eco and secure line: modules correctly mounted · 8i 33 2.2warningofmaterialdamage + the proper...

ECO AND SECURE LINE:MODULES CORRECTLY MOUNTED

2020/07

TABLE OFCONTENTS

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04-06

07-08

09-26

27-31

31-35

INFORMATION REGARDINGTHIS MANUAL

SAFETYINSTRUCTIONS

MECHANICALINSTALLATION

ELECTRICALINSTALLATION

TROUBLESHOOTINGMAINTENANCE

1.1 OBJECT

This manual contains information about theinstallation and safe handling of Luxor Solar GmbHphotovoltaic modules: These modules are hereinafterreferred to as "module„ and Luxor Solar GmbH as"Luxor".

1.2 TARGET GROUP

Special skills and expert knowledge are required forthe installation of photovoltaic systems. Thisdocument is intended for corresponding specialists.This manual must be read and understood prior toinstallation. In case of any questions, please contactour sales department for further explanations. Duringinstallation of the module, the installer must adhereto all safety precautions in accordance with thismanual and to the valid local regulations. Before

installation of a photovoltaic system, the installermust become familiar with the mechanical andelectrical requirements of such a system. Keep thismanual in a safe place for future reference (care andmaintenance) and for the case of the sale or disposalof the modules.

1.3 VALIDITY

Luxor reserves the right to make modifications to themodules or assembly instructions at any time withoutnotice. Applicable are the dates of the orderconfirmation.

Please contact Luxor if you have any questionsregarding the validity of the documents.

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INFORMATION REGARDINGTHIS MANUAL

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1.4 GUARANTEE AND PROPER USE

The current Luxor guarantee policy for photovoltaicmodules shall apply.

1.5 LIABILITY EXCLUSION

As the use of these instructions and the circum-stances or methods of installation, operation, use andmaintenance of the photovoltaic (PV) products arebeyond its influence, Luxor shall not assume anyresponsibility and explicitly rejects any liability forloss, damage or expenses resulting from or in anyway associated with the installation, operation, use ormaintenance. Luxor shall not assume responsibilityfor any infringement of patents or other third-partyrights resulting from the use of the PV product. Alicense under a patent or patent rights shall not begranted, neither by implication nor by any other way.The information in these instructions are based onthe knowledge and experience of Luxor and arestated in good faith. This information, including theproduct specifications (without restrictions) andsuggestions, neither represent an explicit nor implied

guarantee. Luxor reserves the right to change theinstructions, the PV product, the specifications orproduct information sheets without notice.

1.6 USED SYMBOLS

The following symbols are used in the manual:

Warning of life-threatening injuriesin case of non-observance

Warning of material damagein case of non-observance

Indication of usefulinformation

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1.7 REGULATORY PROVISIONS

All technical rules for planning, installation andoperation of PV systems must be adhered to.The following standards and regulations merelyrepresent an excerpt:

+ DIN VDE 0100 Installation of power installationswith nominal voltages up to 1,500 V

+ VDI 6012 p. 2 Local energy systems in buildings+ DIN 1055 Load assumptions for structures+ VDE 0185 Lightning protection+ BGR 203 Safety regulations of the trade

association for roof work BGV A2, A3 Electricalsystems and equipment

+ Regulations of the central organization of theGerman roofing craft – professional association ofroofing, wall and waterproofing technology

+ Regulations of the local grid operators+ Regional building regulations

1.8 PRODUCT IDENTIFICATION

Each module has labels on the back containing thefollowing information:

+ Identification label: describes the product type;rated output, rated current, rated voltage, opencircuit voltage, short circuit current acc. to thestandard conditions, as well as the maximumsystem voltage, dimensions and weight and theposition of the mounting holes and othertechnical specifications can be taken from thedatasheets provided.

+ Barcode: Each individual module has a uniqueserial number. There is only one barcode on eachmodule. It is permanently attached to the insideof the module and is visible from the front. Thisbarcode is inserted before lamination

Caution!Removal or defacing of one or severallabels is not permissible! In case ofinfringement, all guarantee claimsbecome null and void!

2.1 HAZARD WARNINGS

+ Installation may only be performed by specialists.+ Keep children away from the system during the

transport and installation of the mechanical andelectrical components.

