SHARP NB-JD590 Crystalline Photovoltaic Module Installation Manual

1. Introduction

This INSTALLATION MANUAL contains essential information for the electrical and mechanical installation of SHARP PV modules. It also includes important safety information. All information is the intellectual property of SHARP. This document does not constitute a guarantee. SHARP disclaims liability for loss or damage arising from installation, operation, use, or maintenance. SHARP reserves the right to make changes without prior notice.

2. Components

The main components of the photovoltaic module system include:

• Solar Photovoltaic Cell: The primary component that converts sunlight into electricity.
• Electrical Cable: Connects the module to the rest of the system.
• Front Glass: A protective layer on the front of the module.
• Connector: Used for electrical connections between modules or to the system.
• Junction Box (on the back glass): Houses electrical connections and bypass diodes.
• Frame: Provides structural support and mounting points for the module.

3. General Information (Including Warning and Safety)

Installation requires significant skill and should only be performed by qualified licensed professionals. There is a risk of injury, including electric shock. SHARP PV modules are equipped with permanently attached junction boxes for wiring ease and do not require special assembly.

General Warning:

• PV modules are heavy; handle with care.
• Ensure complete understanding of this manual before installation, wiring, operation, or maintenance.
• Contact with electrically active parts can cause burns, sparks, or lethal shock, whether connected or not.
• PV modules produce electricity when illuminated. Series connection increases voltage; parallel connection increases current. Large systems can produce high voltage and current, posing increased hazards.
• Do not connect PV modules directly to loads like motors, as power variations due to solar irradiation can cause damage. Brushless motors may activate lock functions damaging Hall ICs; brush motors may damage coils.
• In case of snow build-up, snow may slide off roofs. Take preventive measures (e.g., snow stoppers) to avoid injury or damage from sliding snow.

General Safety:

• Consult local codes and laws for required permits and regulations.
• Contact appropriate authorities to determine installation and inspection requirements.
• Install and ground frames according to applicable rules and regulations.
• PV modules should be installed and maintained by qualified personnel only.
• Follow appropriate safety practices and use required safety equipment, especially for roof-mounted installations. Fireproofing may be required depending on local codes.
• Non-integral PV modules must be mounted over a fire-resistant roof.
• Use PV modules with the same cell size within a series connection.
• Follow safety precautions for all system components.
• Prevent individuals with limited knowledge of PV modules or safety measures from approaching the module, especially if damaged.
• Avoid prolonged shading of PV module surfaces, as it can cause hot spots, solder joint failure, reduced power, or operational failure.
• Do not clean glass surfaces with chemicals. Avoid prolonged water collection on glass, which can lead to white efflorescence (glass disease) and reduced energy generation.
• Do not install PV modules horizontally to prevent dirt accumulation or white efflorescence due to water.
• Do not cover the frame's water drain gap to prevent frost damage from water accumulation.
• If there's a risk of sliding snow, take measures to prevent damage to PV module frames at the lower edge.
• Do not expose PV modules to concentrated sunlight from mirrors or lenses.
• Turn off inverters and circuit breakers immediately if a problem occurs.
• If module glass is broken, wear goggles and tape the glass to secure broken pieces.
• Defective modules may generate power even when removed. Handle them carefully in sunlight; place defective modules in a shaded carton.
• For series connections, ensure the maximum open circuit voltage does not exceed the specified system voltage. For parallel connections, use fuses or blocking diodes to prevent reverse current flow and protect against unbalanced string voltages.
• Keep PV modules away from children.

Important Safety Instructions

Follow these instructions for PV module maintenance to reduce the risk of electric shock. Do not perform servicing unless qualified.

• Installation must be performed by a certified installer/servicer for system integrity and safety.
• Installation is permitted only after understanding this manual. Contact your local SHARP office if you lack a copy.
• Do not pull PV cables.
• Do not touch any PV module surface.
• Do not place or drop objects onto PV modules.
• Do not disassemble or attempt to repair the PV module yourself.
• Do not drop the PV module.
• Do not damage, pull, or bend cables, or place heavy material on them.
• After service or repairs, have the installer/servicer perform routine checks to ensure the PV modules are in safe and proper operating condition.
• When replacement parts are needed, ensure the installer/servicer uses manufacturer-specified parts with identical characteristics to the original parts. Unauthorized substitutions can lead to fire, electric shock, or other hazards.
• Consult local building and safety departments for required permits and regulations.
• Sliding snow can increase mechanical load. For portrait orientation with more than 3 rows, accumulated snow may deform the lower edge of the PV module frame. Implement measures like snow stoppers to prevent damage.
• Periodically remove overhanging snow and ice from the PV module framework to prevent frame deformation.

CAUTION: HIGH VOLTAGE ⚠️ To reduce the risk of electric shock, do not touch.

