Installation Guide

200 Series Photovoltaic Panels

200 Series Installation Guide English Version 2.1 Release Date: 11 August 2010

Solyndra, Inc. 47700 Kato Road Fremont, CA www.solyndra.com

INSTALLATION DISCLAIMER
This document provides safety and installation instructions for UL-listed and IEC-listed Solyndra photovoltaic (PV) modules , as named herein. Disclaimer of Liability: The installation techniques, handling and use of this product are beyond company control. Therefore, Solyndra does not assume responsibility for loss, damage or expense resulting from improper installation, handling or use.

GENERAL DISCLAIMER
Advisory information contained in Solyndra instructions, guides, application notes, or any other document is advisory only. The customer must work with qualified personnel to ensure that all designs are safe and in compliance with all local codes. Solyndra makes no representation that any reference technique or method is necessarily safe, legal, or compliant with application codes. Solyndra assumes no legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by Solyndra.

WARRANTY DISCLAIMER
Except as specifically provided herein, Solyndra disclaims any and all express or implied warranties relating to sale and/or use of Solyndra products including (but not limited to) liability or warranties relating to fitness for a particular purpose, merchantability, or infringement of any patent, copyright, or other intellectual property right. The warranty rights for Solyndras products are governed solely by the express terms of the Solyndra Limited Warranty provided to the purchaser of Solyndra panels. Solyndra may make changes to specifications, instructions, and products at any time without notice. Contact your local Solyndra Sales Office to obtain the latest specifications before placing your purchase order.

Copyright Notice
This document provides information on Solyndra products. By issuance of this document Solyndra assumes no liability. The rights and obligations of Solyndra and any owner of Solyndra panels are governed solely by the express terms and conditions contained in the sale agreement for such panels. Except as provided in Solyndras Terms and Conditions of Sale for such products, Solyndra assumes no liability whatsoever. Copyright (circle logo ) Solyndra Inc. 2009-2010. Printed in the United States of America. All Rights Reserved.

Trademarks & Patents

The following terms are trademarks or servicemarks of Solyndra Inc.: Solyndra; The New Shape of Solar. All other trademarks and registered trademarks are the property of their respective companies. Solyndra products are covered by patents in the US and many other countries.

Contact Information
Solyndra, Inc. 47700 Kato Road Fremont, CA 94538 USA Tel. (+1) 510-440-2400 877-511-8436 Toll-free in North America Fax (+1) 510-662-4877 http://www.solyndra.com customersupport@solyndra.com salesinfo@solyndra.com

200 Series Installation Guide

Solyndra, Inc. 47700 Kato Road Fremont, CA 94538 www.solyndra.com

Contents
Chapter1 Purpose Chapter2 SafetyAdvisoryandProductSpecifications Chapter3 InstallationPreparation Chapter4 PanelInstallation AppendixAConnectionTesting AppendixBInCaseofBreakage 3 4 7 12 24 27

Purpose

Chapter 1 Purpose
This document is a guide to installing Solyndra 200 Series solar panels and mounting components. It is intended to be used by experienced photovoltaic (PV) systems installers. Please read this manual and follow installation procedures carefully. This guide assumes that the system will be installed according to a completed PV system design. For system design information, refer to Solyndras Design Guide. This manual provides guidelines for installation, but it does not guarantee the quality of installation work. Electrical work should be performed in a professional manner by a qualified electrician.

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SafetyAdvisoryandProductSpecifications

Chapter 2 Safety Advisory and Product Specifications

The Safety Alert Symbol
This symbol appears throughout, to alert the reader to important safety precautions. For safe equipment installation and operation, all precautions must be understood and followed.

Electrical Hazards
DANGER
Photovoltaic panels produce potentially hazardous electricity whenever exposed to a light source. Output cables connected to the panels are live! Touching exposed connector contacts or conductors attached to the panels (or leaving them where others may touch them) risks electrical shock, injury, or death. Always handle panels according to Solyndras labeling and instructions. Do not touch exposed connector contacts or cable conductors attached to the panels. Dangerous shocks can result. Tape and label or terminate cut ends of cables before connecting to the panels. Never disconnect panels while under load (i.e. with the inverter turned on and operating). Dangerous arcs of electrical current can occur and may cause injury or death.

Safety First

This section contains important safety information. It Solar Panels Are Always Live is required to read and understand it before working Solyndra panels are live: whenever light is present, voltage is preswith Solyndras 200 Series panel products.
This document describes proper methods for handling and installing Solyndras products which should be performed by qualified and trained service personnel. Some of the procedures described herein require special tools and knowledge. Any attempt at unpacking, installation, relocation, or replacement of the Solyndra products without proper training and understanding of the potential hazards involved could cause serious injury or property damage. Damage may also occur to equipment or to the balance of system (BOS), or could potentially cause an unsafe condition. ent. Panels cannot be switched off. Even at modest illumination, there is enough voltage to cause serious injury or death. Furthermore, the surprise of a shock could result in a fall or other secondary injury.

Signal Words and Definitions

Solyndra panels are equipped with connectors that shield an inner metallic contact. This shield reduces the possibility of contact with electrical conducting components during normal handling and installation. ALWAYS treat the panel electrical connectors as live wires. Observe all safety precautions and handle the panels according to the labeling and instructions provided by Solyndra.

