the modules with an opaque material. For reasons of personal safety, proceed as follows: Disconnect the photovoltaic generator from the inverter with the isolator. If the photovoltaic generator is earthed, disconnect it from its earthing. Opening the isolator almost always switches off the earthing. Ensure the photovoltaic system cannot be accidentally turned on again. Check that the inverter is currentless and that the PV generator is unearthed. If there are parallel connected module strings, electrically disconnect the affected module string and check that electrical disconnection has occurred. Only carry out work on the module after completing all of the above steps. Before connecting or disconnecting electrical components, switch off the current of the photovoltaic generator. If there are parallel connected module strings and work needs to be done on a particular module string, the current of the module string should also be switched off. This prevents possible damage to the bypass elements of the modules. GID AS033c WARNING During the installation or maintenance of live parts, only use approved, insulated tools. Work only in dry conditions whenever possible. Ensure that the electrical connections of the solar modules, the cables used during installation, and the tools used are all dry. Page 26/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

27 Precautionary measures in inverters Observe the following warning for inverters: aleo GID AS044c DANGER For some time after disconnecting the photovoltaic generator, the terminals of an inverter may still be live with a dangerous voltage until the capacities in the inverter have discharged themselves. Read the documentation for the inverter Health and safety protection GID AS039c CAUTION Solar modules warm up as a result of solar irradiation. Under extreme conditions (e.g. high irradiation, high ambient temperature, still air) the module surface and the frame can reach temperatures of 70 C (158 F) or more. This also applies to modules that have been disconnected, had their current switched off, or have been short-circuited. Modules in a string may heat up unevenly. Protect yourself against burns by wearing gloves and, if necessary, other suitable clothing. Protect yourself against solar irradiation when working outside. This applies particularly in the case of strong solar irradiation and longer periods outdoors. Protect yourself by wearing sun protection, as well as by wearing UV-absorbing protective goggles and suitable clothing. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 27/60

28 7. Mechanical Installation Carry out the installation of the photovoltaic system in such a way that the installed photovoltaic system has a high resistance with respect to the environmental influences affecting it (wind, rain, hail, snow, etc.) ([21]). aleo modules are suitable for an increased pressure load of 5400 Pa and a suction load of 5400 Pa [28]. The permitted pressure load correlates to a surface load of approx. 540 kg/m². When mounting with clamps at an angle steeper than 45, we recommend using slip protection that prevents the modules from sliding out of their original position. Locally applicable regulations may, if necessary, require the use of slip protection. Avoid direct contact of the glass surface with the supporting structure during installation. In fixed installations, avoid movement of the base frame onto which a module has been installed. Only use installation material that: is stable and corrosion-resistant prevents corrosions on the solar modules ([32]). Do not under any circumstances drill extra holes into aleo modules or their frames. RECOMMENDATION Information on using anti-theft protection with the need for holes can be found in Ch. 5.10, 'Anti-theft protection'. The following information applies to the modules as long as the product-specific information for the respective module type does not include any instructions to the contrary. Arrange the aleo modules in such a way that the rear junction boxes remain as dry as possible and that no water can accumulate in the sockets. Only install aleo modules: vertically (the short module edge is horizontal, the junction box is at the top) -OR- horizontally (the long module edge is horizontal) Visually attractive roof installation In order to install the modules on a roof in a visually attractive manner, please observe the information in Ch. 5.8, 'Visually appealing installation' during planning Types of installation Framed aleo modules may be installed in the following ways: clamping bolt installation lay-in installation 7.3. Support area If supports are necessary, ensure that the contact surface is at least 70 mm² per support Spacing and clearances Spacing between the module frames Allow for a minimum spacing during installation. This prevents the occurrence of mechanical stress resulting from thermal expansion. When mounting at with spacing between the module frames leave a gap of at least 3 mm between individual module frames. When using flush mounting ensure for an expansion gap of 20 mm, at the least every 7 m. aleo solar recommends mounting at intervals. Also note Ch. 5.8, 'Visually appealing installation'. Please also observe the guidelines provided by the mounting system manufacturer as these may stipulate the use of larger intervals. Details about the mounting options for aleo modules can be found in Ch. 9, 'Mechanical Mounting Details'. Page 28/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

