OPERATING MANUAL
CX SERIES
REV2.0 May 2017 – EN/EU-USA-Canada
1.
INTRODUCTION .................................................................................................
3
2.
BEFORE YOU BEGIN ...........................................................................................
4
2.1
PRODUCT FEATURES ................................................................................................
4
2.2
SAFETY INSTRUCTIONS .....................................................................................
5
3.
RULES, STANDARDS AND LEGAL REQUIREMENTS ..........................................
7
4.
MECHANICAL SPECIFICATION AND DRAWING .............................................
10
5.
ELECTRICAL SPECIFICATION .............................................................................
11
6.
INSTALLATION ......................................................................................................
12
6.1
MOUNTING .......................................................................................................
12
6.2
MOUNTING VARIANTS ....................................................................................
14
6.3
INSTALLATION SITE, MODULE ORIENTATION ...................................................
15
6.4
AVOIDING SHADE ..........................................................................................
16
6.5
ELECTRICAL LAYOUT .....................................................................................................
17
7.
OPERATIONS MANAGEMENT .......................................................................
22
8.
SERVICE .......................................................................................................................
24
9.
WARRANTY TERMS AND CONDITIONS ........................................................
24
10.
GENERAL ............................................................................................................
25
11.
NOTES ....................................................................................................................
26
1. Introduction
This operating manual is a customer document of the company Calyxo GmbH, based in Thalheim,
Germany. It describes how to handle Calyxo solar modules and construct solar fields using modules
made by Calyxo. Please read this operating manual carefully before you store, install
or handle the modules in any other manner. This manual includes safety instructions for using,
installing, mounting, wiring and storing Calyxo CdTe solar modules.
Calyxo CdTe solar modules allow you to transform the unlimited energy provided by the sun into
environmentally friendly electrical power. Please take note of all the following requirements and
instructions in order to be able to make full use of the performance capacity of Calyxo solar modules.
Ensure that the installation, operational and maintenance work is only undertaken by qualified
personnel having the specialist expertise described in this operating manual, are being familiar with this
operating manual and are aware of and observe the applicable regulations for occupational safety and
accident prevention.
Store this operating manual for future reference.
This manual exclusively applies to installations in Germany, Europe, USA and Canada. Prior to
installing Calyxo solar modules at any other location, please contact your distributor. Additional
guidelines and instructions or indication about country-specific information will be provided upon
request.
2. Before you begin
Introductory NOTES
This operating manual includes notations and symbols that make it easier for you to read this
document and which are intended to ensure that you are able to work safely with Calyxo solar
modules.
SYMBOLS FOR SAFETY INSTRUCTIONS
Possible danger, injuries or damage
Warning: dangerous electrical voltages
Important information
2.1 Product features
PROPER USE
Calyxo solar modules are used to generate electrical power in photovoltaic systems. To generate power,
the solar modules are attached to connectors and electrically connected to a control device such as an
inverter or a charge controller.
Calyxo solar modules are developed and constructed in keeping with the latest technological
developments. When used properly, in accordance with all of the instructions outlined in this operating
manual and in combination with regular maintenance, they guarantee the highest level of safety.
The operator is responsible for full compliance with the instructions for mounting, transporting, wiring,
storing, operating, cleaning and maintaining Calyxo solar modules outlined in this operating manual.
Any usage of Calyxo solar modules other than that described in this operating
manual is prohibited. Calyxo shall assume no liability for damage to or caused by
solar modules resulting from improper use.
DISCLAIMER
This manual only applies to the products in the CX series (CX1, CX3, CX3
pro
, CX4) made by Calyxo
GmbH. Calyxo does not assume any liability for damage caused by failure to comply with this
manual. Please note that the person setting up the system is responsible for wiring and dimensioning
the system as well as complying with all necessary safety guidelines during the layout planning and
installation processes. This manual does not provide a basis for liability on the part of Calyxo GmbH.
Calyxo GmbH shall only be liable in the context of contractual agreements or accepted warranties.