+ Installers are liable themselves for the entire riskwith regard to accidents and injuries duringinstallation, including but not restricted to injuriescaused by electric shock.

+ Please adhere to the safety instructions forworking with direct current.

+ A single module can generate direct currentvoltages of more then 30 volts in direct sunlightIn case of series connection of the modules, thetotal voltage corresponds with the total of theindividual module voltages. If the modules areconnected in parallel, the total current strengthcorresponds with the total of the currentstrengths of the individual modules. Even contactwith a direct current voltage of 30 volts or higher

is potentially dangerous.+ Never disconnect the module under load. Before

working on the PV system, disconnect the AC andDC inverter circuits.

+ Cover the module fully with a non-transparentmaterial during installation to avoid thegeneration of current.

+ Only use insulated tools approved for working onelectrical equipment. Do not insert anyelectrically conducting parts into the ports of themodules.

+ Do not carry out any work on the PV system incase of wet weather conditions or strong winds.

+ Use proper fall arrest systems on the roof.+ Adhere to the safety regulations for all other

components used in the system including cables,plugs, charge controllers, inverters, accumulatorbatteries, rechargeable batteries etc.

SAFETYINSTRUCTIONS

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8 I 35

2.2 WARNING OF MATERIAL DAMAGE

+ The proper conception of the rack is theresponsibility of the system designers andinstallers.

+ Never short-circuit the modules.+ Only use equipment, connections, cables and

racks suitable for an electric solar system.+ Always use the same type of module within a

certain PV system.+ Do not use defective or damaged modules.+ Do not attempt to disassemble the module, and

do not remove any of the existing identificationlabels or components from the module.

+ No coloring agents or adhesives may be appliedto the top surface of the module.

+ Do not use any mirrors or other magnifyingequipment to artificially concentrate the sunlightonto the modules.

+ Do not expose the rear film to direct sunlight.+ Do not use the module near equipment or in

places where flammable gases are generated ormay accumulate.

+ Do not drill any additional mounting holes in themodule frames. The guarantee becomes null andvoid in case of infringement.

+ Do not attempt to drill any holes in the glasssurface of the modules. The guarantee becomesnull and void in case of infringement.

+ Do not lift the module by the junction box or theelectrical cables.

+ Do not stand on or step onto the module. Do notplace any heavy objects on the module.

+ Avoid dropping the module and do not set it downjerkily. Prevent objects from falling onto themodule.

+ When installing the system you must adhere to alllocal, regional and national ordinances.If applicable, apply for a building permit.

+ The product must be professionally unpacked toprevent damage. Packaging material must beopened and removed with a suitable tool, forcables and plug systems e.g. open cable ties witha cable ties cutter. Damage to the product, e.g.the cable or crimping, etc. must be excludedduring the unpacking process.

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MECHANICALINSTALLATION

3.1 SELECTION OF THE LOCATION

+ Select a suitable location for the installation ofthe modules. Modules can be installed on theground, on roofs, vehicles or waterborne vessels.

+ In northern latitudes, the modules should beorientated towards the south and vice versa. Youwill find detailed information about the best angleof inclination for installation in specializedliterature or from an experienced solar installer orsystem designer.

+ Shading, including temporary shading or partialshading must be avoided.

+ The modules are evaluated at Fire Classification Cand can be mounted on Class A roofs.

+ Upon installation of modules „ECO SMART LINE“or „SECURE SMART LINE“ make sure you followthe instructions of the manufacturers of theoptimiser.

+ If the modules are installed upright the cableshould face to the ground and the junction boxshould be facing upwards.

+ For every installation corridors for maintenancemust be scheduled.

+ It is advisable to create a roof plan with all serialnumbers of the installed modules.

+ The bifacial gain depends on the albedo of thesurface under the modules and the installationheight.

3.2 DIMENSIONAL MODULE DRAWINGS

Rear/ Front/Side view

+ Tolerance L/W = +/- 3 mm+ L/W/H = Dimensions of panel can vary, dimensions

given in the order confirmation are decisive+ CL = Length of cable can vary from standard+ A, B, C, D = Position of mounting holes upon request.

