Owner’s Guide and Installation Instructions · Owner’s Guide and Installation ... relevant...

Solahart PVSP Series PV Systems must be installed and serviced by a suitably qualified person.

Please leave this guide with the householder.

Owner’s Guide

and

Installation Instructions

PVSP Series PV Systems

PATENTS

This PV System may be protected by one or more patents or registered designs in the name of Solahart Industries Pty Ltd.

TRADE MARKS ® Registered trademark of Solahart Industries Pty Ltd.

™ Trademark of Solahart Industries Pty Ltd.

Note: Every care has been taken to ensure accuracy in preparation of this publication.

No liability can be accepted for any consequences, which may arise as a result of its application.

CONTENTS

HOUSEHOLDER – We recommend you read pages 3 to 5.

The other pages are intended for the installer but may be of interest.

About Your PV System ............................................................................................................... 3

Electrical Safety ........................................................................................................................... 4

Periodic Maintenance ................................................................................................................. 5

Wiring Diagrams .......................................................................................................................... 6

Installation – Overview ............................................................................................................. 11

Installation – PV Modules ......................................................................................................... 18

Installation – Labelling .............................................................................................................. 35

Installation – Commissioning .................................................................................................. 36

Engineering Certification .......................................................................................................... 38

Document Revision ................................................................................................................... 40

Solahart PVSP Series PV System Warranty ........................................................................... 41

Warning: For continued safety of this PV System it must be installed, operated and maintained in accordance with the “Solahart PVSP Series PV System Owners Guide and Installation Instructions” and the relevant “Photovoltaic Inverter Installation and Operator‟s Manual”.

Caution: Only qualified and accredited personnel should perform work on PV systems, such as installation, commissioning, maintenance and repairs. Be sure to follow the safety instructions for all system components. It is also important to observe relevant local codes and regulations for health and safety and accident prevention.

Only Solahart parts and Solahart approved parts may be used. No substitute parts may be used without prior approval from Solahart Industries Pty Ltd. Only parts supplied by Solahart Industries Pty Ltd are covered by the Solahart warranty.

The warranty can become void if safety devices are tampered with or if the installation is not in accordance with these instructions.

3

ABOUT YOUR PV SYSTEM

MODEL TYPE

Your Solahart® PV System is designed for the polycrystalline photovoltaic modules to be roof and/or stand

mounted with the inverter installed in a serviceable position and connected to the electrical distribution grid as per AS 4777.1. These instructions together with the installation instructions supplied with inverter give limitations on positioning of the inverter.

SYSTEM OPERATION

The Solahart® PV System is comprised of two main components; a string or array of photovoltaic modules

and an inverter.

The photovoltaic (PV) modules transform solar radiation into electrical energy in the form of direct current (DC). In order to utilise this energy and feed it back into the grid, the direct current is transformed into alternating current (AC) by the inverter. This conversion is also known as DC to AC inversion.

The alternating current generated by the inverter is fed into the main switchboard, which in turn is connected to the electrical distribution grid.

Note: For safety reasons, the inverter will only operate when the mains electrical supply is available from the grid. Your Solahart PV System cannot provide a backup electricity supply to your home appliances if the mains supply is interrupted.

If the energy generated by the PV System is not sufficient to meet domestic demands, the energy necessary to ensure the standard operation of the connected devices is drawn from the electrical distribution grid.

If the energy produced exceeds that required by domestic demands, the difference is directly fed into the electrical distribution grid and becomes available to other users. This excess energy is sold to the electrical network operator according to national and local standards and regulations.

SYSTEM OVERVIEW

A photovoltaic module is composed of many photovoltaic cells assembled on the same frame.

A string is composed of a certain number of modules electrically connected in series.

An array is composed of one or more strings connected in parallel.

The inverter converts direct current produced by the array into alternating current.

The Solar DC Isolator provides a means of isolation and over current protection of the array.

The Inverter AC Isolator provides over current protection of the inverter and a method of isolating the PV System from the electrical distribution grid.

Warning! For the inverter to be effectively electrically isolated, both the DC and AC circuit breaker/isolators must be in the OFF position.

ABOUT YOUR PV SYSTEM

4

TO TURN PV SYSTEM ON

1. Turn on Solar DC Isolator(s) located adjacent to inverter.

2. Turn on Inverter AC Isolator located adjacent to inverter. TO TURN PV SYSTEM OFF

1. Turn off Inverter AC Isolator located adjacent to inverter.

2. Turn off Solar DC Isolator(s) located adjacent to inverter.

Warning! Depending upon the system there may be more than one Solar DC Isolator.

Warning! To effectively isolate the wiring between the AC isolator and switchboard, the Solar Supply Main Switch located in the switchboard must also be in the off position.

Warning! Dangerous voltages may be present at PV modules and PV module wiring even when all isolators are in the OFF position.

ELECTRICAL SAFETY

UNIQUE HAZARDS OF DC ELECTRICITY

Solar modules generate direct current (DC) electricity. Once the current is flowing, breaking or opening a connection (e.g. disconnecting a DC cable from the inverter) can cause a DC electrical arc. Unlike arcs occurring in conventional low voltage AC wiring, DC arcs are not self-extinguishing. They are a potentially lethal burn and fire hazard, capable of creating high temperatures that can destroy contacts and connectors. Always:

Follow the module and inverter manufacturer‟s installation, handling and operating instructions

Remove/open the inverter AC fuse/circuit breaker before you disconnect the inverter from the public grid

Switch off or disconnect the inverter and wait for the time specified by the manufacturer before working on it - its high-voltage components need sufficient time to discharge.

SAFETY REQUIREMENTS

The voltage produced by individual modules and modules connected in series (voltages are added together) or in parallel (currents are added together), can give rise to dangerous voltage and current.

5

PERIODIC MAINTENANCE

GENERAL

Maintenance should be performed according to AS/NZS 5033. In addition to these requirements it is recommended that the following be inspected annually by a suitably qualified person:

All fastenings are tight, secure and free of corrosion.

All cable connections are tight, secure and free of corrosion.

Cables are not damaged in any way.

Verification of module and module rail earthing resistance. Bonding points to earth are tight, secure and free of corrosion.

Verification of OFF operation for all AC and DC isolator/circuit breakers.

Installation of a roof mounted PV system may also require additional maintenance for the roof and measures for access to conduct maintenance tasks. Refer to roofing manufacturers guidelines.

Contact your Solahart Dealer for any maintenance requirements.

PV MODULES

Solahart PVP2XX Series modules have been designed for easy maintenance. Normal rainfall will naturally clean the modules if the modules are installed in a position with sufficient tilt. The need for cleaning will vary with the location of the installation, amount of rainfall and pollution. To optimize electrical output, it is recommended that the modules are cleaned when dirt can be seen on the glass surface.

If dirt remains on the module surfaces, it will cause cell shading which can reduce system power output. If necessary, cleaning can be performed as for normal glass with a non alkali window cleaner or denatured spirits followed by rinsing with water. Cleaning liquid/agents which are acidic solutions (low pH value < 5) can therefore also be used in diluted form to remove for example calcium (except hydrofluoric acid!). Always finish cleaning by rinsing with plenty of water.

For removal of moss, fungi and/or bacteria from the glass surface, a cleaning agent with the active component Benzalkonium chloride can be used. Rodalon® sold through the company Brenntag is recommended.

Please do not use any of the following:

Alkaline (pH value > 9) cleaning liquid/agents.

Hydrofluoric acid (HF).

Harsh cleaning materials such as scouring powder, steel wool and cloth with course metal treads in the weave, scrapers or other sharp instruments.

6

WIRING DIAGRAMS

SB1600TL-10 Inverter Systems (1.47 & 1.72 kW Solahart Systems)

Nominal System Size (kW)

Number of Modules

Number of Strings

Modules Per String

PVP245-S1 Modules PVP250-S1 Modules

Isc (A) * Voc (V) * Isc (A) * Voc (V) *

1.47 6 1 6 8.7 223.2 8.8 225.0

1.72 7 1 7 8.7 260.4 8.8 262.5

* Values measured at standard test conditions (STC) defined as: irradiance of 1000 W/m

2, Spectrum AM 1.5

and cell temperature 25º. Variations from STC values will affect actual Isc and Voc and should be allowed for. For earthing arrangement and wiring diagram refer to „Earthing Arrangement – All Systems‟ on page 10. SB2100TL Inverter System (1.96 kW Solahart System)


Number of Modules

Number of Strings

Modules Per String



1.96 8 1 8 8.7 297.6 8.8 300.0


2, Spectrum AM 1.5

and cell temperature 25º. Variations from STC values will affect actual Isc and Voc and should be allowed for. For earthing arrangement and wiring diagram refer to „Earthing Arrangement – All Systems‟ on page 10.

WIRING DIAGRAMS

7

SB2000HF-30 Inverter Systems (1.96 & 2.21 kW Solahart Premium Systems)


Number of Modules

Number of Strings

Modules Per String



1.96 8 1 8 8.7 297.6 8.8 300.0

2.21 9 1 9 8.7 334.8 8.8 337.5


2, Spectrum AM 1.5

and cell temperature 25º. Variations from STC values will affect actual Isc and Voc and should be allowed for. For earthing arrangement and wiring diagram refer to „Earthing Arrangement – All Systems‟ on page 10. SB2500 Inverter System (2.45 kW Solahart System) Note: For SB2500HF-30 inverter systems refer to following page.


