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HelioSphera HS Series Safety And Installation Instructions Manual

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SAFETY AND INSTALLATION
INSTRUCTIONS
Page 1 of 51
10-SSI-001_rev.005_ENG

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Summary of Contents for HelioSphera HS Series

  • Page 1 SAFETY AND INSTALLATION INSTRUCTIONS Page 1 of 51 10-SSI-001_rev.005_ENG...

  • Page 2: Table Of Contents

    SAFETY INSTRUCTIONS ....................7 General Safety ......................7 Electrical Safety ......................8 Fire Safety ........................9 Hazardous Locations ....................9 MECHANICAL INSTALLATION ..................10 HS Series ........................10 5.1.1 HS Atlas Series .......................11 5.1.2 HS Venus Series .....................15 5.1.3 HS Glass-Glass Series ....................18 Location and Tilt Angle ....................23...
  • Page 3 12.4 Connectors .........................49 12.5 Factory Inspection.......................50 12.6 Quality Management System ..................51 Edition: October 2011 Page 3 of 51 10-SSI-001_rev.005_ENG...

  • Page 4: Introduction

    1. INTRODUCTION HelioSphera S.A. (HS) thin-film PV modules (Micromorph™ technology) are distinguished in the marketplace by their efficacy in numerous applications, superior longevity and maximum efficiency. Micromorph™ solar cell has a dual structure with an amorphous and microcrystalline silicon layer. The amorphous layer is sensitive to the visible range of the solar radiation, while the microcrystalline layer converts the infrared part of the spectrum into electricity which results to an excellent performance in comparison with other solar cell technologies.

  • Page 5: Purpose Of This Document

    2. PURPOSE OF THIS DOCUMENT The purpose of this document is to provide clear instructions on how to install HelioSphera photovoltaic modules, in order to use them as easy and safely as possible. HS products not installed according to guidelines will void the warranty. HelioSphera assumes no liability for damages incurred due to non-compliance with these instructions.

  • Page 6: General Information

    Also, carefully read the module data sheet provided with this product. This guide pertains to modules installed within the European Union only. If a module is being installed outside of Europe, contact HelioSphera or the product distributor.  Determine local permits, installation and inspection requirements before installing module(s).

  • Page 7: Safety Instructions

    4. SAFETY INSTRUCTIONS 4.1 General Safety Solar modules should only be used for the purposes for which they are intended (see module installation for further details). All works on the PV system, i.e. installation, commissioning, servicing and repairs, should be carried out by qualified and authorized personnel only.

  • Page 8: Electrical Safety

     Avoid application of excessive bending or twisting forces to the modules. Mandatory use of Mandatory use of Safety helmet must Mandatory use of gloves or other hand protective footwear be worn safety goggles protection 4.2 Electrical Safety Be familiar with the basic principles of electricity and electrical equipment. Use properly insulated tools and appropriate protective equipment such as safety shoes and insulated gloves as well as protection goggles.

  • Page 9: Fire Safety

    The modules are qualified for application class A: Hazardous voltage (IEC 61730: higher than 50V DC: EN 61730: higher than 120V), hazardous power applications (higher than 240W) 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 requirements for safety class II).

  • Page 10: Mechanical Installation

    5. MECHANICAL INSTALLATION HS Series Unpacking the product  Make sure the pallet is placed on a horizontal surface  Remove the modules one-by-one from each side of the box ATTENTION: Make sure that the modules in the center of the box are the last to be removed Fig.

  • Page 11: Hs Atlas Series

    5.1.1 HS Atlas Series The HS Atlas modules incorporate four anchors bonded to the rear glass of the modules, showed in Fig. 2. The anchor design is shown in Chapter 5. Front view Rear view Fig. 2 HS Atlas with 4 anchors The aluminum anchors, which are shown in Fig.
  • Page 12 6. The specified fixation points at the approved mounting assemblies are shown in Fig. 7 In order to place the mounting rails at the right distances, HelioSphera provides a helpful tool with 2 hooks fixed at the same distance as the Atlas module. ( Fig. 5) Page 12 of 51 10-SSI-001_rev.005_ENG...
  • Page 13 Fig. 5 Mounting distance tool Modules, after installation, should have a 4 cm gap vertically and a 2 cm gap horizontally, between each other, as shown in Fig. 6. Fig. 6 Detailed distances between modules Page 13 of 51 10-SSI-001_rev.005_ENG...
  • Page 14 Fig. 7 Mounting configuration HelioSphera modules have been designed and tested, according to IEC 61646 paragraph 10.16, to a maximum mechanical load of 2400 Pa or 2.4 N/m2.This load can be any combination of snow, ice or wind. In order for the solar modules to withstand this load, the module must be supported as shown in Fig.