Safety messages may appear in a written procedure. They will use Compliance with all applicable building, electrical, and safety codes standard symbols and language to call attention to them. for the design and installation of an entire photovoltaic solar system typically involves many components in addition to the Solyndra products. The use of trained, qualified and experienced local professionals is the best way to ensure compliance with such codes, many DANGER Indicates a hazardous situation which, if not avoidof which are local.
ed, will result in death or serious injury. This signal word is limited to the most extreme conditions.

Site Preparation

The installation plan should include a detailed description of the wiring methods to be used and a detailed description of the mechanical mounting. These plans should specify, at a minimum: Size, type, and temperature rating of all wiring components. Wire should be type USE-2, 12 AWG (4 mm2), or larger if required by local codes. Note that this is a UV-resistant grade rated for 90C operation (North America) or 120C (Europe). Identification and wiring orientation of each electrical sub-array within the system. Selection and use of appropriate materials such that fire rating of the roof is maintained. Solyndra-supplied panels and hardware will preserve fire ratings.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

NOTICE

NOTICE indicates a precaution message not related to personal injury. It can describe a potential hazard to equipment, for example.

Safe Work Practices

Safety at an installation site is covered by national and local laws, codes, and employer practices. The specific policies at a given site are outside of the scope of this safety advisory, but here are some

200 Series Installation Guide

Solyndra, Inc. 47700 Kato Road Fremont, CA 94538 www.solyndra.com

generally applicable guidelines that should be followed:

UV Light Protection
Solyndra panels are typically installed on highly-reflective cool roof surfaces. Bright sunlight and light reflected from the roof surface can cause permanent vision damage. Sunglasses which filter out ultraviolet light are recommended. Persons on the roof should wear sunscreen to protect skin from the sun.

Array Setbacks
For stability on the roof, Solyndra design guidelines require that panel arrays be set back at least 5 feet (1.52 meters) from the roof edge. Roof conditions and local codes and regulations may require additional setbacks for worker safety, equipment access, or other considerations.

SafetyAdvisoryandProductSpecifications

Roof Safety
Take care when working on rooftops. Even a short fall can result in serious injury or death. Use fall protection or take other precautions when working near roof edges. Roof surfaces can become slippery when wet or icy. Take additional precautions or avoid working on the rooftop when wet in these conditions.

String Size
Never connect more panels in series than the maximum voltage rating of the system, or 1000V, whichever is less. The number of strings which can be wired in parallel is limited by the series fuse rating. When selecting fuses (or other components), use the Fault Current Equation to determine the correct sizes and ratings. Please refer to NEC Article 690 for additional fusing requirements where applicable. Note that per applicable NEC and UL code, the equation requires a safety factor of 1.25. This requirement may be duplicated in local codes.

Panel Safety
ALWAYS stack the crates so panels are oriented with the tubes horizontal. ALWAYS use two people to move each panel: this is a requirement. Observe each other at all times to coordinate movements. ALWAYS carry and lift panels by the frame only. 200 Series panels only have frame rails on their long sides. Do not handle panels by the tubes. ALWAYS make sure that the packaging crate and crate lid are properly secured when unloading or moving the crates, especially where winds are prevalent. NEVER carry more than one panel at a time. NEVER carry or move panels by grabbing the glass tubes. NEVER flex the frames while handling them. NEVER lean, sit, or lie on top of panels. Stepping or lying on a panel while the array is under construction will also put the tubes under stress and should never occur: installing the panels in the correct order will make this unnecessary. NEVER place anything on panels. This could damage the glass tubes or shade the panels, causing improper operation. NEVER place panels on areas where people could walk on them or trip over them. NEVER carry objects that might obstruct the view of the floor while in the vicinity of the panels. NEVER expose the panels to artificially concentrated sunlight. In the event of breakage: Solyndra panels contain a silicone-based Optical Coupling Agent (OCA) fluid. While OCA is not toxic, the fluid is slippery and may create a slip hazard if left on the roof surface. If a panel is broken, clean up the broken glass and any OCA immediately. Use proper precautions when handling broken glass or injuries could occur. Solyndra supplies a Clean-Up Kit: see Figure 17. Solyndra Clean-Up Kit on page 27. Replacement materials and additional kits are available from Solyndra.

Equipment Grounding
Panels and components meet the requirements for double insulated Protection Class II . Components are VDE Approved (IEC61646, IEC61730-1, IEC61730-2)

200 Series panels, mounts and cable management components require no grounding when used in accordance with the installation instructions.

Self-Ballasting
Solyndra panels are self-ballasting: there is no need for attachment to the roof when used in accordance with the product specifications and Solyndra Design Guide. They must meet the array size requirements stated in the Solyndra Design Guide for the permissible number in an array for the roof conditions and panel configuration. The panels are designed to be installed horizontally, parallel to the roof, on low-slope roofs (less than 2:12 slope). Panels shall only be placed over firmly-attached roof surfaces. Loose-laid membranes or other materials are not acceptable. Panels should not be considered ballast for the roof surface.

