Rayzon Installation Manual - Mono PERC Bifacial - IEC
Rayzon Installation Manual - Mono PERC Bifacial - IEC
Rayzon Installation Manual - Mono PERC Bifacial - IEC
INSTALLATION
MANUAL
TABLE OF CONTENTS
1. Introduction 1
2. Disclaimer of Liability 1
3. General Information 1
4. Safety Instructions
4.1 General Safety ……………………………………………………… 3
4.2 Electrical Safety ……………………………………………………. 3
4.3 Electrical Specifications ……………………………………………. 4
4.4 Fire Safety ………………………………………………………….. 5
7. Installation Guidelines
7.1 General ……………………………………………………………… 10
7.2 Mounting Methods ………………………………………………….. 11
7.3 Grounding …………………………………………………………... 13
7.4 Wiring ………………………………………………………………. 14
7.5 Bypass Diodes ……………………………………………………… 15
7.6 Blocking Diodes ……………………………………………………. 15
7.7 Fuse Rating …………………………………………………………. 16
7.8 Inverter Compatibility & Selection ………………………………… 16
8. Maintenance
8.1 General ……………………………………………………………… 16
8.2 Module Cleaning Guidelines ……………………………………….. 16
9 Notes ………………………………………………………...……………… 17
Figure 4 Lifting Support Fixture to be used when lifting using a hydra …………………... 6
For your safety and the safety of others, please read the entire
Installation, Operation and Maintenance Manual carefully prior to
installing, wiring, operating and performing maintenance of PV
modules. Also, carefully read the Module Data Sheet provided with
this product. Determine local permits, installation and inspection
requirements before installing module(s). If not otherwise specified,
it is recommended that the requirements of the National Electric
Code (NEC) be followed.
3. General Information
3.1 The installation of the solar panels should be performed by trained personnel like licensed
contractors and electricians, since there are chances of injury and/or electric shock hazard if the
panels are not handled carefully.
3.2 The flat plate Photovoltaic (PV) module, also referred to as solar panel, converts power of the
visible portion of electromagnetic spectrum to DC electrical power. The construction consists
of laminated assembly of individual solar cells and interconnecting ribbons encapsulated within
an insulating material. This encapsulated assembly is sandwiched between a transparent top
surface (superstrate) and an insulating back surface (substrate). Field wiring connections to the
module are made to output wiring connectors emanating from a weatherproof terminal
assembly.
Page | 1
3.3 The solar panel is a multi-layered laminate comprising of a top cover of glass (superstrate),
encapsulant, solar cells, a back cover of insulating polymer sheet or glass (substrate) and frame
as indicated in the Figure 1. The solar cells are interconnected using interconnect ribbons. The
cables of the solar panel (one with “positive” and other with “negative” polarity) are attached
to the junction box as shown in Figure 2.
Figure 2: Module schematic (backside) for 144 half-cut cell modules with transparent back cover
(glass/ transparent backsheet). Please refer to the datasheet for the dimensions of the respective
models.
3.4 The solar panels produce DC voltage when light falls on the front or back surface of the Bifacial
panels. The open circuit voltage produced by the solar panel is indicated in the name plate (back
label) of the solar panel in addition to the other important electrical parameters like the short
circuit current, and the voltage and current at the maximum power point. Apart from the back
label, two other labels are carried by the solar panel – current grading label (visible on back
side of the panel) and the barcode label (visible from front-side of the panel).
3.5 Each module is provided with a unique serial number for identification, into which is encoded
the date of manufacturing and other details. It is a 19-letter code which is explained below.
Page | 2
RS A G 1 M0 02 04 22 000001
RAYZON POWER MODULE LINE CELL MFG. MFG. MFG. SR.NO.
SOLAR CODE CODE NUMBER SIZE DATE MONTH YEAR
The Power Code is related to the nominal power output of the module - "A" for 540 Wp, "B"
for 545 Wp, etc.