29 Clearance behind the modules Minimal clearance For the ventilation of aleo modules in on-roof or free-field installations, leave a clearance of at least 4 cm between the rear edge of the module frame and the installation surface (e.g. to the roof tiles or to the backing tray in an in-roof installation system). This makes it possible for the module to be cooled through air convection and it allows water to drain off and condensed water to evaporate. Dry, cool operation can have a positive effect on the output and the service life of an aleo module Free space under the modules aleo Leave the space behind the laminate free of objects. This prevents damage to the insulating back sheet and the junction box. Make sure that no conductive bare parts (e.g. bolts or nails) protrude into the space behind the module. a Maximum clearance GID AS041c The maximum permitted clearance is set by national standards. In addition to other functions, this serves to ensure that the installation is suitable for the expected wind and suction conditions. The maximum clearance for an installation is determined by the chosen substructure. Please ensure that the substructure complies with the permitted clearance. Fig. 14 Free space under the module, diagram a: free space Avoidance of sealing Avoid the use of sealant between an aleo module and its installation surface. Such an installation otherwise worsens the ventilation and causes output losses. It can also prevent the drainage of water. These conditions may cause premature ageing and a shorter module service life. Dry, cool operation can have a positive effect on the output and the service life of an aleo module. For an in-roof installation, please ensure for good ventilation through the available options in order to minimise yield losses that result from a higher module temperature. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 29/60

30 8. Electrical Installation GID AS033c WARNING Protect yourself against the danger of an electric shock by wearing suitable protective clothing and following the relevant regulations. Do not alter the connecting cables and connectors of the module. Doing so avoids the danger of an electric shock and upholds the conditions of the manufacturer warranty. Only use approved components and tools for connecting a module string to the inverter. All cabling should be done according to the applicable regulations. Ensure that all connections are in a flawless mechanical and electrical condition. Check that the cover of the junction box is firmly attached Order of work steps For a safe and time-saving electrical installation process, aleo solar recommends carrying out the work steps in the following order: connect the modules into strings if applicable, parallel connect module strings lay the cables to the inverter install the inverter connect the isolator to the inverter connect the fire prevention switch to the isolator connect the cables to the generator side close the fire prevention switch and the isolator 8.2. Series connection Solar modules are usually connected in a row (series) in order to create a module string. String diodes are not necessary when modules are only connected in series at a given inverter input Wiring aleo solar normally delivers its modules with firmly installed junction boxes and flexible connection cables with preinstalled connectors and sockets. Avoid tensile as well as pressure loads on the junction box during installation. This may cause damage to the cable entry points and affect the service life. Also avoid excessive tensile loads to the preassembled plug connections during installation. In plug connections without locks this can lead to loosening or detachment of the plug connections. In plug connections with locks this can, in extreme cases, lead to loosening or detachment of the crimp. This can cause increased transition resistance, heat build-up, and fire hazards. Observe the laying regulations for the respective cable types. Lay all cables in such a way that: you comply with the minimum bending radii (e.g. the 15-fold cable diameter) close proximity to sharp corners and edges is avoided, or the cables are correspondingly protected cables with differing voltages, such as the positive and the negative connection of a module string do not rub against one another module string cables have a sufficient distance from earth, potential equalisation, and lightning conductors all cables run as close to one another as possible in order to minimise the inductive area and, accordingly, the effects of a lightning strike or stray current (see also Ch , 'Wiring and lightning protection'). Carefully lay the wiring to protect the laid cables from damages caused by: direct environmental influences, such as precipitation movements through direct environmental influences, such as wind indirect environmental influences, such as snow or ice that can slip behind the modules. Page 30/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