Fire
Solyndra panels are rated (US) Class C - Electrical equipment. The panels should be installed over a fire resistant roof covering rated for the application.

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SafetyAdvisoryandProductSpecifications

Solyndra Panel Product Specifications

200 Series Electrical data
Power Rating (Pmp) Power Tolerance (%) Vmp Imp Voc Isc Temp. Coefficient of Voc Temp. Coefficient of Isc Temp. Coefficient of Power Wp %/Wp Volts Amps Volts Amps %/C %/C %/C SL-200-182 182 Wp +/-4 85.1 V 2.14 A 119.6 V 2.33 A -.28 -.02 -.38

Measured at Standard Test Conditions (STC) irradiance of 1000 W/m2, air mass 1.5 and cell temperature 25C.

SL-200-191 191 Wp +/-4 88.6 V 2.16 A 122.8 V 2.34 A

SL-200-200 200 Wp +/-4 91.7 V 2.18 A 124.6 V 2.35 A

SL-200-210 210 Wp +/-4 95.1 V 2.21 A 125.3 V 2.36 A

SL-200-220 220 Wp +/-4 98.4 V 2.23 A 125.8 V 2.37 A

System Information
Cell type Maximum System Voltage Dimensions Mounts Connectors Series Fuse Rating Roof Load Panel Weight Snow Load Maximum Hailstone Impact Wind Performance Operating and Storage Temperature NOCT Certifications/Listings Warranty Cylindrical CIGS Universal design: 1000 V (IEC) & 600V (UL) systems Panel: 2.28 m x 1.09 m x 0.06 m; Height: 0.36 m to top of panel on mounts Non-penetrating, steel-reinforced, high-performance engineered plastic 4 Tyco Solarlok; 0.20 m cable 24.4 Amps 13.9 kg/m2 (2.8 lb/ft2) panel and mounts 31.8 kg (69 lb) without mounts 1850* Pa / 1200 Pa (38.6 lb/ft2 / 25.1 lb/ft2) 25 mm, 7.53 g at 23 m/s per IEC 61646 208 km/h (130 mph) maximum. Self-ballasting with no attachments -40C to +85C 44C at 800 W/m2, Temp = 20C, Wind = 1m/s UL1703, IEC 61646, IEC 61730, Protection Class II Application Class A per IEC 61730-2, Fire Class C, CE Mark, CEC listing, MCS/BRE(UK) 25 year limited power warranty; 5 year limited product warranty

Specifications are subject to change without notice. Specification is only valid when using the product in accordance with Solyndras design and installation guidelines using Solyndra supplied mounting and interconnecting hardware. The electrical characteristics are within 10 percent of the indicated values of Isc and Voc under standard test conditions (irradiance of 100 mW/ cm2, AM 1.5 spectrum, and a cell temperature of 25C (77F)). *1850 Pa snow rating requires optional Snow Mount.

200 Series Installation Guide

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Chapter 3 Installation Preparation

Drawings and Plans
Clear and accurate engineering plans are critical to a successful installation. To ensure arrays are positioned and aligned properly on the roof, array plans should clearly indicate array setback distances to roof edges and significant roof obstructions (e.g. HVAC units, skylights). Plan sets should include stringing detail drawings which depict series and parallel electrical connections between panels, including any jumper cables that may be required to complete connections where panel connectors are not directly adjacent. Home run connection points and routing to the array exterior should also be shown. For large systems, it may be necessary to produce detail drawings for individual sub-arrays to depict connection details.

InstallationPreparation

Roof Preparation
Access to roof will be limited once the panels are installed. The roof must be in good condition before beginning the solar installation. The roof should be inspected for any potential leaks or significant drainage issues. Ensure roof drains are cleared and any leaks or drainage issues are repaired before installing the solar array. Solyndra recommends cleaning the roof before installing the solar panels since walking on soiled areas can compress soil into the roof surface, making it more difficult to clean later. Following the roof manufacturers O&M recommendations, remove loose debris using the rinse and flush method and/or blow debris out of service areas. According to construction best practices and roof manufacturers, any high-traffic areas on the roof require walkway pads or a sacrificial layer. Since the solar installation will create high traffic, Solyndra recommends use of temporary walkways during the installation.

Crate Handling
CAUTION
72-inch forks must be used when forking crates in the lengthwise direction. Panel crates should only be moved using proper equipment in good working condition and operated by persons trained in equipment use. Solyndra 200 Series panel crates are designed to allow forklift access from any side. Because of the length of crates, it is necessary to use forks at least 72 inches (180 cm) long when forking in the lengthwise direction. Using short forks will allow the crate to tip and possibly fall which will damage the panels. Depending on the delivery vehicle used, it may be necessary to fork panel crates in the lengthwise direction upon delivery to the job site.

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InstallationPreparation

Figure 1.

Long Forks for Use on Solyndra Crates

Lifting Materials to the Roof

CAUTION

A crate of Solyndra panels weighs approximately 1146 lbs (520 kg). If panel crates are to be placed and staged on the roof, the roof must be structurally capable of supporting this load. Placement of panel crates on the roof must be confirmed by a qualified structural engineer.

