Installation Manual and User Manual for BYD
Contents
1. Fig 6 The array of backblocks on 72 cells double glass modules BYD COMPANY LIMITED Rev Feb 11th 2014 3 3 2 General Installation 1 When the modules in a PV system are connected in series or parallel generally we recommend simple methods of connecting them in series or parallel as shown below Series connection of modules 2 The bypass diode should have a Rated Average Forward Current at least 10A and a Rated Repetitive Peak Reverse Voltage of at least 40V 3 The cable must not be bent or crushed on the direct exit of the cable screw joint include connecter and box A minimum bending radius R5 cable diameter must be maintained The cable must be routed in a way that tensile stress on the conductor or connections is prevented The pictures are as below ir 7 R Radius R 24 Xcable 5 4 The maximum number of series connected modules depends on the system design the type of inverter used and environmental conditions Our modules can be used both in 1500V system and 1000V system According to the system voltage 1000V of the IEC standard we recommend the maximum number of series connected modules for each module series as stated below2. BYD COMPANY LIMITED The maximum number of modules in series BYD P6 30 DG M6 30 DG P6C 30 DG M6C 30 DG P6C 36 DG M6C 36 DG 4 For parallel connection the current will be added up and the used connectors will be limited by the number of parallel connection The fuse protection needs to be determined as well 5 There is no general limitation on the number of parallel connected modules but the number of modules is determined by system design parameters such as current or power output Every PV array in parallel should install a protection circuit 6 Please refer to local laws and regulations to determine the system wires size type and temperature To prevent the cables and the connectors from overheating the cross section of the cables and the capacity of the connectors must be selected to suit the maximum system short circuit current the recommended cable cross section is 4mm for a single module or a rated current of the connectors of more than 104 No more than twenty NOTE Please note that the upper temperature limit is 90 C and 100 C for the connectors 10 Rev Feb 11th 2014 4 Maintenance and Care 4 1General Maintenance The following inspections of the modules should be carried out in regular intervals 1 Regularly check the mechanical installation of the module Check the support equipment for fastness and symptoms of corrosion or other damages Check bolts and nuts for loosening espec
3. is no defect in the packing the junction box or on the surface of module 10 The user should design and select a metallic bracket for installing that is suitable to bear the weight of the PV modules The brackets should be selected by the user according to their destined places of installation such as open land or a rooftop For safety reasons all brackets should be grounded In order to insure good BYD COMPANY LIMITED conductivity electroplated brackets should be used 11 As a general rule PV modules should be installed in a location where they will receive maximum sunlight throughout the year In the Northern Hemisphere the modules should typically face south and in the Southern Hemisphere the modules should typically face north When choosing a site avoid trees buildings or other obstructions which might block the sunrays When selecting a clamping or insertion system appropriate anticorrosive brackets should be selected according to the specification of the module 12 Put the modules on the frame and tighten the screws after putting on the underlying washers Don t cover the drain holes with other components when installing the modules The junction box should be placed at the top of the module in order to facilitate correct positioning of ventilation holes 13 Don t grasp the junction box or cables during the installation process 14 In case of installing the module on a roof top the roof top should be made fire resi
4. Installation Manual and User Manual for BYD Double Glass Photovoltaic Modules Shanghai BYD Co Ltd ADD No 999 Xiangjing Road Songjiang Shanghai P R China TEL 86 21 5777 8888 FAX 86 21 5777 5086 www byd com cn BYD COMPANY LIMITED Rev Feb 11th 2014 CONTENT eli jeje NT Y 3 hg Produc BCID cid o p EE EE E A E 3 NEPE 50 EE 3 zer ne Cee a ent cme nee eee ee eet ene ee ee ee eee ee ee eee d M OO oe V 3 2 Transportation and Storag manual e 4 JNS TON ea E R A EEATT E A EA 4 BU WAIN AEA E E T A EE N O O E A E E E E E A E E A ani E E E 4 3 2 Mechanical installation cccccccccccccssscsccssscscscsssscscsssscscscsscscsssscacsssssscasssuscscssusvasssvssasssassasscssvasasasvscssssvasasssasescassuavasssssvasssssvasssuscacssssscacassacasassscssssscacsees IR REX RE 3 2 1 MOUNTING EST CIAA ER AE MBE BZ GS UN ce sacs crepes RT C s fate AEM BE 323 inser On yl sete E RTT Em fate AEM BE CES S AR E Ta AN ON sacs T m u E 8 TU IN E RE Tm mmE 8 SERE 21 sir LM a
5. a ESL FUN e m c 9 A Mamtenance ard Care gee en a er ee oe EE E 10 4 1General MAINTENANCE 0 c1ccccccsssccccsssccccccscsccsssccccsncsccscsssccusossscassecausssesaunseseasusessaneaescaunssscauasecaunaessaaunneseasaunsasauosescaunsecaunacasacunseecaunsecauaasesaunsssaaauasesauaacesaunssscauasesausacessausuces 10 LEON a O T e ener ee ne EENE E E ee ee eee ee ee ee A ee ee EE ae ee ee 11 S AGAIN ooo ce ces ne sete wesc emir E E A 11 BYD COMPANY LIMITED Foreword This manual describes the transportation installation and maintenance of PV double glass modules hereafter referred to as module Please read this manual carefully before installing and using the modules Please get in touch with the provider if you have any questions This manual applies to all the standard modules of BYD Company Limited Keep this guide in a safe place for future reference care and maintenance and in case of sale or disposal of the modules NOTE All statements in this manual refer to our 3 bus bar polycrystalline cell PV modules as well as to our monocrystalline cell modules The illustrations in this manual which show 2 bus bar cell PV modules are only used for reference purposes Rev Feb 11th 2014 1 Product identification 1 1 Label The label shows the product type rated power rated current rated voltage open circuit voltage short circuit current w
