Loading...
The URL can be used to link to this page
Your browser does not support the video tag.
13030126
CITY OF CUPERTINO BUILDING PERMIT BUILDING ADDRESS: 7719 CARRIAGE CIR CONTRACTOR: SUN WORK PERMIT NO: 13030126 RENEWABLE ENERGY PRODUCTS OWNER'S NAME: RAVI ALLADI ` PO BOX 60250 DATE ISSUED: 03/25/2013 OWNER'S PHONE:. 4083804018 PALO ALTO, CA 94306 PHONE NO: (650) 520-9918 .::. LICENSED CONTRALTO i'S DECLARATION JOB DESCRIPTION: RESIDENTIAL U COMMERCIAL License Class C y 6 . Lie. # / 2 6 7' — Sc,wt/•�k Contractor 6v,s.Date` Zr I hereby affirm that I am licensed under. the provisions of Chapter 9 (commencing with Section 7000) of Division 3 of the. Business &Professions Code and that my license is in full force and effect. I hereby affirm under, penalty of perjury one of the following two declarations: I have and will maintain a certificate of consent to self -insure for Worker's Compensation, as provided for by Section 3700 of the Labor Code, for the performance of the work for which this permit is issued. I have and will maintain Worker's Compensation,Insurance, as provided for by Section 3700 of the Labor Code, for the performance of the work for which this permit is issued. APPLICANT CERTIFICATION I certify. that I have read this application and state.thatthe above information is correct. I agree to comply with all city and county ordinances and state laws relating to building construction, and hereby authorize representatives of this city to enter upon the above mentioned property for inspection purposes. (We) agree to save indemnify and keep harmless the City of Cupertino against liabilities, judgments, costs, and expenses which may accrue against said City in consequence of the granting of this permit. Additionally;the applicant understands and will comply with all non -point source regulations per the Cupertino Municipal Code, Section 9.18. y� Cionafiirr. — .f .Dat. INSTALL 16 PANELS TO ROOFTOP 6.0 KW *SEE NOTES Sq. Ft Floor Area: I Valuation: $11600 APN Number: 35906048.00 1 Occupancy Type: PER12T EXPIRES IF WORK IS NOT STARTED IT W1 DAYS OF PERMIT ISSUANCE OR 180 S ROM LAST CALLED INSP C //ON. Issued by: Date:3 .WC RE -ROOFS: All roofs shall be inspected prior to any roofing material being installed. If a roof is installed without first obtaining an inspection, I agree to remove all new materials for inspection. ❑ OWNER-BUILDER'DECLARATION I_ hereby affirm, thatl am exempt from the:Contractor's License Law for one of Signature of Applicant: Date; the:following two reasons:. ALL ROOF COVERINGS TO BE CLASS "A" OR BETTER I, as owner of the property, or my employees with wages as their sole compensation, will do the work, and the structure is:not intended or'offered for sale (Sec.7044, Business & Professions Code) I, as owner of the property, am exclusively contracting with licensed contractors to HAZARDOUS MATERIALS DISCLOSURE construct the project (Sec.7044, Business & Professions Code). I have read the hazardous materials requirements under Chapter 6.95 of the California Health & Safety Code, Sections 25505, 25533, and 25534. I will I hereby affirm. under penalty of perjury one.of the following three maintain compliance with the Cupertino Municipal Code, Chapter 9.12 and the declarations: Health & Safety Code, Section 25532(a) should I store or handle hazardous I have and will maintain a Certificate oft, ons'ent to self -insure for Worker's material. Additionally, should I use equipment or devices which emii.bazardous Compensation, as provided for by Section 3700 of the Labor Code, for the air contaminants as defined by the Bay Area Air Quality Management District I performance of the work for which this permitis issued. will maintain compliance with the Cupertino Municipal Code, Chapter 9.12 and I have and will maintain Worker's Compensation Insurance, as provided for by the Health & Safety Code, Sections 25505, 25533, and 25534. Section 3700 of the Labor Code, for the performance of the work for which this 00 Owner or authorized agent: Date: l permit is issued. I certify that in the performance of the work for which this permit is issued, I shall not employ any person in any manner so as to become subject to the Worker's Compensation laws of California. If, aftermakingthis certificate of exemption, I CONSTRUCTION LENDING AGENCY become subject to the Worker's Compensation provisions of the Labor Code, I must I hereby affirm that there is a construction lending agency for the performance of. forthwith comply with such provisions 'or this permit shall be deemed revoked. work's for which this permit is issued (Sec. 3097, Civ C.) Lender's Name APPLICANT CERTIFICATION Lender's Address I certify that I have read this application and state that the above information is correct. I agree to comply with all city and:countyordinances and state laws relating to building construction; and hereby authorize representatives of this city to enter upon the above mentioned property for inspection purposes. (We) agree to save ARCHITECT'S DECLARATION indemnify andkeep harmless the Cityof Cupertino against liabilities, judgments, costs, and: expenses which may accrue against said City in consequence of the I understand my plans shall be used as public records. granting of this permit. Additionally,; the applicant understands and will comply with all non -point source regulations per the Cupertino Municipal Code, Section Licensed Professional 9.18. Signature Date CUPERTINO 1 -77 101 ALTERNATIVE ENERGY PERMIT APPLICATION COMMUNITY DEVELOPMENT DEPARTMENT • BUILDING DIVISION rr`` 10300 TORRE AVENUE • CUPERTINO, CA 95014-3255 v� (408) 777-3228 • FAX (408) 777-3333 • building aacupertino.org CARRIAGE CIRCLE \ AE PROJECT ADDRESS T q c . r� APN N 3 C C J_ 1 6 CP jj��q / OWNERNAME avo'SGpy� V(OM%�' All�d,� PH?NE V- ,. E-MAIL �Ni�, N �l�RG(•• N+A.%. �.�., STREET ADDRESSST''A)TE, ZIP FAX CONTACT NAME vYRiGt PH NE 6Coj S2o- q9r4 E-MAIL CUA4~11 . STREET ADDRESS S �� � ^ !� C:g ST.ATE, ZIP �� ,I v.��,.,,CA 9 q043 FAX ❑ OWNER ❑ OWNER -BUILDER ❑ OWNER AGENT XCONTRACTOR ❑ CONTRACTOR AGENT ❑ ARCHITECT ❑ ENGINEER ❑ DEVELOPER ❑ TENANT CONTRACTOR NAME 1220.6eM LICENSE NUMBER 420-nZ LICENSE TYPE L 4 6 BUS. LIC # COMPANY NAME nGJ�c Q N" E-MAIL /'r' O Sunwar4 • E! FAX STREET ADDRE S fro $ov 6DZSo CITY STATE, ZIP ? , Af4CA -9k306 PH NE bS'7S2o—'34, ARCHITECT/ENGINEER NAME LICENSE NUMBER BUS. LIC 9 COMPANY NAME E-MAIL FAX STREET ADDRESS CITY, STATE, ZIP PHONE USE OF ?9 SFD or Duplex ❑ Multi -Family STRUCTURE: ❑ Commercial PROJECT IN WILDLAND URBAN INTERFACE AREA ❑ Yes ❑ NO PROJECT IN FLOOD ZONE ❑ Yes ❑ No SOLAR PANELS ❑ ELECTRIC VEHICLE CHARGING STATION ❑ SOLAR WATER HEATING ❑ OTHER: FOR.SO/AR PANEL S: NUMBER OF PANELSIUNITS: / # KILOWATTS: I /� o b "T TOTAL VALUATIO 1 t 1 d ao DESCRIPTION OF WORK , YoCIL PU 'RECEIVED BY: `. By my signature below, I certify to each of the following: I am the property owner or authorized agent to act on the property owner's behalf. I have read this application and the information I have provided is correct. I have read the Description of Work and verify it is accurate. I agree to comply with all applicable local ordinances and state laws relating to building construction. I authorize representatives of Cupertino to enter the above -identified property for inspection purposes. Signature of Applicant/Agent: � V� Date: SUPPLEMENTAL INFORMATION REQUIRED OFFICE USE ONLY W ❑ OVER-THE-COUNTER a F U ❑ EXPRESS U W x ❑ STANDARD U - a ❑ LARGE y ❑. MAJOR PVApp_2012.doc revised 06120112 CITY OF CUPERTINO FFF FSTIMATOR — BUILDING DIVISION ADDRESS: 7719 carriage cic DATE: 03/25/2013 REVIEWED BY: Mendez APN: BP#: *VALUATION: 1$11,600 PERMIT TYPE: Building Permit PLAN CHECK TYPE: Alteration / Repair PRIMARY SFD or Duplex USE: PENTAMATION SOLAR-RES PERMIT TYPE: WORK install 16 panels, 4.0 gri.d tie to rooftop 5.0 kw SCOPE kd Xfech. Plan Check Plumb. Plait Check Elec: Plan Check vl-h. Permit Fee: Plumb. Permit Fee: Elec. Permit Fee: Other ttlech. Ins). Other Plumb Insp.IT—t— Other Elee. Insp. Rlech. Ins). Fee:, Plumb. Insp. Fee: Eke. Insp. Fee: NOTE: This estimate does not include fees due to other Departments (Le. Planning, Public Works, Fire, Sanitary Sewer District, School istrict etc). These fees are based on the Prefintina information available and are only an estimate. Contact the Dept for addn'1 in c FEE ITEMS (Fee Resolution 11-053 E . 711112.1 FEE QTY/FEE MISC ITEMS Plan Check Fee: $0.00 = # $219.00 Alternative Energy System IPHOTO- Photovoltaic System Suppl. PC Fee: Reg. OT 0.0 his $0.00 PME Plan Check: $0.00 Permit Fee: $0.00 Suppl. Insp. Fee:% Reg. 0 OT 0,0 hrs $0.00 PME Unit Fee: $0.00 PME Permit Fee: $0.00 Construction Tax. 4.dltninistrative .F(-,e: E) Work Without Permit? 0 Yes (j) No $0.00 Advanced Planning Fee: $0.00 Select a Non -Residential Building or Structure i Travel Documentation Fees: Strong Motion Fee: IBSEISILIICR $1.16 Select an Administrative Item Bldg Stds Commission Fee: IBCBSC $1.00 $2.16 $219.00� s — $221.16 Revised: 01 /01 /2013 PROJECT DETAILS: ARRAY PITCH: 18.50 (4:12) ARRAY FACING: 1800 (S) SITE LATITUDE: 37.310 (37019'N) TYPE OF STRUCTURE: residence ROOF CONSTRUCTION: 4:12 cross gable, 3/4" simple planks over 2x4" rafters, spaced 24" on center, 7' 6" maximum span AGE OF STRUCTURE: 42 years ROOFING TYPE: dimensional composition shingle AGE OF ROOFING: 12 years NUMBER OF STORIES: 1 EXPOSURE CATEGORY: B HOUSE ACCESS REQUIRED: yes, do conduit routed in attic CONTACT NAME: Ravishankar Alladi CONTACT PHONE NUMBER: (408) 380-4018 home (408) 643-5851 cell CUSTOMER NAME: Alladi, Ravishankar SITE ADDRESS: 7719 Carriage Circle, Cupertino, CA 95014 AUTHORITY HAVING JURISDICTION: City of Cupertino DATE: 20 March 2013 PROPERTY LINES: DrmR lTTmu- nl ITLj^mrr%/ AI^-rm'o- • The installation of the PV system shall conform to ------------------ J----------------------------------------- `----------------------- the requirements of the 2010 California Building Code and the 20/0 3alifornia Electrical Code, Article 690 and any other applicable articles or standards. COMM! t JJTY DW, BUILDING 6IVI 1 _ •Installation shall be provided by a California 140 ' 2013 API IR 2 5 Licensed Contractor (B, C-46 or C-10). Of nh ns a' she ifications MUST be kept at t • Buildings with utility services and a PV system eshall have a plaque or directory indicating the i °`�s`° `'o � +s-�fWfirrhio mal�ce an ° "- location of the service disconnecting means and the lo!> s or same, or to deviate t ova from the Building PV system disconnecting means. Official. 0 T' `� p{,=n Md specifications SHALL • Any solar structure that requires variation from the NO ?proval of the violation r setback or height restrictions of the R1 Ordinance nf a: 'i Cr'y 01 dinance or State Law. maybe allowed with a minor Residential Permit (per Section 19.28.090). Solar installations may not Fr 2�- result in privacy impacts, shadowing, intrusive noise or other adverse impacts to the surrounding area. n , CUPERTINO ,- 1301ding Department a PLOT PLANS MAR 2 5 2013 CUECKED BY F;>rVIE1AlI+U rOR CODE COMPLIANCE DATE Reviewed By: ------------------------------------------- 1-------------------- DATE o BLDG. DEFT. --------------------------------------------------- - Carriage Circle lunWroirkRenewablcts CA License No. 920732 PO Box 60250 Palo Alto, CA 94306 (650) 520-9918 (650) 350-4331 fax Project Drawing SYSTEM SIZE: 4.000 kWdc-stc I SYSTEM RATING: 3.170 kWac-field MODULE TYPE AND NUMBER: REC Solar REC-250-PE BLK (16) INVERTER TYPE AND NUMBER: KACO blueplanet 3502xi (1) DRAWING NUMBER: SW.0066.PD.A.01 I SCALE: 1:240 (1 inch = 20 feet) '/z" EMT conduit carrying 4, #10 conductors (2 ungrounded ac lir and equipment ground) and 1, 4 conductor (dc grounding electro Existing Main Service Panel CUSTOMER NAME: Alladi, Ravishankar SITE ADDRESS: 7719 Carriage Circle, Cupertino, CA 95014 AUTHORITY HAVING JURISDICTION: City of Cupertino DATE: 20 March 2013 FRONT OF HOUSE S1,111W01'�C Renewable Ener cts CA License No. 920732 PO Box 60250 Palo Alto, CA 94306 (650) 520-9918 (650) 350-4331 fax --`1-tie Solar Inverter with NEC- ,C Disconnect, mounted on exterior '/2" EMT conduit transitioning to 1/z" FMC conduit through the attic carrying 2, #10 AWG USE-2/ RHW-2 conductors (dc positive and grounded do negative) and 1, #10 AWG solid bare conductor (equipment ground), with penetration through the roof waterproofed using an EPDM- collared galvanized roof flashing Array of 16, 250-watt Photovoltaic Modules, mounted using Unirac SolarMount standard rail attached to rafters every 48" using lag screws, with STRUCTURAL LOAD CALCULATIONS: [As per ASCE 7-05, see Unirac design load worksheet for additional detail] Building height = 12 ft Building least horizontal dimension = 29 ft Exposure category = B Basic wind speed = 85 mph Roof pitch = 18.5 degrees Roof zone location = 2 — end zones Effective wind area = 10.9 sf Net design wind pressure = <8.4 psf, -23.2 psf> Topographic factor = 1 Adjustment factor for height and exposure = 1 Importance factor = 1 Design wind load = <8.4 psf, -23.2 psf> x 1 x 1 x 1 = <8.4 psf, -23.2 psf> Dead load = 2.6 psf Snow load = 0 psf Total design load, downforce case 1 = 2.6 psf + 0 psf = 2.6 psf Total design load, downforce case 2 = 2.6 psf + 8.4 psf = 11.0 psf Total design load, downforce case 3 = 2.6 psf + .75 x (0 psf + 8.4 psf) = 8.9 psf Total design load, uplift = .6 x 2.6 psf + -23.2 psf = -216 psf penetrations through the Per penetration area = 10.9 sf composition shingle flashed Point load, dead = 2.6 psf x 10.9 sf = 28,Ibs using EcoFasten Solar Point load, downforce = 11.0 psf x 10.9 sf = 120 lbs GreenF -bushed UPER-rR*tyad, uplift = -21.6 psf x 10.9 sf ==235166 aluminur ings and sealed u Building Daparment performe ymer Lag screw type = 5/16" x 4" SS bonding' MAR Z 5 2013 Embedded thread depth = 4" - 11/2" = 21/2" Rafter wood type = Douglas Fir —Larch REVIEWED FOR CODE COMIPIO { lag screw withdrawal cap. = lbs n = 6: drawal cap. = 2Y2 x 266 Ibsen = 665 Its Reviewed By �i� ter letails = 2x4", 24" on center, 7' 6" span SYSTEM SIZE: 4.000 kWdc-stc Site Drawing SYSTEM RATING: 3.170 kWac-field MODULE TYPE AND NUMBER: REC Solar REC-250-PE BLK (16) INVERTER TYPE AND NUMBER: KACO blueplanet 3502xi (1) DRAWING NUMBER: SW.0066.SD.A.01 I SCALE: 1:120 (1 inch = 10 feet) 2x4" interior walls with double top plates and studs 16" on center M 2x4" rafters spaced 24" on center with 7' 6" maximum span above 2x4" ceiling joists 2x4" exterior walls with double top plates and studs 16" on center 4x6" purlin beam CUSTOMER NAME: Alladi, Ravishankar SITE ADDRESS: 7719 Carriage Circle, Cupertino, CA 95014 AUTHORITY HAVING JURISDICTION: City of Cupertino DATE: 20 March 2013 0. I I ► I I; I I I I ;� k� - - -- ----- ---- ---- ----- 1----- 1---- -I-- F----1 I- t I I Sunwork Renewable Ener cts CA License No. 920732 4x4" post PO Box 60250 Palo Alto, CA 94306 (650) 520-9918 (650) 350-4331 fax 2x6" ridge beam with diagonal bracing to walls below 2x6" purlin with diagonal bracing to walls below 2x6" hip and valley rafters SYSTEM SIZE: 4.000 kWdc-stc CUPERTINO Building Depattrnent MAR 15 2013 EWEO FOR GORE COMPLIANCE Reviewed By: J Framing Drawing SYSTEM RATING: 3.170 kWac-field MODULE TYPE AND NUMBER: REC Solar REC-250-PE BLK (16) INVERTER TYPE AND NUMBER: KACO blueplanet 3502xi (1) DRAWING NUMBER: SW.0066.FD.A.01 I SCALE: 1:60 (1 inch = 5 feet) REC Solar REC-250-P Unirac top -mounting cl, 1/4" SS bolt and locking Unirac SolarMount star 3/8" SS bolt and lockini EcoFasten Solar comp EcoFasten Solar Greer 4 0 @ 941BONDING SEALANT 1. PRODUCT NAME GeoGreen 4500e Roof Bonding Sealant 2- MANUFACTURER: GEOCEL, LLC P.O. Box 398 Elkhart, IN 46515 USA Phone: (600)348.7615 Far: (800) 348-7009 www.GeocelUSAcom 3 PRODUCT DESCRIPTION: GeoGreen 45000 Roof Bonding Sealant is a premium Scypolyrrem onecomponent, proprietary, non -wont bonding sealant specificalN designed for roofing applicafiona and systems. The advanced technology of 45M Roof Sealant results n a product that immediately withstands ponding water while bonding to many common roofing substrates. Ad�enes To: Asphalt shingles, steel, concrete, EPDM, primed TPO, printed PVC, Hypalon (black onto, metal, wood, and other common building substrates Composition end Materiels: Proprietary, ran -solvent technology Grade: Gun grade consistency Rimer Not required on most surfaces. On TPO and PVC membrane applications, a primar is requred. Geocel recommends using45PTM Low VOC, TPO & PVC Printer. PackagirKS 10 fl. cL cartridge Colors: Black and white Lirritatio ns • Do rat use on unprimed TPO or PVC membranes • Do not use black 4600 Rod sealant on white EPDM • Do not use while 4500 Roof Sealant on black EPDM RarLs t Banefifs and Existing composition shingle, with single -point penetration sealed using a high-performance scypolymer ■ 2products in1- lap adhesive & scrim eeland bonding sealant (Geocel 4500, see Data Sheet) . No No additional adhesives or sealants needed . Rernainsfaxible _ in WorhswilhEPDM mermnbrenee,tapes, and patches 5/16" SS lag screw and bonded sealing washer ■ Mee UEM&NAHBguidellinae in Sells, non-flammable, non -solvent formulation ic Bmmuma:Far. IS CUPC7eOGLd Existing 3/4" simple plank decking anpdrlof,as RO. BDX age rdadhesive erBGr9 (.iildirtQ FJeurt, In Raa1308-7616 a16- Fax Wa%a48-7oW w.rw.BumaU9Aaom ! Existing 2x4" rafter i MAR 7 5 2013 yr` REVIEWED FOR CODE, COMPLIANGE Reviewed By. :-. ��•d /T CUSTOMER NAME: Alladi, Ravishankar SITE ADDRESS: 7719 Carriage Circle, Cupertino, CA 95014 AUTHORITY HAVING JURISDICTION: City of Cupertino DATE: 20 March 2013 S nWork Renewable Ener c:ts CA License No. 920732 PO Box 60250 Palo Alto, CA 94306 (650) 520-9918 (650) 350-4331 fax SYSTEM SIZE: 4.000 kWdc-stc Attachment Detail SYSTEM RATING: 3.170 kWac-field MODULE TYPE AND NUMBER: REC Solar REC-250-PE BLK (16) INVERTER TYPE AND NUMBER: KACO blueplanet 3502xi (1) DRAWING NUMBER: SW.0066.AD.A.01 I SCALE: 1:2 (1 inch = 2 inches) REC Solar REC-250-PE BLK Photovoltaic Modules (2 parallel source circuits of 8 in series) Y Y Y Y Y Y Y Y Y Y Y Y) Y Y Y Y --- -------------------------�-------'-------------'-------'------'------'------'----------- ................................................................................................................................. i '/2" EMT/FMC conduit: #10 AWG USE-2/RHW-2 positive #10 AWG USE-2/RHW-2 negative #10 AWG solid bare eq. ground J bonded to mounting rails and module frames Existing Zinsco KACO blueplanet 3502xi 100 A Single -Phase 240 V Grid -Tie Solar Inverter Main Service Panel , N L1 L2 DC+ DC- 240 Vac 2-pole Circuit Breaker 100 A n8................ M = UTILITY GRID CUSTOMER NAME: Alladi, Ravishankar SITE ADDRESS: 7719 Carriage Circle, Cupertino, CA 95014 AUTHORITY HAVING JURISDICTION: City of Cupertino DATE: 20 March 2013 (2) '/2" EMT conduit: #10 AWG THWN-2 line 1 #10 AWG THWN-2 line 2 #10 AWG THWN-2 neutral #10 AWG THWN-2 eq. ground S n ork Renewable Ener cts CA License No. 920732 ................................... 1 Integrated 600 Vdc 40 A 4-pole DC/AC Disconnect ' Integrated Ground -Fault 1 Protection Circuit w/ 1 A fuse - - '-------------------------� # 6 AWG THWN-2 GEC bonding do system to main building grounding electrode (ground rod) — PO Box 60250 Palo Alto, CA 94306 (650) 520-9918 (650) 350-4331 fax ELECTRICAL CALCULATIONS: [As per the 2010 revision of the California Electrical Code, pertinent articles cited below] PV Array Electrical Specifications: Pmp = 4000 W Maximum System Voltage [690.71 Vmp = 242V Imp 16.6 A Array nominal open circuit voltage = 299 V V O0__= 299 V Lowest temperature on record = -7°C IS0 17.7 A Open circuit voltage temperature coeff. =-.27%/°C Low temperature voltage correction coeff. = 1.09 Limit open circuit voltage = 299 V x 1.09 = 326 V (1) Maximum Circuit Current 1690.81 Array nominal short circuit current = 17.7 A Possible sustained irradiance coeff. = 1.25 Limit short circuit current = 17.7 A x 1.25 = 22.1 A Circuit 1 Allowable Continuous Current Conductor size = #10 AWG Conductor temperature rating = 90°C Base conductor ampacity [310.16] = 40 A Highest ambient temperature = 67°C Ambient temperature derating coeff. [310.16] = .58 Inverter Electrical Grouped current -carrying conductor count = 2 Specifications: Multiple conductor derating coeff. [310.15] =1 Pmax-ac = 3500 W Corrected ampacity = 40 A x .58 x 1 = 23.2 A Vmax do = 600 V Allowable continuous current = 23.2 A x .8 A = 16A Imax-dc = 28.0 A Vnom.ac = 240 V Circuit 2 Allowable Continuous Current Imax-ac = 16.0 A CUPERIT"tor size = #10 AWG o du�c�tQr temperature rating = 90°C Uilding del 156liductor ampacity [310.16] = 40 A Highest ambient temperature = 45°C MAR 2 5 2013 Ambient temperature derating coeff. [310.16] _ .87 Grouped current -carrying conductor count = 3 REVIEWED FOR CODE C0'1,A 41 g,r�onductor Berating coeff. [310.15] 1 Cd rFLl�ti6tttt ampacity = 40 A x .87 x 1 = 34.8 A Reviewed By :r!*§W continuous current = 34.8 A x .8 = 27 8 A SYSTEM SIZE: 4.000 kWdc-stc Electrical Drawing SYSTEM RATING: 3.170 kWac-field MODULE TYPE AND NUMBER: REC Solar REC-250-PE BLK (16) INVERTER TYPE AND NUMBER: KACO blueplanet 3502xi (1) DRAWING NUMBER: SW.0066.ED.A.01 I SCALE: N/A Labeling for DC Disconnect, engraved sun resistant placard mechanically attached to the front surface of the enclosure of the inverter -integrated do/ac disconnect with aluminum rivets Labeling for System Conduit, reflective outdoor sticker affixed at regular intervals to all do conduit runs CUSTOMER NAME: Alladi, Ravishankar SITE ADDRESS: 7719 Carriage Circle, Cupertino, CA 95014 AUTHORITY HAVING JURISDICTION: City of Cupertino DATE: 20 March 2013 Labeling for AC Disconnect, engraved sun resistant placard mechanically attached to the front surface of the enclosure of the inverter -integrated do/ac disconnect with aluminum rivets Labeling for Disconnect Switch, reflective outdoor sticker affixed to the right side of the inverter -integrated do/ac disconnect SunWork Renewable Ener US CA License No. 920732 PO Box 60250 Palo Alto, CA 94306 (650) 520-9918 (650) 350-4331 fax Labeling for Main Service Panel, engraved sun resistant placard mechanically attached to the front surface of the enclosure of the existing main service panel with aluminum rivets CUPERTINO 9ui'ding Department Labeling for Circuit Breaker, ref outdoor sticker affixed to the de MAR i 5 2013 face of the existing main service pane REVIEVVE"a t OR, CODE COMPLIANCE Reviewed By SYSTEM SIZE: 4.000 kWdc-stc Labeling Detail SYSTEM RATING: 3.170 kWac-field MODULE TYPE AND NUMBER: REC Solar REC-250-PE BLK (16) INVERTER TYPE AND NUMBER: KACO blueplanet 3502xi (1) DRAWING NUMBER: SW.0066.LD.A.01 I SCALE: 1:1 (1 inch = 1 inch) m 0 :->-> ENERGIZING LIFE TOGETHER pREC a` R 6555--0.t All measurements in inches REC240PE REC24SPE REC2SOPEO• Nominal Power-Pmpp(Wp) 235 240 245 250 255 260 Watt Class Sorting-(W) 0/+5 0/+5 0/+5 0/+5 0/+5 0/+5 Nominal PowerVottage-VH,,,(V) 29.5 29.7 30.1 30.2 30.5 30.7 Nominal PowerCurrent-Ir,,,(A) 8.06 8.17 8.23 8.30 8.42 8.50 - Open Circuit Voltage -Vdc(V) 36.6 -- 36.8 371 - 37.4 37.6 37.8 Short CircuitCurrent- Isc (A) 8.66 8.75 8.80 8.86 8.95 9.01 Panel Efficiency(%) 142 14.5 14.8 15.1 15.5 15.8 Analysed data demonstrates that 99.7% of panels produced have current and voltage tolerance of ±3 % from nominal values. Values at standard test conditions STC (airmass AM 1.5, irradiance 1000 `N/m', cell temperature 25'C). At low irradiance of 200 W/m2 (AM 1.5 and cell temperature 2S"C) at least 97%of the STC panel efficiency will be achieved. Nominal Power -Pti P(Wp) 179 183 187 189 193 197 Nominal PowerVottage-V,,,,(V) 27.5 27.7 28.1 28.3 28.5 29.0 Nominal PowerCurrent-IMpe(A) 6.51 6.58 6.64 6.68 6.77 6.81 Open Circuit Voltage-Vcc(V) 34.2 34.4 34.7 35.0 35.3 35.7 Short CircuitCurrent-Isc(A) 6.96 7.03 7.08 7.12 7,21 7.24 Nominal operating cell temperature NOCT (800 W/m2, AM 1.5, windspeed 1 m/s, ambient temperature 20°C). CERTIFICATION ( E 10 year product warranty. c(Dus 25 year linear power output warranty LISTED Fol (max.degressioninperformance of0.7%p.a.). UL 1703, IEC 62716 (ammonia resistance) & IEC 61701 (salt mist corrosion - severity level 6). r2EC is a leading glob at provider of solar electricity solutions. With nearly two decades of expertise. we offer sustainable, high -performing ^ �• products, services and investment opportunities for the solar and electronics industries. Together with our partners, we create value by y h ' providing solutions that better meet the world's growing electricity needs. Our 2,300 employees worldwide generated revenues of more than NOK 7 billion in 2012, approximately USD 1.3 billion. www.recgroup.com ENERGIZING LIFE TOGETHER M!Q -��x R C C CONTENTS TABLE OF FIGURES 2 INTRODUCTION 3 HOW TO USE THIS MANUAL 3 YOUR RESPONSIBILITYASAN INSTALLER 3 SUPPORT 3 LIABILITY DISCLAIMER 3 ELECTRICAL INSTALLATION T ELECTRICAL REQUIREMENTS 4 1) SYSTEM REQUIREMENTS 4 II) CONNECTION 4 III) STRING CONFIGURATION 4 IV) WIRING LAYOUT 4 V) JUNCTION BOX, CONNECTORS AND MATERIALS 4 VI) CABLE MANAGEMENT 4 VII) ELECTRICAL RATINGS 4 SAFETY MEASURES 4 1) SAFETY IN THE WORKING AREA 4 II) PREVENTING CURRENT GENERATION 4 IQ SPECIFIC HAZARDS OF DC ELECTRICITY 4 IV) SAFETY REQUIREMENTS 4 MECHANICAL INSTALLATION 5 FIRE GUIDELINES 5 ORIENTATION 5 ENVIRONMENTAL FACTORS 5 PANEL HANDLING 5 MOUNTING THE PANELS 6 PANEL INSTALLATION 6 1) RAIL SPECIFICATIONS 6 11) CLAMP SPECIFICATION 6 III) MOUNTING HOLES 7 IV) SLIDE -IN SYSTEMS 7 V) DRAINAGE HOLES 7 VI) LONG SIDE MOUNTING USING CLAMPS 8 VII) SHORTSIDE MOUNTING USING CLAMPS 8 VIII) GROUNDING 8 MAINTENANCE 9 CLEANING INSTRUCTIONS 9 SYSTEM INSPECTION 9 RECYCLING 9 PANEL INFORMATION 10 TECHNICAL INFORMATION 10 DOCUMENT HISTORY 11 TABLE OF FIGURES i NIT b.,; Tate age IVmt3r .. 9.. Title Page Fig.1 -------._..............---._....... Panel mounting options _......_........---........... ....... _...._._._.............._-._....._._...._...__._.-. 6 Fig. 7 Drainage holes 7 Fig. 2 ........_._...__..__.......... Rail specifications . ..................... -....._.........._...__._...-------._......-------._...._...__......._..---._.._........__.._.._...---...._..._ ...... _.._.... _.._......_...-_ 6 .._..._......._....----- - Fig. 8 _.................... _............._.._.....__.._........ .. - - Long side mounting .................... 8 Fig. 3 ....._.....---...... Clamp specifications 6 .............._.._...._..........._........._..........._............................_..._.......__._._....._.._.........._._._._................_......__.................. Fig. 9 Short side mounting ...... _...... 8 -..._.....__.._._.............--- Fig. 4 - ----.._....—-..._._...... —......._..._.__.._._._.__.........__.._...._...__._.._..._.._...._.. Panel secured at four points 6 ... _........_................. ..._............ Fig. 10 _........... _............... -.............. _........ _........... _.._..._..... ......_....__......_.... _........ ..... _.................................... Recommended grounding _.. 8 ................._Fig. 5 Mounting 7 Panel dimensions 10 Fig. 6 Mounting using mounting holes ..................._............. 7 ............ ....................... _................_Fig...l_1....................... Fig.12 .......... _........... ..._.._........................._... Frame cross-section and dimensions 10 Caution: Only qualified personnel should perform work on photovoltaic systems such as installation, commissioning, maintenance and repairs. Be sure to follow the safety instructions for all system components. Ensure relevant local codes and regulations for health and safety and accident prevention are observed. 2 RE�p=?