31 If necessary, only clean soiled sockets, connections, and plug connections mechanically with a damp cloth or very carefully with compressed air. Do not use substances containing oil, fat, or alcohol for cleaning in order to prevent embrittlement of the plastic material that can cause dangerous insulation malfunctions. Do not use any contact sprays in order to prevent embrittlement of the plastic material. Handle all aleo module junction boxes and their connected cables with care. Avoid both heavy pressure and tensile loads. Doing so avoids burst sockets and damage to cable entries which could destroy the protective insulation of the solar module and lead to a danger of electric shock. Furthermore, such damage can significantly reduce the service life and/or the output of a solar module. aleo Installation String diodes often come ready-made and equipped with the right connectors and housing. Select a time with solar irradiation for the installation and, if necessary, remove the covers of the modules so that the module strings create a measurable voltage. This makes it possible to test the polarity with a suitable voltmeter. Connect the following: the anode of the string diode to the positive connection of this module string the cathode of the string diode 6 with the mutual exit of the parallel connection. This connection point leads to the positive direct current connection of the inverter Installation of direct current string fuses If the use of direct current string fuses is planned (see Ch , 'Direct current string fuses'), please install them accordingly. Carefully connect the plug connections and, after plugging in, check that the plug connection and its seal are firmly attached. Do not use excessive force when connecting or disconnecting under any circumstances Parallel switching, special requirements If you would like to connect the module strings in parallel, install the planned string diodes or direct current string fuses in every module string. Details can be found in Ch , 'Parallel connection of module strings' String diodes Interconnection 8.7. Inverter connection Connect the inverter(s) according to the system design, (see Ch , 'Inverter connection'). Pay attention to the polarity of the module strings when connecting a module string to an inverter. Check the polarity of the current provided by the module string with a suitable measuring device before connecting a module string to the inverter. Please observe the instructions provided in the inverter manual Cabling on the AC voltage side Cabling on the AC voltage side of the inverter is beyond the scope of this manual. See also: [33], [34], [35], [36], [37], [38], [39], [40], [41], [42], [43]. = GID AS013b Fig. 15 Interconnection of string diodes, diagram 6 In a diode that is not ready-made, the cathode is usually marked with a ring. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 31/60

32 8.8. Protective potential equalisation (earthing) Protective potential equalisation (earthing) of the module frame may be advisory, necessary, or required. 7 Local regulations may require a protective potential equalisation (an earthing). Please also observe any recommendations from the inverter manufacturer and insurance companies. Be absolutely sure to create a safe electrical connection of the module frame to the substructure for protective potential equalisation. For clamp installation: use earthing clamps with spikes that penetrate the corrosion protection films of the module frame during installation and therefore establish the electrical connection. Alternatively, use special liners between the module frame and substructure that are correspondingly equipped with spikes. aleo solar recommends including the frames of the solar modules in the so-called protective potential equalisation (in other words: to earth). Doing so reduces the danger of electric shock in the event of damages or installation errors. aleo solar also recommends individually earthing of the frames of the solar modules so that the other modules remain earthed when a single module is removed from the photovoltaic system. This protective potential equalisation can be made by taking additional measures in clamp or bolt installation or with the help of earthing holes. Please observe the following information with respect to protective potential equalisation: When clamping to the long side, protective potential equalisation can be achieved together with the clamping, see Ch , 'Earthing through clamping'. When clamping to the short side, protective potential equalisation should be achieved with the earthing holes, see Ch , 'Earthing with earthing holes'. When using bolting, protective potential equalisation can be achieved together with the bolting, see Ch , 'Earthing with bolts'. For lay-in systems, use the earthing holes for protective potential equalisation, see Ch , 'Earthing through clamping' Earthing through clamping aleo solar recommends protective potential equalisation with the help of earthing clamps. These clamps have spikes that penetrate the anodised film of the module frame to create a safe electrical connection. A simple earthing clamp (end clamp) can earth a module frame; an earthing mid-clamp can earth two module frames so that an earthing clamp may only be necessary for every second mid-clamp. a b c Fig. 16 Potential equalisation through earthing clamp (end clamp), diagram a: earthing spike of the clamp, b: module laminate, c: module frame, d: clamp, d: bolt, f: substructure. Alternatively, protective potential equalisation may be done with the help of electrically conductive connection units. These should also have spikes. WEEBLugs 8 (mainly used in the USA) are permitted. a b Fig. 17 Potential equalisation in the case of clamping, diagram a: module laminate, b: module frame, c: clamp, d: bolt, e: electrical connector with spikes, f: substructure. d e f GID AS060a c d e f GID AS019a 7 Notes: modules do not require protective potential equalisation to function. 8 See Ch. D.1, 'Abbreviations'. Page 32/60 installation instructions Edition 01/2012 en-gb-intl (120508b)

