AirSolar PVMW-375M-FB Power Standard Photovoltaic Module Installation Guide
- June 9, 2024
- AirSolar
Table of Contents
PVMW-375M-FB Power Standard Photovoltaic Module
Installation Guide
Installation Manual
PVMW-375M-FB
PVMW-500M-FB
Power Standard Photovoltaic module
22.AW.PVMW375.IOM.EN.29.09
22.AW.PVMW500.IOM.EN.29.09
PVMW-375M-FB Power Standard Photovoltaic Module
Please read carefully. This document is binding for any warranty case. *Suitable for installation of PV system up to 500m away from the Coastline.
PURPOSE OF THIS GUIDE
This guide contains information regarding the installation and safe handling
of AIRSOLAR SOLUTIONS, Ltd.(hereinafter referred to as “AIRSOLAR SOLUTIONS”)
photovoltaic modules (hereinafter referred to as “PV modules” or “modules”).
Installers must read and understand this guide prior to installation. For any
questions, please contact AIRSOLAR SOLUTIONS’s Global Quality & Customer
Support department or our local representatives for more detailed information.
Installers must follow all safety precautions as described in this guide as
well as local requirement and regulations by law or authorized organizations.
Before installing a solar photovoltaic system, installers should familiarize
themselves with its mechanical and electrical requirements. Keep this guide in
a safe place for future reference (care and maintenance) and in case of sale
or disposal of the modules.
1.1. General safety
Modules that fall under this application class may be used in system operation
at more than 50V DC or 240W, where general contact access is anticipated.
Modules complying with IEC 60417-5172 are considered to meet Class II
(
).
The environmental temperature in which the PV modules work is between -40°C
and 40°C with relative humidity of less than 85%, while their operating
temperature is from -40°C and 85°C.
PV modules are recommended to be installed at an altitude of less than 2000m.
Installing solar photovoltaic systems requires specialized skills and
knowledge. Installation must only be performed by authorized and trained
personnel.
Installers must assume all risks of injury that might occur during
installation, including, but not limited to, the risk of electric shock.
One single module may generate more than 30V DC when exposed to direct
sunlight. Contact with a DC voltage is potentially hazardous and should be
always avoid.
Do not disconnect the modules or any electrical part under load.
PV modules generate electricity when exposed to sunlight. Number of modules
string connected can cause lethal shock and burn hazards. Only authorized and
trained person should have access to the modules.
Modules convert light energy to direct current electrical energy. They are
designed for outdoor use. Modules can be ground mounted, mounted on rooftops.
The responsibility of proper design of support structures lies in the system
designers and installers.
When installing the system, abide to all local, regional and national
statutory regulations. Obtain a building permit if necessary.
The electrical characteristics are within ±3% of the indicated values of Isc,
Voc and Pmax under standard test conditions (irradiance of 1000 W/m², AM 1.5
spectrum, and a cell temperature of 25 °C (77 °F)).
Only use equipment, connectors, wiring and support frames suitable for solar
electric systems. Do not use mirrors, magnifiers or artificially concentrated
sunlight onto the modules. Always use fall protection equipment when working
at a height of 6 feet (183cm) or above. Follow Occupational safety and Health
Act (OSHA) or local governing safety regulations regarding Fall Protection.
(UL Only)
Do not sit, stand, step or walk on any side of the module, including the
frames.
Do not permit any part of the module(s) to be submerged or allow for constant
water to soil the module(s) unless it’s natural rain fall or periodic
cleaning.
Do not permit constant dew on any part of backsheet of the module.
The module is considered to be in compliance with this standard only when the
module is either mounted in the manner specified by the mounting instructions,
or when the mounting method has been evaluated with this PV module to UL 2703.
A module with exposed conductive parts is considered to be in compliance with
this standard only when it is either electrically grounded in accordance with
the manufacturer’ s instructions and the requirements of the National
Electrical Code, ANSI/NFPA 70 (2014-2017), or when the bonding means has been
evaluated with this PV module to UL 2703. (UL Only)
1.2. Handling safety
Do not lift the module by holding the module’s junction box or electrical
leads.
Do not place any heavy or sharp objects on the module.
Be cautious when placing the module down onto a surface, particularly when
placing it in a corner. Inappropriate transport and installation may break the
module and void the warranty.
Do not attempt to disassemble the modules, and do not remove any attached
nameplates or components from the modules.
Do not apply paint or adhesive to the module top surface or backsheet.
