Installer Guide Item 17392-01
Required tools and fixings Electric drill (non-impact setting) T-30 Torq bit (wedge type) 8mm hex socket Pozi head drill bit Tape measure Pencil/pen Hammer Tin snips Angle grinder (to cut tiles down to the correct size) Roofing Nails No.4 x 70mm Screws (Zinc Coated)
General heath and safety The Construction (Design and Management) Regulations 2015* and general construction site training must be followed. Safe working at heights training must be adhered to. Anybody handling photovoltaic (PV) modules should be trained in correct manual handling practice. All appropriate health and safety regulations should be followed correctly. Avoid installing the system in poor weather conditions, including strong wind, rain, ice or snow. Tile courses should be laid in accordance with BS 5534:2014* unless told otherwise. All components as specified in this manual must be used and instructions followed fully to ensure a safe and weather tight installation. Product has been designed to meet the requirements of the UK Building Regulations. Installation must also meet UK Building Regulation requirements. Artificially concentrated sunlight shall not be directed on the module or panel. *latest at time of print Health and Safety i
Electrical hazards ii WARNING: PV modules produce a DC voltage whenever exposed to light. This voltage cannot be switched off. PV modules are pre-wired with touch proof connectors to prevent an electric shock during general handling. WARNING: Care must be taken not to cut or damage cable insulation or expose bare wire. Each Sunstation module is factory fitted with three bypass diodes. Please see the product data-sheet for specifications. No additional bypass diodes are necessary. Removal or replacement of any diode without written authority of Solarcentury will invalidate the Solarcentury product warranty. Whenever necessary to comply with local codes, use a listed fuse or circuit breaker, rated for the maximum series fuse rating of the module and system voltage. Under normal conditions, a photovoltaic module is likely to experience conditions that produce more current and/or voltage than reported at standard test conditions. Accordingly, the values of I SC and V OC marked on this module should be multiplied by a factor of 1. 25 when determining component voltage ratings, conductor current ratings, fuse sizes, and size of controls connected to the PV output. All work must be carried out with the Sunstation system disconnected from the mains electrical supply. Please see appendix for grounding guidelines. Any grounding connections made must be in accordance with the requirements in BS EN 61557-2:2007 Electrical installations should be designed and installed in accordance with BS 7671:2008 incorporating Amendment No 1:2011*. *Latest at time of print. Sunstation module is tested and meets the requirements of IEC 61215 and IEC 61730.
Installation limitations Sunstation has been designed to integrate with a variety of roof and tile types. However depending upon the age, type and location of the roof some strengthening work may be necessary; i.e. changing or adding extra battens. The following are minimum recommendations for the roof construction: The system should not be installed within: 2 tile widths, 2 tile heights at the top of the array, and 1 tile height at the bottom of an array, from the edge of the roof Residential buildings with a truss rafter roof Duopitch, monopitch or hip roof construction A roof pitch between 25 and 60 For integration with profiled or flat single lapped tiles Additionally information of roof coverings types are specified in the datasheet available at: www.gosunstation.com Rafter gauge must be no more than 600mm Batten gauge must no more than 330mm* Battens must meet the requirements of BS 5534:2014** or BS 5534:2004** Battens must be 50x25mm in size Battens, rafters, and the general state of the roof must be in good condition and not subject to rot or other degradation Can only be installed as four sided shapes i.e. squares and rectangles Must only be installed in portrait orientation * For details of any additional battening that may be required to strengthen the roof contact Solarcentury **Sunstation must be installed using battens that are graded to BS 5534. In some cases this may require replacing the battens where the modules are to be mounted. For roof constructions that fall outside the above limitations then please contact Solarcentury for installation requirements. iii
Environmental limitations iv Sunstation is intended for use in terrestrial applications only. Modules must not be installed where they could be submerged in water The recommended ambient temperature should be within -20 C (-4 F) to 46 C (115 F). The temperature limits are defined as the monthly average high and low of the installation site. The limit operating temperature should be -40 C (-40 F) to 85 C (185 F). Ensure modules are not subject to wind or snow loads exceeding the maximum permissible loads. The modules should be installed in a location where there is no shading throughout the year. Ensure there are no obstacles to block light near the installation site. Modules should not be installed in a location that is within 50m of the sea. Lightning protection is recommended for PV systems that are to be installed in locations with high probability of lightning strikes. Do not use modules near equipment or in locations where flammable gasses may be generated or collected. Modules must not be installed nor operated in areas where hail, snow, sand, dust, air pollution, soot, etc., are excessive. Modules must not be sited in locations where aggressive substances such as salt, salt mist, salt-water, chemically active vapours, acid rain, any other type of corrosive agent, could affect the safety and/or performance of the module. Please adopt appropriate measures to ensure the performance and safety of the modules when they are installed in extreme conditions.
