Sharp ND-255QCS User Manual

INSTALLATION AND USER MANUAL

FOR SHARP PHOTOVOLTAIC MODULES

ND-255QCS / ND-250QCS / ND-245QCS

ND-250QCJ / ND-245QCJ / ND-240QCJ

ND-Q250F7 / ND-Q245F7

IMPORTANT SAFETY INSTRUCTIONS

PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING OR USING THE MODULES.

PLEASE PASS ALONG THIS MANUAL TO YOUR CUSTOMER.

A) GENERAL MANUAL

Ver. 6.0U _ Sep 6, 2012

A-1. INTRODUCTION

Thank you for choosing SHARP photovoltaic (PV) module. This
Installation Manual contains essential information for electrical and
mechanical installation that you must know before installing SHARP
photovoltaic modules. These modules are listed to standard UL 1703.
This Manual also contains safety information you need to be familiar with.
All the information described in this Manual is the intellectual property of
SHARP and is based on the technologies and experience that have been
acquired and accumulated over the long history of SHARP. This Manual
does not constitute a warranty, expressed or implied. SHARP does not
assume responsibility and expressly disclaims liability for loss, damage, or
expense arising out of or in any way connected with installation, operation,
use or maintenance of PV modules. No responsibility is assumed by
SHARP for any infringement of patents or other rights of third parties that
may result from use of PV modules. SHARP reserves the right to make
changes to the product, specifications or Installation Manual without prior
notice.

A-2. GENERAL INFORMATION

(INCLUDING WARNING AND SAFETY)

The installation of PV modules requires a great degree of skill and should
only be performed by qualified licensed professionals, including licensed
contractors and licensed electricians. Please be aware that there is a serious
risk of various types of injury occurring during the installation including the
risk of electric shock. These SHARP PV modules are equipped with a
permanently attached special cable assembly for ease of installation which
does not require special assembly.

< GENERAL WARNING >

1. PV modules are heavy. Handle with care.

2. Before you attempt to install, wire, operate and maintain the PV
module, please make sure that you completely understand the
information described in this Installation Manual.

3. Contact with electrically active parts of a PV module such as terminals
can result in burns, sparks and lethal shock whether the PV modules
are connected or not.

4. PV modules produce electricity when sufficient sunlight or other
light source illuminates the module. When modules are connected
in series, voltage is cumulative. When modules are connected in
parallel, current is cumulative. PV systems can produce high voltage
and current which could present an increased hazard and may cause
serious injury or death.

5. Do not connect PV modules directly to motor loads. Variation in PV
module output power as a function of solar irradiance may damage
directly-connected loads. For example,

1: In the case of a brushless motor, the lock function may become

active and the motor may be damaged;

2: In the case of a brush type motor, the coil may be damaged.

6. Always use gloves when handling the module, never touch the glass
surface with bare hands.

< GENERAL SAFETY >

1. Wiring and grounding method of the frame of arrays shall comply with
national, regional and local codes, laws and standards.

2. PV modules should be installed and maintained by qualified personnel.
Only installation/service personnel should have access to the PV
module installation site.

3. Keep children away from PV modules.

4. Prior to installation, do not store modules outdoors or in a damp
environment to prevent glass from damage due to white efflorescence.

5. When PV modules are installed on roofs or any other structures
above ground, appropriate safety practices should be followed
and appropriate safety equipment should be used in order to avoid
possible safety hazards. Note that the installation of PV modules on
some roof types may require the addition of fireproofing, as required
by local building/fire codes.

6. Roof mounted PV modules are to be mounted over a fire resistant roof.

7. Only PV modules with the same cell size should be connected in series.

8. Follow all safety precautions of other components used in the system.

9. In order to avoid risk of injury or electrical shock, do not allow anyone
to handle damaged PV modules if the person is unqualified or has
limited knowledge of PV modules. Place defective PV modules in
cartons so PV cells are completely shaded, because a defective PV
module or module with broken glass may generate power even if it is
removed from the system.

10. Avoid uneven shade on the PV module surface. Shaded cells may
become hot (“hot spot” phenomenon) which may result in permanent
damage to the module (e.g., solder joints may peel off).

11. Do not clean the glass surface with chemicals. Do not let water stay on
the glass surfaces of PV modules for a long time. This creates a risk of
permanent damage to the glass, such as white efflorescence, otherwise
known as “glass disease,” which may cause reduced power output.

12. To avoid dirt accumulation or white efflorescence due to water
accumulation, do not install PV modules horizontally (flat).

13. In case of snow build up, snow would be slide down easier on the
module than other parts of the roof. When snow suddenly slide and
fall off the module’s surface, it may fall to under the roof and reach
nearby areas. Ensure that the installment of the modules would not
cause any damage to objects (carport, bicycle, entrance) nearby.
Apply appropriate safety measures and/or safety equipments (e.g.
snow stopper) when necessary.