To avoid damage to the backsheet and cells, do not scratch, dent or hit the
backsheet.
During the transportation, do not to apply direct pressure on the backsheet or
front glass.
Do not drill holes in the frame. This may compromise the frame strength, cause
corrosion of the frame and void the warranty. Do not scratch the anodized
coating of the frame (except for grounding connections at the grounding
connection point on the back side of the module). It may cause corrosion of
the frame or compromise the frame strength.
A module with broken glass or torn backsheet cannot be repaired and must not
be used since contact with any module surface or the frame can cause an
electric shock.
Work only under dry conditions, and use only dry tools.
Do not handle modules under wet conditions unless wearing appropriate
protective equipment.
When storing uninstalled modules outdoors for any period of time, always cover
the modules and ensure that the glass faces down on a soft flat surface to
prevent water from collecting inside the module and causing damage to exposed
connectors.
1.3. Installation safety
Never disconnect electrical connections or unplug connectors while the circuit
is under load.
Contact with electrically active parts of the modules, such as terminals, can
result in burns, sparks and lethal shock whether or not the module is
connected.
Do not touch the PV module unnecessarily during installation. The glass
surface and the frame may be hot; there is a risk of burns and electric shock.
Do not work in the rain, snow or in windy conditions.
Avoid exposing cables and connectors to direct sunlight and scratches or cuts
in order to prevent insulation degradation.
Use only insulated tools that are approved for working on electrical
installations.
Keep children well away from the system while transporting and installing
mechanical and electrical components.
Completely cover the module with an opaque material during installation to
prevent electricity from being generated.
Do not wear metallic rings, watchbands, earrings, nose rings, lip rings or
other metallic objects while installing or troubleshooting photovoltaic
systems.
Follow the safety regulations(e.g., safety rules for working on electrical
power plant stations) of your regions and for all other system components,
including wires and cables, connectors, charging regulators, inverters,
storage batteries, rechargeable batteries, etc.
Under normal conditions, a photovoltaic module is likely to experience
conditions that produce more current and/or voltage than reported at standard
test conditions. Accordingly, the values of Isc and Voc marked on this module
should be multiplied by a factor of 1.25 when determining component voltage
ratings, conductor current ratings, minimum factor of fuse sizes, and size of
controls connected to the PV output. Only use same connectors to connect
modules to form a string, or connect to another device. Removing the
connectors will void the warranty.
1.4. Fire safety
Consult your local authority for guidelines and requirements for building or
structural fire safety. Roof constructions and installations may affect the
fire safety of a building; improper installation may create hazards in the
event of a fire.
Use components such as ground fault circuit breakers and fuses as required by
local authority. Do not use modules near equipment or in places where
flammable gases may be generated.
Modules rated for Module Fire Performance Type must be installed on a roof
which has appropriate fire resistance. Before mounting on the roof, please
consult your local building related department to make sure the approved
roofing materials.
A minimum slope of 5 in/ft. for installation on a roof is required to maintain
the fire class ratings. Any module or panel mounting system have limitations
on inclination required to maintain a specific System Fire Class Rating. (UL
only)
MECHANICAL INSTALLATION
2.1. Selecting a location
Select a suitable location for installing the modules.
The modules should face south in northern latitudes and north in southern
latitudes.
For detailed information on the best installation angle, refer to standard
solar photovoltaic installation guides or consult a reputable solar installer
or systems integrator. Modules should not be shaded at any time. If a module
is shaded or even partially shaded, it will fail to perform at ideal
conditions and result in lower power output. A permanent and/or regular shade
on the module voids the warranty.
This installation manual is applicable for any PV system that is 500m way or
more from the coastline. Do not use modules near equipment or in locations
where flammable gases may be generated or collected.
2.2. Before Installing
Before installing modules check for any optical deviations. Any optical
deviations noticed after system installed may cause the warranty invalid. Any
potential costs for labor, material or other cost such as documentation,
safety or performing the (de/ re-) installation will not be covered.
The module mounting structure must be made of durable, corrosion-resistant and
UV-resistant material. Always use a tested and certified mounting structure
approved for your system design.
In regions with heavy snowfall in winter, adjust the height of the mounting
system so that the lower edge of the module is not covered by snow. In
addition, ensure the lower part of the module is not in the shadow of plants,
trees or damaged by ground soil moved by or through the air.
