Lennox SunSource Home Energy Retail Book July 2013

Lennox SunSource Home Energy System

Retail Sales Book Complied by John Flinn, Lennox TM

Section # – 2013 SunSource Home Energy Retail Book – Revised July

#1 Beyond – A Simple Way to Go Solar

#2 Are You a SunSource Solar-Ready Dealer?

#3 SunSource Home Energy System Planning Checklist

#4 SunSource FAQs – Leave for Homeowner

#5 Efficiencies of the XC25/ XC21/ XC17

#6 Efficiencies of the XP25/ XP21/ XP17

#7 SunSource System Components – List of Modifications to Home

#8 SunSource Communication Brochure – “Speedometer of System”

#9 Solar Incentives/ Rebates /Loan Programs – Federal & State of

Maryland

(SRECs) – Solar Renewable Energy Certificates

-What they are and how your Customer can Profit from them.

Net Metering – What it is and the benefits of it.

#10 PV WATTS DATA – How much Energy will your “Solar Array”

Produce

#11 Net Costing Sheets – Materials Work Sheet – How to price up your

customers individual SunSource Home Energy System

#12 Consumer “Incentive Worksheet” – Show your Customer how

affordable the SunSource Home Energy System will be.

#13 Score Selling System – A Consultative Sales Approach

#14 - SolarWorld “Installation Best Practices”

- SolarWorld – Sunfixplus – Pitched Roof Mounting System

Section # – 2013 SunSource Home Energy Retail Book – Revised July

#15 - Enphase Microinverter – Model M215

- Enphase Quickstart Guide

- Envoy Communications Gateway

#16 SunSource Home Energy System – Solar Subpanel

#17 SolarWorld – The SolarWorld Standard – Our Quality Commitment

#18 SunSource Home Energy System Frequently Asked Questions

#19 SolarWorld Awards

beyond

A simple way to go solar.And save on energy costs.With demand for electricity rising, right along with energy costs, a typical homeowner can easily spend hundreds of dollars a month on utility bills, which can be the equivalent of a house payment. The bulk of a home’s energy costs, up to 54%,* comes from heating and cooling. Fortunately, there’s a bright spot.

The SunSource® Home Energy System puts you in control of your monthly bills by creating and using solar energy, reducing your need for electricity from your utility provider. Solar energy generated by the system is first used to power your heat pump or air conditioner. When your heating and cooling system is not in use, the solar energy can operate other appliances and electronics. Any excess energy that’s not needed will be sent back to the utility company, possibly entitling you to a credit.

Power from the sun also has major benefits for the environment. It reduces the need for electricity generated by power plants, which in turn leads to a reduction in greenhouse gas emissions.

Heating and

Cooling Costs

54%

U.S. Household Energy Consumption

More efficient than a home comfort system

As a home energy system, complete with a Lennox solar-ready heat pump or air conditioner and SolarWorld solar modules, SunSource is different from a typical home comfort system in that it harnesses the abundant, clean and completely free energy of the sun to reduce your home’s utility operating costs. (See page 7 for savings estimates.)

Simpler and more affordable than a solar-only system

The cornerstone of the SunSource Home Energy System is a high-efficiency air conditioner or heat pump from the Dave Lennox Signature® Collection. These units come solar-ready, which means they can be easily integrated with solar modules in a solar energy system, if and when you want one. You can start small, with four to six modules, and add more (up to 17 total, per outdoor unit) when budget permits.

* U.S. Department of Energy statistics. ** The SunSource Home Energy System meets the requirements for federal tax credits listed under the U.S. Emergency

Economic Stabilization Act of 2008, covering 30% of the cost of the solar modules, including installation. ***Based on the $11,541 retail cost of the XC/XP25 5-ton unit ($11,541 x 9%). † To learn more, review the actual IRS specifications for each credit, visit the “Tax Credits for Energy Efficiency” section

at www.energystar.gov.

brilliant

The system may also qualify for state and local tax credits, as well as rebates and other incentives from local utility companies. Ask your local Lennox Dealer for more information.

an idea that’s beyond

SunSource® Home Energy SystemThe simplest way to bring money-saving solar power into the home

30% of the cost of the solar modules, including installation, may be offset by government tax credits.** Because the Lennox air conditioner or heat pump is solar-ready, you may also receive up to a $1039 tax credit.*** And, you may receive up to an additional $500 energy efficiency tax credit† for the heat pump or air conditioner. Consult your tax advisor for more information.

