solargen solar pv homekit assembly manual

7/30/2019 Solargen Solar PV Homekit Assembly Manual

1/32

Solargen

Please read these instructions before installing or commissioning.

This Solar Photovoltaic system should only be installed by a competent person.

PLEASE LEAVE THESE INSTRUCTIONS WITH THE USER FOR SAFE KEEPING.

P H O T O V O L TA I C M A N U A L

BAXI Heating UK Ltd 2011


2/32


3/32Solargen solar PV 3

Index.........................................................................................................................Table Index................................................................................................................

Figure Index..............................................................................................................

Safety information.....................................................................................................

1.INTRODUCTION...................................................................................................

1.1.Preface...............................................................................................................1.2.Supply and Packaging........................................................................................

1.3.Security Warnings...............................................................................................1.4.Installation Standards.........................................................................................

1.4.1. Safety and Care..............................................................................................

2.KIT CONTENTS..................................................................................................

3.PV KIT INSTALLATION.......................................................................................3.1.PV module........................................................................................................

3.1.1.Choosing the site...........................................................................................

3.1.2.Installation guidelines.....................................................................................3.1.3.Mechanical characteristics..............................................................................

3.1.4 Mechanic Installation.....................................................................................

3.2.PV Generator....................................................................................................3.2.1.PV series connection.....................................................................................

3.2.2.PV module fastening......................................................................................3.3.DC Electric Box (available as an optional extra)...............................................

3.3.1.Components....................................................................................................

3.3.2.Location..........................................................................................................3.3.3.Electric Scheme.............................................................................................

3.3.4.Crimp connectors...........................................................................................

3.4.Inverter..............................................................................................................3.4.1.Installation requirements................................................................................

3.4.2.Clearances.....................................................................................................

3.4.3.Position..........................................................................................................3.4.4.Mounting the inverter.....................................................................................

3.4.5.Connecting PV strings to the inverter.............................................................

3.5. AC electric box (available as an optional extra)...............................................3.5.1.Description.....................................................................................................

3.5.2.Location..........................................................................................................3.5.3.Single line diagram.........................................................................................

3.6.Connection to the grid.......................................................................................

3.6.1.AC cable size.................................................................................................3.7.Energy meter.....................................................................................................

3.7.1.Warnings........................................................................................................

3.7.2.Environmental requirements..........................................................................

3.7.3.Cabling...........................................................................................................3.7.4.Cable specication.........................................................................................

3.7.5.Installation data..............................................................................................3.7.6.Dimensions and mounting..............................................................................

3.8.Electrical diagrams............................................................................................

4.PV SYSTEM PROTECTION................................................................................

4.1.Protection against lightening.............................................................................4.1.1.Array Frame Earthing Decision Tree..............................................................

4.2.Protection against direct contact.......................................................................

4.3.Protection against indirect contact....................................................................4.4.Warning and note signs.....................................................................................

4.4.1.Location of the safety labels...........................................................................

5.PV SYSTEM COMMISSIONING..........................................................................

5.1.Connect a PV system........................................................................................

5.2.Disconnect the PV system................................................................................5.3.Security notes...................................................................................................

6.MAINTENANCE MANUAL.................................................................................

6.1.General information..........................................................................................

6.2.PV generator....................................................................................................6.3.Inverter.............................................................................................................

6.3.1.Safety Warnings............................................................................................

6.3.2.Inverter operation conditions.........................................................................

7.SUPPORTING STRUCTURE ASSEMBLING MANUAL....................................

7.1.Flat roof............................................................................................................7.2.Parallel to pitched roof......................................................................................

8.WARRANTY........................................................................................................9.MAINTENANCE..................................................................................................3010.NOTES..............................................................................................................31

Index

34

5

6

8

88

88

9

10

1111

11

1111

11

1212

1213

13

1313

13

1414

14

1415

15

1616

1616

16

1617

17

17

1717

1717

18

19

1919

20

2020

20

21

21

2121

22

22

2222

22

22

23

2626

29 Baxi Heating UK Ltd 2011.All rights reserved. No part of this publication may be reproduced ortransmitted in any form or by any means, or stored in any retrieval system of any nature (includingin any database), in each case whether electronic, mechanical, recording or otherwise, without

prior written permission of the copyright owner, except for permitted fair dealing under Copyrights,

Designs and Patents Act 1988.

Applications for the copyright owners permission to reproduce or make other use of any part ofthis publication should be made, giving any details of the proposed use to the following address:

The Company Secretary, Baxi Heating UK Ltd, Brooks House, Coventry Road, Warwick CV34 4LL.

Full acknowledgement of author and source must be given.

WARNING: Any person who does any unauthorised act in relation to a copyright work may be

liable to criminal prosecution and civil claims for damages.


4/32Solargen solar PV4

Table index

IndexTable 1. Equipment contained within the photovoltaic kit...................................Table 2. Equipment available as an optional extra.............................................Table 3.Table 4. Inverter installation Minimum distances.............................................Table 5. AC cable cross sections.......................................................................

Table 6. Relation between the kits and the inverter power................................

Table 7. Maximum earth resistance....................................................................Table 8. Spacing between A-frames..................................................................

Table 9. Spacing between the roof supports.....................................................

1010

11

1416

18

2023

27

Mechanical specications.....................................................................



IndexFigure 1. Handling.................................................................................................Figure 2. Fastening the modules to the roof mountings.......................................Figure 3. Modules physical dimensions..............................................................Figure 4. Module Fixing........................................................................................

Figure 5. Cable Routing.......................................................................................Figure 6. PV module junction box........................................................................Figure 7. PV series connection............................................................................

Figure 8. Diagram for the modules ground connection......................................Figure 9. Example of PV mounting......................................................................Figure 10. DC Electric Box.....................................................................................

Figure 11. DC Electric Box location.......................................................................Figure 12. Correct crimping pliers..........................................................................Figure 13. Example of a single line scheme for the DC Electric Box.....................Figure 14. Inverter installation requirements.......................................................Figure 15. Minimum distances...............................................................................

Figure 16. Mounting position..................................................................................Figure 17. Mounting the inverter............................................................................Figure 18. Connecting PV strings to the inverter...................................................