ECO LINE 48MONOCRYSTALLIN LX-XXXM/156-48+POLYCRYSTALLIN LX-XXXP/156-48+

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Height (H)

Leng

th (

L)

Width (W)

Cabe

l len

gth

(CL)

Drilled holes:A: 4 x drainageB: 16 x ventilationC: 4 x mountingD: 2 x earthing




ECO LINE 54MONOCRYSTALLINE LX-XXXM/156-54+POLYCRYSTALLINE LX-XXXP/156-54+

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Height (H)

Leng

th (

L)

Width (W)

Cabe

l len

gth

(CL)





ECO LINE 60 / ECO SMART LINE 60MONOCRYSTALLINE LX-XXXM/156-60+

LX-XXXM/158-60+POLYCRYSTALLINE LX-XXXP/156-60+

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Height (H)

Leng

th (

L)

Width (W)

Cabe

l len

gth

(CL)


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ECO LINE 120 HALF CELLMONOCRYSTALLINE LX-XXXM/156-120+

LX-XXXM/158-120+LX-XXXM/166-120+

POLYCRYSTALLINE LX-XXXP/156-120+

Height (H)Width (W)

Leng

th(L

)

Cable

leng

th(C

L)


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ECO LINE 144 HALF CELLMONOCRYSTALLINE LX-XXXM/156-144+

LX-XXXM/158-144+LX-XXXM/166-144+

POLYCRYSTALLINE LX-XXXP/156-144+

Height (H)Width (W)

Leng

th(L

)

Cable

leng

th(C

L)





ECO LINE 120 HALF CELL GLASS-GLASSMONOCRYSTALLINE LX-XXXM/158-120+ GG

LX-XXXM/166-120+ GG

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Height (H)Width (W)

Leng

th(L

)

Cable

leng

th(C

L)





ECO LINE 144 HALF CELL GLASS-GLASSMONOCRYSTALLINE LX-XXXM/166-144+ GG

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Height (H)Width (W)

Leng

th(L

)

Cable

leng

th(C

L)


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ECO LINE 120 HALF CELL GLASS-GLASS BIFACIALMONOCRYSTALLINE LX-XXXM/158-120+ GG

LX-XXXM/166-120+ GG

Kabe

lläng

e(KL)

Width (W)

Leng

th(L

)

Height (H)

Cable length (CL)

Drilled holes:B: 8 x ventilation

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ECO LINE 144 HALF CELL GLASS-GLASS BIFACIALMONOCRYSTALLINE LX-XXXM/166-144+ GG

Kabe

lläng

e(KL)

Width (W)

Leng

th(L

)

Height (H)

Cable length (CL)

Drilled holes:B: 8 x ventilation




ECO LINE 60 GLASS-GLASSMONOCRYSTALLINE LX-XXXM/156-60+ GG

LX-XXXM/158-60+ GGPOLYCRYSTALLINE LX-XXXP/156-60+ GG

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Height (H)

Leng

th (

L)

Width (W)

Cabe

l len

gth

(CL)





ECO LINE 72MONOCRYSTALLINE 6” LX-XXXM/156-72+

LX-XXXM/158-72+POLYCRYSTALLINE 6” LX-XXXP/156-72+

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Height (H)

Leng

th (

L)

Width (W)

Cabe

llen

gth

(CL)





SECURE LINE 60 / SECURE SMART LINE 60MONOCRYSTALLINE LX-XXXM/156-60+ GGPOLYCRYSTALLINE LX-XXXP/156-60+ GG

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Height (H)

Leng

th (

L)

Width (W)

Cabe

llen

gth

(CL)





ECO LINE 72MONOCRYSTALLINE 5” LX-XXXM/125-72+

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Height (H)

Leng

th(L

)

Width (W)

Cabe

llen

gth

(CL)


a

1/4 a 1/2 a 1/4 a

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3.3 SELECTION OF A SUITABLE ASSEMBLY RACK

+ The assembly rack for the module must be madeof durable, corrosion- and UV-resistant material.

+ The assembly rack must be sufficiently sized forthe regionally occurring snow and wind loads.

+ The modules with the four anchorage pointsmust be securely fastened to the assembly rack.Additional anchorage points must be provided incase of the occurrence of increased snow andwind loads. Please refer to the following drawingfor detailed information. Load calculations areperformed by the system designer or installer.