Solar power for heating and cooling—and beyond.

Solar Modules

Future Modules

CondensingUnit

StandardOutlet

CommunicationModule

Performance-Monitoring

Website

BroadbandInternet

Connection

ElectricalPanel

How the system works to reduce your utility costs

The SunSource® Home Energy System allows you to tap into the utility-saving benefits of solar. Here’s how:

•Solarmodules*harness clean, sustainable energy from the sun and send it to a SunSource® Solar-Ready heat pump or air conditioner.

•Solarenergyisfirstusedtomeet heating and cooling demands. When the heat pump or air conditioner isn’t running, the system powers lighting, appliances and other electronics in the home. Any surplus power goes back to your utility company for a possible credit.**

•Acommunicationmoduleallows you to see how your home energy system is working to lower your utility operating costs. It also shows the environmental benefits of using renewable energy for your home.

SunSource Solar-Ready outdoor unit – Offers many innovative features beyond solar technology designed to deliver optimal comfort and efficiency. Six models are available:

•XP25/XC25–Themostpreciseandefficientheatpumpand air conditioner you can buy***

– Variable-speed inverter controlled motor provides a quiet and consistent flow of air for an ideal balance of temperature and humidity

–Efficiency ratings of up to 25.00 SEER††

•XP21/XC21–Thequietestandmostefficienttwo-stageheatpump and central air conditioner you can buy†

– Two-stage operation, combined with exclusive SilentComfort™ technology, allows the units to run at low speed most of the time to maximize comfort and efficiency, while reducing sound levels


•XP17/XC17–Themostefficientsingle-stageheatpumpandcentral air conditioner you can buy†††

–Engineered with exclusive SilentComfort™ technology


The SunSource Home Energy System is powered by SolarWorld solar panels made in the U.S.A.

Solar Modules

Future Modules

CondensingUnit

StandardOutlet

CommunicationModule


Website

BroadbandInternet

Connection

ElectricalPanel

Solar modules – Unlike typical solar-panel systems, which have one large inverter for the complete array, each SunSource module has its own scaled-down microinverter that converts solar energy into usable electrical power. This has three key advantages:

•Adedicatedmicroinverterforeach module allows a higher capture of solar energy, compared to traditional single-inverter systems.‡

•Youhavetheflexibilitytostartsmall and add more modules at a later date for greater energy savings.

•Anyissuethatmightaffectone module, like tree shading or cloud cover, doesn’t impact the operation of other modules.

Beyond efficient performance, the modules offer superb durability and aesthetics:

•Modulesareweather-andimpact-resistant.

•Modelsavailablewithsilver or black frames.

•Modulescanbeeasilymaintained and serviced.

Communication module – Sends performance information for each solar module to a website, where you can view system status.

*Maximumof17solarmodulesperoutdoorSunSourceSolar-Readyunit. **Check with the utility company in your area, as credits are determined and regulated on a state-by-state basis. *** Efficiency claim based on comparison of air conditioning and heat pump products’ SEER as published in AHRI (January 2013). Actual system combination

efficiency may vary; consult a Lennox Dealer or AHRI for exact system efficiencies. Precision claim based on the cooling capacity range of the XC/XP25-036 units as compared to equivalent-sized competitive variable capacity compressor units.

† A combination of sound ratings established per AHRI’s test standard: 270; and efficiency ratings established per AHRI’s test standard: ANSI/AHRI 210/240-2008 of two-stage central AC/HP equipment.

†† The Seasonal Energy Efficiency Ratio is a cooling efficiency rating for air conditioners and heat pumps. The higher the SEER, the better the energy performance, the more you save.