6. e 90 90 BYD COMPANY LIMITED Rev Feb 11th 2014 Fig 2 The structure of the backblocks High strength high sticking long life durability silicone is used to stick the backblocks to the backside of the modules M6 type threaded tubular rivets GB T 17880 1 1999 or UNI 9201 1988 Threaded tubular rivets with cylindrical head are mounted in the center of the backblocks The material of the rivets is stainless steel The performance stage is 8 8 The bolt tightening torque of the joint is in the range of 16 to 26 N M The rivet nuts can only be changed together with the backblock when got invalidated The bolts can be changed conveniently if necessary One module is fastened on two U shape steel brackets by four M6 bolts to the rivets in the backblocks see in Fig 3 and Fig 4 Four convex parts are designed to help locating the modules before fastening the bolts There are 2mm tolerance for mounting the modules The direction of the modules can only be changed by adjusting the brackets Fig 3 Two double glass modules are mounted on the brackets Fig 4 Backblocks fastened on U shape brackets by bolt BYD COMPANY LIMITED Rev Feb 11th 2014 Since glass and steel have different thermal conductivity the heat stress of the module surfaces will be changed outdoor Therefore please locate the site of the brackets precisely to limit the bending height
7. eight dimensions etc 1 2 Barcode Each module has only one bar code as shown below SH 140107 P636 ASKCD 001 SH Manufacturer location Shanghai 140107 Date YYMMDD P P for Poly Si M for Mono Si L for Mono like Si 6 6 for the cell dimension of 156 156mm 5 for the cell dimension of 125 125mm 36 the voltage of the modules ASKC Engineering Code referring to different shifts materials etc D D for Double Glass module 001 Number of product components three digit sequence 0 to 999 for sequential production starting on each new day of production at 001 2 Transportation and storage manual Please observe the following criteria after packing 1 Don t tilt the packing boxes for more than 15 during handing 2 Please follow the instruction labels up and down during placing the packing boxes and avoid placing them upside down during transit 3 Be careful while handing the boxes during transit and avoid heavy pressure or jolting of the boxes 4 The packing boxes should be protected from rain b Transportation conditions should conform to the requirements of the packing boxes and of the modules regarding their environmental conditions 3 Installation 3 1 Warning 1 Do not use mirrors or other magnifiers to artificially concentrate sunlight on the module 2 Do not touch the connectors with bare hands and use insulated tool
8. ially the places with exposure to hard winds or at times of jolting Ensure that the fixing is fast and fasten immediately in places with some looseness If conditions permit the metal fittings that fasten or support the modules such as the bolts and nuts should be protected from corrosion A firs inspection should be carried out 12 months after installation and inspections every 10 years thereafter 2 Regularly check the electric wiring of the modules for reliable connection to the components of the equipment and the grounding system Check regularly if the value of the grounding resistance is still reaching the designated requirement If connections are not fast fasten them by soldering After a thunderstorm or before the start of the stormy season check the convergence box and the lightning protection systems installed inside the equipment for loss of function and change them immediately if necessary 3 Check cables connectors and joints for current leakages and deal with it in order to prevent leakage currents caused by rainy or snowy weather when checking the wiring people must take insulation BYD COMPANY LIMITED equipment such as tools and gloves etc with them and avoid touching the bare parts of connectors or joints with bare hand Check the system for loosen parts of the connectors and fasten where necessary to ensure good contact Wipe the dust from the equipment regularly to keep it clean 4 If the module appears in need
9. in one percent of the edge length The maximum values are 16mm and 10mm for the long edge and short edge respectively The bending height on the diagonal should be limited in 30mm The modules can be mounted along the long edge or the short edge as required Fig 5 Two modules are mounted along the long edge 3 2 2 Mounting system for 72 cells double glass module The modules are also fastened by bolts to rivets like 60 cells modules as Is shown in Fig 6 and 7 BYD COMPANY LIMITED Rev Feb 11th 2014 ll i o er BE HEP FER FER L oe oe eee Ss Ce Meo ee oso CS O ece e e e oO O oS OS CSS lt 7 lt m LA NI Cj E Mounting backblock 1967 1954 1200 Fig 7 Two 72 cell modules are mounted on two brackets 3 3 Electric installation Scupper 3 3 1 Grounding 1 The material of all frames of the double glass modules is polymer with high electric resistance There is no need of grounding for the double glass modules The brackets must be grounded C 2 When designing the PV systems inverters with power transformers should be used 3 Please follow local electrical code before installing 4 The grounding system must be installed well