Solyndra panels and mounting components are typically lifted to the rooftop using either a telehandler (high reach forklift) or a crane. Mounting components should usually be lifted and staged on the roof prior to lifting panels.

Figure 2.

Crate Lifting Methods

Telehandler Crane

200 Series Installation Guide

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Lifting with a Telehandler

When lifting panel crates with a telehandler and when roof loading is an issue, it is most efficient to remove and install panels from the crate as it is being held above the roof surface by the telehandler. Using this method the structural loading of panel crates on the roof is eliminated.

InstallationPreparation

Lifting with a Crane

When lifting panel crates with a crane, crates should be placed on the roof as directed by a qualified structural engineer. Panel crates should be spaced to allow access to all sides of each crate by installers. Place panel crates close to array installation locations, if structurally permissible, to reduce installation time and labor. Care should be taken, so that panel crates do not obstruct the array assembly.

Unpacking and Staging Materials

CAUTION

Wind and wind gusts can lift unsecured panel crate lids from crates, the roof surface, or the ground, potentially leading to injury or property damage. Make sure crate lids are secured when loading and unpacking crates, and when storing and moving crate materials on the job site. Remove panel mounts and other mounting system components from their packaging and position near their planned array installation locations.

NOTICE Solyndra strongly recommends against staging individual panels on the

roof prior to installation (i.e. spreading panels around the roof ). This results in additional panel handling which will increase installation time and labor, and increases the potential for panel damage. It is generally more efficient to unpack and install panels directly from the crate.

NOTICE Do not discard panel crate materials. Solyndra will collect panel crate mate-

rials for re-use and recycling. This service is available in most locations at no charge. Refer to the Solyndra Crating and Recycling Guide (document no. 0920-30101) for detailed information on Solyndras crate recovery program and guidelines for packing crate materials for pick-up. Crate materials pick-up can be scheduled by completing an on-line request form at www. pangreen-logistics.com/solyndra/ or by contacting Solyndra Customer Support at +1-877-511-8436 or customersupport@solyndra.com.

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InstallationPreparation

Tools
Panel Assembly Tools
NOTICE Tools are not required to assemble arrays of Solyndra panels. To avoid

inadvertent damage to panels, instruct installers not to carry heavy tools or other items that could damage panels.

No tools are required to assemble Solyndra panels into arrays. Depending on the installation conditions, installers may require certain personal protective equipment (PPE) such as work gloves, work boots, hard hats, sunglasses and sunscreen.

Tyco Solarlok Assembly Tools

Solyndra panels utilize Tyco Solarlok connectors for panel electrical connections. Specialized tools are required to assemble Solarlok connectors for jumper and homerun cables that will connect to the panels.

Table 1.

Tyco Solarlok Connector Tools

Required

Cable Stripping Tool Tyco #1-1579002-2

Crimping Tool Tyco #1-1579004-2

Extraction Tool Tyco # 1102855-3

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Installation Teams
Crew Size
CAUTION
For safety reasons, a panel must be carried by at least two people working in close coordination. Panels should be lifted and carried only by their side rails. Never grasp, lift or carry panels by the glass tubes.

InstallationPreparation

Solyndra panel arrays can be efficiently assembled by a core team of three persons. Two persons (the panel carriers) carry panels from the panel crate to the array installation location, and assist with placement of each panel into the array. A third person (the array lead) remains at the array installation location and manages the array assembly, including electrical connections and array alignment. If there is a long distance between the panel crates and the array installation location, installation speed can be increased by adding additional two-person panel carrying teams. For large installations, multiple teams can be employed to work on different array sections. Additional team members may be required to support the system installation including: Foreman or installation supervisor to oversee and coordinate all activities. Lift equipment operators. Electricians and other trades to complete the electrical balance of system installation.

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PanelInstallation

Chapter 4 Panel Installation

4.1. TheSolyndraPanelMountingSystem
The Solyndra panel mounting system is designed for flat and low-slope commercial rooftops. Arrays assembled with Solyndra panels and mounting system are self-ballasting and require no mechanical attachment to the roof. Panel mounts are shared among adjacent panels. Panels are installed such that each panel rests on four mounts one mount at each corner.

4.1.1. PanelMounts
Solyndra standard panel mounts are used to support panels at the corners. Mounts have a fixed hook on one side and a spring-loaded latch on the other for capturing panel frames. Each panel will rest on four mounts one at each corner. At array edges panel mount position can be moved inward so that mounts do not protrude into aisleways. Panel mounts at array edges must have the orange positioning tabs removed. See Perimeter Mode on page 17. Figure 4. Panel Mounts at Array Interior and Perimeter on page 13 shows the panels at the edge of an array circled in green.

Figure 3. Panel Mount

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Figure 4. Panel Mounts at Array Interior and Perimeter

PanelInstallation

4.1.2. OptionalSnowMounts
Snow mounts attach to the middle of the panel frame to provide additional support in geographic locations where high snow loads are expected. The system design engineer should determine whether snow mounts are required for a given installation.

