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General rules for handling modules, emphasizing safety and proper procedures during installation and transport.
Safety precautions related to electrical hazards, voltage, and current produced by modules during operation and installation.
Explanation of warning symbols and icons found on module packaging for safe handling and transport.
Guidelines for safe unloading, transportation, and storage of PV modules at the project site.
Detailed instructions and precautions for safely unpacking the PV modules.
Guidance on selecting optimal locations for module installation considering sunlight and environmental factors.
Specifies structural requirements, material standards, and installation methods for module mounting.
Information specific to the installation of framed photovoltaic modules.
Details on using clamping systems for mounting framed modules onto support structures.
Table detailing installation methods, clamp positions, and load capacities for various module models.
Explanation of the clamping system for fixing modules to supports, including torque specifications.
General installation considerations including structure compatibility, grounding, and connector handling.
Guidelines for connecting modules in series and parallel, including voltage, current, and fuse recommendations.
Recommendations for selecting cable cross-sections and connector capacities based on system current.
Procedure for grounding modules using stainless steel bolts, washers, and copper conductors.
Methods for grounding module frames and mounting structures using lugs and appropriate hardware.
This document outlines the installation and maintenance procedures for Monofacial Modules manufactured by TW Solar Energy Co., Ltd. It serves as a comprehensive guide for professionals involved in the setup and upkeep of these solar photovoltaic modules, ensuring safe and efficient operation.
The primary function of these modules is to convert sunlight into DC electrical current, which can then be integrated into a larger photovoltaic system. They are designed for use in systems operating at greater than 50 V DC or 240W, where general contact access is anticipated, classifying them as Class A (IEC61730:2005) and Class II (IEC61730:2016) appliances. The modules are specifically designed with ½ cut of 182 mono c-Si cells, contributing to their performance characteristics. It is crucial to note that these modules are only approved for installation at altitudes below 2000m above sea level.
The installation process requires careful attention to detail and adherence to safety protocols. Modules must be installed by professionals who are familiar with both mechanical and electrical requirements, as well as local regulations and laws. Before installation, it is essential to read the manual thoroughly and keep it for future reference, especially for care, maintenance, or in case of sale or disposal.
When handling the modules, several precautions must be observed. All modules and electrical connectors should be kept clean and dry. Modules must be carried with both hands and should not be overlapped. Slip-proof gloves are necessary when carrying them due to their fragile nature. Supportive disassembling tools should be used during unpacking. It is strictly prohibited to stamp on modules, put weight on them, disassemble them, or remove any nameplate or component. Mirrors or magnifiers should not be used to concentrate sunlight onto the modules. Lifting the module by grasping the junction box or cable wire is forbidden, as is using any sharp object with the modules. Direct pressure on the glass surface or backsheet is to be avoided, and the surface of the coated glass should not be touched with bare hands. Ensuring all contacts and the operating environment are clean and dry is paramount for optimal performance and safety.
The manual provides specific instructions for unloading, transportation, and storage. When modules are delivered to the project site, the freight car should be parked in a flat, even, and open area for unloading. Forklift unloading requires choosing an appropriate forklift based on commodity weight and placing modules on flat ground. For crane unloading, lifting belts must be affixed to the wood supporting frame buckle, and only one pallet should be lifted at a time. Before lifting, it is necessary to confirm the integrity of the pallet and paper box and ensure the lifting rope is robust. Once lifted close to the ground, the paper box should be gently placed on a relatively flat position by two people. Stacking modules at the project site is prohibited, and during transportation within the site, only one layer is allowed.
For storage in a project site warehouse, the environment must maintain humidity below 85% and a temperature range of -20°C to +50°C. Modules can be statically stacked for up to two layers. For temporary storage at the project site, modules should be kept in a dry, well-ventilated place, not stacked, and covered with waterproof cloth to prevent dampness.
Unpacking should not occur in rainy conditions. In windy conditions, special attention is required, and handling the module is not recommended during heavy winds; unpacked modules must be properly secured. The packing box should be placed on a stable, level surface to prevent overturning. Protective gloves must be worn during unpacking to avoid scratching hands or leaving fingerprints on the glass. Minor fall-off of protective corners due to unskillful operation is considered normal, as these corners primarily reduce transport damage and do not affect module reliability. Before unpacking, product information on the carton box and unpacking instructions must be carefully checked. Each module should be carried by two people, and pulling the junction box while carrying is prohibited.
Location selection for installation is critical. Modules in the north latitude region should face south, and those in the south latitude region should face north. Installation sites must have sufficient sunlight and no shade at any time, as shading, even partial, can reduce power output and potentially damage the module, voiding the warranty. Modules should not be stored, installed, or used where combustible gas is easily generated or gathers. The straight-line distance from the installation site to the coastline should be at least 1 km, unless written approval from TW or a contractual agreement specifies otherwise. All modules within the same string should be installed at the same angle to ensure uniform irradiation and prevent current differences, which can decrease system efficiency.
Installation requirements emphasize a robust support system capable of handling preset loading conditions, with necessary guarantees and certifications from the installer or supplier. The support system must pass third-party inspection for static mechanical analysis and comply with local, national, or international standards like DIN1055. Support structures should be made of durable, corrosion-resistant, and UV-resistant materials, and modules must be firmly mounted. Proper installation height is necessary to prevent shading by plants, damage from flying sand, or prolonged snow cover. When installed on roofs or buildings, the roof structure must be firm and protected against heavy wind or snow, with adequate ventilation (minimum 10cm gap) for cooling. A minimum distance of 10mm between modules is required to account for linear thermal expansion. The module backside must not contact the support or architectural structure, even under external pressure. Drilling holes in the glass surface or frame is prohibited, as it invalidates the warranty. Roof installations must ensure the roof structure is suitable and modules do not extend beyond the roof zone, with proper sealing to prevent water leakage. For column installations, the supporting column and module structure must withstand expected local wind.