The Module Code will depend on type of back cover - “ L ” for regular backsheet, “ G ” for
glass and “ B ” for transparent backsheet.
The Cell Size will be coded as "M0" for M10 cell (182 x 182 mm), "M2" for M12 cells (210 x
210 mm) etc.
4. Safety Instructions
To avoid the hazard of electric shock and injury when installing, wiring,
operating and maintaining the PV modules, below guidelines shall be
strictly followed.
Page | 3
g) Take necessary measures to avoid electric discharges when installation and wiring the solar
panels. Surge protection devices should be installed in the array junction boxes to
safeguard the solar panels from lightning surges.
h) Do not artificially concentrate sunlight on the solar panel.
i) Connectors from different manufacturers should not be used in the same PV system due to
compatibility issues. Ensure that there is no gap between the connectors (as any loose
connection in connectors can cause electrical arcing and lead to fire hazard).
j) Ensure all the connectors are corrosion free and protected from soiling.
k) It is strictly prohibited to remove or cut any connector of PV Module for installation
easiness by the installer/ customer and the modules are deemed out of warranty in such
cases.
l) Ensure that all the modules are grounded properly to avoid any shock hazard.
m) If the front glass or the junction box is broken, there are chances of electric shock from
the module, so such a broken module should be handled only using insulated cut-resistant
gloves.
n) There are no serviceable parts in the module so the user is requested not to try to change
or repair any component of the module.
o) Maximum string voltage must not exceed the allowable system voltage as marked on the
name plate (1500V DC).
p) The top structure and installation may affect the building fire safety - improper installation
may lead to fire hazards. Use of safety devices such as ground fault cut-outs and fuses is
recommended to reduce chances of fire hazard.
q) The grounding method of the frame of arrays shall comply with the NEC, article 250.M.
In Canada, installation should be done in accordance with CSA C22.1, Safety Standard for
Electrical Installations, Canadian Electrical Code, Part 1, and other applicable local
standards.
c) Under normal conditions, a photovoltaic module may experience conditions that produce
more current and/or voltage than reported at Standard Test Conditions. Factors to consider
include module temperature and front side irradiance (and, for bifacial modules, ground or
roof albedo, row spacing, and installation height). Accordingly, the values of VOC and ISC
(or for bifacial modules, ISC at BSI) marked on this PV module should be multiplied by a
factor of 1.25 when determining voltage and current ratings for components connected to
the PV output.
Page | 4
d) The safety factor of 1.25 given for the minimum voltage rating of the components in the
example statement above may be modified during the design of a system according to the
minimum temperature of the location of the installation and the temperature coefficient for
VOC. The safety factor of 1.25 given for conductor current ratings values for ISC (or for
bifacial modules, ISC at BSI) may be adjusted based on the maximum values of irradiance
incident on the front side of the module (and the rear side for bifacial modules). To this
purpose, a full simulation for the specific location and module orientation (and for bifacial
modules, ground albedo, row spacing and installation height) is required. Further guidance
for the choice of a safety factor other than 1.25 is given in the National Electrical Code.
e) Please refer to Section 690-8 of the National Electric Code for an additional multiplying
factor of 1.25 which may be applicable. Please also consider the backside power gain of
bifacial modules (which will increase the module current) when deciding the component
electrical ratings.
f) It is also necessary to refer to the local electricity codes and standards while determining
the ratings of the electrical components.