Figure 19. AC electric Box.....................................................................................Figure 20. Example of a single line diagram of the AC electric box.......................Figure 21. Energy meter.........................................................................................

Figure 22. Meter terminal layout............................................................................Figure 23. Meter xing points.................................................................................

Figure 24. 1.32 - 2.64 kWp unilar electrical diagram............................................

Figure 25. 3.96 kWp unilar electrical diagram......................................................Figure 26. Ex. electrical diagram with AC and DC electrical box...........................Figure 27. PV system protection............................................................................Figure 28. Array Frame earthing decision tree......................................................Figure 29. Safety Labels........................................................................................

Figure 30. Warning Sign Injury or death risk.......................................................Figure 31. PV system startup steps.......................................................................Figure 32. Steps for the string disconnection from the inverter..............................

Figure 33. Operational state of the inverter...........................................................Figure 34. A-frame assembly.................................................................................Figure 35. A-frame mounting................................................................................

Figure 36. Spacing between A frame proles........................................................

Figure 37. Transverse prole mounting.................................................................

Figure 38. A frame bracing....................................................................................Figure 39. PV module centre clamp......................................................................Figure 40. PV module side clamps & plastic end caps..........................................Figure 41. Typical structure.....................................................................................Figure 42. Prole connections...............................................................................

Figure 43. Anchors for at tiles.............................................................................Figure 44. Anchors for mechanical tiles................................................................Figure 45. Anchors xed on a pitched roof...........................................................

Figure 46. Standard Mounting kit for portrait installations.....................................

Figure 47. Standard Mounting kit Landscape accesory for Lands. installations...Figure 48. Transverse prole mounting to the roof brackets.................................

Figure 49. PV module centre clamps....................................................................

Figure 50. PV modules side clamps......................................................................Figure 51. End covers for the transverse proles..................................................

Figure 52. Structure for 2 PV modules..................................................................Figure 53. Prole connectors................................................................................

Figure index

9

11

1111

11

1212

1212

13

1313

13

1414

14

1515

16

1617

1717

18

1818

19

1920

20

2121

22

2323

2324

24

2425

25

25

2626

2627

2727

27

2728

28

28



Safety information

In order to reduce the number of deaths and major accidents attributa-

ble to work at height, the health and Safety Executive has introduced

comprehensive regulations and guidance that should be followed by all

businesses working at height.

We consider in the following paragraphs some of the main features of the

regulations and guidance. This is, however, only a limited summary andit is recommended that all businesses planning on undertaking solar PVinstallations obtain a copy of the regulations and guidance issued by the

Health and Safety Executive and carefully consider the contents.

The regulations and guidance state that you are required to carry out

a risk assessment for all work conducted at height and to put in place

arrangements for: Eliminating or minimising risks from work at height.

Safe systems of work for organising and performing work at height.

Safe systems for selecting suitable work equipment.

Safe systems for protecting people from the consequences of work at

height.

The regulations and guidance highlight a hierarchy for safe work at

height:

Avoid the risk by not working at height if practicable.

Prevent falls, where it is not reasonably practicable to avoid work at

height; you are required to take suitable and sufficient steps to prevent

the risk of a fall including selecting the most suitable work equipment (in

accordance with the regulations).

Mitigate the consequences of a fall; where tha risk of a person or object

falling still remains, take suitable and sufficient measures to minimise the

distance and consequences of any fall.

Collective protection measures, such as guard rails on scaffold, should

be given priority over personal protection measures, such as safety har-

nesses.

Within the regulationsframework, you are required to:

1) Assess the risk to help you decide how work safely.

2) Follow the hierarchy for safe work at height (i.e.avoid, prevent andmitigate).

3) Plan and organise your work properly, taking account of weather con-

ditions and the possibility of emergencies.

4) Make sure those working at height are competent.5) Make use of appropriate work equipment.

6) Manager the risks from working on or around fragile surfaces and from

falling objects.7) Inspect and maintain the work equipament to be used and inspect the

place where the work will be carried out ( including access and egress).

When preparing to install a solar Photovoltaic system, it is required thatyou perform a risk assessment in relation to work at height and plan how

you will organise your work, taking into account the site, the weatherconditions and the experience and competence of colleagues or and the

experience and competence of colleagues or contractors who may beworking at height with you.

Risk Assessments

The HSE has published a number of very useful free publications thatadvise how to undertake risk assessments.

Two of these that you should obtain are:Five Steps to Risk Assessment.

A Guide to Risk Assessment Requirements.

The five steps outlined in the HSE leaflet are:

Step 1: Look for the hazardsThis will mean looking at the site and identifying significant hazards. The-

se could be features such as a steep roof, a fragile surface where thecollectors may be mounted, unecen ground or obstructions where access

to the roff might be required.



Step 2: Decide who may be harmed and how

This might mean considering the particular risks that young workers or

trainees might face and thinking about the residents of the household or

visitors who could be hurt by your activities.

Step 3: Evaluate the risks and decide which precautions should be made.

You should consider how likely it is that each hazard will cause harm, de-cide which precautions you might take and then assess, after you havetaken those precautions, whether the remaining risk will be high, medium

or low.Where you identify remaining risks, you should consider which

further action you could take to control the risks so thar harm is unlikely.

Step 4: Record your ndings

If you have fewer than ve employees you do not need to write anything

down, though it is useful to keep a written record of what you have done.If you employ ve or more people you must record the signicant ndings

of your assessment. You must also tell your employees about your n-

dings. You need to be able to show that a proper check was made, that

you considered who might be affected, that you dealt with all the obvioussignicant hazzards, that the precautions you propose are reasonable

and that the remaining risk is low.

Step 5: Review your assessment if necessaryEach solar Photovoltaic installation may bring its own challenges and

present its own particular hazards. You should therefore be careful no

to rely on a standard risk assessment for installing a solar Photovol-

taic system in a house, but at the preparation stage you should considerwhere scaffold or other access equipament might be positioned and look

out for any obvious obstacles to this, such as a conservatory or porch.

In addition to the risks associated with work at height, you should alsoconsider the risks associated with lifting and carrying solar collectors,

using electric drills and using blow lamps or blow torches for soldering.