Figure 5. Snow Mount

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4.1.3. OptionalLoadDistributionFoot(LDF)
LDFs can be placed beneath standard mount feet on roofs with soft insulation layers to prevent compression from point loads. The LDF distributes point loads at the mount feet over a wider area of the roof surface. The system design engineer should determine whether LDFs are required for a given installation: see the Solyndra Design Guide for details.

Figure 6. Load Distribution Foot

4.1.4. PanelOrientation
Panels have a top and a bottom. Panels are stacked right side up in the panel crates. Panels have positive and negative rails (the frame pieces on long sides of panels). Panels have several features to assist in identifying positive and negative polarity: The female Tyco Solarlok connectors are keyed with red (positive) and blue (negative) o-rings. The connector leads on the positive rail have red wrap-around labels on the connector cable; the negative leads have white wrap-around labels. The panel nameplate and serial number barcode labels are affixed to the positive rail. The serial number barcode label includes a large + sign to indicate positive polarity.

Figure 7. Identifying Panel Polarity, Solarlok Connectors

Male, Negative

Negative Side

Female, Negative

Serial Number Label

+ Positive Side Female, Positive Male, Positive

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4.1.5. OptionalPanelConnectorsandDustCaps
When two connectors are mated together, the Tyco Solarlok connectors form a weather-tight seal that will protect the inner contacts for the design life of the panel. When left open, however, the connectors are not weather-resistant. Solyndra recommends installing connector dust caps on all connectors that will be left unused. Solyndra includes quantities of male and female dust caps with every panel shipment for this purpose.

PanelInstallation

Figure 8. Male and Female Dust Caps

4.1.6. CableManagementSystem

NOTICE Cable channels must be installed to protect energized cables from contact

with other mounting system components that could cause wear or damage to the cables.

The Solyndra Cable Management System is provided to manage home run cables that must be routed from the inside and outside the array to a common exit point (from where the cables enter a combiner/ junction box or conduit system). The Cable Management System includes cable routing channels and components for attaching the channels in both the length-wise and width-wise direction beneath the panels.

Figure 9. Cable Management System Components

Long Cable Channel Cable Channel Pegs

Short Cable Channel

Panel Mount Cable Channel

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PanelInstallation

4.2. PanelInstallationInstructions
CAUTION
For personal and equipment safety: before working with the panels, read, understand, and follow all precautions in the Safety Advisory section of this guide.

CAUTION

For safety reasons, a panel must be carried by at least two people working in close coordination. Panels should be lifted and carried only by their side rails. Never grasp, lift or carry panels by the glass tubes.

CAUTION

Wind and wind gusts can lift unsecured panel crate lids from crates, the roof surface, or the ground, potentially leading to injury or property damage. Make sure crate lids are secured when loading and unpacking crates, and when storing and moving crate materials on the job site.

4.2.1. BasicPanelInstallationProcessFlow
1. Mark the outlines of the array with chalk or string lines. 2. Place mounts in their approximate positions on the roof for the initial row of panels. 3. Place the first panel on four mounts. 4. Add the next panel in the row, making connections as indicated in the system engineering plans. 5. When the first row of panels is complete, position mounts for the next row of panels. 6. Continue adding panels row by row until the array is complete. 7. Connect home runs to completed string blocks and route them to array exterior using Solyndra Cable Management System components. 8. For systems with multiple sub-arrays, repeat steps 1 7 until all sub-arrays are complete. 9. Complete installation of electrical balance of system (wire runs, conduit, combiner boxes, disconnects, inverters, AC interconnection, etc.).

4.2.2. RemovingPanelsfromCrates
A panel crate list containing panel serial numbers is attached to the outside of every panel crate. Remove this sheet and keep with installation records. Completely remove wrapping materials and external crate components to access the panels stacked inside the crate. Do not use a knife to cut the shrink wrap, or the panels may be damaged. Before lifting and removing each panel from the crate, free the connector leads at each corner from the frame retention clips. This will make accessing the connector leads easier when the panel is installed into the array. For lifting, one person should be positioned on either side of the panel at the middle of the long frame. Lift the panel by grasping the long frame rail with both hands. Never grasp, lift or carry the panel by the glass tubes. Carry the panel to the array location for installation.

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Figure 10. Carrying Panel from Side Rails

PanelInstallation

4.2.3. PerimeterMode
Panel mounts at array edges can be positioned on the panel frame so that the mount does not protrude into aisleways. Remove the inner positioning tab from the mount: see Figure 11. Removable Tabs . Slide the mount inward along the panel frame rail until the mount center divider aligns with the panel frames positioning notch. Close both spring loaded latches on the mount. Note that only the outer latch will capture the frame rail interface feature.

Figure 11. Removable Tabs

To remove tabs: push down on the release on the tabs latch side and push it through to the hook side

2 removable tabs per mount

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PanelInstallation

4.2.4. OrientingthePanelforInstallation
Attention must be given to orientation of each panel as it is added to an array. Panel polarity (positive and negative rails) must be oriented to facilitate electrical connections with adjacent panels. Panel polarity and inter-panel connections should be indicated on array stringing diagrams included in the engineering plan sets for the installation.

