DesignGuide150 EN 20110401 V1-1 N

Design Guide - 100/150 Series
Version 1.1
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English. 0920-30144 r002 Release Date: 2011-04-01 Visit http://www.solyndra.com for the mostcurrent version of this document.
Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com
GENERAL DISCLAIMER
The information contained in Solyndras instructions, guides, application notes, or any other document is advisory in nature only. Solyndra makes no representation or warranties that any referenced techniques or methods are necessarily safe, legal, or compliant with applicable codes and regulations. The customer must work with qualified system designers, installers and other professional personnel as required to ensure that all Solyndra photovoltaic system designs and installations are safe and in compliance with all applicable codes and regulations. Solyndra assumes no legal liability or responsibility for the accuracy, completeness, or usefulness of any information or processes disclosed herein. Reference herein to any particular 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
The warranty terms for Solyndras photovoltaic products are governed solely by the express terms of the Solyndra Limited Warranty provided to the purchaser of Solyndra products as may be transferred there under. Solyndra expressly disclaims any and all other express warranties and any and all implied warranties, including but not limited to those relating to the sale and/or use of Solyndra photovoltaic products, fitness for a particular purpose, merchantability or non-infringement or infringement of any intellectual property right. Solyndra may make changes to specifications, guidelines, and products at any time without notice. Purchasers or potential purchasers, designers and installers should contact their local Solyndra representative or the Solyndra website to ensure that they have and are working with the most up-to-date information and documentation relating to Solyndras photovoltaic products.
Trademarks /Patents/Copyright Notice

The following terms are trademarks or service marks of Solyndra LLC.: 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. Copyright (circle logo ) Solyndra LLC 2011. Printed in the United States of America. All Rights Reserved. UB.EN.20110317-V1.1.
Contact Information
Headquarters Solyndra LLC 47488 Kato Road Fremont CA 94538 USA Fax (+1) 510-662-4877 Regional Support Contacts US & Canada EMEA Belgium France Solyndra International AG Lindenstrasse 16 6340 Baar, Switzerland Germany Greece Italy Spain UK 877-511-8436 353 61 79 1124 0800 50735 0800 942896 0800 0004366 English DE, EN, FR, IT English French, English German, English customersupport@solyndra.com customersupporteu@solyndra.com customersupportbe@solyndra.com customersupportfr@solyndra.com customersupportde@solyndra.com customersupporteu@solyndra.com customersupportit@solyndra.com customersupportes@solyndra.com customersupportuk@solyndra.com
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Contents
Chapter 1
1.1. 1.2. 1.3.
Designing with Solyndra
Code Compliance & Safety ...........................................................................................................................................4 Required Information ...................................................................................................................................................5 Design Sequence ..........................................................................................................................................................5
Chapter 2
2.1. 2.2. 2.3. 2.4. 2.5. 2.6.
Wiring
The Solyndra Connector System ..................................................................................................................................6 String Blocks .................................................................................................................................................................8 String Wiring .................................................................................................................................................................9 Home Run Wiring ........................................................................................................................................................ 10 Grounding ....................................................................................................................................................................11 Array Installation over Lightning Grids ......................................................................................................................12
Chapter 3
3.1. 3.2. 3.3. 3.4. 3.5. 3.6.
Planning the Panel Layout
13
Wind Clearance ........................................................................................................................................................... 13 Roof Zone Definitions................................................................................................................................................. 14 Placing Panels Over Roof Objects .............................................................................................................................. 19 Mounting on Uneven Roofs .......................................................................................................................................20 Use of the Multi-Hole Mount .....................................................................................................................................20 Estimating Energy Yield ...............................................................................................................................................21
Chapter 4
4.1. 4.2. 4.3.
Design in Seismic Areas
22
Clearance Tables for Building Site Zones B, C, D ....................................................................................................... 23 Clearance Tables for Building Site Zone E .................................................................................................................25 A Note on Code Compliance ..................................................................................................................................... 27
Chapter 5
5.1. 5.2. 5.3. 5.4.
Solyndra Panel System
28
Part Definitions and Identification .............................................................................................................................28 Solyndra Parts .............................................................................................................................................................28 Quantities of Parts ......................................................................................................................................................30 Roof Loads .................................................................................................................................................................. 31
Chapter 6
6.1. 6.2. 6.3.
Optimum Inverter Selection
33
Actual Power versus Wp Rating .................................................................................................................................33 Inverter Sizing .............................................................................................................................................................33 Summary .....................................................................................................................................................................34
Chapter 7
Solyndra CAD Toolkit
35
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Solyndra Confidential
Design Guide - 100/150 Series 3
Chapter 1 Designing with Solyndra

The purpose of this Design Guide is to provide design guidance for Solyndra 100 Series and 150 Series photovoltaic systems. The target audience is system designers who are already skilled in photovoltaic design. This guide highlights the unique properties of the Solyndra 100 and 150 Series technology and their impact on system design, but is not intended to cover all aspects of system design. Projects that do not follow Solyndras design and installation guidelines may not provide the expected energy yield, and will not be covered by Solyndras warranty. This Guide applies to Solyndra 100 Series and 150 Series panels. These panels are electrically incompatible, even though they are identical mechanically. As a result, panel string sizes and string-block sizes may be different between the two panel series. Solyndra 100 Series and 150 Series panels must NEVER be used in the same electrical array. Solyndra 100 Series and 150 Series panels should NEVER even be placed on the same roof, to avoid any chance of mixing panel types. Care should be taken to insure that the correct panels are being used when adding to or replacing panels in an existing array. Panel and crate identifying labels are shown in Figure 1.
Figure 1. Example Panel and Crate Identifying Labels

100 Series Labels Panel Nameplate
PMP VMP IMP VOC ISC
PMP Tolerance +/- 4% Specifications at 1000 W/m , AM1.5 and 25C Cell Temp Certified to UL 1703, ed.3
150 Series Labels

Warning!
PMP VMP IMP VOC ISC
PMP Tolerance +/- 4% Specifications at 1000 W/m , AM1.5 and 25C Cell Temp Certified to UL 1703, ed.3
191 W 76.1 V 2.51 A 98.2 V 2.77 A
Solar Module Max. System Voltage Max. Series Fuse Fire Rating
SL-001-191U 600 V 23 A CLASS C
Electrical Hazard!
191 W 95.8 V 1.99 A 126.3 V 2.35 A
Solar Module Max. System Voltage Max. Series Fuse Fire Rating
SL-150-191U 600 V 24 A CLASS C
Electrical Hazard!
Warning!
Field Wiring: Use Copper ONLY, 12 AWG Min Insulated for a minimum of 90C LABEL NO. 0950-30052 R003 Made in USA
Field Wiring: Use Copper ONLY, 12 AWG Min Insulated for a minimum of 90C LABEL NO. 0950-30052 R003 Made in USA
Panel Label
- none -
Crate Label
1.1.
Code Compliance & Safety

System installations should be designed by a properly-licensed professional in accordance with all applicable codes and standards. Solyndra panels are made of glass and can be broken. Hazardous voltage is present in photovoltaic cells at all times when they are exposed to any light source. Before handling Solyndra panels, read and understand all Solyndra procedures, safety recommendations, and all local safety requirements applicable for working on roofs and around electrical equipment. Please refer to the Solyndra Installation Guide for safety recommendations.
1.2. Required Information

In order for an effective design to be produced, the designer needs information about the installation site. For a preliminary design, have: Address of site. Roof diagram with dimensions, including height. Roof slope. Roof contour if available. Building orientation (with respect to North-South). Roofing material type. Roof deck and load bearing capacity. Height of nearby structures, if any. Design wind speed, snow-load, and hail exposure. Seismic requirements, if any. Locations and dimensions of all roof obstructions. Shading analysis.
1.3. Design Sequence

Design begins with the determination of string length using Solyndras Inverter and String Sizing Tool (see 2.3. String Wiring on page 9), or other calculation methods, to achieve proper voltage match for an inverter type. Next, a rooftop layout is prepared. This will allow the most accurate determination of panel count, at which stage an energy yield forecast can be prepared. The final step is the preparation of a complete Bill of Materials for purchase, and an installation plan, including roof loading (structural) design.
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Wiring
Chapter 2 Wiring
2.1. The Solyndra Connector System
Each Solyndra panel has four connectors; two for positive and two for negative. The connectors are arranged to make it possible to implement series and parallel connections between panels in an array. The panel and its connectors are shown in Figure 2, along with the CAD tool symbol from the CAD package that Solyndra offers. Refer to Chapter 7 on page 35 for detail of the CAD tool package.
Figure 2. Solyndra PV Panel and Power Connections

+ Positive Side
Male +
Female +
Male Positive
Female Positive
CAD Symbol Female Male Negative Negative
Negative Side Female Male -
The preferred orientation for Solyndra panels is with the modules (tubes) oriented north-south. Panels are then wired in series, as shown in Figure 3. This type of connection is commonly referred to as a string.
Figure 3. Two Panels Wired in Series