<Er�r�__resfr5ta?i:aa^?ka_a.G- Re'I-�22Q_ INTRODUCTION Thank you for choosing REC photovoltaic panels. REC Peak Energy panels are ideal for delivering long-lasting and reliable power output. The panels have been created through intelligent design and are manufactured to the highest quality and environmental standards. With correct installation and maintenance, REC panels will provide clean, renewable energy for many years. Please read this entire manual carefully. It contains critical information on safety, as well as detailed instructions for installation, operation and maintenance of this panel. Failure to follow the procedures contained within will invalidate the warranty. Review all instructions and safety notes before working on the system. Failure to do so may lead to injury or damage to property. HOW TO USE THIS MANUAL This installation manual describes the installation procedures for the mounting of all REC's UL 1703 certified REC Peak Energy solar panels in a photovoltaic array. Review the entire manual before installing the panels and ensure you are working from the latest version. Throughout the manual, you will see the below icons which highlight important information or notes: AA Indicates potential for damage to the array or property or personal safety. Indicates important notes on best practice to help with the installation or to avoid potential damage to the panels, array or property. For further information on installation procedures, please call your distributor or contact your local REC Solar office. Details available at www.recgroup.com. YOUR RESPONSIBILITY AS AN INSTALLER Installers are responsible for the safe and effective installation and operation of the photovoltaic system and for adhering to all local and national standards and regulations. Prior to installation, check all applicable regulations and permits concerning solar systems and ensure all local directives are observed. • Ensure the REC panels are in a suitable condition for use and appropriate for the particular installation and environment • Use only parts that convene to the specifications set out in this manual • Ensure a safe installation of all aspects of the electrical array All equipment should be properly maintained and inspected prior to use. SUPPORT Do not attempt to install when you are unsure of the procedure or suitability. For questions orguidance with your installation, please call your distributor or contact your REC sales office, which can be found at: www.recgroup.com/en/contacts. LIABILITY DISCLAIMER REC Solar AS accepts no liability for the usability and functionality of its photovoltaic panels if the instructions in this guide are not followed. Since compliance with this guide and the conditions and methods of installation, operation, use and maintenance of the panels are not checked or monitored by REC Solar AS, REC Solar AS accepts no liability for damage arising from improper application or incorrect installation, use, operation or maintenance. This does not apply to damages due to a panel fault, in cases of loss of life, bodily injury or damage to health or in the event of a grossly negligent breach of obligations on the part of REC Solar AS and/or in the event of an intentional orgrossly negligent breach of obligations by a legal representative or vicarious agent. ELECTRICAL INSTALLATION ELECTRICAL REQUIREMENTS i) System Requirements REC panels are only for use where they meet the specific technical requirements of the complete system. Ensure other components do not cause mechanical or electrical damage to the panels. ii) Connection If panels are connected in series, they should have the same amp rating. If panels are connected in parallel, they should have the same voltage rating. iii) String configuration When using string configuration, plan and execute it according to inverter manufacturer's instructions. The number of panels connected to an inverter should be within the inverter voltage limits and operating range. Do not exceed the total system voltage permitted by the manufacturer, nor under any circumstance exceed the maximum system voltage of 600 V. The maximum reverse current is 15 A and the maximum series fuse rating is 15 A. iv) Wiring layout To minimize voltage surges (e.g. indirect lightning strikes), cables of the same string should be bundled together so loops are as small as possible. String configurations must be checked before commissioning. If open circuit voltage (Von) and short circuit current (ISC) deviate from specification, this may indicate a configuration fault. Correct DC polarity should be observed at all times. v) Junction box, connectors and materials The panel junction box is rated IP67. All connectors and cables must be secure and tight as well as electrically and mechanically sound. UV -resistant cables and connectors approved for outside use must be used. Conductor gauge must ensure DC power losses (voltage drop) are kept to a minimum (< 1%). Observe all local regulations when selecting cables. For field connections, use minimum 12 AWG (4 mm2) or copper wires insulated for a maximum operating temperature of 90°C. vi) Cable Management Cables must be secured using UV -resistant cable ties or other sunlight -resistant device. Loose and unsecured cables should be protected from damage (e.g. mechanical, abrasion, sharp objects, animals). As far as possible, avoid exposing cables to direct sunlight and permanent tension. vii) Electrical Ratings Under normal conditions, a photovoltaic panel is likelyto experience consitions that produce more current and/or voltage than reported at STC. The requirements of the National Electric Code (NEC) in Article 690 must be followed to address these increased outputs. In installations not under the requirements of the NEC, the values of Isc and Voc Marked on the panels must be multiplied by a factor of 1.25 when tt determining component voltage ratings, conductor ampacities, overcurrent device ratings and size of controls connected to the PV output. SAFETY MEASURES Wiring installation shall be in accordance with the NEC (or CSA C22.1, Safety Standard for Electrical Installations, Canadian Electrical Code, Part 1 where applicable). All relevant electrical installation codes and regulations should be observed for regulations on working at heights and fall protection. i.) Safety in the working area Installation of REC Peak Energy panels may involve working on a roof. Ensure all local regulations regarding working at heights are followed. Before beginning work on a photovoltaic system, ensure all working surfaces are structurally sound and capable of bearing the weight of employees and required equipment. Rememberto isolate the system from the grid before carrying out any maintenance or repair work. ii) Preventing current generation Solar panels automatically generate current (electricity) when exposed to light. To prevent this, shield the system with a non -transparent cover during installation, maintenance or repair work. Ii) Specific hazards of DC electricity Solar panels generate direct current (DC). Once current is flowing, breaking or opening a connection (e.g. removing DC cable from the inverter) can cause an electrical arc. Unlike low voltage AC wiring, DC arcs are not self -extinguishing. They are potentially lethal burn and fire hazards, capable of high temperatures that can destroy contacts and connectors: Follow panel and inverter manufacturers' installation, handling and operating instructions Remove/open the inverter AC fuse/circuit breaker before disconnecting from the public grid. Switch off or disconnect the inverter and wait forthe time specified by the manufacturer before commencing work. High -voltage components need sufficient time to discharge. iv) Safety requirements The voltage produced by a single panel and panels connected in series (voltages added together) or in parallel (currents added together) can be dangerous. Although the fully insulated plug contacts on the panel's output cables provide touch -safe protection, the following points must be observed during handling to avoid the risk of sparking, fire hazards, burns and lethal electric shocks. • Excercise extreme caution when wiring panels and look outfor damaged or dirty cables etc. • Never insert metallic or other conductive objects into plugs or sockets. • Ensure that all electrical connections are completely dry before assembly. • Keep all materials, tools and working conditions dry and tidy. I ISe appropriate Safe 'D,i equipment e.g. nonslip foot -.,ear, insulated gloves and insulated tools. • Solar panels produce current when exposed to sunlight. Do not connect the system to the inverter during solar exposure. rd:CrozrErer��7ere; Iretaiztia-:�L_n-a -t;` i7u3 R�rl-D227L- MECHANICAL INSTALLATION FIRE GUIDELINES REC Peak Energy Series panels have a Class C Fire classification. Utilize the followingfire safety guidelines when installing REC Peak Energy Series panels: • Check with local authorities for fire safety guidelines and requirements for any building or structure on to which the panels will be installed. • The system design should ensure that it can be easily accessed in the event of a buildingfire. • Check with local authorities for applicable regulations concerning setbacks or other placement restrictions that may apply for roof -mounted arrays. • The use of DC ground fault interrupters is recommended. This may also be required by local and national codes. • All electrical appliances are a fire risk. The panel should therefore be mounted over a fire retardant roof covering rated forthe application and a suitable distance of 4 in between the panel and the mounting surface, allowingfree circulation of air beneath the panels, should be respected at all times. ORIENTATION To maximize system output, panels should be installed at the optimum orientation and tilt angle. The specifics of this depend on location and can be calculated by a qualified system designer. A lower angle of panel installation increases the requirement for regular cleaning. The optimal mounting position of panels results in the sun's rays falling perpendicular (i.e. at 90°) to the surface. All panels in a string should, wherever possible, have the same orientation and tilt to ensure the system does not underperform due to mismatched outputs. AThe panels should not be exposed to artificially concentrated sunlight. ENVIRONMENTAL FACTORS REC Peak Energy Series panels are designed to provide decades of durable and stable output. Operating temperatures should be between -40 and 176°F (-40 and +80°C). The panels are not suitable for installation in potentially hazardous locations nor should they be installed in the following locations: • Near sources of flammable gases or vapors • Near open flames. • Under water or in water features. • Where exposed to sulfur e.g. near sulfur springs or volcanoes. • Where the panels may be exposed to harmful chemicals. Ensure panels are not exposed to direct contact with salt water/spray and avoid installation in areas subject to high salt mist content e.g. coastal areas. PANEL HANDLING Panels should be handled with care. All warnings and instructions on the packaging should be observed. Follow these guidelines when unpacking, transporting or storing the panels: • Record the serial numbers prior to installation and note the information in the system documentation. • Carry the panels using both hands and avoid using the junction box as a grip. • Do not allow the panels to sag or bow under their own weight when being carried. • Do not subject the panels to loads or stresses. Do not stand on them or drop them. • Keep all electrical contacts clean and dry. • Store panels in a dry and properly ventilated room. • Do not apply force to the backsheet. • Avoid using sharp or pointed objects if panels require marking. • Never apply paints, adhesives or detergents to the back of the laminate. • Do not use any solar panel that is damaged or been tampered with. • Never attempt to disassemble the panels. If the panel front glass is broken or laminate back sheet is damaged, it can expose personnel to hazardous voltages. R=CF�a,E-rg•a. ;-_nsr;ati�n?A=raa-U_?iG'_ MOUNTING THE PANELS REC Peak Energy Series panels are designed for capturing solar radiation and are not suitable for installation as overhead or vertical glazing. The panels are considered to be in compliance with UL 1703, only when the panel is mounted specified by the mounting instructions below. The REC junction box on the back of the panel is protected to IP67 and hence panels can be mounted in any orientation. PANEL INSTALLATION REC Peak Energy panels are typically installed on a rail -based mounting system. There are three different methods of installing an REC Peak Energy panel, each decribed below, depending on the design load of the array. The rails can run under the frame or parallel to the frame, directly under the clamping zones (fig la & lb). Ensure the mounting structure is able to withstand anticipated wind and snow loads. Fig.1: Panel mounting options (a) Long side mounting using( (b) Short side mounting using clamps (c) Mounting holes Ensure a minimum distance of 4 in (10 cm) between the uppermost part of the roof and the lowest part of the panel to ensure sufficient r= airflow beneath the panels and aid cooling. i) Rail specifications The clamps should be fastened to C or H channel rails (fig. 2). Thickness of walls for mechanical connections: min. 0.156 in (4.0 mm) Thickness of wails exposed to buckling load: min. 0.08 in (2.0 mm) Moment of Inertia for profile area about X-X: min array mounting diagram 0.4 in4 (19.2 cm4) Fig.2: Rail specification Watts' ormechanical connectors Walls exposed to buckling load H channel rail The overlap between support rail and the outer edge of the panel frame must be a minimum of 1/64 in (6 mm). ii) Clamp Specification REC Peak Energy panels have been evaluated by UL for mounting using C-channel-rails in combination with end and mid clamps, 5/16 in (8 mm) ASTM F593C stainless steel screw and rail nuts. Alternatively clamps with the below ratings and dimensions can be used to secure the panel to the mounting structure (fig. 3): iniinun yield strength of 2089 ton/fie (200 i�ipa) • Minimum tensile strength of 2610 ton/ftz (250 Mpa), e.g. 6005 T5 alloy. • Minimum grip length of 1.75 in (44.45 mm) • Minimum grip depth of 0.29 in (5 mm) • Minimum thickness of load carryingwalls of 0.156 in (4 mm) • Screw connection — 5 j I6 in (8 mm) stainless steel bolt, 51 6 i� � split washer (8 mm), nut Grip depth 0.2 in Fig. 3: Clamp specifications :h in gi Walls expposed to load min 0.156 in Grip depth min 0.2 in Each panel must be securely fixed to the mounting structure at a minimum of four points (fig.4). Fig. 4: An array mounting system with each panel secured at four points. Poi=?a�:Errrg�5aree�nste;tio-'�k-,�-a-i.'70.-: Rwl-OZ2013 ill) Mounting holes Mounting utilizing the four elongated holes (0.26 x 0.43 in (6.6 x 11 mm)) on the underside of the panel frame (at a distance of 17.72 in (450 mm) from the midpoint of the long side) have been found to comply with UL 1703 requirements for a maximum design load of 75.21bs/ft2 (3600 Pa) (fig. 5). When mounting using mounting holes, the frame and panel edge must be supported by two transverse rails (fig.1, p 8), of aluminium or galvanized steel to avoid galvanic corrosion and be appropriate for the local environment. These must be held in position by bolts and flange nuts accordingto the specifications below. If bought in a kit, do not use the washers and bottom mounted clips provided: When using mounting holes, fixings must be fastened to 9 ft-lbs (12 Nm) of torque and installation must be according to fig. 6. PartName�k Iat$Yia1 Specxfic�twr,, - Bolt ASTMF593(stainless steel) 1/4"x20-5/8" ...... _..._......_..................__......_................._..........._...--...._ — _..__._ _..__.._.......__..__ ...-_..--.._._...— ............... Flange Nut ASTM F594 stainless steel) 1/4"x 20 Install the above parts as shown in fig. 6. Consult the Unirac Code Compliant Installation Manual for further details where necessary. For areas where discrepancy may exist, this installation manual shall take precedence. Fig.5: Mountingholes Mounting holes Fig. 6: Observe the following procedures when using mounting holes (fig. 5): • Additional electrical bonding to Earth is required for the support structure (see page 12). • All four mounting holes in the frame must be used (for long or short -sided mounting orientation). • Fixings must be tightened to 9 ft-lbs (12 Nm) using a torque wrench. The warranty will be voided if additional holes are made in the frame. All fixing and fastening materials should be corrosion resistant. iv) Slide -in Systems REC Peak Energy panels have not been certified by UL for use with slide -in type mounting systems. If you have any questions regarding a mounting system and its suitability for REC Peak Energy panels, please contactyour local office for technical support. v) Drainage holes There are eight drainage holes, 0.47 x 0.30 in (12 x 7.5 mm) in the panels frame, each spaced 2.2 in (55 mm) from the corner of the panel frame (fig. 5). This allows water caused by rain or snow melt to exit the frame easily and minimizes the damage caused by freezing and thawing. Ensure these holes are not covered by any part of the mounting structure. Fig. 7: Drainage holes R_�PaxEra-�y_er snzt?i."!Wna-U_D0-' Rev:-022j.- vi) Long side mounting using clamps Mounting utilizing clamps on the two long sides of the panel have been found to be in compliance with UL 1703 requirements for a maximum design load of 75.2 Ibs/ft2 (3600 Pa) (fig. 8). • Clamps must be secured between a distance of 8.2 in to 16.4 in (208 mm -416 mm) from the corner of the panel (measured from the mid -point) to the clamp edge. • Tightening torque must be tightened to 9 ft-lbs (12 Nm). • The distance between the end clamp and the end of the rail must be minimum 1 in (25 mm). Fig. 8: Long< Fig. 9: Short vii) Short side mounting using clamps Mounting utilizing clamps on the two short sides of the panel have been found to be in compliance with UL 1703 requirements for a maximum design load of 33.4 lbs/ftz (1600 Pa) (fig. % • Fix the panels so that the lower short side of the frame is supported by the mounting structure (to reduce risk of damages due to sliding snow load). • Clamps must be secured between a distance of 4.9 and 9.8 inches (125 - 250 mm) from the panel cornerto the clamp edge. • Tightening torque must be tightened to 9 ft-lbs (12 Nm). • The minimum distance between the end clamp and the end of the rail is 1 in (25 mm). • Mechanical load must not exceed 33.4lbs/ft (1600 Pa). • The overlap between support rail and frame must be a minimum of 1/4 in (6 � � m). In areas of snow build-up, panels can be subjected to forces in excess of the stated limit even when snow depth does not appear extreme, causing damage to the framework. If the installation is likely to be affected, further suitable panel support is recommended on the lower row of panels. IEnsure the drainage holes are not covered by the mounting structure. viii) Grounding A panel ;with exposed conductive parts is considered to be in compliance with UL 1703 onlywhen the it is electrically grounded in accordance with the inc ±ruic±ions nrocPn nH hPlnw anri the rPr iirPmPntc of the NFC_ Grmindina is achieved through securementto the Danel frame of the following UL Listed grounding Clips / Lugs in combination with the REC Peak Energy panel(s). • Suitable grounding lugs must be used: Listed (KDER) ILSCO, GBL-4DBT (tin plated) (E34440). Grounding cable size should be between 4-14 AWG (2.1 mmz - 21.2mm2). • Attach grounds to the grounding holes in the panel frames. • Fix lug to the frame using a star washer (#10) and lock nut (#10), ensuring a conductive connection (fig.10). Tighten according to manufacturer's instructions. Where common grounding hardware (nuts, bolts, star washers, split -ring lock washers, flat washers and the like) are used to attach a listed . grounding/bonding device, the attachment must be made in conformance with the grounding device manufacturer's instructions. Fig.10: Recommended ground Star washer Cross section [AWG] Type Torque ]in-ibs] ........... .......... _:::::.._: _ ........: _.................... ............ 4-6 Stranded 35 8 Stranded 25 ... _. .._.... ... unding 10-14 Stranded/Solid 2.8 ...... .....__..... _ le Groundingrlug dimensions and wire fastening torque for GBL-anB . To avoid galvanic corrosion, stainless steel fastening materials are preferred, however galvanized or hot dipped zinc plated fasteners are equally suitable. RfCR==ktrx�/5=re=in;[ai31a-M14o_a -��. U_ RcJ-02 20_ MAINTENANCE CLEANING INSTRUCTIONS REC Peak Energy panels have been designed for easy maintenance. Normal rainfall will naturally clean the panels if installed at a sufficient angle. The need for cleaning will vary dependent on location, rainfall, pollution and angle of installation - the lower the angle of installation, the more cleaning will be required. To optimize electrical output it is recommended to clean the panels when dirt can be seen on the glass surface. Cleaning of the panel should be carried out in the early morning when the panels are cool to avoid thermal shock. If dirt remains on the panel, it may cause cell shading which will reduce power output or even cause further damage. To clean either the front or rear of the panels, use only deionized water at ambient temperature and a sponge, micro fiber cloth or a soft brush to wipe away the dirt (rainwater, tap water or diluted alcohol may also be used as a secondary solution). Forfurther cleaning a mild, biological and biodegradable washing-up liquid may be used. When cleaning the panel, take care notto scratch the surface or introduce foreign elements that may cause damage. Ensure water used is free from grit and physical contaminants that may damage the panel. Always rinse the panel with plenty of water. If soiling remains, repeat the cleaning process. If stains require more effort to be removed, Iso-propyl alcohol of a concentration less than 10%. Acid or Alkali detergent may not be used Use of high pressure hoses or clearners is not permitted as these may damage the panel, laminate or celis. Using a rubber squeegee, wipe the panel surface from the top downwards motion to remove any residual water from the panel glass. Panels can beleftto dry in the air or wiped dry with a chamois. Avoid putting pressure on the panel surface when drying. For more information on cleaning REC panels, consult the Cleaning Information Sheet available to download from the online REC Installer Portal www. recgroup.com/instalters. SYSTEM INSPECTION The system should be inspected regularly to ensure that: • Fasteners are secure, tight and free from corrosion. • Electrical connections are secure, tight, clean, and free of corrosion. • The mechanical integrity of the cables is intact. • Bonding points to ground are tight, secure and free from corrosion (which could break the continuity between the panels and ground). RECYCLING REC has made every effort to ensure panel packaging is kept to a minimum. The paper and cardboard packaging can be recycled and the protective wrapping and panel separating blocks are also recyclable in many areas. Please recycle according to local guidelines and regulations. RKP-xE--oy5_a:e=_n=ri ari_ �!n=sr ai-U_'7G PANEL INFORMATION TECHNICAL INFORMATION Fig.11: Panel dimensions (in) *Diagram indicates a genericjuncdon box design, position may vary slightly. 65.55t0.1 ................... Dimensions: 65.55 x 39.02 x 1.5 in Area: 17.76 ft2 Weight: 39.6 tbs Operational Temperature: -40...+80"C Maximum System Voltage: 600 V Design Load: 75.2 Ibs/ft2 (3600 Pa)* 33.4lbs/ft2 (1600 Pa)* 'Dependent on mounting method as described above Max Series Fuse Rating: 1S A Max Reverse Current: 1S A 0.47 1.5 1.24 t.- - J.07 1.1 Fig.12: Frame cross-section and dimensions (in) GENERALDATA Ceti Type: 60 REC PE multi -crystalline 6 x 6 in (156 x156 mm) 3 sub -strings of 20 cells with bypass diodes Glass: 1/8" (3.2 mm) solargtass with anti -reflection surface treatment Back Sheet: Double !alter Munk/ resistantpolyester Frame: Anodized aluminium Junction Box: IP67r aced 4 mm2 solar cable, 35'+47" (0.9+ 1.2 m) Connectors* MC4 (4 mm2) MC4 connectable (4 mm2) Radox twist lock (4 mm2) `Dependent on function box design . , ,. ,. - Nominal Power-PMpp(Wp) 235 240 245 250 255 260 Watt Class Sorting- (W) 0/+5 0/+5 0/+5 0/+5 0/+5 0/+5 Nominal Power Voltage -VMPP(V) 29.5 29.7 30.1 30.2 30.S 30.7 Nominal Power Current- IMpp(A) 8.06 8.17 8.23 8.30 8.42 8,50 Open Circuit Voltage-Voc(V) 36.E 36.8 37.1 37.4 37.6 37.8 Short CircuitCurrent -Isc(A) 8.66 8.75 8.80 8.86 8.95 9.01 Panel Efficiency(%) 14.2 14.5 14.8 15.1 15.5 15.8 The electrical characteristics are within+/-10 percent of the indicated values of Isc, Vccand PMpp under standard test conditions (STC). Values at STC (airmass AM I.S. irradiance 1000 W/m', cell temperature 25'C). At low irradiance of 200 W/m2 (AM 1.5 and cell temperature 25'C) at least 97 % of the STC panel efficiency will be achieved •followed by PE, PE(BLK), PE ECO. 10 dl&Er> at;=n=anstoervx:, n.a-iA.'7U F(wl-0��7i= DOCUMENT HISTORY Date Revision Number Reason 01.2010 A First release 02.2010 B Textual updates 02.2010 C Textual updates 03.2010 D Textual updates 05.2010 E Textual updates 07.2010 F Textual updates 03.2011 G Textual updates, update of electrical data 10.2012 H Release of separate IEC 61215/61730 and UL1703 specific installation manual version. 01.2013 H.2 Textual update of technical characteristics 01.2013 H.3 Correction of available grounding lug information 02.2013 1 Textual updates. Update of junction box and connector information in Technical Information 835 Aerovista Place, Ste 230 San Luis Obispo, CA 93401 Dir 805 704 3226 Fax 805 457 6104 .w recaroup.corn, a SunWork Renewable Energy Projects PO Box 60250 Palo Alto, CA 94306 ATTN:Reuben Veek RE: Unirac UGC-1 Clip Grounding Authorization San Luis Obispo, May 18, 2012 To Whom It May Concern: REC Solar approves the the Unirac UGC-1 product to electrically bond and ground the REC Peak Energy series module frame. Using this system meets the manufacturer requirements for bonding and grounding and will not void the warranty for installations performed in accordance with the manufacturer's guidelines. Best regards, � � � E E41- E George McClellan REC Solar US LLC Technical Sales Manager UN I RAC A HILT[ GROUP COMPANY SolarMount Technical Datasheet Pub 100602-1td V1.0 June 2010 SolarMount Module Connection Hardware.................................................................. 