Instruction sheet

www.solarworld.com

MOUNTING SYSTEM FOR SOLAR POWER SYSTEMS PLANNING AND DESIGNOriginal instruction sheet for installers

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Proven quality – simply clever

With for solar arrays you acquired a high quality product from the SolarWorld AG product line. Only the highest quality components are used in the system and frame technology in order to ensuretrouble-free operation of your solar array. The following information explains the proper arrangement of the

based on a sample roof to help you install the system and frame technology without any pro-blems. Any unique structural features must be documented so that the unique features of the roof can be taken into account when planning the frame.

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Table of Contents

Page

Safety information A1 Safety notice classification 4A2 Safety information 5A3 Information about system design 6A4 Installation information 7

System description B1 Proper and improper use 8B2 Technical overview 8B3 System arrangement 10

Mounting example C1 Determining the system position 15C2 Measuring the surface of the roof 16C3 Placing supports 17C4 Installing the ballast trays 18C5 Installing the modules 20C6 Installing the second row 21C7 Interconnecting the installation 22C8 Grounding/equipotentional bonding 23

Maintenance/Cleaning Maintenance and cleaning 24

Liability Liability 25

A

B

C

DE

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Safety informationA

f Ensure that the Sunfix aero duo is used only as intended. Observe local standards, building codes and acci-dent prevention regulations during installation. Safety information for other system components must also be followed.

f Noncompliance with the following instructions may result in electric shock, fire and/or severe injury. f Keep this instruction sheet in a safe place.

Warning symbol, signal word Warning levels

DANGER! Warns of immediate risk of death.

WARNING! Warns of possible risk of death and/or severe injury.

CAUTION! Warns of possible personal injury.

CAUTION Warns of possible property damage without possibility of personal injury.

Read the entire instruction sheet and observe the safety information!

How to use additional notice symbols

Indicates additional important information.

Obey applicable accident prevention regulations during installation.

Do not stand or walk on solar modules.

A1 Safety notice classification

55

A2 Safety information

DANGER! Risk of fatal electric shock

f Solar modules generate power as soon as they are exposed to light. The voltage of a single solar module is less than 50 V direct current (DC). When several solar modules are connected in series, the voltages accumulate and can be dangerously high. When several solar modules are connected in par-allel, the currents are cumulative. Although touch protection is provided in the form of the fully insu-lated plug contacts, the following points must be observed when handling the solar modules to avo-id the risk of fire, sparking and fatal electric shock:

f Do not install solar modules and lines with wet sockets and plugs!

f All work on the lines must be carried out with extreme caution!

f High-contact voltages can occur in inverters even when disconnected!

f Caution is advised in all work performed on the inverter and lines!

DANGER! Risk of fatal arcing

f Solar modules generate direct current (DC) when exposed to light. Breaking a connected string of modules (e.g., when disconnecting the DC line from the inverter under load) may result in dangerous arcing. Please follow the following instructions:

f Never disconnect the solar generator from the inverter while it is still connected to the power grid.

f Ensure that the wire connections are in perfect condition (no cracking, no contamination)!

WARNING! Risk of falling

f Risk of falling when working on the roof and when climbing up and down. Observe accident preven-tion regulations and use suitable fall protection equipment under all circumstances.

WARNING! Flammable materials

f Solar modules must not be operated in the vicinity of equipment or spaces in which flammable gases or dust occur or can collect.

CAUTION! Risk of hand injury

f Hands may be crushed during frame and solar module installation.

f Work must be carried out by trained personnel only.

f Wear protective gloves!

CAUTION! Beware of falling objects

f Tools, mounting materials or solar modules may fall from the roof during installation and injure persons below.

f Block off the area at risk on the ground before starting installation work and warn persons in the vicinity.

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A3 Comments regarding system design

f Ensure adequate load capacity (based on dimen-sions, condition and suitable material properties) of the substructure, support structure and other affected layers (such as an insulation layer).

f Make sure that rainwater runoff is not impeded. f Consider any physical structural issues. f It is to be ensured that the roof structure is even.