Number of Modules

Number of Strings

Modules Per String



2.45 10 1 10 8.7 372.0 8.8 375.0


2, Spectrum AM 1.5


WIRING DIAGRAMS

8

SB2500HF-30 Inverter Systems (2.45 & 2.70 kW Solahart Premium Systems) Note: For SB2500 inverter system refer to previous page.


Number of Modules

Number of Strings

Modules Per String



2.45 10 1 10 8.7 372.0 8.8 375.0

2.70 11 1 11 8.7 409.2 8.8 412.5


2, Spectrum AM 1.5

and cell temperature 25º. Variations from STC values will affect actual Isc and Voc and should be allowed for. For earthing arrangement and wiring diagram refer to „Earthing Arrangement – All Systems‟ on page 10. SB3000HF-30 Inverter Systems (2.94 & 3.19 kW Solahart Premium Systems)


Number of Modules

Number of Strings

Modules Per String



2.94 12 1 12 8.7 446.4 8.8 450.0

3.19 13 1 13 8.7 483.6 8.8 487.5


2, Spectrum AM 1.5


WIRING DIAGRAMS

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SB4000TL-20 Inverter Systems (3.92, 4.17 & 4.41 kW Solahart Premium Systems & 1.96, 2.21 & 2.45 kW Upgradable Solahart Premium Systems)


Number of Modules

Number of Strings

Modules Per String



1.96 8 1 8 8.7 297.6 8.8 300.0

2.21 9 1 9 8.7 334.8 8.8 337.5

2.45 10 1 10 8.7 372.0 8.8 375.0

3.92 16 2 8+8 8.7 297.6 8.8 300.0

4.17 17 2 8+9 8.7 297.6 (8) 334.8 (9)

8.8 300.0 (8) 337.5 (9)

4.41 18 2 9+9 or

8+10 8.7

297.6 (8) 334.8 (9)

372.0 (10) 8.8

300.0 (8) 337.5 (9)

375.0 (10)


2, Spectrum AM 1.5


WIRING DIAGRAMS

10

SB5000TL-20 Inverter Systems (4.90, 5.15 & 5.39 kW Solahart Premium Systems & 2.21, 2.45 & 2.70 kW Upgradable Solahart Premium Systems)


Number of Modules

Number of Strings

Modules Per String



2.21 9 1 9 8.7 334.8 8.8 337.5

2.45 10 1 10 8.7 372.0 8.8 375.0

2.70 11 1 11 8.7 409.2 8.8 412.5

4.90 20 2 10+10

or 9+11

8.7 334.8 (9) 372.0 (10) 409.2 (11)

8.8 337.5 (9) 375.0 (10) 412.5 (11)

5.15 21 2 10+11 8.7 372.0 (10) 409.2 (11)

8.8 375.0 (10) 412.5 (11)

5.39 22 2 11+11 8.7 409.2 8.8 412.5 (11)

* Values measured at standard test conditions (STC) defined as: irradiance of 1000 W/m2, Spectrum AM 1.5

and cell temperature 25º. Variations from STC values will affect actual Isc and Voc and should be allowed for.

Earthing Arrangement – All Systems

Earth wires must be run so that the removal of one component (e.g. a module) does not interrupt the earthing to other parts of a system (e.g. other modules). Daisy chaining is not permitted. The PV system earth connection must be directly connected to the switchboard earth link, not via the inverter earth connection.

Note: Solahart approved earth bonding plates may be used to earth modules via the racking, instead of wiring directly to the module frames. Refer to „Earth bonding method 2 – Earth bonding plates‟ on page 11 for more information.

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INSTALLATION – OVERVIEW

The following installation instructions detail installation procedures for photovoltaic modules, module racking systems and labelling. PV Modules

PV modules generate electricity as soon as they are exposed to sunlight. One module generates a safe extra low voltage however multiple modules connected in series (summing voltage) or in parallel (summing current) represent a danger. The warnings on page 18 must be observed when handling solar modules to avoid the risk of fire, sparking and/or electric shock.

If modules are connected in series the total voltage must not exceed the inverter‟s maximum input voltage rating. For the maximum number of series connected modules permissible refer to the relevant wiring diagram in this document for the inverter model installed.

Solahart modules should only be used in systems where they meet the specific technical requirements of the system as a whole. Ensure that other system components will not cause mechanical or electrical damage to the modules

Connection:

If the modules are to be connected together in series, they should have the same amperage.

If the modules are to be connected in parallel, they should have the same voltage. Earth bonding

Modules and module rails must be earthed. Earthing connections must be made by a suitably qualified person according to the relevant standards outlined on page 19. It is also recommended that a reliable lightning protection system be installed.

Earth wires must be run so that the removal of one component (e.g. a module) does not interrupt the earthing to other parts of a system (e.g. other modules). Daisy chaining is not permitted. The PV system earth connection must be directly connected to the switchboard earth link, not via the inverter earth connection.

Stainless steel serrated washers must be used so that rail and/or module anodising is pierced to provide good electrical continuity. Stainless steel nuts, bolts and washers must be used and all ferrous metal in conductive connections should be specially treated such as by spray painting or coating with a galvanising paint to prevent corrosion. Also refer to „Verification of module earthing resistance‟ in the „Commissioning‟ section on page 37. Earth bonding method 1 – Earth bonding wire

To earth modules and rails, connect a suitably sized earth wire (4 mm

2 minimum) to earth clamps or lugs as

depicted and explained in the earthing arrangement wiring diagram on page 10 and tighten to 5 Nm. Earth bonding method 2 – Earth bonding plates

To earth modules and rails, connect a suitably sized earth wire (4mm2 minimum) to earth clamp or lug on

one rail of each string, use earth bonding plates supplied in BOS kit when mounting modules and install earth bonding plates in accordance with the instructions below. When installed correctly, earth bonding plates will provide earth bond continuity between rails and modules whilst allowing removal of a module without affecting the earthing integrity of other components.


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Earth Bonding Plate – End Clamp Installation

1. Position end clamp with Z-module and Allen head bolt in rail and slide into position. For easy use of Z-modules ensure that Allen head bolt threads do not project through lower side of Z-module (flush max) so that Z-module is free to move.

2. Slide earth bonding plate over threaded section of Allen head bolt and press earth bonding plate into rail so that rail retention tabs hold earth bonding plate in position.

3. Install PV module, ensure frame of module is located on top of earth bond protrusions on earth bonding plate and tighten end clamp bolt to 21 Nm.

Earth Bonding Plate – Mid Clamp Installation

1. Position mid clamp with Z module and Allen head bolt in rail and slide into position. For easy use of Z module ensure that Allen head bolt threads do not project through lower side of Z module (flush max) so that Z module is free to move.

2. Slide earth bonding plate over threaded section of Allen head bolt and press earth bonding plate into rail so that rail retention tabs hold earth bonding plate in position.

3. Install next PV module, ensure both module frame edges are located on top of earth bond protrusions on earth bonding plate and tighten mid clamp bolt to 21 Nm.

Warning: Only Solahart approved earth bonding plates are to be used.

Warning: Module frames must be located on top of earth bonding plate earth bond protrusions.

Warning: Earth bonding plates are intended for single use only and must not be reused.

Warning: If rails are not of a continuous length, or rail splices do not provide satisfactory earth continuity, earth bond jumper cables must be used across rails or rail splices or each section of rail must have an earth wire connection. Inverter

For inverter installation instructions and warranty exclusions refer to the PV Inverter Installation Guide supplied with the inverter. The following points must also be observed when installing the inverter:

Inverters must not be installed where they receive direct sunlight.

Inverters must not be installed in a habitable room or in a confined space such as a cupboard.

If inverter is to be mounted on a combustible surface such as wood, a heat resistant backing (such as a fibre cement board) must be installed behind the inverter. Backing must protrude a minimum of 20 mm past all edges and sides of the inverter.

Inverter mounting clearances and requirements outlined in the relevant PV Inverter Installation Guide must be adhered to. The following illustrations provide a summary of these clearances and maximum permissible tilt angle:


13

4000TL and 5000TL model inverters have two separate zones (zone A & zone B) and each zone has its own maximum power point tracker (MPPT). When separate strings are installed on different roof planes (as in the illustration shown opposite) ensure these strings are connected to the different zone inputs i.e. string 1 to „zone A‟ input and string 2 to „zone B‟ input. Connecting strings in this manner ensures maximum power point tracking of each string and optimises system performance.

It should be noted that although each zone has two string input connections, these inputs are paralleled inside the inverter and are therefore connected to the same MPPT.

Minimum & maximum modules by inverter table

The table below shows the minimum and maximum number of PVP245S1 or PVP250S1 modules that can be connected to an inverter and the number of module strings required.

Inverter Min number of modules per

string

Max number of modules per

string Number of strings

Inverter zone inputs

1600TL 6 7 1 1

2100TL 8 8 1 1

2000HF 8 9 1 1

2500 10 10 1 1

2500HF 10 11 1 1

3000HF 12 13 1 1

4000TL 8 10 * 1 or 2 2 (A & B)

5000TL 9 11 1 or 2 2 (A & B)

* Total number of modules must not exceed 18.

Refer to wiring diagrams on pages 6 ~ 9 for module and string wiring arrangements.

Wiring

Only UV-resistant cables and connectors approved for outside use should be used.