Installation considerations Do NOT walk on the surface of the module. Ensure no cable ends are left exposed to the weather during work breaks or after completion of works. Units must be kept in a weatherproof environment before installation. Do not leave tools or unsecured materials above the module installation area, to avoid potential damage to the units. Only load as many modules onto the roof as you expect to install during the installation time you have available. Modules should be handled carefully to avoid any damage before installation. Ensure all cable connectors are dry and free of dirt before making connections. Tile family compatibility: interlocking thick leading edge interlocking thin leading edge interlocking profiled tile interlocking pantile non-interlocking pantile For other tile types please contact Solarcentury. Sunstation has been tested to meet the requirements of BS 476-3:2004 and EN 13501:2005 + A1:2009 and achieved a fire rating of EXT.S.AA, B roof (t1) and B roof (t4). As a result Sunstation may be installed anywhere on the roof and without limitation to the area covered. v
Wiring considerations vi Sunstation PV panels should be connected in series in strings. Strings can be connected horizontally or vertically.! WARNING: PV modules produce a DC voltage whenever exposed to light. This voltage cannot be switched off. PV modules are pre-wired with touch proof connectors to prevent an electric shock during general handling.
Beware of partial shading Position your array to reduce partial shading. When arrays are connected in strings if one panel is under shading this will effect the efficiency of the whole array.! WARNING Cables must not be trapped between panels and battens vii
Preparation 1 Pre installation check list Before you go on to the roof, check that: Roof tiles are compatible with sunstation For the up to date list of compatible tiles see the Sunstation datasheet, available at: www.gosunstation.com Roof can accommodate array (see page iii ) Accessories box contains the correct number of parts (see your configurator bill of materials) Modules are undamaged, check surface and cables Roof is facing south (between east & west) You have all the required tools ready (see inside cover) You have read and understood this guide fully
Positioning the array Find the A size of your array in the table below A height A dimensions show the visible area of the array once tiles are re-laid. This is marked with a dashed red line: A width (for example 325cm) Number of columns 2 3 4 5 6 7 8 A width of array 225cm 325cm 430cm 535cm 640cm 745cm 850cm 5 535cm 7 745cm Width of array Number A height of rows of array 1 180-190cm 2 360-365cm 3 535-545cm 4 715-720cm Height of array 2
Measure the size of the roof 3 Decide on the approximate position of the array, considering shading and minimum tile restrictions: There must be a minimum of 2 complete tiles at the sides and top of the array, and 1 complete tile at the bottom
Positioning the array The complete B size of the array is shown below: 235mm (from min A height) A width 146mm 146mm Flexible flashing B dimensions are marked with a dotted green line 146mm 250mm 4
All tiles within the B area must be removed for installation. Additional tiles may need to be removed to install the flexible flashing. 5 Ensure there are no clashes with flues or other components on the roof within this area.
Finalise horizontal position Remove the tiles from the bottom right hand corner of the array and mark the A line on a batten. Desired position (for example centre of roof) Remove corner tile to reveal batten Detail on sheet 7 6
Shift position to reduce tile cutting 7 Consider tile cutting when positioning the array. You may want to align the A line with a full tile (excluding interlock) on one side to reduce cutting or shift the array to have equal cutting on both sides Detail from page 6 Array shifted to reduce tile cutting Check both sides of the array and mark final A line on batten
Remove tiles Remove all tiles within the B area. Ensure there are no clashes with flues or other components on the roof within this area. Next rafter Additional tiles may need to be removed as battens must be screwed to one rafter beyond the array. 8
Reinforce battens 9 All battens within the B area must be screwed to every rafter Battens Recommended Screw Min No.4 x 70mm Zinc - Coated Battens must be reinforced on both sides when they meet on a rafter. Screw using a skew screwing technique.! WARNING - If sarking present then increase reinforcement screw length by sarking thickness
Batten requirements Measure batten spacing. If batten spacing is less than 330mm skip to page 11 If batten spacing is greater than 330mm add an additional 25 x 50mm graded batten above every batten: Additional battens added 10
Build up support for flexible flashing 11 A line 250mm
Build up a support structure for the flexible flashing using battens or feather board Keep the angled section as shallow as possible but at a min of 5 from horizontal to stop water pooling Support (angled section) Batten Tile Rafter minimum of 5 Horizontal Ensure there are no gaps in the support Tip Featherboard or battens can be used 12
Lay flexible flashing 13 Tack in place to flexible flashing support. Keep nails within the top 30mm when securing flexible flashing. Ensure overlap with tile is approx 100mm 100mm! WARNING - Do not stick flexible flashing to tiles as this stage.
