Installer Guide - Solarcentury · Lightning protection is recommended for PV systems that are to be...

InstallerGuide

Item 17392-01

Required tools and fixings

Tape measure

Hammer

Electric drill(non-impact setting)

Pencil/pen

Roofing Nails

Pozi head drill bit

Tin snips

Angle grinder(to cut tiles down to the correct size)

No.4 x 70mm Screws(Zinc Coated)

8mm hex socket

T-30 Torq bit(wedge type)

i

General heath and safety

The Construction (Design and Management) Regula-tions 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

Electrical hazardsWARNING: 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 ISC and VOC 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 Amend-ment No 1:2011*. *Latest at time of print.

Sunstation module is tested and meets the requirements of IEC 61215 and IEC 61730.

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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 ISC and VOC 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 Amend-ment 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:

* 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.

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 roofResidential buildings with a truss rafter roofDuopitch, monopitch or hip roof constructionA roof pitch between 25° and 60°For integration with profiled or flat single lapped tilesAdditionally information of roof coverings types are specified in the datasheet available at:www.gosunstation.comRafter gauge must be no more than 600mmBatten gauge must no more than 330mm*Battens must meet the requirements of BS 5534:2014** or BS 5534:2004**Battens must be 50x25mm in sizeBattens, rafters, and the general state of the roof must be in good condition and not subject to rot or other degradationCan only be installed as four sided shapes i.e. squares and rectanglesMust only be installed in portrait orientation

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Environmental limitationsSunstation 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 probabili-ty 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.

iv

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, Broof(t1) and Broof(t4). As a result Sunstation may be installed anywhere on the roof and without limitation to the area covered.As a result Sunstation may be installed anywhere on the roof and without limitation to the area covered. v

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!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.

Wiring considerations

Sunstation PV panels should be connected in series in strings . Strings can be connected horizontally or vertically.

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.

!WARNINGCables must not be trapped between panels and battens

vii

1

Pre installation check list

Before you go on to the roof, check that:

Roof tiles are compatible with sunstationFor 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

Preparation

A width(for example 325cm)

Aheight

Positioning the array

2

Number of rows

1234

A heightof array

180-190cm360-365cm535-545cm715-720cm

Number of columns

2345678

A widthof array

225cm325cm430cm535cm640cm745cm850cm

325cm3

5 535cm

7 745cm

‘A’ dimensions show the visible area of the array once tiles are re-laid. This is marked with a dashed red line:

Width of array

Height of array

Find the ‘A’ size of your array in the table below

Number of rows

1234

A heightof array

180-190cm360-365cm535-545cm715-720cm4 715-720cm

360-365cm2

3Measure the size of the roof

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

Flexible flashing

146mm

146mm 146mm

250mm

A width

235mm(from minA height)

4

Positioning the array

The complete ‘B’ size of the array is shown below:

‘B’ dimensions are markedwith a dotted green line

All tiles within the B area must be removed for installation. Additional tiles may need to be removed to install the flexible flashing.

Ensure there are no clashes with flues or other components on the roof within this area.

5

6

Finalise horizontal position

Desired position(for examplecentre of roof)

Remove cornertile to revealbatten

Detail on sheet 7

Remove the tiles from the bottom right hand corner of the array and mark the ‘A’ line on a batten.

7Shift position to reduce

tile cutting

Check both sides of the array andmark final A line on batten

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 shiftedto reduce tilecutting

Remove tiles

Next rafter

Remove all tiles within the ‘B’ area. Ensure there are no clashes with flues or other components on the roof within this area.

Additional tiles may need to be removed as battens must be screwed to one rafter beyond the array.

8

9Reinforce battens

Battens

RecommendedScrew MinNo.4 x 70mmZinc - Coated

Battens must be reinforced on both sides when they meet on a rafter.Screw using a skew screwing technique.

All battens within the B area must be screwed toevery rafter

! 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 flexibleflashing

11

‘A’ line 250mm

Tile

Batten

Support(angled section)

Rafter Horizontal

TipFeatherboard or battens can be used

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

12

minimum of 5°

Ensure there are no gapsin the support

Lay flexible flashing13

Mark bottom of temporary modules left extrusion. Remove module and top pe-rimeter.

Tack in place to flexible flashing support. Keep nails within the top 30mm when securing flexible flashing.

Ensure overlap withtile is approx 100mm

100mm

! WARNING - Do not stick �exible �ashing to tiles as this stage.

Lay flexible flashing

TipEnsure flashing is taught and fold over top edge for extra water proofing

14

Nail to top of support

Use self adhesive backadhere to tiles

Fold over top and side 20mm (min) for extra water barrier

Finalise vertical position

Using a module and a top perimeter set your top tile angle to match the laid tile angle.