Handling Safety

• Avoid excessive load or twisting the PV module frame, as the glass or cells can break easily.
• Do not stand or step on the PV module; the glass surface is slippery, and the weight can cause damage.
• Do not hit or apply excessive load on the glass, as the PV cells are very thin and fragile.
• Do not damage junction boxes or pull cables, as junction boxes can crack.
• Never touch junction boxes or output cable ends with bare hands when the module is irradiated. Cover the module surface with opaque material and wear rubber gloves when handling wires to avoid electric shock.
• Do not scratch or forcefully bend output cables, as insulation can break, leading to leakage or shock.
• Do not pull output cables excessively, as they may unplug and cause leakage or shock.
• Do not drill holes in the frame, as it compromises strength and can cause corrosion.
• Do not scratch the frame's insulation coating (except for grounding) to prevent corrosion or framework weakening.
• Do not touch the PV module with bare hands; the frame has sharp edges that can cause injury.
• Do not drop the PV module or allow objects to fall on it.
• Do not concentrate sunlight artificially on the PV module.
• Do not hold the PV module on one side; the frame may bend or twist. Hold it at opposite sides.

Installation Safety

• Always wear protective headgear, insulating gloves, and safety shoes (with rubber soles). Avoid metallic jewelry to prevent electric shock.
• Keep PV modules in their packaging until installation.
• Avoid unnecessary touching of PV modules during installation, as glass surfaces and frames can become hot, posing a burn or electric shock risk.
• Do not work during rain, snow, or high winds.
• Use dry, insulated tools.
• Do not drop tools or hard objects onto PV modules.
• When working at heights, wear a safety belt and secure all items to prevent them from falling.
• Ensure no flammable gases are present at the installation site.
• Completely cover the PV module surface with opaque material during installation and wiring.
• Ensure connectors are plugged in tightly and wiring is secure. Connectors must be locked by a snap-in latch; do not modify them.
• Do not perform work if PV module terminals are wet due to the risk of electric shock.
• Do not touch junction boxes or output cable ends with bare hands during installation or under sunlight, whether the module is connected or not.
• Do not unplug connectors if the system circuit is connected to a load.
• Do not step on the glass during work, as broken glass poses an injury or electric shock risk.
• Do not work alone; always work with a team of two or more people.
• Avoid damaging the PV module glass when setting mounting or equipotential bonding bolts.
• Do not damage surrounding PV modules or mounting structures when replacing a module.
• Secure cables using insulation locks. Prevent cables from drooping from the junction box to avoid issues like animal biting or electrical leakage in puddles.
• Take measures to prevent the laminate (resin, cells, glass) from detaching from the frame if the glass breaks.
• Position plastic components like cables and connectors to avoid direct sunlight exposure after installation to prevent degradation.
• If using batteries, follow the battery manufacturer's safety precautions.
• In case of heavy snow, the module frame may deform under the snow's weight. Implement preventive measures to minimize potential damage.

4. Site Selection

PV modules should be installed in locations with no shading throughout the year. In the Northern Hemisphere, modules should face south; in the Southern Hemisphere, they should face north. Ensure no obstructions surround the installation site. Take proper steps to maintain reliability and safety in challenging environments such as areas with heavy snow, extreme cold, strong winds, proximity to water, salt water damage risk, corrosive gas environments, small islands, or desert areas.

5. Tilt Angle

The tilt angle is the measurement between the PV module and a horizontal surface. Maximum output is achieved when the module faces the sun directly. A tilt angle of 5 degrees or more is recommended for maintenance. For standalone systems with batteries attached to permanent structures, determine the tilt angle to optimize performance during periods of scarcest sunlight. For grid-connected installations on permanent structures, tilting the module at an angle equal to the site's latitude optimizes year-round power generation.

6. Wiring

To ensure proper system operation and warranty, observe correct cable polarity when connecting modules to batteries or other modules. Incorrect connections can destroy bypass diodes.

Series Connection: Connect the positive terminal of one PV module to the negative terminal of the next to increase voltage. (See Figure 1 description).

Parallel Connection: Connect the positive terminal of one PV module to the positive terminal of the next to increase current. (See Figure 2 description).

Bypass Diodes: These are built into the junction box.

PV Module Configuration Recommendations:

• Maximum series configuration: Refer to Table 1.
• Maximum parallel configuration: Parallel connection of each string is permitted only with diodes (1 diode per max 2 parallel strings) or fuses (1 fuse per every string) for protection against reverse current overload. Other parallel connections are prohibited.

Connection Cables: Use specified connectors (Type: C1, System voltage 1,500V) from brands like Solargiga Energy Holdings Limited or Jinzhou Yangguang. If connectors are replaced, ensure qualified personnel follow manufacturer instructions; module guarantees remain valid per terms.

Diagram Description (Figure 1 - Series): Illustrates modules connected in series, with positive terminals connected to negative terminals of adjacent modules, increasing voltage. Bypass diodes are shown within the junction box.

Diagram Description (Figure 2 - Parallel): Illustrates modules connected in parallel, with positive terminals connected together and negative terminals connected together, increasing current. Bypass diodes are shown within the junction box.