This is not an exclusive list and you should consider all aspects

Safety information



1. INTRODUCTION

1.1. Preface

Attention

The installation of this photovoltaic kit must only be performed by peoplequalied to the current standards and who are competent to do so.

Any solar PV system must comply with heath & safety requirements,

BS7671 and other relevant standards & codes of practice (working at

heights etc).Other standards which must be adhered to are:

Engineering Recommendation G83/1 (2003) Recommendations forthe connection of small scale embedded generators (up to 16A per pha-

se) in parallel with the public low voltage distribution networks

IEE Guidance Note 7 to BS7671 Special Locations, section 12 SolarPhotovoltaic (PV) Power Supply Systems (ISBN 0 8596 995 3, 2003)

This manual is not intended to replace any best practice guides such

as Photovoltaics in Buildings Guide to the Installations of PV Systemspublished by the DTI or any other standards which maybe relevant which

are in force at the time of writing.

1.2. Supply and Packaging

The photovoltaic (PV) kit will be provided in a package properly develo-

ped for this purpose.This package contains the PV modules, inverter, generation me-

ter, protection switch gear, solar cable, connectors and acces-

sories suitable for use with the Baxi roof mountings supplied.The proles are packaged apart, due to their length.

The package should be transported upright and xed, in order to elimi -

nate any chance of slips and shocks, to avoid damage to the equipment.

Please ensure no materials are placed on top of the packaging.

1.3. Security Warnings

DANGER

Risk of death due to high voltages inside the inverter

All works on the PV System should be performed only by someone qua-

lied to do so, in accordance with CURRENT REGULATIONS & stan -

dards.

CAUTION

Risk of burns due to hot parts of the inverter housingDo not touch the inverter housing during operation.

PV MODULE EARTH CONNECTIONTake into account regulations for earth connection. It is advised to con-nect all exposed metal parts, including the PV frames to ground via ap-

propriate methods suitable in accordance with BS 7671 current edition.

1.4. Installation Standards

The PV system should be installed in accordance with the current electri-

cal regulations; BS7671.

All the safety standards and regulations in force should be known at thetime of installation.

Baxi Heating UK are not responsible for any damage to the equipment

during installation works..The PV modules should be carefully installed; predicting possible adver-

se weather conditions which may causes difculties with the installation,

i.e. high winds & rain.PV modules should be installed facing true South where possible in orderto obtain maximum electrical generation. Slight deviation from South can

be acceptable; this should be checked by a competent person before

commencing with the installation.



1.4.1. Safety and Care

During the installation, the following operation and maintenance

recommendations when handling the photovoltaic modules mustbe taken in consideration:

1. It is recommended to maintain the modules properly packaged, in-side the box, on its transport pallet, until the moment of installation.

2. The front surface of the photovoltaic module should remain covered

with an opaque material until all connections are established and

veried.

3. When exposed to sunlight or other light source, the module produ-ces electricity (in DC current); the association in series of 2 or more

modules produces enough energy to cause fatalities from electro-

cution in case of contact with active parts of the electrical circuit.4. Do not touch the terminals of the connectors when the module is

exposed to light sources; take precautions to avoid the contact with

voltages equal to or higher than 30 Volts DC; the installer should not

forget that a string of modules associated in series will have a totalvoltage equal to the sum of the individual voltages of the modules.

5. Use appropriate tools for electrical work in installation and mainte-

nance operations.

6. Do not disconnect the wires from the module while it is working; therisk of accident is very high due to the electric arcs generated, and

it may also damage the product.

7. The modules should only be connected in a dry place with favorable

climatic conditions.8. DO NOT walk on the module(s), DO NOT place loads on their sur-

faces, DO NOT drop objects on the module, DO NOT knock on the

module with any object.9. When handling, prevent the dropping of modules; a module with

broken glass cannot be used or repaired.

10. The module should always be moved by two people and seized by

the aluminum frame, as shown in (Figure 1).11. Keep the module away from objects that could damage it.

12. Do not install the module near ammable materials, for example fuel

tanks or areas where there are ammable vapors; the connectors

of the module, if poorly coupled, can generate electric arcs causingignition of ammable materials; Keep ammable materials at a mi-

nimum distance of 30 cm between the active parts of the electrical

installation, such as connectors or other connection points.

13. Do not bend, damage or place loads on connecting cables and mo-dule connectors.

14. Do not pierce the aluminum frame, glass or the back protection sur-

face of the module; these actions will void the warranty.15. NEVER, under any circumstances, open the junction

box of the photovoltaic module; besides the personal safety

risk, exposing the electrical parts of an active photovoltaic

module may compromise the proper functioning of the mo-dule.

16. Verify that no other equipment in the facility may cause electrical or

mechanical damage to the module.

17. The installation, operation and maintenance of the module shouldbe performed only by qualied personnel.

18. Take actions to keep children or outsiders away from any element

of the installation.

19. Do not paint or paste any type of adhesive on the module.20. Do not dismantle or remove any part of the module.

21. Do not use metal objects, jewelry and accessories during installa-

tion or maintenance of the module.22. When installing the module, be sure that the cables are always at

the bottom of the junction box.

1. INTRODUCTION

Figure 1. Handling



AC Electric Box

DC Electric Box

2. KIT CONTENTS

Table 1: Equipment contained within the photovoltaic kit

Image Equipment

PV Module

Inverter

Energy meter

Supporting structure

4mm Solar Cable

Connectors

Main AC switch

Main DC switch

Table 2: Equipment available as an optional extra.



410

98235

1229

1639

Figure 3. Modules physical dimensions

Figure 4. Module Fixing

Figure 5. Cable Routing

Table 3. Mechanical specications

3. PV KIT INSTALLATION

Figure 2. Fastening the modules to the roof mountings

3.1. PV module

3.1.1. Choosing the site

The installation site must obey the following points: The modules should be installed facing south

The angle of orientation must be adequate to the site latitude. PV modules must not be shaded. Do not install the system near ammable products.