+ For the clamping torque 6-14 Nm are advised. Ithas to be checked expertly whether the torqueis under- or oversized.

+ Depending on the assembly rack, the modulescan be fastened to the assembly rack by meansof bolted connections or module clamps.

+ Adhere to the instructions and safetyprecautions of the assembly rack manufacturer.

Length a consists with the stated dimension in the order conformity

+ For mounting of laminates and glass-glassmodules, use the appropriate mounting clamps,please refer to manufacturer specification. Atthe end of each module row, use correspondingdesigned end clamps, as well as a security hookand anti-sliding device as to manufacturerspecifications.

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3.4 CLAMP MOUNTING POSITIONS

The panels can be fixed an both the long and theshort side of the panel with a minimum of fourclamps, as is shown in the following figure. Thepanels are built to withstand horizontal mounted adownward force of up to 5400 Pa (550 kg/m!) or2400 Pa (244 kg/m!) according to where they areclamped. Site-specific loads such as wind or snowwhich may exert forces in a different way need to betaken into consideration to ensure this limit is notexceeded for each respective mounting option.Note, as the mounting angle increases, the downwardforce is supplemented by an accelerating force (e.g.sliding snow). The greater the distance between themodule edge and the underlying ground, the higherthe forces can be. These forces primarily affect themodule frame, which should be protected from thoseforces.If the length of ‘side a’ of a module exceeds 1685 mm(glass-backsheet modules) or 1721 mm (glass-glassmodules), clamping on the short side of the modulesis only permitted afterLuxor Solar GmbH checked theclamping which causes possible restrictions andreductions or conditions.

A minimum of four clamps must be fully located inthe same colored zone to be certified to that value.lf the panel is secured by four clamps in twodifferent zones (i.e. green and yellow), it is certifiedto the lowest value only.

FIGURE: CLAMP MOUNTING POSITIONS

Clamping within the green zone is certified fordesign loads up to 5400 Pa (550 kg/m! )

Clamping within the yellow zone is certified fordesign loads up to 2400 Pa (244 kg/m!)

Clamping within the red zone is not permittedwhen only using four clamps

a

b

1/8 a 1/8 a 1/8 a 1/8 a1/2 a

1/4

b1/

4 b

1/2

b

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3.5 TYPES OF ASSEMBLY

Caution!Danger of material damage!Treat the modules with great careduring unpacking, transport andassembly. Do not enter the modules.Avoid bending. Do not use the cablesor junction box as a handle.

Caution!Danger of material damage!Only use the existing mounting holes inthe module frame (see dimensionaldrawing). Do not carry out anyindependent modifications on themodule.

Depending on the module type, they have 8 or 16ventilation openings and 4 drainage openings in themodule frame. During assembly, make sure that theseopenings are not covered. Keep a distance of 5millimeters between the modules, as they expandslightly when heated.If possible, the modules should be mounted at aninstallation angle of at least 15° in order to support

their self-cleaning effect.The modules are suitable for on-roof, in-roof orfreestanding installation. Rod and mast mounting arealso possible.The end clamps should be 8-10 cm from the end ofthe mounting rail.

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FREE-STANDING INSTALLATIONDuring free-standing installation, particularly iflocated close to the ground, attention must be paidthat the lower module area is also not covered withsnow for a long period of time in regions with heavysnowfall. Furthermore it must be ensured that themodule is not located in the shade of plants or treesand that it is not damaged by flying sand and stonesin strong winds.

In case of several rows of modules, reciprocalshading must be prevented by adhering toappropriateminimum distances.

Caution!Danger of insufficient fastening!For free-standing installation on flatroofs, an edge clearance in accordancewith DIN 1055 Part 4 must beobserved.

ROOF-PARALLEL MOUNTINGSufficient rear ventilation of the modules must beensured for roof-parallel mounting (recommended areat least 100 mm airspace between the module andthe mounting surface).Each penetration required for the installation of themodule must be properly sealed to prevent the rooffrom leaking.

