Evergreen Solar ES-C-70-fa5, ES-C-120-fa2, ES-C-110-fa2, ES-C-80-fa5, ES-C-115-fa4 Safety, Installation, And Operation Manual
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ELECTRICAL EQUIPMENT — CHECK WITH YOUR INSTALLER
Evergreen Solar ES-C Series photovoltaic (PV, solar electric) panels are designed to produce DC electrical energy from light. This manual contains
important safety, installation and operating information with which you should be familiar before using Evergreen Solar ES-C Series panels.
This Manual is valid in North America only
(ETL listed; conforms to UL Standard 1703)
3190157
ES-C Series Photovoltaic Panels
Safety, Installation and Operation Manual
Limited Warranty
Copyright © 2009 Evergreen Solar, Inc.
General Information
• All installation and safety instructions should be understood before attempting to install, wire, operate and maintain
the panel.
• When installing, observe all local, regional, national and international statutory regulations, guidelines, norms and
code requirements.
• Installation or maintenance should only be performed by qualied professionals.
• Panels produce voltage even when not connected to an electrical circuit or load. Panels produce nearly full voltage
when exposed to as little as 5% of full sunlight, and both electrical current and power increase with light intensity.
• Panels can produce higher output than the rated specications.
• Industry standard rated specications are made at conditions of 1000W/m2 irradiance and 25°C (77ºF) solar cell
temperature. Colder temperatures can substantially increase voltage and power.
• Ensure that panels are only subjected to ambient temperatures in the range -40 to +80°C (-40 to +176°F).
• Reection from snow, water or other surfaces can increase light and therefore increase both the current and power
generated by the panel.
• Do not articially concentrate light on the panel.
• Panels are intended for outdoors, land-based applications only. Panels are not intended for indoor use.
• Excluded applications also include, but are not limited to, installations where panels come into contact with salt
water or where likely to become partially or wholly submerged in fresh or salt water, examples of which include
boats, docks and buoys.
• Use only equipment, connectors, wiring and support frames suitable for use in a solar electric system.
• Follow all safety precautions of other used components.
• Each panel is marked with a serial number, including the date of manufacture and the manufacturing location.
Example: XXxxYYYYMMDDzzzzzzz
- XX = country code (49 for Germany, 01 for US, 86 for China)
- xx = manufacturing building code, can be 01 or higher
- YYYY = year, MM = month, DD = day
- zzzzzzz = serial number
Handling Safety
• Do not use the junction box to hold or transport the panel.
• Do not stand or step on the panel.
• Do not drop panel or allow objects to fall on panel.
• Do not damage or scratch the rear surface of the panel.
• Avoid setting the panel down hard on any surface, particularly when placing it on a corner.
• Do not disassemble, modify or adapt the panel or remove any part or labeling installed by Evergreen Solar.
Doing so will void the warranty.
• Do not drill holes in the frame or glass of the panel. Doing so will void the warranty.
• Do not apply paint or adhesive to the rear surface of the panel.
• Never leave a panel unsupported or unsecured.
• Panels are constructed with tempered glass, but must still be handled with care.
• A panel with broken glass or torn back-skin cannot be repaired and must not be used since contact with any
panel surface or the frame can produce electrical shock.
• Broken or damaged panels must be handled carefully and disposed of properly. Broken glass can be sharp and
cause injury if not handled with the appropriate protective equipment.
• Work only under dry conditions, and use only dry tools. Do not handle panels when they are wet unless wearing
the appropriate protective equipment.
• When storing un-connected panels outside for any length of time, always cover panels which have the glass
facing down to stop water collecting inside the panel and causing damage to exposed connectors.
1
Installation Safety
• Keep children away from the system and panels when installing.
• Do not carry out installation work when there are strong winds.
• When installing panels above ground, avoid any possible falling or other safety hazards by following appropriate
safety practices and using required safety equipment.
• Solar electric panels have no on/off switch. Panels can be rendered inoperative only be removing them from
light, or by fully covering their front surface with an opaque material, or by working with panels face down on
a smooth, at surface.
• When working with panels in light, follow all applicable regulation regarding working with live electrical
equipment.
• Do not touch electrical terminals or the ends of any wire while the panel is exposed to light or while installing
the panel.
• Do not wear metallic jewelry while performing mechanical or electrical installation.
• Never open electrical connections or unplug connectors while the circuit is under load.
• Contact with electrically active parts of the panels, such as terminals, can result in burns, sparks and lethal
shock whether the panel is connected or disconnected.
• Always use insulated tools and rubber gloves that are approved for working on electrical installations.
Fire Safety
• Refer to your local authority for guidelines and requirements for building or structural re safety.
• The roof construction and installation may affect the re safety of a building; improper installation may contribute
to hazards in the event of re.