For ground mounting systems, the minimum distance recommends from the ground
to the lower edge of the module is at least 24 inches (60cm).
Modules must be securely attached to the mounting structure. For Clamping
System installation methods, the recommended maximum compression for each
clamp is 2900 PSI (20 Mpa) in order to avoid potential damages to module
frames. Follow the instruction of the clamping system supplier.
Provide adequate ventilation under the modules in conformity to your local
regulations. A minimum distance of 10 cm between the roof plane and the frame
of the module is generally recommended.
Always observe the instructions and safety precautions included in the module
support frames. Before installing modules on a roof, always ensure the roof
construction is suitable. In addition, any roof penetration required to mount
the module must be properly sealed to prevent leaks.
Dust built up on the surface of the module can impair with the module
performance. The modules shall be installed with a tilt angle no less than 10
degrees, making it easier for dust to be removed by rain. A flat angle
requires more frequent cleaning.
Observe and take into account the linear thermal expansion of the module
frames (the recommended minimum distance between two modules is 2 cm). Always
keep the front and backsheet of the module free from foreign objects, plants
and vegetation, structural elements, which could come into contact with the
module, especially when the module is under mechanical load.
When installing a module on a pole, select a pole and module mounting
structure robust enough to withstand the anticipated wind load and snow load
in the area.
Ensure modules are not exposed to wind or snow load exceeding the maximum
permitted values, and are not exposed to excessive forces due to the thermal
expansion of support structures. Never allow modules overlap or exceeds the
rooftop: Refer to the following mounting methods for more detailed
information.
2.3. General Installation
Modules can be installed by using mounting holes, clamps or an insertion
system, recommended torque is 20Nm-25Nm. Modules must be installed according
to the following examples. Strictly follow the guidelines when installing,
otherwise the warranty will be affected.
The required length for each
clamp is minimum 50 mm, and wall thickness of its upper part is no less than
5mm
Module can be installed in both landscape and portrait modes. The modules must
be properly secured to their support so that they can withstand positive and
negative load they have been certified for. Installer must ensure that the
clamps used to secure the modules are robust enough.
2.4. Mounting Methods and Mechanical Loads
Select a proper installation method based on the required load (See below for
more detailed information). All installation methods herein are only for
reference, and AIRSOLAR SOLUTIONS will not provide related mounting
components. The system installer or trained professional personnel must be
responsible for the PV system’s design, installation, and mechanical load
calculation and security of the system. For each installation, modules can be
installed either in portrait or landscape mode.
DIMENSIONS
RECOMMENDED MOUNTING METHOD
**Mounting method*| Mechanical load| Installation location|
Module type**
---|---|---|---
Four bolts mounting with
beams underneath| Test load:
Positive 5400Pa
Negative 2400Pa
Safety factor: 1.5| | PVMW-375M-FB
Four bolts mounting with
beams underneath| Test load:
Positive 3800Pa
Negative 2400Pa
Safety factor: 1.5| | PVMW-375M-FB
Four bolts mounting with
beams underneath| Test load:
Positive 5400Pa
Negative 2400Pa
Safety factor: 1.5| | PVMW-375M-FB
Eight bolts mounting with
beams underneath| Test load:
Positive 5400Pa
Negative 3800Pa
Safety factor: 1.5| | PVMW-375M-FB
Four clamps mounting with
beams underneath| Test load:
Positive 6000Pa
Negative 3800Pa
Safety factor: 1.5| L = 200mm Clamping zone:
A = 200 mm| PVMW-375M-FB
Four clamps mounting with
beams underneath| Test load:
Positive 2400Pa
Negative 2400Pa
Safety factor: 1.5| Clamping zone: A = 1/4 long
frame length±50 mm| PVMW-375M-FB
Four clamps mounting with
beams underneath| Test load:
Positive 5400Pa
Negative 3800Pa
Safety factor: 1.5| M6/60 series L = 200 mm
G1/60 series L = 200 mm
S/120 series L = 200 mm
S7/120 series L = 200 mm
S8/108 series L = 200 mm
M6/72 series L = 300 mm
G1/72 series L = 300 mm
S/144 series L = 300 mm
S8/120 series L = 300 mm
S7/144 series L = 380 mm
S8/132 series L = 380 mm
S9/108 series L = 380 mm
Clamping zone: A = 200 mm| PVMW-375M-FB
PVMW-500M-FB
CUSTOMIZED MOUNTING METHOD
Note: The installation methods below are based on the internal evaluation
results in AIRSOLAR SOLUTIONS.
