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AB1-Series Photovoltaic Modules

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					AB1-Series Photovoltaic Modules
Safety and Installation Manual




Please read this manual carefully before installing Abound Solar modules.

Abound Solar, Inc.
www.abound.com




                                                     Document # 3105410 Rev B
                                                     Effective December 7, 2010
                                                                                                    Abound Solar
                                                                              Safety and Installation Instructions
                                                                                                      AB1-Series

Introduction                                                       1.0     Compliance Information
                                                                   TÜV ID#: 0000018894
Thank you for selecting Abound Solar
photovoltaic modules. Abound Solar products                        UL File #: E320912
provide high efficiency with long-term stability.
                                                                   Report #: US-UL-10-0009-PV
This instruction manual provides safety and
installation instructions for Abound Solar’s AB1-
Series of products.



About this Manual

“Bold Italicized” (and quoted) items have a
document reference number which appears in
Section 9.0, References.

Figures are referenced by section number; prior
to section 4.0, there are no figures in this
document.




Table of Contents                                                  2.0     Module Overview
1.0      Compliance Information................... 1               Abound Solar modules are comprised of two
                                                                   sheets of glass that are bonded together. The
2.0      Module Overview ............................. 1           interior of this assembly contains a
3.0      Safety .............................................. 2   semiconductor film, which will produce electricity
                                                                   when exposed to sunlight. Wires with industry
4.0      Installation ....................................... 3
                                                                   standard MC4 style connectors provide for the
  4.1       Mechanical installation ................. 3            electrical connections. The junction box is on
                                                                   the rear of this module assembly and provides
  4.2       Electrical installation .................... 5
                                                                   strain relief to the wires. These are frameless
5.0      Operation and Maintenance ............ 7                  modules. Each module weighs about 12 kg,
                                                                   which is about 25 pounds.
6.0      Disposal and Recycling ................... 7
7.0      Warranty Terms and Conditions ...... 8                    Ratings
8.0      Disclaimer of liability ........................ 8
                                                                   These modules have been evaluated by
9.0      References ...................................... 8       Underwriters Laboratories, Inc., to meet or
10.0     Product Label .................................. 9        exceed a positive or negative loading of 2,400
                                                                       2          2
                                                                   N/m (50 lbs/ft ).




Page 1
                                                                                       Abound Solar
                                                                 Safety and Installation Instructions
                                                                                         AB1-Series

3.0      Safety                                               store modules prior to installation, keep
                                                              them indoors in original shipping
All instructions should be read and understood
                                                              containers.
before attempting to install, wire, operate, and/or
maintain the photovoltaic module.
                                                              It is required that the installation meet all
Caution: Risk of Electrical Shock                             requirements of local and applicable
PV modules generate DC electrical energy when                 codes – such as the latest National
exposed to sunlight or other light sources.                   Electrical Code (USA) or Canadian
Contact with electrically active parts of the                 Electrical Code (Canada) or other
module such as terminals can result in                        national or international electrical
burns, sparks, and lethal shock whether the                   standards..
module is connected or disconnected. The
shock hazard increases as modules are                         Safety Application: Class A: General
connected in parallel, producing higher current,              access, hazardous voltage, hazardous
and as modules are connected in series,                       power applications.
producing higher voltage.
                                                              Module Meets Safety Class II
             Caution: Risk of Broken Glass. Since
             the module consists primarily of            Handling precautions
             glass, the possibility of broken glass
exists. Broken glass can be sharp and cause                   Protective gloves should be worn when
injury if not handled with protective equipment               handling solar modules to protect
such as gloves and eyewear.                                   against sharp objects or electric shock.