††† Efficiency claim based on comparison of single-stage air conditioning products’ SEER as published in AHRI (December 2009). Actual system combination efficiency may vary. Consult a Lennox Dealer or AHRI (www.ahridirectory.org) for exact system efficiencies.

‡According to tests conducted by Enphase Energy, Inc. ‡‡Performance-monitoring website provided by an independent third party, Enphase Energy, Inc.

Performance-monitoring website‡‡ – This website gives you 24/7 access to real-time data showing system status, energy production, and environmental benefits, including carbon offsets. Monitoring service is provided free for the life of the system.

•Performanceinformationcanbeviewed“ataglance”or in detail, including graphs, totals by day/week/ month/lifetime and via time-lapse videos. Info can also be accessed by web-enabled mobile devices.

•Displaysanaerialviewofyourroofandsolarmoduleconfiguration, so you can see energy production information for each module.

•Time-lapsevideosofyoursolararrayshowhowpowergeneration is affected by the sun and obstructions such as shade trees.

A system with possibilities beyond the immediate horizon.Overall Impact of the SunSource® Home Energy System on Heating and Cooling Costs

Estimated annual operating cost savings* of a 3-ton XC25 air conditioner (AC) or XP25 heat pump (HP) with solar modules, compared to a 10 SEER AC or 10 SEER/7.0 HSPF HP.

with 6 Modules with 12 Modules with 17 Modules

HP AC HP AC HP AC

Region 1 76% 83% 98% 108% 117% 128%

Region 2 78% 95% 105% 131% 128% 161%

Region 3 73% 111% 99% 162% 121% 205%

Region 4 59% 135% 82% 211% 100% 274%

Region 5 includes Canada**

45% 208% 65% 356% 82% 480%

Region 6 72% 294% 102% 530% 127% 726%

* Equipment cost-savings estimates are based on the U.S. Department of Energy (DOE) annual performance factor (APF) method for heat pumps (10CFR part 430). Estimates of annual solar energy production are calculated for a centrally located city in each DOE heating region, using National Renewable Energy Laboratory’s (NREL) PVWatts, Version 1.

**Percent savings for Canada based on 2750 heating load hours (same as US region 5). Northern regions of Canada may have even higher heating load hours.

Region 1

Region 2

Region 3

Region 4

Region 5

Region 6

Climate Regions

Air conditioners typically only run during the summer, so they have lower annual operating costs than heat pumps, which are used year-round for heating and cooling needs. Less annual energy consumption for ACs translates to greater savings percentages.

Lennox is proud to be named a four-time winner of the ENERGY STAR® Manufacturing Partner of the Year award by the U.S. Environmental Protection Agency and the Department of Energy. We are the first manufacturer in the heating and cooling industry to receive this prestigious award, which reflects our ongoing leadership in environmentally responsible climate control.

Choice of solar-ready systems

All new heat pumps and air conditioners from the Dave Lennox Signature Collection are solar-ready, which means they can be easily integrated with solar modules in a complete SunSource Home Energy System.

Peace-of-mind protection*

In addition to world-class quality from a name you can trust, you can take comfort knowing the SunSource Home Energy System is backed by solid warranties:

•XP25/XC25,XP21/XC21andXP17/XC17solar-ready heat pumps and air conditioners include a 10-year limited warranty on the compressor and covered components.

•SolarmodulesfromLennox’partnerSolarWorldare made in the U.S.A. and come with a 25-year performance guarantee and product workmanship warranty of 10 years. The Enphase microinverters include a 25-year limited warranty.

* Warranties apply when modules are installed under normal residential application, use and service conditions. Some limitations apply. See your local Lennox Dealer for full details.

Dealers you can count on

You can trust Lennox Dealers to design the right system for your home, install it properly, and keep it running perfectly for many years to come. Because Lennox has more than 6,000 dealers throughout North America, you can rest assured there’s a dealer near you.

We’re obsessed with the pursuit of creating perfect air, and doing so with absolute efficiency.

Since 1895, Lennox has been on a continuous quest to reinvent home comfort. Perfect air is our purpose and our obsession. Today, that pursuit takes shape in many innovative ways: the most precise and energy-efficient air conditioners, the most efficient and quietest furnaces, heat pumps, Wi-Fi-enabled thermostats, air handlers, air cleaners, small-space comfort systems, boilers and more.