RSG265WC to RSG280WC
Page | 5
5. Unloading, Handling, Storage & Unpacking
5.1 Unloading using Forklift
a) Forklift should be used for loading/unloading of modules (and not pallet trucks, which are
useful for positioning of modules only). Forklift should be selected according to the size
of the pallets. When unloading, please ensure that suitable aids (front loader, forklift, or
similar) with the following minimum requirements are used:
Fork length: > 1.20 m
Lifting height: > 1.30 m
Load capacity: > 2.0 tonne (for handling 2 pallets)
b) If fork length is less than the size of pallet, then extension sleeves should be fitted on the
forks before the assembly is lifted.
c) It is recommended to upload the pallets from the rear side of the trailer, using an unloading
ramp. In case unloading ramp is not available, the pallets may be unloaded from the long
side of the trailer.
d) When unloading to the side, ensure that the front pallets are first unloaded from the truck
trailer.
e) The spacing between the two forks should be adjusted as required, such that the load on
the forks is balanced.
f) When lifting double stacked pallets with forklift, first ensure that the pallets are properly
aligned.
g) One side of the pallets should be close to the forklift retainer (do not keep any space).
h) The lifting and lowering of the pallets using forklift should be done slowly and steadily
without any jerks.
i) Unload the pallets on a flat and dry place at the project site.
j) Do not stack more than 2 pallets at the project site.
Page | 6
f) Before lifting, please confirm the pallet are not damaged and the lifting belt is firm and
solid.
g) Before lowering the pallet back on the ground, two persons should support the two sides
of the pallet gently to put it on a relatively flat place.
Page | 7
vii.Cut the inner horizontal straps using cutter (refer Fig. 6e).
viii.Unwrap the plastic wrapping on top of the cardboards (refer Fig. 6f).
ix. Remove the cardboards from all sides (refer Fig. 6g).
x. Two persons should now hold the panels from two ends, while two other
persons can proceed to remove the panels as follows.
xi. Remove the plastic wrapping using cutter or by hand. Do not use any sharp
object like blade, as it can scratch the panel glass/backsheet (refer Fig. 6h).
xii. While two workmen are supporting the panels vertically, other two workmen
can lift one panel at a time and place on the other pallet (refer Fig. 6i).
xiii. While laying the solar panel on the pallet, ensure that the panel glass side is
facing down, and panels should be stacked on top of each other in perfect
alignment (refer Fig. 6j).
c) Do not place more than 27 panels in one stack.
d) Cover the modules with a waterproof cover to prevent water from accumulating on the
modules.
Page | 8
(h) (i) (j)
Figure 6: Unpacking of pallet
Page | 9
should be at least 1 meter. The bifacial power gain will also depend on the type of ground
(sand, grass, white concrete, etc.).
d) It is recommended to check the optimum tilt angle for the site in professional PV system
design software like PVSyst or online available tools like PVGIS.
e) When selecting a site in a flood prone region, the structures should be designed with
sufficient height such that the lowest edge of the solar panels are above the flood water
level based on historical records (in order to avoid damage to panels due to submergence
in water during floods).
f) In areas having high wind speeds, the mounting structures should be suitably designed to
withstand the high wind forces, and the panels should be mounted on at least 8 bolting
points. The tilt angle may need to be adjusted (reduced) in such areas to avoid wind induced
damage to the panels. In case of trackers, the tracker should be orientated such that the
panels are almost horizontal during storms, so as to reduce the wind load on the solar
panels.
g) The maximum irradiance and ambient temperatures during sunshine hours at the site need
to be considered during system design. The panel’s current will depend on the maximum
irradiance and module temperature, and the current ratings of the balance of system
components need to be selected accordingly. Also, the panel voltage will increase with
decrease in the panel temperature.
h) It is recommended to multiply the current and voltage ratings of the panel by suitable safety
factor (1.25 for weather related enhancement x 1.25 for equipment derating = 1.56) to
calculate the electrical ratings of balance of system components. In case of bifacial
modules, the backside power gain should also be factored in.
i) The safety factor of 1.25 for the minimum voltage of the components can be modified
during the system design according to the minimum temperature of the location of
installation and the temperature coefficient for Voc. Similarly, the ISC can be adjusted based
on the maximum temperature, irradiance and orientation of the module. For this purpose,
it would be necessary to perform a full simulation of the PV system using long term weather
data, for which specialised software like PVSyst (or other alternatives) may be used.
j) PV modules may be connected in series in order to increase the system voltage, but
maximum modules that can be connected in a series string is limited by the maximum
system voltage or the maximum input voltage rating of the inverter (whichever is lower).