| Mounting method* | Mechanical load | Installation location | Module type |
|---|
Four clamps short end
mounting with beams parallel
with long frame| Test load:
Positive 5400Pa
Negative 2400Pa
Safety factor: 1.5| A0 = 1/4 short frame
length±50mm| PVMW-375M-FB
Four clamps short end
mounting with beams parallel
with long frame| Test load:
Positive 2400Pa
Negative 1600Pa
Safety factor: 1.5| A0 = 1/4 short frame
length±50mm| PVMW-375M-FB
Short frame insertion / Slidein| Test load:
Positive 2400Pa
Negative 2400Pa
Safety factor: 1.5| | PVMW-375M-FB
Six clamps mounting with
beams underneath| Test load:
Positive 5400Pa
Negative 3800Pa
Safety factor: 1.5| Clamping zone: A0 = 1/4
short frame length ±50 mm
A1 = 100 mm| PVMW-375M-FB
PVMW-500M-FB
Six clamps mounting with
beams underneath| Test load:
Positive 5400Pa
Negative 3800Pa
Safety factor: 1.5| Clamping zone: A1 = 100 mm
A2 = 200 mm| PVMW-375M-FB
PVMW-500M-FB
Insertion installation with two
clamps in the middle| Test load:
Positive 5400Pa
Negative 3800Pa
Safety factor: 1.5| | PVMW-375M-FB
- The module clamps must not come into contact with the front glass or deform the frame in any way. Avoid shading effects caused by clamps or insertion systems. Drainage holes in the module frame must not be closed or obscured by the clamps.
** 35mm or 30mm represents the height of frame.
ELECTRICAL INSTALLATION
3.1. General Electrical Connection
Any hardware used must be compatible with any other used material to avoid
galvanic corrosion. Defects caused by corrosions void the warranty.
It is not recommended to use modules with different configurations (grounding,
wiring) in the same system.
Excessive cables must be organized or fixed in an adequate way, e.g. attached
to the mounting structure by using non-metallic cable ties. Solar cables,
connectors and junction boxes should not be exposed to water, snow, or rain or
water submersion for a long period of time (IP65/67/68).
For applications requiring high operating voltage several modules can be
connected in series to form a string of modules; the system voltage is then
equal to the sum of the voltage of each module.
For applications requiring high operating currents several strings of modules
can be connected in parallel; the system current is then equal to the sum of
the current of each string of modules.
The maximum system voltage is 600 volts, 1000 volts or 1500 volts depending on
the product family DC according to standards. The maximum number of series
connected modules depends on system design, the type of inverter used and
environmental conditions.
Based on the maximum series fuse rating of module and local electrical
installation code, always make sure AIRSOLAR SOLUTIONS PV modules are
assembled with the appropriate string fuse for circuit protection.
There is no specific limitation on the number of modules that can be connected
in parallel, the number of modules is determined by system design parameters
such as current or power output. To prevent the cables and the connectors from
overheating, the cross section of the cables and the capacity of the
connectors must be selected to suit the maximum system short circuit current.
The recommended cable is PV wire with a cross section of at least 4mm².
Caution: do not secure the cables too tight. Any cable damage caused by
cable management system is not covered under AIRSOLAR SOLUTIONS’s warranty.
Always refer to the cable manufacturer’s bending radius which includes the
radius just behind the connectors. When designing large modules arrays
connected to a single inverter, always take into account the resulting
isolation resistance (Riso), which decreases increasing the number of modules
in the array. A too low Riso can results in inverter faults.
Please refer to local regulations to determine the system wires size, type and
temperature. AIRSOLAR SOLUTIONS modules come with connectors used for system
electrical connections.
To ensure reliable electric connection and to prevent possible intrusion of
humidity, two connectors must be mated and locked together until a click can
be heard. Long-term exposure to wet environments may cause connectors’ poor
connectivity, resulting in current leakage and poor conductivity which voids
the warranty.
AIRSOLAR SOLUTIONS recommends proper connector/cable/wire management to
prevent moisture intrusion. Depending on the amount of humidity, AIRSOLAR
SOLUTIONS recommends periodic inspections of the installation system to
maintain optimal module performance.
The DC current generated by photovoltaic systems can be converted into AC and
fed into a public Grid. As local utilities’ policies on connecting renewable
energy systems to the Grids vary from region to region. Always seek the advice
from a qualified system designer or integrator.