+ Positive Side
Male +
Female +
Negative Side Female Male +
Male Female +
+ Positive Side
Female -
Negative Side
Male -
Horizontal string connections are also possible, as shown in Figure 4. It is important when connecting panels in horizontal strings, as shown in Figure 4, that only one connector pair be connected. Connecting both pairs would create a short circuit between the two panels.
Wiring
Figure 4. Series Connection, End-to-End Panels

Do not connect! + Positive Side Male, Negative Side
Male +
Female, +
Female -
Female -
Negative Side
Male, Female, +
+ Positive Side
Male +
Correct four-panel strings are shown in Figure 5. Notice how positive connectors are connected to negative connectors starting at the tail end of the string arrow (in green) and going towards the head of the arrow, increasing the total voltage with each panel.
Figure 5. Four-Panel Series Connections
Figure 6 shows connections between panels in a typical view from underneath the array.
Figure 6. Interpanel Connection of Positive and Negative Pigtails
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Wiring
2.2. String Blocks

A string is a group of panels whose electrical connections are in series. The number of panels needed in each string depends on the inverter chosen. Strings can be connected in parallel within an array to reduce home run wiring costs. Four typical arrays are shown in Figure 7. Note the parallel connections, indicated by the red jumper symbols at the top of the array, and the blue jumper symbols at the bottom of the array. All series and parallel connections can be made using only the built-in panel connectors.
Figure 7.
String Block Examples

(b) 5 by 3 String Block, Typical for 100 Series @600V
Home Run Connection
Home Run Connection
(a) 4 by 4 String Block, Typical for 150 Series @600V
Home Run Connection
Home Run Connection
(c) 6 by 4 String Block, Typical for 150 Series @1000V

Home Run Connection
(d) 8 by 3 String Block, Typical for 100 Series @1000V

Home Run Connection
Home Run Connection
Home Run Connection
In some cases, the standard string-block arrangement may not be convenient for a roof location due to obstacles or other factors. As an example, Figure 8 shows the 4 by 6 array of Figure 7(c) arranged as a 24-panel horizontal string block. In this design, short jumper cables (shown in red and blue) will be required to make the parallel connections on the positive and negative ends of the string block. Note that the two 24-panel string blocks, while physically different, are electrically equivalent.
Figure 8. A 4 by 6 String Block
Home Run Connection Negative Jumpers Positive Jumpers
Home Run Connection
2.3. String Wiring

Solyndra offers an inverter and string sizing tool to assist in determining the optimum string length and the correct inverter size for the array. The tool is available in North American (up to 600V) and one for European (up to 1000V) versions. These tools are Excel spreadsheets named: Inverter_and_StringSizing-100Series-EU Inverter_and_StringSizing-100Series-NA Inverter_and_StringSizing-150Series-EU Inverter_and_StringSizing-150Series-NA These tools can be obtained from Solyndra or an authorized distributor.
Wiring
2.3.1. Determining String Length

The number of panels placed in series determines the system voltage. The system voltage must stay below the smallest of: the maximum voltage rating of the inverter. the rated working voltage of the wiring. all applicable electrical codes. In the US, electrical equipment and wiring is rated for 600 volts maximum; in Europe the maximum rating can be as high as 1000 volts. Because panel voltage varies with temperature, the maximum voltage occurs when the temperature is cold and the inverter is off. Similarly, array voltage should be designed to stay above the minimum inverter tracking voltage when the temperature is hot and the array is operating at its maximum power point voltage, Vmp. Refer to the panel data sheet for specific temperature coefficients.
2.3.2. Parallel Strings

Connecting strings in parallel within the array reduces the amount of home run wiring needed, saving time and cost. First, the series fuse size for each string block must be determined. The equation is: Eqn 1. I fuse = 1.56 (N : I sc) Where N is the number of strings to be connected in parallel and Isc is taken from the panel data sheet. The calculated value must be rounded up to the next larger size. Values for 100 Series panels are listed in Table 1; values for 150 Series panels are listed in Table 2.
Table 1.
Isc One String Two Strings Three Strings
100 Series - Minimum Series Fuse Size for Strings in Parallel

150 2.72 5 9 13 157 2.73 5 9 13 165 2.74 5 9 13 173 2.75 5 9 13 182 2.76 5 9 13 191 2.77 5 9 13 200 2.78 5 9 14 Watts Amps Amps Amps Amps
Panel Power Rating
Table 2.
Isc One String Two Strings Three Strings Four Strings
150 Series - Minimum Series Fuse Size for Strings in Parallel

165 2.29 4 8 11 15 173 2.30 4 8 11 15 182 2.31 4 8 11 15 191 2.33 4 8 11 15 200 2.35 4 8 11 15 Watts Amps Amps Amps Amps Amps
Panel Power Rating
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Wiring
Maximum Number of Parallel Strings

The maximum number of strings which can be wired in parallel is limited by the series fuse rating of the panel. In order to determine the number of strings, use a Fault Current Equation as specified by the controlling code authority. As an example, the IEC Fault Current Equation is shown in Eqn 2: Eqn 2.
where N is the number of strings to be connected in parallel while still keeping the maximum fault current (Ifault) less than the series fuse rating, as specified in the data sheet. This can be solved for N, the number of strings, as: Eqn 3. N = (
I fault = I fuse + 1.25 ^N - 1 h I sc
I fault - I fuse ) + 1 1.25I sc
The series fuse rating and the short-circuit current rating as specified in the data sheet can be substituted into Eqn 3 and the maximum number of strings can be calculated. The results are shown in Table 3 and Table 4.
Table 3.
Isc N, calculated
100 Series - Number of Parallel Strings per Fused Home Run

150 2.72 3.46 3 157 2.73 3.44 3 165 2.74 3.43 3 173 2.75 3.42 3 182 2.76 3.41 3 191 2.77 3.40 3 200 2.78 3.39 3 Watts Amps Amps Amps
Panel Power Rating
N, rounded down
Table 4.
Isc N, calculated
150 Series - Number of Parallel Strings per Fused Home Run

165 2.29 4.24 4 173 2.30 4.22 4 182 2.31 4.21 4 191 2.33 4.17 4 200 2.35 4.14 4 Watts Amps Amps Amps
Panel Power Rating
N, rounded down
It is permissible to have string blocks of fewer than the maximum number of strings in parallel.
2.4. Home Run Wiring

Home run wires from string blocks are connected in parallel inside combiner boxes. Just as each panel has four connections, each of the four corners of a string block will have a positive or negative pigtail available. Run a positive home run cable and a negative home run cable from the corners in a way that minimizes cable length. Use the Solyndra Cable Management System to keep wires organized and prevent them from dangling. It is shown in Figure 9, and it includes long and short channels, and clips.
Figure 9. Cable Management System and Close-up View of Corner
10
2.5. Grounding
Solyndra recommends grounding the frames of all 100 Series and 150 Series panels. Safety requires that Solyndra panel arrays be properly grounded. To avoid electrical shock, ground the panel as soon as it is placed, before doing any other wiring. As the array is built, the first panel of each column should be connected to earth ground as soon as it is placed, using the supplied ground lug or equivalent. As each panel is added, connect a ground strap between it and the previous panel. These connections ensure that the aluminum frame is grounded. Use a grounding method that meets applicable national and local code requirements. The design goal is to keep resistance to ground below 0.1 ohm, per UL 1703. Grounding in the Solyndra array is accomplished by three primary elements: 1) system ground lugs (ILSCO GBL4-DBT), 2) a ground wire, and 3) interpanel ground straps. One ground lug is installed on the first panel in every column, and every 15 rows thereafter. Each of these rows of lugs is connected together and then to ground via 10 AWG solid copper ground wire to system (earth) ground. If local codes require a larger ground wire, a different ground lug may be required. Additional ground lugs and ground bus wire must be installed whenever an obstruction creates a hole in an array. When building around obstructions, the first row after the obstruction requires a ground wire and lugs to connect the obstructed column to either one of the neighboring columns. The third component of the ground system is the inter-panel ground strap. To complete the ground path, ground straps are used to ensure that panels in each column are a grounded unit. Refer to 5.2. Solyndra Parts on page 28 for details on all grounding system components. Equipment ground conductors must be connected with stainless steel hardware. Make sure that there is no copper-to-aluminum contact; this will cause rapid galvanic corrosion. A stainless steel washer must be used to isolate copper wire from the aluminum frame. Solyndra panels can be grounded using a grounding washer or clip system, provided such system has been tested and certified to meet UL467 requirements for bonding and grounding systems, and are installed according to the manufacturers specifications. All threaded holes in a Solyndra panel are ground connections, regardless of labeling.
Wiring
Figure 10. Grounding Connections for Solyndra Array