Maximum number of series connected modules
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑜𝑓 𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑖𝑛𝑝𝑢𝑡 𝑟𝑎𝑡𝑖𝑛𝑔 𝑎𝑛𝑑 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑦𝑠𝑡𝑒𝑚 𝑣𝑜𝑙𝑡𝑎𝑔𝑒
= 1.25 𝑥 𝑀𝑜𝑑𝑢𝑙𝑒 𝑂𝑝𝑒𝑛 𝐶𝑖𝑟𝑐𝑢𝑖𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒
k) PV modules (series connected module strings) may be connected in parallel to increase the
current. Maximum number of parallel connected strings
𝐹𝑢𝑠𝑒 𝑟𝑎𝑡𝑖𝑛𝑔
=
1.25 𝑥 𝑀𝑜𝑑𝑢𝑙𝑒 𝑆ℎ𝑜𝑟𝑡 𝐶𝑖𝑟𝑐𝑢𝑖𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡
l) Module connected in series should have same orientation and tilt angle so that there are no
mismatch losses in the modules.
m) The modules can be connected in series to increase the array voltage, but care should be
taken to keep the array voltage below the maximum system voltage rating of the modules
(considering the module temperature in the coldest day of the year).
n) The recommended standoff height is 150 mm. If other mounting means are employed this
may affect the UL Listing or the fire class ratings.
o) A minimum slope of 5 inch/feet is necessary when mounting on a roof in order to ensure
the Class C fire rating of the modules.
Page | 10
7. Installation Guidelines
7.1 General
a) The outer packaging of the pallets should be opened only when the installation starts.
b) Do not expose the Backsheet directly to sunlight for long period of time.
c) Do not damage or scratch the glass/ backsheet of the Module.
d) Installation should be done in dry environment using insulated gloves.
e) Do not transport the panels by resting them on the head, to avoid generating micro-cracks
in the panels.
f) Do not stand or step on the modules.
g) Do not drop Module or allow objects to fall on the Module.
h) Only PV modules with the same cell type and in same current bin should be connected in
series. Intermixing modules from different current bins in a series string will lead to
mismatch loss in the string.
i) Do not drill holes in the frame or glass of the module. It may compromise the frame
strength and cause corrosion of the frame and also voids the warranty.
j) The solar panels should not be used as overhead glazing.
k) Avoid forming wiring loops in the PV system in order to prevent surge currents during
lightning.
l) We recommend leaving a space of at least 10 mm between two modules considering linear
thermal expansion of the module frames.
m) Modules shall be mounted so that the junction box remains in the uppermost position to
minimize the ingress of moisture/water.
n) Avoid the direct contact of the aluminium frame of modules with steel or copper as this
may result in galvanic corrosion of the module frame.
o) Clearance between the module frame and the mounting surface is required to allow cooling
air to circulate around the back of the module. The module should never be sealed to the
mounting surface with sealant that prevents air from circulating under the module. For roof
mounted systems, adequate rear ventilation (minimum 100 mm gap) should be provided.
p) The mounting structure and all hardware like bolts, nuts and washers should be of stainless
steel so as to eliminate the possibility of rust.
q) Avoid using a mounting method that will block the drainage holes in the module frame.
Do not drill additional mounting holes on the frame & glass surface of the
Module. Doing so will void the warranty.
