Renogy Solar Panel Installation and Maintenance Manual

1. Introduction

Thank you for choosing Renogy's solar panels. This guide covers everything from installation to cleaning and maintenance. It contains important electrical and mechanical installation information, as well as safety guidelines that must be understood before installing components. Failure to follow the requirements in this manual may void the limited warranty. The recommendations are designed to improve safety during installation and have been tested and proven. Please provide this manual to the PV system owner for their reference and inform them of all relevant safety, operational, and maintenance requirements.

2. Statutes and Regulations

Mechanical and electrical installation of PV modules must comply with appropriate regulations, including electrical codes, building codes, and electrical connection requirements. These vary by installation location (e.g., rooftop, vehicle-mounted) and system voltage or current type (DC/AC). Consult your local authority for specific terms.

3. General Information

3.1. Solar Panel Identification

The nameplate provides information on type, power rating (STC), current rating, voltage rating, open circuit voltage (Voc), short circuit current (Isc), certification marks, and maximum system voltage. Each component has a unique serial number printed on a barcode, embedded before lamination, and also located near the nameplate.

Key components of a solar panel include:

• 1. Aluminum alloy frame
• 2. PV Glass
• 3. EVA (Ethylene Vinyl Acetate)
• 4. Solar Cell
• 5. Backplate
• 6. Silicone
• 7. Junction Box
• 8. Nameplate
• 9. Cable Wires
• 10. Connector
• 11. Mounting holes
• 12. Grounding hole
• 13. Leakage hole
• 14. Bar Code

[Note: The rest of the version's corresponding solar panel specifications shall prevail.]

3.2. Junction Box Style and Wiring Method

The junction box facilitates series and parallel connections. Diagrams illustrate recommended connection and wiring methods for both series and parallel configurations, showing standard line lengths for vertical and horizontal installations. These are for reference, and actual wiring should minimize line length and avoid cross-wiring.

3.3. General Safety

When installing modules on roofs, consider the overall fire rating and maintenance. Always use safety precautions like fall protection, ladders, and personal protective equipment (PPE) when working at heights. Avoid installing or handling components in hazardous environments such as strong winds, wet or sandy roofs.

3.4. Electrical Safety

Photovoltaic products generate DC voltage under light. Take protective measures (insulated gloves, shoes) to avoid contact with DC voltages of 30V or higher, which can be fatal. Modules can generate voltage even without a load or external circuit. Use insulated tools and rubber gloves when handling modules in sunlight. Modules do not have switches; they stop working when moved away from light or covered with an opaque material. Do not disconnect electrical connections under load to prevent arcing and electric shock. Keep connectors dry and clean. Do not insert metal objects into connectors. Low temperatures increase output voltage, and reflections can increase irradiation intensity and output current.

If module glass or encapsulation is damaged, wear PPE and disconnect the module. Do not touch wet components without shock protection. Avoid contact between connectors and chemicals such as gasoline, oils, solvents, cleaning agents, mold release agents, adhesives, and plasticizers. Refer to the manual for specific cleaning procedures.

3.5. Operation Safety

• Unpack components upon arrival at the installation site to ensure safety during transportation and storage.
• Protect packaging from damage or dropping.
• Never lift a module by grasping the junction box or wires.
• Do not stand or walk on modules.
• Avoid excessive loads or twisting modules to prevent glass breakage.
• Do not drill holes in the module frame, as this can reduce load resistance, lead to corrosion, and void the warranty.
• Do not scratch the anodic oxide layer on the aluminum frame, except for grounding connections, as this can cause corrosion and affect performance.
• Self-repair of components is strictly prohibited.

3.6. Fire Protection and Safety

Comply with local laws and regulations regarding building fire resistance requirements. Ensure adequate ventilation between the backsheet and the installation surface. Improper installation can affect fire safety. Maintain a minimum distance of 10 cm between the module frame and the roof surface for roof installations to ensure fire rating. For vehicle-mounted modules, use brackets and avoid bonding directly to the roof. Use proper accessories like fuses, circuit breakers, and ground connectors as required by local codes. Do not use modules near exposed combustible gases.

4. Renogy Solar Panels Installation Method

4.1. Installation Location and Environment

Modules are not suitable for space environments. Do not use mirrors or magnifying glasses to focus sunlight. Avoid locations with a risk of water flooding. Recommended ambient operating temperature is -40°C to 40°C (average monthly max/min), with a maximum operating range of -40°C to 85°C. Ensure the module is not subjected to wind or snow pressure exceeding maximum allowable loads. Install in locations free from shade year-round and without obstructions. Protect modules from lightning strikes in high-activity areas. Do not install or use modules near flames or combustible materials, or in environments with excessive hail, snow, sand, soot, air pollution, etc. Avoid installing on surfaces susceptible to aging and corrosion, such as wood or PVC plastic.