15

! WARNING - Ensure the tiles over-lapping the top perimeter match the laid tile angle of the roof



100mm

! WARNING - Ensure a minimum tile overlap of 170mm on top perimeter

Finalise vertical position

Shift module and top perimeter up and down until laid tile angle is matched

16

170mmminimum

Mark bottom of temporary modules left extrusion. Remove module and top perimeter.

Measure down from bottom of temporary modules left extrusion using the table below.


Moduleshigh

1234

Distance

0mm1770mm3541mm5312mm

1770mm2

4 5312mm

Remove temporary module and top perimeter

Bottom datum17


Detail on page 18


Bottom datum

! WARNING - This may e�ect 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.top and be within zone at bottom.

18

Measurement must be within 100 - 200mm from the top of the bottom row of tiles

200mm100mm

Shift vertical position to meet both parameters


Position starter rail19

!WARNING - Position is critical this determines the position of the array

Position starter rail using vertical datum and horizontal ‘A’ line.

Detail on page 20


Bottom of fixing trayin line with vertical datum

Position starter rail

Ensure bottom of starter rail aligns with vertical datum as show below.

! WARNING - Ensure a minimum 150mm overlap between starter rail and �exible �ashing. Cutting top course of tiles may be required to achieve both laid tile angle at top correct overlap.

20

100mm

150mmminimum


Die

cut r

emov

ed a

rea

35 mm

Line up with marked ‘A’ line, see page 7

Place edge of starter rail here

Template can be used to position starter rail

!WARNING - Batten buddy may fall under �exible �ashing. Ensure screw penetrates batten buddy.

Do not over torque screws

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

21

330mm maximum spacing.Add extra battens if required.

Reinforcement battens

!WARNING - All battens within the B area must be screwed to every rafter

22

Reinforcement battens may be required in higher wind load zones.

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.

If in a high wind load zone and a batten If in a high wind load zone and a batten If in a high wind load zone and a batten

Within95mm

Within45mm - 95mm

23

Screws over rafters

If the screw is over a rafter and a batten buddy cannot be used, pre-drill �xing tray and use screw B. Screw used to reinforce batten must be removed �rst.

Screw into groove when securing starter rail and modules

Groove

Screw B

Screw bottom of starter rail to batten

A line /tile cut line(see page 7)

Use 1x Screw Aand batten buddy

35mmSee template

!WARNING - Ensure screw pene-trates batten buddy if hidden under �exible �ashing

24

2400mm

Top edge of bottom row of tiles

1800

mm

3000mm

TipSquare to the bottom row of tiles using the 3,4,5 rule

Square the starter rail

25Start

Screw starter rail to battensand mark position

26

Mark position of starter rails on battens

Screw to 5 battensusing screw A andbatten buddies

! WARNING - Do not screw through the top 90mm of the starter rail fixing tray

Do not screw through top 90mm

1. Use tin snips to cut along 70mm perforated section

2. Fold bottom section up

3. Fold side section back

70mm

To avoid the perimeter from damaging the �exible �ashing the end needs to be folded at an angle

Prepare first right perimeter

27

Fit right perimeterand fix usingperimeter clips

Perimeter clips (x3)using screw C

Align topof perimeter like this

28

3 perimeter clips must be used, one at the top, one at the bottom and one in the middle of the perimeter

! WARNINGDo not pierce right perimeter. This is a weather protection component, piercing may lead to leakage

Lay foam

29

If possible, position foam in the highest point on the tile

Starter rail Tile

Right perimeter Foam Lip

Replace tiles

!WARNINGTiles must be replaced in accordance withBS 5534:2014

30

Replace tiles over perimeter,lip on perimeter mayneed to be flattened by handto stop tiles kicking up.Remove interlock from tiles.

0 - 20mmGap

Check panel cables

!WARNINGPanels are live, they cannot be switched off

31

Electrical installation must be in accordance with the national regulations of the country where the installation shall be installed

Panel must be returned if cables are damaged

Fit panel32

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

TipMove the cables to one side so they can be accessed easily

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). Do not over torque screws. Ensure screw penetrates batten buddy.

33

Screw through drill line

Do not screw through top 90mm of fixing tray

34Fit corner, slide into

right perimeter

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.

! 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)than 330mm apart additional battens must

35

Bottom of next starterrail should align with the perimeter cornerclip slot

Fit next right perimeter


3 perimeter clips must be used, top, middle and bottom.

36

Fit foam

Ensure end of foamstrips meet

37


Replace tiles38

Fit panel, consider wiringto previous panel

TipMove the cables to one side so they can be accessed easily

There is 10mm of adjustment within the joint. Use this ‘float’ to square panel.