Page | 11
b) The module frame is provided with mounting holes as indicated in Figure 2. The position
of the holes (X-pitch and Y-pitch) is indicated in the module datasheet.
c) The PV module has been evaluated by UL for mounting using this bolting method for a
maximum positive design load of 3600 Pa and negative design load of 1600 Pa, with a
safety factor of 1.5.
d) The module design has been tested with 8 mounting holes and it is the recommended
mounting configuration if the maximum design load has to be achieved. Mounting the
module on only 4 bolts will partly reduce the load bearing capacity of the modules.
e) Mounting should be done using M8 stainless steel nut, stainless steel bolt (8 mm), flat
stainless steel flat washer (8 mm), and stainless steel spring washer (8 mm).
f) Mounting should be done using the pre-drilled holes in the frame, and no new holes should
be drilled in the frame as it will reduce the strength of the frame and hence void the
warranty.
g) The length of the mounting screw should be selected such that there is a gap of at least 5
mm between the screw’s face and the module backside, to avoid any scratches in the
module while tightening.
h) The nuts should be tightened using torque wrench, with a torque of 15 – 20 Nm for M8
stainless steel bolts with washer and nut.
i) There should be sufficient clearance (at least 10 cm) below the module for free circulation
of air so that the module can be cooled naturally.
Figure 7: Bolting of the module at the mounting hole provided in the module frame.
Page | 12
Figure 8: Mounting of modules using 8 mounting holes. Values of Y1 and Y2 are as per the Y-
pitch mentioned in the module datasheet.
7.3 Grounding
a) The module frame should be grounded to prevent any shock hazards due to failure of
insulation from the internal circuitry or lightning induced voltages.
b) The aluminum frame of the modules is anodised to generate a corrosion resistant layer
on the frame which, however, is non-conductive in nature and cannot provide grounding
to the module. So, separate grounding holes are provided in the module (marked with the
earthing symbol).
Page | 13
Figure 11: Grounding mechanism of the PV module, using Tyco grounding bolt
7.4 Wiring
a) The junction box is pre-fitted with UV-resistant, halogen-free, low smoke, flame
retardant photovoltaic cable (4 sq.mm. size, rated for 1500 V), suitable for operation up
to 90 °C ambient temperature.
b) The cables come pre-fitted with PV connectors (rated 1500V DC, 35A, conforming to
IEC 62852) which have been evaluated to UL 6703 Standard. Further details of the
connector is available from the manufacturer website.
PV Connector Male Connector Female Connector Mating
Manufactured by Model No. Model No. Connector
c) The wiring of the system should be done in accordance with the National Electricity Code
(NEC) and all other relevant local regulations.
d) The junction box comes pre-fitted with bypass diodes and their wiring/connections
should not be changed under any circumstance.
e) When wiring the PV system, avoid forming loops to minimize risk in the event of an
indirect lighting strike.
f) Modules can be connected in series to increase the operating voltage by plugging the
positive plug of one module into the negative socket of the next module. Before
connecting modules always ensure that the contacts are corrosion free, clean and dry.
g) Module may get damaged if an array string is connected in reverse polarity to another, so
always verify the voltage and polarity of each individual string before making a parallel
connection. Do not connect two strings in parallel if their voltages differ by more than 10
V.
h) When connecting the modules in series using the MC4 connectors, ensure that the
connection is tight and the mating connectors are locked. There should not be any outside
stress/load on the cables and connectors.
i) PV modules may be connected in parallel to increase the array current, but the maximum
array current should be less than the Inverter specification for maximum input current. In
case of parallel connection, each series string of modules should be provided with a series
fuse (fuse rating shall be as specified in the module datasheet).
j) Do not cut/remove any connector when connecting the cables, and always use compatible
MC4 connector, of the same manufacturer as provided with the PV module. Use of
Page | 14
different connector can lead to lose connections which can result in sparking and fire
hazards.
k) Use UV-resistant cable ties to tie the cables to the purlin or other support structure.
l) For extension of the cables to the DCJB or inverter, use single core extension cables that
are UV resistant, fire retardant and can operate up to 90 °C ambient temperature. The
cable should be rated for 1500 V insulation capacity, and have compatible male & female
MC4 connectors.