Electrical performance safety is paramount. PV modules generate DC current under sunlight, and contact with exposed metal parts can cause electrical shock or burns, with 30V or higher DC voltage being fatal. Modules can produce voltage even without a connected load; therefore, insulation tools and rubber gloves must be used when operating modules in sunlight. PV modules have no switches; operation can only be stopped by covering them with hardboard or UV-proof materials, or by placing them on smooth, flat surfaces. To prevent electric arcs or shocks, electrical connections should not be broken under loaded conditions. Connectors must be kept dry, clean, and fully connected, with a click sound indicating proper connection. Snow, water, or other reflective media can intensify light reflection, increasing output current and power, especially under low temperatures. If module glass or sealing materials are damaged, personal protective equipment must be worn, and modules isolated from the circuit. Work should only be done under dry conditions with dry tools, unless wearing personal protective equipment. Installation must be guided by a qualified electrician, and personnel must wear safety helmets, insulating gloves, and shoes.
General electrical installation guidelines include ensuring the installation structure is compatible with the module to prevent galvanic corrosion, which voids the warranty. The DC-side system potential should be chosen carefully, with negative grounding often preferred for crystalline silicon modules to mitigate potential induced degradation (PID). Non-professionals are forbidden from opening connector lock nuts. Connectors must be clean, dry, and fully connected to prevent electric arcs. Modules can produce higher current/voltage than reported at standard test conditions, so ISC and VOC values should be multiplied by 1.25 when determining component ratings. Modules must be completely covered with opaque material during conductor disassembly. Different module models should not be used in the same solar photovoltaic system. When connected in series, the string voltage must not exceed the maximum system voltage, calculated as maximum system voltage divided by (1.25 * open-circuit voltage). In parallel connections, the current output equals the sum of each string's current, and fuses are necessary for each module string, with maximum parallel module configurations based on fuse rating divided by (1.25 * short-circuit current). Local regulations should be consulted for fuse sizing.
System wire size, types, and temperatures must comply with local regulations. Cable cross-section and connector capacity must suit the maximum system short-circuit current (recommended 4 mm² for single modules, and connector rated current > 20A). Cables and connectors can overheat under large current; maximum cable temperature is 85°C, and connector temperature is 105°C. All electrical components, including connectors and inverters, must be off during installation. Loop areas should be kept small to reduce lightning damage, and fuses are recommended for each string.
Grounding is essential for safety. Grounding bolts, made of stainless steel, must be used in specified grounding holes. The M3.5 stainless steel bolt passes through spring washer, flat washer, cup washer (copper conductor 2.1 mm diameter), and star washer, then through the grounding hole, flat washer, and spring washer on the frame, tightened with an M3.5 nut. The conductor's upper temperature limit is 85°C. All module frames and mounting structures must be grounded according to regional and national electricity regulations, using recommended hardware to connect grounding cables. If a metal structure is used, its surface must be electroplated to ensure good conductivity. Suitable grounding conductors connect the module frame to the mounting structure. The grounding conductor must connect to ground via an appropriate grounding electrode, preferably using lugs. If a grounded module is mechanically connected without bolts and nuts, the mounting system must also be grounded. The grounding cable should be peeled to a proper length without damaging the metal core, inserted into the lug, and the screw tightened. The lug is then connected to the aluminum frame with stainless steel bolts, with a recommended tightening torque of 2.3N•m for M3 bolts.
Bypass diodes and block diodes are critical for module protection. In series-connected systems, if part of a module is shaded, a high reverse current can flow through the shaded cells, causing overheating and potential damage. Bypass diodes in junction boxes mitigate these effects. Disassembling the junction box to replace diodes is prohibited for non-professionals. In systems with batteries, if the controller lacks backswing protection, block diodes installed between the battery and module prevent reverse current from damaging the module.
Normally, the modules do not require repair. Regular maintenance ensures optimal performance. In most conditions, rainwater keeps the module glass clean. If necessary, glass surfaces can be cleaned with a wet soft sponge or cloth, using a mild non-abrasive cleaning agent for stubborn dirt. Cleaning a module with broken glass or a perforated backsheet is dangerous and can cause serious electrical shock.
A regular inspection of grounding, mechanical, and electrical connections should be performed every 6 months. All module connectors must be securely connected, clean, and free from damage or corrosion. When disassembling connectors, all components must be in good working order; otherwise, the connector should be replaced. Damaged connectors can cause electronic leakage. The tightening torque for the connector nut should be between 1.5 N•m and 3 N•m.
During any repair work, modules must be completely covered with opaque material to avoid electric shock, as they produce high voltage when exposed to sunlight. All repair work must be carried out by professionals. A warning emphasizes the importance of shutting down the system before any electrical repair, as improper maintenance can lead to electric shock or fire.
General| Model | TW550MAP-144-H |
|---|---|
| Type | Monocrystalline |
| Maximum Power (Pmax) | 550 W |
| Efficiency | 21.3% |
| Number of Cells | 144 |
| Dimensions | 2279 x 1134 x 35 mm |
| Operating Temperature | -40°C to +85°C |
| Open Circuit Voltage (Voc) | 49.7 V |
| Maximum Power Voltage (Vmp) | 41.7 V |
| Maximum System Voltage | 1500 V DC |
| Weight | 28.5 kg |
| Warranty | 25 years |
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