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ELECTRICALINSTALLATION

4.1 DESIGN

The electrical nominal values are within a range of± 3 percent of the stated values of Isc, Uoc and Pmax

under standard test conditions (radiation density of1,000 W/m!, AM 1.5 spectrums and a celltemperature of 25 °C) in the sense of the tolerancesof the measuring instruments used.In normal outdoor use conditions, the currentstrength and voltage produced by the module deviatefrom the values stated on the datasheet. Thedatasheet values are the values achieved understandard test conditions.The short circuit current values and the open circuitvoltage values should be correspondingly multipliedby a factor of 1.25 during system design in order tobe able to sufficiently size the component voltage,current load capacity of the conductors, size of thefuses and size of the regulating devices connected tothe modules or to the system output.The open circuit voltage of the PV system must notexceed the maximum permissible input voltage of the

inverter used and the maximum system voltage acc.to the module datasheet (1,000 V). The maximumsystem voltage of other system components mustalso be observed.Do not use modules with different configurations inthe same system.

The cross-sectional area of the cable and theconnection capacity must correspond with thehighestshort circuit current of the system (the recommendedcross-sectional area of the cable is 4 mm! for a singlemodule, nominal current of a connection > 10 A), asotherwise the cable and the connection over heat athigh current strength.The modules fulfil the requirements of applicationclass A (IEC 61730), protection class II.

Max. number of modules (N) = Umax systemUoc @ tempmin

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The direct current generated by photometric systemscan be converted into alternating current and fed intothe local grid. As the grid operators have differentinfeed conditions from town to town for the connec-tion of renewable energy systems, contact with theresponsible grid operator should be made in duetime. Approvals for the installation of such a systemare usually required (application for grid connection).Connection to the grid may only be carried out by alicensed electrician.

Please refer to the valid moduledatasheet for detailed module data. Theelectrical rated parameters of themodules are also stated on the moduletype plate.

4.2 EARTHING

Caution! Danger of material damage!The local regulations and directives forearthing must be observed.

Caution! Danger of material damage!Bolts, screws or other earthingconnections may not be used to fasten

the module to the mounting rail. Themodules have two holes on the back offor fastening the potential equalizationin the module frame. The modules aretested for protection class II accordingto IEC 61730. So earthing is notmandatory but recommended.

Earthing with earthing clips on the back side of theframe is permitted.

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4.3 CABLING

Caution! Danger of electric shock!Please observe the safety instructionsforworking with direct current!

Caution! Danger of electric shock andburns!Do not disconnect the plug-in moduleconnections under load! Otherwisenon-extinguishing electric arcs mayresult.

In general only plugs of the same type should beconnected to each other during installation or anecessary module replacement. Should this requirethat the plug must be replaced in order to connectthe same types of plugs, this requires professionalcrimping. Note, that still existing guarantees are notaffected except for the crimping.

Only use special, UV-resistant solar cables andsuitable connectors. Do not fold the cables andobserve the minimum bending radius (at least 8 timesthe outer diameter of the cable at a distance of at

least 5cm from the junction box). Please make surethat the cables are laid such that they cannot rubagainst sharp-edged objects or roof tiles. UV-resistantcable ties, for example, are suitable for fastening.Some mounting systems also have special cablefastenings and guides. Make sure the cables are notinstalled under tensile stress. Replace damagedcables. If possible, ensure short cable lengths tominimize intrinsic losses. Please check the opencircuit voltage and the short circuit current for eachinstalled strand (see also section 4.4).

r

! 5 cm ! 5 cm

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Packaging material must be opened and removedwith a suitable tool (e.g. cut cable ties using a cabletie cutter to open the cable). Damage to the product,e.g. the cable or crimping, etc. must be excluded.

Caution! Danger of material damage!The traction torque on the cable andconnector system must never exceed 50N (5 kg).In general, any traction on the cable andplug system must be avoided.

Use a rounded professional tool for cutting the

cable ties

DO NOT pull on the plug!

DO NOT pull

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4.4 TEST

Test all electric and electronic components of thesystem before use. Follow the instructions in themanuals provided with the components andequipment. Perform a test of the open circuit voltageand short circuit current before connection of thesystem.

OPEN CIRCUIT VOLTAGECheck the open circuit voltage of each strand with adigital multimeter. The measured values shouldcorrespond with the total of the open circuit voltagefor the individual modules. You will find the nominalvoltage in the datasheet of the module used*. If themeasured value is substantially lower than theexpected value, continue in accordance with thesection "Troubleshooting at low voltage".