If this is not the case, it is to be professionally cor-rected.

f In case of doubt, consult an expert (e.g. a structural engineer, specialist).

f Protect wires installed outdoors from weather, UV light and mechanical damage using suitable precautions (such as by using UV-resistant plastic tubes or wire conduits).

CAUTION! f Escape, rescue and service paths must be obser-

ved when setting up the frame and kept clear.

CAUTION! f The horizontal force on the PV system caused by

wind loads are transferred to the roof structure via anti-slip mats and the resulting static friction. For correct system design it is therefore necessary to determine the static friction between frame, anti-slip mat and roof covering during the planning stage.

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f Obey applicable accident prevention regulations during installation.

f For installation in the roof area, observe all appli-cable regulations.

f Maintain all applicable directives and standards during the installation and commissioning process.

f All persons who are on the roof of a building at least 3 m tall must use fall protection.

f Use barriers to protect persons on the ground below from falling debris.

f Also obey the safety instructions for all other system components (e.g., inverters and solar modules).

f The system must be connected to the public power grid by a professional electrician only. Observe the instruction sheet for solar modules and inverters included in the delivery as well as the mounting and wiring diagram.

f Ensure that all screw connections are securely tigh-tened.

f To prevent damage to the roof covering, do not car-ry out sawing work (base frames) on the roof.

A4 Comments regarding installation

Required tools

1 Cordless screwdriver (15 Nm)

2 Allen wrench (6 mm)

Additionally required materials

1 Ballast elements (e.g. concrete slabs)

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B1 Proper and improper use

System descriptionBProper useThe Sunfix aero duo assembly system is intended for installation of solar power modules on flat roofs of standard construction and height.

Proper use includes observing the instruction sheet and compliance with maintenance, repair and cleaning instructions. The manufacturer does not accept liability for damage resulting from failure to adhere to the instruction sheet.

Improper useThis list does not include all conceivable types of improper use and thus does not make any claim of completeness. The information supplied is intended merely to provide a sense of what constitutes impro-per use.

f The instructions in this installation manual were disregarded.

f The assembly system was:• Not used properly to secure the solar power

modules,• Not installed according to the framework

conditions of this instruction sheet (such as for attachment to a facade)

• Improperly assembled, • Maintained improperly or not at all, • Modified,• Exposed to improper design loads.

f Repairs were improperly carried out. f The system was combined with components from

other manufacturers.

The Sunfix aero duo assembly system is a versatile support structure for installing solar power modules on flat roofs. It is custom-built in advance as a com-plete mounting kit. Information on the existing roof construction and on the static requirements (snow and wind loads, etc.) at the installation site serve as the basis for the customized planning. With each

B2 Technical overview

system, you receive a "frame diagram" and a "DC wiring diagram" custom-made for your PV system. These show the arrangement of the Sunfix aero duo elements as well as the wiring of the modules to the inverters, customized to your roof structure and module arrangement.

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f Permissible building height H ≤ 25 m

f Permissible roof pitch ≤ 5° (flat roof)

f Frame available for module inclinations 10°

f Minimum system size 2 x 4 modules

f Standard static friction value: µ ≥ 0.70 [-]

Lower values are possible after consultation with us and may require an increase in ballast! f The required ballast is determined within the scope of the system design and depends on the system size,

wind load (site, building height), static friction between the system and roof, as well as the presence of an attic.

f Flat roof insulation: The existing flat roof insulation must permit a minimum surface pressure of 60 kN/m².

Sunfix aero duo assembly system features

NOTEThe system is not connected to the roof structure. Stability is only ensured by its own weight and bal-last. The measurement is carried out in accordance with current wind load standards. Nonetheless,

the system is to be checked after extreme wind events as a shift by a few centimeters can never be completely ruled out.