  • Page 15: Hs Venus Series

    HS Venus modules are designed to be mounted on the substructure without using any special tool, accelerating the whole installation procedure. HelioSphera is aiming to provide different procedures for HS Venus modules to be valid for different applications. The aluminum frame, shown in Fig. 9, is attached to the rear glass of the module using a proven adhesive from the structural glazing industry.
  • Page 16 PV modules are exposed to a wide range of mechanical conditions, so that surface stress may appear. Due to the different thermal coefficient of glass and metal structures, thermal stress can occur as a result of the module’s outdoor exposure. DIN 1055 sets basics for the planning of a structural framework regarding building structures which must be taken into account.
  • Page 17 This is a fully integrated on roof mounting system. It is composed by:  Assembly system: Model S2 PLUS, made by aluminum, EN-AW 6063. HelioSphera modules have been designed and tested, according to IEC 61646 paragraph 10.16, to a maximum mechanical loading of 2400 Pa (2, 4 N/m or 240 Kg/m ).This loading can...

  • Page 18: Hs Glass-Glass Series

    5.1.3 HS Glass-Glass Series The HS Glass-Glass modules are HelioSphera modules without any aluminum structure attached, Fig. 13. Front view Rear view Fig. 13 HS Glass-Glass PV modules are exposed to a wide range of mechanical conditions, so that surface stress may appear.
  • Page 19 (all in mm), these are mandatory to fulfill HelioSphera installation requirements mentioned above. Page 19 of 51...
  • Page 20 There are two kinds of clamps:  End clamps  Middle clamps (between two modules) (A) Support frame of the substructure (B) Middle support frame of the substructure (horizontal) (C) Vertical clamps. (D) Horizontal holding clamps Fig. 15 View on the two-sided linear fixation set-up Both clamps dimensions are presented in Fig.
  • Page 21 13 +/-1 mm 13 +/-1 mm Fig. 16 Mounting clamps A possible variation of the mounting system is shown in Fig. 17, Fig. 18 and Fig. 19. Fig. 17 Mounting configuration Page 21 of 51 10-SSI-001_rev.005_ENG...
  • Page 22 (E) Support frame with rubber (F) Middle support frame of the substructure (vertical) with rubber (C) Vertical clamps. (D) Horizontal holding clamps Fig. 18 View on the two-sided linear fixation set-up 13 +/-1 mm 13 +/-1 mm Fig. 19 Mounting clamps Page 22 of 51 10-SSI-001_rev.005_ENG...

  • Page 23: Location And Tilt Angle

    A minimum angle of 10° is recommended in order to help the self-cleaning of the modules. Nevertheless, one of the merits of Heliosphera modules is that they have minimal losses in non-optimum tilt angles and orientation or in diffuse light conditions.

  • Page 24: Electrical Installation

    6 modules may be connected in series (when using inverter with 1000V max DC input voltage). Contact HelioSphera engineers if you are not sure for the total number of modules you can connect in series, with any specific inverter you are going to use.
  • Page 25 1. *Put a fuse of 2A or a diode of 3A in the positive pole of each string you parallel Fig. 21 Parallel connection of strings (back view) – Type 1  Maximum protection against reverse currents.  Use of many protection fuses/diodes (one per string) Page 25 of 51 10-SSI-001_rev.005_ENG...
  • Page 26 2. *Put a fuse of 4A or a diode of 5A in the positive pole of every set of strings: Fig. 22 Parallel connection of strings (back view) – Type 2  Normal protection and use of fuses/diodes Page 26 of 51 10-SSI-001_rev.005_ENG...
  • Page 27 3. *Put a diode of 8A (only option) in the positive pole of every 3 paralleled strings: Fig. 23 Parallel connection of strings (back view) – Type 3  Minimum protection and use of diodes Page 27 of 51 10-SSI-001_rev.005_ENG...
  • Page 28 Fig. 24 DC box with 5A diodes in each (+) input *HelioSphera can provide you with special diodes/fuses integrated in 6mm² solar cables and pre-assembled with MC4 (or MC4 compatible) connectors. This useful and cost effective plug-and-play solution looks like this: Fig.
  • Page 29 The definitive number of modules connected in parallel depends on the plant topology (Inverter sizing according to known practice, protection means, etc). To avoid electrical shock, ground the understructure of the module before wiring the circuit, using a grounding method that meets the appropriate standards or directive requirements for grounding solar electrical systems.

  • Page 30: Grounding

    If the Atlas HS modules are connected to an inverter with transformer, the negative pole should be grounded (see paragraph “6.1 Grounding”). Please refer to Heliosphera engineers if you need to be sure that the inverter you are using has a transformer or not.

  • Page 31: Bypass Diode

    In order to choose the most appropriate inverter the following criteria must be met:  The maximum open circuit voltage (Voc) of the PV generator must never exceed the maximum input voltage of the inverter. Please take into account that Voc is affected by weather conditions.