Ground Lugs Ground Bus Wire - 10AWG or Equivalent
Ground Strap
Grounding Holes 4 per Frame
Roof Obstruction
Additional Ground Bus & Lugs
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Wiring
2.6. Array Installation over Lightning Grids

Rooftops may be fitted with a lightning grid to deal with lightning. A lightning grid is an array of wires running in both horizontal directions across a roof. Dimensions vary, but typically the wires are spaced a few meters apart. The entire grid is carefully grounded to earth. These grids are occasionally fitted with vertical conductors as well. These are called air terminals, but are also referred to as lightning rods. A Solyndra array, when installed, may be placed over a lightning grid, but not over air terminals. Certain guidelines should be followed.
2.6.1. Lightning Guidelines

1. In all cases, a qualified lightning-grid designer shall be consulted during the design and installation phase of the Solyndra array. 2. Engineering for a photovoltaic system on roofs with lightning grids requires obtaining the S dimension required by code, either from the original designer or by re-calculating it. The S dimension is the minimum separation distance from the lightning grid required if additional precautions are not taken. 3. If panels are to be installed within distance S of the lightning grid components there are certain electrical code requirements. These may include requirements to connect exposed metal components to the lightning grid and that conductors coming into the building be protected by voltage shunt devices. 4. Solyndra panels should never be placed over air terminals. Any air terminals that are under the array must be moved. 5. Modifying the lightning protection system to protect the Solyndra panels is not necessary.
12
Chapter 3 Planning the Panel Layout

This chapter explains the rules for placing panels on a building roof. Solyndra panels are designed to be installed flat, elevated above the roof surface by Solyndra panel mounts. The open design of the Solyndra panel reduces wind effects, so they are self-ballasted against sliding and uplift. By attaching groups of panels together, mass is increased such that panel movement does not occur. A properly-assembled array has sufficient mass to resist movement without the need for attachment to the roof. In order to insure that high winds do not lift the panels, certain minimum clearances from building edges and other structures must be maintained. Panels shall only be placed over firmly-attached roof surfaces. Loose-laid membranes or other materials are not acceptable. As with any rooftop solar system, the design must also meet fire, safety, and access clearance requirements, as dictated by applicable codes.
3.1. Wind Clearance

The Solyndra panel and mount system, when installed according to Solyndra instructions, has been certified at wind speeds up to 130 mph (208 kph) in wind tunnel and outdoor studies. Wind speeds are defined as a 3-second gust measured at 10 meters, per ASCE 7-05, Figure 6.1. Wind speed-up due to local topography must be considered when establishing design wind speed. Consult ASCE 7-05, Section 6.5.7. Tornadoes have not been considered in developing this specification.
3.1.1.
Physical Sub-Array Definition

For purposes of wind analysis, the term sub-array is defined as a group of panels which are physically connected together. The manner of electrical connection(s) is not relevant to this definition. The larger the sub-array, the greater the physical stability of the system.
3.1.2. Coefficients of Friction

Friction between the Panel Mounts and the roof makes the panels resist moving in windy conditions. Solyndra has tested various combinations of Panel Mount materials and roof materials. The results are shown in Table 5. Pads are available as an option from Solyndra.
Table 5.
Roof material
TPO membrane PVC membrane
Coefficients of Friction for Common Roofing Materials

Panel Mount 0.40 0.43 1.48 0.77 Panel Mount with EPDM pad 1.0 Not recommended 1.0 Panel Mount with PVC pad Not recommended 0.53 Panel Mount with TPO pad 0.58 Not recommended 1.0
EPDM membrane Field-applied Coating
Not recommended Not recommended
Not recommended means that the combination is not chemically compatible. Care should be taken during installation on icy or dirty surfaces as these can reduce friction below measured values.
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3.2. Roof Zone Definitions

Wind clearance rules are defined according to corner, edge, and middle zones of the roof. Following the approach of ASCE 7-05, four roof zones have been defined: The minimum setback zone, a strip 5 feet (1.52 m) wide all around the rooftop perimeter. Panels are never permitted here. This zone is based on extensive wind testing and analysis. Zone A, a strip adjacent to the setback zone. Panels may be placed here, with conditions. Zone B, an arc segment at each roof corner. Panels may be placed here, with conditions. Zone C, the portion not included in A or B. Panels may be placed here, with conditions.
Slopes and Parapets

Roof zone definitions depend on both roof slope and the height of the parapet wall, if any. Roof slopes can be less than 1:10 (5.7), or up to 2:12 (9.6). Solyndra panels using Solyndra-supplied mounts are not recommended for use on roof slopes greater than 2:12 (9.6).
Zone A
Zone A is defined as the area of the roof between the 5-foot (1.52 m) setback line and the line defined by Dimension A. Dimension A is defined as including the 5-foot (1.52 m) setback. This means that if the calculation gives a value of 5 feet (1.52 m), there is no Zone A. In other words, for rectangular buildings less that 12.5 feet (3.8 m) high, or less than 50 feet (15.2 m) wide, the 5-foot (1.52 m) setback is sufficient, and the width of Zone A is effectively zero, that is, there is no Zone A.
Determining Dimension A
Step 1: Calculate two values: 40% of the building height. 10% of the lesser of building length or width. Step 2: Select the smallest of these possible dimensions. Step 3: Compare the result with 5 feet (1.52 m). Dimension A is the largest of these values.
Zone B
Zone B is the intersection of the pie-shaped section at each exterior corner and Zone A. The pie-section is defined by Dimension B, which is a radius, from the corner of the building, equal to 100% of the building height. The shape of Zone B is different for high and low parapet roofs. For high-parapet roofs, the intersection of Zone A and Zone B is defined as Zone B. For low-parapet roofs, the intersection of Zone A and Zone B is a forbidden area.
Definition of Building Dimensions

For rectangular buildings, the definitions of length, width, and height are clear. If the building is nonrectangular, consult ASCE 7-05 for definitions. Height is defined as the height, above the surrounding terrain or ground, of the portion of the roof on which the array is installed. There should be no surrounding buildings taller than 150% of roof height within a distance equal to 200% of roof height. The rules cited here should be considered minimums. When more panels are connected together in an array, the array has more resistance to wind effects. Whenever possible, build arrays larger than the minimum. When setting up a small array for evaluation purposes, place it in the center of the roof; well away from Zone A and Zone B.
14
Zone definitions depend on roof slope, parapet height, and whether there is a roof ridge. Zone definition drawings are shown in Table 6. A high parapet is one that is 19 (48 cm) or more in height. For slopes less than 1:10, no distinction is made between monoslope and ridged.
Table 6.
Roof Slope
Zone Definition Drawing Key

High Parapet Monoslope Monoslope Ridged Figure 11 Figure 13 Low Parapet Figure 12 Figure 14
Less than 1:10 (5.7) Between 1:10 and 2:12 (5.7-9.6) Between 1:10 and 2:12 (5.7-9.6)
In each of the figures, red represents roof area in which panels may never be placed.
Figure 11. Roof Zone Definition - High Parapet; Monoslope < 2:12; Ridged < 1:10
5 ft (1.52 m) edge setback Zone A Zone B Zone B
5 ft (1.52 m) edge setback Zone A
Dimension A
Zone A
Building Wall 5 ft (1.52 m) edge setback Zone B
Zone C
Dimension B
Zone B
Zone B Zone A 5 ft (1.52 m) edge setback
Zone B
Figure 12. Roof Zone Definition - Low Parapet; Monoslope < 2:12; Ridged < 1:10
5 ft (1.52 m) edge setback Zone A Zone B Zone B
5 ft (1.52 m) edge setback Zone A
Dimension A
Zone A
Building Wall 5 ft (1.52 m) edge setback Zone B
Zone C
Dimension B
Zone B
Zone B Zone A 5 ft (1.52 m) edge setback
Zone B
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Zone A 5 ft (1.52 m) edge setback
Zone A 5 ft (1.52 m) edge setback
Figure 13. Ridged Roof Zone Definition - High Parapet; Slope 2:12
5 ft (1.52 m) edge setback Zone B Zone A Zone B Roof Ridge Zone B Zone A Zone B
Dimension B
Zone A Zone A Zone A Zone C
Dimension B
Zone A Zone B Zone B Zone B Zone A Zone A Zone C
Dimension A (note)
Dimension A
Zone B
Zone B
Zone A
Zone B
Zone A
Figure 14. Ridged Roof Zone Definition - Low Parapet; Slope 2:12
5 ft (1.52 m) edge setback Zone A Zone B Zone B Zone B Roof Ridge Zone A
Dimension B
Zone A Zone A Zone A Zone C
Dimension B
Zone C
Dimension A (note) Zone B Zone A Zone B Zone B
Dimension A
16
3.2.1. Minimum Sub-Array Sizes for Roofs up to 1:10