+

+

=

=

+

+ + 37%Fig. B 2-1

+= +

9,6 kg/ m²

14,18kg/ m²

18,86kg/ m²

23,49kg/ m²

10,86kg/ m²

14,54kg/ m²

18,98kg/ m²

23,43kg/ m²

10,84kg/ m²

12,79kg/ m²

15,45kg/ m²

18,21kg/ m²

6x

36x

144x

= 1,5 kN/m²

= 0,5 kN/m² = 0,75 kN/m² = 1,0 kN/m² = 1,25 kN/m²

10 m

1010

B3 System layout

Fig. B 3-1 Detail 1 Fig. B 3-1 Detail 2

Fig. B 3-1 System layout

A

B C

D

A B

5

4

1111Fig. B 3-1 Detail 4Fig. B 3-1 Detail 3

Sunfix aero duo component list

1 Module

2 Module end clamp

3 Module middle clamp

4 Front rack 10°

5 Connecting rack small

6 Connecting rack large

1

DC

32

6

1212

Fig. B 3-1 Heavy load version

Heavy load version

Fig. B 3-1 Detail 1 Heavy load version Fig. B 3-1 Detail 2 Heavy load version

E F

E

F

4

3

6

5

8

7

2

1313

NOTEApplication of heavy load rack from 2,4 kN/m² combined pressure load on module.

Sunfix aero duo component list

1 Modul

2 Module clamp

3 Module middle clamp

4 Front rack 10°

5 Connecting rack small

6 Connecting rack large

7 Heavy load rack 10°

8 Heavy load rack large

1

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System layout dimensions (example)

Fig. B 3-2 Detailed system layout

Fig. B 3-3 System layout side view

1515

Sample installation CThe following describes an example installation of a system with 2 x 4 modules.

Fig. C 1-1

C1 Determining the position of the system

NOTEEdge distances: For the installation of systems on flat roofs, it should be considered that there are particular load assumptions in the edge areas of roofs due to possible turbulence. Details can be found in DIN 1055 and/or EN 1991 (Eurocode 1). SolarWorld's Sunfix aero duo installations are only able to meet these requirements if the solar system maintains a continuous distance of at least 0.6 m to the edge of the roof and/or to the parapet. It must not fall below the 0.6 m distance specification. Installation of Sunfix aero 2.0 in the roof edge zone with a distance between 0,6 m and 1,2 m to the edge is possible, but requires higher ballast than the installation in the core zone of the roof (more than 1,2 m distance to the roof edge) due to high wind loads. The technical feasibility to install Sunfix aero in the roof edge zone with a distance less than 0,6 m to the roof edge has to be checked individually.

Securing against slipping: Due to linear thermal expansion of metal compo-nents of SolarWorld's Sunfix areo duo 2.0 system, movement of the system on the roof in the direc-tion of the cullis may occur in extreme cases. This is relevant for roofs with a slope angle of 3° or more. In this case, the system should be secured on site against long-term slipping. As the following list shows, there are several ways to do this:

f For roofs with a symmetrical layout with respect to a central roof ridge, the system can be secured against slipping by fastening both parts of the system (of the same weight) across the ridge.

f If other attachment points are available it should be verified if these can also be used.

f A principle alternative would be to fasten the system to the parapet via a suitable connection, however, this should also be verified and carried out on site.

In general, for all work that serves to provide additional fastening of SolarWorld Sunfix aero duo systems to the roof on site, the relevant codes of practice, in particular regarding the structural-physical correct sealing when interfering with the roofing shall apply.

0,6 m0,6 m

1616

C2 Measuring the surface of the roof

Fig. C 2-1

NOTEMax. 192 modules should be installed in a con-nected generator field. In one row only a max. of 12 transverse modules may be connected to each other! Then, a new generator field has to be star-ted in each direction!

1. Prior to starting installation, the surface of the roof must be measured in accordance with the planning documents and an initial installation point deter-mined. Marking the front base line using a chalk line and then measuring and appropriately marking the side edge line at a right angle is recommended.