Calyxo shall not assume any responsibility extending beyond the functionality and safety of the
modules. Calyxo GmbH shall particularly not be held liable in cases of force majeure or external
influences over which Calyxo GmbH has no control. Please also observe the instructions for the other
system components that could be included in the solar power system. It may be necessary to generate
statics for the entire project. If this manual does not sufficiently answer your questions, please contact
your system suppliers. In the event of misinterpretation, inconsistencies or misunderstanding, the
German version of this limited warranty clause shall prevail. Information contained within is subject to
change without notice.
Further information is available on our website: www.calyxo.com.
2.2 Safety instructions
ELECTRICAL SYSTEMS
Solar modules generate electric current and voltage even at low levels of illumination. Physically
disconnecting a closed electrical circuit could cause electrical voltage and currents, such as electric arcs
to arise. These could result in life-threatening injuries. The risk increases when several modules are
connected. Requirements for special installations or locations - Photovoltaic (PV) power systems- must
be observed.
• Cover the solar module with opaque material during the entire assembly process. This is the only
way to ensure that the modules are reliably de-energized.
• All guidelines and safety instructions that apply to the installation of electrical devices and
systems e.g. IEC60364 -7-712 , must be observed.
• Installation shall be in accordance with the National Electrical Code, ANSI/NFPA 70 (in the US) and with CSA
C22.1, Safety Standard for Electrical Installations, Canadian Electrical Code, Part I (in Canada).
• The extra-low voltage range is exceeded for module or phase voltages of over 120 V. Take the
necessary safety and precautionary measures.
• Do not insert any electrically conductive parts into the plugs or junction box. Do not touch the
contacts or exposed terminals.
• Keep children and unauthorized persons away from the modules.
• In the event of malfunctions or damage to installed modules, always contact your installer or the Calyxo After
Sales service (see ‘Troubleshooting’).
• Immediately take damaged solar modules (such as ones with broken glass) out of operation.
• Do not disconnect the plugs under load.
• Wear electrically rated PPE when working on interconnected modules or system components.
Please inform yourself about actual or additional information on handling electrical systems, and about
the regulations of your local energy supplier.
WARNING!
Danger of death due to electric shock!
PRODUCT PROTECTION
Protect the modules from scratches and other damage, especially impact at the edges and improper
temporary storage.
Do not submit the module surface to any mechanical stress. Do not stand on the modules. Do not drop
or place any objects on the modules.
Only make changes to the modules that have been previously confirmed by Calyxo in writing. Do not
carry out any additional drilling (for example, for fasteners) on the solar modules. Do
not under any circumstances open the splash-proof junction box.
Never use light concentrators (such as mirrors or lenses or any other means to artificially concentrate
light) to increase the power output of the modules. Doing so can damage the modules and shall render
the extended warranty void.
TRANSPORT AND STORAGE
Transport the module in its original packaging through to installation.
Use a glass suction cup to remove and transport the module, or hold the module by the edges. You need
to carry the module upright across longer distances.
Do not under any circumstances lift or move the module by the connecting cables or the junction box!
Store the module securely in cool and dry rooms. The packaging is not weather-resistant! Do not
rest the module unprotected on its edges. Doing so can damage the module.
3. Rules, standards and
legal requirements
APPLICABLE RULES/GENERAL SAFETY INSTRUCTIONS
The rules and instructions below will help you handle Calyxo solar modules safely. They provide an
overview, without making any exclusive claim to completeness, of the most important aspects of safely
working with Calyxo solar modules. They do not in any way replace expert instruction
or training. Please inform yourself prior to beginning work of the current national or regional regulations
on occupational safety and accident prevention.
The accident presentation regulations ‘Fundamentals of prevention’ (BGV A1) and ‘Construction work’
(BGV C22), especially the provisions on fall protection, ‘Electrical systems and equipment’ (BGV A3), as
well as the respectively applicable security regulations, guidelines and data sheets on occupational
safety published by professional associations need to be upheld.
HANDLING GLASS
Glass is a durable, long-lasting material. Handling glass requires complying with several basic rules and
guidelines. The key to safely handling glass is correctly selecting and using personal protective
equipment. Always ensure your own safety and wear safety goggles, safety shoes and cut-resistant
gloves. Gauntlet gloves protect your forearms. You need to wear them when you are wearing short-
sleeved clothing.