Table 7 defines the minimum sub-array sizes for roofs up to 60 feet (18.3 m) high and with a slope less than 1:10. A tall parapet is one that is 19 (0.48 m) or more in height.
Table 7.
Fc (1) Roof Zone A (2, 3)
Minimum Sub-Array Sizes: Buildings 60 Ft (18.3 m) High, 1:10 Slope

Wind 85 mph 90 mph 95 mph 100 mph 105 mph 110 mph 115 mph 120 mph 125 mph 130 mph Speed 137 kph 145 kph 153 kph 161 kph 169 kph 177 kph 185 kph 193 kph 201 kph 208 kph
8 35 6 4 1 1 1 1 1 1 1 1 1 1 1 1
8 50 (5) 8 6 4 4 1 4 1 1 1 1 1 1 1 1
15 50 (5) 25 8 4 8 1 4 1 1 1 1 1 1 1 1
25 NA 49 16 8 8 4 4 4 4 1 4 4 1 1 1
35 NA NA 25 8 16 4 8 4 4 1 4 4 4 1 4
49 NA NA 25 8 36 4 8 4 4 4 4 4 4 4 4
NA NA NA 30 16 NA 8 8 8 8 4 8 4 4 4 4
NA NA NA 36 16 NA 16 16 8 8 4 8 4 4 4 4
NA NA NA 49 25 NA 25 25 8 8 4 8 8 8 4 8
NA NA NA NA 35 NA 49 25 8 15 4 8 8 8 4 8
0.4
B, low (4) B, high (4) C A (2, 3) B, low (4) B, high (4) C A (2, 3) B, low (4) B, high (4) C A (2, 3) B, low (4) B, high (4) C
0.58
0.83
1.0
Figure 15. Notes for Table 7, Table 8, and Table 9.

1. Fc is the coefficient of friction, from Table 5. 5 ft (1.52 m) edge setback 2. The array must be as deep, or deeper, than it Building Wall is wide, that is, the number of panels in direcZone A tion towards center of roof must equal or exceed number of panels along perimeter (see drawing at right). 3. No array can be fully inside Zone A. An array Zone C shall have at least two times as many panels in Zone C as in Zone A (see drawing at right). 4. Zone B is defined by Figure 11, Figure 12, Figure 13, or Figure 14. Not Acceptable Not Acceptable Acceptable 5. This array size cannot be fully inside Zone B. Array shall have at least as many panels in Zone C as in Zone B. 6. NA = Not Allowed. 7. Panels are not permitted on buildings over 300 feet high in wind zones over 95 MPH.
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Table 8.
Minimum Sub-Array Sizes: Taller Buildings, 1:10 Slope

60-120 ft (18.3-36.6 m) Wind 85 mph Speed 137 kph 120-180 ft (36.6-54.9 m) 180-240 ft (54.9-73.2 m) 95 mph 153 kph 130 mph 208 kph 95 mph 130 mph 85 mph 153 kph 208 kph 137 kph 95 mph 130 mph 85 mph 153 kph 208 kph 137 kph
30 NA NA 20 9 16 1 7 1 1 1 1 1 1 1 1
55 NA NA 30 15 55 9 9 6 4 4 6 4 4 4 4
NA NA NA NA NA NA NA NA 49 NA 36 36 36 55 4 25
45 NA NA 25 9 36 4 7 4 4 4 4 4 4 4 4
NA NA NA 49 25 NA 25 20 9 4 4 8 5 4 4 5
NA NA NA NA NA NA NA NA NA NA NA 55 45 NA 20 35
55 NA NA 30 12 55 7 9 5 4 4 5 4 4 4 4
NA NA NA NA 32 NA 49 23 9 9 4 9 6 4 4 7
NA NA NA NA NA NA NA NA NA NA NA NA 49 NA 36 40
0.4
0.58
0.83
1.0
240-300 ft (73.2-91.4 m) Fc (1) Roof Zone A (2, 3) 0.4 B, low (4) B, high (4) C A (2, 3) 0.58 B, low (4) B, high (4) C A (2, 3) 0.83 B, low (4) B, high (4) C A (2, 3) 1.0 B, low (4) B, high (4) C NA NA NA 30 16 55 7 9 6 4 4 5 4 4 4 4 NA NA NA NA 40 NA 49 23 12 9 4 9 6 4 4 7 NA NA NA NA NA NA NA NA NA NA NA NA 49 NA 36 40 Wind 85 mph Speed 137 kph
300-400 ft (7) (91.4-122 m) 95 mph 153 kph
400-500 ft (7) (122-152 m) 85 mph 137 kph 95 mph 153 kph
500-600 ft (7) (152-183 m) 85 mph 137 kph 95 mph 153 kph
95 mph 130 mph 85 mph 153 kph 208 kph 137 kph
NA NA NA 49 25 NA 25 20 8 4 4 7 5 4 4 5
NA NA NA NA 55 NA NA 36 16 42 4 16 9 4 4 9
NA NA NA NA 32 NA 49 24 9 16 4 9 7 4 4 7
NA NA NA NA NA NA NA 45 22 49 4 20 12 16 4 12
NA NA NA NA 35 NA 55 25 9 25 4 9 8 4 4 7
NA NA NA NA NA NA NA 49 25 NA 9 24 15 25 4 15
18
3.2.2. Minimum Sub-Array Sizes for Roofs up to 2:12

Table 9 defines the minimum sub-array sizes for roofs up to 60 feet (18.3 m) high and with a slope less than 2:12.
Table 9.
Minimum Sub-Array Sizes: Buildings 60 Ft (18.3 m) High, 2:12 Slope

Wind Speed 85 mph 137 kph 95 mph 153 kph 130 mph 208 kph
NA NA 48 75 40 36 36 14 6 6 12 4 5 5 5 1
NA NA 60 NA 56 40 48 21 18 6 27 12 5 5 5 1
NA NA NA NA NA NA 96 84 30 30 36 21 25 20 5 10
0.4
0.58
0.83
1.0
3.3. Placing Panels Over Roof Objects

Never place panels over objects more than 8 inches (20 cm) tall, or block up panels to clear objects. Any building steps or obstructions more than 8 inches (20 cm) high, such as overruns, HVAC units or skylights, shall have a minimum clearance equal to the lesser of the obstructions width or twice its height.
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3.4. Mounting on Uneven Roofs

Panel mounts should not be placed wholly or partially on raised areas such that the surface contact area between the mount and roof is reduced, or that there is a large height disparity between panels. For stability, it is recommended that the mounts be placed in the valleys of a non-flat patterned roof, versus the peaks. It is also recommended that the roof structures load-bearing capability be assessed wherever the mounts are placed.
Figure 16. Right and Wrong Ways to Place Panels on Uneven Roofs
Acceptable
Acceptable
Unacceptable
3.5. Use of the Multi-Hole Mount

Solyndra offers a panel mount with multiple holes, shown in Figure 17. This allows the mount to be moved slightly toward the middle, or the end, of the panel. This feature is useful when installing on standing seam metal roofs or other roofs that have a regular pattern of high and low places. It is also useful on conventional flat roofs in cases where there is a small projection or bump of some sort, right where the regular mount would normally sit.
Figure 17. Multi-Hole Panel Mount

[993.39] 39.110 (POR) [917.19] 36.110 (POR) [839.72] 33.060
[1069.59] 42.110 [1147.06] 45.160 [1083.33] 43.635 [1070.23] [1032.13]42.135 42.135 [993.39] 39.110 [954.66] [916.56] 37.585 36.085 [878.46] 34.585
[917.19] [955.29] 36.110 [1031.49] 37.610 40.610
20
3.5.1. Mount Spacing Options

Depending on the mounting hole locations selected, a number of possible spacings are available. These are listed in Table 10. The Panel Mount Pitch columns show the center-to-center spacing of mounts. The intra-panel dimension refers to mounts on the same panel, and the inter-panel dimension refers to mounts on adjacent panels. Note that the total pitch is always 1819 mm, or 68-13/16 inches. The intra-panel spacing column shows the clear space between the mounts, that is, it allows for the width of the mount. The inter-panel spacing column shows the clear space between the mounts for mounts on adjacent panels. The highlighted line is the standard spacing. If the roof requires mount spacing wider than standard (0, highlighted in gray in the table) and the installation must meet snow load requirements, consult Solyndra.
Table 10.
Possible Panel Mount Pitches

Panel Mount Pitch intra-panel inter-panel mm 672 699 749 826 902 953 979 inches 23-5/8 24-11/16 26-11/16 29-11/16 32-11/16 34-11/16 35-3/4 mm 1076 1049 999 922 846 795 769 inches 42-3/8 41-5/16 39-5/16 36-5/16 33-5/16 31-5/16 30-1/4 mm 601 628 678 755 831 882 908 inches 23-21/32 24-23/32 26-23/32 29-23/32 32-23/32 34-23/32 35-1/4 mm 1147 1120 1070 917 866 840 inches 45-3/16 44-1/8 42-1/8 39-1/8 36-1/8 34-1/8 33-1/16 Intra-panel Spacing Inter-panel Spacing
Mount Position mm +76.8 +63.5 +38.0 -38.0 -63.5 -76.8 inches +3 +2-1/2 +1-1/2 -1-1/2 -2-1/2 -3
0 - standard position 993
3.6. Estimating Energy Yield