3.1.2. Installation guidelines

The modules should be properly fastened to the supporting structure, to

be able to withstand wind and snow accumulation. This should be done

only with the equipment supplied and cabling facing downright. (Figure 2)

The module assembly must be in accordance with the procedures descri-

bed in the PV module installation manual.

3.1.3. Mechanical Characteristics

3.1.4. Mechanic Installation

1. Before starting the installation you must be fully equipped in order to

perform the work safely.

2. Check the instructions and precautions including those of the sup-port structure.

3. Do not perforate the structure or the module.

4. The module should be installed with a minimum angle inclinationof 1.

5. The installation must be done with the Junction Box on the upper

side of the module, as shown on the left picture (a); on the right pic-

ture (b), the modules were installed upside down, meaning that thebreather of the Junction Box will be blocked, which will damage the

module in the future; see ( Figure 4).

6. Modules shall be mounted in order to guarantee that minimum 100

mm clearance between the module frames and the support shall bemaintained to assure ventilation.

7. The cable must not be bent or crushed on the direct exit of the cable

screw joint; a minimum bending radius R, equal to or greater than

the cable diameter multiplied by 5, must be maintained; the cablemust be routed in a way that tensile stress on the conductor or con-

nections is prevented see ( Figure 5).

Mechanicalspecifcations

Module dimensions (LxWxH) 1.639 mm 982 mm x 35 mm

Weight 20kg

Solar Cells60 polycrystalline 6 Inch

Cells

Front CoverTempered and Textured 4

mm Glass

EncapsulantEVA (Ethylene Vinyl

Acetate)

Back CoverPPE (Polyester Polyester

Primer)

Frame Silver Anodized Aluminum

Diodes 3 Bypass Diodes (16A)

Junction Box IP 65W/ 3 Bypass Diodes

Cables2 Cables of 0,9 m w/ Tycoconnectors

a b



Electrical installation

You should not use modules with different characteristics in the sameinstallation. The maximum number of modules to be installed in series on

the installation, N_(max), is calculated using the following formula:

N_(max) = V_(Max System) / V_(OC (CTS))

The maximum voltage supported on an installation, with Baxis photovol-

taic modules is 1000 (V)

In Series connection

The resultant voltage of connecting two or more modules in series is thesum of individual voltages of each module. You should never connect

a number of modules whose resultant voltage exceeds the maximum

system voltage (Vsyst).

Parallel connection

The resultant electrical current of connecting two or more modules in

parallel, is the sum of the individual electric currents in each module.Please use an external junction box to make the parallel connection bet-

ween modules.

Whenever more than 2 strings of modules in parallel are connected, eachof those strings should be protected with a fuse that could cut the string

in case of default. The value of the fuse must be 10 A or at maximum 12A. A fuse must be used in each polarity.

Grounding

For safety electrical reasons, the module frame and the installation must

be grounded, to ensure the equipotentiality. This connection also ensu-res that any electric current leakage from the equipment will ow to the

ground. The connection of the frame should be performed by clamping

and should ensure the contact.

MPrime recommends the use of suitable accessories for this purpose.In the frame there are 4 holes with a 4 mm diameter, indicating the earth

symbol, to tighten the connectors of ground protection (see Fig 8). The

section of the protective earth conductor must be equal to or greater thanthe section of the active conductor.

The number of PV modules connected in series depends on the kW out-

put of the inverter.

3.2.2. PV module fastening

The PV modules should be mounted to frames or roof mountingssupplied. No other frame is suitable for the mounting. (Figure 9)


3.2. PV Generator

3.2.1. PV series connection

The PV generator is a group of one or more PV modules connected in

series, parallel or both. (Figure 6)

The series connection of the PV modules is accomplished by connectingthe positive connector to the negative connector of the following module.

(Figure 7)

Figure 7. PV series connection

Figure 8. Diagram for the modules ground connection

junction box

+ - + - + - + - -

+

+ -

Figure 6. PV module junction box

1

2

3

4

5

Figure 9. Example of PV mounting.



+ - + - + - + - + - + - + - + -+ -


Figure 10. DC Electric Box

Figure 11. DC Electric Box location

Figure 12. Correct crimping pliers

WIRING DIAGRAM

Earth Pin MG Earth wire 6mmHO7Z1-K

PE

STRING 1

STRING 2

TYCO CONNECTORS

TYCO CONNECTORS

INVERTER

Wire RV-K 6mm Black

OVP Weidmller

Ref. 8882340001

OK CHANGE OK CHANGE

2

2

PE

WDU 10

Figure 13. Example of a single line scheme for the DC Electric Box

3.3. DC Electric Box (available as an optional extra).

3.3.1. Components

The DC Electric Box contains one type two overvoltage discharger for

protection against indirect lightening strikes. (Figure 10)

3.3.2. Location

The DC Electric Box should be placed at the input on the inverter. If the

cable length between the PV generator and the inverter is longer than

10 m, an additional protection should be used next to the PV generator.

(Figure 11)

3.3.3. Electric Scheme

Figure 8 shows an example of a single line diagram of the DC switch-board. If the PV generator is composed of 3 or more strings, string fuses

should be added to the DC Electric box.

3.3.4. Crimp connectors

When the crimping of connectors is needed to create whips, correct crim-

ping pliers should be used. The left gure shows the pliers required to

crimp the connectors. (Figure 12)




Figure 14. Inverter installation requirements

Table 4. Inverter installation Minimum distances

Figure 15. Minimum distances

Minimum distance

Sides 20 cm

Top 20 cm

Under 20 cm

Front 5 cm

Install inverter in vertical position or tilted backwardswith a maximum angle of 45

Figure 16. Mounting position

Do not install inverter in horizontal or in forward tiltedposition

41 kg

min 45

3.4. Inverter

3.4.1. Installation requirements (Figure 14)

The location and type of installation should be adequate to the inverters

dimensions and weight.

It must be installed on a solid base.The installation should be always accessible (do not install in areas withlimited access), and allow an easy removal of the equipment.

The ambient temperature for operation should be between 25 and +60C.

Do not place the inverter in direct sunlight. Power reduction and overhea-

ting can occur.Do not fasten directly to studded walls, use brick or block walls only.The

inverter may produce noise during operation that may be considered a

nuisance, site the inverter where vibration cannot cause any nuisance.