To minimise the risk of indirect lightning strikes, avoid forming closed loops when designing the system. Check to ensure that system wiring is correct before commissioning modules. If the measured open circuit voltage (Voc) and short circuit current (Isc) differ from specifications a wiring fault may be present.

Recommended cable size for plug connectors is 4 – 6 mm2, with a temperature range of -40 to +80ºC. Plug

connectors are polarised and should be firmly connected. All connections should be secure, tight and electrically and mechanically sound. Correct DC polarity should be observed at all times Plug connectors should never be used to turn the system on or off i.e. do not connect or disconnect plug connectors under load conditions.

Use only plug connectors supplied with your Solahart PV system. Only solar DC cables with appropriate labelling are to be used. Ensure that all plug connectors and plug wiring are in good electrical and mechanical condition and are not subjected to mechanical stress.

Ensure that all materials meet system requirements such as maximum voltage, current, moisture and temperature when exposed to sunlight.

Under normal conditions, a photovoltaic module is likely to experience conditions that produce more current and/or voltage than that reported under standard test conditions. Accordingly, the values of Isc and Voc marked on the module should be multiplied by a factor of 1.25 when determining electrical component voltage ratings, conductor current ratings, fuse sizes and size of control components connected to the PV module output.


14

Ensure cables are fixed to mounting structure and are not in contact with roof or rear surface of module(s) using UV-resistant cable ties, or other sunlight-resistant devices. A roof flashing such as a Dektite® must be used where wiring penetrates tile or metal roofing. Flashings must be sealed using an appropriate waterproofing compound such as silicone.

All wiring must be protected from mechanical damage and external wiring must be protected from UV radiation. Do not expose the cables to permanent tension. Component plug type and DC cable sizing table

Component / Wiring Plug Cable Size IP Rating

Inverter DC terminal plug connectors Supplied with inverter 4mm2 IP67

Module fly leads Pre crimped on fly leads 4mm2 IP67

5 metre module extension lead Pre crimped on lead 4mm2 IP67

12 metre module extension lead Pre crimped on lead 4mm2 IP67

Wiring – Roof isolator to inverter isolator (NS)

Not required – hard wired 4mm2 N/A

Wiring – Inverter isolator to inverter (NS)

Supplied 4mm2 IP67

(NS)

= Not supplied. All cables/wiring double insulated Solar DC type cable. Inverter DC Plug Connectors

String positive (+) and string negative (-) DC cables connect to all inverters by means of SUNCLIX DC plug connectors, which are supplied with the inverters. Plug type (polarity) can be determined from the polarity symbol marked on the side of the connector.

Inverter DC Plug Connector Assembly

1. Strip DC cable insulation to a length of 12 mm. 2. Insert stripped end of cable into plug as far as it will go.

Proceed to step 6

Proceed to step 5

3. Press clamping clip down until clip audibly snaps into place.

4. Ensure cable is correctly in place and is held in position by clamping clip. If conductors are not visible in the hollow cavity the cable is not in the correct position. Proceed as directed above.

5. Loosen clamping clip with the aid of a small flat bladed screwdriver, remove cable and start again from step 2 after ensuring cable insulation is correctly stripped as described in step 1.

6. Push threaded collar into position and screw to tighten. Collar should be tightened to 2 Nm.

Dektite


15

Warning: Any inverter string inputs which are not used MUST have a DC plug connector with sealing plugs installed to maintain the inverter IP rating. Sealing plugs are provided with the inverter and are inserted into the rear of the relevant DC plug connectors as shown below. AC cable sizing table

Inverter AC cabling must be sized according to the table below and installed in accordance with AS/NZS 3000, AS/NZS 3008 and any local applicable codes. The values shown in the table below will provide a voltage drop of less than 1% which is the maximum permissible.

Conductor cross section

Maximum cable length by inverter

1600TL 2100TL 2000HF 2500 2500HF 3000HF 4000TL 5000TL

2.5 mm2 18.0 m 18.0 m 18.0 m 16.7 m 14.5 m 12.0 m N/A N/A

4.0 mm2 38.1 m 30.0 m 30.0 m 26.0 m 23.0 m 19.0 m N/A N/A

6.0 mm2 57.3 m 45.7 m 45.7 m 40.2 m 39.0 m 39.0 m 23.3 m 18.6 m

10.0 mm2 95.4 m 76.5 m 76.5 m 67.0 m 65.2 m 65.2 m 38.8 m 31.1 m

DC circuit breaker/isolator wiring

The DC circuit breaker/isolators utilised in Solahart PVSP Series PV Systems are not polarity sensitive (non polarised type) however for uniformity they should be wired as shown in the diagram below.

Warning: DC circuit breaker terminal screws must be tightened by hand only. Do not use power tools.

Roof top DC circuit breaker/isolator enclosures must be mounted on an isolator bracket (provided in kit) which is fixed to the module frame. To help prevent UV degradation, roof top DC circuit breaker/isolator enclosures should always be mounted on the south side of the string or array wherever possible. Drill two 4.5 mm holes on the bottom of the module frame and secure isolator bracket to frame using two M4 stainless steel screws, nuts and washers.

The isolator enclosure should be fixed to the bracket in a sideways position using two M4 stainless steel screws, nuts and washers as depicted above. Do not mount the enclosure facing up. Note: All stainless steel screws, nuts and washers are provided in BOS kit.

Warning: Do not drill holes in sides of module frame as doing so will void warranty.

Warning: Place a block of wood between module frame and bottom of module when drilling frame to prevent drill bit from inadvertently damaging rear of module. Drill damage to rear of module will void warranty.

Roof top Isolator mounting diagram


16

String wiring procedure

Warning! Use insulated tools and wear PPE when performing wiring to prevent the risk of electric shock.

It is suggested that modules be covered with an opaque material during wiring to reduce the voltage generated by the string.

The following procedure should be adhered to whilst wiring module strings to prevent the risk of electric shock or inadvertent short circuiting of live cables whilst wiring the roof top DC circuit breaker/isolator:

1. Ensure roof top DC circuit breaker/isolator is in the OFF position and connect first module positive (+) cable to roof top DC circuit breaker/isolator.

2. Connect each module‟s negative (-) cable to the following module‟s positive (+) cable as modules are being installed until the halfway point is reached i.e. fourth module in an eight module string.

3. Install and connect remaining modules but do not connect fourth module negative (-) cable to fifth module positive (+) cable (refer to wiring diagram on page 16). These two cables will be connected at the end of this procedure.

4. Connect last module‟s negative (-) cable to roof top DC circuit breaker/isolator.

5. Complete the circuit by connecting the two string halves together by connecting the positive (+) and negative (-) cables of the two modules left previously disconnected in step 3.

Note: Modules may be connected in different order provided all modules in a string are connected in series.

Environmental factors

Solahart‟s limited warranty is based upon modules being installed in accordance with the following conditions:

Operating temperature -40 to +80ºC. Ensure adequate ventilation behind module(s) especially in hot environments. The minimum clearance between the bottom of the module and the roof is 11 cm.

Modules are designed to be installed in moderate/temperate climatic conditions.

Modules are not suitable for installation in potentially hazardous locations.

Modules should not be installed at the following locations:

Near sources of flammable gases and vapours, such as gas/petrol stations, gas storage containers, spray paint facilities.

Near open flames.

Underwater or in a fountain or other similar water feature.

Where they are exposed to salt. Installations are to be a minimum of 500 meters from the sea.

Where they are exposed to sulfur, such as near sulfur springs or volcanoes, because of the danger of corrosion.

Where they can be exposed to corrosive chemicals.

Note: Warranty does not cover hail, snow or storm damage.

Disclaimer of liability & warranty

Solahart assumes no responsibility for loss, damage or expense resulting from improper installation, handling or misuse of PV modules. Refer to „PVSP Series PV Systems Warranty‟ on page 41 for full warranty terms and conditions.


17

IEC 61730 information

Solahart PVP245S1 and PVP250S1 modules are designed to fulfil the criteria of application class A requirements according to IEC 61730. Modules are qualified for application class A: Hazardous voltage (Higher than 50 V DC) and hazardous power (higher than 240 W) applications where general contact access is anticipated. Modules qualified for safety through EN IEC 61730-1 and -2 within this application class are considered to meet the safety requirements for Safety Class II.

Rated electrical characteristics are within -0/+5% of measured values at standard test conditions of: 1000 W/m

2, 25ºC cell temperature and solar spectral irradiance of AM 1.5 spectrum.

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INSTALLATION – PV MODULES

Ensure „Installation Overview‟ section is read and understood before commencing installation procedures.

SAFETY REQUIREMENTS

The voltage produced by individual modules and modules connected in series (voltages added together) or in parallel (currents added together), can give rise to dangerous voltage and current.

Although the fully insulated plug contacts on the module‟s output cables provide touch-safe protection, you must observe the following points when handling modules, in order to avoid the risk of sparking, fire hazard, burn risk, and lethal electric shocks.

Exercise extreme caution when wiring modules and look out for damaged cable ends, split cable ends, dirt, etc.

Never insert metallic or otherwise conductive objects into plugs or sockets.

Ensure that all electrical connections are completely dry and free from contaminants before they are assembled. Ensure that connections are tightly connected.

Keep all materials, tools and working conditions clean and dry.

Always use appropriate safety equipment such as insulated tools and wear personal protective equipment such as insulated gloves.