Carefully plan for installation:                              Proper Personal Protective Equipment
                                                              should be worn at all times.
         Prior to design of the system and
         installation of the product, please make
                                                              Do not stand or step on a module.
         sure that you have the latest versions of
         all applicable product documentation.
                                                              Do not drop a module.
         Check that all other system components
                                                              Do not break the glass surfaces of a
         (inverters, wires, racks, balance of
                                                              module.
         system materials, etc.) are mechanically
         and electrically compatible.
                                                              To avoid the hazard of electric shock
                                                              and injury, covering the front surface of
         Do not artificially concentrate sunlight on
                                                              the modules with a dense, opaque
         a module.
                                                              material such as a cardboard box,
                                                              during installation and handling of the
         Pay attention to the design of the PV
                                                              modules is recommended.
         system and electrical capacity of system
         components (especially the inverter),
                                                              All Abound Solar modules are shipped
         because under certain conditions this
                                                              with an intact junction box and edge
         module may generate more than its
                                                              seal. If either of these features is
         STC rated power (PMPP).
                                                              missing or appears damaged at time of
                                                              delivery, please contact your module
         Do not remove modules from packaging
                                                              supplier.
         until ready to install. If it is necessary to




Page 2
                                                                                      Abound Solar
                                                                Safety and Installation Instructions
                                                                                        AB1-Series

                                                    Installations in Canada must be in accordance
         Do not carry a module by its wires or      with CSA C22.1, Safety Standard Electrical
         junction box.                              installations, Canadian Electrical Code, Part 1.

         Do not drop or place heavy items or
         tools on the surface of the module.
                                                    4.1 Mechanical installation
         Never leave a module unsupported or        Mounting safety
         unsecured.
                                                                Caution: Modules should be handled
                                                                with care during installation, as heavy
         Do not use or install broken modules.
                                                                impact on the front, back or edges
                                                    could result in damage to the module. Do not
         Do not allow any foreign objects such as
                                                    attempt to install the modules in high wind or wet
         clips or tools to damage, intrude or
                                                    conditions.
         penetrate into the edge seal.
                                                    All installations must comply with safety laws.
         Do not disassemble the module, or          Check applicable building codes to ensure that
         remove any part installed by the           the construction or structure (roof, façade,
         manufacturer.                              support, etc.) where the modules are being
                                                    installed has enough strength.
         Do not treat any portion of the module
         with paint or adhesives to avoid damage    For modules mounted on roofs, special
         to the module, inoperable conditions, or   construction or structures may be required to
         reducing the module's functionality.       help provide proper installation support.

                                                    Both roof construction and module installation
         Do not penetrate any portion of the
                                                    design have an effect on the fire resistance of a
         module with screws, drills, or any other
                                                    building. Improper installation may contribute to
         foreign object.
                                                    fire hazards. Additional devices such as ground
                                                    faults, fuses, and disconnects may be required.
         Do not set or strike modules on their
         edges or corners.                          Check and follow all safety precautions of other
                                                    system components used.
         Do not disconnect plugs while under
         load.                                      Site selection

                                                    For stationary mounting, orient modules to face
         Make sure you comply with all local and
                                                    the average position of the sun. A fixed-tilt
         national codes and permit requirements.
                                                    mounting is recommended, with a tilt range from
                                                    0 degrees to 50 degrees.

4.0      Installation                               Avoid installing modules where they may be
To ensure safe and proper application, prior to     shaded. Pay special attention to partially
installation and activation of warranty, all        shading modules by objects such as buildings,
applications must be submitted and                  trees, windmill blades, and poles during the
acknowledged through Abound Solar’s “Project        daytime or due to seasonal sunlight variation.
Architecture Report (PAR)” process.




Page 3
                                                                                       Abound Solar
                                                                 Safety and Installation Instructions
                                                                                         AB1-Series

Modules should be firmly fixed in place in a         The mounting structure must not cause any twist
manner suitable to withstand all expected loads,     or stress to be placed on the modules.
including wind and snow loads.
                                                     Mounting Orientation
Operating conditions
                                                     Abound Solar AB1-Series solar modules should
The ambient operating temperature must be            typically only be installed in a portrait orientation
between -20°C (-4°F) and 45°C (113°F). The           where the long dimension is perpendicular to the
temperature limits are defined as the monthly        ground. Be especially careful to avoid conditions
average low and high of the installation site.       that may shade one entire cell of the module;
                                                     shading of an entire cell over prolonged periods
The pressure load of the installation site should    may cause permanent damage to the module.
                      2
not exceed 2,400 N/m (50PSF); testing has
been performed to this rating per UL                 The module should be mounted so the junction
procedures.                                          box is towards the upper half of the module.
                                                     This will minimize the possibility of water ingress
For optimal performance, avoid operating             into the junction box.
modules where:
                                                     Frame
         Modules could experience shading from
         seasonal sunlight variation, structures,    Abound Solar AB1-Series solar modules are
         or passing objects.                         intended to be installed without a frame.