Building permits, inspections and approvals by the local utility are generally
required. Especially for larger installations AIRSOLAR SOLUTIONS recommends
lightning protection following the local requirements and regulations.
When the installation finished and after connecting to the grid, please do a
professional hand over to the owner including an installation protocol is
required. Provide a clear documentation of the system to the owner consisting
of following minimum data such as: user guide, system layout, data sheets,
performance expectations, electrical system data e.g. a copy of the
installation test report following minimum requirements of IEC 62446 / IEC
60364-6.
3.2. Electrical property
Module under standard test conditions of: irradiance of 1000W /m2, cell
temperature of 25 °C and air mass of AM1.5.
Normally, a module is likely to produce more current and/or voltage than
reported at standard test conditions.. Accordingly, the values of Isc and Voc
marked on this module should be multiplied by a factor of 1.25 when
determining component voltage ratings, conductor ampacities, fuse sizes, and
size of controls connected to the PV output. Voltages are additive when
modules are connected in series, and modules currents are additive when
Modules are connected in parallel, as illustrated in Figure 1. Modules with
different electrical characteristics must not be connected directly in series.
3.3. Series Wiring and Parallel Wiring
Series wiring
Parallel wiring The maximum number of Modules that can be connected in series
within a string must be calculated in accordance with applicable regulations
in a way that the specified maximum system voltage of the modules and all
other electrical DC components will not exceed in open-circuit operation at
the lowest temperature expected at the PV system location.
Recommended maximum series configuration: system voltage / (1.25* Voc)
Recommended maximum parallel configuration: overcurrent rating / (Isc +1)
Recommended installation method of full cell solar module:
The modules in PV array are recommended for portrait connecting, and cable
length is not less than 0.7 m
Recommended mounting method
of half cell solar module:
The head and tail of the modules in PV array are placed in portrait layout,
and cable length is not less than 0.65 m.
3.4. Grounding
For grounding and bonding requirements, please refer to regional and national
safety and electricity standards. If grounding is required, use a recommended
connector type for the grounding wire.
For grounding, this guide refers to module frame grounding. If grounding is
required, make sure module frames (metal exposed to touch) are always
grounded.
AIRSOLAR SOLUTIONS recommends always refer to local state and national code
requirements for PV module grounding. AIRSOLAR SOLUTIONS highly recommends
negative grounding if it’s allowed by local authorities.
When attaching the frame grounding hardware and wire to the frame it must be
placed corresponding to the ground symbol stamped location to ensure proper
electrical connection.
AIRSOLAR SOLUTIONS recommends one of the following parts for grounding:
-
Use M5 bolt and washer to bond the ground wire and aluminum frame through the grounding hole (as shown below). The tightening torque is 3-7Nm. All nuts and washers should be made of stainless steel. 4-14 mm² (AWG 6-12) exposed copper wire recommended as ground wire.
-
To bond solar modules to module mounting brackets
-
Use Schletter clamps to bond solar module to module mounting brackets
MAINTENANCE
To ensure optimum module performance, AIRSOLAR SOLUTIONS recommends the
following maintenance measures:
Clean the module minimum once a year or more often when required depending of
the pollution. Remove all organic from the surface. Module with soiling or
contamination may reduce the power generation of the system.
Always use clean water and a soft non-abrasive sponge or cloth for cleaning. A
mild, non-abrasive cleaning agent may be used to remove stubborn dirt.
Uncontrolled pollution is voiding the warranty or not cleaning the modules in
time voids the warranty. Check the electrical, grounding and mechanical
connections every six months to verify that they are clean, secure, undamaged
and free of corrosion. Or else the warranty may be voided.
In the event of a ground fault condition, NEVER wash or spray modules with
water until ground fault has been identified, corrected by an authorized solar
inverter service technician and the inverter is fully operational. This can
cause electrocution or a serious safety issue.
If any problem arises, consult a professional solar service provider for
suggestions.
Caution: observe solar manufacturers’ maintenance instructions for all
components used in the system, such as support frames, charging regulators,
inverters, batteries etc.
10, rue du fort de Saint Cyr – 78180
Montigny-le-Bretonneux, FRANCE
Tél. : +33 (0)1 76 21 82 00
– www.airwell.com
Imprimé en France
22.AW.PVMW375.IOM.EN.29.09
22.AW.PVMW500.IOM.EN.29.09
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