  • Page 32: Maintenance

    This build up can reduce the performance of the module. Normally, the buildup of dust particles will be washed away by periodic rainfall, but for some instances module surface cleaning may be required. To ensure maximum solar module performance, HelioSphera recommends cleaning the module surface with water or a conventional glass cleaner. It is...

  • Page 33: In Case Of Breakage/Recycling System

    8. IN CASE OF BREAKAGE/RECYCLING SYSTEM In case of a module breakage please follow these simple rules: • Stop all other work and be sure to keep anyone from walking through the area • Use cut resistant gloves • Pick up all large pieces of broken glass. Place them in a suitable plastic or metal container.

  • Page 34: Packaging And Transportation Specifications

    9. PACKAGING AND TRANSPORTATION SPECIFICATIONS 9.1 Storing PV modules are fragile. Handle with care the transportation box as well as the PV modules. Please follow these instructions: • Keep the PV module in the transportation box until installation • Do not remove stretch film and polyethylene bands before installation •...

  • Page 35: Transportation Box Specifications

    9.2 Transportation box specifications Number of Products 20 units / Box Box external dimensions Length 1.20cm x Width 0.80cm x Height 1.50cm Box weight 530kg Stack Limitation No stacking Polyethylene Wp Label Bands Page 35 of 51 10-SSI-001_rev.005_ENG...
  • Page 36 Warning signs No Hooks This side up Keep dry Fragile No stacking Recyclable product Handle with care Do not step Page 36 of 51 10-SSI-001_rev.005_ENG...

  • Page 37: Physical Specifications

    10. PHYSICAL SPECIFICATIONS 10.1 Module Dimensions mm 1300 x 1100 -1/+3 Thickness (without junction box) mm 6,9 mm; (+/- 0,4mm) Weight approx. 25 Surface area 1,43 Encapsulation Polyvinylbutyral (PVB) Cell type a-Si/μc-Si tandem Front glass mm 3,2+/-0,2 white glass, low iron Back glass mm 3,2+/-0,2 Junction box...
  • Page 38 Fig. 27 Laser marking & 2D barcode Fig. 28 Module label Page 38 of 51 10-SSI-001_rev.005_ENG...

  • Page 39: Junction Box

    10.2 Junction Box PV-JB-LC- Type 2/N2,5SXL Cable cross 2,5 mm section L1 L2 800-1000 mm Rated current Insulation material Rated 600V, (pol/pol) voltage 1000V, pol/ Degree of IP65 protection 4,26kV (50Hz 1min.), (pol./pol) Test voltage 6,6kV (50Hz 1min.), pol/ Flame class UL94-V0 Contact resistance...

  • Page 40: Diode

    10.2.1 Diode Diode BY255 Nominal Current Repetitive peak reverse 200...2000 V voltage Plastic case ~ DO-201 Weight approx 0.8 g Plastic material has UL classification 94V-0 Repetitive peak reverse 1300 V voltage Surge peak reverse 1300 V voltage 10.2.2 Cables Type FLEX-SOL-XL 2,5 Nominal cross section...

  • Page 41: Connectors

    10.2.3 Connectors Type (MALE) PV-KST4/2,5 I-UR Ǿ range of cable gland 3-6 A (mm) 1,5 -2,5 mm Conductor cross section 14 AWG 3 mm Type (FEMALE) PV-KBT4/2,5 I-UR Ǿ range of cable gland 3-6 A (mm) 1,5 -2,5 mm Conductor cross section 14 AWG Page 41 of 51 10-SSI-001_rev.005_ENG...

  • Page 42: Electrical Characteristics

    The module electrical ratings are measured under Standard Test Conditions (STC) of 1 kW/m² irradiance with AM 1.5G spectrum and a cell temperature of 25ºC. Under these conditions, HelioSphera modules deliver the specific electrical characteristics shown above. A photovoltaic module may produce more current and/or voltage than reported at STC.

  • Page 43: Certificates

    12. CERTIFICATES 12.1 Modules Page 43 of 51 10-SSI-001_rev.005_ENG...
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  • Page 46 Page 46 of 51 10-SSI-001_rev.005_ENG...

  • Page 47: Junction Boxes

    12.2 Junction boxes Page 47 of 51 10-SSI-001_rev.005_ENG...

  • Page 48: Cables

    12.3 Cables Page 48 of 51 10-SSI-001_rev.005_ENG...
  • Page 49 12.4 Connectors Page 49 of 51 10-SSI-001_rev.005_ENG...
  • Page 50 12.5 Factory Inspection Page 50 of 51 10-SSI-001_rev.005_ENG...
  • Page 51 12.6 Quality Management System Page 51 of 51 10-SSI-001_rev.005_ENG...

This manual is also suitable for:

Hs atlas seriesHs-120Hs-125Hs venus seriesHs-115Hs-110

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