4.2.5. FirstRowofArray:PlacingPanelsSidebySide
The first panel of an array or sub-array must be placed on four mounts. Position four mounts on the roof at the approximate locations of the panel corners. The spring loaded latches on all four mounts should be facing inward. The array lead can can remove the orange positioning tabs as necessary (see Perimeter Mode on page 17). While the panel carriers lower and hold the panel in place, the array lead adjusts the position of each mount onto the panel corners (see Figure 12, A and B). Once the panel is placed and resting on the mounts, close the spring loaded latches to capture the panel frame. The process above should be repeated to complete a row of panels. Each additional panel should be placed on two mounts shared with the adjacent panel, and two new mounts at the opposite end.

Figure 12. Placing the First Panel

A B

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4.2.6. SecondRowandBeyond:AddingPanelsontoPrecedingRow
Panel carriers should orient the panel polarity correctly upon arrival to the array location. The panel carrier holding the frame rail that will be adjacent to the preceding row should lower the frame rail carefully to rest on the roof surface (see Figure 13, A). With both panel carriers side-by-side and holding the raised panel frame rail, lift the panel vertically and place the lower panel frame rail on the mounts shared by the panels in the preceding row (see Figure 13, B and C). With the panel resting on the mounts in the vertical position, the array lead should make any panel electrical connections required at the forward interior panel corner. The panel carriers should slowly lower the panel to the horizontal position while applying downward and forward pressure to ensure the panel frame is captured by the hooks on the forward panel mounts (see Figure 13, D). Also see Figure 14. Hook, Capture, and Lower Panel into Position on page 20. The array lead should assist in positioning mounts for the back of the panel as it is lowered into place. Once the panel is placed and resting on the mounts, close the spring loaded latches to capture the panel frame.

PanelInstallation

Figure 13. Adding Panels to the Second Row

A B

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PanelInstallation

Figure 14. Hook, Capture, and Lower Panel into Position

NOTICE

Avoid twisting the panel while lowering it into place this can stress the glass tubes and damage the panel. Panel carriers should communicate and coordinate their motions at all times to avoid damage to the panel.

4.2.7. MakingPanelConnections

DANGER

Photovoltaic panels produce potentially hazardous electricity whenever exposed to a light source. Output cables connected to the panels are live! Touching exposed connector contacts or conductors attached to the panels (or leaving them where others may touch them) risks electrical shock, injury, or death.
Always handle panels according to Solyndras labeling and instructions. Do not touch exposed connector contacts or cable conductors attached to the panels. Dangerous shocks can result. Tape and label cut ends of cables before connecting to the panels. Never disconnect panels while under load (i.e. with the inverter turned on and operating). Dangerous arcs of electrical current can occur and may cause injury or death.

Make electrical connections between panels as each panel is added to the array. For some connections the panel carriers may need to hold the panel in the vertical position resting on the mounts while the array lead makes connections at the bottom side of the panel. Cover any un-used panel connectors with dust caps that are provided for this purpose. Stow any un-used connector leads in the clip features provided in the panel rails. Additional considerations for panel electrical connections: Panel electrical connections should be indicated on array stringing diagrams included in the engineering plan sets for the installation. Panels should be oriented to facilitate electrical connections with adjacent panels. A typical Solyndra array will included both series and parallel connections between panels; two or more series strings connected in parallel at the panels is referred to as a string block.
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 In a well designed array it should be possible to make most series and parallel connections using only the connector leads on the panels. Some arrays may include atypical stringing configurations that require jumper cables to make series or parallel connections between panels. Solyndra recommends testing voltage and current of each string block as it is completed to verify that stringing connections have been made correctly; see Appendix A for connection testing recommendations.

PanelInstallation

4.2.8. InstallingLDFs
When needed to distribute point loads, LDFs are placed beneath panel mounts. There is no attachment between panel mounts and the LDFs; panel mounts rest on top of the LDFs. LDFs can be placed beneath panel mounts as each panel is installed at the same time panel mounts are positioned beneath the panel. Alternately, LDFs can be placed beneath panel mounts after each row of panels has been assembled; for this method, lift each mount and panel, then slide the LDF beneath the panel mount.

4.2.9. InstallingSnowMounts
When needed to support anticipated snow loads, snow mounts are installed at the mid-point of each frame rail. Snow mounts ratchet to achieve the proper height to support the panel. Start with the snow mount stem fully retracted. Hook and swing snow mount onto frame rail at the rail mid-point. Snow mount stem must be extended until the snow mount contacts the roof surface while partially supporting the panel. To achieve this: With the snow mount attached to panel frame rail, extend the snow mount stem until the snow mount foot contacts the roof surface. With one foot holding down the snow mount foot, gently lift the panel at the frame rail mid-point until the snow mount stem ratchets one additional click. The snow mount should now be firmly in contact with the roof and partially supporting the weight of the panel. The locking clip can be removed from the snow mount stem to retract the stem for removal and reinstallation.

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PanelInstallation

Figure 15. Snow Mount Attachment

4.2.10. InstallingtheCableManagementSystem

NOTICE Homerun and jumper cables must be installed in a manner which prevents contact between energized cables and other mounting system components (e.g. the panel mounts).