When the layout is completed, Solyndras on-line energy yield forecast tool can be used to estimate hourly, daily, monthly, and annual energy yield. Detailed results are available on-screen, in a downloadable report, and in a downloadable Excel spreadsheet. For instructions in the use of this tool, refer to the Energy Yield Forecast Tool User Guide. Contact a Solyndra representative to obtain access to the tool.
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Chapter 4 Design in Seismic Areas

A Solyndra array, properly installed on a rooftop, functions as a seismically-isolated system. It is designed to have some movement in the largest seismic events. When designing systems for seismically-active areas, clearances must be maintained around the array to allow for maximum possible displacements in a worstcase seismic event. In order to determine the amount of clearance required, the engineer must determine the parameters listed below. Solyndra recommends that designers work with a qualified seismic engineer who is familiar with seismic conditions in the region where the array will be installed, and can determine the building period of the structure where the array will be installed.
Understanding Seismic Hazard Levels

The seismic hazard at a given location can be defined by two parameters: the short period Maximum Considered Earthquake (MCE*) spectral response acceleration (SS), and the 1-second MCE spectral response acceleration (S1). The levels of seismic hazard are defined by maximum spectral response acceleration parameters. Four levels are defined: Low (Level 1), Moderate (Level 2), High (Level 3), and Very High (Level 4) seismic activity. Any site with spectral response parameters equal to or lower than the maximum values for a seismic hazard level are within that level. The expected seismically-induced array displacements for any Solyndra installation can be determined from the seismic hazard level of the site. The spectral response parameters that define the four seismic hazard levels are shown in Table 11.
Table 11.
1 2 3 4
Seismic Level Spectral Parameters

Seismic Hazard Description Low Medium High Very High Maximum SS 0.533 1.500 2.000 2.893 Maximum S1 0.210 0.600 0.940 1.237 Units G G G G
Seismic Hazard Level
Multiple soil conditions are also considered for each of the four levels in this study by adjusting the SS and S1 values by site soil coefficients (Fa and Fv) per ASCE 7-05. Only site Classes B, C, D, and E (as defined by ASCE 7-05) are considered in this study. Site Class A is not considered as it is rarely encountered in occupied areas. The adjusted values are then used to define the MCE response spectra for each soil type considered.
Wiring
Combiner boxes must be set back from the array a distance greater that the specified displacement. Home run wiring must be flexible and include strain-reliefs. It must be long enough not to restrict any possible movement of the panels in a seismic event.
Roof Slope.
Arrays should not be installed on roofs with slopes greater than 1:12 (4.76 degrees) in seismically-active areas.
* The MCE is defined as an earthquake of such intensity that there is a 2% probability that it would be exceeded in a time period of 50 years (or equivalently with a return period of 2,475 years). 22 Design Guide - 100/150 Series Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com
Coefficient of Friction Table 12. Coefficients of Friction for Common Roofing Materials
Roof material
TPO membrane PVC membrane EPDM membrane Field-applied Coating Panel Mount (no pad) 0.40 0.43 1.48 0.77 Panel Mount with EPDM pad 1.0 Not recommended 1.0 Panel Mount with PVC pad Not recommended 0.53 Panel Mount with TPO pad 0.58 Not recommended 1.0
Not recommended means that the combination is not chemically compatible. Care should be taken during installation on icy or dirty surfaces as these can reduce friction below measured values.
4.1. Clearance Tables for Building Site Zones B, C, D

Table 13.
Seismic Hazard Level 1
Clearance for Coefficient of Friction 0.4; Site Classes B, C, D

Building Period 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches 4 1 2 4 4 4 7 12 21 cm 10 2.5 5 10 10 10 17.5 30 52.5 Clearance, 1/2:12 slope inches 1 0 3 5 5 4 7 14 cm 2.5 0 7.5 12.5 12.5 10 17.5 35 Clearance, 1:12 slope inches 1 2 4 9 9 5 9 cm 2.5 5 10 22.5 22.5 12.5 22.5
0.1 0.2 0.3 0.4 0.5
Not Recommended
Not Recommended Not Recommended Not Recommended
3, 4
Table 14.

Building Period 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches 1 1 1 2 3 2 5 9 17 18 4 7 11 17 20 10 15 20 30 31 cm 2.5 2.5 2.5 5.1 7.6 5.1 12.7 22.9 43.2 45.7 10.2 17.8 27.9 43.2 50.8 25.4 38.1 50.8 76.2 78.7 Clearance, 1/2:12 slope inches 1 1 2 3 3 2 6 11 20 21 4 8 13 20 25 10 17 26 34 cm 2.5 2.5 5.1 7.6 7.6 5.1 15.2 27.9 50.8 53.3 10.2 20.3 33.0 50.8 63.5 25.4 43.2 66.0 86.4 Clearance, 1:12 slope inches 1 1 2 5 5 2 8 18 26 32 5 10 19 28 12 18 35 cm 2.5 2.5 5.1 12.7 12.7 5.1 20.3 45.7 66.0 81.3 12.7 25.4 48.3 71.1 30.5 45.7 88.9
0.1 0.2 0.3 0.4 0.5
0.1 0.2 0.3 0.4 0.5
Not Recommended
0.1 0.2 0.3 0.4 0.5
Not Recommended Not Recommended Design Guide - 100/150 Series 23
Not Recommended
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Table 15.

Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 0 0 1 2.5 1 2.5 2 5.1 2 5.1 1 2.5 3 7.6 8 20.3 10 25.4 14 35.6 2 5.1 6 15.2 8 20.3 13 33.0 17 43.2 6 15.2 11 27.9 16 40.6 26 66.0 27 68.6 Clearance, 1/2:12 slope inches cm 0 0 1 2.5 1 2.5 2 5.1 2 5.1 1 2.5 4 10.2 8 20.3 12 30.5 16 40.6 2 5.1 6 15.2 10 25.4 15 38.1 19 48.3 7 17.8 13 33.0 19 48.3 28 71.1 32 81.3 Clearance, 1:12 slope inches cm 0 0 1 2.5 1 2.5 3 7.6 3 7.6 1 2.5 5 12.7 12 30.5 17 43.2 23 58.4 3 7.6 8 20.3 13 33.0 21 53.3 27 68.6 7 17.8 14 35.6 25 63.5 34 86.4 Not Recommended
Table 16.

Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 0 0 0 0 1 2.5 1 2.5 1 2.5 1 2.5 3 7.6 6 15.2 8 20.3 11 27.9 2 5.1 4 10.2 7 17.8 12 30.5 13 33.0 4 10.2 9 22.9 14 35.6 22 55.9 26 66.0 Clearance, 1/2:12 slope inches cm 0 0 0 0 1 2.5 1 2.5 1 2.5 1 2.5 3 7.6 7 17.8 9 22.9 13 33.0 2 5.1 5 12.7 7 17.8 13 33.0 14 35.6 4 10.2 10 25.4 15 38.1 24 61.0 28 71.1 Clearance, 1:12 slope inches cm 0 0 0 0 1 2.5 2 5.1 1 2.5 1 2.5 3 7.6 8 20.3 11 27.9 18 45.7 2 5.1 5 12.7 10 25.4 16 40.6 20 50.8 5 12.7 12 30.5 19 48.3 29 73.7 36 91.4
24
4.2. Clearance Tables for Building Site Zone E

Table 17.
Clearance for Coefficient of Friction 0.4; Site Class E

Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 2 5.1 3 7.6 5 12.7 9 22.9 3 7.6 5 12.7 10 25.4 16 40.6 18 45.7 Clearance, 1/2:12 slope inches cm 1 2.5 2 5.1 4 10.2 6 15.2 12 30.5 3 7.6 6 15.2 11 27.9 19 48.3 Not Recommended Not Recommended Clearance, 1:12 slope inches cm 1 2.5 3 7.6 5 12.7 11 27.9 20 50.8 3 7.6 7 17.8 Not Recommended Not Recommended Not Recommended
3, 4
Table 18.

Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 2 5.1 3 7.6 6 15.2 1 2.5 4 10.2 7 17.8 12 30.5 16 40.6 3 7.6 6 15.2 9 22.9 14 35.6 18 45.7 7 17.8 12 30.5 16 40.6 25 63.5 26 66.0 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 2 5.1 4 10.2 7 17.8 1 2.5 5 12.7 9 22.9 15 38.1 18 45.7 3 7.6 7 17.8 11 27.9 16 40.6 21 53.3 7 17.8 12 30.5 19 48.3 28 71.1 34 86.4 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 3 7.6 6 15.2 10 25.4 2 5.1 6 15.2 15 38.1 20 50.8 26 66.0 4 10.2 9 22.9 16 40.6 24 61.0 33 83.8 9 22.9 14 35.6 27 68.6 Not Recommended Not Recommended
0920-30144 r002
Table 19.

Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 2 5.1 2 5.1 5 12.7 1 2.5 3 7.6 6 15.2 8 20.3 11 27.9 3 7.6 4 10.2 7 17.8 11 27.9 13 33.0 5 12.7 9 22.9 13 33.0 21 53.3 25 63.5 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 2 5.1 3 7.6 5 12.7 1 2.5 3 7.6 6 15.2 9 22.9 13 33.0 2 5.1 5 12.7 8 20.3 13 33.0 15 38.1 5 12.7 9 22.9 15 38.1 23 58.4 28 71.1 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 2 5.1 4 10.2 7 17.8 1 2.5 4 10.2 9 22.9 12 30.5 19 48.3 2 5.1 6 15.2 11 27.9 17 43.2 22 55.9 5 12.7 11 27.9 20 50.8 30 76.2 Not Recommended
Table 20.

Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 1 2.5 1 2.5 3 7.6 1 2.5 2 5.1 5 12.7 6 15.2 9 22.9 1 2.5 3 7.6 6 15.2 10 25.4 10 25.4 3 7.6 8 20.3 11 27.9 17 43.2 21 53.3 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 1 2.5 2 5.1 4 10.2 1 2.5 2 5.1 5 12.7 7 17.8 11 27.9 1 2.5 3 7.6 6 15.2 11 27.9 11 27.9 3 7.6 8 20.3 12 30.5 19 48.3 23 58.4 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 1 2.5 3 7.6 5 12.7 1 2.5 2 5.1 6 15.2 8 20.3 15 38.1 1 2.5 4 10.2 8 20.3 13 33.0 15 38.1 3 7.6 9 22.9 15 38.1 24 61.0 30 76.2
26
4.3. A Note on Code Compliance

The Solyndra array is designed to not be attached and to minimize lateral forces on the roof diaphragm as it acts as an isolation system. It is exempt from the prescribed requirements described in Section 1613 of the 2007 CBC (California Building Code) and Section 13.1.4 of the ASCE 7- 05, 9. under specific exemption for non-structural electrical components with weights of less than 400 pounds (182 Kg), mounted less than 4 feet (1.22 m) above floor level, provided that flexible connections are provided and testing has been done. The applicable code sections are shown Table 21 in for reference.
Table 21.
A Selection of Applicable Seismic Codes
2007 CBC, Section 1613 EARTHQUAKE LOADS 1613.1 Scope. Every structure and portion thereof, including nonstructural components that are permanently attached to structures and their supports and attachments, shall be designed and constructed to resist the effects of earthquake motions in accordance with ASCE 7, excluding Chapter 14 and Appendix 11A. The seismic design category for a structure is permitted to be determined in accordance with section 1613 or ASCE 7. ASCE 7-05, Chapter 13 SEISMIC DESIGN REQUIREMENTS FOR NONSTRUCTURAL COMPONENTS 13.1.4 Exemptions. The following nonstructural components are exempt from the requirements of this section: 4. Mechanical and electrical components in Seismic Design Categories D, E, or F, where the component importance factor, Ip, is equal to 1.0 and both of the following conditions apply: a. Flexible connections between the components and associated ductwork, piping, and conduit are provided, and b. Components are mounted at 4 ft (1.22 m) or less above a floor level and weigh 400 lb (1780 N) or less. 2007 CBC, Section 1708.5 1708.5 Seismic qualification of mechanical and electrical equipment. The registered design professional in responsible charge shall state the applicable seismic qualification requirements for designated seismic systems on the construction documents. Each manufacturer of designated seismic system components shall test or analyze the component and its mounting system or anchorage and submit a certificate of compliance for review and acceptance by the registered design professional in responsible charge of the design of the designated seismic system and for approval by the building official. Qualification shall be by an actual test on a shake table, by three-dimensional shock tests, by an analytical method using dynamic characteristics and forces, by the use of experience data (i.e., historical data demonstrating acceptable seismic performance) or by a more rigorous analysis providing for equivalent safety.
0920-30144 r002
Chapter 5 Solyndra Panel System

5.1. Part Definitions and Identification
Figure 18 shows the major components of a Solyndra PV panel and their names. Fasteners and other small parts are listed in Table 22.
Figure 18. Panel Parts and Assemblies

Ground Lug Hole (underside) Ground Strap Hole SolarLok Male, Positive Lateral Clip Hole SolarLok Female, Negative Ground Strap Hole Panel Mount Ground Lug Hole (underside) Ground Strap Hole SolarLok Female, Positive Lateral Clip Hole SolarLok Male, Negative Ground Strap Hole
5.2. Solyndra Parts

Table 22 lists the parts which are a standard part of the Balance of System (BOS) in Solyndra arrays. Table 23 lists the optional BOS parts.
Table 22.
Panel Installation Hardware - Provided as Balance of System

Illustration
Item Part Number Panel SL001-XXX Solyndra photovoltaic panel. -XXX is the power rating of the SL150-XXX panel. Panel Mount Panel mount for Solyndra photovoltaic panel. 0040-30175
M5 Screw 0520-30658 M5-0.8 x14 mm stainless steel screw Ground Strap 0011-30029 10 AWG tinned stranded wire with lugs at each end. Lateral Clip 0020-30213 Has teeth on one side; these go against aluminum frame to insure a good connection. Panel Prep Block 0205-30029 Used to support the panel while installing panel mounts onto panel. OCA Cleanup Kit 0240-30833 Clean up kit in case of panel breakage. One kit needed per building or installation site.
28
Table 23.
Item
Panel Installation Hardware - Optional, from Solyndra

Part Number 0020-30198 0020-30199 0024-31632 Illustration
Long Cable Channel Short Cable Channel Used for routing the home run cables around the array. Load-Distributing Foot Used on mineral-wool or other soft roofs. Cable Channel Clips
0020-30205
Cable channel clips are installed on the short side of the panel. They support the cable channel that contains the home run power connections. Dust Cap for Female Solarlok Connectors 0048-30094
May be used to cover unused Solarlok female connectors. Not required. Dust Cap for Male Solarlok Connectors 0048-30100
May be used to cover unused Solarlok male connectors. Not required. Also available from Tyco . Ground Lug 0700-30198 The wire-clamping portion is open-jawed; permits the use of a continuous length of grounding wire. Also available as ILSCO GBL-4DBT. Pad, Panel Mount, TPO Pad for panel mount, at the option of end user. Pad, Panel Mount, PVC Pad for panel mount, at the option of end user. Pad, Panel Mount, EPDM Pad for panel mount, at the option of end user. 0020-30227 0020-30226 0020-30225
Tyco Solarlok Connector Information

Table 24 lists part numbers for Tyco Solarlok connectors for 10 AWG (5.3 mm2) wire, commonly used for home run connections. Table 25 lists part numbers for Tyco Solarlok connectors for 12 AWG (4 mm2). These should be used if it is necessary to replace a connector on a Solyndra panel.
Table 24.
Tyco Solarlok Connector Part Numbers, 10 ga (5.3 mm2) Wire

Female Cable Connector Plus Keyed Minus Keyed 5-1394462-5 Male Cable Connector Plus Keyed 1394461-7 Minus Keyed 1394461-8 Unkeyed 6-1394461-3
Plus Coupler Minus Coupler Male Coupler, Neutral
5-1394462-5 -
Table 25.
Tyco Solarlok Connector Part Numbers, 12 ga (4 mm2) Wire

Female Cable Connector Plus Keyed Minus Keyed 1394462-4 Solyndra Confidential Male Cable Connector Plus Keyed 1394461-3 Minus Keyed 1394461-4 Unkeyed 6-1394461-2 Design Guide - 100/150 Series 29
Plus Coupler Minus Coupler Male Coupler, Neutral 0920-30144 r002
1394462-3 -
5.3. Quantities of Parts

Solyndra panels share mounts and certain other components. Therefore the number of parts needed is determined by both the number of panels and the arrangement of the arrays, i.e. the number of rows and columns of panels. Figure 19 shows a detailed view of the placement of each part. The Solyndra CAD Toolkit will automatically calculate exact part counts for all designs. If determining part counts manually, be sure to include two short-channel clips for each short channel.
Figure 19. Parts Arrangement in a Typical Sub-Array

Wiring Polarity + Panel Row + Panel Row + Panel Row + Panel Row + Panel Row Panel Column (String) Panel Column (String) Panel Column (String) Cable Channel
Ground Lugs
Ground Bus Wire
Ground Strap
Grounding Holes 4 per Frame