1 BottomUp Module Clip.................................................................................................1 MidClamp....................................................................................................................2 EndClamp....................................................................................................................2 SolarMount Beam Connection Hardware......................................................................3 L-Foot........................................................................................................................... 3 SolarMountBeams..........................................................................................................4 SolarMount Module Connection Hardware BE SolarMount Bottom Up Module Clip Part No. 321001, 321002 1.24 Y r 1.00 -0X r Dimensions specified in inches unless noted • Bottom Up Clip material: One of the following extruded aluminum alloys: 6005-T5, 6105-T5, 6061-T6 • Ultimate tensile: 38ksi, Yield: 35 ksi • Finish: Clear Anodized • Bottom Up Clip weight: —0.031 Ibs (14g) • Allowable and design loads are valid when components are assembled with SolarMount series beams according to authorized UNIRAC documents • Assemble with one'/Z-20 ASTM F593 bolt, one'/<"-20 ASTM F594 serrated flange nut, and one'/<" flat washer • Use anti -seize and tighten to 10 ft Ibs of torque • Resistance factors and safety factors are determined according to part 1 section 9 of the 2005 Aluminum Design Manual and third - party test results from an IAS accredited laboratory • Module edge must be fully supported by the beam * NOTE ON WASHER: Install washer on bolt head side of assembly. DO NOT install washer under serrated flange nut Applied Load Direction Average Ultimate Ibs (N) Allowable Load Ibs (N) Safety Factor, FS Design Load Ibs (N) Resistance Factor, O Tension, Y+ 1566 (6967) 686 (3052) 2.28 1038 (4615) 0.662 Transverse, X± 1128 (5019) 329 (1463) 3.43 497 (2213) 0."1 Sliding, Z± 66 (292) 1 27 (119) t 2.44 41(181), 0.619 so UNIRAC A HILTI GROUP COMPANY SolarMount Mid Clamp Part No. 320008, 320009, 320019, 320020, 320021, 320084, 320085, 320086, 320087, 320120, 320122 1.00 DISTANCE BETWEEN MODULES I i Y iX Dimensions specified in inches unless noted SolarMount End Clamp Part No. 320002, 320003, 320004, 320005, 320006, 320012, 320013, 320014, 320015, 320016, 320017, 320079, 320080, 320081, 320082, 320083, 320117, 320118, 320123, 320124, 320173, 320185, 320220, 320233, 320234, 320331 ---WA 1.5 MINIMUM HEIGHT VARIES MODULE rHlpriuccc '.. Dimensions speci d • Mid clamp material: One of the following extruded aluminum alloys: 6005-T5, 6105-T5, 6061-T6 • Ultimate tensile: 38ksi, Yield: 35 ksi • Finish: Clear or Dark Anodized • Mid clamp weight: 0.050 Ibs (23g) • Allowable and design loads are valid when components are assembled according to authorized UNIRAC documents • Values represent the allowable and design load capacity of a single mid clamp assembly when used with a SolarMount series beam to retain a module in the direction 'I Idicated • Assemble mid clamp with one Unirac'/4"-20 T-bolt and one'/4"-20 ASTM F594 serrated flange nut • Use anti -seize and tighten to 10 ft-Ibs of torque • Resistance factors and safety factors are determined according to part 1 section 9 of the 2005 Aluminum Design Manual and third - party test results from an IAS accredited laboratory Applied Load Direction Average Ultimate Ibs (N) Allowable Load Ibs (N) Safety Factor, FS Design Load Ibs (N) Resistance Factor, m Tension, Y+ 2020 (8987) 891 (3963) 2.27 1348 (5994) 0.667 Transverse, Z± 520 (2313) 229 (1017) 2.27 346 (1539) 0.665 Slid'irig, X± 1194 (5312) 4, (2179) 2.44 741 (3295) 0.620 • End clamp material: One of the following extruded aluminum alloys: 6005-T5, 6105-T5, 6061-T6 • Ultimate tensile: 38ksi, Yield: 35 ksi • Finish: Clear or Dark Anodized • End clamp weight: varies based on height: -0.058 Ibs (26g) • Allowable and design loads are valid when components are assembled according to authorized UNIRAC documents • Values represent the allowable and design load capacity of a single end clamp assembly when used with a SolarMount series beam to retain a module in the direction indicated • Assemble with one Unirac'/4"-20 T-bolt and one'/4"-20 ASTM F594 serrated flange nut • Use anti -seize and tighten to 10 ft-Ibs of torque Resistance factors and safety factors are determined according to part 1 section 9 of the 2005 Aluminum Design Manual and third - party test results from an IAS accredited laboratory • Modules must be installed at least 1.5 in from either end of a beam Applied Load Direction Average Ultimate Ibs (N) Allowable Load Ibs (N) Safety Factor, FS Design Loads Ibs (N) Resistance Factor, m Tension, Y+ 1321 (5876) 529 (2352) 2.50 800 (3557) 0.605 Transverse,Z± 63(279) 14(61) 4.58 21 (92) 0.330 Sliding, X± 142 (630) 1 52 (231) 1 2.72 79(349)1 0.555 an UNIMC A HILTI GROUP COMPANY SolarMount Beam Connection Hardware SolarMount L-Foot . Part No. 310065, 310066, 310067, 310068 Y X —T i 3.01 3X SLOT FOR I 3%HARDWARE 1 2.01 Dimensions specified in inches unless noted • L-Foot material: One of the following extruded aluminum alloys: 6005- T5, 6105-T5, 6061-T6 • Ultimate tensile: 38ksi, Yield: 35 ksi • Finish: Clear or Dark Anodized • L-Foot weight: varies based on height: -0.215 Ibs (98g) • Allowable and design loads are valid when components are assembled with SolarMount series beams according to authorized 3olt UNIRAC documents L-Foot For the beam to L-Foot connection: • Assemble with one ASTM F593 Y."A 6 hex head screw and one ASTM F594 3/s"serrated flange nut • Use anti -seize and tighten to 30 ft-Ibs of torque • Resistance factors and safety factors are determined according to part 1 section 9 of the 2005 Aluminum Design Manual and third -party test results from an IAS accredited laboratory NOTE: Loads are given for the L-Foot to beam connection only; be sure to check load limits for standoff, lag screw, or other attachment method Applied Load Direction Average Ultimate Ibs (N) Allowable Load Ibs (N) Safety Factor, FS Design Load Ibs (N) Resistance Factor, 0 Sliding, Z± 1766 (7856) 755 (3356) 2.34 1141 (5077) 0.646 Tension, Y+ 1859 (8269) 707 (3144) 2.63 1069 (4755) 0.575 Compression, Y- 3258 (14492) 1325 (5893) 2.46 2004 (8913) 0.615 Traverse, X± 486 (2162) .213(949) 2.28 323 (1436) 0.664 ��ff ii �IV���C A HILTI GROUP COMPANY SolarMount Beams Properties Units SolarMount SolarMount HD Beam Height in 2.5 3.0 Approximate Weight (per linear ft) plf 0.811 1.271 Total Cross Sectional Area in 0.676 1 1.059 Section Modulus (X-Axis) in 0.353 0.898 Section Modulus (Y-Axis) in 0.113 0.221 Moment of Inertia (X-Axis) in' 0.464 1.450 Moment of Inertia (Y-Axis) in 0.044 0.267 Radius of Gyration (X-Axis) in 0.289 1.170 Radius of Gyration (Y-Axis) in 0.254 0.502 SLU T FOR T -BOL 1 4" HEX HEAD SCR 2X SLOT FOR BOTTOM CLIP SLOT FO 38" HEX BOL .38-j .7 2.500 1.316 Y SolarMount Beam SLOT FOR T-BOLT OR 14" HEX HEAD SCREW SLOT FOR BOTTOM CLIP SLOT FOR HEX BOLT 1.728 ' 3.000 —TI 1.385 1.207 Y 1.875 -� i ►X SolarMount HD Beam Dimensions specified in inches unless noted C9 TY RM UNT Code -Compliant InstallationManual 227.3 U.S. Des. Patent No. D496,2485, D496,z49S. Other patents pending. Table of Contents L installer's Responsibilities.................................................................2 Part I. Procedure to Determine the Design Wind Load ........................................... 3 Part H. Procedure to Select Rail Span and Rail Type.............................................10 Part III. Installing SolarMount [3.1.] SolarMount rail components ................................................ 14 [3.2.] Installing SolarMount with top mounting clamps...............................15 [3.3.] Installing SolarMount with bottom mounting clips ............................. 21 [3.4.]Installing SolarMount with grounding clips and lugs ............................ 25 0 Oma n U N I RAC A HILTI GROUP COMPANY Unirac welcomes input concerning the accuracy and user -friendliness of this publication. Please write to publications@unirac.com. on d U N 'RAC Unirac Code -Compliant Installation Manual SolarMount L Installer's Responsibilities Please review this manual thoroughly before installing your SolarMount system. This manual provides (1) supporting documentation for building permit applications relating to Unirac's SolarMount Universal PV Module Mounting system, and (2) planning and assembly instructions for SolarMount SolarMount products, when installed in accordance with this bulletin, will be structurally adequate and will meet the structural requirements of the IBC 2006, IBC 2003, ASCE 7- 02, ASCE 7-05 and California Building Code 2007 (collectively referred to as "the Code"). Unirac also provides a limited warranty on SolarMount products (page 26). C 2 SolarMount is much more than a product. It's a system of engineered components that can be assembled into a wide variety of PV mounting structures. With SolarMount you'll be able to solve virtually any PV module mounting challenge. It's also a system of technical support: complete installation and code compliance documentation, an on-line SolarMount Estimator, person -to -person customer service, and design assistance to help you solve the toughest challenges. This is why SolarMount is PV's most widely used mounting system. • Complying with all applicable local or national building codes, including any that may supersede this manual; • Ensuring that Unirac and other products are appropriate for the particular installation and the installation environment; • Ensuring that the roof, its rafters, connections, and other structural support members can support the array under all code level loading conditions (this total building assembly is referred to as the building structure); • Using only Unirac parts and installer -supplied parts as specified by Unirac (substitution of parts may void the warranty and invalidate the letters of certification in all Unirac rnihliratinncl • Ensuring that lag screws have adequate pullout strength and shear capacities as installed; • Verifying the strength of any alternate mounting used in lieu of the lag screws; • Maintaining the waterproof integrity of the roof, including selection of appropriate flashing; • Ensuring safe installation of all.- electrical aspects of the PV array; • Ensuring correct and appropriate design parameters are used in determining the design loading used for design of the specific installation. Parameters, such as snow loading, wind speed, exposure and topographic factor should be confirmed with the local building official or a licensed professional engineer- SolarMount Unirac Code -Compliant Installation Manual .81MUNIRAC Part I. Procedure to Determine the Design Wind Load [1.1.] Using the Simplified Method - ASCE 7-05 The procedure to determine Design Wind Load is specified by the American Society of Civil Engineers and referenced in the International Building Code 2006. For purposes of this document, the values, equations and procedures used in this document reference ASCE 7-05, Minimum Design Loads for Buildings and Other Structures. Please refer to ASCE 7-05 if you have any questions about the definitions or procedures presented in this manual. Unirac uses Method 1, the Simplified Method, for calculating the Design Wind Load for pressures on components and cladding in this document. The method described in this document is valid for flush, no tilt, SolarMount Series applications on either roofs or walls. Flush is defined as panels parallel to the surface (or with no more than 3" difference between ends of assembly) with no more than 10" space between the roof surface, and the bottom of the PV panels. This method is not approved for open structure calculations. Applications of these procedures is subject to thefollowing ASCE 7-05 limitations: 1. The building height must be less than 60 feet, h < 60. See note for determining h in the next section. For installations on structures greater than 60 feet, contact your local Unirac Distributor. 2. The building must be enclosed, not an open or partially enclosed structure, for example a carport. 3. The building is regular shaped with no unusual geometrical irregularity in spatial form, for example a geodesic dome. 4. The building is not in an extreme geographic location such as a narrow canyon or steep cliff. 5. The building has a flat or gable roof with a pitch less than 45 degrees or a hip roof with a pitch less than 27 degrees. 6. If your installation does not conform to these requirements please contact your local Unirac distributor or a local professional engineer. If your installation is outside the United States or does not meet all of these limitations, consult a local professional engineer or your local building authority. Consult ASCE 7-05 for more clarification on the use of Method I. Lower design wind loads may be obtained by applying Method II from ASCE 7-05. Consult with a licensed engineer if you want to use Method II procedures. The equation for determining the Design Wind Load for components and cladding is: pnet (psf) = AKztl pnet3o pnet (psf) = Design Wind Load A = adjustment factor for height and exposure category Kzt = Topographic Factor at mean roof height, h (ft) I = Importance Factor pnet3o (psf) = net design wind pressure for Exposure B, at height =30,I=1 You will also need to know the following information: Basic Wind Speed = V (mph), the largest 3 second gust of wind in the last 50 years. h (ft) = total roof height for flat roof buildings or mean roof height for pitched roof buildings Roof Pitch (degrees) This manual will help you determine: Effective Wind Area (sf) = minimum total continuous area of modules being installed (Step 2) Roof Zone = the area of the roof you are installing the pv system according to Step 3. Roof Zone Dimension = a (ft) (Step 3) Exposure Category (Step 6) [1.2.] Procedure to Calculate Total Design Wind The procedure for determining the Design Wind Load can be broken into steps that include looking up several values in different tables. Table 5 has been provided as a worksheet for the following 9 steps (page 8) Step 1: Determine Basic Wind Speed, V (mph) Determine the Basic Wind Speed V (mph) by consulting your local building department or locating your installation on the maps in Figure 1, page 4. Step 2: Determining Effective Wind Area Determine the smallest area of continuous modules you will be installing. This is the smallest area tributary (contributing load) to a support or to a simple -span of rail. That area is the Effective Wind Area, the total area of the fewest number of modules on a run of rails. If the smallest area of continuous modules exceeds 100 sq ft, use 100 sq ft (See Table 2). If less, round down to values available in Table 2. Pogr 3 U N I RAC Unirac Code -Compliant Installation Manual SolarMount Figure 1. Basic Wind Speeds. Adapted and applicable to ASCE 7-05. Values are nominal design 3-second gust wind speeds at 33 feet above ground for Exposure Category C. Step 3: Determine Roof/Wall Zone The Design Wind Load will vary based on where the installation is located on a roof. Arrays may be located in more than one roof zone. Using Table 1, determine the Roof Zone Dimension Length, a (ft), according to the width and height of the building on which you are installing the pv system. 90(40) 100(46) 110(49) 120(54) 130(68) 140(63). Miles per hour (meters per second) 140(63) �31S167) Table 1. Determine RooffV`r/all Zone, dimension (a) according to building width and height a = 10 percent of the least horizontal dimension or 0.4h, whichever is smaller, but not less than either 4% of the least horizontal dimension or 3 ft of the building. Roof Least Horizontal Dimension (ft) Height (ft) 10 15 20 25 30 40 50 60 70 80 90 100 125 150 175 200 300 400 500 t0 3 3 3 3 3 4. 4 _. .'`4 _6 ' 4' 4 4 ?4 - 15-= 7 6 1,2 1 J64:. '— 3 3... .. ' it d z 5 6 6 5 6 6 7 8 12 16 20 20 3 3 3 3 3 4= 5 6, 7 8 8 8 8. 8 8 8 42 16 10; 25 3 3 3 3 3 4 5 6 7 8 9 10 10 10 10 10 12 16 20 30 13 3 3 3 4, : 5 6 7 8 . ; , 9 0 L2:; •12 . t2 . 42 12 ; . k6 20 35 3 3 3 3 3 4 5 6 7 8 9 10 12.5 14 14 14 14 16 20 !? 3 ,3: 3. ,.' 3 3 4 5 6. 7 8 9 t0 1:2.5 45 L6 16 16 :. 16 20.; 45 3 3 3 3 3 4 5 6 7 8 9 10 12.5 15 17.5 18 18 18 20 3 3 3 _ 4 '_ .5 "" :6 7 EQ . 42.5> .15 ` 1.7_5 . 20 . .20. 20 _ W 60 3 3 3 3 3 4 5 6 7 8 9 10 12.5 15 17.5 20 24 24 24 Source: ASCEISEI 7-05, Minimum Design Loads for Buildins and Other Structures, Chapter 6. Figure 6-3. b. 41. SolarMount Unirac Code -Compliant Installation Manual : ' U N I RA[ Step 3: Determine Roof Zone (continued) Using Roof Zone Dimension Length, a, determine the roof zone locations according to your roof type, gable, hip or monoslope. Determine in which roof zone your pv system is located, Zone 1, 2, or 3 according to Figure 2. Figure 2. Enclosed buildings, wall and roofs Fls T• h y G T Hip Gable F-1 Interior Zones ■ End Zones ■ Corner Zones Roofs -Zone I (Walls -Zone 4 Roofs - Zone 2/Walls - Zone 5 Roofs - Zone 3 Source. ASCE/SEI 7-05, Minimum Design Loads for Buildings and Other Structures, Chapter 6, p. 41. Step 4: Determine Net Design Wind Pressure, pnet3o (psp Using the Effective Wind Area (Step 2), Roof Zone Location (Step 3), and Basic Wind Speed (Step 1), look up the appropriate Net Design Wind Pressure in Table 2, page 6. Use the Effective Wind Area value in the table which is smaller than the value calculated in Step 2. If the installation is located on a roof overhang, use Table 3, page 7. Both downforce and uplift pressures must be considered in overall design. Refer to Section 11, Step 1 for applying downforce and uplift pressures. Positive values are acting toward the surface. Negative values are acting away from the surface. ftV 5 U N I RA( Unirac Code -Compliant Installation Manual SolarMount Table 2. pnet3o (pso Roof and Wall Basic Wind Speed V (mph) �0 /00 rt0 ,. 120 :L`39 - 140 130 ? 170 Ettecave WndArea Zane (sfJ f?ownface .CJph([ Downforce Uplift U,plif't` Downforce Uplift Downforee UoMc,' Downforce Upbfe uwnib'ce-kldi7c - Downforce Uolif, [ 10 f4.6 , 7.3 -18.0 8 9 10.5 -25 9 (2-4 3Ov. 14.3 35 3 Eli S -4EJ 5 21.1 -52.0 1 20 t 3 6.9 -17.5 83 -2t.2 9.9 -252 [L' 296f' 13.4 344 19.8 -50.7 d 1 50 7 = 6.3 -i6.9 76 -205 9.0 -244 t06 286 12.3 33 2>4 t 38 [ I8.1 48.9 i [00 3 5.8 -Ib.S G = 9.9 :` 8.3 -237 ,'2.8 5 11.4 323 t G, n 7.G; I6J 47.6 '�° 2 I0 F4 ' 7.3 -30.2 $9 -3C:5 10.5 -43 5 f24I G 14.3 592 lb 679' 2!.! -87.2 o 2 20 S6 2>3 6.9 -27.0 83 .-2:6 9.9 -38856�= 13.4 52954 7� 19.8 -78.0 c 2 50 I 1 t3.4 ' 6.3 -22.7 7 6 -�7.5 9.0 -32 7 �t� fi � �# ; 12.3 -44.5 j:'14 � �_1 � 18.1 -65.7 c 0 2 100 7 tS.8 5.8 - 19.5 7 Q 23.6 8.3 -28 I 9 8 33 0` [ 1.4 38 2 ; f 3 0 -43 9 16.7 -56.4 3 10 5 95 7.3 45.4 9 %55t 10.5 -65 4� 4f $, 14.3 89 0 :16 5 -E02.2 21.1 - 131.3 3 20 6 6.9 -37.6 8 3 5 ; 9.9 -54 2 1:16 63.6, r, 13.4 73 8 4 7 19.8 -108.7 3 SO 5 t 6.3 -27.3 6 ` 33 ! � - 9.0 -39 3 l n 6 -4b�?- 12.3 53.5 k�€ � t 5 18.1 -78.9 3 100 4'.-7t58 5.8 -19.5 70 -236a- 8.3 -281 9:6 33©' 11.4 382 ,t@ e3.g; 16.7 -56.4 I I 10 84 1373 10.4 -16.5 t2.5 -19.9 14.9 -23.7 47 -27.8 20.3 -32.3 233 µ47.0 ' 30.0 -47.6 I 207 1( 9.4 -16.0 tt4 -494 13.6 -230 t6.0 270: 18.5 314t3 6tE• 27.3 46.3 (i 1 50 67 t .5 8.2 -15.4 C00 .-f9A 11.9 -222 t3:9 260 16.1 302 ,FS5t =3'" 23.8 -44.5 i 100 9 62 t ; 7.3 -. 4.9 $: - t8. t _ 10.5 -2 [ .5 _' 25 2 - 14.3 -29.3 (6 5 -3 6 2 i . I -43.2 2 10 4 23;2 10.4 -28.72.5 =3'4.7 14.9 -41 3 t7 -48 4 20.3 56 2 23 34.5 30.0 -82.8 e 2 20 Z 21 4 9.4 -26.4 44.4 e31 9 13.6 -38 0 t 8 46 ' 18.5 5 17 3 41 3 27.3 -76.2 2 50 7 1 8.2 -23.3 01f . 28 2 � _ 11.9 -3 .6 6 4 � 39 4 16.1 -45 7 , 8 5 23.8 -67.4 w 2 100 0 ` 7.3 -21.0 -S5 10.5 -30 3 .6 _ 14.3 -41.2 3 21.1 60.8 0 3 10 $ 4 10.4 ,42.4 12.5. =5 Q, 14.9 -61 0 7S 7t ¢ 20.3 -83.1 Z3 3 54,:. 30.0 -122.5 3 20 17 32.1 " 9.4 -39.6 11.4 4 7.9 13.6 -57 [ . F6.0 4;' 18.5 -77.7 213 49.2 27.3 -! 14.5 3 50 4,71 29>t _ 8.2 -36.0 f0 6, 43S 11.9 -5 18 16.1 70.5 `> 8 5 $ i-0 23.8 -104.0 3 100 7.3 -33.2 8 9 ; =40:2 10.5 -47 9 `3 4 -56.2 14.3 65 1 ' k6 5 MIA 21.1 -96.0 ' �.� ! 10 tr3 16.5 -18.0IfY 92t:8, 23.7 -25 9 2B -3th4 32.3 35 3 37 fi �}.5 47.6 -52.0 I 20 t:30 J,* 16.0 -17.1 9.4 -20.7 23.0 -24.6 2TU =28.9 31.4 -33.5 :36.0 8.4 46.3 -49.3 d i 50 t25 f2.8 15.4 -15.9 F8.6 -19.2 r 22.2 -22.8 0 -26:8 30.2 31 I 46 3 :7: 44.5 -45.8 i [ 00 t z l 12.1 14.9 -14.9 t8. l . - 118. t 21.5 -21.5 25.2 725.2 29.3 -29.3 33 6 33.6 43.2 -43.2 2 10 133 -17-0 16.5 -21.0 1,9,9 -25.5 23.7 -30.3 27.8 45.6� 32.3 -41.2 70, - 7.3- 47.6 -60.8 e 2 20 1,10 463 3 16.0 -20.1 i4.4 -24,3 23.0 -29.0 27 } " -340 31.4 -39.4 - 5 3 46.3 -58.1 2 50 1-25 45:3 15.4 -18.9 '18.6 -22.9 22.2 -27.2 260 =12.0 ` 30.2 -37.1 346 '425 44.5 -54.6 2 100 1.2 t .44.6 14.9 -18.0 21.5 -25.9 25.2 30 4 _ _ 29.3 -353 33 6 4;0.5 43.2 , -52.0 c 3 10 17:0 16.5 -21.0 t9.9 -25.5 23.7 -30 3 27.8 35,.6 32.3 41 2 >37 0 -47.3 47.6 -60.8 3 20 t3 0 t 3 16.0 -20. I t9 4 °-24.3 . 23.0 -29 0 27.k 340 . 31.4 39 4 b 0 5 3 46.3 -58. I 3 50 [0.3 15.4 -18.98f22$ _. 22.2 -272 26t n 32:0_� 30.2 37.1 _ . 5; 44.5 -54.6 3 100 14.9 -18.0 18: F 4t.$ ; 21.5 -25 9 ? 2 -30 4- 29.3 -35.3 -3 b :4,' 43.2 -52.0 4 10 C44 6 1-5.8 18.0 -19.5 21 8 -23:6 25.9 -28 i 30.4 33:G 35.3 38 2 40.5 -43 9 " 52.0 -56.4 i 4 20 4,51 17.2 -18.7 20:$ �22 6 24.7 -26 9 29 0 _ 31.6 33.7 36 7 ;38 7 -42 1 49.6 -54.1 1 4 50 t3 0 443 16.1 -17.6 t4.5-21.3 23.2 -25.4 27.2 -2'3,& . 31.6 -34.6 36 2 39 2 46.6 -51.0 4 100 t2 4 1 6 15.3 -16.8 48 5 .. -24 22.0 -24 2 5.9 28 4. , 30.0 -33.0 '-34 4 44.2 -48.6 4 500 60 t2 I 13.4 - 14.9 16 2 = 68 119.3 -2 15 22:7 25 22. 26.3 29.3 _316 313 2 33 38.8 43.2 ' 5 10 t4 6 t 5 18.0 -24.1 2 L8 -291 t 25.9 -34 7 3i):4 -�tO.T, 35.3 -47 2 44 5 54 2 52.0 -69.6 5 20 t3; 0 ,: 17.2 -22.5 20.8. ' 2 1 - 24.7 -32 4 .29.0 38 0-- 33.7 44 0 ,3€#7 5Q.5 49.6 -64.9 5 50 13 0 = t6 5 16.1 -20.3 19.5 -24-6 ' 23.2 -29 3 27 3 34 3 31.6 39 8 36 2 7 46.6 -58J 5 i OG t2.4 ' -15. t 15.3 -18.7 1$:5 22.6 22.0 -26 9 25.9 31.6` 30.0 36 7 34 4 -42.1 ` 44.2 -54. [ 1 1 5 1 500 i 1 1, 7 - ei ! :v. 13.4 - [ A 38.8 -43.2 Source: ASCE/SEI 7-05, Minimum Design Loads for Buildings and Other Structures, Chapter 6, Figure 6-3, p. 42-43. use 6 SolarMount Unirac Code -Compliant Installation Manual pp U N I RAC Table 3. p„et30 (psq Roof Overhang Source: ASCEISEI 7-05, Minimum Design Loads for Buildings and Other Structures, Chapter 6, p. 44. Step 5: Determine the Topographic Factor, Kzt For the purposes of this code compliance document, the Topographic Factor, Kzt, is taken as equal to one (1), meaning, the installation is surrounded by level ground (less than 10% slope). If the installation is not surrounded by level ground, please consult ASCE 7-05, Section 6.5.7 and the local building authority to determine the Topographic Factor. Step 6: Determine Exposure Category (B, C, D) Determine the Exposure Category by using the following definitions for Exposure Categories. The ASCE/SEI 7-05 defines wind exposure categories as follows: EXPOSUxe B: is urban and suburban areas, wooded areas, or other terrain with numerous closely spaced obstructions having the size of single family dwellings. F"osuRE c: has open terrain with scattered obstruc- tions having heights generally less than 30 feet. This category includes flat open country, grasslands, and all water surfaces in hurricane prone regions. EXPOSURE D: has flat, unobstructed areas and water sur- faces outside hurricane prone regions. This category includes smooth mud flats, salt flats, and unbroken ice. Also see ASCE 7-05 pages 287-291 for further explanation and explanatory photographs, and confirm your selection with the local building authority. PW 7 :: U N I RA( Unirac Code -Compliant Installation Manual SolarMount Step 7: Determine adjustment factor for height and exposure category, A Using the Exposure Category (Step 6) and the roof height, h (ft), look up the adjustment factor for height and exposure in Table 4. Step 8: Determine the Importance Factor, I Determine if the installation is in a hurricane prone region. Look up the Importance Factor, I, Table 6, page 9, using the occupancy category description and the hurricane prone region status. Step 9: Calculate the Design Wind Load, poet (psf) Multiply the Net Design Wind pressure, pner3o (psf) (Step 4) by the adjustment factor for height and exposure, A (Step 7),the Topographic Factor, Kzt (Step 5), and the importance Factor, I (Step 8) using the following equation, or Table 5 Worksheet. pnet (psf) = AKztlPnet3o pnet (psf) = Design Wind Load (10 psf minimum) A = adjustmentfactor for height and exposure category- (Step 7) Kzt = Topographic Factor at mean roof height, h (ft) (Step 5) I = Importance Factor (Step 8) pner3o (psf) = net design wind pressure for Exposure B, at height = 30, I = 1 (Step 4) Use Table 5 below to calculate Design Wind Load. The Design Wind Load will be used in Part II to select the appropriate SolarMount Series rail, rail span andoot spacing. In Part H, use both the positive (downforce) and the negative (uplift) results from this calculation. Table 4. Adjustment Factor (A) for Roof Height & Exposure Category Mean roof height (ft) B Exposure C D 15 1.00 1.21 1.47 20 1.00 1.29 1.55 25 1.00 1.35 1.61 30 1.00 1.40 1.66 35 1.05 1.45 1.70 40 1.09 149 1.74 45 1.12 1.53 1.78 50 1.16 1.56 1.81 55 1.19 1.59 1.84 60 1.22 1.62 1.87 Source: ASCEISEI 7-05, Minimum Design Loads for Buildings and Other Structures, Chapter 6, figure 6-3, p. 44. Table S.Worksheet for Components and Cladding Wind Load Calculation: IBC 2006,ASCE 7-05 Variable Description Symbol Buifding Height h Building, Least Horizontal Dimension Roo€ Pitch Exposure Category Basic Wind Speed V Effective Wind Area Roof Zone Setback Length a Roof Zone Location Net Design Wind Pressure pnm�o Topographic Factor Kzt Adjustment factor for height and exposure category A Importance Factor I Total Design Wind Load Pnet N. Value Una Step Reference ft degrees> ._ . 6 mph I- Figure I sf 2 3, Table i , 3 Figure 2 psf 4 Table 2,3 x 5 x _ 7 Table 4 x 8 Table 5 psf 9 SolarMount Unirac Code -Compliant Installation Manual CF U N I RAC Table 6.Occupancy Category Importance Factor Non -Hurricane Prone Regions and Hurricane Prone Regions Hurricane Prone Re- with Basic Wind Speed,V = gions with Basic Wind Category Category De—"- Building Type Examples 85-100 mph, and Alaska SpeedV> I00mph I Buildings and other Agricultural facilities 0.87 0.77 structures that Certain Temporary facilities represent a low Minor Storage facilities hazard to human life in the event of failure, including, but limited to: All buildings, and other II structures except those I I listed in Occupancy Categories I, III, and IV. Buildings and other Buildings where more than 300 people congregate structures that Schools with a capacity more than 250 1.15 1.15 III represent a substantial Day Cares with a capacity more than 150 hazard to human life in Buildings for colleges with a capacity more than 500 the event of a failure, Health Care facilities with a capacity more than 50 or including, but not limited more resident patients to: Jails and Detention Facilities • Power Generating Stations • Water and Sewage Treatment Facilities • Telecommunication Centers • Buildings that manufacture or house hazardous materials Buildings and other Hospitals and other health care facilities having 1.15 1.15 structures designated surgery or emergency treatment IV as essential facilities, Fire, rescue, ambulance and police stations including, but not limited Designated earthquake, hurricane, or other to: emergency shelters • Designated emergency preparedness communication, and operation centers • Power generating stations and other public utility facilities required in an emergency • Ancillary structures required for operation of Occupancy Category IV structures • Aviation control towers, air traffic control centers, and emergency aircraft hangars • Water storage facilities and. pump structures required to maintain water pressure for fire suppression • Buildings and other structures having critical national defense functions Source: IBC 2006,Table 1604.5, Occupancy Category of Buildings and other structures, p. 281; ASCEISEI 7-05, Minimum Design Loads for Buildings and Other Structures, Table 6-1, p. 77 NV 9 ' U N � RAC:Unirac Code -Compliant Installation Manual SolarMount Part H. Procedure to Select Rail Span and Rail Type [2.1,] Using Standard Beam Calculations, Structural Engineering Methodology The procedure to determine the Unirac SolarMount series rail type and rail span uses standard beam calculations and structural engineering methodology. The beam calculations are based on a simply supported beam conservatively, ignoring the reductions allowed for supports of continuous beams over multiple supports. Please refer to Part I for more information on beam calculations equations and assumptions. If beams are installed perpendicular to the eaves on a roof steeper than a 4/12 pitch in an area with a ground snow load greater than 30psf, then additional analysis is required for side loading on the roof attachment and beam. In using this document, obtaining correct results is dependent upon the following: 1. Obtain the Snow Load for your area from your local building official. 2. Obtain the Design Wind Load, pnet• See Part 1 (Procedure to Determine the Design Wind Load) for more information on calculating the Design Wind Load. 3. Please Note: The terms rail span and footing spacing are interchangeable in this document. See Figure 3 for illustrations. 4. To use Table 8 and Table 9 the Dead Load for your specific installation must be less than 5 psf, including modules and Unirac racking systems. If the Dead Load is greater than 5 psf, see your Unirac distributor, a local structural engineer or contact Unirac. The following procedure will guide you in selecting a Unirac rail for a flush mount installation. It will also help determine the design loading imposed by the Unirac PV Mounting Assembly that the building structure must be capable of supporting. Step 1: Determine time Total Design load Figure 3. R spacing an �gr 10 The Total Design Load, P (psf) is determined using ASCE 7-05 2.4.1 (ASD Method equations 3,5,6 and 7) by adding the Snow Load', S (psf), Design Wind Load, pnet (psf) from Part I, Step 9 and the Dead Load (psfl. Both Uplift and Downforce Wind Loads calculated in Step 9 of Part 1 must be investigated. Use Table 7 to calculate the Total Design Load for the load cases. Use the maximum absolute value of the three downforce cases and the uplift case or sizing the rail. Use the uplift case only for sizing lag bolts pull out capacities (Part II, Step 6). Use the following equations or Table 7. P (psfl =1.0D + 1.05' (downforce case 1) P (psf) = I.OD + I.Opnet (downforce case 2) P (psfl = I.OD + 0.755' + 0.75pnet (downforce case 3) P (psfl = 0.6D + I.Opnet (uplift) D = Dead Load (psfl S = Snow Load (psfl pnet = Design Wind Load (psf) (Positive for downforce, negative for uplift) The max:.mum Dead Load, D (psf), is 5 psf based on market research and internal data. ' Snow Load Reduction - The snow load can be reduced according to Chapter 7 ofASCE 7-05. The reduction is a function of the roof slope, Exposure Factor, Importance Factor and Thermal Facto: Please refer to Chapter 7 of ASCE 7-05 for more information. 