4.2. Selection of Inclination Angle

Module inclination is the angle between the module surface and the horizontal plane. Maximum power output is achieved when modules face sunlight directly. For the Northern Hemisphere, modules should face south; for the Southern Hemisphere, they should face north. Follow standard installation guidelines or installer recommendations for specific angles. A minimum inclination of 10 degrees is recommended to facilitate self-cleaning by rain and prevent water accumulation, which can affect appearance and performance. Serially or parallel connected modules should have the same orientation and angle to avoid output power loss due to differing solar radiation. Select optimal orientation and tilt for maximum annual power production, ensuring sunlight reaches modules even on the shortest sunny day. For stand-alone systems, adjust the angle seasonally for maximum output.

5. Renogy Solar Panels Installation - Mechanical Installation

5.1. General Requirements

• PV panels can be installed vertically or horizontally; keep drain holes on the frame unblocked.
• Ensure the backboard of PV panels does not contact other structures, especially under external pressure.
• Maintain at least a 10mm gap between PV panels to accommodate thermal expansion and contraction.
• Ensure the installation site (e.g., roof, RV) is properly sealed to prevent unexpected problems or permeation.
• Leave a 10cm clearance between the panel frame and the roof/wall for ventilation and moisture dissipation when mounting parallel to surfaces.
• Mount PV panels firmly on the roof or RV.

5.2. Mechanical Mounting of Single-Sided & Double-Sided Components

Renogy components are primarily installed using bolt-on or bracket mounting methods. Always follow provided examples and recommendations. Using alternative methods may void the warranty.

5.2.1. Bolt Mounting Method

Renogy components feature mounting holes detailed in component layouts. The primary mounting method is bolt mounting. The following table lists common mounting kits, bolt sizes, and applicable component models:

[Note: Figure 2 shows a schematic diagram of single-sided component mounting holes. Remaining holes are shown in corresponding component layouts.]

5.2.2. Bolt Mounting Method with Brackets

Renogy offers angled mounting brackets for adjustable module angles. The module is fixed to the bracket via bolts.

5.2.3. Mounting Method of Brackets

5.2.4. Other Installation Methods

5.3. Introduction of Flexible Module Installation Method

For flexible modules, Renogy recommends silicone mounting. Ensure the roof and module backsheet are clean for strong adhesion. Silicone mounting helps prevent mechanical damage.

[Figure 3: Schematic diagram of the structure of flexible components.]

5.3.1. Introduction to Flat Roof Mounting Methods

Clean module surfaces. Apply double-sided tape to each short edge for fixing. Apply silicone along the component horizontally (6-10mm width, 3-5mm thickness), with recommended spacing between lines for heat dissipation and drainage. Install within 5 minutes to prevent silicone curing. Lightly press along the bonding surface with a professional tool. Maintain a 5-10mm gap between components.

Operating Notes:

• Do not completely seal all four sides of the flexible component with silicone to ensure heat dissipation and drainage. Renogy recommends leaving short edges unsealed.
• The number of horizontal silicone applications can be adjusted; Renogy recommends applying glue to the edge of the double-sided tape (6-10mm width, 3-5mm thickness).
• Double-sided adhesive tape should be flush with the edge.
• Allow 72 hours for silicone to fully cure, avoiding direct sunlight and harsh weather during this period.
• The maximum bend for flexible modules is 240° (for storage), but for installation, horizontal mounting or a bend less than 30° is recommended to ensure power generation efficiency.
• When a short edge is the bending edge, the angle must not exceed 30°.

[Diagram showing sunlight on a curved module and the effect on illuminated area. Note: As the installation angle becomes more curved, the non-illuminated area increases. Bending beyond 30° can cause over 30% non-illuminated area, affecting output.]

5.3.2. Introduction to Non-Flat Roof Mounting Methods

Clean flexible modules. Apply double-sided tape to each long edge. Apply silicone according to the width of the corrugated roof protrusion. Install within 5 minutes. Use a professional pressing tool to lightly press along the gluing direction. Maintain a 5-10mm gap between components.

Flexible components can be further fixed with bolts using the provided mounting holes.

[Figure 3: Non-flat gluing diagram] [Figure 4: Schematic diagram of flexible component mounting holes]

[Note: Renogy recommends a minimum of 6 silicone lines on the back for non-flat roofs. If this condition is not met, the module is not suitable for that roof.]

