Solar Power System Installation Manual SRS Mounting System Rectangular Modules Version 2008.03.
F or installation personnel • Please read this manual carefully before installing the system and carry out the installation procedures correctly. • This manual does not list all precautions needed for safe work. Be sure to follow OSHA guidelines. • This manual provides guidelines for installation, but it does not guarantee the quality of installation work. Please complete all work in a responsible and professional manner. Electrical work should be performed by a qualified electrician.
TAB L E O F CO N T E N TS 6 For Installation Personnel ����������������������������� 2 Installation Work ��������������������������������� 21-44 Table of contents ������������������������������������������������ 3 6.1 Preparing shingle roof for installation........................................................ 21 For Safe Installation Work ��������������������4-9 6.2 Checking layout.................................................... 22 1.1 Cautions regarding installation of solar power systems...
1 For Safe I nstallation Work This system shall be installed only by individuals who have completed the SRS training course established by Sharp Electronics Corporation. Please visit our website http://solar.sharpusa.com to learn about Sharp training. Call us at 1-800-solar06 to find a certified installer in your area. Safety icons Various safety icons appear in this installation manual and on the products it describes.
1 For Safe I nstallation Work UL Required Information: 1. Artificially concentrated sunlight shall not be directed on the module. 2. “Rated electrical characteristics are within 10 percent of measured values at Standard Test Conditions of: 1000 W/m2, 25°C cell temperature and solar spectral irradiance per ASTM E 892 or irradiation of AM 1.5 spectrum.” 3.
1 For Safe Installation Work 1.1 Cautions regarding installation of solar power systems This manual contains critical information regarding electrical and mechanical installation and safety information which you should know before starting installation. 3 Do not stand or step on solar module. 4 Do not install near flammable gases. 5 Do not drop or allow objects to fall onto module.
1 For Safe I nstallation Work 1.2 SRS MOUNTING SYSTEM WARNING Always follow OSHA guidelines. Solar modules are installed on rooftops where there is danger of personnel falling off of the roof. Scaffolding, stepladders, and ladders may be dangerous and require caution. The installation of solar modules involves work in high places; take extreme precautions to avoid falling from roof. To prevent accidents, safety regulations must be observed.
1 For Safe I nstallation Work 7 Protect against falling objects. 8 Other • When objects are thrown down from a height of 6 ft or more, appoint a surveillance person on the ground and warn others about falling objects. • When there are electric power lines near the roof or eaves, request the power utility to take advance measures to prevent shock. • Do not allow third parties to enter the work area during construction. • Check the health of workers before starting work.
1 For Safe I nstallation Work 4 Measuring array output voltage 5 Grounding the mount • See the description of how to measure the output voltage for each array. • To prevent shock, always connect a ground wire from the SRS mounting system to earth. • Make sure that all solar modules are exposed to sunlight. (Remove lightproof sheets, if present.) • Use a minimum #10 AWG ground wire. • Follow NEC 690 grounding provisions.
2 Points to Check when Selecting the Installation Location Example ROOF CONSTRUCTION Ridge Roofing-felt Asphalt shingles Rake Facia board Roofing deck Rafters Examples of poor roof condition Damaged shingles Broken shingles and sagging roof 10
2 Points to Check when Selecting the Installation Location 2.2 Checking the solar power system installation location Code Compliant installation 1. Determine the wind loads for the installation site. Check with your local building and safety department for the specific requirements. 7. Reference the chart wind speeds to determine your design wind pressure (psf). Determine exposure categories A through D for various roof heights. 8.
2 Points to Check when Selecting the Installation Location 1. Install solar modules facing south, if possible. Installations facing east and west are also possible, although the amount of power generated will be lower. Check the roof from a southern orientation, and check for obstacles that will cast a shadow. These factors will lower the amount of power generated. Explain this to the users and obtain their consent. 2. Install in a location that has good sun exposure throughout the year.