3.4.2. Clearances

The clearances shown in table 3 should be observed to ensure heat

dissipation and to have enough space to remove the Electronic Solar

Switch. (Figure 15)

3.4.3. Position

The inverter should be placed on a vertical wall. However, if strictly ne-

cessary, it can be installed at a maximum angle of 45. (Figure 16)

Do not install the inverter:

On ammable materials

Near places where highly ammable materials are stored

Potentially explosive atmospheres




Figure 17. Mounting the inverter

Figure 18. Connecting PV strings to the inverter.

communication

connection AC

3.4.4. Mounting the inverter

Use of the support provided to install the inverter is recommended. For a

vertical installation, the support should be mounted using 8mm x 50mmhexagonal head bolts & wall plugs supplied. (Figure 17)

1 Installation with stainless steel hexagonal head bolts and wall plugs;2 Mark the three holes for the bolts with the template3 Drill the holes and insert the wall plugs;

4 Install the top screws leaving 4mm protruding from the wall

5 Hook the inverter with the upper mounting slots on the rear panel, so

as to introduce both splints in the openings at the upper end of the rearpanel.

Visual Inspection: The inverter is properly mounted, only if both splintsare tucked into the rear panel openings.

6 Fasten the bottom bolt to prevent the removal.7 Check the rm mounting of the inverter.

3.4.5. Connecting PV strings to the inverter. (Figure 18)




Figure 19. AC electric Box

Figure 20. Example of a single line diagram of the AC electric box

Table 5.AC cable cross sections

Note: Considering 1% U (Voltage Drop)

OK CHANGE

PIN WDU 35 mm2

2

L1

N

PE

Wire HO7V-K 6mm yellow/green

230 VAC 50 HzPIN WPE 6mm

2

PIN WDE 35mm2

2

PEN

L1Wire HO7V-K 6mm blue

2

Wire HO7V-K 6mm black

R

ID 230V 40A

300 mA

Thermal protector

c shape

25A

1 3

2 4

N

N L1

1

N 2

OVP Weidmller

Ref. 8859730000

INVERTER

3.5. AC electric box (available as an optional extra).

3.5.1. Description

The AC electrical panel consists of a surge protection of type II power

surge from the grid or from the protective conductors. This will also con-

sist of a circuit breaker for over current protection and a circuit breaker forindirect contact protection. (Figure 19)

3.5.2. Location

The AC electric box should be installed as close as possible to theinverters AC output.

3.5.3. Single line diagram

Figure 20 shows the single line diagram of the AC electric box.

3.6. Connection to the grid

3.6.1. AC cable size

The connection to the inverter should be done with 3 core cable (L, N, E).

The AC terminals for grid connection, included in the inverters package,allow the connection of a maximum cross section of 4 mm.

Table 4 presents the maximum length of cables, according to the sectionand output power of the inverter.

Cable cross

secon

Maximun Length

1200 1700 2500 3300

4 mm 51 m 38 m 25 m 16 m

6 mm 77 m 57 m 37 m 25 m

10 mm 128 m 95 m 62 m 41 m

16 mm 205 m 152 m 100 m 66 m

25 mm 321 m 238 m 156 m 104 m

35 mm 449 m 333 m 218 m 146 m




Figure 22. Energy meter

Figure 22. Meter terminal layout

3.7.6. Dimensions and mounting

The meter is provided with two xing points located within the terminal

area, which can be accessed only by removing the terminal cover.

(Figure 23)

3.7. Energy meter

The meter provided in the PV kit is illustrated on the gure 21.

3.7.1. Warnings

DANGER OF ELECTRIC SHOCK

Meters must be installed only by suitably-qualied personnel, observe

the following safety advice. Ensure all activities are undertaken in accordance with the relevant

electrical regulations.

Before installing or removing a meter, or removing the terminal cover

for any reason, isolate the meter from the mains supply by removing

the supply-side fuses or using alternative local arrangements. Take ap-

propriate measures to ensure that the isolation cannot be overridden by

another person. For example, keep physical possession of the supplyfuses.

Clean meters only with a damp cloth or sponge. Do not use excessive

or running water. Install meters in accordance with environmental specications given in

the installation information of the meter manual (P 25).

Use only tools that have been approved for electrical installations.

Do not install meters that are obviously damaged.

Do not install meters that have been dropped or otherwise subjected to

signicant impact even if no damage can be seen.

Following installation, ensure that the meter terminal covers are co-

rrectly tted and sealed to prevent user access.

Ensure that the meter supply cabling is isolated from the mains supply,

and that the isolation cannot be overridden by another person.

Following installation, ensure that the meter covers are correctly tted

and sealed to prevent user access.

3.7.2. Environmental requirements

This meter is certied for indoor use only.Notes: The meter environment must provide sufcient ventilation to pre-

vent overheating when the meter is operating at maximum current. The

meter should not be positioned where it will be subject to direct sunlight.

Operating environment: Temperature: -10C to +45C

Humidity: 40% to 95% RH

3.7.3. Cabling

The terminal layout and details of the mains connections are shown at

Figure 17. For optional input/output connections details, refer to the con-nection diagram provided on the meter. The symbols used on the con-

nection diagram are illustrated in the relevant topics in the Inputs and

Outputs meter manual section (page 22). (Figure 22)

Terminal Function

1- Live in

2- Neutral in

3- Neutral out4- Live out

3.7.4. Cable specication

Any cables used must be suitable for use in accordance with the electri-

cal regulations, BS7671 current edition.

3.7.5. Installation data

Cross sectional cable area: Maximum 35mm

Figure 23. Meter xing points

5mm

25mm

52mm 52mm

130mm

105mm




3.8. Electrical diagrams

The gure 24 and 25 shows the electrical diagrams for installation the

Solar Photovoltaic system with the components provided in the PV kits.

AC and DC electrical box are available as an optional accessory kit and in

the gure 26 show the electrical diagram to install the Solar PV System.

The table below links the inverter to use with the specied Denomination

kit.

Figure 24. 1.32 - 2.64 kWp Unilar Electrical diagram

Figure 25. 3.96 kWp Unilar Electrical diagram

Figure 26. Example Electrical diagram with AC and DC electrical box.