FIRE GUIDELINES

Utilise the following fire safety guidelines when installing Solahart PVP2XX series modules:

Solahart modules have a Class C Fire Rating.

Check with local authorities for guidelines and requirements concerning fire safety for any building or structure that the modules will be mounted on or attached to.

The system design should ensure that fire fighting personnel can access the system in the event of a building fire. Check with local authorities for any applicable regulations concerning setbacks or other placement restrictions that may apply for roof-mounted PV arrays.

We recommend that you use DC Ground Fault Interrupters. This may also be required by local and national codes.

All electrical appliances are subject to fire risk. Modules should therefore be mounted over a fire retardant roof covering rated for the application and the minimum distance to the roof top should be 11 cm.

WARNINGS

Warning: This document provides sufficient information for system installation heights up to 20 m. If the installation site is more than 20 m in height contact Solahart Industries for further advice.

Warning: This system has not been certified for, and should not be installed in, wind regions D.

Warning: During installation and when working on the roof, be sure to observe the appropriate OH&S safety regulations and relevant regulations of your local region.

Warning: Ensure electrical connection/ disconnection is performed when the relevant circuit is isolated. Do not connect / disconnect wiring under load conditions.

Warning: Do not expose the PV modules to artificially concentrated light.

MODULE HANDLING

Modules should be handled with care, and the warnings and instructions on module packaging should be observed. Follow these guidelines when unpacking, transporting or storing modules:

Record module serial numbers before installation and note the information in the system documentation.

Carry modules using both hands and do not use the junction box/electrical wiring as a grip.

Do not allow modules to sag or bow under their own weight when being carried.

Do not subject modules to loads or stresses and avoid stepping on or dropping modules.

Keep all electrical contacts clean and dry.


19

If you need to store modules temporarily, keep them in a dry, properly ventilated room.

Do not apply any forces to the module back sheet.

Note that if the module front glass is broken or the laminate back sheet is damaged, it can expose personnel to hazardous voltages. Therefore:

If you must mark modules, avoid using sharp or pointed objects.

Never apply paints, adhesives, or detergents to the back of the laminate.

Do not use any solar module that is damaged or has been tampered with.

Never attempt to disassemble modules.

MOUNTING

Solahart modules are designed strictly for capturing solar radiation and are not suitable for installation as overhead or vertical glazing.

The distance between the modules and the installation surface must be at least 11 cm to ensure adequate cooling.

The array mounting structure should be able to withstand anticipated wind and snow loads. At the bottom of the module frames there are openings which allow rain water to flow away.

NOTE: Do not cover module corner drain holes.

The maximum load the module should be subjected to must not exceed the maximum module load of 551 kg/m² (5400 Pa) (IEC61215). Site-specific loads such as wind and snow need to be taken into consideration to ensure that this weight loading is not exceeded.

Modules are built to withstand a downward force no greater than 551 Kg/m² (5400 Pa). Site-specific loads such as wind or snow need to be taken into consideration to ensure that this limit is not exceeded.

NOTE: In areas of snow build-up modules can be subjected to forces in excess of the stated limit even when snow depth does not appear extreme, thus causing damage to the framework. If the installation is likely to be affected by this, further suitable module support is recommended on the lower row of modules. Fastening the modules to the mounting structure

Each module must be securely fixed to the mounting structure at a minimum of four points. The module mounting clamps should be fastened between 208 ~ 416 mm from the corner of the module. Refer to drawing opposite:

The distance between the end clamp and the end of the rail should be minimum 25 mm.

Before proceeding, note the following:

This document addresses only wind loads on the assumption that wind produces the maximum load factor affecting an installation. Verify that other local factors, such as snow loads do not exceed the wind loads. Give precedence to any factor that does. Wind loads are considered to act on the entire projected area, or may be perpendicular to any surface.

The roof on which the PV system is to be installed must have the capacity to resist the combined Design Dead Load and Live Load at each mounting point.

The installer is solely responsible for:

Complying with all applicable local or national building codes, including any that may have superseded this manual;

Ensuring that the installation complies with AS/NZS 3000, AS/NZS 5033, AS 4509, AS/NZS 1170.2, AS/NZS 1562.1, AS 4777.1, AS/NZS 1768, AS/NZS 3008, AS 2050 and any relevant electrical service and installation rules for the state or territory where the system is installed;

Ensuring that the PV System and associated components are appropriate for the particular installation and the installation environment;

Ensuring that the roof, roof rafters, battens, purlins, connections, and other structural support members can support the total assembly under building live load conditions.

Ensuring only parts supplied by Solahart Industries and installer supplied parts as specified by Solahart Industries are utilised (substitution of parts may void the warranty and invalidate certification);


20

Ensuring that lag screws have adequate pullout strength and shear capacities to suit the installation;

Maintaining the waterproof integrity of the roof, including selection of appropriate flashing; and

Ensuring safe installation of all electrical aspects of the PV system. Installation tools

4 & 6 mm Allen keys or 4 & 6 mm Allen Key fittings to suit torque adjustable drill (for racking components).

Cordless torque adjustable drill.

4.5 mm drill bit (for mounting roof top DC isolator(s) to module frame).

Open-end spanner set 9, 10, 17, 19 mm (required only for mounting with hanger bolts).

Angle grinder with stone disk (for tile cutting if required).

Electricians hand tools (screwdrivers, pliers etc.).

String line.

Timber to shim roof hooks (if required). 1. Determine wind region of installation site

Use the wind region diagram shown below to determine the wind region of the installation site.

Wind region notes:

Wind regions are pre defined for all of Australia by Australian Standard AS/NZS 1170.2. The Wind Region has nothing to do with surrounding topography or buildings.

Most of Australia is designated Region A which indicates a Regional Ultimate Basic Wind Velocity of 45 m/s.

Some areas are designated Region B (57 m/s). Local authorities will advise if this applies in your area.

Region C areas (66 m/s) are generally referred to as Cyclonic and are generally limited to northern coastal areas. Most Region C zones end 100 km inland.

Region D (80 m/s) Australia's worst Cyclonic Region between Carnarvon and Pardoo in Western Australia.


21

2. Determine terrain category of installation site

Terrain, over which the approach wind flows towards a structure, must be assessed on the basis of the following category descriptions:

Terrain Category 2: Water surfaces, open terrain, grassland with few, well-scattered obstructions having heights generally from 1.5 m to 10 m.

Terrain Category 3: Terrain with numerous closely spaced obstructions 3 m to 5 m high, such as areas of suburban housing.

3. Determine PV module orientation and inclination

To maximize system output, install modules at optimum orientation and inclination (tilt) angles. The specifics of this will depend on the installation location and must be calculated by a qualified system designer.

The ideal angle for mounting a module should result in the sun‟s rays falling perpendicular (i.e. at a 90° angle) to the module surface. All modules in each series string should have the same orientation and inclination to ensure that modules do not under perform due to a mismatching of each module‟s output.

Even minor or partial shading of the modules/array will reduce array/system output. A module is considered shade free when it is both:

Free from shade or shadows all year round.

Exposed to several hours of direct sunlight, even during the shortest days of the year.

Note: The following information is provided as a guide only.

Modules should be installed facing toward true north. Where this orientation is not practical, a system facing up to 45° (NW or NE) from true north is satisfactory however losses of up to approximately 6% will occur. A module facing due east or due west will experience a loss in performance of approximately 18%.

Inclination of modules should be approximately equal to the local latitude angle. The latitude of some Australian cities is shown in the „Latitude of Some Australian Cities Table‟ below. Modules may be installed at the roof angle for simplicity of installation and appearance, however, if inclination varies by ±15º or more from the correct inclination, performance losses of 4% or more will occur.

Losses for incorrect orientation and incorrect inclination will be compounded.

If the roof angle is flat, adjustable or fixed tilt legs should be considered to optimise inclination depending upon area.

For an installation at right angles to (across) a tile roof pitch, landscape tile roof hooks are required.

Modules must be installed in a shade free position.

The installer must ensure the structural integrity of the building is not compromised by the PV system installation and the roof structure is suitable to carry the full weight of the modules and racking system. If in doubt consult a structural engineer, who may recommend that the roof structure should be suitably strengthened.

Each module and its fittings including racking weighs approximately 25 kg.

The installation must comply with the standards outlined on page 19.

LATITUDE OF SOME AUSTRALIAN CITIES

Adelaide 35°S Cairns 17°S Hobart 42°S Port Hedland 20°S

Alice Springs 24°S Canberra 35°S Mildura 34°S Rockhampton 24°S

Brisbane 27°S Darwin 12°S Melbourne 38°S Sydney 34°S

Broken Hill 31°S Geraldton 28°S Perth 32°S Townsville 19°S


22

4. Determine type of PV module racking system required

Based on the determination of inclination performed in step 3, determine the type of module racking system required to suit the installation‟s roof pitch and type.

Module racking systems are available as follows:

System Name / Options Suit Roof Type Roof Pitch

1 Std tile / metal roof system Tile / Metal (1)

10 - 45º

2

30° fixed tilt legs Metal (2)

Flat roof

10 - 15° adjustable tilt legs Metal (2)

± Fine tune for optimisation of inclination


± Fine tune for optimisation of inclination


± Fine tune for optimisation of inclination (1)

Non adjustable i.e. follows roof pitch.

(2) Designed for metal roof however system can be installed on tile roof using additional rails and hardware.