3 Specifications 3.1 Solar module and array specifications moduleS: ND-187U1, ND-187U1F, ND-167U1Y 1 Array specifications (typical examples) Array: Layout of series connected solar modules ND-187U1 ND-167U1Y Quantity of Solar modules 18 20 24 27 18 20 24 27 Solar power capacity (kW) STC 3.4 3.74 4.5 5.0 3.0 3.3 4.0 4.5 284.9 316.6 379.9 427.4 255.8 284.2 341.0 383.7 Solar module area (sq.ft.
3 S P E C I F I C AT I O N S 3.2 ND-187u1, ND-187U1F, ND-167U1Y module array layout dimensions 353 1/4"* 262 1/4"** Eave cover 1 5/8" 58 7/8"* 52 7/16"** 117 3/4"* 104 15/16 "** 176 5/8"* 157 3/8"** 235 1/2"* 157 3/8"** 294 3/8"* 209 13/16"** Ridge cover 1 5/8" The location of the mounting feet and rails is dependent on the layout of the array. Use the following grid to determine the overall size of the array that will fit on the installation location.
4 PA RTS STANDARD PARTS Part No. Model name AD804 XA52 AD801 AD105 Dock washer M8 Bolt 20 (shown appx. size) Module mounting clip Threaded tab Anti-corrosion coated steel Dimensions M8 x 20 mm Material Anti-corrosion coated steel Stainless steel Anti-corrosion coated steel Part No. AD101 AD802 XA05 Model name Splice Side cover M4 Side cover screw (shown appx. size) Dimensions M4 x 12 mm Material Anti-corrosion coated steel Aluminum Stainless steel Part No.
4 PA RTs ROOF TILE PARTS AE105 AE106 AE107 Tile roof bottom butyl pad Tile roof top butyl pad assy Silicone caulking Butyl rubber Anti-corrosion coated steel Silicone AE110 AK111 AE104 AE102 Model name Tile roof slider Support AL plate Tile roof stand off Tile roof slider bracket Material Anti-corrosion coated steel Aluminum Anti-corrosion coated steel Anti-corrosion coated steel Part No. AE112 Model name Roof tile drill bit per piece (6 pcs/case) Material Part No. Part No.
4 pA RTs ASPHALT ROOF PARTS AS801 AS804 AS105 AD805 Model name Standard slider assembly Mounting Flash assembly Standard slider bottom bracket Standard slider top bracket Dimensions 11" x 2" x 1" 14" x 10" x 1.25" Part No. Material Part No. Model name Material Anti-corrosion coated steel Anti-corrosion coated steel AE107 XA02 Silicone caulking Standard slider mounting screw 5.5 x 80 (shown appx. size) Silicone Stainless steel XA58 Part No.
4 pA RTs OPTIONAL PARTS AD803 AD806 AE107 Cable support bar Cable clip Silicone caulking Material Stainless steel Anti-corrosion coated steel Silicone Part No. AK113 AK114 XA53 0.1" shim 0.4" shim M8 Bolt 30 (shown appx. size) Part No. Model name Model name Dimensions M8 x 30 mm Material Anti-corrosion coated steel Part No. XA54 XA55 Model name M8 Bolt 40 (shown appx. size) M8 Bolt 50 (shown appx.
4 pA RTs Tech note Anti-corrosion coated steel is steel coated with a layer consisting primarily of zinc plus another metal, such as aluminum or magnesium. Coated layer Fine-grained protective layer Oxidation becomes less prominent. After it is cut, mild corrosion develops initially at the cut surface, but then the components of the coating layer dissolve to form a stable protective layer over the cut.
Points to Check Before I nstallation Wor k Cordless drill Socket drivers 8 mm & 13 mm Phillips driver bits Drill Screw driver set Needle nose pliers Line man’s pliers Wire cutters Hammer Chisel Crimping tool Knife Tape measure Extension cord Chalk line Gloves & safety helmet Rope Tool belt Ladders Safety Harness Safety glasses Air mask Ratchet Wrench Tools 5 8 mm 13 mm Calculator Solar insolation meter Measurement Compass 20 Digital multimeter
6 Installation Wor k 6.1 Preparing SHINGLE roof for installation 3 locations. Snap a chalk line. This marks the location of the bottom edge of the slider feet. 1. Locate roof rafters or trusses. Here are 3 options to finding the locations: Note: This line needs to be 0.22" (5.5 mm) away from the nearest front edge of shingles. A. Locate and measure the locations of the rafters in the attic or at the outside eave and transfer measurements to the roof. 4. Measure up from chalk line 0.