Cable Channel
Lateral Clip
Panel Mount
5.3.1. Materials Recommendations

Do not substitute for any Solyndra-specified parts without the express written consent of Solyndra. Use of non-Solyndra-specified parts will void the warranty. Materials used outdoors should be sunlight/UV resistant. Materials such as wire insulation and other components should be certified to withstand the temperatures to which they are exposed. Dissimilar metals (such as steel and aluminum) should be isolated from each other using non-conductive shims, washers, or other methods. Only high quality stainless steel fasteners should be used.
30
5.4. Roof Loads

All roof-top photovoltaic designs should be reviewed by a qualified structural engineer. The following data should be considered as advisory only. The roof deck may be made of any material as long as it is securely fastened, has a slope of 2:12 or less, can support the load, and provides proper friction. High-reflectivity white material is preferred; lower-reflectivity roofs will reduce energy output.
Table 26.
Item
Distributed Roof Loading

Dead Load (US units) 3.3 pounds/square foot Dead Load (Metric) 16.3 kg/ square meter
Panels with mounts and home run wiring
From a design viewpoint, adding an array to a roof adds 3.3 lbs/ft2 (16 kg/m2) of loading to the roof. However, in some cases the roof s live load allowance of 20 lbs/ft2 (100 kg/m2) may be eliminated because it will no longer be possible to place materials in areas occupied by the array.
5.4.1. Snow Loads

Solyndra panels have been tested per Section 10.16 of IEC 61646. They can withstand 50 pounds per square foot (245 kg/m2, or 2400 Pascals) of snow load. In many cases, snow will accumulate on the tubes, although light snow sometimes falls through.
5.4.2. Roof Mount Point Loads

Some roof materials, such as mineral wool and certain types of foam insulation, have a specific local pressure loading limit. These soft roofs may required the use of a panel mount with a larger footprint to reduce localized pressure. Solyndra offers a Load Distribution Foot (LDF) for installation situations which must meet a local pressure loading limit. The LDF attaches to the standard panel mount. The attachment allows the LDF to tilt slightly to accommodate uneven roof surfaces. When used in accordance with Solyndras installation guidelines (see next page), the LDF limits roof compression to less than 3 mm.
Table 27.
Material Area of Foot Weight, each
Standard Panel Mount and Load-Distribution Foot

Standard Mount Powder-coated aluminum 0.0138 m 0.48 Kg
2
Load-Distribution Foot Powder-coated aluminum 0.123 m2 0.6 Kg

Panel Mount
LDF
The maximum pressure at the foot of each mount is shown in Table 28. These are worst-case values, based on an average of two mounts per panel.
0920-30144 r002 Solyndra Confidential Design Guide - 100/150 Series 31
Table 28.
Standard Panel Mount Maximum Loading

psf 0 8.35 16.7 25.1 33.4 41.8 50.1 Total Weight kg lbs 32 70.3 112 247 192 424 272 601 353 777 433 954 513 1131 Pressure per Mount, Standard psi psf kg/m2 pascals 1.65 237 1453 7123 6.81 832 5097 24992 12.0 1427 8741 42861 17.1 2022 12386 60730 22.3 2617 16030 78600 26.4 3211 19674 96469 3806 23318 114338 Pressure per Mount, LDF psi psf kg/m2 pascals 0.19 27 132 647 0.65 94 458 2245 1.1 161 784 3843 1.6 227 1110 5441 2.0 294 1436 7039 2.5 361 1761 8637 3.0 428 2087 10235
Snow Load pascals kg/m2 0 0 400 40.8 800 81.6 1200 122 1600 163 2000 204 2400 245
5.4.3. Minimum Pressure Rating for Roofing Material

At the maximum rated snow load of 2400 Pascals, the minimum roof load pressure specification must be 7100 Pascals. For applications with less snow or softer roofing materials, contact Solyndra.
5.4.4. Hail
Solyndra panel hail specifications are shown in Table 29. When planning installations, check historical weather data to determine the possibility of receiving hail in excess of the panels hail specification.
Table 29.
Hail
Hail Specification
Size 25 mm Mass 7.53 g Velocity 23 m/s
Specification
5.4.5. Construction Materials Placement

In addition to dead loads, the roof must withstand live loads during installation. Solyndra panels are packed horizontally onto pallets for shipment. The pallet weighs approximately 1100 lbs (500 kg). (Refer to Solyndras shipping documentation for exact weight and size.) Make sure that the roof surface is not overloaded when pallets are placed on the roof.
32
Chapter 6 Optimum Inverter Selection

An inverter almost never needs to be rated at the same Wp as the array. Figure 20 shows how the power output varies over the course of the year, from the best (summer) days to the worst (winter) days. The hour-by-hour variation in power output over the year can be plotted as a histogram, showing the number of hours in each year which reach a given power level. The histogram shows that only on a few days of the year is the output power close to the Wp value; on most days it is significantly less.
Figure 20. Annual Power Output Variation & Histogram

100
100
Percentage of Wp
60 40 20 0
Intermediate Panel Power Outputs Panel Power Output; Darkest Days

6 AM 9 AM Noon 3 PM 6 PM
Percentage of Wp
80
Panel Power Output; Brightest Days
80 60 40 20 0
Hourly Data
4000
6.1. Actual Power versus Wp Rating

The actual power produced by a panel is usually less than the Wp rated power for three reasons: The sun is usually not as intense as the 1000W/m2 used for measuring Wp. Power decreases as temperature increases, and the panel is usually warmer than the 25C temperature used for measuring Wp. This is especially likely to be the case in the summer. The panel is not aimed directly at the sun; that is, it is not perpendicular to the sunlight.
6.2. Inverter Sizing

A typical solar array will seldom generate the STC-rated power. The inverter can and should be smaller. The amount depends on both technical factors and economic factors.
Technical Factors
Solyndras energy yield forecast tool produces an hour-by-hour forecast of energy production. From this, the peak power produced by the array can be determined. An inverter sized to this value will be sufficient. As an example, a nominal 250 kW array installed in Sacramento, California will produce, for a few days around June 22nd, a maximum of 206 kW. This is the peak output, so an inverter of 210 kWp is more than sufficient for this array.
Economic Factors
It may make economic sense to use an even smaller inverter than the technical factors alone suggest. Inverters are not harmed by being connected to an array which produces more watts than the inverter rating. The inverter simply de-tunes the array, an effect known as clipping. In the above example, a 200 kW inverter will sacrifice only 0.2% of total energy; a 180 kW inverter will sacrifice only 3.6%. The Levelized Cost of Energy (LCOE) metric is an useful indicator of the optimum inverter size, as it accounts for both the cost benefit and the lost energy penalty. Figure 21 shows the LCOE for different inverter sizes for the nominal-250 kW example system. At the ratio of 1.45, the inverter size is 172.4 kW, for a loss of only 8.4%.
Solyndra offers an Excel spreadsheet tool that will automatically import the hourly data from the energy yield model and evaluate the performance of various inverter sizes.
Figure 21. LCOE vs DC:AC Ratio & NPV vs DC:AC Ratio

$0.256 $0.254 $0.252 LCOE $0.250 $0.248 $0.246 $0.244 $0.242 1.00 1.20 1.45 1.40 1.60 DC:AC Ratio 1.80 2.00
$700 1.75 $600 $500 $400 $300 $200 $100 $0 1.00 1.20 1.40 1.60 1.80 2.00 DC:AC Ratio
6.2.1. Maximizing Value for AC-Limited Incentive Applications

Some feed-in tariffs are tied to the AC rating of the inverter, rather than the DC output of the array. There are breakpoints in the FIT at various AC sizes. This incentive system means that the economic goal is to determine the most cost-effective DC array size for a given AC inverter rating. This DC-to-AC ratio is called the oversize ratio. There is an optimum oversize ratio which will maximize the net present value (NPV) of the project to the investor. Figure 22 shows the economically-optimum oversize ratio for an array installed where there is a change in FIT rates for a 250 kW-rated inverter. At a 1.75 ratio, the array is 437.5 kWp. A 250 kWp array at this location will yield 302 MWh of energy. By increasing the array size to 437.5 kWp, the total energy yield increases to 392 MWh. This is illustrated in Figure 22. The area in red is the energy lost; the area in green is the energy gained due to the oversize array.
Figure 22. Energy-Cost Trade-off for Oversized Array

400 350 300 250 200 150 100 50 0
400 350 300 250 200 150 100 50 0
Clipped Optimized 1.2 DC:AC Ratio
kW Output
1 218 435 652 869 1086 1303 1520 1737 1954 2171 2388 2605 2822 3039 3256 3473 3690 3907 4124 4341
kW Output
1.2 DC:AC Ratio
NPV
Histogram of Hourly Energy Output
6.3. Summary
In all cases, it makes sense to determine the actual power output of the array, and size the inverter accordingly. In most cases, it will make economic sense to select an inverter somewhat smaller than the actual peak power output of the array. The precise oversize ratio will depend on the tariff regimen, actual insolation, and inverter cost. Regardless of the tariff, Solyndras Excel tool can be used to evaluate inverter size options. Solyndras Design Team can also assist in determining the optimum inverter size.
34
1 218 435 652 869 1086 1303 1520 1737 1954 2171 2388 2605 2822 3039 3256 3473 3690 3907 4124 4341 Histogram of Hourly Energy Output
Chapter 7 Solyndra CAD Toolkit