Lay flexible flashing Fold over top and side 20mm (min) for extra water barrier Nail to top of support Use self adhesive back adhere to tiles Tip Ensure flashing is taught and fold over top edge for extra water proofing 14
Finalise vertical position 15 Using a module and a top perimeter set your top tile angle to match the laid tile angle.! WARNING - Ensure the tiles overlapping the top perimeter match the laid tile angle of the roof
Finalise vertical position Shift module and top perimeter up and down until laid tile angle is matched 170mm minimum WARNING - Ensure a minimum tile! overlap of 170mm on top perimeter 16
Bottom datum 17 Measure down from bottom of temporary modules left extrusion using the table below. Detail on page 18 Remove temporary module and top perimeter Modules high Distance 1 0mm 2 1770mm 3 3541mm 4 5312mm
Bottom datum Measurement must be within 100-200mm from the top of the bottom row of tiles 200mm 100mm Shift vertical position to meet both parameters WARNING - This may effect your! top perimeter tile angle. Cutting top course of tiles may be required to match laid tile angle at top and be within zone at bottom. om. 18
Position starter rail 19 Position starter rail using vertical datum and horizontal A line. Detail on page 20! WARNING - Position is critical this determines the position of the array
Position starter rail Ensure bottom of starter rail aligns with vertical datum as show below. Bottom of fixing tray in line with vertical datum 150mm minimum! WARNING - Ensure a minimum 150mm overlap between starter rail and flexible flashing. Cutting top course of tiles may be required to achieve both laid tile angle at top correct overlap. 20
Place edge of starter rail here 35 mm Die cut removed area Line up with marked A line, see page 7 Template can be used to position starter rail
Batten buddies Every time screw A is used a batten buddy must also be used. Choose 5 equally spaced battens with one at the top and one at the bottom. Screw A 330mm maximum spacing. Add extra battens if required.! WARNING - Batten buddy may fall under flexible flashing. Ensure screw penetrates batten buddy. Do not over torque screws 21
Reinforcement battens 22 Reinforcement battens may be required in higher wind load zones. Within 95mm Within 45mm - 95mm If in a high wind load zone and a batten does not naturally occur, battens must be added at the top and bottom of every module/ starter rail as shown above.! WARNING - All battens within the B area must be screwed to every rafter
Screws over rafters If the screw is over a rafter and a batten buddy cannot be used, pre-drill fixing tray and use screw B. Screw used to reinforce batten must be removed first. Screw B Groove Screw into groove when securing starter rail and modules 23
Screw bottom of starter rail to batten 24 A line / tile cut line (see page 7) Use 1x Screw A and batten buddy 35mm See template! WARNING - Ensure screw penetrates batten buddy if hidden under flexible flashing
Square the starter rail 3000mm 1800mm 2400mm Top edge of bottom row of tiles Tip Square to the bottom row of tiles using the 3,4,5 rule Start 25
Screw starter rail to battens and mark position 26 Mark position of starter rails on battens Do not screw through top 90mm Screw to 5 battens using screw A and batten buddies WARNING - Do not screw through the! top 90mm of the starter rail fixing tray
Prepare first right perimeter To avoid the perimeter from damaging the flexible flashing the end needs to be folded at an angle 1. Use tin snips to cut along 70mm perforated section 2. Fold bottom section up 3. Fold side section back 70mm 27
28 Fit right perimeter and fix using perimeter clips Align top of perimeter like this Perimeter clips (x3) using screw C 3 perimeter clips must be used, one at the top, one at the bottom and one in the middle of the perimeter! WARNING Do not pierce right perimeter. This is a weather protection component, piercing may lead to leakage
Lay foam Starter rail Tile Right perimeter Foam Lip If possible, position foam in the highest point on the tile 29
Replace tiles 30 0-20mm Gap Replace tiles over perimeter, lip on perimeter may need to be flattened by hand to stop tiles kicking up. Remove interlock from tiles.! WARNING Tiles must be replaced in accordance with BS 5534:2014
Check panel cables Panel must be returned if cables are damaged Electrical installation must be in accordance with the national regulations of the country where the installation shall be installed! WARNING Panels are live, they cannot be switched off 31
Fit panel 32 Ensure panel is fully engaged Align bottom of panel with bottom of perimeter Use float to square panel to bottom row of tiles
Screw panel to all battens Screw to 5 battens using screw A and batten buddies. Do not screw through top 90mm of fixing tray Screw through drill line Tip Move the cables to one side so they can be accessed easily! WARNING - Panel must be screwed to at least 5 battens. If battens are spaced more than 330mm apart additional battens must be added (see page 10). Do not over torque screws. Ensure screw penetrates batten buddy. 33
Fit corner, slide into right perimeter 34 If array is only 1 row tall skip to page 43
Fit next starter rail Screw to 5 battens using screw A and batten buddies. Screw through drill line. Bottom of next starter rail should align with the perimeter corner clip slot! WARNING - Panel must be screwed to at least 5 battens. If battens are spaced more than 330mm apart additional battens must be added (see page 10) 35
Fit next right perimeter 36 Perimeter clips (x3) using screw C 3 perimeter clips must be used, top, middle and bottom.