© 2013 Lennox Industries Inc. All rights reserved. PC74647 06/13 (72W36)

A system beyondcompare.

www.lennox.com 1-800-9-LENNOX

Matching your system

Replacing only one part of a system may result in a mismatch that compromises energy efficiency. For best performance, it’s a good idea to replace the entire system at once.

Optimizing your system

The SunSource Home Energy System offers ultimate comfort and efficiency when it’s integrated with the following:

iComfort™ Technology – Allows SunSource-enabled cooling systems to exchange information with other home comfort system components and make adjustments as needed, so that you feel comfortable without thinking about it.

iHarmony™ Zoning System – Divides your home into up to four separate, customizable comfort zones.

Heating and cooling systems from the Dave Lennox Signature® Collection have always been a cut above when it comes to innovation. The SunSource® Home Energy System is light years ahead of competitors’ offerings, especially when combined with the Lennox® products below:

SLP98V The quietest high-efficiency furnace you can buy*

PureAir™ Air Purification System Cleans the air inside your home better than any other single system you can buy

Healthy Climate Solutions™ Wide array of options beyond air purification, including industry-leading dehumidification, all designed to improve air quality without producing ozone

iComfort Wi-Fi® Thermostat** Offers advanced, innovative features like remote access, emailed system alerts, a five-day weather forecast, precise temperature control and much more

For a complete list of the registered and common law trademarks owned by Lennox Industries Inc., please visit www.lennox.com.

* Based on sound pressure levels during steady-state, high-fire and low-fire operation of Lennox SLP98VUH070V36B and leading competitive units asofMarch2010atmid-pointtemperatureriseandminimumexternalstatic pressure when set up per Section 4.4.4 of AHRI 260-2012. Efficiency ratings of all SLP98V models established per test standard: ANSI/ASHRAE 103-2007.

**MustbeinstalledwithaniComfort™-enabled outdoor unit.

© 2010 Lennox Industries Inc. PC61999 05/10www.lennoxdavenet.com 1-800-4-LENNOX


Are you a SunSource® Solar-Ready Dealer?

The SunSource® Home Energy System provides a remarkable growth opportunity for your business, allowing you to tap into growing consumer demand for lower utility costs. It combines the benefits of a high-efficiency HVAC system with that of a solar-power system in one innovative solution. Are you solar-ready? The following checklist will show you the way.

SunSource® Solar-Ready Dealer Checklist:

Complete recommended training modules

•SalesandtechnicaltrainingavailableviaonlineeLearning,webinarsorlivesessions

Byparticipatinginthetrainingcurrentlyofferedandanyfuturesessions,LennoxDealerswillearntheSunSource®Solar-ReadyDealerdesignationthatwillbeaddedasaniconontheLennox.com dealer locator.

Investigate local certification requirements for residential solar installations

•Thesemayincludelicensingforelectrical,solarandroofing

Investigate local jurisdiction code requirements for solar installations

Determinelocalutilityrequirementsforgridinterconnection

Research available federal, state, local and utility company rebates and incentives in your area

•TheDatabaseofStateIncentivesforRenewables&Efficiency(DSIRESolar)providesagoodstartingpoint to learn what is available in your area: http://www.dsireusa.org/solar

ReviewallLennoxSunSource®HomeEnergySystemliteratureavailableonDaveNet

Consider partnering with a solar installer in your area. You can find certified solar installers using the following resources:

•NorthAmericanBoardofCertifiedEnergyPractitioners(NABCEP)website:www.nabcep.org

•YourlocalYellowPages

Consider pursuing a solar training or certification program. For more information check the following online sites:

•U.S.DOE:http://www1.eere.energy.gov/solar/professionalresources.html

•SolarEnergyInternational:http://www.solarenergy.org

•InterstateRenewableEnergyCouncil:http://irecusa.org

P a t e n t P e n d i n g

SOLAR READY

™

SUNSOURCE® HOME ENERGY SYSTEM PLANNING CHECKLIST Lennox Industries, Copyright 2013

50715701

3/2013

Supersedes 506546-01

SUNSOURCE® HOME ENERGY SYSTEM PLANNING CHECKLIST

CUSTOMER NAME: DATE:

CUSTOMERADDRESS

(STREET, CITY,STATE AND ZIP

CODE)

ELECTRICUTILITY:

SECTION I � SITE AND CUSTOMER

1.