'EVULW c ivivuuies MUI&L ue ceruereu syrantetrwaliy on the rails (+/- 2 x), as shown in Figure 3. SolarMount Unirac Code -Compliant Installation Manual p: U N I RAC Table 7. ASCE 7 ASD Load Combinations Note: Table to be filled out or attached for evaluation. Step 2: Determine the Distributed Load on the rail, w (p1V Determine the Distributed Load, w (pif), by multiplying the module length, B (ft), by the Total Design Load, P (psi) and dividing by two. Use the maximum absolute value of the three downforce cases and the Uplift Case. We assume each module is supported by two rails. w = PB/2 w = Distributed Load (pounds per linear foot, plf) B = Module Length Perpendicular to Rails (ft) P = Total Design Pressure (pounds per square foot, psO Table 8. L-Foot SolarMount Series Rail Span SM - SolarMount HD - SolarMount Heavy Duty Step 3: Determine Rail SpiuV L Foot Spacing Using the distributed load, w, from Part II, Step 2, look up the allowable spans, L, for each Unirac rail type, SolarMount (SM) and SolarMount Heavy Duty (HD). The L-Foot SolarMount Series Rail Span Table uses a single L-foot connection to the roof, wall or stand-off. Please refer to the Part III for more installation information. 11 :: U N I RAC Unirac Code -Compliant Installation Manual SolarMount Step 4: Select Rail Type Selecting a span and rail type affects the price of your installation. Longer spans produce fewer wall or roof penetrations. However, longer spans create higher point load forces on the building structure. A point load force is the amount of force transferred to the building structure at each connection. It is the installer's resnonsibility to verify that the building structure is strong enough to sunnort the point load forces. Table 10. Downforce Point Load Calculation Step 5: Determine the Downforce Point Load R (lbs), at each connection based on rail span When designing the Unirac Flush Mount Installation, you must consider the downforce Point Load, R Obs) on the roof structure. The Downforce, Point Load, R (lbs), is determined by multiplying the Total Design Load, P (psf) (Step 1) by the Rail Span, L (ft) (Step 3) and the Module Length Perpendicular to the Rails, B (ft) divided by two. R (lbs) = PLB/2 R = Point Load (Ibs) P = Total Design Load (psfl L = Rail Span (ft) B = Module Length Perpendicular to Rails (ft) It is the installer's responsibility to verify that the building structure is strong enough to support the maximum point loads calculated according to ctep C Total Design Load (downforce) (max of case 1, 2 or 3): P psf Step I Mod ile length ---di- -1— to a G, Rail Span: L x ft Step 4 /2 Downforce Point Load: R Ibs Page 12 SolarMount Unirac Code -Compliant Installation Manual :N U N I RACo Step 6: Determine the Uplift Point Load, R (lbs), at each connection based on rail span You must also consider the Uplift Point Load, R (lbs), to determine the required lag bolt attachment to the roof (building) structure. Table 11. Uplift Point Load Calculation Total Design Load (uplift): Module length perpendicular to rails: Rail Span: Uplift Point Load: P B x L x R f2 psf Step I ft ft Step 4 Ibs Table 12 Lag pull-out (v&Wr&nQ capacities (Ibs) in typical roof lumber (ASD) Use Table 12 to select a lag bolt size and embedment depth to Lag screw sped fications satisfy your Uplift Point Load Force, R (lbs), requirements. Specific 6/6- shaft,* Divide the uplift pointload (from gravity per inch thread depth Table 11) by the withdrawal capacity in the 2nd column of Douglas Fir, Larch 0.50 266 Table 12. This results in inches of 5/16 lagbolt embedded thread Douglas Fir, South 0.46 235 depth needed to counteract the Engelmann Spruce, Lodgepole Pine uplift force. If other than lag (MSR 1650 f & higher) 0.46 235 bolt is used (as with a concrete or steel), consult fastener mfr Hem, Fir, Redwood (close grain) 0.43 212 documentation. Hem, Fir (North) 0.46 235 I Southern Pine 0.55 307 Thread It is the installer's responsibility depth to verify that the substructure Spruce, Pine, Fir 0.42 205 L and attachment method is strong enough to support the Spruce, Pine, Fir maximum point loads calculated (E of 2 million psi and higher according to Step 5 and Step 6. grades of MSR and MEL) 0.50 266 Sources:American Wood Councii, NDS 2005,Table 11.2A,11.3.2A Notes: (1) Thread must be embedded in the side grain of a rafter or other structural member integral with the building structure. (2) Lag bolts must be located in the middle third of the structural member. (3) These values are not valid for wet service. (4) This table does not include shear capadties. If necessary, contact a local engineer to specify lag bolt size with regard to shear forces. (5) Install lag bolts with head and washer flush to surface (no gap). Do not over -torque. (6) Withdrawal design values for lag screw connections shall be multiplied by applicable adjustment factors if necessary. See Table 10.3.1 in the American Wood Council NDS for Wood Construction. *Use flat washers with lag screws. ftr 13 :- U N I RAC Unirac Code -Compliant Installation Manual SolarMount Part III. Installing SolarMount The Unirac Code -Compliant Installation Instructions support applications for building permits for photovoltaic arrays using Unirac PV module mounting systems. This manual, SolarMount Planning and Assembly, governs installations using the SolarMount and SolarMount HD (Heavy Duty) systems. [3.1.] SolarMount rail components Rail — Supports PV modules. Use two per row of modules. Aluminum extrusion, anodized. Rail splice — Joins and aligns rail sections into single length of rail. It can form either a rigid or thermal expansion joint, 8 inches long, predrilled. Aluminum extrusion, anodized. 0 Self -drilling screw — (No. 10 x 3/4") — Use 4 per rigid splice or 2 per expansion joint. Galvanized steel. 0 L-foot — Use to secure rails either through roofing material to building structure or standoffs. Refer to loading tables for spacing. *.Tote: Please contact Unirac for use and specification of double L-foot. © L-foot bolt (3/8" x 3/4") — Use one per L-foot to secure rail to L-foot. Stainless steel. Flange nut (3/8") — Use one per L-foot to secure rail to L-foot. Stainless steel. Flattop standoff (optional) (3/8") — Use standoffs to increase the height of the array above the surface of the roof or to allow for the use of flashings. Use one per L-foot. One piece: Service Condition 4 (very severe) zinc -plated -welded steel. Includes 3/8" x 1/4" bolt with N' 14 Figure 4. SolarMount standard rail components. lock washer for attaching L-foot. Faashings: Use one per standoff. Unirac offers appropriate flashings for both standoff types. Note: There is also a flange type standoff that does not require an L-foot. 0 Aluminum two-piece standoff (optional) (4" and 7") - Use one per L-foot. Two-piece: Aluminum extrusion. Includes 3/8" x 3/4" serrated flange bolt with EPDM washer for attaching i -fnnt and twn S/l(_," lea }Jnitg OLag screw for L-foot (5/16") —Attaches standoff to rafter. 4' Top Mounting Clamps 4D Top Mounting Grounding Clips and Lugs Installer supplied materia:s! • Lag screw for L-foot — Attaches L-foot or standoff to rafter. Determine the length and diameter based on pull- out values. If lag screw head is exposed to elements, use stainless steel. Under flashings, zinc plated hardware is adequate. • Waterproof roofing sealant — Use a sealant appropriate to your roofing material. Consult with the company currently providing warranty of roofing. SolarMount Unirac Code -Compliant Installation Manual 0: U N I RA[ [3.2.] Installing SolarMount with top mounting clamps This section covers SolarMount rack assembly where the installer has elected to use top mounting clamps to secure modules to the rails. It details the procedure for flush mounting SolarMount systems to a pitched roof. ✓� YS� Mid Clamp ..mom End Clamp -foot SolarMount Rail ° Meunt Rail Figure 5. Exploded view of a flushmount installation mounted with L feet. Table 14. Clamp kit part quantities End Mid Y4- module Y4-x %- A" flange All top down clamps must be installed with anti - Modules clamps clamps clamp bops safety bolts nuts seize to prevent galling and provide uniformity Q in clamp load. UniRac Inc recommends Silver 2 4 2 6 2 8 Grade LocTite Anti -Seize Item numbers: 38181, 3 4 4 8 2 10 80209,76732,76759,76764, 80206, and 76775, or 4 4 6 10 2 12 equivalent. 114" - 20 hardware used in conjunction 5 4 8 12 2 14 with top down clamps must be installed to 10 ft-lbs 6 4 10 14 2 16 of torque. When using UGC-1, UGC-2, WEEB 9.5 and 7 4 12 16 2 18 WEEB 6.7, 114" - 20 hardware must be installed to 8 4 14 18 2 20 10 ft-lbs of torque. Additionally, when used with a top down clamp, the module frame cross section must be boxed shaped as opposed to a single, 1-shaped member. Please refer to installation supplement 910: Table 15.Wrenches and torque Galling and Its Prevention for more information on galling and anti -seize and installation manual Wrench Recommended 225: Top Mounting Unirac Grounding Clips size torque (ft4bs) and WEEBLugs for more information on Grounding Y4- hardware '(67 10 Clips." Y8- hardware 9/,C Torques are not designated for use *,M wood connectors P-V 15 :: U N I RA[ Unirac Code -Compliant Installation Manual SolarMount [3.2.1] Planning your SolarMount installations The installation can be laid out with rails parallel to the rafters The width of the installation area equals the length of one or perpendicular to the rafters. Note that SolarMount rails module. make excellent straight edges for doing layouts. The length of the installationri area is equal to: 111G Center the installation area over the structural members as the total width of the modules, much as possible. Leave enough room to safely move around the array during installation. Some building codes require minimum clearances around such installations, and the user should be directed to also check The Code'. Page 16 • plus 1 inch for each space between modules (for mid - clamp), • plus 3 inches (11/2 inches for each pair of end clamps). Peak I i w w � Low -profile mode � � High -profile mode Tj Gutter Figure 6. Rails maybe placed parallel or perpendicular to rafters. SolarMount Unirac Code -Compliant Installation Manual :: U N I RA[ [3.2.2] Laying out L-feet L-feet (Fig. 7) can be used for attachment through existing roofing material, such as asphalt shingles, sheathing or sheet metal to the building structure. Use Figure 8 or 9 below to locate and mark the position of the L-feet lag screw holes within the installation area. If multiple rows are to be installed adjacent to one another, it is not likely that each row will be centered above the rafters. Figure 7 Adjust as needed, following the guidelines in Figure 9 as closely as possible. �— Overhang 25% L max 25% of moduleIwidth mo— Foot spacing/ Rail S an " !I 111 7, II i \ Tf` 1 II II 11 'I I " 50%of module II I: width (TYP) I 11 \ I I Note: Modules must be Lower roof edge Rafters centered symmetrically on the (Building Structure) rails (+/-2'). If this is not the case, call Uniracfor assistance. Figure ti. Layout with rails perpendicular to rafters. Installing L-feet Drill pilot holes through the roof into the center of the rafter at each L-foot lag screw hole location. Squirt sealant into the hole, and on the shafts of the lag screws. Seal the underside of the L- feet with a suitable sealant. Consult with the company providing the roofing warranty. Securely fasten the L-feet to the roof with the lag screws. Ensure that the L-feet face as shown in Figure 8 and 9. For greater ventila- tion, the preferred method is to place the single -slotted square side of the L-foot against the roof with the double -slotted side perpen- dicular to the roof. If the installer chooses to mount the L-foot with the long leg against the roof, the bolt slot closest to the bend must be used. Figure 9. Layout with rails parallel to rafters. NP 17 M U N I RA[ Unirac Code -Compliant Installation Manual SolarMount [3.2.3] Laying out standoffs Standoffs (Figure 10) are used to increase the height of the array above the surface of the roof. Pair each standoff with a flashing to seal the lag bolt penetrations to the roof. Use Figure 11 or 12 to locate and mark the location of the standoff lag screw holes within the installation area. Remove the tile or shake underneath each standoff location, exposing the roofing underlayment. Ensure that the standoff base lies flat on the underlayment, but remove no more mate- rial than required for the flashings to be installed properly. The standoffs must be ftrmlyattached to the building structure. Figure 10. Raised,flange standoff (left) and fiat top standoff used in conjunction with an L-foot. Overhang 25% L max 1�z 25%module width Foot spacing/ each end RailWan,_L 17/s" 50% module width (TYP) Lower roof edge I �— Rafters —� (Building Structure) Note: Modules must be centered symmetrically on the rails (+/- 2' ). If this is not the case, call Unirac for assistance. Figure 11. Layout with rails perpendicular to rafters.perpendicular to rafters. Overhang 25% of 50% B typical' E module width (TYP) I �\ Foot spacing] s - Span "L" Lower roof edge ( Overhang 25% L;max i y Rafters (Building Structure) Note: Modules must be centered symmetrically on the rails (+/- 2*). If this is not the case, tali Unirac for assistance. Figure 12. Layout with rails parallel to rafters. If multiple high -profile rows are to be installed adjacent to each other, it may not be possible for each row to be centered above the rafters. Adjust as needed, following the guidelines of Fig. 12 as closely as possible. Installing standoffs: Drill 3/16 inch pilot holes through the underlayment into the center of the rafters at each standoff location. Securely fasten each standoff to the rafters with the two 5/16" lag screws. Ensure that the standoffs face as shown in Figure 11 or 12. Unirac steel and aluminum two-piece standoffs (1-5/8" O.D.) are designed for collared flashings available from Unirac. Install and seal (lashings and standoffs using standard building practices or as the company providing roofing warranty directs. SolarMount Unirac Code -Compliant Installation Manual p: U N I RAC [3.2.4] Installing SolarMount rails Keep rail slots free of roofing grit or other debris. Foreign matter will cause bolts to bind as they slide in the slots. Installing Splices: If your installation uses SolarMount splice bars, attach the rails together (Fig.13) before mounting the rails to the footings. Use splice bars only with flush installations or those that use low -profile tilt legs. Although structural, the joint is not as strong as the rail itself. A rail should always be supported by more than one footing on both sides of the splice. (Reference installation manual 908, Splices/Expansion Joints.) If using more than one splice per rail, contact Unirac concerning thermal expansion issues. Mounting Rails on Footings: Rails may be attached to either of two mounting holes in the L-feet (Fig.14). Mount in the lower hole for a low profile, more aesthetically pleasing installation. Mount in the upper hole for a higher profile, which will maximize airflow under the modules. This will cool them more and may enhance performance in hotter climates. Slide the %-inch mounting bolts into the footing bolt slots. Loosely attach the rails to the footings with the flange nuts. Ensure that the rails are oriented to the footings as shown in Figure 8, 9, 11, or 12, whichever is appropriate. Aligning the Rail End: Align one pair of rail ends to the edge of the installation area (Fig.15 or Fig.16). Figure 13. Splice bars slide into the footing bolt slots of SolarMount rail sections. The opposite pair of rail ends will overhang the side of the installation Figure 14. Foot -to -rail splice attachment area. Do not trim them off until the installation is complete. If the rails are perpendicular to the rafters (Fig.15), either end of the rails can be aligned, but the first module must be installed at the aligned end. If the rails are parallel to the rafters (Fig.16), the aligned end of the rails must face the lower edge of the roof. Securely tighten all hardware after alignment is complete (30 ft lbs). Mount modules to the rails as soon as possible. Large temperature changes may bow the rails within a few hours if module placement is delayed. Edge of installation area 1 I 1 Figure 15. Rails perpendicular to the rafters. Edge of installation area Figure 16. Rails parallel to the rafters. PW 19 d U N I RA( Unirac Code -Compliant Installation Manual SolarMount [3.2.51 Installing the modules Pre -wiring Modules: If modules are the Plug and Play type, no pre -wiring is required, and you can proceed directly to "Installing the First Module" below. If modules have standard J-boxes, each module should be pre -wired with one end of the intermodule cable for ease of installation. For safety reasons, module pre -wiring should not be performed on the roof. Leave covers off J-boxes. They will be installed when the modules are installed on the rails. Installing the First Module: In high -profile installations, the safety bolt and flange nut must be fastened to the module bolt slot at the aligned (lower) end of each rail. It will prevent the lower end clamps and clamping bolts from sliding out of the rail slot during installation. If there is a return cable to the inverter, connect it to the first module. Close the J-box cover. Secure the first module with T-bolts and end clamps at the aligned end of each rail. Allow half an inch between the rail ends and the end clamps (Fig.18). Finger tighten flange nuts, center and align the module as needed, and securely tighten the flange nuts (10 ft lbs). Installing the other Modules: Lay the second module face down (glass to glass) on the first module. Connect intermodule cable to the second module and close the J-box cover. Turn the second module face up (Fig.17). With T-bolts, mid -clamps and flange nuts, secure the adjacent sides of the first and second modules. Align the second module and securely tighten the flange nuts (Fig.19). For a neat installation, fasten wire management devices to rails with self -drilling screws. Repeat the procedure until all modules are installed. Attach the outside edge of the last module to the rail with end dW Ts. Trim off any excess rail, being careful not to cut into the roof. Allow half an inch between the end clamp and the end of the rail (Fig. 18). Figure 17 Figure 18 Figure 19 J-boxes High -lipped module w (cross section) Spacer Low -lipped module I (cross section) - ; - aun, _ J.T� Quell Figure 20. Mid clamps and end clamps for lipped -frame modules are identical. A spacer for the end clamps is necessary only if the lips are located high on the module frame. Page 20 SolarMount Unirac Code -Compliant Installation Manual ;; U N I RAC [3.3] Installing SolarMount with bottom mounting clips This section covers SolarMount rack assembly where the installer has elected to use bottom mounting clamps to secure modules to the rails. It details the procedure for flush mounting SolarMount systems to a pitched roof. Solarmoont tail Figure 21. SAM and CB components Table 16. Wrenches and torque Wrench Recommended size torque (ft4bs) Y4 - hardware %s" 10 '/s" hardware %b" 20 Note. Torque specifications do not apply to lag bok connections. Footing bolt slot Bottom mounting clip QStainless steel hardware can seize up, a process called galling. To significantly reduce its likelihood, (1) apply lubricant to bolts, preferably an anti -seize lubricant, available at auto parts stores, (2) shade hardware prior to installation, and (3) avoid spinning on nuts at high speed. See Installation Supplement 910, Galling and Its Prevention, atwww.unirac.com Pw 21 N U N I RAC Unirac Code -Compliant Installation Manual SolarMount [3.3.1 ] Planning the installation area Decide on an arrangement for clips, rails, and L-feet (Fig. 22). Use Arrangement A if the full width of the rails contacts the module. otherwise use Arrangement B. Caution. if you choose Arrangement B, either (1) use the upper mounting holes of the L feet or (2) be certain that the L feet and clip positions don't conflict. If rails must be parallel to the rafters, it .s unlikely that they can be spaced to match rafters. In that case, add structural supports — either sleepers over the roof or mounting blocks beneath it. These additional members must meet code; if in doubt, consult a professional engineer. Never secure the footings to the roof decking alone. Such an arrangement will not meet code and leaves the installation and the roof itself vulnerable to severe damage from wind. Leave enough room to safely move around the array during installation. The width of a rail -module assembly equals the length of one module. Note that L-feet may extend beyond the width of the assembly by as much as 2 inches on each side. The length of the assembly equals the total width of the modules. NP 22 Distance between Icig bolt Centers: i z'i-2i^ z'i zr^� Distance botw8en module mounting he Pb module i Module belt Clip j� Rail rLr -foot —s Lag bait Distance between ling bolt centers 1�27/ Distance between module mounting holes I � � i Figure 22. Clip Arrangements A and B SolarMount Unirac Code -Compliant Installation Manual 0 U N I RA[ [3.3.21 Laying out the installing L-feet L-feet are used for installation through existing low profile roofing material, such as asphalt shingles or sheet -metal. They are also used for most ground mount installations. To ensure that the L-feet will be easily accessible during flush installation: • Use the PV module mounting holes nearest the ends of the modules. • Situate the rails so that footing bolt slots face outward. The single slotted square side of the L-foot must always lie against the roof with the double -slotted side perpendicular to the roof. Foot spacing (along the same rail) and rail overhang depend on design wind loads. Install half the L-feet: • If rails are perpendicular to rafters (Fig. 23), install the feet closest to the lower edge of the roof. • If rails are parallel to rafters (Fig. 24), install the feet for one of the rails, but not both. For the L-feet being installed now, drill pilot holes through the roofing into the center of the rafter at each lag screw hole location. Squirt sealant into the hole and onto the shafts of the lag screws. Seal the underside of the L-feet with a sealant. Securely fasten the L-feet to the building structure with the lag screws. Ensure that the L-feet face as shown in Figure 23 or Figure 24. Hold the rest of the L-feet and fasteners aside until the panels are ready for the installation. I I 11 L _ Install Second II � lei SolarMouht Rails Install First Lower II roof edge Rafters Figure 23. Layout with rails perpendicular to rafters. N&I 23 :: U N I RA( Unirac Code -Compliant Installation Manual SolarMount [3.3.3] Attaching modules to the rails Lay the modules for a given panel face down on a surface that will not damage the module glass. Align the edges of the modules and snug them together (Fig. 21, page 22). Trim the rails to the total width of the modules to be mounted. Place a rail adjacent to the outer mounting holes. Orient the footing bolt slot outward. Place a clip slot adjacent to the mounting holes, following the arrangement you selected earlier. Assemble the clips, mounting bolts, and flange nuts. Torque the flange nuts to 1-0 foot-pounds, [3.3.4] Installing the module -rail assembly Bring the module -rail assembly to the installation site. Keep rail slots free of debris that might cause bolts to bind in the slots. Consider thew. eight of a fully assembled panel. Unirac recom- mends safety1111CJ 1N11C11CJC1 tlll olle tV a tool. Align the panel with the previously installed L-feet. Slide 3/8 inch L-foot mounting bolts onto the rail and align them with the L-feet mounting holes. Attach the panel to the L-feet and finger tighten the flange nuts. Rails may be attached to either of two mounting holes in the footings (Fig. 25). • Mount in the lower hole for a low, more aethetically pleasing installation. • Or mount in the upper hole to maximize a cooling airflow under the modules. This may enhance perfor- mance in hotter climates. Adjust the position of the panel as needed to fit the installa- tion area. Slide the remaining L-feet bolts onto the other rail, attach L-feet, and finger tighten with flange nuts. Align L-feet with mounting holes previously drilled into the roof. Install lag bolts into remaining L-feet as described in "Laying out and installing L-feet" above. Torque all footing flange nuts to 20 foot-pounds. Verify that all lag volts are securely fastened. Page 24 Figure 25. Leg -to -rail attachment SolarMount Unirac Code -Compliant Installation Manual 0NEU N I RAC [3.4] Installing SolarMount with grounding clips and lugs Clips and lugs are sold separately. UGC-1 Nib Conforms to UL Standard 467 WEEBLug Figure 28. UGC-1 layoutfor even and odd number of modules in row. `W" denotes places to install UGC-1. �iwneio iauoaeu :amm000m umureWmE roa remmee■ iemmrm■ rue rereruas somm!/a■ r!lamili oUMe ■ /rerr/ee eee/ee■• a/a■ eUM■ r//!e/r/a e//!■ :arsm::: ae■■a ee/r//eom ee/esomm errrreee eeaeeeo■ rr r euuris e�du`e�r esi*��r� i���R�s• is�riu r/arramr errrraar relenan• ■errnnr■ aneaaer■ -rr000 er!lrrr/ uaerua !mono: euaree■ uuera noero:::IMm oomar■ ■oeaao ieiii/ee iefrer/eeeeire/e ieeeie/i ■eel/i■r arrrrair arnnriar anreaemr inraenre ■raaraaa ■■rleOr r///rlri !r!N■/! alOer/m eer/er/■ !rrrrlrr rareamrr anemone! ■lnomma■ ■mooaro■ rileeeer !/e/r/ee ■leriere rnaarnee ■erraer■ Odd Numberrr r ' To I` mounting .�� clamps f I Module T-bolt e s UGC-1 - _Lr aSim R= SolarMount@ rail (any type) Figure 27. Insert a bolt in the aluminum rail or through the clearance hole in the stainless steel flat washer. Place the stainless steel flat washer on the bolt, oriented so the dimples will contact the aluminum rail. Place the lugportion on the bolt and stainless steel flat washer. Install stainless steel flat washer, lock washer and nut. Tighten the nut until the dimples are completely embedded into the rail and lug. The embedded dimples make agas-tight mechanical connection and ensure good electrical connection between the aluminum rail and the lug through the WEEK. Figure 29. Single wire grounding with spliced rails. KEY PV module O SolarMount rail (any type) 0 Roil splice X Grounding lug — Copper wire Figure 26. Slide UGC-1 grounding clip into top mounting slot of rail. Torque modules in place on top of clip. Nibs will penetrate rail anod- iaation and create grounding path through rail (see Fig. 3, reverse side). LON WEEBLug !!!! ountC�l (any type) Peg: 25 an U N I RA[ Unirac Code -Compliant Installation Manual SolarMount 10 year limited Product Warranty, 5 year limited Finish Warranty Unirac, Inc., warrants to the original purchaser ("Purchaser') of product(s) that it manufactures ("Product") at the original installation site that the Product shall be free from defecu In material and workmanship for a period often (10) years, except for the anodized finish, which finish shall be free from visible peeling, or cracking or chalking under normal atmospheric conditions for a period of five (5) years, from the earlier of 1) the date the installation of the Product is completed, or 2) 30 days after the purchase of the Product by the original Purchaser ("Finish Warranty"). The Finish Warranty does not apply to any foreign residue deposited on the finish. All installations in corrosive atmospheric conditions are excluded. The Finish Warranty is VOID if the practices specified byAAMA 609 & 610-02 —"Cleaning and Maintenance for Architecturally Finished Aluminum" (wwwaamanetorg) are not followed by Purchaser.This Warranty does not cover damage to the Product that occurs during its " shipment, storage, or installation. This Warranty shall be VOID if installation of the Product is not performed in accordance with Unirarc written installation instructions, or if the Product has been modified, repaired, or reworked in a manner not previously authorized by Unirac IN WRITING, or if the Product is installed in an environment for which it was not designed. Unirac shall not be liable for consequential, contingent or incidental damages arising out of the use of the Product by Purchaser under any circumstances. If within the specified Warranty periods the Product shall be reasonably proven to be defective, then Unirac shall repair or replace the defective Product, or any part thereof, in Unirac's sole discretion. Such repair or replacement shall completely satisfy and discharge all of Unirac's liability with respect to this limited Warranty. Under no circumstances shall Unirac be liable for special, indirect or consequential damages arising out of or related to use by Purchaser of the Product. Manufacturers of related items, such as PV modules and flashings, may provide written warranties of their own. Unirac's limited Warranty covers only its Product, and not any related items. se I RAC 1411 Broadway Boulevard NE 2e 26 so Albuquerque NM 87102-1545 USA Albuquerque w` ■ Colorado Spring§ �+ k' ,{PA VA + &l.OY Denver Fort Worth 4900 Lang Ave. NE Houston Alb upuertt ue, NM 87109 Kansass CNy Lenexa P.O. Box 94000, 87199-4000 Omaha 505-348-4000 Pasadena 505-348-4055 Fax Phoenix Rio Rancho Salina San BemanNno San Diego Wilson & Company Latin Amedca, LLC 27 February, 2008 Applications Engineering Department UniRac, Inc. 1411 Broadway Boulevard NE Albuquerque, New Mexico 87102-1545 Re: Engineering Certification for UniRac's SolarMount Flush, Code -Compliant Installation Manual 227 WCEA File: 0&IN-204 00 To Whom It May Cern: I have reviewed the portions of the subject manual pertaining to the structural calculation of applied loads and beam selection. Specifically, this consists of "Part I. Procedure to Determine the Design Wind Load", and "Part H. Procedure to Select Rail Span and Rail Type." The procedures, guide the user through the calculation of design wind force, load combinations, and beam selection. All calculations associated with the procedures have been checked and found to be in compliance with the codes listed in the next paragraph The procedures are based on and in compliance with the following codes/standards: 1. 