Contact Solahart Industries for details. 5. Install PV modules & module racking system

For System 1 installation (standard tile / metal roof system) proceed directly to section „Installation of Standard Tile / Metal Roof System – System 1‟ on page 23.

For System 2 installation (fixed or adjustable tilt legs) proceed directly to section „Installation of Fixed / Adjustable Tilt Leg System – system 2‟ on page 30.


23

INSTALLATION OF STANDARD TILE / METAL ROOF SYSTEM – SYSTEM 1

Determine required roof area

Use the table below to determine the required roof area of the array.

Number of modules

1 2 3 4 5 6 7 8 9 10 11 12 13

1 row 1665(H)

X 1051(W)

1665(H) X

2060(W)

1665(H) X

3069(W)

1665(H) X

4078(W)

1665(H) X

5087(W)

1665(H) X

6096(W)

1665(H) X

7105(W)

1665(H) X

8114(W)

1665(H) X

9123(W)

1665(H) X

10132(W)

1665(H) X

11141(W)

1665(H) X

12150(W)

1665(H) X

13159(W)

2 rows 3330(H)

X 1051(W)

3330(H) X

2060(W)

3330(H) X

3069(W)

3330(H) X

4078(W)

3330(H) X

5087(W)

3330(H) X

6096(W)

3330(H) X

7105(W)

3330(H) X

8114(W)

3330(H) X

9123(W)

3330(H) X

10132(W)

3330(H) X

11141(W)

3 rows 4995(H)

X 1051(W)

4995(H) X

2060(W)

4995(H) X

3069(W)

4995(H) X

4078(W)

4995(H) X

5087(W)

4995(H) X

6096(W)

4995(H) X

7105(W)

4 rows 6660(H)

X 1051(W)

6660(H) X

2060(W)

6660(H) X

3069(W)

6660(H) X

4078(W)

6660(H) X

5087(W)

5 rows 8325(H)

X 1051(W)

8325(H) X

2060(W)

8325(H) X

3069(W)

8325(H) X

4078(W)

6 rows 9990(H)

X 1051(W)

9990(H) X

2060(W)

9990(H) X

3069(W)

7 rows 11655(H)

X 1051(W)

11655(H) X

2060(W)

11655(H) X

3069(W)

Notes:

Modules installed in portrait as per diagram.

For tilt leg systems use row 1 values only. 2 ~ 7 row values do not allow for possible

shading of rows behind. Tilt leg system row spacing must prevent shading of one row

by another and needs to be calculated on an individual site basis, taking into account

orientation, roof pitch and module inclination.

All dimensions in mm.


24

Determine installation area on roof (roof position areas)

The standard tile / metal roof system array must be located on the roof according to the installation‟s wind region and terrain category, as previously determined in steps 1 & 2, and allowable roof position areas.

The diagram opposite details roof position areas 1, 2 & 3. Position 2 & 3 areas are subject to higher wind loadings.

The following table details the allowable position of the array according to wind region, terrain category and roof pitch.

If a position area indicates a roof pitch, any part of the array may be located in the relevant position area provided the roof pitch is greater than or equal to the roof pitch indicated.

If the roof pitch is less than the roof pitch indicated, no part of the array may be located in that position area.

If a position area is not allowed, no part of the array may be located in that position area.

Standard tile / metal roof system roof position installation area

Terrain category 2 Terrain category 3

Pos 1 Pos 2 Pos 3 Pos 1 Pos 2 Pos 3

Wind region A ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 10⁰ pitch

Wind region B ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 15⁰ pitch ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 10⁰ pitch

Wind region C ≥ 10⁰ pitch ≥ 17⁰ pitch Not allowed ≥ 10⁰ pitch ≥ 10⁰ pitch ≥ 13⁰ pitch

Wind region D Not certified for wind region D

Determine maximum rail support spacing (fixing centres for tile roof hooks or metal roof L brackets)

Use the following tables to determine base rail support spacing for the relevant roof type (tile or metal) based on the previously determined wind region, permissible roof position area(s) & maximum height of installation.

Tile Roof – Tile Roof Hook Rail Support Spacing (mm)

Max Height

Wind Region A Wind Region B Wind Region C * Wind Region D

Pos 1 Pos 2 Pos 3 Pos 1 Pos 2 Pos 3 Pos 1 Pos 2 Pos 3 Not certified for wind region D

5 m 1850 1500 1500 1690 1200 1200 1380 980 980

10 m 1850 1370 1370 1540 1090 1090 1260 890 890

* Wind region C installations in terrain category 2 areas with a roof pitch < 17.5⁰ require three rails per

module(s) and reduced rail support spacing. Divide table spacing by 1.4. Contact Solahart Industries for further information.

Tile roof table notes:

Refer to diagram above for position 1, 2 & 3 roof area locations.

Installations with a roof pitch < 17.5⁰ require reduced rail support spacing. Divide table spacing by 1.4.

Tile roof hooks must be fixed to rafters using a minimum of two 14G X 80 mm wood screws (refer to diagram on page 25 for batten/purlin/rafter identification).

Metal Roof – L Bracket Rail Support Spacing (mm)

Max Height

Wind Region A Wind Region B Wind Region C * Wind Region D

Pos 1 Pos 2 Pos 3 Pos 1 Pos 2 Pos 3 Pos 1 Pos 2 Pos 3 Not certified for wind region D

5 m 1320 1110 1110 1320 690 690 770 470 470

10 m 1200 1010 1010 1200 630 630 700 430 430

* Wind region C installations in terrain category 2 areas with a roof pitch < 17.5⁰ require three rails per

module(s) and reduced rail support spacing. Divide table spacing by 1.4. Contact Solahart Industries for further information.

Refer to following page for important metal roof table notes.


25

Notes to metal roof table on previous page:

Refer to diagram above for position 1, 2 & 3 roof area locations.

Installations with a roof pitch < 17.5⁰ require reduced rail support spacing. Divide table spacing by 1.4.

L brackets must be fixed to:

o timber rafters or metal purlins located under sheet metal roof using 14G X minimum 90 mm screws through sheet metal roof with gasket. Longer screws may be required depending upon the installation‟s roof type. 50 mm minimum embedment applies to timber rafters; or

o timber battens located under sheet metal roof using wood screws through sheet metal roof with gasket, provided that battens have been determined to be suitable to carry system load. Advice should be sought from a structural engineer. Length of screws will be determined by the installations roof type. 35 mm minimum embedment applies to timber battens. Note: L bracket spacing for wind regions A & B remains unchanged however L bracket spacing for wind region C must be reduced by 10% when fixing to timber battens.

Metal purlins must be ≥ 0.75 mm thick.

Screws provided are wood screws suitable for timber only. Screws used in metal purlins must be suitable for metal structures and have a TPI (thread per inch) of 14.

Verify acceptable rail end overhang

Rail end overhang must be no greater than 50% of rail support (fixing centre) spacing. For example; if rail support spacing is 1200 mm, rail end overhang can be up to 600 mm. In this case, two rail support brackets can support a rail as long as 2400 mm (1200 mm between brackets and 600 mm of overhang at each end). Continued on next page.


26

Plan the module layout

Overview of components

Overview of components for tile roof

Rail Rail splice Rail end clamp Inter-module clamp

Tile roof hook

Z-module with Allen head bolt

Overview of components for metal roof

Rail Rail splice Rail end clamp Inter-module clamp

Metal roof L bracket



27

Installation procedure

Note: Modules must be wired and grounded (earth bonded) according to AS/NZS 3000, AS/NZS 5033 and any relevant electrical service and installation rules for the state or territory where the system is installed. All module wiring should be performed as modules are being installed (refer to „String Wiring Procedure‟ on page 16). For earth bonding details refer to page 11.

For tile roof installations start at step 1.

For metal roof installations start at step 8.

Incorrect Correct

1. Determine and mark position of tile roof hooks according to your plans. Remove roof tiles at marked positions or, if possible, simply move tiles up slightly.

2. Fix tile roof hooks to rafters using two 14G X 80 mm wood screws. Warning! Do not fix screws to tile battens. Ensure a 50 mm minimum screw embedment into rafters.

3. Warning! Tile roof hooks must not press against roof tile and must be fixed flush with rafters. If necessary pack underneath tile roof hook with timber.

4. Perform this step for grooved tiles only. If plain flat tiles are used (such as shingles) proceed directly to step 6.

If necessary use an angle grinder to chase a recess (or remove raised groves) on the tile that covers the tile roof hook at the point where the tile roof hook protrudes through so as the tile lies flat. If grooved tiles are used it will also be necessary to cut a recess into the tile located below the tile roof hook.

5. Warning! Do not use tile roof hooks as a climbing support as extreme loading of this point could cause damage to the tile below. Proceed directly to step 10.

6. Variation for tile roof hook installation on plain tile roof such as shingles: With plain tile roof cladding a portion of tile must be cut and removed from the tile around the position of the roof hook.

7. A titanium zinc metal sheet must be cut to fit with an overlap of at least 20 mm around the recess and installed under roof hooks. Note warnings in steps 3 & 5 and when complete proceed directly to step 10.

8. For metal roof installation L brackets are utilised instead of roof tile hooks. Pre drill through roof cladding (on top of crest) at planned locations and screw L bracket with sealing gasket into rafter, timber batten or metal purlin using 14G X 90 mm screw taking note of requirements outlined in step 9.

