This document serves as the installation manual for Photovoltaic Modules manufactured by TW Solar Energy Co., Ltd. (referred to as TW). It provides comprehensive guidelines for the safe and efficient installation, operation, and maintenance of TW's solar photovoltaic modules. The manual is intended for professional installers who are familiar with mechanical and electrical requirements, ensuring adherence to both the manual's instructions and local regulations.
Function Description
The TW Photovoltaic Modules are designed to convert sunlight into DC electrical power. This DC power can then be converted into AC power and fed into the electrical grid, or used in off-grid systems with batteries. The modules are suitable for various applications, including residential, commercial, and utility-scale solar power systems. The manual details the specific models covered, including monofacial modules with half-cut 210 mono c-Si cells (TW645MCP-132-H, TW650MCP-132-H, TW655MCP-132-H) and half-cut 182 mono c-Si cells (TW545MAP-144-H, TW550MAP-144-H, TW555MAP-144-H, TW405MAP-108-H, TW410MAP-108-H, TW415MAP-108-H, TW420MAP-108-H). These modules are designed for systems operating at greater than 50 V DC or 240W, indicating their capacity for significant power generation.
Usage Features
The manual emphasizes several key usage features and installation considerations to ensure optimal performance and longevity of the modules:
- Installation Environment: Modules are restricted to installation below 2000m above sea level. They must be installed in locations with sufficient sunlight and without any shading, as even partial shading can significantly reduce power output and potentially damage the module, voiding the warranty. It is crucial to avoid areas where combustible gas is easily generated or gathers. For installations near coastlines, a minimum straight-line distance of 1 km is required unless specific written approval from TW or a contract specifies otherwise.
- Module Orientation and Tilt: For optimal energy capture, modules in the north latitude region should face south, and those in the south latitude region should face north. Modules within the same string must be installed at the same angle to ensure uniform irradiation and prevent current differences that can decrease system efficiency. The manual provides a table with recommended mounting tilt angles based on local latitude, ranging from 15° for 0°-15° latitude to local latitude + 20° for latitudes greater than 40°.
- Mechanical Installation: The support system must be robust enough to withstand specified loading conditions and should be made of durable, corrosion-resistant, and UV-resistant materials. The module must be firmly mounted, with a minimum gap of 10cm between the module and the installation surface to ensure proper ventilation and cooling. A minimum distance of 10mm between modules is recommended to account for linear thermal expansion. The manual explicitly prohibits drilling holes in the glass surface or frame of the module, as this will invalidate the warranty. When installing on roofs, the roof structure must be suitable, and penetrations for module installation must be properly sealed to prevent water leakage. For column installations, the support structure must withstand expected local wind loads.
- Mounting Methods: The manual describes two primary mounting methods for framed modules:
- Mounting Hole System: This involves using corrosion-resistant M8 bolts to fix the module through pre-drilled holes in the side frame to the installation support.
- Clamping System: This method utilizes proper clamps to secure the module to the installation support, specifically clamping on the long side of the module. The length of the clamp should be at least 50mm.
- Electrical Installation:
- Galvanic Corrosion: The installation structure must be compatible with the module to prevent galvanic corrosion, which can void the warranty.
- Grounding: The manual emphasizes proper grounding according to regional and national electricity regulations. All module frames and mounting structures must be grounded. Two methods are described:
- Grounding by Cable: This involves using stainless steel bolts (M3.5) with specific washers (spring, flat, cup, star) to connect a copper conductor to the designated grounding holes on the frame. The conductor's upper limited temperature is 85°C.
- Grounding by Lugs: This method involves connecting grounding cables to lugs, which are then attached to the aluminum frame with stainless steel bolts. The metal surface of the system should be electroplated to ensure good conductivity.
- System Potential: For crystalline silicon photovoltaic cells, using a negative grounding system is recommended to maintain a positive circuit potential, which helps mitigate potential induced degradation (PID). Consultation with the inverter manufacturer is advised.
- Connections: Connectors must be clean, dry, and fully connected, indicated by an audible click. Non-professionals are prohibited from opening connector lock nuts.
- Series and Parallel Connections: Modules in the same string should be connected in series, ensuring the total voltage does not exceed the maximum system voltage. For parallel connections, the current output is the sum of each string's current, and fuses are necessary for each module string, with recommendations for maximum parallel module configurations based on fuse rating and short-circuit current.
- Cable Management: To reduce lightning damage, the loop area when laying cables should be kept as small as possible.
- Bypass and Block Diodes: Bypass diodes are integrated into the junction boxes to protect modules from overheating due to partial shading in series-connected systems. Users are warned against disassembling the junction box to replace diodes; this task must be handled by professionals. In systems with batteries, block diodes are recommended between the battery and the module if the controller lacks backswing protection, preventing reverse current damage.
Maintenance Features
The manual outlines essential maintenance practices to ensure the continued optimal performance and safety of the modules:
- Cleaning: Normally, rainwater keeps the module glass clean. If necessary, the glass surfaces can be cleaned with a wet, soft sponge or cloth. A mild, non-abrasive cleaning agent can be used for stubborn dirt. It is strictly prohibited to clean a module with broken glass or a perforated backsheet due to the risk of serious electrical shock.
- Regular Inspections: A regular inspection of grounding, mechanical, and electrical connections is recommended every 6 months. This ensures all module connectors are clean, undamaged, and free from corrosion.
- Connector Replacement: If components are not working well when disassembling connectors, they must be replaced. Damage to connectors can lead to electronic leakage. The tightening torque for connector nuts should be between 1.5 N·m and 3 N·m.
- Safety During Repair: During any repair work, modules must be completely covered with opaque material to prevent electric shock, as modules produce high voltage when exposed to sunshine. All repair work must be carried out by professionals.
- System Shutdown: Before any electrical repair, the system must be shut down. Improper maintenance can lead to electric shock or fire.
The manual serves as a critical resource for ensuring the safe, efficient, and long-lasting operation of TW's photovoltaic modules, emphasizing professional installation and adherence to detailed guidelines.
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