         Exposure to salt water may occur.           Rails

                                                     The mounting rails must provide support for the
         Frequent or large hail, ice, and/or heavy
                                                     modules. To allow the modules to comply with
         snow occur.
                                                     the safety testing that has been done, the clips,
                                                     which mount to the rails, must be placed in
         Air pollution, chemically active vapors,
                                                     specific locations on the modules. These
         acid rain, soot, etc. are excessive.
                                                     locations are shown in the illustration below, and
Racking                                              discussed in the ‘Clips’ section below as well.

Appropriate material should be used for              For systems which have more than one row of
mounting hardware to prevent the module,             modules, it is suggested that the rails be
mounting structure, or hardware itself from          mounted 610 mm apart. This will allow for a
experiencing decay or corrosion.                     symmetric approach to mounting on the
                                                     horizontal rails, as well as enough clearance
For roof-mounted systems, clearance between          between modules for a reasonable safety clip.
the roof surface and module frame is required to
allow cooling air to circulate around the back of    Clips
the module. This also allows any condensation
                                                     Modules are to be mounted with a minimum of 4
or moisture to dissipate. Install modules so that
                                                     rubberized clips (with EPDM rubber – or similar
air can circulate between the roof and the
                                                     material - contacting the module) installed on the
module. Leave a minimum of 100 mm of
                                                     long (1200mm) module edges, with the clips
clearance between the roof and the module
                                                     placed 295 mm +5/-45 mm from the module
surface.
                                                     ends as shown in the Figure 4.0. Be sure to
                                                     follow the clip manufacturer’s recommendations;
                                                     typically a minimum gap of 1 mm is required




Page 4
                                                                                        Abound Solar
                                                                  Safety and Installation Instructions
                                                                                          AB1-Series

between the edge of the rubberized clip and the       seasonal expansion and contraction issues.
edge of the module to allow for thermal               With some racking configurations, this consists
expansion.                                            of a safety clip which is placed along the bottom
                                                      edge of the module.
The mounting contact area that each clip should
have on the module is a minimum width of10            Additional information on the design of
mm, by a minimum length of 70 mm. The clip            mounting equipment for the Abound Solar
should not extend over 12 mm on the topside of        AB1-Photovoltaic module may be found in
the module to avoid intrusion over active cells.      the “AB1 Mounting Application Note”.
The mounting clips which have been
successfully tested through the UL process are
made from aluminum with a material thickness
of 4 mm. It is acceptable to have additional
overlap on the bottom-side of the modules as
                                                      4.2     Electrical installation
this will not interfere with the sunlight gathering   Guidelines
capability of the active cells. The clips should be
                                                      Before installing modules, contact the
engineered so they do not provide excessive
                                                      appropriate authorities to determine
compression of the module.
                                                      permissions, installation and inspection
Please refer to the “AB1-Series PV Module             requirements to follow that apply to your site and
Mounting Application Note” for further                installation.
information.
                                                      Follow all installation and inspection
                                                      requirements, complying with local law. If not
                                                      otherwise specified, it is recommended that
                                                      requirements of the latest National Electrical
                                                      Code (USA) or other similar international
                                                      electrical standard be followed.

                                                      Rated electrical characteristics are within ±10%
                                                      of measured values at Standard Test Conditions
                                                                                         2
                                                      (STC) of: Irradiance of 1000 W/m , 25°C cell
                                                      temperature, and solar spectral irradiance per
                                                      ASTM E 892.

                                                      Inverter Selection

                                                      The Abound AB-1 modules should be utilized
                                                      only in a negatively grounded system utilizing a
                                                      transformer based or otherwise galvanically
                                                      isolated inverter.