14. Do not expose PV modules to sunlight concentrated with mirrors,
lenses or other means.

15. Turn off inverters and circuit breakers immediately, should a problem occur.

16. The maximum open circuit voltage must not be greater than the
specified maximum system voltage. Voltage is proportional to the
number of PV modules in series and is affected by weather conditions.
For strings connected in parallel take proper measures to block
reverse current flow.

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Installation Manual for PV Modules

Ver. 6.0U _ Sep 6, 2012

< HANDLING SAFETY >

1. Do not expose the PV module to excessive loads on the surface of the
PV module or twist the frame. The glass may break.

2. Do not stand or step on the PV module. The glass may be slippery,
and there is a risk of injury or electric shock if glass is broken.

3. Do not hit or put excessive load on the glass or back sheet. PV cells
may break.

4. To avoid damage to the back sheet, do not scratch or hit the back sheet.

5. To avoid damage to the terminal box and electricity leakage or shock,
do not hit the terminal box; do not pull the interconnect cables; do not
scratch the interconnect cable.

6. Avoid the connector from scratching or impacting the back sheet of the
module.

7. Install connector such that it is not exposed to direct sunlight.

8. Do not twist the interconnect cable excessively.

9. Never touch the end of the interconnect cables with bare hands when
the module is illuminated. Cover the surface of module with cloth or other
sufficiently opaque material to block the module from incident light and
handle the wires with insulated gloved hands to avoid electric shock.

10. Do not drill holes in the frame. It may compromise the frame strength
and cause corrosion of the frame.

11. Do not scratch the anodized coating of the frame (except for grounding
connection). It may cause corrosion of the frame or compromise the
frame strength.

12. Do not loosen or remove the screws from the PV module. It may
compromise the strength of the PV module and cause corrosion.

13. Do not touch the PV module with bare hands. The frame of the PV
module has sharp edges and may cause injury. Wear suitable gloves,
such as leather gloves with padding in the palm and finger areas.

14. Do not drop the PV module or allow objects to fall on the PV module.

15. Do not lift the PV module by only one side. The frame may bend.
Always use two hands to lift and carry the PV module on the long side
of the frame.

16. Some PV modules incorporate one or more support bars on the back
of the module. Do not mount or carry the PV module using the support
bar(s) on the back of the module.

< INSTALLATION SAFETY >

1. Always wear protective head gear, insulating gloves and safety shoes
(with rubber soles).

2. Keep the PV module packed in the carton until installation.

3. Do not touch the PV module unnecessarily during installation. The
glass surface and the frame may be hot. There is a risk of burns and
electric shock.

4. Do not work in rain, snow or windy conditions.

5. Due to the risk of electrical shock, do not perform any work if the
terminals of the PV module are wet.

6. Use insulated tools and do not use wet tools.

7. When installing PV modules, do not drop any objects (e.g., PV
modules or tools).

8. Make sure flammable gasses are not generated or present near the
installation site.

9. Insert interconnect connectors fully and correctly. Check all connections.

10. The interconnect cable should be securely fastened to the module
frame, the mounting racking or in a raceway to prevent movement
of the interconnect cable over time. Cable support should be done in
a way to avoid the connector from scratching or impacting the back
sheet of the module.

11. Do not touch the terminal box and the end of the interconnect cables
(connectors) with bare hands during installation or under sunlight,
regardless of whether the PV module is connected to or disconnected
from the system.

12. Do not unplug a connector if the system circuit is connected to an
operating load.

13. Do not work alone (always work as a team of 2 or more people).

14. Wear a safety harness when working above the ground.

15. Do not wear metallic jewelry which may conduct electricity and enable
electric shock during installation.

16. Do not damage the back sheet of PV modules when fastening the PV
modules to a support by bolts.

17. Do not damage the surrounding PV modules or mounting structure
when replacing a PV module.

18. Use UV resistant cable ties or other wire management hardware to
secure the interconnect cables. Drooping cables may cause various
problems, such as leading to electrical shorts.

19. Take proper measures for preventing the laminate (consisting of
encapsulant, cells, glass, back sheet, etc.) from dropping out of the
frame in case the glass is broken.

20. Cables shall be located so that they will not be exposed to direct
sunlight in order to prevent degradation of the interconnect cables.

21. In case of extreme snow build-up, the weight of the snow may causes
the module’s frame to deform. Take appropriate measures to minimize
any possible resulting damage.