2007 California Building Code (CBQ, based on the 2006 International Building Code, by International Code Council , Inc., 2006. 2. Aluminum Design Manual: Specifications and Guidelines for Aluminum Structures, by The Aluminum Association, Washington,, D.C., 2000. Mechanical properties; of the UNIRAC extruded rails and related components are based on data obtained from Walter Gerstle, P.E., Departnient of Civil Engineering, University, of New Mexico, Albuquerque, NM. WILSON & COMPANY, INC., ENGINEERS & ARCHITECTS wwnscm &COMPANY Page 2 certify that the structural calculations in Uni ~ ac's SolarMount Flusb, Code -Compliant Installation Manual 227 are in compliance with the above codes. WILSON & COMPANY Steven J. Metro, Executive Vice President,. P.E. -gwk cc: Gary Kmchen, P.E. e��rrarraaRa IV ku � *6 Greenl asten"' GH — Product Guide Exploded Product View, Bill of Materials Materials Needed for Assem Item No. Description of Material/Part Quantity 1 GF-1 Flashing 1 2 L-102-3" Bracket * (other options available) 1 3 5/16" EPDM Bonded 304-18.8 SS Washer 1 4 Lag Bolt 5/16" 1 877-859-3947 Committed to the Support of Renewable Energy 0 Ecol'asten Solar' All content protected Linder copyright. All rights reserved. 07/24/12 1.1 GreenFasten:' GH -- Product Guide W 01 6 3 4 Installation Instructions 1. Locate the rafters and snap horizontal and vertical lines to mark the installation position for each GreenFasten flashing. 2. Drill a pilot hole (1/4" diameter) for the lag bolt. Backfill with sealant.* 3. Insert the flashing so the top part is under the next row of shingles and pushed far enough up slope to prevent water infiltration through vertical joint in shingles. 4. Line up pilot hole with GreenFasten hole. 5. Insert the lag bolt through the EPDM washer, the top compression component (L-Bracket pictured) and the gasketed hole in the flashing and into the rafter. 6. Torque to 140 inch -pounds Consult an engineer or go to www.ecofastensolar.com for engineering data. *EcoFasten recommends an EPDM mastic. 877-859-:3947 Committed to the Support of Renewable Energy CO3 E coFasten Solar" All content protected under copyright.All rights reserved. 0512.912.012 2.1 GreenFasten'.' GH — Product Guide . Slide flashing up under shingles until leading edge engages nails. Measure remaining distance to adjust upslope. 3. Reinstall flashing with notched area upslope. shingle >hingle Installation Instructions Use for vertical adjustment when leading edge of flashing hits nails in upper shingle courses 2. Remove flashing and cut "V" notch at marks where nail shafts engaged leading edge of flashing the distance desired in Step 1. Notch depth not to exceed 2" length by 1/2" width. T" notch 4. Position notched leading edge underneath nail heads as shown. shingle 877-859-3947 Committed to ttie Suppart of Fteriewable Energy 0 EcoFasten Solar," All content protected under copyright. All rights reserved. 01/1212.012. 2.2 GreenFasten:' GF1 — Product Guide 3 ......... 1 l32" 4X R 0 _g.,: DETAIL A SCALE: 2:1 Cut Sheets: GF1- l.. 812 Finish Options BLK = Matte Black MLL = Mill Finish 877-859-3947 Committed to the Support of Renewable Energy 0 EcoFasten Solar"All content protected under copyright.All rights reserved.0711212012 3,2 GreenFasten"° GF1 — Product Guide 46 SERRATION! q 9 RM5 R.010 r 60.0 0 (� / ''p /(_ ,00.2 Cut Sheets: Bracket Options - SCL.- DETAIL A SCALE 3:1 R1/16" 2X R,01 I ........ ........ ......... ........ 877-859-3947 Comrnitted to the Support of Renewable Energy C EcoFastert Solar" All content protected under copyright.All rights reserved, 0711212012 3,; KACO blueplanet 02xi series ZS0ZXI 3502xi grid -tied inverters 5002xi • Highest efficiency in their class -over 95.5% • Convection cooled aluminum housing - high reliability • Programmable LCD display with night switch • Plug and play web monitoring option • Lockable NEC compliant AC/DC disconnect pre -installed • Field selectable grid voltage (240 / 208 VAC) • Field selectable positive or negative grounding *tested to UL 1741, IEEE 1547, CSA 22.2 �J4 ahel� d e c " : us Arner° • NEMA 3R enclosure - for indoor or outdoor installation 1/2" or 3/4" knockouts on sides, bottom & rear of unit • easyinstall light weight installation bracket • easyLink data interface includes RS485 connection • easySwap 10 year warranty with service reimbursement K A C 0 1 new energy. The KACO 02xi blueplanet series - the latest generation of PV inverters. • Refined power electronics increase operational efficiency, increase CEC efficiency to 95.5% on all units and improve reliability. • All inverters include a factory assembled connection box which includes a safe and NEC compliant AC/DC disconnect switch. • The inverters can be easily and safely removed from the connection box to allow field service. • The connection box allows conduit to connect from both sides, the bottom or the rear for increased installation flexibility. Using the rear knockouts will hide all conduits for a clean install. • Field selectable grid voltages 240 / 208 VAC (220 VAC for Mexico) with or without neutral sensing. • Field selectable positive or negative grounding simplify installs and create more opportunities to use the KACO blueplanet inverters. • Convenient PV system monitoring with integrated plug and play ethernet web monitoring option reduces lifetime system costs by ensuring optimal system performance. • Easy to use push button interface to configure the inverter and access stored PV data on the bluenlanet LCD screen, Nightilhiminatinn5witrh backlights display for access to production data when the inverter is in standby mode. • Light weight design makes the inverters less expensive to ship and easier to handle than other comparably sized inverters. Download the KACO talc string sizing tool from www. kaco-newenergy. com. Distributed by: i DC operating range (MPP) 125 - 400 V,, 200 - 450 V„ 200 - 510 V 200 - 510 V,,- Max. DC input voltage 550 V. 550 V, 550/600* V 550/600* W Nominal DC input current 14.3 A,c 13.5 A,; 18.5 A� 26.5 A„ Max. DC input Isc current Max. continuous output power (CEC) 21.45 A,c 21.45 Aa 28 Au 1500 W 2500 W 3500 W 40 A. 5000 W Max. over -current protection 15 A 20 A 25 A 30 A Max. continuous current 240 V 208 V 8 ARC 12 A,_ 16 A<, 8 k, 12.5 An, 17 A,, 24 A« 24 Ag, 240 V AC operating range 208 V 220 V 211 - 264 V 184 - 226 V 198 - 242 V (for Mexico) Frequency 60 Hz (59.3 — 60.5 Hz) 240 V CEC rated efficiency --- -- 208 V AC/DC disconnect ratings 95.5% 95.5% 95.5% 95.5% - - - - 95% 95% 95.5% 95% AC: 300 V - 36 A / DC: 600 V - 40 A Cooling True convection - ultimate reliability (5002xi - fan assisted) DC reverse polarity protection YES Ground fault protection Integrated ground fault detector/interrupter (GFDI) Grounding Field selectable positive or negative ground option Visual displays Backlit LCD w/ convenient night switch & push button controls Included accessory interfaces easyLink RS485 & SO port Ambient temp @ max AC power -4"F - +104"F -20'C - + 40°C -13°F - +104`F -25"C - + 40°C Thermal protection Yes Noise emissions < 35 dB (silent operation) Night power consumption 0.3 W Warranty Standard easySwap 10 years Safety compliance UL 1741, IEEE 1547, NEC, CSA 22.2 No.107.1-01 Communications compliance FCC Part 15 Class B - Unit will only feed power if the PV voltage is less than 550N/dc Model Height (H) Width (W) Depth (D) Weight 1502xi 30 in. 14 in. 8 1/4 in. 42 Ibs 2502xi 32 in. 14 in. 8 1/4 in. 52 Ibs 3502xi 35 7/8 in. 14 in. 9 1/2 in. 69 Ibs 5002xi 35 7/8 in. 14 in. 9 1/2 in. 70 Ibs Enclosure NEMA 3R T: +1 (866) 522 6765 • F: +1 (41 5) 931 1688 new energy. Printed on 100% post consumer material kacoinfo@kaco-newenergy.com • www-kaco-newenergy.com Instruction Manual • Operator • Authorized Installer blueplanet 1502xi blueplanet 2502xi blueplanet 3502xi blueplanet 5002xi new energy. KACO 4D new energy. For the operator For authorized electricians Operating Instructions Installation Instructions Instructions begin on page 15 blueplanet 1502xi / 2502xi / 3502xi / 5002xi General Notes 1 1 About This Documentation 1 1.1 Retention of documents 1 1.2 Symbols used: in this document 1 1.3 Name plate 1 2 Safety Instructions and Regulations 2 3 Notes on Installation and Operation 2 3.1 Intended use 2 3.2 Factory warranty and liability 3 3.3 Service 3 4 Operation 3 4.1 Overview of controls and displays 3 4.2 LED displays 4 4.3 Keys "1 " and "'2" 4 4.4 Level 1 menu — Display mode 5 4.5 Level 2 menu —Configuration mode 5 4.6 DC/AC switch 6 4.7 Night time start switch 7 4.8 The RS485 interface 7 4.9 Display 7 5 Accessories 10 6 Troubleshooting 11 7 Recycling and Disposal 13 blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 3 Section 1- About This Documentation K A C 0 0 new energy. General Notes By purchasing an inverter from KACO new energy GmbH, you have opted for a reliable, high-performance technology and will profit from KACO new energy's many years of experience in the field of current inverter technology and power electronics. The blueplanet 1502xi, 2502xi 3502xi and 5002xi inverters are galvanically isolated, fanless, robust, high -efficiency inverters. 1 About This Documentation The following notes guide you through all of the documentation. Additional documents are applicable in conjunction with these operating and installation instructions. We assume no liability for any damage caused by failure to observe these instructions. 13 NOTICE Read the manual! We assume no liability for any damage caused by failure to observe these instructions. Other applicable documents Operators, please read any additional operation instructions which may have been included with the inverter. Installers, please refer to the installation manual and any instruction which may have been included with the inverter for information regarding installation of the inverter. 1.1 Retention of documents Please pass these operating And I(Ktallatinn inCtn Irtlnnc on to the installation operator. These documents must be stored near the installation and must be available at all times. 1.2 Symbols used in this document When operating the inverter, observe the safety instructions provided in these operating instructions. MADANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. to observe a warning indicated in this manner may IFailure lead to damage to property. I Useful information and notes. This symbol indicates that a certain action is required. IMPORTANT Failure to observe this information may result in reduced convenience or impaired functionality. Electrical voltage! Risk of burns! 'A OwRead the manual! 1.3 Name plate The name plate showing the exact designation of the unit is located on the left side of the housing. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 1 Section 2 • Safety Instructions and Regulations Section 3 Notes on Installation and Operation 2 Safety .Instructions and Regulations — Danger due to lethal voltages. — Lethal voltages are present within the unit and on the power supply lines. Therefore, only authorized electricians may install and open the unit. — Even when the unit is disconnected, high contact voltages may still be present within the unit. Accident prevention regulations The inverter must be installed by an authorized electrician who is responsible for observing existing standards and regulations. The proper and safe operation of this unit requires proper transportation, storage, assembly and installation, as well as careful operation and maintenance. The inverter may only be operated by persons who have read and understood the operating instructions. Modifications It is generally not permitted to make changes to the inverter. Always consult an authorized electrician for modifications to the installation of the inverter, as they are qualified to undertake such work. Risk of damage due to improper modifications. Never modify or manipulate the inverter or other components of the installation. Transportation The inverter is subjected to extensive testing and inspections in our test field. This is how we ensure the high quality of our products. Our inverters leave our factory in proper electrical and mechanical condition. Special packaging ensures safe and careful transportation. However, transport damage may still occur. The shipping company is responsible in such cases. Thoroughly inspect the inverter upon delivery. Immediately notify the responsible shipping company if you discover any damage to the packaging which indicates that the inverter may have been damaged or if you discover any visible damage to the inverter. If necessary, your solar installer or KACO new energy GmbH will assist you. Damage reports must be received by the shipping company in writing within six days of receipt of the goods. new energy. When transporting the inverter, the original or equivalent packaging is to be used, as this ensures safe transport. El NOTE FCC Compliance NOTE: This equipment has been tested and found to comply with the limits for a Class 6 digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: —Reorient or relocate the receiving antenna. —Increase the separation between the equipment and receiver. —Connectthe equipment into an outlet on a circuit different from that to which the receiver is connected. —Consult the dealer or an experienced radio/TV technician for help. 3 Notes on Installation and Operation 3.1 Intended use The unit converts the DC voltage generated by the photovoltaic (PV) modules into AC voltage and feeds this into the utility grid. blueplanet inverters are built according to all required safety rules. Nevertheless, improper use may cause lethal hazards for the operator or third parties, or may result in damage to the units and other property. The inverter may only be operated with a permanent connection to the public power grid. The inverter is not intended for mobile use. Any other or additional use is not considered the intended use. The manufacturer/supplier is not liable for damage caused by such unintended use. Damage caused by such unintended use is at the sole risk of the operator. Intended use also includes adherence to the operating and installation instructions. Your authorized electrician undertakes the registration with your power supply company and obtains approval for your photovoltaic installation from the supply grid operator on your behalf. Some of the documents that you require in order to register your photovoltaic installation and have it approved are included in the installation instructions. Page 2 31000770-02-112609 blueplanet Operating and Installation Instructions 1502A - 5002xi Section 3 • Notes on Installation and Operation Section 4 • Operation 3.2 Factory warranty and liability KACO new energy GmbH issues a warranty of ten years or 120 months on the blueplanet inverter starting from the date of installation, but at most 130 months after shipment by KACO new energy GmbH. During this time, KACO new energy GmbH guarantees the proper function of the units and to undertake repairs at the factory free of charge in the event of a defect for which we are responsible. Contact your specialty dealer or installer if your unit exhibits a defect or fault during the warranty period. Warranty claims are excluded in the following cases: — Use of the units in ways not intended — Improper installation and installation that does not comply with standards — Improper operation — Operation of units with defective protective equipment — Unauthorized modifications to the units or repair attempts — Influence of foreign objects and force majeure (lightning, overvoltage, severe weather, fire) — Insufficient ventilation of the unit — Failure to observe the relevant safety regulations — Transport damage All warranty claims must be handled at the premises of KACO new energy GmbH. The unit must, where possible, be returned in its original or equivalent packaging. The costs for these services cannot be borne by KACO new energy GmbH. KACO new energy GmbH will perform warranty services only if the defective unit is returned to KACO new energy GmbH together with a copy of the invoice which was issued to the user by the dealer and the completed warranty card. The name plate on the.unit must be fully legible. If these requirements are not fulfilled, KACO new energy GmbH reserves the right to deny warranty services. The warranty period for repairs or replacement deliveries is six months after delivery. However, it continues at least until the end of the original warranty period for the delivery item. 3.3 Service We place special emphasis on the quality and longevity of our inverters, starting with the product development phase. More than 60 years of experience in the field of power conversion device manufacturing support our philosophy. However, despite all quality assurance measures, faults may occur in exceptional cases. In such cases, KACO new energy GmbH will provide you with the maximum possible support. KACO new energy GmbH will make every effort to remedy such faults in an expeditious manner and without a great deal of bureaucracy. Contact our service department directly by telephone at + 1 866 522 6765. KAC00 new energy. s Incorrect use is prohibited. 4 Operation The grid -feed process begins in the morning if sufficient insolation is available, and, therefore, if a certain minimum voltage is present in the inverter. If, as nightfall approaches, the voltage drops below the minimum voltage value, grid -feed mode ends and the inverter switches off. 4.1 Overview of controls and displays Figure 4.1: Overview blueplanet Legend 1 Display See measured values and configuration parameters 2 LED displays Display of the operating state 3 Control keys Switch between displays and configuration of parameters 4 Night time start switch For activating the display after nightfall 5 GFDlfuse Ground Fault Detector lnterruptorFuse. 6 AC/DC switch Disconnects AC and DC power from the inverter blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 3 Section 4 • Operation 4.2 LED displays The inverter is equipped with three LEDs that give information about the various operating statuses as follows: Figure 4.2: LED displays LED (1) (green): The LED begins to light up when the minimum voltage from a photovoltaic array is present and goes out again if the array voltage is lower than the minimum operating voltage. The LED signals that the inverter is in stand-by mode. If it is illuminated the inverter is ready for operation or is currently operating. LED (2) (green): The LED is lit when the inverter is feeding into the grid LED (3) (red): The LED indicates that the grid -feed was stopped due to a fault. Wait approx. 10 mins. to see if the fault is temporary. If this is not the case, notify your authorized electrician. FM If there is a power failure on the public grid, LED (3) does not light up. If this happens, all LEDs and the display go out. The inverter is shut down completely. The inverter can only resume its normal operation when the public utility grid is available again. Check whether the fault in question relates to a general power failure or whether the circuit breaker between the utility service and the inverter has tripped. If the circuit breaker has tripped, notify your authorized technician. If there was a power failure, simply wait until the fault has been cleared. The system automatically re -starts. new energy. 4.3 Keys ' ' and "2" Figure 4.3: blueplanet control keys Key "1" is used to switch between the various displays for measured values and data. You use key "2" to configure settings. Here, menu navigation is divided into two levels. In level 1 (display mode), measured values such as the solar generator voltage can be read. Here, only key "I " is activated. In level 2 (configuration mode), key "1" is used to navigate through the individual displays and settings. ACTION By pressing key "1" you can choose which measured value is to be displayed. The menus are continuous, which means that when you arrive at the last entry in a menu, the first entry is displayed again the next time key 'T' is pressed (see Figure 4.4). Page 4 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 4- Operation K A C 0 0 new energy 4.4 Level 1 menu — Display mode Daily peak capacity The display menu is shown once the blueplanet inverter starts The respective day's peak power that was fed into the grid for up. Measured values and all of the counters are displayed a short time. here. Key " 1" is used to navigate through the individual menu items. Temperature inside unit Displays the current heat sink temperature. If the unit becomes too hot, the unit will reduct power output or switch off. Display of inverter type Counter yield i This counter totals all yields until it is reset. The customer can configure the time periods for this counter, e.g. as a monthly Generator voltage and current counter. The counter can be cleared in configuration mode "Clear yield". Grid voltage, current and power Yield today The power that has been fed into the grid during the current i day. This value resets to zero each morning. Daily peak capacity Total yield The power that has been fed into the grid since installation Temperature inside unit of the inverter. The initial value can be set in configuration i mode. Counter yield (Total) economy of CO, I Shows the CO2 savings of this PV installation compared to the German electricity mix. The CO2 savings are calculated from the I Yield today total yield counter and can also be cleared with this counter. jCounter oper. hours Total yield This counter totals all yields until it is reset again. The customer ( can configure the time periods for this counter, e.g. as a i monthly counter. It can be cleared in configuration mode "Clear (Total) economy of CO2 yield". Operating hours today Counter oper. hours Today's hours of operation. As soon as the inverter is in stand- by mode (i.e. when LED (1) lights up), the running time is added i up. Operating hours today Total operating hours ♦ The hours of operation since installation of the inverter. As Total operating hours soon as the inverter is in stand-by mode (i.e. when LED (1) lights up), the running time is added up. Figure 4.4: Display mode menu Explanation of the individual menu items: Display of inverter type Inverter type - blueplanet 1502xi/2502xii3502xi15002xi display Generator voltage and current The current voltage and current of the PV solar generator that is connected to the inverter. Grid voltage, current and power The current line voltage, line current, and the power that is currently being fed into the power grid. 4.5 Level 2 menu — Configuration mode i To access configuration mode, press both keys at the same time. The software version display appears. Pressing key "1" now switches to the next menu item and changes can be made in the respective menu item by pressing key "21' . The setting value increases each time key "2" is pressed. If the maximum value has been reached, the value returns to the minimum setting choice. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 5 Section 4 • Operation Software version 1 Serial number 1 Current country 1 Language selection 1 Clear the grid -feed counter 1 Define the initial value of the total yield 1 Select the interface and settings of the RS485 address 1 SO interface 1 Quick start Figure 4.5: Configuration mode menu Explanation of the individual menu items: Software version The current software version is displayed here. Serial number Display of the serial number specific to the unit. Current country Display of the current country settings. Language selection The language of the display interface can be selected here. Clear the grid -feed counter When you clear the grid -feed counter, all counters (Counter yield and Counter oper. hours) are reset to zero. To clear the counters, select "Yes" with key "2", and confirm your selection by pressing the "1" key. The required code is "2" and is entered using key "2". By means of an additional confirmation with key "1", all counter are cleared. The display "Grid -feed counter cleared!" confirms that the counters have been cleared. "Counter yield" and "Counter oper. hours" can be cleared separately from the other counters. These counters are cleared in the configuration menu using key 2 and the code 2. "Counter yield" and "Counter oper. hours" are always cleared together. Define the initial value of the total yield Use this menu setting to define or reset the intial value of the total yield of the inverter. K A C 0 0 new energy. Select the Interface and settings of the RS485 address With the menu item "Select interface", you can use key "2" to switch between the RS232 and RS485 interfaces. If the RS485 interface is activated, you can reach the address setting by pressing key "1". By pressing key "2", the address can be set in a consecutive manner from 1 to 32. The address then jumps back to 1. The RS485 interface is used to communicate with the KACO proLOG, watchDOG or other monitor. If several inverters are connected to a KACO proLOG, watchDOG or other monitor each address may only be used once. It is possible to monitor 32 blueplanet inverters with one KACO proLOG. To connect the RS485 interface, please contact your installer. SO interface pulse rate The SO interface is designed as a galvanically isolated transistor output. This interface is designed according to "DIN 43864 — Current interface fortransmitting pulses from a pulsing meter to a tariff metering device". The SO interface pulse rate can be chosen in three unit intervals: 500, 1,000 and 2,000 pulses/kWh. To connect the SO interface, please contact your installer. ACTION Settings are saved only upon exiting configuration mode. If 2 minutes elapse without a key being pressed, the configuration mode is automatically exited. The configuration mode can also be immediately exited by pressing both keys. As a confirmation, "Settings saved" appears on the display. The settings are now permanently saved in the blueplanet inverter. Quick start The inverter can also be started up without any waiting period for the purpose of testing or for the purpose of acceptance by your power supply company. If the inverter is already feeding into the grid, this menu item is not available. If there is insufficient solar generator power, the inverter stops feeding into the grid after a short period of time. 4.6 MAC switch The inverters include a connection box with an internal DC/ AC disconnect switch, which allows for the inverter to be disconnected from the photovoltaic generator and the AC power grid and removed for service. To disconnect the inverter from the photovoltaic generator, turn the internal DC/AC disconnect switch on the right side of the connection box from the ON (1) position to the OFF (0) position (see Fig. 4.1). The ON (1) position is pointing up and the OFF (0) position is pointing toward the front. Page 6 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 4 • Operation 4.7 Night time start switch The unit switches off in the evening as nightfall approaches. The display is no longer shown. In order to retrieve the values from the current day (daily yield, daily hours of operation and max. grid -feed power) after the display switches off, the unit can be activated during the night by pressing the start switch on the right side of the connection box. 17�� 1 - - 8 V To do this, press the "5" switch (see Figure 4.1 — (5)) on the right side of the connection box for approx. 