                                                      Abound is working to rigorously test and verify
                 Figure 4.0
                                                      operation with a variety of inverters and inverter
         Panel Mechanical Reference                   topologies. Please refer to the “AB1 Inverter
                                                      Compatibility Guide” for more information.
Safety Clip
                                                      Wiring specifications
The module must be supported in such a way as
to avoid slippage due to gravity, wind, and




Page 5
                                                                                       Abound Solar
                                                                 Safety and Installation Instructions
                                                                                         AB1-Series

Use only PV rated stranded or solid copper           Wiring Connections
single-conductor cable which is UV/sunlight
resistant and rated 600V for the US and 1000V        Use only approved MC4 or compatible
Europe with temperature rating of -40°C to           connectors. When connecting the MC4
+90°C with a minimum gauge of 14AWG and              connectors, fully insert and engage both locking
6mm minimum cable diameter for modules and           tabs.
interconnect wiring that is exposed to weather.
                                                     The wire length on the module is 600 mm; this is
There are no wire clips supplied with the            enough length to allow the modules to be
module. If wire clips are used, ensure that they     connected in series when mounted next to each
are of sufficient specification to hold a 6mm        other in portrait mode.
diameter cable. When routing the cable, do not
exceed the minimum bend radius of the cable,         Series Connections
which is 4X the diameter, or 24 mm.
                                                     The modules are intended to be wired in series
Under normal conditions, a photovoltaic module       within each string. The maximum number of
may experience conditions that produce more          modules which can be wired in series is
current and/or voltage than reported at STC.         dependent upon the local codes and the inverter
Refer to section 690-8 of the National Electrical    dc input voltage limitations. Consult the latest
Code (USA) or equivalent for additional              datasheet for Voc and the appropriate
multiplying factors which may be applicable          temperature compensation of the modules being
when determining voltage ratings, conductor          used. It is imperative not to exceed local code
capacities, fuse sizes, and size of controls         limitations and the operating voltages of the
connected to the module output.                      chosen inverter.

General Wiring Guidelines                            Typically, installation for series strings shall be
                                                     no more than 12 modules for a 600V string
         All wiring should be done in accordance     taking in account Voc without temperature
         with applicable electrical codes.           coefficient calculations. For 1000V strings no
                                                     more than 20 modules shall be in a string.
         A qualified, licensed professional should
                                                     Blocking Diode
         do all wiring.
                                                     Within normal installations the AB1 modules do
         Wiring should be protected to help          not require the use of a blocking diode. For
         ensure personal safety and to prevent       some applications, such as multi-paralleled
         its damage.                                 superstrings (see the European applications
                                                     below), a blocking diode may be required.
         The wires should be secure and routed
         in an appropriate, water free wire way.     Overcurrent Protection

         All modules connected in series should      In jurisdictions falling under the US National
         be of the same module number and/or         Electrical Code (NEC), installations that contain
         type.                                       more than two strings require overcurrent
                                                     protection on each string. A 4-Amp (maximum)
         Use copper wire that is PV system           fuse or circuit breaker is recommended for each
         rated; it must be sunlight resistant and    series-connected group of modules for over-
         insulated to withstand the maximum          current protection.
         possible system open circuit voltage.




Page 6
                                                                                       Abound Solar
                                                                 Safety and Installation Instructions
                                                                                         AB1-Series

The required rated voltage for such overcurrent      have been mounted on the racking, the modules
protective devices shall be based on the             should be left in open circuit no more than 90
rated open-circuit voltage corrected for expected    days. Do not short circuit the modules;
ambient temperature. The open-circuit voltage is     permanent damage may result.
the sum the open-circuit voltage of the series
connected PV modules. Note that this value can       5.0     Operation and
greatly exceed the maximum power point (mpp)
                                                             Maintenance
voltage.
                                                     Under normal operating conditions, the modules
                                                     should not require any maintenance. However,
Parallel Connections
                                                     due to local conditions, the modules may
In jurisdictions which are not covered under the     become soiled. It is up to the site operator to
US NEC, it is typical to wire several strings in     determine if cleaning is appropriate.
parallel prior to combining these strings into one
                                                     Cleaning
fuse. The individual strings are referred to as
substrings, and the overall series/parallel          Regular maintenance may help to maintain
combination is referred to as a superstring.         optimal system performance. Under most
                                                     conditions, normal rainfall is sufficient to keep
For such applications, no more than three            the module glass clean if the module is tilted.
substrings should be connected in parallel
without the use of blocking diodes. With             If the module's front surface becomes dirty,
blocking diodes, no more than six strings should     power output will likely be reduced.
be connected in parallel. Each substring should
have its own blocking diode.                                 The front surface of the module may be
                                                             cleaned with water and a soft cloth or
In such applications, the size of the current                sponge on a regular basis. It is
limiting device must also be adjusted based on               recommended to clean the back surface
the expected output of the modules. The                      only as needed.
overcurrent device should be approximately
1.5X the combined rating of the paralleled                   A mild non-abrasive detergent may be
strings.                                                     applied for persistent dirt. Do not use
                                                             harsh cleaning materials or sharp
For more information on this topic please refer to           instruments.
the “AB1 Series/Parallel Configuration
Guide”.                                              Maintenance