22. It is recommended to install the PV module with the junction box at the
highest point.

A-3. PV MODULE COMPONENTS

A-4. TILT ANGLE SELECTION

The tilt angle of the PV module is measured between the surface of the
PV module and a horizontal ground surface. The PV module generates
maximum output power when it faces the sun directly. Five (5) degrees or
more is recommended for the tilt angle (see A-6 Maintenance).
For standalone systems with batteries where the PV modules are
attached to a permanent structure, the tilt angle of the PV modules should
be selected to optimize the performance based on seasonal load and
sunlight. In general, if the PV output is adequate when irradiance is low
(e.g., winter), then the angle chosen should be adequate during the rest
of the year. For grid-connected installations where the PV modules are
attached to a permanent structure, PV modules should be tilted so that the
energy production from the PV modules will be maximized on an annual

basis.

A-5. ELECTRICAL INSTALLATION

To ensure proper system operation and maintain the warranty, be
careful to observe the correct cable connection polarity (Figure 1) when
connecting the modules to a battery or to other modules. If not connected
correctly, the bypass diode(s) could be destroyed. All PV modules must
be grounded by electrical connection of the module frames to ground.
Care must be taken to arrange the system ground so that the removal of
one module from the circuit will not interrupt the grounding of any of the
other modules.

Cable characteristics

Cable category : PV Wire as described by UL Subject 4703
Cable size : 4mm

2

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Installation Manual for PV Modules

Ver. 6.0U _ Sep 6, 2012

For grounding, each PV module has a hole in the frame for either a bolt,
nut and washer, a ground lug fastened by bolt or screw, or an appropriate
screw (hardware not provided). Installation for wiring and grounding
method shall be in accordance with national, regional and local codes,
laws, standard, and the relevant instructions below. In a connection of this
type, the hardware (such as a star washer) must score the frame surface
to make positive electrical contact with the frame. The ground wire must
not be smaller than No.12 AWG.

The National Electrical Code (NEC) 690.33 requires that connectors are
installed in a readily accessible location, circuits operating at over 30
volts, shall require a tool to open. PV module’s connectors comply with
the NEC corresponding section.

Grounding

(1) Grounding Using Existing Ground Hole (Figure 2, GBL-4DBT)

1. Place Grounding lug (GBL-4DBT, Ilsco corp, E34440) onto the frame,
making sure that the #8-32 or #10-32 ground bolt (Material; stainless
steel) straddles the grounding hole.

2. Thread the lock nut (Material; stainless steel) and tooth washer onto
the end of the bolt, tighten the nut. Recommended torque is between

2.0 and 2.2 Nm.

3. Insert the grounding wire into the lug. The grounding conductor wire
should be sized according to national, regional and local codes, laws,
and standards.

4. Fix the grounding wire by tightening the wire binding screw. This will
terminate the wire.

Please contact ”Ilsco corp.” about detail information of “GBL-4DBT”.

(2) Grounding Using Existing Ground Hole (Figure 3, 1954381-2)

The grounding clip (SolKlip grounding Clip Assemblies 1954381-2,
Tyco electronics corp., E69905) assembly consists of a slider, base and
#8-32 screw and hex nut (screw and hex nut are parts in component of
1954381-2).

1. Place the grounding onto the frame, making sure that the screw
straddles the grounding hole.

2. Thread the hex nut onto the end of the screw, tighten the nut.
Recommended torque is between 2.0 and 2.2 Nm.

3. Insert the grounding wire into the wire slot. Press down on both ends
of the wire (the wire slot will cause the wire to form a slight curve).
The grounding conductor wire should be sized according to national,
regional and local codes, laws, and standards. Note that the TYCO
SolKlip 1954381-2 only accepts wire sizes 10 -12 AWG.

4. Manually, or using channel lock pliers, push the slider over the base
until it covers the base. This will terminate the wire.

Please contact “Tyco electronics corp.” about detail information of
“1954381-2”

A-6. MAINTENANCE

SHARP PV modules are designed for long life and require very little
maintenance. If the angle of the PV module is 5 degrees or more, normal
rainfall is usually sufficient to keep the module glass surface clean under
most weather conditions. Do not touch the glass since finger prints or
stains will easily mark the glass. For AR coating - Sharp modules utilize
special materials to increase energy harvest. Always use gloves when
handling the module, never touch the glass with bare hands. If dirt build­up becomes excessive, clean the glass surface with water only. If cleaning
the back of the module is required, take utmost care not to damage the
back side materials. In order to ensure proper operation of the system,
please check all wiring connections and the condition of the wire insulation
periodically.

SERIES WIRING (VOLTAGE ADDITIVE)

PARALLEL WIRING (CURRENT ADDITIVE)

Figure 1

Figure 1

Wire Binding Screw

Figure 2 (Ilsco, GBL-4DBT)

Figure 3 (Tyco Electronics Corp. 1954381-2)

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Installation Manual for PV Modules