This document is an installation manual for solar photovoltaic (PV) modules manufactured by Tongwei Solar Co., Ltd. (referred to as TW Solar). It provides comprehensive guidelines for the installation, operation, safety, and maintenance of their PV modules.
Function Description:
The manual outlines the process of installing TW Solar PV modules, which are designed to convert sunlight into DC electrical power. This DC power can then be converted into AC power and fed into the grid, or used in off-grid systems. The modules are intended for use in systems operating at greater than 50V DC or 240W, suitable for applications where general contact access is anticipated. The manual covers both monofacial and bifacial module types, with various models listed, including TWMPD, TWMND, and TWMPF series, differentiated by cell size (182 mono c-Si cell or 210 mono c-Si cell) and power output.
Important Technical Specifications:
The manual provides detailed technical specifications related to module installation and load capacity. It categorizes installation methods into four types (A, B, C, D) for clamping on the long side and short side, and two types (E, F) for mounting with holes on the long side. For each module model, it specifies the height of the frame, mounting clamp position (K and M in mm), and test load (front/back in Pa). For example, the TWMPD-54HS/HB and TWMND-54HS models with a B30 frame height can withstand a front/back test load of 5400/2400 Pa with clamp position K ranging from 200-300 mm, and 3600/2400 Pa with clamp position K ranging from 100-240 mm for method A and B respectively. Similarly, for mounting with holes, models like TWMPD-54HS/HB and TWMND-54HS with a B30 frame height require a mounting clamp position M of 990 mm and N of 1085 mm, with a test load of 5400/2400 Pa for method E. The clamping system requires an overlap of at least 10 mm with the module frame, and the bolt tightening torque for M8 bolts is specified as 16-20 N·m. The recommended section area for a single module's cable is 4 mm², and the connector's rated current should be greater than 20A. The maximal temperature of the cable is 85 °C, and the upper limited temperature of the connector is 105°C.
Usage Features:
The manual emphasizes several usage features to ensure safe and efficient operation:
- Location Selection: Modules should be installed in locations with sufficient sunlight and no shade, as shading can lead to lower power output and potential module damage, voiding the warranty. Installation near combustible gas sources is prohibited. Modules can be installed 50 to 500m from the coastline, but connectors must be well-protected with dust-proof plugs and anti-rust measures.
- Installation Methodologies: Various clamping and mounting hole methods are detailed, allowing for flexibility in installation depending on the support structure. The length of the clamp must be ≥50mm.
- Electrical Connections: Modules produce DC current under sunlight, and contact with exposed metal parts can be dangerous. Insulation tools and rubber gloves are required during operation in sunlight. Connections should be dry, clean, and fully engaged to prevent electric arcs or shocks. It is crucial not to break down electrical connections under loaded conditions.
- System Design: The manual advises consulting a senior system designer for grid-connected systems, as policies vary by region. It also discusses the importance of negative grounding systems for crystalline silicon PV cells to prevent potential induced degradation (PID).
- Bypass and Block Diodes: Bypass diodes are integrated into junction boxes to protect modules from overheating due to partial shading in series-connected systems. Block diodes are recommended between the battery and the module in systems with batteries if the controller lacks backswing protection, to prevent reverse current damage.
- Environmental Considerations: Snow, water, or other reflective media can increase output current and power. Module voltage and power increase under low temperature conditions. The storage environment requires humidity below 85% and temperatures between -20°C and +50°C, with modules stacked for no more than two layers. Temporary storage requires a dry, well-ventilated place, covered with waterproof cloth.
Maintenance Features:
The manual outlines essential maintenance practices to ensure optimal performance and longevity of the PV modules:
- Cleaning: Normal rainwater can keep the module glass clean. For stubborn dirt, wet soft sponges or cloths with mild non-abrasive cleaning agents are recommended. Cleaning modules with broken glass or perforated backsheets is strictly prohibited due to the risk of electrical shock.
- Regular Inspections: A regular inspection of grounding, mechanical, and electrical connections is recommended every 6 months. All module connectors must be connected, clean, and free from damage or corrosion.
- Component Replacement: If connectors are damaged, they must be replaced by professionals to prevent electronic leakage. The tightening torque of the nut should be 1.5 N·m - 3 N·m.
- Safety during Repair: During any repair work, modules must be completely covered with opaque material to prevent electric shock from high voltage generated by sunlight. All repair work must be carried out by professionals, and the system must be shut down before any electrical repairs.
- Corrosion Prevention: Installation structures should be compatible with modules to avoid galvanic corrosion, which can void the warranty.
The manual emphasizes that modules must be installed by professionals who are familiar with mechanical and electrical requirements, and who adhere to all rules in the manual, as well as local regulations. TW Solar disclaims responsibility for any loss or damage resulting from non-compliance with the manual's guidelines.
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