Solyndra Cable Management System components can be used to manage home run cables that must be routed out of and around an array. Cable Management System components can also be used to manage jumper cables that must be routed between panels within an array. Cable Management System includes long and short cable channels for routing cables along the long and short sides of panels. Both long and short cable channels can be used on the outside edges or in the interior of an array. Long and short cable channels should first be installed on the panel array structure prior to loading cables into the channels. Long cable channel hangers attach to the panel frame rails to hold the Long Cable Channels. Three hangers should be used and evenly spaced on each panel frame rail where a cable channel is to be attached.
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PanelInstallation

Cable Channel Pegs should be inserted into the ends of the short cable channels. Short cable channels can then be hung between panel mounts by inserting the other ends of the pegs into the feature provided on the panel mounts. Load cables into the channels through the openings along the length of the channels. After cables have been loaded, cable channels should be snapped shut. Panel Mount Cable Channels should be utilized wherever cables are routed around panel mounts to prevent contact between the cables and the mount legs which could wear or damage energized cables. Cables must be loaded into the panel mount cable channels prior to attaching the channels to the panel mounts. Attach the Panel Mount Cable Channels to the panel mounts by inserting the pegs on the channels into the features provided on the panel mounts. Cable Channel Pegs can be removed from panel mounts by depressing tabs accessible on the bottom side of the panel mounts.

Figure 16. Cable Management System In Use

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ConnectionTesting

Appendix A Connection Testing

To ensure proper operation of the system, it is important that all electrical connections between panels are made correctly. Solyndra recommends testing string block voltage and current to verify that both series and parallel connections have been made properly. Solyndra recommends performing these tests at three points during the installation: String block verification testing performed as assembly of each array string block is completed. Combiner box verification testing performed at home run terminations in combiner boxes or inverters prior to system commissioning. System commissioning testing performed at home run terminations to confirm functionality of completed system.

DANGER

Photovoltaic panels produce potentially hazardous electricity whenever exposed to a light source. All electrical tests should be performed by a qualified electrician or PV technician. Always wear appropriate personal protective equipment (PPE), such as electrically insulated gloves, when working with live circuits.

A.1. StringBlockVerification
To ensure that panel connection errors are identified early when errors are easiest and safest to correct, Solyndra recommends checking open circuit voltage (Voc) and short circuit current (Isc) of each string block in an array as soon as the panels of the string block have been installed. With sunlight present, Voc should be roughly equal to the nameplate Voc of a single panel times the number of panels in series with the string block (+/- 5%).

DANGER

A DC rated switching device should be used when short-circuiting a panel or string block for Isc measurements. Short-circuiting a panel or string block without a properly rated switch can result in dangerous arcs of electrical current. When a string block contains parallel connections between panels, Isc should be measured to verify that all parallel connections have been made correctly. Isc will vary significantly with sunlight and other site specific conditions which can change rapidly. This can make it difficult to judge whether Isc measurements are acceptable or indicate possible connection errors. Comparing Isc for the entire string block and a single series string within the string block provides a more reliable indication of possible connection errors. The ratio of the string block Isc and the single series string Isc should be equal to the number of series strings in the string block. If Voc or Isc measurements are not within expected values, electrical connections within the string block should be inspected. After correcting any connection errors, Voc and Isc should be re-tested to verify that connections are all correct.

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A.2. CombinerBoxVerification
Solyndra recommends repeating Voc and Isc measurements for each string block circuit at combiner box or inverter terminations prior to inserting and/or closing string fuses. In addition to verifying proper panel connections as in String Block Verification, a key objective of Combiner Box Verification is to ensure that all string block circuits are connected into the combiner box or inverter with the correct polarity.

ConnectionTesting

DANGER

Solyndra panels do not contain bypass diodes to prevent reverse currents. A string block that is connected into a combiner box in reverse polarity to other string blocks will draw current from the other string blocks. This can cause dangerous arcs of electrical current. Always verify circuit polarity before connecting homeruns into a combiner box, inverter or other circuit combining equipment. With sunlight present, Voc of each string block should be roughly equal to the nameplate Voc of a single panel times the number of panels in series with the string block (+/- 5%). The voltage polarity of each string block circuit should be confirmed to be correct prior to inserting and/ or closing fuses.

DANGER

A DC rated switching device should be used when short-circuiting a panel or string block for Isc measurements. Short-circuiting a panel or string block without a properly rated switch can result in dangerous arcs of electrical current. When string blocks contain parallel connections between panels, Isc should be measured to verify that all parallel connections have been made correctly. Isc will vary significantly with sunlight and other site specific conditions which can change rapidly. This can make it difficult to judge whether Isc measurements are acceptable or indicate possible connection errors. During Combiner Box Verification, Isc for multiple string blocks should be measured in rapid succession under stable lighting conditions. The Isc of the string blocks can then be compared to identify possible connection errors. Measured Isc will be proportional to the number of series strings in parallel in each string block. String blocks with fewer series strings will have proportionally lower Isc than string blocks with more series strings. If Voc or Isc measurements are not within expected values, electrical connections within the string block should be inspected. After correcting any connection errors, Voc and Isc should be re-tested to verify that connections are all correct.