33 GID AS043a Local regulations may require an additional connection for potential equalisation, e.g. its own earthing cables that is connected to the connection units. Only suitable connection units should be used. In this case, the substructure should be earthed separately. b c d e f GID AS021c aleo a b Fig. 18 Potential equalisation with cable lug for earthing cable, diagram a: module laminate, b: module frame, c: clamp, d: bolt, e: electrical connector, f: cable lug, g: substructure Earthing with bolts aleo solar recommends the use of earthing clamps. Electrical connectors (e.g. WEEBLugs 9, mainly used in the USA) are permitted. Ensure that the electrical connector has a contact surface area of at least 70 mm². GID AS042a Fig. 19 Bolt connection with earthing, diagram a: bolt, b: locking washer, c: flat washer, d: module frame, d: module frame, e: electrical connector with spikes, f: substructure, g: nut bolt Earthing with earthing holes It is possible to earth a module frame with a bolt connection. The module frames have two earthing holes on each long side near the short side and are marked with the earthing symbol. For potential equalisation when clamping to the narrow sides or for lay-in systems, only earthing holes should be used. c d e f g GID AS020a a b c d e f c b g Fig. 21 Potential equalisation with earthing holes, diagram b: module laminate, c: module frame, d: self-cutting bolt, e: eyelet, f: locking washer. When installing modules with a bolt connection and using suitable additional components, the bolt connection can also provide the required potential equalisation, see Ch , 'Earthing with bolts' Lightning protection GID AS033c WARNING The planning and installation of the outdoor and, if necessary, indoor lightning protection should only be carried out by qualified professionals. Be sure to avoid using the module frame or its protective potential equalisation (earthing) as an active part of the lightning protection system. Be sure to use additional lightning conductors to connect the lightning rods with the lightning protection earthing. Doing so ensures the safety and reliability of the photovoltaic system, as well as its lightning protection. If the module frame is earthed, the only function of this earthing is the protective potential equalisation between the module frame and the supporting structure. Fig. 20 Earthing symbol The diameter of the earthing holes is 4.36 mm; the frame thickness is 2.5 mm. Use suitable self-cutting bolts and a locking washer (both made from stainless steel) for a reliable contact between bolt and eyelet. 9 See Ch. D.1, 'Abbreviations'. installation instructions Edition 01/2012 en-gb-intl (120508b) Page 33/60

34 9. Mechanical Mounting Details 9.1. Position of mounting rails Always position the mounting rails for a module parallel to one another. Position the rails either horizontally or at a right angle (parallel to the roof inclination, upper edge is horizontal). Select the proper length for the rails so that both fastening points of the opposite module sides are attached to the same rail or combine two rails with a connector. Always position the mounting rails at right angles to the module side which will be clamped or bolted. GID AS022a Fig. 22 Permissible positioning of mounting rails GID AS025a a b c d Fig. 25 Impermissible clamp configurations a: Missing clamp; b: Clamps extend outside the frame; c: Opposing clamps are placed at a different distance from the module corner; d: Asymmetrical clamping to the narrow side Mounting with clamps Use clamps suitable for framed aleo modules that firmly attach the module to the substructure and distribute the load over the entire surface of the module frame. Avoid other types of clamping where the load is only distributed over a small area of the module Clamping dimensions Please note the following information regarding clamping length, clamping depth, and the clamping area: Clamping length and clamping depth GID AS023a Fig. 23 Impermissible positioning of mounting rails a 9.2. Configuration of the clamps for clamp mounting Attach at least two clamps per mounting edge (long or short side). Attach all clamps in such a way that they are fully in contact with and within the side of the module frame. Be sure to avoid having clamps that extend outside of the module frames. Attach all clamps to a module symmetrically so that all clamps are the same distance from the nearest module corner. Any exceptions to this rule will be explicitly noted. Please also refer to Ch. 5.8, 'Visually appealing installation'. Fig. 26 a: clamping length; b: clamping depth. b GID AS014a GID AS024a Fig. 24 Permissible clamp configurations a: symmetrical clamping to the long side; b: asymmetrical clamping to the long side (permissible for certain load levels); c: symmetrical clamping to the short side. Page 34/60 a b c installation instructions Edition 01/2012 en-gb-intl (120508b)