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C3 Placing supports

Fig. C 3-2 Fig. C 3-3

1. After determining the entire base surface of the system, mark the distance to the front rack, posi-tion them and ballast them with a ballast block. To protect the roof covering, beneath the stone, a structural protective mat must be placed on the right and left of each starting piece!

2. Lay down the connection rack large and measure the spacing to the front rack. The connecting rack

can still be shifted while installing the modules. Then, position the next racks at a distance of 1.615 m.

Fig. C 3-1 - a Detailed

983 mm

Auminium

Fig. C 3-1 - b Detailed

Fig. C 3-1 -a

1615 mm

Fig. C 3-1 -b

Aluminium

1818

Fig. C 4-1

A

B

B

Fig. C 4-1 Detailed 2Fig. C 4-1 Detailed 1

C4 Installing the ballast trays

A

Dome-head screwM8x20

Dome-head screwM8x16

Washer M8

Hexagon socket nut

Small ballast tray

Hexagon socket nut

Washer M8

1919

Fig. C 4-2 Detailed 1

Fig. C 4-2

C

D

D

FIg. C 4-2 Detailed 2

C

Washer M8Dome-head screwM8x20

Hexagon socket nut Dome-

head screwM8x16

Washer M8

Hexagon socket nut

Large ballast tray

2020

C5 Installing the modules

f Place the modules on the mounting racks and align them with a spacing of 115 mm between the eastern and western modules. This distance is pre-set by mechanical stops. Insert the end and middle clamps and fixate them using M8 screws.

f From the second module, the cables are coupled with the plug connections prior to laying and attached to the module frame using cable ties.

Torque MA= 15 NmDriver for module clamping: Allen wrench (6 mm)

NOTERecommended tool: Cordless screwdriver

Placing one side down (east or west) first and then placing the opposite module row down is recom-mended.

f Then, the end or center clamps of the previous modules can be mounted and a further module can be installed. An end clamp is then placed at the end of the row and firmly screwed on after ali-gning the last module.

Fig. C 5-1

Fig. C 5-3Fig. C 5-2

2121

C6 Installing the second row

1. After finishing the first row, the distance to the following module row results automatically and the assembly procedure repeats from Fig. C 3-2. The end racks are installed with the last row and

ballasted according to the planning specifications. The number and positioning of the ballast stones can change depending on the wind loads.

Fig. C 6-1

Fig. C 6-1 Detailed 1 Fig. C 6-1 Detailed 2 Fig. C 6-1 Detailed 3

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C7 Interconnecting the solar modules

1. Wire the solar modules according to the wiring diagram.

f Adhere strictly to the specifications of the wiring diagram (distribution of strings, any separating fil-ters, cable groups). Improper wiring can destroy the inverter and/or solar modules.

f In order to minimize inductive coupling in case of strike lightning current, the outgoing and return lines (+/-) of the string must be laid as closely to one another as possible (while avoiding looping).

f Do not under any circumstances allow less than the minimum bending radius for wires (5x wire dia-meter).

f Do not mount or install solar modules at tempera-tures below -5°C.

f Keep sockets and plugs dry during installation.

2. Lay the cable group.3. In doing so, fasten the wires to the supporting profile

with UV-resistant wire ties.4. Mount and wire the next module rows, making

sure of correct polarity.

Testing1. Check that the multi-string solar generator is correctly

connected by measuring the open circuit voltage of the individual strings.

2. Compare the measured values with the specifications.

Deviations are a sign of wiring error.

DANGER! Lethal voltages

f Connecting solar modules in series can cause let-hal voltages!

f Never connect the inverter for testing. f The solar power system must be connected to the

public grid and isolated by a certified electrician only.

f The technical instructions enclosed with the unit shall be strictly adhered to for the installation, electrical connection and operation of the grid-connected inverter.

CAUTION! f Note the currently valid instruction sheet for the

assembly of multi contact plug connectors. Use only approved tools for assembling the cable group. Do not deviate from the procedures descri-bed in the instruction sheet as otherwise there is no guarantee of safety nor compliance with tech-nical data in the case of DIY assembly.