A.3. SystemCommissioning
System commissioning is typically performed at the conclusion of a system installation or during postinstallation maintenance or service. To ensure that a system is in a fully operational condition, Solyndra recommends checking Voc and operating current (Imp) of each string block circuit during system commissioning. Voc checks should be performed on each string block circuit at the combiner box or inverter with the inverter switched off and/or disconnected from the array. With sunlight present, Voc of each string block should be roughly equal to the nameplate Voc of a single panel times the number of panels in series with the string block (+/- 5%).
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ConnectionTesting

Imp checks should be performed on each string block circuit using a current clamp with the inverter operating and in maximum power point tracking mode. Imp will vary significantly with sunlight and other site specific conditions which can change rapidly. This can make it difficult to judge whether Imp measurements are acceptable or indicate possible connection errors. During System Commissioning, Imp for multiple string blocks should be measured in rapid succession under stable lighting conditions. The Imp of the string blocks can then be compared to identify possible connection errors. Measured Imp will be proportional to the number of series strings in parallel in each string block. String blocks with fewer series strings will have proportionally lower Imp than string blocks with more series strings. If Voc or Imp measurements are not within expected values, electrical connections within the string block should be inspected. After correcting any connection errors, Voc and Imp should be re-tested to verify that connections are all correct.

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Appendix B In Case of Breakage

The Solyndra panel contains a silicone-based Optical Coupling Agent to improve its performance. While this fluid is not toxic, it is slippery. If a panel is broken, clean up the spill immediately. The OCA Manufacturers MSDS is available from Solyndra. Solyndra supplies a Clean-Up Kit designed expressly for this purpose. The kit is pre-packed in a blue drum, which can be used to hold the material after clean-up. Replacement materials and additional kits are available from Solyndra. The kit is shown in Figure 17, and the contents are listed below.

InCaseofBreakage

Figure 17. Solyndra Clean-Up Kit

Clean-Up Kit
Item 0240-30833 Plastic container Plastic bag Plastic tie wraps (for bags) Plastic dustpan Brush for dustpan Absorbent mats Simple Green cleaner, plastic spray bottle Safety glasses Nitrile (plastic) safety gloves Cut-resistant gloves Qty 1 2 4 1 1 40 .946 1 10 1 Unit each each each each each each liter pair pair pair

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InCaseofBreakage

WARNING

A broken tube still produces voltage, and the glass pieces can cut. DO NOT insert fingers or any metal object inside a broken tube. BE CAREFUL when picking up pieces. Wear cut-resistant rubber gloves.

CAUTION

Spilled Optical Coupling Agent is a slip hazard. Immediately isolate spill and clean it up. Use absorbent mats and the recommended cleaning fluid to remove residue on all surfaces that came into contact with spilled OCA. 1. Immediately stop all other work in the area and isolate the spill area to protect people from the slip hazard. Avoid stepping in spilled OCA if possible. 2. Put on the safety glasses, nitrile gloves, and cut-resistant gloves. 3. Remove the broken panel from the array. 4. Using two people to carry it by the rails (see Carrying Panel from Side Rails on page 17), set the panel to one side. Place a mat (or mats) underneath it to catch any fluid. 5. Pick up all large pieces of broken glass. Temporarily place them in the drum, or another suitable plastic or metal container. (Dont put broken glass in the plastic bags; it will cut the bag.) Be careful; the gloves are cut-resistant but not cut-proof. Broken tubes still produce voltage. DO NOT insert fingers or any metal object inside a broken tube. 6. Use the brush and dustpan to sweep up smaller pieces of glass. 7. Carefully spread the absorbent mats over the spill area. 8. Allow the mats time to absorb the fluid. This only takes a few moments. 9. Pick up the mats and place them in the plastic bags. 10. If there are still puddles of fluid or standing liquid, repeat the mat application. 11. Use the cleaning fluid to clean up any remaining fluid. Be sure to clean shoe soles, and anything else that can in contact with the fluid. Wash the brush and dustpan as well. 12. If possible, remove the stub ends of the broken tubes and place them with the broken glass in the drum. 13. Dispose of the mats and other waste in a manner compliant with all applicable laws. 14. A broken panel cannot be re-used. Package up the broken panel and return it to Solyndra for recycling: contact Solyndra to schedule pickup.

NOTICE

Because the fluid is non-toxic, it is permissible for Simple Green-fluid mixtures to flow into sanitary drains in most jurisdictions. Check local laws to be sure.

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Revision History
File Name
200SeriesInstallGuide_N_V2-1EN

Revision History
Revision 1.0 2.0 Part Number TBD--001 0920-30031-002 Date January 2010 10 August 2010 Notes Initial Release (Qualification Only) Initial Product Launch verison. Added Safety Advisory and Product Specifications Section, edited since its initial distribution. Wordless Installation diagram cut back for new pictures when available. Added Site Preparation, formerly from Design Guide; edited. Panel Installation section written. Connection Testing added. In Case of Breakage section added. Correction of drawing labels page 14

2.1

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Solyndra Quality Policy Solyndra provides state-of-the-art solar photovoltaic systems and expert support that meet customers expectations for quality, delivery, technology, and responsiveness. We are committed to continually improving the quality of our products and processes.

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