10. of repair the surface of the module should be covered with fabric or other material There is a danger of high voltage if the sun ray directly hit the module 4 2 Module Cleaning Excess dirt and dust accumulating on the glass surface of the module can reduce its power output Therefore BYD recommends periodic cleaning of PV modules especially during times when the modules do not have the expected power output Please check the glass surface of the module for cracks and damages before cleaning If there are already cracks on the module please do not clean but inform the installer or maintenance service provider Do not wear a watch or jewellery during cleaning and use a soft cloth to clean the surface from dust and dirt In places with dirt that is hard to remove clear water might be used first for soaking and then a piece of clean gauze for carefully wiping up the water Do not use any hard tools or mordant solution for 11 Rev Feb 11th 2014 wiping in order to avoid scratching the module surface so as to affect the light transmission efficiency Any power attenuation caused by scraping the module is beyond our guarantee range A time of the day without sunshine or early evening should be chosen as the time for cleaning while broad daylight should be avoided The use of cold water to clean a PV module heated up sunshine might cause cracks in the glass cover of the module 5 Claim As the adherence to this manual and the condition
11. s during electrical work 3 Although the glass surface of the modules is rather durable and able to withstand pressure the glass might break and the module will no longer work properly if it is dropped or hit by tools or other heavy objects BYD COMPANY LIMITED Rev Feb 11th 2014 4 Under certain conditions the module might produce a higher electric current and or voltage than measured under standard test conditions Accordingly the values of lse and Voc marked on this module should be multiplied by 1 25 when determining the component voltage ratings conductor current ratings fuse sizes and size of controls relating to the PV output 5 The installation work of the PV array can only be done under the protection of sun sheltering covers or sunshades and only qualified persons should install modules or perform maintenance work 6 Systems should be installed by qualified personnel only and at least by two persons The system involves electricity and can be dangerous if the personnel are not familiar with the appropriate safety procedures 7 Follow the recommendations of the battery manufacturer if batteries are used with the modules Please observe national and local laws and regulations when installing modules If required an architecture license should be obtained before carrying out this work 8 Please unpack carefully 9 A visual inspection should be carried out before installation in order to make sure that there
12. s or methods of installation operation use and maintenance of photovoltaic PV products are beyond BYD s control BYD does not accept responsibility and expressly disclaims liability for any loss damage or expense arising out of or in any way connected with incorrect installation operation use or maintenance The information in this manual is based on BYD s knowledge and experience and is believed to be reliable This manual provides reference only and consumers are free to choose an appropriate way of installation according to place and environment BYD reserves the right to change the manuals PV products specifications and product information sheets without prior notice NOTE A note provides information about installation operation or maintenance of the module that is important to know but it is not necessarily hazardous BYD COMPANY LIMITED CAUTION A caution message indicates a potential threat to minor injury or alerts against behavior that can lead to property damage DANGER A danger message indicates a hazard in the immediate area which if not avoided can result in death or serious injury 12 Rev Feb 11th 2014
13. stant first Do not use modules near equipment or in places where flammable gases may be generated 15 In case of roof top installation the PV array should fulfill the requirements regarding fire resistance of the norm IEC 61730 2 16 The ambient temperature range at the location of installation should not exceed 40 C 85 C Rev Feb 11th 2014 DANGER One single module may generate more than 30V DC when its front is exposed to direct sunlight If modules are connected in series the total voltage is equal to the sum of the partial voltages of each module If modules are connected in parallel the total current is equal to the sum of the partial currents of each module Therefore direct contact should be avoided after installing a greater number of modules in series or parallel in order to avoid electric shocks CAUTION Please unpack the module in an appropriate environment and use special tools The modules need to be kept water proof and damp proof 3 2 Mechanical Installation 3 2 1 Mounting system for 60 cells double glass module Four stainless steel backblocks are stick to backside of double glass modules on two metallic brackets The system can withstand 5400 Pa mechanical load The positions of the backblocks are shown in Fig 1 and the structure of the backblock is shown in Fig 2 990 1 Junction box o Mounting backblock Fig 1 Array of backblocks on the modul
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