7. Grounding

Frame grounding must comply with local requirements and regulations. If grounding is required, follow the example connection shown in Figure 3. Ensure the system ground is arranged so removing one module does not interrupt the grounding of others. Ground modules to the same electrical point. A hole with an equipotential bonding symbol on the side frame can be used for grounding with a bolt, nut, washer, or an appropriate screw. An example connection uses a bolt, nut, washer, and a wire binding lug. The hardware, such as a toothed or star washer, must score the frame surface for electrical contact. The ground wire must comply with local requirements.

Diagram Description (Figure 3 - Ground Connection): Depicts a grounding connection using a bolt, washer, spring washer, wire binding lug, hexagon nut, and screw terminal. The wire binding lug is attached to the frame using these components, ensuring electrical contact with the frame.

8. Mounting

Ensure all information in this manual is valid for your installation. Mounting methods have been verified by SHARP but are not third-party certified. The approved mounting method is described herein. Frame clamps or clips (not provided) may be used if designed for PV modules and meet specified minimum dimensions. If using clamps, modules must be fixed rigidly without damage from deforming mounting structures. Using improper clamps may void the SHARP PV module warranty. If metal clamps are used, ensure a path to ground from the clamps, potentially using star washers. Mounting must follow these methods to avoid voiding the warranty. System designers are responsible for ensuring protective structures can bear loads different from test conditions defined by IEC standards. Support structures must be rigid for optimal electrical performance; deformation can damage modules. When mounting, ensure no corner displacement exceeds 2mm per 1000mm of the diagonal. The mounting structure must allow free deflection under wind/snow load, with at least 10 cm clearance from the roof surface to the bottom of the module frame. The installer is responsible for selecting and constructing the support structure.

Mounting Using Clamps: Clamps must meet required dimensions (see Figure A1/A2). The clamp center position ('e') relative to the module corner must be within the specified range (Annex). Clamps must hold the frame completely within their width. Heavy loads can cause deflection, potentially cracking cells and degrading performance. Modules must overlap the array rail by at least 10mm.

Mounting Using Frame Bolt Holes: Modules can be fastened using bottom frame bolt holes at locations shown in the Annex. Use four (4) M8 bolts with a recommended torque of 16-20Nm.

Diagram Description (Figure A1 - Clamp Position, Rails Perpendicular): Shows clamp positions ('a', 'c') on the module frame for mounting rails perpendicular to the longer frame side. 'e' indicates the clamp center position.

Diagram Description (Figure A2 - Clamp Position, Rails Parallel): Shows clamp positions ('a', 'c') on the module frame for mounting rails parallel to the longer frame side. 'e' indicates the clamp center position.

Diagram Description (Figure B1 - Bolt Hole Location, Rails Perpendicular): Shows the location of bolt holes ('c') on the module frame for mounting rails perpendicular to the longer frame side.

Diagram Description (Figure B2 - Bolt Hole Location, Rails Parallel): Shows the location of bolt holes ('c') on the module frame for mounting rails parallel to the longer frame side.

Diagram Description (Figure B - Bolt & Nut Components): Lists and describes components for frame mounting: Spring Washer (Stainless Steel, M8 size), Washer (Stainless Steel, M8 size), Bolt (M8 x 20mm max, Stainless Steel), and Nut (M8, Stainless Steel).

9. Maintenance

PV modules are designed for long life with minimal maintenance. If the tilt angle is 5 degrees or more, normal rainfall usually keeps the glass surface clean. For installations with insufficient angles or low rainfall, cleaning is recommended. Use a soft, damp cloth and water for cleaning. Detergents, pressure washers, or specialized cleaning robots may be used at the user's responsibility. Avoid touching the glass with bare hands, as fingerprints can easily mark the anti-reflective coating. If cleaning the back of the module is necessary, take care not to damage the back materials. Periodically check wiring and connections to ensure system operation.

Electrical Output and Thermal Characteristics

Rated electrical characteristics are within ±10% of indicated values for Voc, Isc, and +5/-0% for Pmax under Standard Test Conditions (STC): 1000W/m² irradiance, AM 1.5 spectrum, and 25°C (77°F) cell temperature.

PV modules may experience conditions producing higher current/voltage than STC values due to module temperature, irradiance, albedo, row spacing, and installation height. Multiply Voc and Isc-BSI values by 1.25 for determining component ratings. Refer to IEC 62548 for safety factor guidance.

PV modules are intended for use in temperatures from -40°C to 70°C (98th percentile operating temperature) and up to 100% relative humidity, at altitudes up to 2,000m, per IEC61730. Installers must assess if system design in specific locations results in a 98th percentile module operating temperature exceeding 70°C, considering factors like restricted airflow (refer to IEC TS 63126).

Class for Protection Against Electric Shock: This PV module is classified as "Class II" according to IEC61730, intended for installations where general user access to insulated live parts is anticipated.

Fire Rating: This PV module is rated as "Fire safety class C" according to UL790.

Annex (Normative)

Design Load

The test load is calculated with a safety factor of 1.5 from the design load.

Table A1: Design Load Using Clamps on Long Frames (See Fig. A1)

Table A2: Design Load Using Clamps on Long Frames (See Fig. A2)

Table B1: Design Load Using Bolt Holes (See Fig. B1)

Table B2: Design Load Using Bolt Holes (See Fig. B2)