m) The extension cable should be sized to ensure that the voltage drop in the DC side should
not exceed 2% (minimum recommended cable size is 4 sq.mm.).
n) In case bending of the cable cannot be avoided when routing the cables, the minimum
allowable bending radius is 4 x cable diameter.
o) It is recommended to place the cables inside plastic conduits to prevent any direct
exposure to sunlight and rainfall.
p) The cable routing should be done in such a way there is no tensile stress in the cable.
q) Ensure that the cable is not passed through low lying sections/potholes where water may
accumulate after rainfall.
r) When disconnecting wires under load, an electric arc may result, which can cause fire.
To disconnect the PV system while under load, turn off the inverter first and then switch
off the DC-circuit breaker, before opening the module connections.
Page | 15
b) RAYZON Modules do not contain a blocking diode when shipped from the factory. It is
recommended that a charge controller be used to prevent the batteries from being
overcharged and discharged at night.
c) In battery-based PV systems, it is mandatory to use a blocking diode or reverse current
protection device. If such a device is not used, the warranty on the panels is void.
8. Maintenance
8.1 General
a) Annual inspection of the PV system should be performed by trained professionals to
check for damage to glass, backsheet, frame, junction box, loose connections and
corrosion.
b) Module having critical damage (like broken glass or junction box damage) and should be
removed from the array circuit for the safety of the plant and personnel.
c) There should not be any shading on the module. Tree branches which cast shadow on the
panels should be cut off at regular intervals.
Page | 16
c) Cleaning of modules with water should be done either in early morning or late evening,
and never when the module surface is hot. The temperature difference between the
module glass and the cleaning water should be less than 20 °C.
d) It is recommended to use fresh water with Total Dissolved Solids (TDS) < 1500 mg/L
and total hardness < 75 mg/L. If low mineral water is not available in some regions, it
is advisable to add sodium chloride (< 2% by weight) in water to avoid depositing the
dried minerals on glass.
e) If needed, a mild, non-abrasive, non-caustic detergent may be mixed in water such that
the pH level of the solution is within 6.5 – 8.5.
f) Abrasive cleaners, acid or alkali detergents must not be used. Do not use solutions
containing hydrochloric acid, D-Limonene, ammonia or sodium hydroxide.
g) Water pressure at the nozzle should not exceed 35 bar (500 Psi) when cleaning the front
side glass.
h) The module backsheet does not need any cleaning in the conventional (monofacial)
modules. In bifacial modules with transparent backsheet, it is preferable to clean the
backsheet gently with cotton cloth or with compressed air (at pressure less than 2.4 kPa).
Water should not be sprinkled on the backside of the modules to avoid water ingress
inside the junction box.
i) If excessive soiling is present, a non-conductive soft brush, non-abrasive sponge, or
other mild agitating method may be used before using water. Ensure brushes or agitating
tools are not abrasive to glass.
j) Do not let water stay on the glass surfaces of PV modules for a long time. This creates a
risk of permanent damage to the glass, such as white efflorescence, otherwise known as
“glass disease,” which may cause reduced power output.
9. Notes
9.1 Installation of the modules should be done by trained professions, in accordance with the
provisions of the installation manual (latest updated version at the time of sales).
9.2 The applicable models and electrical parameters are given in Annexure 1.
9.3 After PV module has reached its end of life, the customer is advised to hand over the module
to nearby E-Waste recycling centre, as per the local re-cycling regulations.
9.4 The installer/system owner may contact Rayzon Solar at the following address for further
clarifications regarding the safe installation and maintenance of the solar panels.
Page | 17
ANNEXURE 1: LIST OF APPLICABLE MODELS
Page | 18
STC 45.06 38.23 1500 12.83 13.49 490
RSG490WC 25 II
BNPI 45.06 38.23 1500 14.13 14.86 540
Page | 19
96 Half-cut cell series
Page | 20