6. Renogy Solar Panels Installation - Electrical Installation

6.1. Electrical Parameters

Nominal electrical performance parameters (Isc, Voc, Pmax) are determined under Standard Test Conditions (STC): 1000W/m² irradiance, 25°C cell temperature, AM1.5 spectrum. When components are connected in series, Voc adds up, and Isc remains the same. When connected in parallel, Voc is the same, and Isc adds up. It is not recommended to connect components with different parameters, models, or brands. The maximum number of series-connected components depends on the maximum system voltage (e.g., DC600V/DC1000V/DC1500V). The open circuit voltage correction factor (CVoc) can be calculated using CVoc=1-Voc*(25-T), where T is the minimum ambient temperature and is the temperature coefficient of Voc. Use overcurrent protection devices (fuses, circuit breakers) if reverse current might exceed component fuse current or if multiple parallel strings are used in series.

6.2. Cable and Wiring

6.2.1. Introduction of Cables and Connections

Renogy modules use junction boxes with appropriate protection ratings for safe wiring and connections. Each module has positive and negative wires connected via MC4 connectors. Use special solar cables and connectors compliant with local regulations. Cables should be aging-resistant, protected from mechanical damage, direct sunlight, and rain, with a minimum bending radius of 43mm.

6.2.2. Extension Cable Selection for Component-to-Component Connection

Renogy offers inter-module connection cables (SKU: RNG-EXTCB) with 10/12AWG wire diameter, up to 40FT long.

6.2.3. Extension Cable for Connecting the Component to the Controller

Renogy provides connection cables between modules and controllers (SKU: RNG-AK) with 10/12AWG wire diameter, up to 40FT long.

6.3. Connector

Keep connectors dry and clean, ensuring nuts are tightened before connecting. Do not connect wet or dirty connectors. Connectors are not waterproof if not connected correctly (positive to negative). Connect modules as soon as possible after installation or take measures to prevent water/dust infiltration. Avoid direct sunlight and immersion. Prevent connectors from falling to avoid contamination. Ensure all electrical connections are secure and fully locked. Do not mix different connector types.

6.4. Bypass Diode

Solar cells are protected by bypass diodes encapsulated in the junction box. These diodes activate during hot spot events to prevent current flow through the affected cell, limiting heating and performance loss. Bypass diodes are not overcurrent protection devices. Contact Renogy if a diode is suspected faulty. Do not open the junction box.

7. Renogy Solar Panels Installation - Grounding

The anodized aluminum alloy frame must be grounded for safety and protection against lightning and static electricity. The grounding device must ensure full contact with the aluminum alloy interior, penetrating the oxide film. Do not add extra grounding holes to the frame. Grounding conductors must be made of suitable materials (copper, copper alloy) meeting national electrical specifications and connected to an earth electrode. Holes marked with the grounding symbol are for grounding only. Modules without grounding holes can be grounded via connection to a grounded electrical device.

8. Renogy Solar Panels Installation - Operation and Maintenance

Regular inspection and maintenance are required, especially during the warranty period. Contact Renogy within 2 weeks if any abnormality or damage is found.

8.1. Solar Panel Cleaning

Accumulated foreign substances (dust, bird droppings) can reduce power output and cause hotspots. The impact depends on the material's transparency. Light dust usually has minimal effect, but heavy accumulation or shading can significantly reduce output. Keep panel surfaces unobstructed during sunlight. Cleaning frequency depends on accumulation; rain often cleans the surface. Wipe the glass with a wet sponge or soft cloth. Avoid acidic or alkaline cleaning agents. Clean early morning or dusk to prevent electrical shock or burns. Do not clean panels with damaged glass, backboard, or wires.

8.2. Visual Inspection of PV Panels

Visually inspect panels for defects, including:

• Broken glass.
• Corrosion along busbars, indicating moisture ingress from damaged encapsulation.
• Evidence of burning.
• Check encapsulation of connectors with cables.
• Ensure panels are not touched by sharp objects.
• Ensure panels are not shaded.
• Check connections between panels and mounts/brackets.

8.3. Inspection of the Connector and the Cable

Perform preventive maintenance every 6 months:

• Check connections between PV panels and other off-grid components.
• Check the junction box sealing gel for cracks or crevices.

9. Schedule - Renogy Solar Panel Iteration/Mix Recommendation

The following table provides a summary of Renogy solar panel models, their versions, dimensions, mounting hole specifications, and mixability recommendations. This information is crucial for system design and compatibility when combining different panel models.

[Note: This table lists various Renogy solar panel models (SKUs), their different versions (e.g., G1, G2), physical dimensions, mounting hole specifications, and compatibility for mixing different versions within a system. Consult specific product datasheets for detailed electrical specifications.]

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[Note: Renogy reserves the right to change the contents of this manual without notice.]