5 seconds until a display appears. You can now scroll through the menu and retrieve the saved values. If over one minute elapses without a key being pressed, the unit switches off automatically once again. The "Counter oper. hours ", "Total operating hours", "Counter yield", and "Total yield" data are permanently saved and totaled. This data remains in memory even if the inverter is switched off for a long time. The daily yield, daily hours of operation and the max. daily grid -feed power are available until the following morning and are cleared when PV generator voltage is present again. 4.8 The RS485 interface Blueplanet inverters are also equipped with an RS485 interface in order to enable remote monitoring of your photovoltaic installatinn. Several inverters ran be monitored over this interface at the same time. Using the KACO proLOG, watehDOG or other monitoring device you can receive yield and operating data as well as error messages by SMS (text message) or e-mail. These monitoring options are especially recommended for situations where you are unable to check the functionality of the installation on -site at regular intervals, e.g if vnu live far away frnm the installatinn citp Cnntart vniir installer if you wish to integrate remote monitoring into your system. 4.9 Display Inverters in. the bl" eplanet series are equipped with a backlit LCD (see figure 4.1 — (1) which displays measured values and data. In normal mode, the backlighting is switched off. As soon as you press one of the keys, the backlighting is activated. if approx. 1 minute elapses Without a key being pressed, it switches off once again. El NOTE Calculating efficiency by measuring the current and voltage values leads to unusable results due to the tolerances of the measuring devices. The sole purpose of these values is to monitor the basic operation of the system. A new energy. Due to measuring tolerances, the measured values may not always correspond to the actual values. The inverter's measuring elements have been selected to ensure maximum solar yields. Due to these tolerances, the daily yields displayed on the inverter may deviate from the values on your supply grid operator's grid -feed counter by up to 15%. At low power operation the sensors within the unit are not as accurate as when at higher power therefore long term operation may cause tilis high deVlatl Ull. Under norrnal operating conditions this deviation is minimal. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 7 Section 4 • Operation Operating States K A C 0 0 new energy. Status Explanation Comment 0 Inverter has just switched on Only for a brief period after being first switched on in the morning. 1 Waiting to start Grid parameters and generator voltage are checked. 2 Waiting to switch off Insufficient generator voltage and generator power. The status before it switches over to night shutdown mode. 3 Constant voltage regulator The inverter continues to operate with minimum MPP voltage when the grid -feed power is low. 5 Grid -feed mode The inverter is feeding into the grid. 8 Self test The line relay and the shutdown of the power electronics are tested prior to the commencement of grid -feed mode. 9 Test mode For internal operation only. 11 Power limitation If the generator is producing too much power, the inverter limits to the max. power. This can occur in the midday hours if the generator has been too largely dimensioned. This is not a malfunction. 57 Waiting time after a fault After a fault, the inverter waits a defined country -specific amount of time before it switches on (installation Instructions, section 4, Technical Data). 60 PV voltage is too high for feeding into Protective function of the inverter. The inverter can only begin feeding into the the grid grid once the PV voltage falls below a specified value. The PV voltage is below the maximum permissible no-load voltage, this status is not an error. 62 Standalone mode The inverter was switched to standalone mode by the blueplanet Grid -Save. function. The inverter is disconnected from the public utility grid. The power indicator percentage refers to the maximum AC power. 64 Output current limit The AC current is limited once the specified maximum value has been reached. Table 4.1: Explanation of the operating states Fault signals When these error messages are displayed, the grid -feed is interrupted, the red LED (3) lights up, and the fault signal relay has switched. This error correction takes a country -specific length of time (see Installation Instructions, section 3, Technical Data). Afterwards the red fault LED (3) goes out, the fault signal relay drops out again, and the display signals that it is ready to feed into the grid once again. Once the fault is gone, the blueplanet inverter feeds in again. Many of these fault signals point to a fault in the grid, and are, therefore, not an operational fault on the part of the blueplanet inverter. The minimum triggering levels are determined by applicable standards (e.g. VDE0126-1-1 or UL 1741), and the inverter must switch off if the permitted values are exceeded. Page 8 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 4- Operation K A C 0@ new energy. DisplayStatus • • 10 Temperature too high inside The temperature in the unit has become too high (> 1761F). When the internal reaches 158°F, the inverter limits the power. An internal tempera- ture of 176°F is only reached if convection cooling is impeded by external factors, e.g. by covering the cooling fins. 29 Error GFDI - Check Fuse! A ground fault was detected on the DC side. Notify your authorized electrician so that the solar generator can be checked. 3C Error Measurement The current and voltage measurements in the inverter are not plausible. This can be caused by very dynamic weather conditions if there are quick changes between low grid -feed power (e.g. 200 W) and high grid_fPed power (e.g. the maximum grid -feed power). 32 Error Selftest The internal grid separation relay test has failed. If this internal error occurs several times, notify your authorized electrician. 33 Error DC-gridfeeding The DC feed into the grid has exceeded the permitted limit value. This grid - feed can be impressed from the grid on the blueplanet inverter so that no inverter fault exists. If this error occurs several times, notify your authorized electrician. 34 Error Communication A communication error has occurred in the internal data transmission. If this error occurs several times, notify the service department. 35 Protection Protection shutdown of the software (AC overvoltage, AC overcurrent, DC shutdown link overvoltage). This is not an error, but instead a grid -related shutdown. 36 Protection Protection shutdown of the hardware (AC overvoltage, AC overcurrent, DC shutdown HW link overvoltage). This is not an error, but instead a grid -related shutdown. 38 Failure The voltage of the PV generator is too high. The solar generator is wrongly PV-Overvoltage dimensioned. Notify your authorized electrician. 41 Line failure The voltage of the grid -feed phase is too low. The grid cannot be fed Undervoltage into. This error can be grid -related. 42 Line failure The voltage of the grid -feed phase is too high. The grid cannot be fed Overvoltage into. This error can be grid -related. 48 Line failure The line frequency is too low. This error can be grid -related. Underfrequency 49 Line failure The line frequency is too high. This error can be grid -related. Oven requency 50 Line failure average value voltage The average value of the EN50160 voltage measurement is above the set shut down value. 51 Line failure overvoltage L7 Phase voltage L1 is above the set maximum phase voltage. 52 Line failure undervoltage L1 Phase voltage L1 is below the set maximum phase voltage. 53 Line failure overvoltage L2 Phase voltage L2 is above the set maximum phase voltage. 54 Line failure undervoltage L2 Phase voltage L2 is below the set maximum phase voltage. 55 Error DC link The voltage at the DC link is too high, or the DC link cannot be charged (IGBT damage). 57 Waiting for reactivation Waiting for reactivation after an error. 58 Overtemperature The temperature is too high. To avoid damage, the grid -feed was stopped. controlling unit Provide for sufficient ventilation. 59 Error self test An error occurred during the buffer inspection. Internal error EPROM An error occurred in the EPROM. No parameters Error, no parameters. Table 4.2: Fault signals blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 9 Section 5 • Accessories 5 Accessories KACO offers its customers a comprehensive range of helpful accessories. The array of products includes monitoring, display, visualisation and data transmission equipment of the highest quality. KACO-proLOG Are you looking for professional monitoring and data logging equipment? The KACO-proLOG is the high -end solution for your PV installation. Error messages by SMS (text message), fax or e-mail, remote access to the installation, the presentation of the PV installation on the Internet and much more are no problem whatsoever for the KACO-proLOG. Up to 32 inverters can be connected to the KACO-proLOG via the RS485 interface. Figure 5.1: KACO proLOG K A C 0 0 new energy. KACO-watchDOG The KACO-watchDOG card is the integrated communication option from KACO for monitoring your PV installation. Up to three inverters can be monitored with one affordable card. The KACO-watchDOG can be installed inside the blueplanet inverter in a few easy steps. For more about the functions and installation of the KACO-watchDOG and KACO-proLOG please visit www.kacosolar.com where you may download the installation manuals for all KACO products. You can access your PV data at: www.kaco-newenergy.com/blueplanetweblogin.php Ficlure 5.2: KACO watchDOG Information about additional accessories can be found in our general catalogue, price list and website. Page 10 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 6 - Troubleshooting 6 Troubleshooting K A C 0 new energy. In line with our continuously expanding quality assurance system, we endeavor to eliminate all errors and faults. You have purchased a product which left our factory in proper condition. Each individual unit has successfully passed an endurance test as well as extensive tests for the purpose of assessing the operating behavior and the protective equipment. If your photovoltaic installation does not function properly despite these measures, we suggest the following troubleshooting procedures: The first step is to monitor the inverter closely and, where applicable, make a note of the displays and LEDs. The next step is to contact your installer and explain the problem encountered. The following faults may occur and should be remedied as described. Error Cause of .. .. Inverter displays an Faults in the line voltage. The inverter continues to operate as normal without losses to impossible daily peak the yield, even when an erroneous daily peak value is displayed. value. The value is reset overnight. To immediately reset the value, the inverter must be switched off and switched on again by using the DC/AC switch in the connection box. Daily energy yields do Tolerances of the The measuring sensors of the inverter have been selected to not correspond with measuring elements in the ensure maximum solar yields. the yields on the energy inverter. Due to these tolerances, supply company's grid- the daily yields displayed on the inverter may deviate from the feed counter. values on your supply grid operator's grid -feed counter by up to 15%, especially if operating at very low power for extended periods of time. (see section 4.9) The display is blank and — The unit is in night The inverter switches to night shutdown mode as soon as the the LEDs are not lighting shutdown mode. solar generator voltage is below the minimum grid -feed voltage up. — There is no AC line for a longer period of time. In this case, the display will also voltage. switch off. In order to still be able to view the currently measured The solar generator values, you can switch on the inverter via the night start-up voltage is too low. key. DC/AC switch is OFF (0). A grid failure will also cause the display to go blank and the grid - feed to stop. Wait until the public utility grid is available again. Also check to see if the DC/AC switch is OFF (0) and if so, switch it to ON (1). If the display does not light up during normal daytime hours, please contact your solar installer. The inverter is active but — Insufficient generator After sunrise, at sunset and when there is not enough solar does not feed into the voltage available. insolation due to bad weather conditions or due to the solar grid. The line voltage or the modules being covered with snow, the generator voltage or solar generator voltage the generator power that comes from the roof may be too low is not stable. to be able to feed in. Before the grid -feed process begins, the inverter has to check the line parameters for a certain period of time. The length of the switch -on time differs by country according to applicable standards and regulations and can take several minutes. The irn ester is active but !I The inverter has I After an interruption of the grid -feed due to a fault (line failure, ' does not feed into the I interrupted the grid -feed overtemperature, overload, etc.), the inverter checks the line grid. The insolation is I due to a fault. parameters for certain period of time. The length of time it sufficient. takes to switch back on again differs by country according to applicable standards and regulations and can take several minutes. With faulty grids, interruptions can occur during the day. Notify your solar installer if the inverter shuts down regularly over a period of several weeks (more than 10 times per day). For an explanation of the individual display error texts, please see the fault signals. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 11 Section 6 - Troubleshooting K A C 0 0 new energy. Error Cause of error Troubleshooting/Explanation The inverter stops Faulty grid separation relay Although there is sufficient sunlight, the inverter feeds into the supplying power to in the inverter. grid only for a few seconds before switching off again. During the the grid shortly after short grid -feed period, the inverter shows that the power being being switched on, even fed into the grid is between 0 and 5 W. If the inverter is definitely though there is sufficient receiving sufficient generator power, the grid separation relay is sunlight. presumably faulty, thus preventing the inverter from connecting. Please contact your solar installer. The line fuse trips. The line fuse capacity is too In cases of high insolation, the inverter can — depending on the low. solar generator — exceed its rated current for a short period. For Damage to the inverter's this reason, the capacity of the inverter's pre -fuse should be hardware. somewhat higher than the maximum grid -feed current. If the line fuse immediately trips when the inverter switches to grid -feed mode (after the start-up period is complete), the inverter's hardware is probably damaged. Contact your solar installer. Noise emission from the Particular ambient When there are certain ambient conditions, the units may inverter. conditions. emit audible noises. The following causes may be determining factors in this regard: — Line interference or line failure caused by particular loads (motors, machines, etc.) which are either connected to the same point on the grid or located in the vicinity of the inverter. — In cases of dynamic weather conditions (frequent switching between sunny and cloudy conditions) or strong solar insolation, a light hum may be audible due to the high output. — With particular grid conditions, resonances may form between the unit's input filter and the grid, which may be audible even when the inverter is switched off. — People with very sensitive hearing (particularly children) may be able to hear the high -frequency hum caused by the inverter's operating frequency of approx. 17 kHz. Such noise emissions do not affect the operation of the inverter. Nor can they lead to loss of efficiency, failure, damage or to a shortening of the unit's service life. In spite of high Unit is too hot and The temperature inside the unit became too high. The inverter insolation, the inverter the power is reduced. reduced the power to prevent damage to the unit. Above an does not feed in the internal temperature of 158°F, the inverter limits the power maximum power into and levels off at a temperature between 1580C and 176°C. low -voltage grid. An internal temperature of 185'C is only reached if convection cooling is impeded by external factors, e.g. by covering the cooling fins. Provide for sufficient cooling of the unit. Table 6.1: Troubleshooting If the measures described in this guide do not assist in clearing the fault, please notify your installer. In order for our factory customer service department to respond in an appropriate and expeditious manner, some details are imperative: Details pertaining to the inverter — The unit's serial number — Model — A short description of the error — Is the error reproducible? If yes, how? — Does the error occur sporadically? — Describe the prevailing insolation conditions when the error occurred? — Time of day Details pertaining to the photovoltaic module — Module type, manufacturer (if available, also send the data sheet) — The number of modules in series — The number of strings — Generator power Page 12 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 7 • Recycling and Disposal new energy. 7 Recycling and Disposal For the most part, both the inverter and the corresponding transport packaging are made from recyclable materials. KACO does it's best to ensure our vendors follow a low carbon manufacturing process as we do ourselves. It is not always possible but if you have questions about our products or the components in our products don't hesitate to call +1 (866) 522-6765 and ask. Device Do not dispose of faulty inverters or accessories together with household waste. Ensure that the old unit and, where applicable, any accessories are disposed of in a proper manner. Most areas have public electronic waste disposal and/or recycling plants. Feel free to contact KACO at +1 (866) 522-6765 to request information about a -waste recycling in your area. Packaging Ensure that the transport packaging is recycled. blueplanet Operating and Installation Instructions 15O2xi - 50O2xi 31000770-02-112609 Page 13 For authorized electricians Installation Instructions K A C 0 0 new energy. 1 About This Documentation 15 1.1 Retention of documents 15 1.2 Symbols used in this document 15 1.3 Name plate 15 2 Safety Instructions and Regulations 16 3 Technical Data 17 4 Unit Description 20 4.1 Included in box 20 4.2 Designing the PV array 20 4.3 Protection concepts 20 4.4 Dimensions and weights 21 4.5 Inverter knockout dimensioning 21 5 Installation and Start -Up 22 5.1 Selecting an appropriate place for installation 22 5.2 Installing the inverter 23 5.4 Grounding the inverter 28 (A) Grounding single inverters: 28 (B) Grounding multiple inverters: 28 5.5 Connecting to the Public Grid 30 5.6 Electrical connection 31 (A) Grid Connection 32 5.7 Interfaces 33 (A) Connecting the fault signal relay 34 (B) Connecting the SO output 34 (C) The RS485 interface connection 34 5.8 Starting up the inverter 35 5.9 Parameter programming 36 6 Two -Stage Shutdown in Accordance with IEEE(standard values for < 30 kVN) 37 7 Maintenance 38 7.1 Cleaning the fan 38 7.2 Removing the fan 38 8 blueplanet as Part of a PV Installation 40 8.1 Design of installation 40 8.2 Installation with multiple inverters on a three phase system 42 9 Troubleshooting 43 10 Efficiency curves 44 11 Compliance Certificates 48 Page 14 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 1- About This Documentation K A C 0 new energy. 1 About This Documentation The following notes guide you through all of the documenta- tion. Additional documents are applicable in conjunction with these operating and installation instructions. Read the manual! We assume no liability for any damage caused by failure to observe these instructions. Other applicable documents When installing the inverters, be sure to observe all assembly and installation instructions for components and other parts of the installation. These instructions are delivered together with the respective components and additional parts of the installation. Please refer to the installation manual and any instructions which may have been included with the inverter for information regarding installation of the inverter. 1.1 Retention of documents Please pass these operating and installation instructions on to the installation operator. The installation operator retains the documents. The instructions must be available whenever they are needed. 1.2 Symbols used in this document When installing the inverter, observe the safety instructions included in these installation instructions. EADANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. P indicates a hIER" l f not avoided, could rh or serious I I injury. I CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. 1 Failure to observe a warning indicated in this ma=Hqay lead to damage to property. Useful information and notes. This symbol indicates that a certain action is required. r-M-- IMPORTANT Failure to observe this information may result in reduced convenience or impaired functionality. Electrical voltage! Risk of fire or explosion! Risk of burns! (09,Read the manual! 0 "_ Switch off the power! 1.3 Name slate The name plate showing the exact designation of the unit is located on the left side of the housing. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 15 Section 2 • Safety instructions and Regulations 2 Safety Instructions and Regulations MADANGER — Danger due to lethal voltages. — Lethal voltages are present within the unit and on the power supply lines. Therefore, only authorized electricians may install and open the unit. — Even when the unit is disconnected, high contact voltages may still be present within the unit. These servicing instructions are for use by qualified personnel only. To reduce the risk of electric shock, do not perform any servicing other than that specified in the operating instructions unless you are aualified to do so. Standards and regulations Electrical conformity according to U.S., Canadian and international safety operating standards and code requirements: — UL 1741-1:1999 Rev. May 2007 — CSA 22.2 No. 107-1:2001 Rev 2006 — IEEE Std. 1547-2003 — IEEE Std. 1547.1-2005 — FCC Part 15 Class B — NEC Sections 690 (ANSI/NFPA 70) — Directive concerning Electromagnetic Compatibility with Class B (Council Directive 2004/108/EC) — Low Voltage Directive (Council Directive 2006/95/EC) The blueplanet inverter has complete on -board overcurrent, over -temperature and anti-islanding protection. Technical rules The installation must be suited to the on -site conditions and comply with local regulations and technical rules. This symbol designates the Equipment Grounding Conductor Accident prevention regulations The inverter must be installed by a licensed and authorized - electrician. The electrician is responsible for observing existing standards and regulations. The proper and safe operation of this unit requires proper transportation, storage, assembly and installation, as well as careful operation and maintenance. K A C 0 0 new energy. Only authorized electricians who have read and fully under- stood all of the safety instructions contained in these operat- ing and installation instructions, as well as other instructions concerning assembly, operation and maintenance, may work on this unit. When this unit is operating, certain parts of the unit unavoid- ably carry hazardous voltages, which can lead to death or serious bodily injury. The precautions listed below must be followed in order to minimise the risk of death or injury. — The unit must be installed in compliance with safety regulations, as well as all other relevant national or local regulations. To ensure operational safety, proper grounding, conductor dimensioning and appropriate protection against short circuiting must be provided. — Keep all covers on the unit closed during operation. — Prior to performing any visual inspections or maintenance, ensure that the power supply has been switched off and is prevented from being inadvertently switched back on. — Never touch the electrical connections when you have to take measurements while the power supply is switched on. — Remove all jewellery from your wrists and fingers. — Make sure that the testing equipment is in good and safe operating condition. — When working on the unit while it is switched on, stand on an insulated surface, ensuring that there is no grounding connection. — Follow the instructions contained in these operating and installation instructions and observe all danger, warning and safety information. — This list does not constitute a complete listing of all measures required for the safe operation of the unit. Contact your specialty dealer if any specific problems arise which are not sufficiently covered for the purposes of the buyer. Modifications It is generally not permitted to make changes to the inverter. Changes to the installation of the inverter are only permitted if they comply with local and national standards. ,zx Risk of damage due to improper modifications. Never modify or manipulate the inverter or other components of the installation. Information regarding the following topics can be found in the Operating Instructions.: • Transportation • Intended use • Factory warranty and liability • Service Page 16 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 3- Technical Data K A C 0 10 new energy. 3 Technical Data Input — Electrical data u DC rated power 1600 W 2650 W 3700 W 5300 W Max. recommended PV generator power 2000 W 3000 W 4000 W 6000 W MPP range 125-400 V 200-450 V 200-510 V 200-510 V No-load voltage 550 V 550 V 600 V/ 550V* 600 V/ 550 V* Monitoring input voltage Stand-by from Stand-by from Stand-by from Stand-by from V < 125 V V. < 200 V Vin < 200 V V < 200 V Max. DC input current (Isc) 21.45 A 21.45 A 28 A 40 A Polarity safeguard Short-circuit diode Feed -In only, if PV-Voltage is smaller 550 V Output — Electrical data y W Rated power 1500 W 2500 W 3500 W 5000 W Maximum power 1650 W 2500 W 3500 W 5000 W Line voltage 212 V-264 V @ 240 VAS 184 V-228 V @ 208 VA, Rated current 6.5 A @ 240 Vac 10.4 A @ 240 VA, 14.6 A @ 240 VAS 20.8 A @ 240 VAS 7.2A@208VAc 12.0A@208VAc 16.8A@208V, 24.0A@208VA, Max. current 8.0 A @ 240 VA, 12.0 A @ 240 VAc 16.0 A @ 240 VA, 24.0 A @ 240 VAc 8.0A@208VAc 12.5A@208VAc 17.0A@208VAc 24.0A@208VAc Power factor 0.99 Rated frequency 60.0 Hz Frequency range 59.3 Hz-60.5 Hz Distortion factor according to VDE0838 part 2 (EN 61000 < 3% at rated power 3-2) < 5% over the entire range Fault signal relay Potential -free NO contact (make contact), max. 30 V / 3 A SO output Open collector -output max. 30 V / 50 mA Overvoltage protection Varistors and spark gaps blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 17 Section 3- Technical Data K A C 0 Q new energy. Inverter — Electrical data Max. degree of efficiency 95.9% m 240 Vc 96 1•, r. 240 41 C 240 C 208 Vc 95.6% C 208 Vc 95.9% C 208 . 