Since the modules consist mainly of glass, they need to be handled with corresponding caution. Before
transporting the modules, ensure that the transport route is clear and that the mounting location of the
solar modules is easily accessible. When using a hand vacuum for transport, ensure that the sealing
surface of the hand vacuum is clean, dry and free of damage in order to ensure sufficient holding force.
If you are carrying the modules by hand, ensure that you have a good grip on the modules and that your
gloves are clean and dry. In order to guarantee safe mounting, act in keeping with the national
regulations on occupational safety and accident prevention. Wear suitable protective work wear (such as
protective footwear and cut-resistant gloves) to prevent injuries.
Failure to comply with safety regulations may lead to damage and injury!
WARNING!
Danger of being cut by broken glass! Risk of injury from falling modules!
Additional information on handling glass is available from sources such as the DGUV (German Social
Accident Insurance) or the German Federal Flat Glass Association.
• DGUV-SI 8027 Safely handling broken glass
• BGI 5084 Glass and window work
• TRLV-2006 ‘Technical regulations for the use of glazing with linear supports’
• TRPV-2006 ‘Technical regulations for the use of glazing with punctual supports’
• Wear safety glasses (ANSI Z87.1-2003) and cut-resistant gloves when working on non-interconnected modules
or systems
WORKING AT HEIGHTS
Calyxo solar modules are suitable for assembly at ground level or installation on rooftops. Ensure that
the substructure is correspondingly designed for local wind and snow loads in accordance with DIN
1055-4 (2007) and 1055-5 (2005). Ensure that the regionally or locally applicable building regulations are
upheld. Comply at all times with the BVG C 22 regulations of the German Builder’s Union for accident
prevention at construction sites.
If you intend to install the modules on a rooftop or at a height, observe the specialist regulations set
out by the roofing trade. Ensure proper fall protection, since falls from heights are the most common
cause of fatal workplace accidents. Ensure that the modules can be safely transported with protection
from the ground-level unloading site to the mounting location on the rooftop.
• BGV C 22: Accident prevention at construction sites
• BGI 694 Handling ladders and steps
• BGI 720 Lifting platforms
If you have additional questions or require training for yourself or the people who are or will be
storing, assembling or installing the Calyxo solar modules, please contact your system supplier or
vendor.
Never place the module on its edges, even for a short period of time. This runs the risk
of damaging the edges of the module, even when no damage is visible. Never stand on
the modules, not even on their outsides or for a short period of time.
Doing so may damage the modules, generate voltage and cause damage that
could detract from the modules’ longevity.
WARNING!
Danger of unprotected falls from heights
ADDITIONAL INFORMATION FOR INSTALLERS
Ensure that the solar power system is installed, expanded, changed and kept in good operating
condition in accordance with all applicable laws and regulations as well as the generally recognized
national regulations for technology. The products must be installed by a licensed electrician in
accordance with the applicable electrical code (i.e. the NEC for the USA and CEC for Canada).
After installation, hand over the operating manual as well as the corresponding installation
documentation (construction drawings, site plans, wiring diagrams, data sheets on components,
measurement and test reports such as VDE 0126-23 , DIN EN 62446 and so on) to the respective
operator of the solar power system. Inform the operator that this manual is part of the product and is to
be kept for the duration of the system’s service life.
ADDITIONAL INFORMATION FOR OPERATORS
Request documentation, an acceptance report and an inspection report for the PV system with the
minimum requirements set out by IEC (DIN EN) 62446 or VDE 0126-23 from the installer.
Store these reports together with this manual for the duration of the module’s service life. Without
presenting these documents, especially the inspection or commissioning report in accordance with the
above standards, the guarantee or warranty (in accordance with PAS-11-05-0173-EN) shall not apply.
Pay particular attention to the ‘Troubleshooting’ and ‘Cleaning and maintenance’ sections. For
information on the formal requirements for solar power systems, please refer to your system suppliers.
Prior to installing the solar power system, make sure to inform yourself of the guidelines and approval
requirements set out by the relevant local authorities and energy suppliers. To protect your own
interests, please obtain the required approvals from authorities as well as the necessary contracts with
energy suppliers. We recommend that you secure your solar power system against natural hazards (such
as lightning strikes).
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