The Solyndra CAD Toolkit is an AutoCAD .DWG file with blocks representing Solyndra panels and mounting system components. The blocks have been assigned attributes that make it possible to extract parts counts from a drawing. Additional files in the CAD tools folder are provided to assist with this extraction process. The toolkit includes two AutoCAD .DWG files. One is based on U.S. standard units and the other is based on SI (metric) units.
Blocks
The parts required for a Solyndra installation are drawn as blocks in the Model space. The panel block contains handles for attaching the other mounting system parts. The Model space also contains blocks containing pre-built sub-arrays for typical stringing configurations. These sub-array blocks have been built up from the individual parts blocks and can be used as building blocks for assembling larger arrays. Where an array section calls for a configuration not provided in the pre-built sub-arrays, the designer can build up that array section from detailed panel and parts blocks. Each block may be copied from the example already inserted in the Model space or accessed from the Insert Block menu.
Panel Details
The Panel Details sheet contains blocks for individual parts and single panel assemblies. Panels are drawn to scale; panel dimensions have been increased slightly to allow for typical spacing between panels when installed. Panel Mounts (feet only) are drawn to scale and positioned accurately on the panel. All other parts are symbolic representations and are not drawn to scale.
Vertical String Blocks & Horizontal String Blocks

The Vertical String Blocks sheet contains blocks of pre-built strings and sub-arrays with panels arranged in typical vertical (or horizontal) stringing configuration.
Attributes
Each individual part block has text attributes attached to it, which allow parts counts to be extracted from a drawing. The attributes assigned to each part block are as follows:
Block Name PANEL_W_ANCHOR PANEL_MNT_DBL LATERAL_CLIP GROUND_STRAP GROUND_LUG CABLE_CHANNEL_LONG CABLE_CHANNEL_SHORT Attributes of that Block PANELS PANEL_MOUNTS FASTENER_1 LATERAL_CLIPS FASTENER_2 GROUND_STRAPS FASTENER_2 GROUND_LUGS FASTENER_2 CABLE_CHANNEL_LONG CABLE_CHANNEL_SHORT CABLE_CHANNEL_CLIP FASTENER_2 Description Panel Panel mounts (pair) Panel mount fastener Lateral clip Multi-purpose fastener Ground strap Multi-purpose fastener Ground lug Multi-purpose fastener Long cable channel Short cable channel Cable channel clip Multi-purpose fastener Default value (qty) 1 2 2 1 2 1 2 1 1 1 1 2 2
Important Note: To avoid clutter in the drawing, the attributes are set as Invisible and Constant. If the blocks are exploded, the attributes will appear in the model space, and they will no longer be attached to a block and will prevent counting of parts.
Layers
Layers have been assigned to drawing elements to allow the designer to control the desired level of visible detail in a drawing. The defined layers are as follows:
SOL-ATTRIBUTES SOL-BLOCK DESCRIPTIONS SOL-CABLE CHANNELS SOL-COMPONENT HANDLES SOL-PANEL CONNECTIONS SOL-PANEL MOUNTS SOL-PANELS SOL-PROOFING SOL-GROUND LUGS SOL-GROUND STRAPS SOL-LATERAL CLIPS SOL-SHEET OBJECTS SOL-STRING BRANCHES
The SOL-PROOFING layer displays colored indicators of the different panel assembly blocks. There are four color coded panels in the CAD Toolkit. This color coding provides visual cues that allow the designer to quickly verify that the correct panel and array blocks were used in creating an array design. The yellow (TL) panel is always in the upper left corner of the sub-array. The light blue (T) panel is the top row of the sub-array, excluding the upper left corner panel. The pink panel (L) is the left edge of the sub-array, excluding the upper left corner panel, and the dark blue (F) panel is the remaining fill of the sub-array.
Mounting BOS Extraction (ATTEXT)

The attribute extraction command, ATTEXT, (Note 1) can be used to extract Solyndra mounting system parts counts for a completed array layout design. After entering the ATTEXT command a dialogue box will appear. Follow these instructions to extract attributes to a comma-delimited file (Note 2) which can be used to get a total parts count for the Solyndra mounting system. 1. Choose Comma Delimited File. 2. Click on Select Objects, and select the portion of the drawing for which a parts count is desired. 3. If the Template File field is blank, click the button and locate SOL_BOM_NOTEPAD_TEMPLATE.txt on the computer. (This file is in the Solyndra CAD Toolkit folder.) 4. Click the Output File button to select the location for the output text file. The default file name is the name of the drawing file. Note: in order to ensure the template file is not overwritten, name the output file differently from the template file, and click OK. 5. There is now a text file with a line for each block instance, and values for the associated attributes separated by commas. 6. Locate and change its file extension to .csv; open the file with Excel, select all and copy. 7. Open the Solyndra BOS summary Excel file ([Solyndra] bos summary template.xls). (Note 2) 8. Paste the copied data from the extract file into the location in the BOS summary template spreadsheet. The spreadsheet will total the number of panels and the parts counts extracted from the drawing. The spreadsheet will also compute an average parts per panel value for each mounting system component. 9. Save and close the BOS summary template file. Note: to keep the original template for later use, save the working copy to a different directory and/or file name from the master copy.
8. The spelling of the attribute extraction command differs depending on AutoCAD language choice: English ATTEXT Czech ATREXT German ATTEXT French ATTEXTR Spanish ATREXT Italian ESTRATT Portuguese EXTRATRIB Russian
9. Not all systems use comma-delimited (,) files. Most US/English configured systems do; in Europe and other parts of the world a semi-colon (;) is common. If desired, the list delimiter can be changed. After step 7, do start -> settings -> control panel -> regional & language options -> regional options -> customize. Alternatively, it is possible to open the csv file as a text file ,and use a replace command to change the delimiter.
36
History
Version 1.0 1.1 Part Number 0920-30144 r001 0920-30144 r002 Date 2010-08-07 2011-04-01 Notes Initial Version Updated for LLC
0920-30144 r002
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.
Design Guide - 100/150 Series Solyndra LLC 47488 Kato Road Fremont CA 94538

DesignGuide150 EN 20110401 V1-1 N

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Design Guide - 100/150 Series

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Trademarks /Patents/Copyright Notice

Design Guide - 100/150 Series

Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com

Designing with Solyndra

Planning the Panel Layout

Design in Seismic Areas

Solyndra Panel System

Optimum Inverter Selection

Solyndra CAD Toolkit

Design Guide - 100/150 Series 3

Designing with Solyndra

Chapter 1 Designing with Solyndra

Figure 1. Example Panel and Crate Identifying Labels

150 Series Labels

191 W 76.1 V 2.51 A 98.2 V 2.77 A

SL-001-191U 600 V 23 A CLASS C

191 W 95.8 V 1.99 A 126.3 V 2.35 A

SL-150-191U 600 V 24 A CLASS C

Code Compliance & Safety

Design Guide - 100/150 Series

Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com

1.2. Required Information

Designing with Solyndra

1.3. Design Sequence

Design Guide - 100/150 Series 5

Figure 2. Solyndra PV Panel and Power Connections

CAD Symbol Female Male Negative Negative

Negative Side Female Male -

Figure 3. Two Panels Wired in Series

Negative Side Female Male +

Design Guide - 100/150 Series

Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com

Figure 4. Series Connection, End-to-End Panels

Figure 5. Four-Panel Series Connections

Figure 6. Interpanel Connection of Positive and Negative Pigtails

Design Guide - 100/150 Series 7

2.2. String Blocks

String Block Examples

(a) 4 by 4 String Block, Typical for 150 Series @600V

Home Run Connection

Home Run Connection

(c) 6 by 4 String Block, Typical for 150 Series @1000V

(d) 8 by 3 String Block, Typical for 100 Series @1000V

Home Run Connection

Home Run Connection

Figure 8. A 4 by 6 String Block

Home Run Connection Negative Jumpers Positive Jumpers

Home Run Connection

Design Guide - 100/150 Series

Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com

2.3. String Wiring

2.3.1. Determining String Length

2.3.2. Parallel Strings

100 Series - Minimum Series Fuse Size for Strings in Parallel

Panel Power Rating

150 Series - Minimum Series Fuse Size for Strings in Parallel

Panel Power Rating

Design Guide - 100/150 Series 9

Maximum Number of Parallel Strings

I fault = I fuse + 1.25 ^N - 1 h I sc