                                                     It is recommended to inspect the electrical and
Conduits
                                                     mechanical connections periodically for loose
For applications where wire conduits are used,       connections and corrosion.
follow the applicable codes for outdoor
installation of wires in conduits. Verify that all
fittings are properly installed to protect wires     6.0     Disposal and Recycling
against damage and prevent moisture intrusion.       Abound Solar has invested in a recycling
                                                     program to ensure that every aspect of the
Prior to Commissioning                               lifecycle of the module is environmentally
                                                     responsible. A Return Materials Authorization
If the remaining system is not ready for
                                                     (RMA) process must be followed to return
commissioning immediately after the modules
                                                     materials. Further information will be found in




Page 7
                                                                                    Abound Solar
                                                              Safety and Installation Instructions
                                                                                      AB1-Series

the “Recycling and Return Material                 For further information, please visit
Authorization (RMA) Process” manual.               www.abound.com or contact your Abound Solar
Abound Solar modules should not be discarded       authorized representative.
into a landfill; they must be returned to Abound
Solar for recycling.                               All details regarding Abound Solar’s offering are
                                                   subject to the terms and conditions set forth in
Modules with broken glass cannot be repaired       Abound Solar’s agreement with its customers.
and should not be used since they may produce
                                                   Unless otherwise indicated, all electrical
electrical shock on contact. Broken or damaged
                                                   characteristics +/-10%. Specifications are
panels must be handled carefully and disposed
                                                   subject to change without notice due to process
of properly.
                                                   adjustment and product improvements. Please
                                                   check with the latest product specifications for
Place broken modules in Abound Solar
                                                   updates.
packaging for transport to a dedicated recycling
facility. Contact Abound Solar for additional
details.
                                                   9.0     References
                                                   The following documents are available through
7.0      Warranty Terms and                        Abound Solar. Please contact Abound directly
                                                   for information on the latest revisions.
         Conditions
Please refer to Abound Solar’s Warranty Terms      Recycling and Return Material Authorization
and Conditions for warranty terms and product      (RMA) Process
return policies. These terms are administered on   (Section 6.0):
a contract basis; please refer to you sales        Abound Solar Document #3106760
contract.
                                                   Project Architecture Report
Please note that any warranty is valid only for    (Sections 4.0 and 7.0)
commissioned projects; commissioned projects       Abound Solar Document: #3106497
require the completion of a “Project
Architecture Report”. The modules are              AB1-Series Photovoltaic Module Mounting
designed only to be installed once and             Application Note
                                                   (Section 4.1)
demounting and remounting into a new site
                                                   Abound Solar Document: #3106761
will void the warranty. Additionally, the
“Product Registration Procedure” must be           AB1 Inverter Compatibility Guide
followed.                                          (Section 4.2)
                                                   Abound Solar Document: #3111669
8.0      Disclaimer of liability
Abound Solar does not assume responsibility        AB1 Series/Parallel Configuration Guide
and expressly disclaims liability for loss,        (Section 4.2)
damage, or expense arising out of, or in any way   Abound Solar Document: #3111670
connected with failure to follow handling or
                                                   Abound Solar Product Registration
installation procedures as prescribed in this
                                                   Procedure
manual.
                                                   (Section 7.0)
For claims arising from issues not related to      Abound Solar Document #3109811
installation or maintenance, contact your module
supplier.




Page 8
                                                                                 Abound Solar
                                                           Safety and Installation Instructions
                                                                                   AB1-Series



10.0 Product Label

Below is a sample image for the product label on an AB1-70B module.




Page 9

				
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