• For roof application, the panels should be mounted over a re resistant covering rated for the application.
• It may be necessary to use components such as earth ground fault circuit breakers, fuses and circuit breakers.
• Do not use panels near equipment or locations where ammable gases can be generated or can collect.
Electrical Installation –General Recommendations
• Avoid all electrical hazards when installing, wiring, operating and maintaining a panel.
• If the total DC system voltage exceeds 100V, the system must be installed, commissioned and maintained by a
qualied professional.
• Contact with a DC voltage 30V or more is potentially hazardous.
• Do not use panels of different electrical or physical congurations in the same system.
• The maximum open circuit voltage of the system must not be greater than the specied maximum system voltage
for the panel.
• When reverse currents can exceed the value of the maximum protective fuse marked on the back of the panel,
a properly rated and certied over-current device (fuse or circuit breaker) must be connected in series with each
panel or string of panels.
• The rating of the over-current device shall not exceed the value of the maximum protective fuse marked on the
back of the panel.
• Panels with a suspected electrical problem should be returned to Evergreen Solar for inspection and possible
repair or replacement as per the warranty conditions provided by Evergreen Solar.
Panel Wiring – Cables and Bypass Diodes Installation
• ES-C panels come with a conduit ready junction box designed to be used with standard wiring, watertight strain
relief ttings and conduit connections.
• To open the junction box, loosen the two captive screws in the cover. The cover is designed to remain open
during wiring and cannot be removed from the panel.
• The junction box has a gasket that ensures the waterproof integrity. Check that the gasket is in the right position
before securing the junction box. Do not over-tighten the cover screws.
2Valid from 1st September 2009 / IMW-ES-C_US_010909_ETL
• The junction has four (4) ½” knockouts; two (2) on the bottom and
one on each side. Use a tool such as a at screwdriver to remove
the knockouts. Remove only the required knockouts by hitting the
perimeter and not the center as shown in Figure 1.
• It is not recommended to run wires through the knockouts without
using a watertight strain relief or conduit.
• Use the appropriate ½” PG or NPT watertight cable strain relief
depending on your installation and the cable diameter. Table 2 shows
some of the ½” NPT options.
• Knockouts are designed to attach to any standard ½” rigid or exible
conduit.
• Steel or nylon lock nuts can be used. Make sure lock nuts are properly tightened to avoid ingress of humidity or
water inside the junction box.
• Cables used to wire ES-C panels may be single or two conductors, from 14 AWG up to 10 AWG gauge.
• For cables exposed outdoors, use only sunlight resistant cables rated for 90ºC and wet locations. Table 1 shows
the outdoor sunlight resistant cable options.
• For cables installed in conduit, types THWN-2, RHW-2 and XHHW-2 are recommended.
Wire Type Insulation (Jacket) Characteristics Watertight Strain Relief
USE-2 XLP/XLPE cross-linked
polyethylene
Underground
service entrance
1
/2” NPT with 1 or 2 round
holes. Steel or nylon lock nut.
TC (Tray) Thermoplastic (PVC, Nylon).
XLP/XLPE for conductors.
2-conductor,
direct burial
1
/2” NPT with 1 oval hole.
Steel or nylon lock nut.
PV Wire XLP/XLPE cross-linked
polyethylene
Thicker jacket per UL4703
Ungrounded arrays,
Transformerless inverters.
1
/2” NPT with 1 round hole.
Steel or nylon lock nut.
Table 1. Sunlight 90ºC Wet Resistant Cables.
Manufacturer Part Number
(Black & Gray)
Opening
(Cable range)
Cable Type Fit
Hummel CD16NS-01 &
CD16NS-02
One oval, 0.24” x 0.55” TC (Tray) AWG #14/2,
12/2 &10/2
Hummel CD13NR-BK &
CD13NR-GY
One round, 0.2” to 0.35”Ø PV Wire AWG #14,12 &10
USE-2 AWG #14,12 & 10
Hummel CD13N4-BK &
CD13N4-GY
Two round, 0.2” Ø USE-2 AWG #14,12 & 10
Heyco 3231 & 3232 One round, 0.17” to
0.45ӯ
PV Wire AWG #14,12 &10
USE-2 AWG #14,12 & 10
Table 2. Watertight Strain Reliefs
• The panel contains factory installed bypass diodes located inside the junction box. These diodes are designed
to protect the panel against partial shading conditions and should not be removed.
• Diodes can be easy replaced in the eld if necessary. Use only Super Barrier type diodes SBR10U45SD1, 45V,
10A or equivalent. Diodes should be installed as shown in Figure 2.
Copyright © 2009 Evergreen Solar, Inc.3
Figure 1. Knockout Removal
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