Fit foam Ensure end of foam strips meet 37
Replace tiles 38! WARNING Tiles must be replaced in accordance with BS 5534:2014
Fit panel, consider wiring to previous panel There is 10mm of adjustment within the joint. Use this float to square panel. Tip Move the cables to one side so they can be accessed easily 39
40 Screw to battens using Screw A and batten buddies. Screw through drill line. DO NOT SCREW to bottom batten until step on page 52! WARNING - Panel must be screwed to at least 5 battens. If battens are spaced more than 330mm apart additional battens must be added (see page 10)
If array is more than 2 rows tall repeat steps 34-40 to top of column Fit next corner (see 34) Fit next starter rail using screw A and batten buddies (see 35) 41
42 Fit next right perimeter (see 36) Fit foam and replace tiles (see 37 and 38) Fit next panel (see 39)
Screw batten for top perimeter Top edge of panel 180mm Batten must start and finish on a rafter Use existing batten if possible 43
Fit last right corner and slide into right perimeter 44! WARNING Tiles must be replaced in accordance with BS 5534:2014
Fit foam and replace tiles on right side! WARNING Tiles must be replaced in accordance with BS 5534:2014 45
Fit top perimeter 46 Ensure it fully engages Align vertically with PV panel. If needed, use 3x wedges to level tiles. Top perimeter Tile Wedge Added batten Panel Batten Rafter Correct tile angle
Screw top perimeter to batten using guide holes If not using a wedge use Screw C 20mm If using a wedge use Screw D 30mm! WARNING Do not pierce top perimeter. This is a weather protection component, piercing may lead to leakage 47
Fit foam over top perimeter 48
Apply foam and tile over top perimeter Don t tile over left most screw hole on top perimeter! WARNING - Tiles must be replaced in accordance with BS 5534:2014, ensure tile overlap is between a minimum of 170mm and a maximum of 250mm 49
Middle 50 Fit first panel on next column, consider wiring and screw to 5 battens Ensure panel is fully engaged and aligned with adjacent panel, use float to square panel Screw to 5 battens using screw A and batten buddies.! WARNING - Panel must be screwed to at least 5 battens. If battens are spaced more than 330mm apart additional battens must be added (see page 10)
Fit soak tray IF array is only 1 row tall skip to page 56 Slide soak tray under previous panel and align centrally with notch Ensure it fully engages with a Click! 51
Fully secure previous panel 52 Screw previous panel to final battens using screw A and batten buddy Screw through the soak tray if necessary
If array is more than 2 rows, continue up column Fit next panel, wire to previous Screw panel to battens using screw A and batten buddies Do not screw to bottom battens until installing panel on next column 53
54 Slide soak tray into position centrally align and Click! Screw previous panel to final battens using screw A and batten buddy If array is more than 3 rows repeat steps 53 and 54
Fit top panel & screw to battens Fit next panel, wire to previous Screw panel to battens using screw A Do not yet screw to bottom battens 55
Add extra batten if needed 56 see page 43 for more details! WARNING Batten must start and finish on a rafter
Slide in soak tray Slide soak tray under previous panel and align centrally with notch Ensure it fully engages with a Click! 57
Fit top perimeter and screw to batten 58 see pages 46 to 48 for more details
Fit foam and tile over top perimeter Repeat steps 50 to 59 stop before installing the first panel on the last column! WARNING Tiles must be replaced in accordance with BS 5534:2014 51 59
End 60 Prepare first left perimeter To avoid the perimeter from damaging the flexible flashing the end needs to be folded at an angle 1. Use tin snips to cut along 70mm perforated section 2. Fold bottom section up 3. Fold side section back 70mm
Fit next panel Screw to 5 battens using screw A and batten buddies. Stick flexible flashing to tiles once batten buddies on last module have been installed! WARNING - Panel must be screwed to at least 5 battens. If battens are spaced more than 330mm apart additional battens must be added (see page 10) 61