Table 6. Relation between the kits and the inverter power

Denominaon KIT Collectors Number Inverter

1.32 kWp 6 SMA Sunny Boy 1200




. . . . . . . .

+ - - - - - -

-

-+ + + + +

+

-

+

=

PV GENERATOR LABEL 1

LABEL 2

LABEL 5

LABEL 6+SCHEMATIC

LABEL 3

LABEL 4

Solar Cable 4mmSMA SB 1200

E.B.AC1E.B.DC1

Detal2Detal1

Installation in Loft

New AC Installation

Existing House AC Installation

kWh

kWh

MainCosumerUnit

UtilityMeter

GenerationMeter

DNO supply

Main isolator ( Double pole)

Securable in off position only

Inverter

Inverter



4. PV SYSTEM PROTECTION

Figure 27. PV system protection

Figure 28. Array Frame earthing decision tree

In Equipotential Zone?(Note: freestanding ground mounted, or building roofmounted arrays (away from building metalwork) will

normally not be within the equipotential zone. However, asolar thermal system, or other building linked metalwork,installed within reach may extend the equipotential zone

outside the normal building envelope)

Install & bond to earth spike(Note: do not take PME out of

equipotential Zone)(Note: Use 10mm braid or equiv)

Bond direct to ConsumerEarthing Terminal

(Note: Use 10mm braid or equiv)

(Note: If an earth spike is already Installed for Lightning Protection, bond to this braid)(Note: Use 10mm braid or equiv)

Leave Floating

PME Earthing?

Class II modules?and

Class Il Cables, connectors/ions & Junction Boxesand

Isolation Transformer in Inverter?(Note: to BS 3535 between a.c. & d.c.)

Yes

Yes

Yes

No

No

In order to prevent damage to the system due to over currents (overload

or short circuits) that might occur during use, measures for adequate

protection should be taken.

4.1. Protection against lightening

PV systems do not increase the buildings risk of being hit by lightning.Any ear thing arrangements must be in accordance with BS-7430,BS-6651, BS-7671.

If there is already a lightening protection system (LPS) in the building the

PV generator must be connected to it. The internal protection circuit of

the PV should be carefully implemented.Exceptions can be made to photovoltaic systems that are situated in ex-

posed locations, which should have a proper separate protection system

against lightening.If the building does not have an LPS the PV support structure should be

connected to earth, and incorporated in equipotential bonding according

to the gure 27.

4.1.1.Array Frame Earthing Decision Tree

The kits are composed with class II modules, class II DC cables & con-

nectors and are connected to the mains via an inverter with an isolationtransformer. This approach is recommended and permits the array frame

to be left oating. (Figure 28)



Do not work on this equipment

unl it is isolated from both mains

and on-site generaon supplies

Label 1

Label 2

Label 3

Label 4

Label 5

Label 6

Isolate on-site generator at

Isolate mains supply at

WARNINGdual supply

PV system-main a.c.

isolator.

Inverter - Isolate a.c.and d.c. before carryingout work.

PV array d.c. isolator.Danger - contains live partsduring daylight.

Do not disconnect d.c. plugsand sockets under load-turn off a.c. supply first.

PV Array d.c. Juncon Box.Danger - contains live partsduring daylight.

4. PV SYSTEM PROTECTION

Earth resistance () In (mA)

R 100 300

Table 7. Maximum earth resistance

Figure 29. Safety Labels

Figure 30. Warning Sign Injury or death risk

4.2. Protection against direct contact

The protection against direct contacts should be carried out by one or

more of the following processes:

Active part insulation

Use of barriers or enclosures Use of low voltage security Use of reduced voltage protection

The active parts must necessarily be isolated by the use of equipment

that is in accordance with regulations in force and its proper implementa-tion in the installation.

The conductor extremities should be always well isolated, to ensure aprotection higher than IP2X

4.3. Protection against indirect contact

The protection against indirect contacts is based on the automatic cutting

of the power, using a residual current device (RCD) connected to an ap-

propriate protective earth system. (Table 7)

4.4. Warning and note signs

All labels must be clear, easily visible, constructed and afxed to last and

remain legible for the lifetime of the system.

Dual supply labeling should be provided at the service termination, meter

position and all points of Isolation to indicate the presence of on site ge-neration and indicating the position of the main a.c. switch disconnector.

Requirements for labeling are contained within the relevant sections of

this guide. The labels provided in the PV kit can be seen at Figure 29and 30.

4.4.1. Location of the safety labels

The PV installations should be labeled in the following way:

Label 1 Array Junction Box

Label 2 DC plugs and socket connectors - must be xed next to con-

nectors, except those that are inaccessible to anyone except trained per-

sonnel in the course of PV maintenance or fault nding.

Label 3 DC Switch

Label 4 Inverter

Label 5 Main AC isolator

Label 6 Dual supply label to be applied to the service termination, meterposition and all points of isolation to indicate the presence of on site ge-

neration and the position of the main a.c.switch disconnector.

(See in the gure 24, gure 25, gure 26 the end location safety labels)



5.1. Connect a PV system

The system start up must only be performed by a qualied technician.

To start up the PV system one should proceed as follows:

1 Assure that the inverter is not damaged due to shipping;2 - Check the voltage of the PV generator in open circuit. This should notexceed the maximum admissible DC input voltage of the inverter;

3 Connect the positive terminal of the string to the positive string input

of the inverter. Connect the negative terminal of the string to the negative

string input of the inverter. CHECK THE POLARITY!!!4 Not used DC plug connectors should be sealed with the proper sea-

ling plugs;

5 Check the correct connection of the AC cable to the inverter;6 Close the built in DC switch in the inverter;

7 Connect the AC circuit turning on the breaker on the PV electric box;

8 Check the display, to see if the inverter is in function mode, or if it is

giving any kind of error. (Figure 31)

Never disconnect the inverter from the PV installation before iso-

lating from the AC voltage (on the electric box, open the breaker).

5.2. Disconnect the PV system

Any works carried out on the PV system must only be done by a qualied

technician.