1'. @ 208 Vc CEC degree of efficiency 95.5% @ 240 VAc 95.5% @ 240 VAc 95.5% @ 240 VAc 95.5% @ 240 VAc 9 Y 95.0% ® 208 VAc 95.0% @ 208 VAc 95.5% @ 208 VAc 95.0% @ 208 VAc Internal consumption Night shutdown: 0.4 W ® 240 VAc / 0.3 W @ 208 VAc Operation: < 5 W Minimum grid -feed power low 15 W 25 W 25 W Maximum Output Fault 30A / loops 50A / 100ps 70A / 100ps 96A/100 us Current (AC) and Duration Maximum Input Short Circuit 21.45 A Current 21.45 A 28.0 A 40.OA Maximum Input Source Backfeed Current to Input OA Source Synchronization In -Rush Current OA Voltage and Frequency Trip Time < 160ms Voltage Trip Limit Accuracy 1.5% of nominal value Frequency Trip Limit Accuracy t 0.06Hz Trip Time Accuracy t 0.1 % Circuit design Galvanically isolating high frequency DC/DC converter with downstream self - commutated inverter Clock frequency 17kHz Grid monitoring complies with IEEE 1547 Page 18 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 3- Technical Data K A C 0 0 new energy. Inverter — Mechanical and technical data LEDs: PV generator (green) Visual displays Grid -feed (green) Fault (red) LCD (2 x 16 characters) Controls 2 keys for display operation and configuration of parameters AC/DC cut-off point Pre -installed and separable AC/DC rotary disconnect switch Screw compression terminals in the connection box Connections Cable connection via conduit fittings using 3/4" or 112" knockouts on connection box Terminals accept AWG 4 to AWG 12, 75'C, copper wire. Torque to 20lb-in (2.2N-m). Interfaces RS485, SO, error transmitting relay Ambient temperature —4°F ... +140'F (> 1040F power derating) —130F ... +140°F (> 104°F power derating) Internal Temperature > 158OF temperature -dependent power limiting monitoring > 176'F disconnection from the grid Max. humidity 95% (not -condensing) Cooling Free convection (no fan) 5002xi: Free convection (fan assist) Protection class NEMA-311 Noise emission < 35 dB (noiseless) 5002xi: <45dB (fan operation) Housing Aluminium wall -mounted housing Dimensions W x D x H 30 x 14 x 8 1/4 in. 32 x 14 x. 8 114 in. 35 7/8 x 14 x 9 1/2 in. 35 7/8 x 14 x 9 112 in. VVe1911t 42lU5 52Ibs 69lbs 70Ibs blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 19 Section 4- Unit Description K A C 0 new energy. 4 Unit Description - UN,Pp (voltage maximum power point) > min. input voltage. Even at very high outside temperatures, the MPP voltage of the connected string should lie within the permitted input voltage range. The MPP voltage of the entire string must always be greater than the lowest MPP voltage of the Incorrect use is prohibited. inverter. The galvanically isolated blueplanet units are available with dif- ferent power ratings. The appropriate inverter type is selected according to the maximum output of the photovoltaic modules that have been installed. The maximum output values can be found in the data sheet (see Technical Data, section 3). You can find the name of your inverter on the name plate on the left side of the inverter. 4.1 Included in box — blueplanet inverter with pre -installed connection box — Wall bracket — Documentation 4.2 Designing the PV array The selection of the PV array is of great importance when designing a PV installation. When doing so, you must ensure that the solar array is compatible with the inverter. Observe the data provided in the data sheet (see section 3, Technical Data) when designing your solar array. NOTE KACO Calc PRO, a dimensioning program for the easy selection of PV modules, can be downloaded at no cost at the following address: http://www.kaco-newenergy.com Designing the PV array: — The number of PV modules connected in series must be selected in such a way that the output voltage of the PV generator stays within the permitted input voltage range of the inverter — even during extreme outside temperatures. Depending on the way in which the modules are installed and the geographic location, a suitable temperature should be used when calculating the voltage. The temperature coef- ficients of the solar modules should be taken into account. The following criteria must be met for calculating the voltage of the PV generator: — Uo (voltage open circuit) < max. input voltage of the inverter. Even at very low outside temperatures, the open circuit volt- age of the connected string must lie within the permitted input voltage range. The open circuit voltage of the entire string must be less than the max. input voltage under all conditions. If the MPP voltage moves outside of the permitted input range, the installation may still appear to function properly. In this situation, the maximum possible amount of power is not fed into the grid; instead, a smaller amount is back fed to the utility grid. The amount of energy fed into the grid will depend on what point the inverter is operating on the PV generator Voltage/Current curve. Provided that the input voltage is within the permitted input voltage range, the inverter will not be damaged if a connected PV generator provides current that is above the max. usable input current. The solar generator still represents the largest factor in the cost of a solar installation. For this reason, it is extremely important to obtain maximum energy yields from the solar generator. To achieve this, solar generators in the northern hemisphere should be oriented to the south at an angle of inclination best suited for the location. The PV generator should never be shaded. This orientation is quite often not possible due to structural reasons. In order to achieve the same energy yield as an opti- mally oriented solar generator, the solar generator power can be increased. For roofs with an east -west orientation, we recommend a multi -string PV installation. To achieve an optimum yield from the installation, half of the strings must be installed on the east side of the roof; the second half on the west side. For exposed locations in mountains or in southern regions with higher than normal solar radiation, we recommend that the power generator be reduced appropriately. Please consult with us or your specialty dealer about this matter. 4.3 Protection concepts The following monitoring and protective functions are inte- grated into blueplanet inverters: — Overvoltage conductors/varistors to protect the power semi- conductors from high-energy transients on the grid side. — Temperature monitoring of the heat sink. — EMC filters to protect the inverter from high -frequency line interference. — PV generator grounded varistors to protect the inverter against bursts and surge pulses. — Islanding detection according to IEEE 1547. — Ground Fault Detector Interrupter (GFDI) according to NEC 690.5. Page 20 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 4- Unit Description K A C 0 0 new energy. 4.4 Dimensions and weights Figure 4.1: blueplanet dimensions refer to table below for dimensions Legend GFDl fuse 2 Night time start switch 3 DC/AC disconnect switch 1502xi 30 in. 14 in. 8 1i4 in. 42 Ibs 2502xi 32 in. 14 in. 8 1i4 in. 52 Ibs 3502xi 35 7/8 in. 14 in. 9 112 in. 69 Ibs 5002xi 35 7/8 in. 14 in. 9 112 in. 70 Ibs 4.5 Inverter knockout dimensioning Figure 5.1 (A): Inverter bottom knockout dimensions 1502xi 4 13/32" g 19/32" 5 13/32" 2502xi 4 13/32" g 19/32" 5 13/32" 3502xi 6" 819/32- 513/32`• 5002xi 6" 819/32 513/32" ,a it i i A�!� i } y Figure 5.1 (B): Inverter left view knockout dimensions 1502xi 3" 4 19/32" NIA 2502xi 3" 4 19/32" N/A 3502xi 3" 4 19/32" N/A 5002xi 3" 4 19/32•• N/A blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 21 Section 4 • Unit Description Section 5 Installation and Start -Up K A C 0 new energy. 5002xi 419/32" 3" 6" Figure 5.1 (D): Inverter back plate access dimensions 1502xi 6 3/16 3 3/32" 3„ 2502xi 6 3/16" 3 3/32" 3" 3502xi 6 3/16" 3 3/32" 3„ 5002xi 6 3/16" 3 3/32" 3„ 5 Installation and Start -Up Risk of fatal injury from fire or explosions. The blueplanet's housing may become hot during operation. — Do not mount the blueplanet on flammable materials. — Do not install the blueplanet in areas which contain highly flammable materials. — Do not install the blueplanet in areas where there is a risk of explosion. Risk of burns from hot housing components. Install the blueplanet so that unintentional contact with heat sink is not possible. 5.1 Selecting an appropriate place for installation T1 � blueplanet inverters meet the requirements of protection class NEMA 313 if all cable feedthroughs are used or appropriately sealed. The units should be installed in areas that are as dry as possible in order to extend their service life. It is recommended that the units are installed in climate -controlled areas in order to protect them from overheating. This also extends their service life. The following items are important when you select the place of installation for the inverter: — Ensure good access to the unit for installation or any service work that may later be required. — Maintain the following minimum clearances around the unit: 7 7/$" side clearance to other units, 271/2" clearance to other stacked units, 19 5/$" clearance to cabinets, ceilings and above unit, 36" from bottom of connection box to ground when mounted outdoors. Page 22 31000770-02-112609 blueplanet Operating and Installation Instructions 1502A - 5002xi Section 5 • Installation and Start -Up — The unit is designed for vertical wall installation. — Air must be allowed to circulate freely around the housing and through the heat sink on the rear side. — If the inverter is built into a switching cabinet or similar provide forced ventilation to ensure that heat is sufficientl, dissipated. — The heat sink may reach a max. temperature of 1940F Therefore, mount the inverter only on walls made frorr heat -resistant material. — Ensure that the wall has adequate load -bearing capacity anc use appropriate installation material. — Be sure to install the inverter in a sufficiently elevated place especially in areas prone to flooding, however it is importan to note that the minimum distance to ground is 3 feet wher mounted outdoors. — Installation at eye level makes it easier to read the display. — Mount the inverter in a location where the ambient tempe rature is ideally in the range of-4° to +104°F. K A C 0 Q new energy. 5.2 Installing the inverter dam_ s ;j `s 1/4" lag bolt or equivalent Figure 5.1: installing the wall bracket blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 23 Section 5- Installation and Start -Up K A C 0 0 new energy. 4�GorA t Knadmulw 2 X 3/4' atd E X Ur E. Walt lradtrt wW lack plate wowi#r Log Mt. V4', r lamp tanlnrm a M"WHdtrta are h lridfea 290i3d —� 1502x1 y, ME t stW - ur S ard.I Fr ranuq ed i.dQt Me t-3tw - u4 nr S hr =ntrq go N%~ an "I" - rs on F an$ S ten .M.riio salt ane I-MW - tiw s rM +l tar n AWM MR use w. 7 hr *W bs4larr of we a Wo so bF OCM+ tN! p MYt t7 14n &W aJl"" " MW AM< tie a erW Y M im CWAA tlragheel M510d3 3.1W-4— L535' Figure 5.2: blueplanet 15O2A and 25O2xi wall bracket dimensions Check the composition and condition of the wall before instal- lation. If necessary, use an alternate means of installing the inverter to the wall. MOM) Page 24 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 5 • Installation and Start-up NoRt"i L Condu►t Kncckoutsa 2 X 3/4• and 2 X L/2' 2. Vat[ Hraclrcet and buck plate mount, Lag Gott. 1/41, 2' tong a. D10wrn am are In inches Figure 5.3: blueplanet 35O2A and 5O02A wall bracket dimensions KAco0 new energy. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 25 Section 5 • Installation and Start -Up — Mount the inverter so that the wall bracket fits into the notch on the rear of the inverter assembly mounting plate. — Then secure the inverter assembly mounting plate with the help of the lower screw. 5.3 Connection box with AC/DC disconnect Intended use The blueplanet connection box is intended to be installed with the inverter as one unit during the initial installation. If an inverter must be removed for service, the connection box must remain installed to protect persons from contact with the live DC and AC conductors inside. The connection box contains an integrated AC/DC disconnect switch to comply with the NEC article 690 disconnecting means. The switch disconnects only the AC Line-1, AC Line-2 and DC Hot conductors. The switch has a hole used for locking into the OFF position during inverter replacement. When the switch is in the off position the AC and DC wiring inside the inverter is disconnected and should be safe for removal. The connection box has a shield which is secured by Torx type screws which protect service personnel from electric shock as the circuits inside are energized by the photovotaic array. For servcing the connections inside the shielded area, the photovoltaic array must be de -energized by applying an opaque cover over the array or other means and the AC circuit must be de -energized by switching off the breaker or other means. MADANGER When replacing the inverter section, the installer must turn off the switch in the connection box, lock it and measure the AC and DC wiring to be sure it is not energized. ADANGER If there is a ground fault in the PV array, the grounded conductor may be live. This is a problem with the requirements of the National Electric Code requiring that only the ungrounded conductor be switched. If a ground fault is present and the GFDI fuse blows, the grounded conductor is no longer grounded and is live with respect to the position of the ground fault. Description of components The DC/AC switch is located on the right side of the connec- tion box. When pointed to the front of the unit it is in the OFF position. When pointed in the UP position the unit is in the ON position. Clearly visible labels can be provided upon request. I Designates the ON or energized position. 0 Designates the OFF or non -energized position. new energy. Safety of components The Authority Having Jurisdiction (AHJ) has a difficult charge and maintains ultimate authority of the solar electric system's final inspection. The AHJ must be well versed with the require- ments of the NEC, understand the local utilities' ruling on the use of a utility external disconnect switch (UEDS), and appli- cable use of a UL 1741 approved product. The following NEC 2008 subsections provide an overview of the solar electric system disconnect requirements: 690.13; 690:14, 690.15, 690.17; 690.64, 230.82.6. Subsections are summarized below. For the complete text refer to the appli- cable NEC version approved for use in your jurisdiction. 690.13: The means to disconnect all current carrying conductors of a solar electric system from all other conductors in a building. 690.14, sections A through D: Section A, the disconnec- tion means are not required to be suitable for service equipment and should be rated in accordance with 690.17. Section B, equipment specific to the photovol- taic source circuits such as over current devices, circuit isolation switches, and blocking diodes are permit- ted on the solar electric side of the disconnection means. Section C, the disconnection means should be located in a readily accessible location, preferably near the points of building entrance, be marked as a solar electric system disconnect, suitable for use for the prevailing conditions, and limits the grouping of disconnects to six per enclosure. Section D, permits utility interactive, or grid tied inverters to be located in areas that are not readily accessible, and details the switch requirements. The AC and DC disconnect should be line of sight with the inverter and be readily accessible. 690.15: The means for disconnecting all aspects of a solar electric system must be provided, and if the equipment is energized from more than one source, the discon- necting means should be grouped and identified. Allowances for several AC circuits to be disconnected is allowed as long as the disconnect complies with 690.17 690.17: The means for disconnect all ungrounded conduc- tors should be readily accessible, externally operable with exposing the operator to live circuits, and plainly indicate the open and closed positions. The discon- nect shall have an interrupting rating sufficient for the nominal circuit voltage and current that is available at the line terminals of the equipment. 690.64: The supply side of the inverter shall be permitted to be connected to the supply side of the service disconnecting means as permitted in 230.82.6. The load side is permitted as long as each interconnection Page 26 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 5 • Installation and Start-up is made with a dedicated circuit breaker rated for the appropriate current back feed rating. 230.82.6: The type of equipment connected to the supply is listed, with subsection six identifying solar electric systems as permissible. All components within a UL 1741 compliant inverter must pass evaluation spacing, voltages and currents that the inverter is rated for. The UL 508 standard, industrial control equipment, auxiliary devices has provisions for testing manually operated switches. The integrated switch passed the UL508 standard under the file E304888 for use within a UL 1741 approved grid tied inverter. The switch was tested 6000 operating cycles at the nominal AC and DC voltages and currents as noted in table one below. Additional operating cycles of 4000 resulted in a total of 10.000 successful operating cycles. The switch was de constructed and evaluated under a pass fail criteria. As referenced in the NEC, subsection 690.17, the switch must meet applicable voltage and current ratings. The AC and DC switch ratings are detailed in this table: DC Nominal 600 550 550 550 550 Voltage: VDC DC Nominal 40 21.45 21.45 40 40 Current IDC AC Nominal 240/ 240/ 240/ 240/ Voltage 300 208 208 208 208 VAC AC Nominal Current: 36 8 12.5 17 24 IAC The disconnect solution offered by KACO new energy complies with all annlirable NEC,and I n 1741 reniiiromantc Tha imp rif rr.......y_.,11_ an integrated disconnect with the inverter is potentially safer due to less electro mechanical connections. The only require- ment which would necessitate an individual disconnect would be the specific ruling of the utility requiring a UEDS. K A C 0 0 new energy. Figure 5.4: DC/AC and night switch, GFDI fuse The GFDI fuse is located on the right side of the connection box. When a ground fault occurs this fuse will open causing the inverter to shut down and indicate a fault. Replace only with the same type and rating fuse. The fuse is a fast -acting 600 VDC/1 A KLKD1(manufacturer: littlefuse) rated device. The night time start switch is located on the right side of the connection box. Press and hold the start switch for up to 5 sec- onds to wake the inverter when there is no DC input voltage. This allows the user to display the power that was produced during that day. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 27 Section 5 • Installation and Start -Up new energy. 5.4 Grounding the inverter (B) Grounding multiple inverters: Grounding must be done according to the NEC (National Use a DC GE (Grounding Electrode — ground rod) and run an Electric Code) and any applicable local electric codes! The appropriately sized conductor from the DC GE to the AC GE. inverter has two sides of grounding we need to consider. This will become a GEC for the inverters. Then use a short appropriately sized conductor jumper to each inverter that is System ground (grounding): connecting the circuit to ground irreversibly spliced to the GEC. (i.e. negative of a PV generator, neutral of a split single phase or bi-polar do system). Equipment ground (bonding): Connecting all non -current carrying metal parts to ground (array structure, metal enclosure, module frame) The AC Grounding Electrode Conductor (GEC) shall be sized as required by NEC 250.66 and the GEC does not have to be larger than #6 copper or #4 aluminum if connected to Rod, Pipe or Plate Electrodes! The DC Equipment Grounding Conductor (EGC) shall be sized in accordance with NEC 250.122, if ground fault protection is used. Otherwise, it should be the same size as the current carrying conductor! (A) Grounding single inverters: For the AC side (system ground) use a continuous irreversibly appropriately sized conductor bare or insulated conductor (GEC) to ground the Inverter to the AC GE (Grounding Electrode - ground rod or in some cases the main water line). If the ground rod is unavailable, splice irreversibly to the AC GEC. The DC side (equipment ground) should start at the PV array. All non -current carrying exposed metal parts of equipment, raceways, and other enclosures of the PV system shall be grounded according to NEC 690.43 (e.g. each PV module, combiner and junction box, metal roofing, mounting structure, DC disconnect, and Inverter). The grounding equipment must be listed and labeled. PV C*eW"tar = ^N.• V'CBe Dracarviect AC DulAkod a AVG ONWuetar IW VM in G 94*Aen�t Grarr4ing Aoct- oLuf*p Ryc 4r Odit Mve+rtar Inverter Inverter Imrerter Irreversle splices splices of the grouncil" Electrode conductor taps In aeoordanice with 25M6 (C) and (D) Ea1sthG c s.rvta upvwat 250M $upo OngiRary. EAS Electrode Ae Ground1m9 Et trodA ttJQWt-* 0 Pl_"Cuao Figure 5.5: System grounding Figure 5.6: System grounding -multiple inverters To ensure maximum protection against hazardous contact voltages while assembling photovoltaic installations, both the positive and the negative leads must be strictly isolated electrically from the ground potential (GP). Risk of damage. Be sure that the polarity is correct when you make the connection. Connecting it wrongly will cause damage to the inverter. The positive or negative connection of the PV generator must be grounded. To find out which way is correct, ask the module manufacturer. If there is no preferred grounded connection by the module manufacturer we recommend grounding the Negative as this is the most common method. Page 28 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 5 • Installation and Start -Up Negative Grounded System (Factory Default) — Connect the positive PV generator connection to Hot in the connection box. — Connect the negative PV generator connection to Return in the connection box. See diagram in 5.8 No modifications should be made to the inverter. In this configuration the Negative of the PV generator is grounded through the GFDI fuse. Figure 5.7: DC connection of the connection box — Negative Grounding System NOTE In this configuration the Negative of the PV generator is connected to the 'Ret' (Return) terminal and is grounded throuah the GFDI fuse. The positive is connected to the "Hot Terminal". Figure 5.8: DC connection 02xi series -Negative Grounding System K A C 0 0 new energy. Positive Grounded System — Connect the negative generator connection to Hot in the connection box. — Connect the positive generator connection to Return in the connection box. — Connect Return (white cable) to DC+ in the inverter. — Connect Hot (black cable) to DC- in the inverter. See diagram in figure 5.10 Figure 5.9: DC connection of the connection box — Positive Grounding System 11 NOTE In this configuration the Positive of the PV generator is connected to the 'Ret' (Return) terminal and is grounded through the GFDI fuse. The negative is connected to the 'Hot' Terminal. Figure 5.10: DC connection 02xi series -Positive Grounding System blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 29 Section 5- Installation and Start -Up K A C O 0 new energy. NOTE A screwdriver (slotted, 3.5 mm) is to be used for the terminals in the inverter. Put the screwdriver into the intended cut-out. Press the screwdriver upwards a bit. Put the cable into the spring terminal. Put the screwdriver back into the original position. Remove the screwdriver. The spring terminal is closed and the cable is held in place. Lightly pull on the wire to be sure it is secure. Be sure the inverter is configured for the proper DC grounding configuration of the system. The voltage of the solar generator must be measured before connecting the DC leads to the inverter terminals. The DC voltage must not exceed the max. generator voltage because this would destroy the unit. ACTION Before connecting the PV generatorto the blueplanet, check that the PV generator is not grounded. — Measure the DC voltage between the protective ground (PG) and the positive lead and between the protective ground (PG) and the negative lead of the PV generator. — If stable voltages can be measured, this indicates a ground fault in the'PV generator or its wiring. The ratio between the measured voltages gives an indication as to the location of this fault. Rectify this fault before taking any further measurements. — Measure the electrical resistance between the protective ground (PG) and the positive lead and between the protective ground (PG) and the negative lead of the PV generator. — Low resistance (< 2 MS2) indicates a high -impedance ground fault of the. PV generator, which must be fixed prior to continuing with the installation. Once the wiring in the connection box is installed the protective cover over the terminals must be secured using the included screws and must not be opened unless the switch is in'the off position, the AC breaker is in the off position, and the PV array is powered down with an opaque cover or other equivalent method to assure there is no DC voltage present in the box. The connection box should be considered the same as any other external DC disconnect switch which has live conductors inside. ACTION The ground for the DC input is provided by the integral GFDI circuit. DC input should not be grounded external to the unit. Circuit board fuse The power section has two internal circuit board fuses. These are labelled F801 or F861 on the circuit board. F801: Model: 179120 5x20 time-lag 250VAC/0.4A Manufacturer: SIBA F861: Model: TR5-Fuse series 372 250VAC/125VDC11A time-lag Manufacturer: Littlefuse/Wickmann A, MEI For continued protection against risk of fire, replace onl with same t e and ratings s of fuse. 5.5 Connecting to the Public Grid The inverter can be installed on the following grid -types: L3 L2 Figure 5.11: 240 V Delta: 120 V Stinger Country setting on the display: USA 240 V Page 30 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 5 • Installation and Start -Up 240V 1 soy L2 120V = N 12 I 1-71 Figure 5.12: 240/120 V Split Phase Country setting on the display: USA 240 V Figure 5.13: 240 V Delta Country setting on the display: USA 240 V no neut 208V 120V 208V — N 120 = 20V L3 208V L2 Figure 5.14: 20SW120V WYE Country setting on the display: USA 208V M N new energy. Figure 5.15: 208V Delta Country setting on the display: USA 208V no neut Figure 5.16: 480V Delta or 480/277V WYE Do not connect the inverter to the 480 V Delta or 48OW277V WYE power grids. 5.6 Electrical connection General iniormati©n The electrical connections can be established after the inverter is installed in its fixed location. Knockouts are provided on the sides, bottom, and rear of the connection box to easily run conduit to the desired locations. i Only conduit ordingU4n!be used. blueplanet Operating and Installation Instructions 1502A - 5002xi 31000770-02-112609 Page 31 Section 5- Installation and Start -Up K A C 0 0 new energy. Inputs and output circuits of this unit are isolated from the enclosure. System grounding must be done in accordance with the National Electrical Code (NEC), ANSIINFPA 70 and is the responsibility of the installer. ACTION Guide the wiring through the conduit pipe. Connect the wiring to the appropriate terminal labeled in the connection box. Torque Field Wirina Terminals to 20 in. lbs. You must adhere to all mandatory safety regulations, the currently required technical connection specifications of the responsible power supply company, as well as to other gener- ally applicable regulations. 