9. Check L bracket to ensure that fastening screw tightly fixes sealing gasket without damaging roof cladding, and ensure that head of fastening screw does not obstruct elongated adjustment hole in L bracket, visible in step 8 diagram. Warning! Ensure a 50 mm minimum screw embedment for rafters or 35 mm for timber battens.


28

10. Install first rail piece onto tile roof hooks (or L brackets). If your rack consists of rails of different lengths, always begin with the shortest piece. Install rail loosely onto roof hooks using Allen head bolt, washer, retaining washer and Z-module (2 to 3 turns of the bolt are adequate for loose installation). Refer to step 11 for method of inserting Z-module into rail.

11. For easy use of Z-modules ensure that Allen head bolt threads do not project through lower side of Z-module (flush max) so as Z-module is free to move. Position Z-modules in rail channel as shown above and fasten loosely with 2 to 3 turns of Z-module Allan head bolt. The rail can then be freely moved along Z-modules.

12. Optimum adjustment of rail vertical and horizontal positioning can be made by taking advantage of the long hole in the tile roof hooks (or L brackets) and the still loose connection of the rail Z-modules. This adjustment will be performed in the next step.

13. Install the first frame rail pieces for each row as explained in steps 10 – 12, align rail ends (use a string line if necessary) and tighten Z-module Allen head bolts to a torque of 21 Nm. If additional rails and rail splices are required proceed to next step otherwise proceed directly to step 15.

14. Slide rail splices half way onto the rear side of each of the previously installed rails and tighten splice Allen head bolt to 21 Nm. Install additional rails as explained in steps 10 – 12 and slide new rails into splices and tighten remaining splice Allen head bolt to 21 Nm.

15. System is now ready for installation of the lowest row of modules. Before installing modules, mount two M8 X 20 mm nuts and bolts (shank downwards) into mounting holes located 200 mm up from bottom of each module (lower row of modules only) and tighten nuts. Place first left hand module onto racking so that bolts sit into rail as detailed above right (these two bolts are utilised to prevent the modules slipping off the rails). Adjust and fix module wiring for later connection.


29

16. Slide a rail end clamp into top of each rail (same procedure as in step 11 but on top of rail). Ensure end clamps are tight against module and do not overhang rail ends. Tighten each end clamp Allen head bolt to 21 Nm. Right hand illustration details cross section of an end clamp when correctly installed.

17. Slide a rail inter-module clamp into top of each rail. Ensure inter-module clamp is tight against module and fasten loosely (approx 2 – 3 turns).

18. Place next module onto rail ensuring anti slip bolt sits in top of rail channel. Slide module into inter-module clamps and tighten each inter-module clamp Allen head bolt to 21 Nm. Perform this procedure for each remaining module on the lowest row.

19. Slide a rail end clamp into top of each rail. Ensure end clamps are tight against module and do not overhang rail ends. Tighten each end clamp Allen head bolt to 21 Nm.

20. Slide first (left hand) module of second row into position and perform steps 16 – 20 for all modules on the second row. Repeat step 22 until all modules have been installed.

Optional variant: Leave 18 mm spacing between rows for aesthetic reasons. Inter-module clamps can be temporarily installed on the centre of each module between rows to keep spacing uniform.

Module installation is now complete.


30

INSTALLATION OF FIXED / ADJUSTABLE TILT LEG SYSTEM – SYSTEM 2

The fixed / adjustable tilt leg system is designed for a metal roof. This system can be installed on a tile roof using additional rails and hardware. Contact Solahart Industries for more information. Determine required roof area

The table on page 23 may be utilised to determine the required roof area for each row of modules by using the „1 row‟ row. Note: The distance between rows needs to be calculated based on orientation, roof pitch and final inclination to prevent rows shading row behind. Do not use row 2 ~ 7 rows. Determine installation area on roof (roof position areas)

The fixed / adjustable tilt leg system array must be located in permissible roof position areas on the roof according to the installation‟s wind region and terrain category, as previously determined in steps 1 & 2.

The diagram opposite details roof position areas 1, 2 & 3. Position 2 & 3 areas are subject to higher wind loadings.

Refer to the following table to determine allowable position fixing areas according to wind region and terrain category.

If a position area is not allowable, no part of the array may be located in that position area.

Fixed / adjustable tilt leg system installation area

Terrain category 2 Terrain category 3

Pos 1 Pos 2 Pos 3 Pos 1 Pos 2 Pos 3

Wind region A YES YES NO YES YES YES

Wind region B YES NO NO YES YES NO

Wind region C NO NO NO YES NO NO

Wind region D Not certified for wind region D

Determine maximum foot spacing (fixing centres for leg feet)

Use the following tables to determine leg foot spacing for the relevant leg type based on previously determined wind region and maximum height of installation.

10 - 15º Adjustable Tilt Leg & Foot Spacing (mm)

Max Height Wind Region A Wind Region B Wind Region C Wind Region D

5 m 1560 975 660 Not certified for wind region D 10 m 1420 890 600

15 - 30º Adjustable Tilt Leg & 30º Fixed Tilt Leg & Foot Spacing (mm)



30 – 60º Adjustable Tilt Leg & Foot Spacing (mm)



Table notes:

Refer to diagram above for position 1, 2 & 3 roof area locations

Feet and legs must be fixed to:


31

o timber rafters or metal purlins located under sheet metal roof using 14G X minimum 80 mm screws through sheet metal roof with gasket. Longer screws may be required depending upon the installation‟s roof type. 50 mm minimum embedment applies to timber rafters; or

o timber battens located under sheet metal roof using 14G X minimum 80 mm screws through sheet metal roof with gasket provided that battens have been determined to be suitable to carry system load. Advice should be sought from a structural engineer. Longer screws may be required depending upon the installation‟s roof type. 35 mm minimum embedment applies to timber battens. Note: feet and leg spacing must be reduced by 20% when fixing to timber battens.

Feet and leg spacings in table apply to metal purlins ≥ 1 mm thick.

Screws provided are wood screws suitable for timber only. Screws used in metal purlins must be suitable for metal structures and have a TPI (thread per inch) of 14.

Verify acceptable rail end overhang

Rail end overhang must be no greater than 50% of leg and foot spacing. For example; if leg or foot spacing is 1200 mm, the rail end overhang can be up to 600 mm. In this case, two feet can support a rail as long as 2400 mm (1200 mm between feet and 600 mm of overhang at each end). Continued on next page.


32

Plan the module layout

Overview of components

Overview of components for adjustable tilt legs

Rail Rail splice Rail end clamp

Inter-module clamp


Front rail & leg foot

Fixed tilt leg

Overview of components for 30º fixed tilt legs

Rail Rail splice Rail end

clamp Inter-module

clamp Z-module with Allen head bolt

Front rail & leg foot

Fixed tilt leg


33

Installation procedure

Note: Modules must be wired and grounded (earth bonded) according to AS/NZS 3000, AS/NZS 5033 and any relevant electrical service and installation rules for the state or territory where the system is installed. All module wiring should be performed as modules are being installed (refer to „String Wiring Procedure‟ on page 16). For earth bonding details refer to page 11.

Adjustable tilt leg foot

30º fixed tilt leg foot

1. Determine and mark position of feet according to your plans. For clip lock type roof where feet will not fit on ridges: Feet may be fixed to valley of roof sheet however ensure feet gaskets are securely sealed.

2. Place rubber sealing gasket under feet and fix feet to rafters using a minimum of two 14G X 80 mm screws. Warning! Ensure a 50 mm minimum screw embedment applies for rafters or 35 mm for timber battens. Use alternative foot type shown on right if 30º fixed legs are utilised.

3. Only perform this step if adjustable tilt legs are utilised. If 30º fixed tilt legs are utilised proceed directly to step 4.

Insert feet U brackets into feet and loosely fasten Allen head bolt and nut to allow for later adjustment. Allen head bolt and Z-module on top of U bracket is utilised to attach rails in next step.

4. Install first front rail piece of each row onto feet. If your rack consists of rails of different lengths, always begin with the shortest piece. Install rail onto feet using Allen head bolt, washer, retaining washer and Z-module and loosely tighten Allen head bolt. Refer to step 5 for method of inserting Z-module into rail. Note: If extra rail and rails splices are to be installed do not install these yet.

5. For easy use of Z-modules ensure that Allen head bolt threads do not project through lower side of Z-module (flush max) so as Z-module is free to move. Position Z-modules in rail channel as shown above and fasten loosely with 2 to 3 turns of Z-module Allan head bolt. The rail can then be freely moved along Z-modules.

6. Optimum adjustment of rail positioning can be made by taking advantage of the still loose connection of the Z-modules. This adjustment will be performed later in this procedure.

Adjustable tilt legs 30º fixed tilt legs

7. For adjustable tilt legs: Place rear legs into feet, insert Allen head bolt, washer, retaining washer and nut and fasten loosely to allow for later adjustment.

For 30º fixed tilt legs: Place rear legs onto feet, insert Allen head bolt, washer, retaining washer and nut and tighten to 21 Nm. Proceed directly to step 10.

8. loosen leg telescopic section Allen head grub screw, adjust leg length according to your plans and tighten grub screw to 21 Nm.

9. Fix leg L bracket to leg using Allen head bolt, washer, retaining washer and nut and tighten loosely to allow for later adjustment.


34

10. For adjustable tilt legs: Loosely fix base rail to leg L brackets using Allen head bolt, washer, retaining washer and Z-module visible on L bracket in step 9 diagram.