Does site have 240VACsplitphase power?

The utilityinteractive SunSource® Home Energy System is for splitphasepower (typical residential service) and will only interconnect and supply power ifthe grid power meets the following specifications:

L1 L2 voltage measures between 211 Volts and 264 Volts

Line to neutral/ground voltage measures between 106 and 132 Volts

Frequency measures between 59.3 Hz and 60.5 Hz

YES

□

NO

□

2.

A. Does site have goodsouthern exposure?

Perform a solar site survey using a Solar Pathfinder™ or other survey tool toassess the solar resource available.

Next, use the webbased program, PVWatts (version 1), from the National Renewable Energy Lab, to estimate the monthly and annual solar energy generation potential

NOTE: For more information concerning Solar Pathfinder, see Lennox Corp1312L2, Application and Design Guidelines for more information.

YES

□

NO

□

B. Is it free of shading?

YES

□

NO

□

3.Is the roof suitable formounting solar modules?

1. Is there enough area for the solar modules? One solar module requiresabout 15 to 20 square feet.

2. What type of roof is it? There are four different types of roof flashings toaccommodate the more common styles of roofs. (Since the solar modulesmust be removed during a reroof, it is best not to install the solar moduleson a roof in poor condition. Take note of the pitch of the roof and the height ofthe eaves. OSHA has fall protection compliance guidelines. For example,see OSHA Directive STD 0300001.

YES

□

NO

□

4.Is the home’s electricaldistribution panel adequate?

Generally, the distribution panel should be rated 100 AMP or more for oneSunSource® Home Energy System installation. (For two systems, the panelshould be 200 AMP or larger. (See also Code Compliance section)

YES

□

NO

□

5.

Will the solar modules becloser to HVAC (outdoorunit) or distribution panel?

There are two different ways to wirein the solar power system. This step in theplanning phase helps determine which method will be faster and easier to use.If the HVAC outdoor unit is nearest to the solar modules it is probably easier touse the Lennox® Solar Subpanel and bring the solar power circuit to the unit. Ifthe electrical distribution panel is closer to the solar modules than the outdoorunit, then it may be easier to bring the solar power circuit to the panel.

HVAC

□

PANEL

□


6.Check for ease of modifications to distributionpanel.

If the solar power circuit connects to the HVAC outdoor unit, the HVAC branchcircuit breaker (in the distribution panel) will need to be relocated to a slot that isat the opposite end from the main breaker. If the solar power circuit is run directly to the distribution panel, a new 20 AMP, 2pole breaker will need to be installed in one of the slots that is at the opposite end from the main breaker. Thisstep is to get an early view of issues such as no available slots or difficulty relocating the HVAC branch circuit breaker.

In addition, the back feed breaker, whether it is the HVAC branch circuit breakeror a separate 20 AMP breaker, is suitable if it is a conventional breaker and theterminals are NOT marked Line and Load. It should not be a GFCI or arcfaulttype circuit breaker.

EASY

□

HARD

□

7.Does the customer havean “always on” Internetconnection?

An Internet connection, with broadband router is required for the Envoy Communications Gateway to connect to the monitoring service. While use of theEnvoy and the service are highly recommended, they are not required for thesolar power system to operate.NOTE: There are some instances when a Communications Booster may be required to insure reliable data communication.

YES

□

NO

□

8.Are there HOA restrictions?

Home Owners Associations (HOA) may require a plan to be submitted forapproval

YES

□

NO

□SECTION II – INTERCONNECTION AND NETMETERING

9.Does the electric utilityhave a netmetering program?