Fit soak tray and screw previous panel 62 Click! Screw previous panel to final battens using screw A and batten buddy
Fit left perimeter Perimeter clips (x3) using screw C 3 perimeter clips must be used, top, middle and bottom.! WARNING - Do not pierce left perimeter. This is a weather protection component, piercing may lead to leakage 63
Fit left corner, foam and replace tiles 64 Bend lip and cut tiles if required! WARNING Tiles must be replaced in accordance with BS 5534:2014
For arrays 2 or more rows tall continue up column Fit next panel, screw to 5 battens using batten buddies and screw A see page 61 for more details Fit next soak tray see page 62 for more details 65
66 Fit next left perimeter using 3 evenly spaced perimeter clips see page 63 for more details Fit left corner, foam and replace tiles. See page 64 for more details If array is more than 2 rows repeat steps 65 and 66
Fit final corner Add top batten if necessary 67
Fit final top perimeter and screw to batten 68
Fit foam and replace any remaining tiles to complete array! WARNING Tiles must be replaced in accordance with BS 5534:2014 69
Appendix 70 Earth bonding General If bonding or grounding is necessary then terminals should be attached in the pre-drilled grounding locations shown below in Figure G.1: (a single location or combination of the locations can be used.) Figure G.1 Top of panel A A B B Bottom of panel C C
Sunstation modules use an anodic oxide aluminium frame to resist corrosion therefore the frame of the modules may need to be connected to the equipment grounding connector to prevent lightning and static injury. For optimal performance it is recommended that the DC cathode of the modules array is connected to ground. Failure to comply with this requirement may reduce the performance of the system. Grounding connectors should be stainless steel studs or bolts with a suitable clamping arrangement of the correct size for the grounding cable being used. The grounding method must not result in direct contact of dissimilar metals with the aluminium frame of the modules that will result in galvanic corrosion. An addendum to UL standard 1703 Flat Plate Photovoltaic Modules and Panels recommends metal combinations not exceeded an electrochemical potential difference of 0.6 Volts. Toothed washers must be used on one side of the joint as shown in figure G.2 to ensure the surface of the oxide film is penetrated and a good electrical contact is made. The grounding locations are pre-drilled in the locations shown in the figure G.1 on page 64 and are marked with a grounding sign. DO NOTE DRILL ANY ADDITIONAL GROUNDING HOLES. 71
Method The grounding method between modules must be approved by a qualified electrician and the grounding device must be produced by qualified electrical manufacturer. Note: grounding components not supplied. A) Choose the applicable pre-drilled grounding hole (shown in Figure G.1) B) Thread the earth wire into earth connection tab and secure in place. The material and size of the grounding wire should meet the relevant requirements of the national, regional and local rule, law and standard. C) Arrange the components as shown in Figure G.2. D) Secure the earth connection tab in place by tightening the lock nut. The recommended torque of the locking nut is 2.0 Nm - 2.2 Nm. 72 Figure G.2 Order of M5 Components Ground bolt* M5 Earth connection tab for M5 bolt Earth wire Module Serrated / toothed washer Washer Locking nut M5 * The head of the ground bolt should not be deeper than 12mm as this may interfere with installation
Components Top perimeter Right corner Soak tray Left corner Right perimeter Starter rail PV panel Left perimeter Flexible flashing Flexible foam
Screw guide Screw A (must be used with batten buddy) Screw B Included washer must be used with screws A and B Screw C Screw D 20mm 30mm
www.gosunstation.com sunstation@solarcentury.com +44 (0)20 7549 1000 50 Great Sutton Street London EC1V 0DF United Kingdom www.solarcentury.com Item 17392-01