2323

C8 Grounding / equipotentional bonding

Professional grounding is the responsibility of the installation company.

X No external lightning protection available Functional grounding recommended for PV mod-ule frames. Connect all electrically conductive parts to one another by suitable means and con-nect them to the main grounding rail (equipoten-tial bonding strip) using at least 6 mm² (copper).

X External lightning protection available PV module frames must be included in the protec-tion concept for direct strikes. Consult a specialist lightning protection company if needed.

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Maintenance, repair and cleaningDCAUTION!

f For repairs, use original factory spare parts only! f The use of other spare parts can cause serious per-

sonal injury and property damage!

PV system maintenanceThe system should be inspected annually for the following:

f All fasteners secure and free of corrosion f All cable connections secure, clean and free of cor-

rosion f Wires and front glass intact

f Do not stand or walk on modules!

f Any solar module cleaning required is to be done in keeping with the Sunmodule user information.

f In case of heavy contamination (reduced per-formance), we recommend cleaning without cleansing material, using large amounts of water (using a hose) and a gentle cleaning tool (sponge). Under no circumstances must dirt be scraped or rubbed off dry, as this may cause micro scratches that would impair module performance.

f The generator array should be inspected at regular intervals for flawless condition (visual inspection, connection check).

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Liability

f Since it is not possible to check or monitor com-pliance with the installation manual and the conditions and methods of the installation, ope-ration, use and maintenance of the Sunfix aero mounting system from SolarWorld, SolarWorld AG can accept no liability for damage arising due to improper use, installation, operation or mainte-nance. Liability on the part of SolarWorld is further excluded if SolarWorld, its representatives or vica-rious agents are not guilty of gross negligence or intent. The preceding constraints are not appli-cable to damage due to loss of life, physical injury or health damage or in cases in which liability is mandated by law, e.g. in liability for acceptance of a warranty, liability under the German Product Liability Law or in cases of culpable violation of essential contractual obligations (cardinal obliga-tions).

f The preceding liability constraints notwithstan-ding, liability on the part of SolarWorld for patent law violations or violations of third party rights arising from the use of solar modules and the assembly systems is excluded unless required by law.

f Text and images in this instruction sheet cor-respond to the state of the art at the time of printing. Subject to change.

E

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Notes

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Notes

SolarWorld AGMartin-Luther-King-Str. 24 53175 BonnGermanyPhone: +49 228 55920-0Fax: +49 228 55920-99service@solarworld.com

www.solarworld.com

SolarWorld AGMartin-Luther-King-Str. 2453175 BonnGermany

SolarWorld Industries America25300 NW Evergreen Rd.Hillsboro, OR, 97124USA

SolarWorld France S.A.S.ZI Bouchayer-Viallet31, rue Gustave Eiffel38000 GrenobleFrance

SolarWorld Africa Pty. Ltd.24th Floor1 Thibault SquareCape Town, 8001South Africa

SolarWorld Asia Pacific Pte. Ltd.107 Amoy Street #03-01 & 04-01 Singapore 069927Singapore

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Production / Research 1 SolarWorld Industries Sachsen / Freiberg, Germany

SolarWorld Innovations / Freiberg, Germany 2 SolarWorld Industries Thüringen / Arnstadt, Germany 3 SolarWorld Industries America / Hillsboro, USA 4 Quatar Solar Technologies / Ras Laffan, Qatar

Sales 5 SolarWorld Headquarters / Bonn, Germany 6 SolarWorld France / Grenoble, France 7 SolarWorld UK / Salisbury, England 8 SolarWorld Italy / Verona, Italy 9 SolarWorld Africa / Cape Town, South Africa 10 SolarWorld Asia Pacific / Singapore, Singapore 11 SolarWorld Japan / Yokohama, Japan

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LOCATIONS OF THE SOLARWORLD-GROUP