0 To conn!therter, the AC and DC sides mustbe discom all power sources and secured against ertently energized. (A) Grid Connection Figure 5.17: Connection of the connection box blueplanet 1502xi and 2502xi Figure 5.18: Connection of the connection box blueplanet 3502xi and 5002xi Page 32 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 5 • Installation and Start -Up AC Connections are a 3 or 4 wire connection. In 4 wire systems incorporating a Neutral there will be the following connections; Line-1, Line-2, Neutral, and Ground. In 3 wire systems not incorporating a Neutral there will be the following connections; Line-1, Line-2, and Ground. We recommend the following conductor cross -sections for cable lengths up to 60 feet: — blueplanet 1502xi: AWG 12 up to AWG 4 75°C Copper Wire — biuepianet 2502xi: AWG 12 up to AWG 4 75°C Copper Wire — blueplanet 3502xi: AWG 12 up to AWG 4 750C Copper Wire — blueplanet 5002xi: AWG 8 up to AWG 4 75°C Copper Wire Larger cross -sections should be used for longer leads. Use Copper Conductors only. The following AC over -current protection must be used for the installation of the inverter. — blueplanet 1502xi 15 A Breaker — blueplanet 2502xi —> 20 A Breaker — blueplanet 3502xi 25 A Breaker — blueplanet 5002xi —> 30 A Breaker Risk of electric shock at live connections. Check that the power lead is voltage -free before inserting it into the connection box. To reduce the risk of fire, connect only to a circuit provided with the required branch -circuit overcurrent device sized in accordance with the National Electrical Code, ANSI/NFPA 70. The maximum size overcurrent device shall not be more than 15 A for the 1502xi, 20 A for the 2502xi, 25 A for the 3502xi and 30 A for the 5002xi. new energy. 1 � Be sure to use cables with a sufficiently large cross-section to avoid excessive line impedance between the building's distribution box and the respective blueplanet unit. When the line impedance is high, i.e. long AC -side leads, the voltage at the line terminals of the inverter will increase as power is being fed in to the grid. The inverter measures this voltage. if the voltage at the grid terminals exceeds the line overvoltage limit, the inverter will switch off due to line overvoltage. This condition must be taken into consideration when wiring the AC and dimensioning the AC lead. Check that the leads are properly connected. : Li :MMM0 Once again, ensure that all connected leads are firmly connected. PV generator connection The PV generator leads are connected on the left side of the connection box terminal block. 5.7 Interfaces All interfaces are connected on the communication circuit board. The circuit board is in the connection box. 101 91 no o ---- t;t :fir ECK)ILI _ q !] 2Lj E 1 "Can 'se E j I N 11� � t ©'ram r ij 1 Figure 5.19: Communication circuit board with highlighted RS485 termination switch blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 33 Section 5- Installation and Start -Up K A C 0 new energy. Figure 5.20: Interface terminals (A) Connecting the fault signal relay The inverter is equipped with a potential -free relay contact to signal faults. This contact closes if a fault occurs. The contact is designed as a NO contact and marked as "ERR" on the circuit board. Maximum contact load • DC: 30 V / 3 A. • AC: 250 V / 1.5 A. IMPORTANT In the event of failure of the grid -feed phase (power failure on the publicgrid), the relaywill nottrigger. Ifthis happens, all LEDs and the display go out. The inverter is shut down completely. A fault signal cannot be sent. (B) Connecting the SO output The inverter is equipped with an SO pulse output. Items such as a large display can be connected to it. The pulse rate is adjustable (see section 5.9, "Parameter programming"). (C) The RS485 interface connection The connection terminal (Figure 5.20) is on the blueplanet communication circuit board. To connect several blueplanet inverters, terminal A of one blueplanet is connected to terminal A of the other blueplanet. Terminal B is connected in the same manner. A twisted, shielded data cable is required for this. The connection to the KACO proLOG is established similarly to the interconnection of inverters. A connection diagram is displayed in figure 5.21. The total length of the RS485 wiring should not exceed 4,000 feet. Proper polarity must be maintained or devices will not be able to communicate. blueplanet blueplanet blueplanet proLOG DSL or Ethernet AA BB AA BB AA BB AB 120VAc AF '<RAax igie'ctets ,: Figure 5.21: Connection diagram for the RS485 interface using the KACO proLOG In figure 5.21, a terminating resistor (R.) is connected to the last inverter in the chain. For proper signal transmission, the last unit in a chain must have a terminating resistor. The terminating resistors in the other inverters of the chain must be deactivated (set to "OFF"). In the last unit of the chain, switch "1" is set to "ON" and switch "2" is set to "OFF". The switch is on the communication circuit board above the terminal block (Figure 5.19). With a bus system such as the RS485, each unit sharing this bus must possess a unique address, regardless of whether it is an inverter or any other device. The exception is the monitoring device which is the master. This unit does not need an address. For inverters, the address range can be selected between 1 and 32. You can define the address for each inverter using the configuration menu (see Operating Instructions). • • TANT Ensure that the A and B wires are properly connected. Communication is not possible if the wires are reversed. Page 34 31000170-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 5 • Installation and Start -Up 5.8 Starting up the inverter After completing the mechanical and electrical installation, the inverter is put into operation as follows: The inverter can be put into operation only under daylight conditions (i.e. at a solar generator voltage of > 100 V). If no daylight or solar generator voltage is present, the inverter can be activated by pressing the night start key if there is AC voltage present (see section 4.4 in the Operating Instructions). However, normal operation is not possible in this condition. Only the values can be read off the display. A CTION �s Switch on the line voltage and the solar generator with the aid of the AC/DC disconnect switch (O .1). K A C 0 0 new energy. During the initial start-up, the corresponding country and language must be selected. Select the appropriate language using the '2' (right) key, press the'1' (left) key to advance to the country selection. Press the '2' key to advance through the various grid types. Once the proper grid type is selected press the'1' key then press both the'1' and '2' keys at the same time to save the settings. If the improper grid settings were selected, hold down the '2' key to start the process again. • 1 • If the power is cycled or 10 minutes elapse the settings for the grid type are locked and a password will need to be obtained from tech support. The top green LED "OK" lights when DC voltage is available and indicates that it is ready to be put into operation. The display now indicates the current PV generator voltage "Start from xx V, meas.: xxx V". If the measured voltage is greater than the starting voltage, the unit will start grid -feeding after a country -specific waiting time. This start-up waiting period is required in order to ensure that the generator voltage is continuously above the power delivery limit of 125 V (1502xi) and 200 V (2502xi, 3502xi and 5002xi). A quick start routine is provided for startup and test purposes. This routine circumvents the start-up delay period. This quick start routine is found in the configuration mode menu (see Operating Instructions). During the normal start-up procedure, the line relays audibly switch on after a country -specific waiting time and the feeding of the grid starts. This is indicated by the middle green LED with the house and power line symbol next to it. The display now shows the power being fed into the grid. Key' 1' (left) can now be used to display the various measured values (see Operating Instructions section 4.4). blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 35 Section 5 • Installation and Start -Up 5.9 Parameter programming Various operating mode parameters can beset in the param- eter mode menu of blueplanetunits, Wrong parameter settings can lead to loss of functionality as well as render your system unsafe. Modifications may be made only in exceptional cases and only after having consulted with the manufacturer and the utility company. Parameter menu Country selection Line under voltage switch -off Line over voltage switch -off Under frequency switch -off Over frequency switch -off Starting voltage 125 V (1502xi) / 200 V (2502xi) ACTION To switch to programming mode, hold down key "2" for approx. 20 seconds. Use key'T to scroll through the various menu items. The menu is continuous. When you reach the end, the display automatically returns to the first item. T.� After the country and grid type have been set, and either the inverter is powered down or 10 minutes have elapsed, and a change to the country or grid type is needed, a pass code must be obtained from KACO support. Please have the inverter serial number available when calling to obtain the pass code. K A C 0 0 new energy. Explanation of the individual parameters: Country selection During the initial start-up, the country can be selected and changed again without entering a code. If no entry is made for 10 minutes or the unit is switched off, the country selection is stored. For further changes, a code is needed that can be obtained from service. Line undervoltage switch -off: The inverter is equipped with 1-phase monitoring. If the line voltage drops below the value set for "Minimum line voltage", the inverter switches off. The minimum cut-off threshold can be set in 1 V increments. Line overvoltage switch -off - If the line voltage exceeds the value set for "Maximum line voltage", the inverter switches off. The cut-off threshold can be set in 1 V increments. Under and overfrequency switch -off: The line frequency is also monitored. If the line frequency drops below the value set in "Minimum line frequency" or exceeds the value set in "Maximum line frequency", the inverter switches off. Both limit values can be set in 0.1 Hz increments. Starting voltage for grid -feeding: After sunrise, the inverter will begin to feed into the grid once the voltage has reached 125 V / 200 V (display: "Start from 125 V / 200 V"). This setting enables safe operation in any solar generator configuration. In rare cases, it may be necessary to adjust this starting voltage threshold. At a low generator voltage (few modules connected in series), the starting voltage may be reduced to ensure a safe start-up, even during unfa- vorable weather conditions. At a high generator voltage, the starting voltage may be increased to ensure that the inverter does not switch itself on and off too often with low power. The starting voltage can be set within a range from 125 V to 150 V or 200 V to 225 V in 5 V increments. ACTION Use the "Settings" key to change the parameter that is shown. The value then either increases or decreases, depending on the parameter. The values here are also continuous, i.e. after you reach the maximum value, they return to the minimum value. j CTION To leave the parameter menu, press both keys at once. Upon leaving the menu, the settings are saved. Page 36 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 6- Two -Stage Shutdown K A C® 0 new energy. 6 Two -Stage Shutdown in Accordance with IEEE (standard values for < 30 kW) The shutdown times and the shutdown values for the line voltage and frequency can be narrowed to within a specified range for the blueplanet 02xi series inverters. The allowed values can be taken from the following tables. The specifications of the grid operator and the applicable standard must be observed. It is particularly important that systems < 30 kW comply with the applicable shutdown values for the line frequency. The clearing time, is the time between the start of the abnormal condition and the inverter stops to feed in. Voltage — USA 208 V Voltage — USA 240 V Voltage — Nlexirn 27n V Frequency Overfrequency range 1 Anlage Gr6sse <— 30 kW Frequency.- 60.0 Hz < f < 60.5 Hz * Clearing finne 0,16 sec (fixed) Underfreouency range 1 59.3 Hz * < f < 60.0 Hz 0,16 sec (fixed) Overfrequency range 1 > 30 kW 60.0 Hz < f < 60.5 Hz 0,16 sec (fixed) Underfrequency range 1 57.0 Hz < f < 59.8 Hz 0,16 sec * - 300 sec. Underfrequency range 2 f < 57.0 Hz 0,16 sec (fixed) * = default blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 37 Section 7 • Maintenance 7 Maintenance ADANGER — Risk of fatal injury by electric shock at live connections. Lethal voltages are still present in the inverter and the connection box even after the electrical connections have been disconnected. — Wait five minutes before reaching into the inverter and the connection box. — When working on the photovoltaic modules, the current must be switched off on the inverter and the solar installation with the aid of the AC/DC disconnect switch on the connection box. � a e Switch off the line voltage and the solar generator with the aid of the AC/DC disconnector (I = on or energized / O = off or deenergized). 7.1 Cleaning the fan If the fan is only covered with loose dust, it can be cleaned with the help of a vacuum cleaner or a soft brush. If the fan is very dirty, or if it s defective, it can be removed. 7.2 Removing the fan If the fan is very dirty or defective, proceed as follows: MADANGER Danger due to lethal voltages. 1. Switch the DC/AC disconnect to the OFF (0) position to de -energize the inverter and lock out to prevent inadvertent energizing of the inverter during service. 2. Wait 5 minutes for the internal components of the inverter to discharge. new energy. 3. Remove the two inverter hinged door screws and open door. 4. Disconnect the fan connections Page 38 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002A Section 7 • Maintenance new energy. 5. Remove the fours screws from the mounting bracket. 6. The fan can be removed along with the mounting bracket. 7. Aftercleaning or replacing the fan, perform this sequence in reverse to reinstall the fan. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 39 Section 8 • blueplanet as Part of a PV Installation K A C 0 new energy. 8 blueplanet as Part of a PV Installation 8.1 Design of installation A sample design of a grid -connected PV installation using a blueplanet is shown below in the overview circuit diagram. PV array blueplanet inverter with blueplanet inverter with } pre -installed AC/DC i pre -installed AC/DC disconnect switch Jf' disconnect switch i Circuit breaker Utility meter Main circuit breaker Figure 8.1 Single -line overview circuit diagram for an installation with two inverters Page 40 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 8- blueplanet as Part of a PV Installation K A C 0 Q new energy. A summary of the components: DC terminal point: Two PV strings car be connected in parallel either at a DC terminal point between the solar generator and the inverter or directly on the inverter (terminals for three strings are provided on the inverter). Of course, you can also connect the strings directly to the solar generator and then run Just one negative and one positive lead to the inverter. External fusing may be required, refer local and national electric codes. DVAC disconnect: In order to be able to disconnect the inverter on the PV generator side from sources of voltage, the inverter comes equipped with an pre -installed AC/DC disconnect switch. As a result, the installation of an external AC or DC disconnect switch is not required. NOTE: Be sure to check with local electrical codes and utility requirements as some inspectors will require a separate visible blade disconnect. Line overcurrent protection: In order to protect the wiring, the inverter's supply leads should be secured with circuit breakers or fuses as appropriate. The circuit breakers or fuses that are used should be appropriate to the length and cross-section of the wiring and fulfill applicable standards and directives (53: Electrical connection — grid connection). Utility power meter: The required utility power meter is specified and installed by the responsible power company. Main circuit breaker: Contact your utility and check with local and national electrical codes if you have questions concerning the required main circuit breaker. blueplanet Operating and Installation Instructions 1502A - 5002xi 31000770-02-112609 Page 41 Section 8- blueplanet as Part of a PV Installation KACO 10 new energy. 8.2 Installation with multiple inverters on a three phase system . Observe the following regarding installations with multiple inverters on a three phase system: Asymmetric grid -feed: The power should be distributed as equally as possible over the three phases. In the US, typically the asymmetry between the phases may be a maximum of 6 kW (This number can vary depending on utility transformer size and codes). i f J /M a Mnwun I x ' u N.. r !l Li u M N LiL2 Ps L2- L3 M— + --- - ----- - - -- ------ --- Figure 8.2: Three phase grid connection for installations with multiple inverters Electrical connection: The blueplanet feeds only on two phases. In order to avoid asymmetries on a 3 phase grid, installations with multiple inverters should be designed so that the inverters feed into the grid in differing phases. The inverter feeds into the con- nections labelled L1 and L2. If you have multiple inverters, connect the actual phases L1 and L2 to terminals L1 and L2 on the first unit. On the second unit, connect phases L2and L3 to terminals Lt and L2. On the third unit, connect phases L3 and L1 to terminals L1 and L2. Continue as above. This distributes the power optimally. Page 42 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 9- Troubleshooting K A C 0 0 new energy. 9 Troubleshooting in line with our continuously expanding quality assurance system, we endeavor to eliminate all errors and faults. You have purchased a product which left our factory in proper working condition. Each individual unit has successfully passed an endurance test as well as extensive tests for the purpose of assessing the operating behavior and the protective equipment. If your photovoltaic installation does notfunction properly despite these measures, we suggest the following troubleshooting procedures: The first step is to check that the solar generator and grid connections are properly connected to the blueplanet. In doing so, observe all the safety instructions specified in this manual. Monitor the inverter closely and, where applicable, make a note of the displays and LEDs. The following faults may occur and should be remedied as described. Error Cause of error Troubleshooting/Explanation The display is blank and — There is no line voltage. The inverter switches to night shutdown mode as soon as the solar the LEDs are not lighting — The solar generator voltage generator voltage is below the minimum grid -feed voltage for a longer up. is too low. period of time. For this reason, check first to see if the solar generator voltage is sufficiently high. The inverter changes to stand-by status once 80% of the minimum grid -feed voltage is reached. Check the AC voltage as well. The permissible voltage ranges for grid - feed can be found in the technical data. If despite these measures the display stays blank, please contact KACO new energy service. The inverter stops Faulty grid separation relay in Although there is sufficient sunlight, the inverter feeds into the grid only supplying ingpower o to the the inverter l for a few second l d s before switching off again. During the short grid grid shortly after being feed period, the inverter shows that the power being fed into the grid switched on, even though is between 0 and 5 W. If the inverter is definitely receiving sufficient there is sufficient sunlight. generator power, the grid separation relay is presumably faulty, thus preventing the inverter from connecting. Please contact KACO new energy service. The inverter is active but The inverter has interrupted Due to a line failure (line impedance too high, over/undervoltage, over/ does not feed into the the grid -feed due to a line underfrequency), the inverter stopped the grid -feed and disconnected grid. The display indicates failure. from the low -voltage grid for safety reasons. Many grid parameters can a line failure. be changed within: the permissible operating limits. More information can be found in the section "Starting up the inverter". If the line failure exists for a long time, please contact the grid operator. The line overcurrent The line overcurrent In cases of high insolation, the inverter can — depending on the solar protection trips. protection capacity is too low. generator — exceed its rated current for a short period. For this reason, the capacity of the inverter's overcurrent protection should be somewhat higher than the maximum grid -feed current. You can find a dimensioning I of the line overcurrent protection in the section "Installation and Start- Uo" The line overcurrent Damage to the inverter's If the line overcurrent protection immediately trips when the inverter protection trips. hardware. switches to grid -feed mode (after the start-up period is complete), the inverter`s hardware is possibly damaged. Please contact KACO new energy service. If the measures described in this guide do not assist In clearing the fault, please notify KACO technical support at +1 (866) 522-6765. In order for our factory customer service department to respond in an appropriate and expeditious manner, some details are imperative: Details pertaining to the inverter — The unit's serial number — Model — A short description of the error and error code if applicable — Is the error reproducible? If yes, how? — Does the error occur sporadically? — Describe the prevailing insolation conditions when the error occurred? — Time of day blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 43 Section 10 • Efficiency curves K A C 0 0 new energy. 10 Efficiency curves 100 99 98 97 96 v � m 95 94 w 93 t Ij —F-125Vdc 92 195 Vdc 91 c I j j 90 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% %of Rated Output Power Figure 10.1: Efficiency curve 1502A / 240 V 100 99 98 97 96 m 95 W 94 93 j 1. 92 125 Vdc Figure 10.2: Efficiency curve 1502A / 208 V Page 44 31000770-02-112609 bluepfanet Operating and Installation Instructions 1502xi - 5002xi Section 10 • Efficiency curves 100 99 I 98 97 T 96 c I95 m I 04 W 93 j 92 91 90 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% %of Rated Output Power I i It200 Vdc —�265 Vdc 450 Vdc ; Figure 10.3: Efficiency curve 2502xi / 240 V 100 99 98 97 1 I e 96 u I = 95 m - i I 94 LU 93 li - 92 L -+-200 Vdc —2 65 Vdc 91 —�450 Vdc 90 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% %of Rated Output Power Figure 10.4: Efficiency curve 2502xi / 208 V KACO18 new energy. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 45 Section 10 • Efficiency curves K A C 0 @ new energy. e Cc m W 100 99 98 97 96 95 94 93 92 91 90 -------------3------ --------------------------------------------- ------------ ---------------- --- --- ---- --- - -------.----- L-20jVd - -28 51 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% % of Rated Output Power Figure 10.5: Efficiency curve 3502xi / 240 V 100 99 ---------------------- - -- J ------ 98------------------------------------ ------------.--------------------1 97 ------------- �------ ------------- 96 -----' 95 --------- ----- ! I m94 m93------- ----- ------ ------ +2jVdc I------ L------'-------------'----- �-2 92 - - - -- ------------—d-5 91 - 90 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% % of Rated Output Power Figure 10.6: Efficiency curve 3502xi / 208 V Page 46 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 10 • Efficiency curves 0 ii m w 100 99------ — -----------'------ — - — --- -'---- ------------I, 98 :— ------------'--------------=--------------------- ------------------- 97------------------------------------------------ ------ ----- ----- 96+-. 95T- -- - - - - ------------- 94 - -- ---- ------ ------ ------ - - - - -- -- - -- — --- --------------- ' t200 Vdc ---_ 1—F280 Vdc 91 = -----------1—�510Vdc -----f------------- - 90 0 % 10% 20% 30 % 40% 50% 60% 70% 80 % 90% 100% % of Rated Output Power Figure 10.8: Efficiency curve 5002xi / 240 V 100 99 98 a, 97 1 96 05 - 94 -------:------- ---- ----- 93 !--*-200 Vdc i 92 ---- --- 91 1 ..-- ----- -- 7-------------------- jt280 Vdc -- --'- --- --- ---- i _,to Vdc 90 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% % of Rated Output Power Figure 10.7: Efficiency curve 5002xi / 208 V K A C 0 new energy. blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 47 Section 11 • Compliance Certificates K A C 0 0 new energy. 11 Compliance Certificates Certificate TOWheintand Certificate W. 913fi}I QT CU 720 License Holder: l&nufacturing Plant: Kano new energy GmbH Kato new energy GmbH :�--tr`ried-Leibniz-Str. 1 Gottfried-Leibniz-Str. 1 74172 Neckarsulm 74172 Necicarzulm Ge nvar_y Germany Test report no.: L'SA-DS, 30981733 001 Client Reference: Matthias Haag Tested to: Lai: 1741:1999 R11.05 CSA C22.2.107.1-0 (R2005) i Certified Product: Solar Inverter with Galvanic Separation License Fee - units Mode' Designation: 1) blueplanet 1502xi 7 2) blueo anet 2502xi Rayed Voltage: 1) DC 550ii Max. (MPP Voltage Range: DC 125-430V 2) DC 550V Max. (MPP Voltage Range: DC 200-450V1 Rar_ed Current: 1) 14.3A 2) 13.SA coned. 7 appendix: 1, 1-16 Licensed Test mark- I Sigttatarc Date of issue (dactmo!cr) ti C ° us 4ms Dipl: ing-. M. G7agla QA Certification Officer rtt+r w.sL-w nP:.onhNrseri= i�, zz c— w—a, N�� cr 0E470, rn • afar azaaeas us wrs Page 48 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 11 • Compliance Certificates K A C 0 0 new energy. I � Certificate TOVRheiniand i I Certificate no. CU 72091301 02 , License Holder- Manufacturing Plant: Ka,c- new en- aY aT:O_± haco ':XeiA energy G=.--T v frle Teilan LZ-Str. t Goth_frie Le_Lbn 2-Str. - ( t "£172 Neckaraa_m 74172 heekarsu,lm ! -!ermar:y Ge-cridt_y i i Test report no.: US-ADS 3098- 733 SOIL Client Reference: Matthias Haag Tested to: 999 P Certified Product: Sol ar ___rer___ w1th 'Ga-lvzri-z Sapaxa--ion License Fee Units - rc C 202 24uV, 6011 fl� u5 Gu p: -uCren 1; AC a.DA max. 2i AC 12.�A max. :00`A max. 21 25Orri Max. I 'Peak Oatvut^Fower: 1 ` i5S0t1 7 250�1w _ _ I 3 -- JZ Class: L a r -?=_,4 NNEMA k Licensed Test mark -Signature ---- Date of Issue i (tiavimorgr) ,i gnetrye/J , f `' 2 r a Di 1 In M. to P g (pia g I a is ° 4meT° Q.A Certification Officer vzs- blueplanet Operating and Installation Instructions 1502xi - 5002xi 31000770-02-112609 Page 49 Section 11 Compliance Certificates K A C 0 0 new energy. Ceftificate TtJVRheinland Certificate no. CU 7209207"7 Q l License Holder: Faco new energy G- H j Ca'-'--cZeiss-SLr. I 74172 Neckarsulm 3e many Manufacturing Plant: Kacc new ene -ay GmbH Friedrich -Gauss -St 74172 Leckarsul:n Germany Test report :na.: USA-DS 30982753 001 Client Reference: Matthias Haag 'rested to: UL 1741:19 99 R11.05 CSA C22.2.107.1-01 (R2406) i Certified Prodnet Inverter with Galvanic Saparati License Fee - Units Model Designation: 1) blueplanet: 3502xi 7 2) blueplanet 5002xi Rated Voltage: DC 200-510V (DC 50OV/550V max.) Rated Current: 1) 18.5A max. 2) 26.5A max. rotection Class: I 'ngress Protection: IP54 / NEMA 3R Appendix: 1, 1-41 Licensed Test mark: C us th 4 mo Signature Dipl -iing M. GhWa QA Certification Officer 7 Pate of Issue (dayinw/yr) 25/'J9/2 09 Page 50 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi Section 11 • Compliance Certificates K A C 0 0 new energy. License Holder: acc new are-. gu.,,bH =72 sec lsarsu' Tt Nbroufaeturing Plant: Kaco new ener-u.y ti:M- b Fried -icc - Jaws - Str . 74172 Neckarsu_r*- e=Tait. f Test report ao": i SA-BS a O 9 3 2 7 5:3 IC I Client Reference: Matti i as Rlaaz Tested to: ,T� 1 7,1_ _ . 19 9 9 �! 1 . Cr _ Certified Product: L1'VerYL+_ wi-t. h %a_.i 3'n„n �'a�i�'r:a t^.i`^.';i License Fee - t nits V pa YI n�IS n. A--2� t3 'Jnr=. , 0, � . Be'-i ; 7.01-1 max. ; 3 ^C 7 i°i Z7oSLi , i 3 ram' J i fi' max. l-i=' 2 4 - J 6 ...._ z 14 .o"A : _ ,.. 3 5.:?''-i Yti i1`Ji't . ; 3 5 0 0 li max- A— FetnC3.rk3s; A1So coanv 2.es-J7:1''_ la._Z 115 7 & Ik-.u..^., SST.?.I. Licensed Test roar%: C e7A. s us s Signature it @ipl.-ing. MGlagla Q& Certification Officer Mte of Nwe (day,,rno{yr2 0 9 2 blueplanet Operating and Installation Instructions 1502A - 5002A 31000770-02-112609 Page 51 Notes • Keep records of your installation and performance K A C 0 0 new energy. Page 52 31000770-02-112609 blueplanet Operating and Installation Instructions 1502xi - 5002xi