6 Installation Wor k 6.2 CHECKing LAYOUT 1. Before installing sliders, check layout of rails and splices. CAUTION The maximum module over hang from the slider to the edge of the array is 16". 2. Place all sliders in desired locations, but do not install screws yet. 2 in 1 rail Rail splice 3. Pre-assemble rails and splices. 16" max from the slider to the edge of the array Eave CAUTION Bolt Tightening Instructions Sliders not to exceed more than 48" on center. Begin tightening bolts by hand.
6 Installation Wor k 6.3 Installing the optional Flashings Flashings can improve water and ice management on the roof by directing the water around the rail slider assembly. It is intended for use in new construction, reroof, and in locations with significant precipitation. The flashings are installed under the standard slider assembly. Each flashing is similar in size to the slider assembly. The flashing has a large flange around it’s perimeter to allow for integration with the surrounding shingles.
6 Installation Wor k 6.4 Installing Standard Slider Assembly 1. Insert standard slider top and bottom brackets into each standard slider assembly prior to installation. site window Eave 4. Install four (XA02) 80 mm self-drilling screws (using 8 mm socket) to achieve the appropriate pullout strength for the site location. Be certain to apply silicone sealant to the hole prior to installation of the screws. 2. Peel off the backing paper from the standard slider.
6 Installation Wor k 6.5 PREPARING TILE ROOF INSTALLATION When using 167 Watt modules, install the next rails 3 courses higher than previous rail. When using 187 Watt modules, install the next rails 4 courses higher than previous rail. 1. Locate roof rafters or trusses. Tip: here are 3 options to finding the locations. A. Locate and measure the locations of the rafters in the attic or at the outside eave and transfer measurements to the roof. 4. Measure up from chalk line 1" and snap a new chalk line.
6 Installation Wor k 6.6 CHECKING LAYOUT 1. Before installing sliders, check layout of rails and splices. CAUTION The maximum distance from the slider to the edge of the array is 16". 2. Place sliders on all tiles that were identified to be drilled for tile standoffs. 2 in 1 rail Rail splice 3. Pre-assemble rails and splices. Eave CAUTION Bolt Tightening Instructions 16" max from the slider to the edge of the array Slider in rafter Rafters You must begin tightening bolts by hand.
6 Installation Wor k 6.7 INSTALLING TILE SLIDER ASSEMBLY Note: Foot placement for tile roof. 1. Identify the locations for the roof tile sliders so that each slider is located in the valley of the tile. Walking up and down roof Rafter chalk line Array horizontal chalk line Balance weight in pan where tiles overlap 2. Number two tiles, one above the other. The lower tile will be removed to install the aluminum support plate.
6 Installation Wor k each hole. This will cool the drill bit. Clean any debris and dust after drilling. 4. Remove the lower tile from the roof. 5. Place the roof tile slider on the lower tile and align with the horizontal line marked above. Mark two holes for roof tile stand off. Press down with about 40 - 50 lb of force.
6 Installation Wor k 8. Place 2 butyl pads under the holes drilled in the tile. The butyl should be located on the underside of the tile. Reinstall the tile on to the roof according to the locations marked previously. 10. Insert 2 top butyl pads onto the tile standoff legs. Tile roof stand off AE104 Bottom side of the tile Insert Bottom butyl pad (AE105) Remove brown backing paper to expose sticky side. Adhere the sticky side of the butyl pad to bottom side of tile.
6 1 Installation Wor the hole k guide line Align the end with 12. Place the tile slider over the standoff and secure with two 135 mm screws (XA50). Silicone Silicone Drill guides. Never use drill guide holes for tile roof standoff screw Front row, holes 1 & 3 CORRECT Top row, holes 3 & 5 Middle row, holes 2 & 4 WRONG 14. Insert the roof tile slider bracket into the slider and prepare for rail installation.