To disconnect the inverter from the PV generator, follow the procedures:

1 Turn off breaker on the AC electric Box;

2 Turn of breaker on the DC inverter;

3 Disconnect strings from the inverter.(Figure 32)

5.3. Security notes

PV modules produce electricity when exposed to daylight and individual

modules cannot be switched off. Hence, unlike most other electrical ins-

tallation work, the electrical installation of a PV system typically involvesworking on a live system. See requirements of Regulation 14 of Electri-

city at Work Regulations 1989.

PV presents a unique combination of hazard due to risk of shock, fallingand other simultaneous manual handling difculty. All of these hazards

are encountered as a matter of course on a building site, but rarely all at

once. While roofers may be accustomed to minimising risks of falling orinjury due to manual handling problems, they may not be used to dealing

with the risk of electric shock. Similarly, electricians would be familiar

with electric shock hazards but wi ll not be used to handling large objects

at heights.

5. PV SYSTEM COMMISSIONING

Figure 32. Steps for the string disconnection from the inverter

Figure 31. PV system startup steps.

3. 4.



6. MAINTENANCE MANUAL

Figure 33. Operational state of the inverter

Operation

Failure

Earth Fault

6.1. General information

This document outlines all the relevant parameters for the correct functio-

ning of the PV system. Additionally, the document includes maintenanceinstructions for the correct performance of the PV system.

Pay close attention to the indications contained in this manual.

The maintenance of the PV systems must be always undertaken by acompetent person or persons.Pay attention to standards & regulations in force in order to prevent injury

to persons or damage to equipment.

The maintenance of a PV installation is mostly preventive than corrective.

Maintenance should be carried out on an annual basis.

6.2. PV generator

The PV modules should be visually inspected for any damage and then

washed with a soap & water solution on an annual basis.

Any mounting rails & brackets should be checked for tightness & adjus-

ted accordingly.

Maintenance must be undertaken using appropriate health & safety pre-cautions.

6.3. Inverter

In order to assure optimal performance, it should be checked regularly

with different levels of solar irradiation to ensure optimisation of the sys-tem.

Cleaning procedures on the inverter is only necessary if the heat dissi-

pation is degraded due to dirt on the loops cover (arrowheads fan), fans,

heat sinks, or the space between the inverter and the wall. The dirt shouldbe carefully removed with a soft brush.

If the status LEDs or display is not visible due to the dirt, clean with a

damp cloth. Do not use solvents, abrasives or caustic substances.

The maintenance of the inverter must be conducted according to the pro-cedures described in the inverters manual.

6.3.1. Safety Warnings

The opening of the inverter and

Electric installation Repair

Any works carried out on the inverter should only be performed by a

competent person. Even without external voltage, high voltages can

be produced inside the inverter.These high voltages can cause severe injury and death

The temperature in some parts of the inverters case especially the tem-

perature of the heat sinks can achieve, even during normal operation,

values above 60 C. There is burning risk by touching hot components.

6.3.2. Inverter operation conditions

The operational conditions are indicated by LEDs on the front part of theinverter, and by the built in display.

For the LEDs to indicate an operational condition, the inverter must be

connected on the DC side. There should be a minimum solar radiation tofeed the inverter with the necessary voltage. (Figure 33)

The homeowner should ensure that the LED is illuminated, if possible du-ring different solar radiation conditions, especially in the rst year of after

installing the system. This way, it is possible to detect sizing or installation

errors and ensure the proper operation of the PV system.

When alarm signs are detected in the inverter, the equipment manual

should be consulted in order to understand the possible issue and to helpidentify the solution.



7. SUPPORTING STRUCTURE ASSEMBLING MANUAL

7.1. Flat roof

Installation sequence

The A-frame assembly should be clamped using the nuts & bolts supplied

with the kit. (Figure 34)

The mounting to the oor should be carr ied out using appropriate xings

for the substrate. If there are questions regarding to validity of the sup-

porting surface or questions relating top safety then a qualied structural

Engineer should be consulted. (Figure 35)

The A-frame mounting should be performed, in a way that the spacing

between them is: (Table 8, Figure 36).

Figure 34.A-frame assembly

Figure 35. A-frame mounting

Figure 36. Spacing between A frame proles

Table 8. Spacing between A-frames

Structure A-frame N Spacing Prole overhang

2 PV modules 3 732 mm 270 mm

Table 7




The mounting of the transverse A frame prole is completed using a

stainless steel M10 nuts & bolts (supplied). (Figure 37)

The A frames are braced using the 30x8mm prole, use the M10 nuts

supplied. (Figure 38)

The centre clamps are tted to the frame with M8 nuts & bolts (supplied).(Figure 39)

Figure 37. Transverse prole mounting

Figure 38. A frame bracing

Figure 39. PV module centre clamp

819 mm




The PV modules should be clamped to the sides of the frame using the

side clamps & nuts & bolts supplied. The plastic end caps should then bepushed into the ends of the proles. (Figure 40)

The following gures present the typical supporting structures for at

roofs for 2 and 4 modules. (Figure 41)

To connect the A frames together use the connection prole piece con-

nected with M10 stainless steel nuts & bolts (supplied). (Figure 42)

Figure 40. PV module side clamps & plastic end caps

Figure 41. Typical structure

Figure 42. Prole connections




7.2. Parallel to pitched roof

Installation sequence

The roof brackets supplied are suitable for use with a wide range of rooftiles. The brackets must be xed to the roof rafter with appropriate xings

suitable for the rafter material. If the rafter is wood then it is advisable topre drill the holes for the xings to ensure the timber does not split. Ensu-

re the drill used is smaller than the xing to allow correct tightening of the

xing can be made. (Figure 43, Figure 44 and Figure 45)

Figure 44. Anchor for mechanical tiles (ava-

ilable as an accessory kit)

Appropriate roong material

(eg Lead/ Felt )1 2

3 4

Figure 43. Anchors for at tiles.

Figure 45. Anchor xed on a pitched roof.



The standard kits are dened to install two PV Panels in portrait position.(Figure 46)

When a Landscape installation is required needs an additional mounting

kit. The nal assembly will use a portrait mounting kit + a Landscape kit

(available as an accessory kit). (Figure 47)

The roof supports must be installed according to the distances presented

in the table 9.