It is necessary to notify the electric utility of the customer's intention to install autilityinteractive solar power generation system. Most utilities are familiar withthese systems and will already have a policy and rules for "netmetering".

YES

□

NO

□

9.Does the utility programhave any special requirements?

Some utilities will require an indicating, lockable disconnect switch on the solarpower system. If the utility has some form of incentive program, they may require the solar power system to be submetered. When the utility has requirements like this, they sometimes provides the required hardware.

YES

□

NO

□

11.If there is an incentiveprogram, is there a minimum kW threshold?

For example, some utilities require a 1kW and 2kW threshold for some rebate/incentive programs.

YES

□

NO

□

12.Does customer understand this is not a grid independent system?

It is important to make sure the customer understands that this is a utilityinteractive PV system and WILL NOT generate power when the grid is down. In addition the SunSource® Home Energy System will not produce power concurrently with a backup generator.

YES

□

NO

□

13Have all the local electrical code requirementsbeen identified?

In almost all US jurisdictions, the National Electric Code (NEC) will be cited asthe authority for electrical inspections and in Canada, it is the Canadian ElectricCode (CE Code). There may be additional local requirements. NEC section 690gives the requirements for solar PV installations. Wind load calculations aresometimes requested by code officials.

If this is the first time to install a SunSource® Home Energy System in this jurisdiction, it is advisable to meet with the local inspection department to find outwhat requirements exist. This will save time in the long run since the permit submission can address any special requirements.

YES

□

NO

□


14Is grounding electroderequired for the solar PVsystems?

Solar PV AC modules are not required by the NEC to have a separate grounding electrode but the local jurisdiction may require one to be installed.

YES

□

NO

□

This checklist is to be used as an aid in assessing the conditions that prevail at a particular site. A NO check box answerdoes not necessarily mean a system cannot be installed. Rather, it means that there may be special activities, such as extra electrical work required.

FOR MORE DETAILED INFORMATION, SEE LENNOX CORP. 1312L2, SUNSOURCE® HOME ENERGY SYSTEM APPLICATION AND DESIGN GUIDELINES.

NOTES:

General InformationQ: What are some of the advantages of solar power?

A: Solar power has a number of substantial advantages, from economical to environmental:

Readily available. Electricity generated from sunlight is free and limitless.

Energy savings. A SunSource Home Energy System with only one solar module can save you money on your monthly utility bills. The U.S. federal government and some states provide a tax credit for renewable-energy systems. Depending on where you live, you may also be eligible for incentives through your utility company. To find out what incentives are available in your area, visit the Database of State Incentives for Renewables and Efficiency at dsireusa.org.

Virtually no environmental impact. Solar is a fast-developing renewable energy source because as the energy is generated it produces no coincident air pollution or hazardous waste. By comparison, electricity generated by coal and gas-fired power plants produces carbon dioxide emissions that are believed to contribute to climate change and pollution.

Can be expanded over time. The SunSource system gives you the flexibility to start small and add more roof modules at a later date for greater energy savings.

Q: Does solar work if I don’t live in the West?

A: No matter where you live, you can take advantage of the money-saving benefits of the SunSource Home Energy System.

Q: Does solar add value to my home?

A: Significant incentives make solar power a wise home investment. Surveys conducted by the U.S. Department of Housing and Urban Development have shown that, for every $1,000 saved per year, $20,000 may be added to a home’s value.

Q: Will I need to carry any special insurance?

A: If your electric utility offers “net metering” or any other incentives for installing a renewable-energy system, they will likely require that you enter into an interconnection agreement. A standard homeowners’ insurance policy is usually adequate to meet the utility’s requirements. See your local utility company for details.

SunSource® Home Energy System

Frequently Asked QuestionsThe SunSource® Home Energy System is the simplest way to bring money-saving solar power into the home.

Q: Will I need a building permit?

A: Yes. You’ll need to obtain building permits to install a SunSource® Home Energy System. Building and electrical codes may also apply. Most jurisdictions have building codes that fully accommodate solar energy technology. Your Lennox Dealer will include the price for permits in your cost estimate.

Q: Do I need approval from my homeowners’ association?