6 Installation Wor k 6.8 system grounding SRS single point SRSutilizes utilizes rail to rail integrated integrated grounding. Use a minimum #10 AWG ground wire for this purpose. The equipment grounding conductor will continue down to the DC disconnect, inverter and AC service equipment.
6 Installation Wor k 6.9 Installing module support rails 1. Create appropriate rail length by incorporating rail splice kit. Place splice under rails to be joined and fasten using 4 M8 bolts (XA52). Hand tighten 5 turns and use a 13 mm socket wrench to tighten to appropriate torque. 3. Insert M8 bolts (XA52) through dock washer (AD804) and fasten to standard slider bottom bracket. 0.4” shim 0.1” shim Note: Do not place two 1 in 1 rail splices next to each other. 0.4” shim 0.
6 Installation Wor k 6.10 Installing front cover Prior to the installation of the bottom row of modules (located close to the eave of the roof) a front cover is installed to provide a finished appearance. 3. Insert an M8 bolt through the clip and rail, and secure to threaded tab (AD105). M8x20 bolt 1. Place each front cover over the top of the support rail as shown below. Front cover Rail Module mounting clip Threaded tab CAUTION Bolt Tightening Instructions Begin tightening bolts by hand.
6 Installation Wor k 6.11 Installing the modules on the SRS mounting system 1. Stand at the ridge side of the roof and face the eave. Place the solar module on the rail so that it fits between the high points of the rail. EAVE 2. Lift the solar module at side facing the ridge of the roof. The solar module will slide forward slightly and will engage the locking clip (as shown). EAVE 3. Push the solar module forward and rotate down to fully engage the locking clip (as shown). EAVE 4.
6 Installation Wor k 5. Install entire row of modules. 6. Push the rail towards the eave of the roof to tighten the fit of the row of modules. This will eliminate all gaps between the modules and rails. EAVE 7. Tighten the rail bolts to fully secure the solar modules and rail. Previous row of solar modules 8. Place the module clips (AD801) on the rail. Two clips are required for each rectangular module. Module mounting clip Secure each clip with an M8 bolt and AD105 threaded tab.
6 Installation Wor k Asphalt shingle EAVE Tile mounting EAVE SECTION RIDGE SECTION MIDDLE SECTIONS EAVE SRS cross section 6.13 InstallING SIDE cover Attach the side covers to the open ends of the rail covers. Side Cover Use two side cover screws to secure each cover. To save time, install side covers prior to installing rail covers. Side cover screws 6.14 Connecting the solar modules 1. Connect each module according to the solar array connection examples.
6 Installation Wor k 4. When you have made direct connections between the specified number of solar modules, use a digital multimeter to measure the voltage and current output of the array. Do this for each string, and record the measurement results. • 6. If the array cables stretch between rows, connect by running them underneath the rail. WARNING Protect the terminals of the array output extension cables by covering them with insulating tape.
6 Installation Wor k Below are illustrations of typical series string wiring connections Solar module Series connection String 1 (+) String 1 (-) String 2 (+) String 2 (-) String output cable Solar module connections example, 4 rows, 4 columns; each string has 8 modules connected in series.
6 Installation Wor k 6.15 Testing module strings for correct voltage The voltage will vary depending on the amount of sunlight, but it should measure, about 360 VDC. Be careful of shock. Note: The examples in this section show values for ND modules. The voltage will differ for other modules. For an array of 11 modules, directly connect the first 10 solar modules and measure in the following order. 3. Check the measurements • 1. Measure the voltage of the 11th solar module.
L I M I T E D WA R R A N T Y SHARP ELECTRONICS CORPORATION (“Sharp”) warrants this Sharp brand product (“Product”), ONLY TO THE FIRST CONSUMER PURCHASER (defined as the first consumer that purchases Product for its own installation) to be FREE FROM DEFECTIVE MATERIAL AND WORKMANSHIP for 10 years from the date of original retail purchase. (“The Warranty Period”). This Limited Warranty shall cover parts and labor.
NOT E S
SHARP ELECTRONICS CORPORATION SOLAR ENERGY SOLUTIONS GROUP • 5901 BOLSA AVENUE • HUNTINGTON BEACH, CALIFORNIA 92647 SESG-SRS-01-29-2008