The transverse prole is mounted to the roof supports using the hammer

head stainless M10 nuts & bolts. (Figure 48)

The mounting of the PV modules to the roof proles is performed with

clamps installed on the sides and in the centres of the modules. These

are xed using M8 nuts & bolts. (Figure 49, Figure 50)


Figure 48. Transverse prole mounting to the roof brackets

Figure 49. PV module centre clamps

Figure 46. Standard Mounting kit for portrait installations

Figure 47. Standard Mounting Kit + Landscape accesory for Landscape insta-llations

Table 9. Spacing between the roof supports

Structure Anchors X1 X2 X3 Y

2 PV Modules Portrait 4 1300 - - 800

2 PV Modules Landscape 8 1300 580 950 520

Figure 50. PV modules side clamps




The plastic end caps supplied should be pressed into the transverse pro-le. (Figure 51)

The next gure shows a supporting structure for pitched roofs for 2 PV

modules. (Figure 52)

To connect the transverse proles together use a connection prole and

x with 2 hammer head stainless M10 nuts & bolts (supplied). (Figure 53)

Figure 51. End covers for the transverse proles

Figure 52. Structure for 2 PV modules

Figure 53. Prole connectors



8. WARRANTY

Standard warranty Terms & Conditions:

PV Modules- 10 yearsInverter- 5 years

To receive your free warranty please complete the form supplied with the

system within 30 days of installation, or simply call heateam, the servicedivision of Baxi Heating UK Limited on 0844 879 7690

Our promise to you

If you experience a fault with your new system, we aim to provide a safeand high quality repair service supported by our dedicated national net-

work of highly skilled engineers. If your installer cant resolve the problem

for you, we will do everything we can to get an engineer out to you asquickly as possible. Nothing in this warranty will affect your statutory con-

sumer rights

What you need to do if you experience a problem with your system.You should always contact your installer rst because the fault may not

be related to the system itself and he/she decides they cant repair it our

friendly customer service team is on hand to help. Simply call our service

division heateam on 0844 879 7690 to book an engineer visit or for any

general advice that you may need. Our contact centre is open Monday toFriday 8 am- 8 pm, weekends and Bank Holidays 8.30am- 2pm, exclu-

ding Christmas Day and New Years Day.

When calling heateam you must have the following information to hand:

System serial number System model number

Your installer name, address details and contact details

Proof of purchase ( if you do not have the serial number)

What this warranty convers

Free of charge repair or replacament of components found to be faulty

from manufacture.

Free of charge replacement of the complete assemblies providedalways that the failure ir related to a manufacturing fault that cannot be

repaired or ir beyond repair.

The warranty starts from the date your product is installed.

What this warranty does not cover Collectors that are installed damaged or damaged during installation. If

a Module is found to be damaged on delivery then it must not be installed,

simply return it to your supplier for replacement under warranty. The warranty will become invalid if the failure is due to frost, transient

voltages, lightning strikes or any act of vandalism or mis use.

Tampering or modication will invalidate this warranty.

The installation must be in an appropriate location.

Due to the varied locations PV modules can be installed Baxi Heating

UK Ltd will only carry out warranty repair/replacement to Modules which

have safe access provided that meets current health & safety working atheights requirements. heateam will cover the cost of any safety equip-ment required to meet this standard after the rst 30 days of installation

up to l year and will appoint a contractor to carry this work out. Prior to

this contact your installer. heateam accept no liability for any third party

damage. Repairs to a system which havent been installed and commissioned

properly, as set out in the installation and commissioning instructions.

Any other defects or failures, either in the connected system or outside

of the system itself. Installations within commercial settings for which this system was not

designed.

Reimbursement of any third party repair or replacement costs that we

havent been told about and agreed you in advance. Compensation for consequential losses (e.g. loss of earnings, businees

losses, stress and inconvenience) arising from a product breakdown, in-cluding repair delays caused by factors outside our reasonable control.



9. MAINTENANCE

Operations

Maintenance operations in a solar photovoltaic system are minimal.However, the following operations are recomended.

1. Clean the surface of the module when needed; the existence ofdust on the module reduces signicantly its performance; always

use water (neutral) with a clean cloth or sponge; DO NOT use an

abrasive solution.

2. Clean only during early morning or late afternoon, when the levels of

solar radiation are low, and the temperature of the modules is lower,to avoid thermal shocks that could damage the photovoltaic cells.

3. Do not use pressurized water or steam cleaning materials, they may

damage the surface of the modules.4. Avoid thermal shock in the modules, it can cause cracks in the cells;

do not clean the modules with hot water when its temperature is too

low or with cold water when its temperature is too high.

5. Check the condition and integrity of electrical connections and me-chanical components each semester.

6. If you notice any abnormality in the installation, immediately contact

a technician; do not attempt to resolve it; also, check the maintenan-

ce of other components of the installation, such as inverters, charge

regulators, batteries, and others.7. Maintenance operations should be done only by qualied personnel.

Tests

The following tests must be performed during maintenance processes.

Checking the open circuit voltage (VOC) in each string of modules.

The value of the measured voltage, string open circuit voltage, should

correspond to the sum of the individual open circuit voltage of all the mo-dules on that string. If the measured value is much lower than expected,

the string may have a problem.

Checking the value of current (ISC) on each string of modules.

Measures can vary signicantly depending on weather, time of the day

and possible shading on the modules.Depending on the number of modules in series, if the voltage exceeds 30

VDC, take all precautionary measures to avoid the risk of electric shock.



10. NOTES


32/32

All descriptions and illustrations provided in this leaet have been carefully prepared but we reserve

the right to make changes and improvements in our products which may affect the accuracy of theinformation contained in this leaet. All goods are sold subject to our standard Conditions of Sale

which are available on request.

Brooks House, Coventry Road, Warwick. CV34 4LLTechnical Enquiries 0844 879 7690

Our contact centre is open Monday to Friday 8am to 6pm,

Weekends and Bank Holidays 8.30am to 2pm.We are closed Christmas Day and New Years Day.

Website www.baxi.co.uk

solargen solar pv homekit assembly manual

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