A: Homeowners’ associations’ ability to restrict or prohibit installation of residential solar devices varies. To see if your state has such laws in place visit dsireusa.org. If you belong to a homeowners’ association, review your covenants for details.

Q: What do terms like “on-grid” and “grid-tied” mean?

A: On-grid solar systems, also called grid-tied systems, are connected to the utility electrical network in your area. SunSource is an on-grid system designed to help you lower your utility operating costs and take advantage of incentives from utility companies. “Off-grid” refers to typically more expensive systems that are not connected to the utility electrical grid.

Q: How do I know if a SunSource® Home Energy System will work for my home?A: SunSource systems are suitable for almost any location in North America and are adaptable to

almost any roof type.

Q: How long does it take to install a SunSource system?A: A qualified Lennox Home Energy Consultant can install the system in one day once the plans are

approved. The system can be running in as little as a few hours, depending on the number of solar modules installed and the roof slope and type.

Information on Energy IncentivesQ: Who provides energy incentives?

A: In the U.S., financial incentives are available at the federal and local levels to support the use of renewable energy:

Federal tax credits. The SunSource Home Energy System meets the requirements for federal tax credits listed under the Emergency Economic Stabilization Act of 2008, which covers 30% of the cost of the solar modules, including installation. You can also receive a tax credit equal to 9% of the total retail cost of the solar-ready heat pump or air conditioner that’s at the heart of the system. For more information, consult your tax advisor.

State tax credits. According to dsireusa.org, there are about 47 states and 600 electric utilities across the U.S. that provide incentives for renewable-energy systems.

Utility net metering. If your utility company offers net-metering agreements, you may be able to receive a credit for any surplus power generated that’s not used in your home, and is fed back to your utility company. To find out if you can get rebates and credits for your excess power generation, check with your local utility company or visit dsireusa.org.

System Performance InformationQ: How does the system work?

A: The SunSource® Home Energy System reduces the amount of electricity needed from your utility provider to put you in control of your utility bills. This energy-saving system harnesses solar energy and uses it first—before using electricity from the utility company—to power your heat pump or air conditioner. The solar power that’s collected can also operate other appliances and electronics when the heating and cooling system is not in use. What’s more, if the SunSource system generates more solar power than is needed, that power will be sent back to the utility company, possibly entitling homeowners to a credit. For more details on how the different system components work together to lower your utility bills, view our solar house on Lennox.com.

Q: Will the system work at night and on cloudy days?

A: Your system will not work at night because the solar modules need sunlight to produce power. Solar modules will still produce power on cloudy or overcast days, but at a reduced level.

Q: How long will the system last?

A: We stand behind the Lennox name and the quality that has made us a global leader in home comfort. Because the SunSource Home Energy System is backed by Lennox, you can take comfort knowing it’s built to exacting standards. Our warranties are designed to give you added peace of mind:

Solar-ready heat pumps and air conditioners from the Dave Lennox Signature® Collection include a 10-year limited warranty on the compressor and covered components.

Solar modules include a 5-year limited warranty against defects from faulty workmanship or damage to the surface. The modules have a 12-year limited performance guarantee that covers a power output of less than 90%, and a 25-year limited performance guarantee that applies to a power output of less than 80%.

Microinverters include a 15-year limited warranty against defects in workmanship and materials.

Some restrictions apply. See your local Lennox Dealer for full warranty details.

Q: How do I know my system is performing to its full potential?

A: The SunSource Home Energy System comes with a communication module that sends performance data for each module to a website, where you can view systems status, energy production and environmental benefits, including carbon offsets, online in real time.

Q: Do I need an Internet connection to use the communication module?

A: Yes, an Internet connection is required to receive the full benefits of the online monitoring system, and to view energy production and environmental benefit information. The monitoring service is provided for free.*

Q: Will going solar compromise my comfort in any way?

A: At the heart of the SunSource Home Energy System is a solar-ready heat pump or air conditioner designed to deliver the same optimal comfort and high-efficiency performance offered by other systems from the Dave Lennox Signature Collection, Lennox’ finest offering of heating and cooling systems.

Q: What happens if the power goes out?