35 The required minimum length of a clamping (parallel to the frame side) is 30 mm. The required minimum depth of a clamping (vertical to the frame side) is 3 mm. aleo solar recommends a clamping depth of 5 mm. Depending on environmental conditions (e.g. inclination angle, suction load, or margins of the substructure) a larger minimum surface area per clamping may be required ([44]). The clamps already give the actual clamping depth and clamping length. Please observe the manufacturer s guidelines. aleo Clamping at the mounting hole If the clamping area extends as far as the mounting hole, it is possible to position the clamp so that its edge sits at the level of the mounting hole: e Permissible clamping areas The clamping area permissible for a module depends on the exact way of mounting. c GID AS017a Fig. 29 Permissible clamping at the mounting hole e: Mounting hole on the module rear side Do not under any circumstances install the clamp so that its edge extends over the hole Tightening torque for clamp mounting Tighten the bolts of the clamps until they are 'hand-tight'. If using an automatic power screwdriver, set a suitable maximum tightening torque. More information about this can be found in the manufacturer documentation for the substructure. Fig. 27 Permissible clamping area c: clamp length; d: clamp depth. d GID AS015a 9.4. Mounting with bolts aleo modules have pre-drilled holes for mounting that have a diameter of 9 mm so that the modules can also be fixed with M8 (5/16 inch) size bolts. aleo solar recommends using a locking washer and a flat washer on every side of the module frame. The flat washers should rest on the module frame and the locking washers on the bolt head or the nut. Clamping near the module corner If the given permissible clamping area for a certain way of mounting a module extends to the corner, install the clamp in such a way that it sits fully on the frame of the module: a b c d e c b f GID AS018a Fig. 30 Bolt connection, diagram a: bolt, b: locking washer, c: flat washer, d: module frame, e: substructure, f: nut bolt. The bolt connection illustrated above is only for mechanical mounting purposes. More information on protective potential equalisation (earthing) with help of bolt connections can be found in Ch , 'Earthing with bolts'. Fig. 28 Permissible clamping at corners GID AS016a installation instructions Edition 01/2012 en-gb-intl (120508b) Page 35/60

36 Tightening torque for mounting with bolts With M8 bolts made from stainless steel, 10 a maximum tightening torque of 24 Nm should be used Lay-in mounting Please observe the guidelines provided by the mounting system manufacturer. For protective potential equalization, use the earthing hole, see Ch , 'Earthing with earthing holes'. Flush mounting is an option (see also Ch , 'Spacing between the module frames'), but, aleo solar recommends mounting at intervals. H GID AS040a 9.6. Load levels Loads through snow and wind that must be taken into account for the site at which the modules will be installed are split into three levels. Fig. 31 Clearance H between module frame rear edge and the mounting surface Load level Permissible pressure Load level I 2400 Pa (equivalent to approx. 240 kg/m²) Load level II 3900 Pa (equivalent to approx. 390 kg/m²) Load level III 5400 Pa (equivalent to approx. 540 kg/m²) 9.7. Diagram key Symbol GID AS034a GID AS035a GID AS036a GID AS037a GID AS038a Explanation Permissible clamping area (red, cross-hatched) Additionally required clamping in this area (green, diagonally-hatched) Additionally required support in this area (blue, cross-hatched) Clamping point (mid-point of the clamping area) Linear mounting H Clearance (height) between the module frame rear edge and the mounting surface in mm (see below) Dimensions All dimensions are given in millimetres (mm). Note: the diagrams are not always to scale. The numerical values are binding. 10 This is valid for non-lubricated bolts with standard-thread and strength category 8.8 (minimum breaking force 29.2 kn). Page 36/60 installation instructions Edition 01/2012 en-gb-intl (120508b)