For 30º fixed tilt legs: Loosely fix base rail to legs using Allen head bolt, washer, retaining washer and Z-module.

11. Align all rail ends, and for adjustable tilt legs, align rail tilt orientation (use string lines if necessary). Tighten all previously loosely installed rail and feet Z-module Allen head bolts to a torque of 21 Nm. If additional rails and rail splices are required proceed to next step otherwise proceed directly to step 13.

12.Slide rail splices half way onto the rear side of each of the previously installed rails and tighten splice Allen head bolt to 21 Nm. Install additional rails as explained in step 10 and slide new rails into splices and tighten remaining splice Allen head bolt to 21 Nm.

13. Place first left hand module onto racking. Slide a rail end clamp into top of each rail (same procedure as in step 5 but on top of rail). Ensure end clamps are tight against module and do not overhang rail ends. Tighten each end clamp Allen head bolt to 21 Nm. Right hand illustration details cross section of end clamp when correctly installed.

14.Slide a rail inter-module clamp into top of each rail. Ensure inter-module clamps are tight against module and fasten loosely (approx 2 – 3 turns).

15. Place next module onto rail. Slide module into inter-module clamps and tighten each inter-module clamp Allen head bolt to 21 Nm. Perform this procedure for each remaining module.

16.Slide a rail end clamp into top of each rail. Ensure end clamps are tight against module and do not overhang rail ends. Tighten each end clamp Allen head bolt to 21 Nm.

17. Slide first (left hand) module of second row into position and perform steps 13 – 16 for all modules on the second row (similar to illustration above). Repeat step 17 until all modules have been installed.

Module installation is now complete.

35

INSTALLATION – LABELLING

This information is supplied here as a guide only. Additional labels may be required depending upon the installation and local requirements. Labels must be constructed to AS 1319 and installed according to AS 4777.1, AS/NZS 5033 and any local regulations. Refer to aforementioned standards for more information.

The purpose of labelling is to clearly indicate that the electrical installation has multiple supplies and which circuits are affected by these supplies. Labelling also identifies the components that isolate the various supplies. Labels relating to the inverter energy system must be placed on the switchboard to which the inverter energy system is directly connected. If the inverter energy system is directly connected to a distribution board, additional labels must also be placed on the main switchboard and all intermediate distribution boards. The following table details labels that are supplied in Solahart PV System BOS kits.

Label Colour Location

White on red Prominent position on main

switchboard

White on red Main switch

White on red

Solar main switch if inverter is located adjacent to switchboard

White on red Solar main switch if inverter is not located adjacent to main

switchboard

White on red Prominent position adjacent to meter box and building‟s main

switchboard

Black on white Rooftop and inverter Solar D.C.

isolators

Black on white Inverter A.C. isolator

White on red

Main switchboard and all intermediate distribution boards

where inverter is directly connected to a distribution

board.

Black on white Prominent position at inverter

OR

36

INSTALLATION – COMMISSIONING

Systems must be commissioned according to AS/NZS 5033. Commissioning tests are required to ensure the system complies with the aforementioned standard. Commissioning information is provided here as a guide only. A copy of relevant commissioning documents should be provided to the owner and a copy kept by the installer.

String open circuit voltage (Voc) test

This test is performed to ensure that wiring polarity and continuity of the PV array is correct. Measurements should be made under stable irradiance conditions close to solar noon if possible. Measure each string open-circuit voltage (Voc) at the module side of the rooftop DC circuit breaker/isolator (which should be in the OFF position).

The voltage measurement obtained should be the number of modules in the string multiplied by the Voc of one module (34.3 V DC for 245 W modules and 34.5 V DC for 250 W modules at NOCT).

I.e. for a string with 8 X 245 W modules: String Voc = 8 X 34.3 V DC = 274.4 V DC

The open-circuit voltage (Voc) of every string must be measured before connecting it to the inverter and must be within 5% of the calculated value. If readings are outside the calculated value by more than 5% then connections must be verified for polarity, continuity and possible faults and repaired where necessary. Once verification has been satisfactorily completed, strings may then be connected to the inverter.

Indicative String Voc Table @ NOCT*

Number of modules in string 6 7 8 9 10 11 12 13

Voc PVP245S1 modules (245 W) 206 240 274 309 343 377 412 446

Voc PVP250S1 modules (250 W) 207 242 276 311 345 380 414 449

* Values measured at normal operating cell temperature (NOCT) defined as: irradiance of 800 W/m2,

Spectrum AM 1.5, wind speed 1 m/s and ambient temperature 20º. Variations from NOCT values will affect actual Voc and should be allowed for.

Solar isolation device(s) tests – rooftop DC circuit breaker/isolator(s)

This test is performed to ensure the rooftop DC circuit breaker/isolator(s) are isolating the string(s) from the inverter when in the OFF position. Note: Ensure correct system start up and shut procedures are observed when conducting tests and reinstating system.

1. Ensure AC circuit breaker/isolator is in the OFF position.

2. Turn all DC circuit breaker/isolators to the ON position (rooftop and inverter DC circuit breaker/isolators).

3. Ensure PV system is operating under irradiance conditions greater than 500 W/m2.

4. Turn OFF all rooftop DC circuit breaker/isolators.

5. Test all inverter DC input terminals for the presence of a DC voltage. If a DC voltage is present a rooftop DC circuit breaker/isolator or system wiring is faulty and will require replacing or repairing.

6. Turn all rooftop DC circuit breaker/isolators to the ON position and verify that the PV strings reconnect to the system by performing a DC voltage test at the inverter.

Solar isolation device(s) test – inverter DC circuit breaker/isolator(s)

This test is performed to ensure the inverter DC circuit breaker/isolator(s) are isolating the string(s) from the inverter when in the OFF position. Note: Ensure correct system start up and shut procedures are observed when conducting tests and reinstating system.

1. Ensure AC circuit breaker/isolator is in the OFF position.

2. Turn all DC circuit breaker/isolators to the ON position (rooftop and inverter DC circuit breaker/isolators).

3. Ensure PV system is operating under irradiance conditions greater than 500 W/m2.

4. Turn OFF all inverter DC circuit breaker/isolators.

5. Test all inverter DC input terminals for the presence of a DC voltage. If a DC voltage is present an inverter DC circuit breaker/isolator or system wiring is faulty and will require replacing or repairing.

6. Turn all inverter DC circuit breaker/isolators to the ON position and verify that the PV strings reconnect to the system by performing a DC voltage test at the inverter.

INSTALLATION – COMMISSIONING

37

Verification of module and module rail earthing resistance

This test is performed to ensure modules and module rails have the correct earthing resistance. Earthing resistance should be 0.5 ohms or less.

1. Using a multimeter on the ohms scale measure between each module and the system earth wire.

2. Using a multimeter on the ohms scale measure between each module rail and the system earth wire. Inverter commissioning

For inverter commissioning procedure refer to the relevant PV Inverter Installation Guide for the model inverter installed.

38

ENGINEERING CERTIFICATION

ENGINEERING CERTIFICATION

39

40

DOCUMENT REVISION

The following table details document changes by revision.

Title: Solahart PVSP Series PV Systems Document No: 122175

Revision Details of change D.O.I.

A Owners Guide issued for PVSP Series PV Systems. 09/11

B

Addition of table and diagram to determine required roof area of PV modules (page 23).

10/11

Changes to roof position areas for tile/metal roof system due to new certification @ 4000 Pa. This affects the whole of the section titled „Determine installation area on roof‟ including table notes (page 24 ~ 25).

Changes to roof position areas for fixed/adjustable tilt leg system due to new certification @ 4000 Pa. This affects the whole of the section titled „Determine installation area on roof‟ including table notes (pages 30 ~ 31).

Addition of Engineering Certification for array racking systems (pages 38 ~ 39).

C Addition of „Engineering Certification‟ section (page 38) 10/11

D

Addition of „Electrical Safety‟ section (page 4)

11/11

Addition of „PV Module‟ section to „Periodic Maintenance‟ section (page 5)

DC roof isolator enclosures to be installed on south side of array (page 15)

Addition of „Environmental Factors‟ section (page16)

Addition of „Safety Requirements‟ section (page 18)

Addition of „Fire Guidelines‟ section (page 18)

Addition of „Module Handling‟ section (page 18)

Addition of „Mounting‟ section (page 19)

Extra text in „Determine PV Module Orientation & Inclination‟ section (page 21)

Additional „Solar Array On Roof‟ label required at main switchboard (page 35)

Warranty revised (page 41)

SOLAHART PVSP SERIES PV SYSTEM WARRANTY

– AUSTRALIA ONLY

Your new PV System comprises a PV Module, an Inverter and certain other components (together the PV

System). Alternatively, you may add Solahart components to your existing PV system. The PV System and

any components supplied by Solahart are covered by a warranty given by Solahart Industries Pty Ltd ABN

45 064 945 848 of 1 Alan Street, Rydalmere NSW 2116 (Solahart). The terms of your warranty are set out

below. This warranty consists of a number of parts:

(a) The specific warranty terms for Solahart Modules;

(b) The specific warranty terms for Solahart Inverters;

(c) The specific warranty terms for the balance of the system;

(d) The specific warranty terms for the labour; and

(e) General terms which apply to all of the above.

This Limited Warranty is valid in Australia for all Solahart PV Systems sold after 1st December, 2011. If a

subsequent version of this warranty is published, the terms of that warranty will apply to products

manufactured after the date specified in the subsequent version.