SHORT CIRCUIT CURRENTTest the short circuit current of each series circuit.This can be measured directly with a digital multi-meter, which is connected to two clamping plates ofthe series circuit or module, or with any load, such ase. g. PV lighting, in order to carry out a roughmeasurement. Please make sure that the nominal

scale of the ampere meter or the rated current of theload must amount to 1.25 times the rated shortcircuit current of the series module. You will find therated current in the datasheet of the module used.The measured value can vary strongly depending onthe weather, time of day and possibly the shade.

*The electrical values of the provided individual measurements allocated tothe respective serial number are decisive.

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TROUBLESHOOTINGAND MAINTENANCE

5.1 BLOCK DIODES AND BYPASS DIODES

Caution!Danger of electric shock!Please observe the safety instructionsforworking with direct current.

Caution!Danger of electric shock!Never disconnect the module underload. Before working on the PV system,disconnect the AC and DC invertercircuits. Cover the module fully with anon-transparent material duringinstallation to avoid the generation ofcurrent.

For systems with more than two in-series modules,high counter-current may flow through shaded solarcells, if only part of the module is affected by shadewhile the other part is exposed to sunlight. Thiscurrent flow can cause the affected cells to overheat,

thus damaging the module. Bypass diodes are used inthe module to protect it from such high reversecurrent.All modules of these series already have bypassdiodes integrated into the junction box. In theimprobable case of a diode failure, it can be easilyreplaced.

Request the type of diode required forreplacement from Luxor, stating thetype of module and the serial number.

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5.2 TROUBLESHOOTING AT LOW VOLTAGE

First of all, determine whether this is normal orexcessive low voltage.

In the case of normal low voltage there is a drop inthe open circuit voltage in the module, caused by atemperature increase of the solar cells or lowerradiation density. Excessive low voltage is usuallycaused by defective connections at the terminals ordefective bypass diodes.

+ First test all cable connections to make sure thatthere is no open circuit or faulty connection.

+ Test the open circuit voltage of each module.+ Cover the modules with a non-transparent

material.+ Disconnect the connection at both module ports.+ Remove the non-transparent material from the

test module and measure the open circuitvoltage at the connections.

+ If the measured voltage is only half the ratedvalue, you can assume that the bypass diode isdamaged. For further information, please refer tothe section "Block diodes and bypass diodes“.

+ If the radiation density is not very low and thevoltage between the terminals deviates by morethan 5 %, then it is probable that the port isdefective.

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5.3 MAINTENANCE

Caution!Danger of electric shock!The grounding of the modules may notbe interrupted or destroyed bymaintenance and repair work.

Caution!Danger of damage to the modules!Avoid scratches and damage to theglass surface. Do not use aggressive,abrasive or hard cleaning agents.

Luxor recommends the following maintenance foroptimum module performance:

+ Clean the glass surface of the module asrequired. Always use water and a soft sponge orcloth for cleaning. A mild, non-abrasive cleaningsolution can be used for the removal of stubborndirt.

+ Check the electrical and mechanical connectionsevery six months to ensure that they are clean,safe and undamaged.

+ If a fault should occur, please contact aspecialist. Important: Follow all maintenanceinstructions for all system components includingthe racks, charge controllers, inverters,rechargeable batteries etc.

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5.4 RECYCLING AND DISPOSAL

Sustainability is a high priority topic for Luxor. This iswhy Luxor Solar GmbH is registered as amanufacturer at the national register for wasteelectric equipment.

As part of the EU Directive 2012/19/EU WEEE(Waste Electrical and Electronic Equipment), therecycling and disposal of solar modules was regulatedby the European authorities. The directive implies thatthe modules are accepted by the local recyclingcenter and then are forwarded to the recyclingprocess. A prior registration for delivery is onlyrequired for a larger number of solar modules.

If you have any questions in spite of the exact legalregulations, you can always contact Luxor.

Luxor Solar GmbHKornbergstraße 29 | 70176 Stuttgart | GermanyT +49.711.88 888-999 | F +49.711.88 [email protected] | www.luxor-solar.com

eco and secure line: modules correctly mounted · 8i 33 2.2warningofmaterialdamage + the proper...

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