39

DO NOT SCREWto bottom batten untilstep on page 52

40

Screw to battensusing Screw A andbatten buddies. Screw through drill line.

! 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

41

Fit next corner(see 34)

Fit next starter rail using screw A andbatten buddies(see 35)

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

180mm

Top edge of panel

Batten must start and finish on a rafter

Use existing batten if possible 43

Fit last right corner andslide into right perimeter

44


Fit foam and replace tiles onright side


45

Fit top perimeter

Batten

Added batten

TileWedge

Panel

Top perimeter

Rafter Correcttile angle

46

Align vertically with PV panel. If needed, use 3x wedges to level tiles.

Ensure it fully engages

!WARNINGDo not pierce top perimeter. This is a weather protection component, piercing may lead to leakage

Screw top perimeter to battenusing guide holes

47

If not using a wedgeuse ‘Screw C’

If using a wedgeuse ‘Screw D’

30mm

20mm

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


Ensure panel is fully engaged and aligned with adjacent panel, use float to square panelScrew to 5 battens using screw A and batten buddies.

Fit first panel on next column, considerwiring and screw to 5 battens

Middle 50

Fit soak tray

51

Slide soak tray under previous panel and align centrally with notch

Ensure it fully engages with a

Click!

IF array is only 1 row tall skip to page 56

Fully secure previous panel52

Screw previous panel to final battens using screw ‘A’ and batten buddyScrew through the soak tray if necessary

If array is more than 2 rows,continue up column

53

Fit nextpanel, wireto previous

Screw panelto battens using screw ‘A’and battenbuddies

Do not screwto bottombattens untilinstallingpanel on nextcolumn

Slide soaktray intopositioncentrally alignand

Click!

Screw previouspanel to finalbattens usingscrew ‘A’ andbatten buddy

54

If array is more than 3 rowsrepeat steps 53 and 54

Fit top panel &screw to battens

Do not yetscrew to bottom battens

Fit nextpanel, wireto previous

Screw panelto battens using screw ‘A’

55

Add extra battenif needed

!WARNINGBatten must start and finish on a rafter

see page 43for more details

56

57

Slide in soak tray

Slide soak tray under previous panel and align centrally with notch

Ensure it fully engages with a

Click!

Fit top perimeterand screw to batten

see pages 46 to 48 for more details

58


Fit foam and tile over top perimeter

Repeat steps 50 to 59stop before installing the first panel

on the last column

515159

1. Use tin snips to cut along 70mm perforated section

2. Fold bottom section up

3. Fold side section back

70mm

To avoid the perimeter from damaging the �exible �ashing the end needs to be folded at an angle

Prepare first left perimeter

End 60

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

61

Fit soak tray and screw previous panel

Click!Screw previous panel to final battens using screw A and batten buddy

62


3 perimeter clips must be used, top, middle and bottom.

Fit left perimeter

! WARNING - Do not pierce left perimeter. This is a weather protection component, piercing may lead to leakage

63

64Fit left corner, foam and

replace tiles

Bend lip and cut tiles if required


For arrays 2 or more rows tallcontinue up column

65

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

If array is more than 2 rowsrepeat steps 65 and 66

66

Fit next left perimeter using 3 evenly spaced perimeter clipssee page 63 for more details

Fit left corner, foam and replace tiles. See page 64 for more details

Fit final corner

Add top batten if necessary

67

Fit final top perimeterand screw to batten

68

Fit foam and replace anyremaining tiles to complete array


69

Earth bonding

Appendix 70

GeneralIf 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

Bottom of panel

Top of panel

A

B C

A

B

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 Photovolta-ic Modules and Panels” recommends metal combina-tions 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

MethodThe 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.

Figure G.2

The grounding method between modules must be

72

Order of M5 Components

Ground bolt* M5

* The head of the ground bolt should not be deeper than 12mm as this may interfere with installation

Serrated / toothed washer

Washer

Locking nut M5

Module

Earth wire

Earth connectiontab for M5 bolt

Right corner

Left corner

Soak tray

Top perimeter

Right perimeterStarter railPV panelLeft perimeter

Flexible flashing

Flexible foam

Components

Screw guide

Screw ‘D’

30mm

Screw ‘C’

20mm

Screw ‘A’(must be used with

batten buddy)

Screw ‘B’

Included washer must be used with screws A and B

50 Great Sutton StreetLondon EC1V 0DFUnited Kingdom

www.solarcentury.com

[email protected]

+44 (0)20 7549 1000

Item 17392-01

Installer Guide - Solarcentury · Lightning protection is recommended for PV systems that are to be...

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