Solahart issues the following voluntary warranty to the end-user who purchased the System in Australia and

put the System into use for the first time (the „Original End-User‟). This warranty is in addition to any rights

and remedies that you may have under the Australian Consumer Law.

Solahart offers national service through its Dealer network. Solahart will repair or replace parts subject to the

terms of the Solahart warranty. Solahart, in addition can provide preventative maintenance and advice on the

operation of the PV System. You can contact Solahart on 1800 638 011 to arrange a service call or to find

out details about this warranty.

PART A - PVSP Series Modules

Warranty coverage for the Module Subject to the terms and conditions of this Limited Warranty, Solahart

warrants that the Modules:

1. Are free from defects in material and workmanship for a period of :

- five (5) years after the date of installation of the Module when you purchase a PV System from the Solahart range; and

- ten (10) years from the date of installation of the Module when you purchase a PV System from the Solahart Premium range,

(the „Warranty Period‟) if installed and used in accordance with the installation instructions set out in the Solahart Owner’s Guide and Installation Instructions which accompanies the Module, and with all relevant statutory and local requirements in the State or Territory in which the Module is installed.

2. Will remain safe and operational if cable and connector plugs are installed professionally and are not permanently positioned in water; provided however, that damage to the cable caused by abrasion on a rough surface due to insufficient fixing or to unprotected running of the cable over sharp edges is excluded. Damage caused by animals is also excluded.

3. Will not experience freezing up of the aluminium frames if installed correctly.

The outer appearance of the Module, including scratches, stains, rust, mould, discoloration and other

signs of normal wear and tear, which occurred after delivery or installation, do not constitute defects,

provided the functionality of the Module is not affected. Glass breakage constitutes a defect only if not

caused by any external influence.

If a defect (as described above) occurs during the Warranty Period materially affecting the functionality

of the Module, Solahart will, at its sole option:

1. Repair the defective Module.

2. Replace the Module with an equivalent product.

3. Refund the original purchase price for the Module as determined by Solahart.

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WARRANTY

42

Warranty Terms, Limitations and Exclusions

This Limited Warranty applies to the original Module and to any approved replacement parts and is not

transferable by the Original End-User, except to the subsequent owner of the property at which the original

PV System was installed and remains installed, provided that this PV System has not been altered in any

way or moved from the structure or property at which it was originally installed.

Notification of a warranty claim hereunder must be given without undue delay after detection of the defect

and prior to the expiration of the applicable Warranty Period and in accordance with the procedure set out

below.

There are many factors that affect the output of your Module. Solahart does not warrant a specific power

output for your Modules. All panels degrade over time and power output is subject to many variables

including the age of the Module.

PART B - PVSP Series Inverters

Warranty coverage for the Inverter

Solahart warrants that its Inverter, when located at its original installation, will operate in accordance with its

specifications in the Solahart's Owner‟s Guide and Installation Instructions for a period of:

- five (5) years from the date of installation of the inverter when you purchase a PV System from the Solahart range; and

- ten (10) years from the date of installation of the inverter when you purchase a PV System from the Solahart Premium range.

If the Inverter fails to operate in accordance with its specifications and this materially affects the usability of

the Inverter, Solahart will, at its sole option:

(a) repair the Inverter;

(b) provide a replacement Inverter swapped; or

(c) refund the original purchase price for the Inverter as determined by Solahart.

PART C - Balance of the System

Warranty cover for the balance of the system

The balance of the PV System (BOS) consists of racking, PV module cabling, circuit breakers and isolators.

Solahart warrants that the BOS supplied by it will operate in accordance with its specifications in the Owner‟s

Guide and Installation Instructions for a period of one (1) year from the date of installation of the BOS. If the

BOS fails to operate in accordance with its specifications and this materially affects the usability of the BOS,

Solahart will, at its sole option, repair or replace the defective component.

PART D - Labour warranty

Warranty cover for labour

In addition to the above coverage, Solahart provides you with 12 months of coverage, from the date of

installation, for all labour costs involved with inspection by Solahart, removal or installation of warranted parts

or components by Solahart of your PV System. Other than this 12 months coverage, this Warranty does not

cover, nor will Solahart reimburse, any on-site labor or other costs incurred in connection with the inspection,

de-installation or removal of defective parts or components, or the re-installation of replaced or repaired parts

or components for your PV System.

PART E - General terms

Back-up if sole or dominant power supply

If PV System is to be the sole or dominant power supply for your business or application, you should ensure

that you have back up redundancy if the PV System were to become inoperable for any reason. We suggest

that you seek advice from your electrician or specifier about your needs and build backup redundancy into

your electricity supply system.

WARRANTY

43

Application of this warranty

This warranty requires that the PV System is installed according to the latest safety, installation and

operation instructions provided by Solahart and with all relevant statutory and local requirements in the State

or Territory in which the PV System is installed, and does not apply to defects, damage, malfunction, power

output or service failures which have been caused by:

1. repair, modifications or removal of the PV System by someone other than a Solahart Service Agent or a Solahart Accredited Service Agent;

2. abuse, misuse or abnormal use, accident, negligent acts, power failures or surges, lightning, fire, flood, hail or any other natural disaster, accidental breakage, actions of third parties and other events or accidents outside Solahart‟s control and/or not arising under normal operating conditions;

3. operating the PV System in an unintended environment or under incorrect safety or protection conditions;

4. failure to operate and/or maintain the PV System in accordance with the Solahart Owner’s Guide and Installation Instructions;

5. transport damage;

6. fair wear and tear from adverse conditions (for example, corrosion, excessive exposure to salt); it is a requirement of this warranty that all installations are to be a minimum of 500 meters from the sea

7. cosmetic defects;

8. any improper attachment, installation or application of the PV System, and any insufficient framing if the PV System is a frameless module;

9. insufficient ventilation of the device;

10. failure to observe the applicable safety regulations; or any factor identified in the Solahart Owner’s Guide and Installation Instructions;

11. Ignoring safety warnings and instructions contained in all documents relevant to the PV System.

If your claim relates to a failure to operate in accordance with the Solahart Owner’s Guide and Installation

Instructions as a result of one of the factors listed above, Solahart may charge you at its standard rates for

its time and materials related to your claim.

Location and positioning

Where the PV System is installed outside the boundaries of a metropolitan area (as defined by Solahart) or

further than 25 km from a regional Solahart Dealer, the cost of transport, insurance and travelling costs to

the nearest Solahart Dealer shall be the owner‟s responsibility. Where the PV System is installed in a

position that does not allow safe, ready access, the cost of accessing the site safely, including the cost of

additional materials handling and/or safety equipment, shall be the owner‟s responsibility.

Replacements

Solahart may use remanufactured or refurbished parts or products when repairing or replacing any PV

System under this Limited Warranty. Any exchanged or replaced parts or PV Systems will become the

property of Solahart. The Warranty Periods set out above will not be extended in any way in the event of a

replacement or repair of a PV System. The replaced PV System does not carry a new Solahart warranty.

Limitation of this warranty

This Limited Warranty is provided voluntarily and free of charge and does not constitute an independent

guarantee promise. Therefore, if any defect materially affects the functionality of the PV System, the Original

End-User‟s remedies under this Warranty are limited exclusively to the remedies set out above in the

warranty cases specified herein.

Subject to any statutory provisions to the contrary, Solahart assumes no warranties, express or implied,

other than the warranties made herein and specifically disclaims all other warranties, merchantability or

fitness for a particular purpose and Solahart excludes all liabilities for any special, incidental, consequential

or punitive damages from the use or loss of use of the PV System to perform as warranted; including but not

limited to damages for loss of power, lost profits or savings nor expenses arising from third-party claims.

This does not apply to the extent Solahart is liable under applicable mandatory laws or in cases of intent or

gross negligence on the part of Solahart.

WARRANTY

44

If you require a call out and we find that the fault is not covered by Solahart's warranty, you are responsible

for our standard call out charge. If you wish to have the relevant component repaired or replaced by Solahart

that service will be at your cost.

Entitlement to claim under this warranty

To be entitled to make a claim under this warranty you need to:

1. Provide proof of purchase documentation and be the owner of the PV System or have the consent of the owner to act on their behalf.

2. Contact your Solahart dealer without undue delay after detection of the defect and, in any event, within the applicable warranty period.

You are not entitled to make a claim under this warranty if your PV System:

1. Does not have its original serial numbers and type plate or numbers are illegible; or

2. Is not installed in Australia.

Warranty Claim Procedure

If you wish to make a claim under this warranty, you need to:

1. Contact your Solahart dealer, provide proof of purchase and owner‟s details, address of the PV System, a contact number and date of installation of the PV System.

2. Solahart will arrange for the PV System to be tested and assessed.

3. If Solahart determines that you have a valid warranty claim, Solahart will organise for the repair or replacement of the PV System or any component in accordance with this warranty.

Any expenses incurred in the making of a claim under this warranty will be borne by you.

The Australian Consumer Law

Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You

are entitled to a replacement or refund for a major failure and compensation for any other

reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced

if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

SOLAHART INDUSTRIES PTY LTD

A.B.N. 45064945848 www.solahart.com.au

FOR SERVICE TELEPHONE 1800 638 011 AUSTRALIA

or refer local Yellow Pages

Revision Date: 2011 November 122175

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