A: In the event of a power outage caused by a storm or some other problem, the SunSource system will shut off. Once power is restored by your utility company, the system should turn back on automatically along with lighting, appliances and other household electronics.

*Performance-monitoring website provided by an independent third party, Enphase Energy, Inc.

Information on Solar ModulesQ: Are the solar modules easily damaged?

A: The modules are made of tempered glass and are laminated to a resilient substrate. They are rugged, durable and weather- and impact-resistant.

Q: Will the modules look awkward or obtrusive on my home?

A: The hardware that mounts the modules to your roof allows them to integrate nearly flush with the surface for a discreet appearance that does not detract from the overall appeal of your house.

Q: Will I need a new roof before the modules are installed?

A: The ideal situation for installing solar is to have a roof that’s in good condition. That way, you won’t have to bear the cost of re-installing the solar modules if your roof needs to be replaced or repaired within a few years.

Q: Do the modules need to face south?

A: Yes, south-facing modules are best to maximize sun exposure. The closer to south the system faces, the greater the electrical output from the solar modules.

Q: What happens if the solar modules are shaded?

A: Ideally, the solar modules should be installed in areas where they are free from obstructions that can cause shading, such as trees and buildings. But the unique design of the modules could provide energy savings, despite varying climate and lighting conditions. Unlike typical solar-panel systems, which have one inverter for the complete array, each SunSource module has its own microinverter that converts solar energy into usable electrical power. So any issue that might affect one module, such as a shadow from a chimney, doesn’t impact the other modules.

Q: What happens if the solar modules are covered by snow?

A: Our solar panels are installed at an angle on the roof, which may allow the snow to slide down and melt within a short period of time under normal circumstances. In the event of an extreme accumulation, you may need to brush off the snow to get solar power.

Q: Do I need to clean the solar modules?

A: In most regions, rain cleans them off automatically. However, if you live in a dusty industrial area, you may see a performance improvement from periodically spraying the panels with water. Please note that detergents and high-pressure hoses should never be used for cleaning.

Buying a SystemQ: How can I get started with solar energy?

A: Talk to your local Lennox Dealer, who will stop by your home to help you decide which Dave Lennox Signature® Collection system best suits your needs, and how many solar modules to add now or over time.

© 2011 Lennox Industries Inc. PC68383 12/11 (71W92)www.lennox.com 1-800-9-LENNOX


SunSource® Home Energy SystemThe simplest way to bring money-saving solar power into your home.The SunSource® Home Energy System provides significant reductions in your utility costs. With as few as four or as many as 17 solar modules (per outdoor unit), the SunSource system converts free, abundant solar energy into electricity for cooling your home—and more!

Air Conditioner Savings

Discover your potential cooling-cost savings.

Estimated annual operating cost savings* of a 3-ton XC25, XC21 or XC17 air conditioner with solar modules,** compared to a 10 SEER air conditioner.

© 2013 Lennox Industries Inc. PC74910 06/13 (10N54)www.lennox.com 1-800-9-LENNOX



**Based on 270 watt solar module from SolarWorld.*** Percent savings for Canada based on 2750 heating load hours (same as U.S.

region 5). Northern regions of Canada may have even higher heating load hours.

Climate Regions

Region 1

Region 2

Region 3

Region 4

Region 5

Region 6Includes Canada***

Number of Solar Modules4 5 6 7 8 9 10 11 12 13 14 15 16 17

XC25 75% 79% 83% 87% 91% 95% 99% 103% 108% 112% 116% 120% 124% 128%XC21 68% 72% 76% 81% 85% 89% 93% 97% 101% 105% 109% 113% 117% 121%XC17 58% 63% 67% 71% 75% 80% 84% 88% 92% 97% 101% 105% 109% 114%XC25 83% 89% 95% 101% 107% 113% 119% 125% 131% 137% 143% 149% 155% 161%XC21 76% 82% 88% 94% 100% 106% 112% 118% 124% 130% 136% 142% 148% 154%XC17 67% 73% 79% 86% 92% 98% 105% 111% 118% 124% 130% 137% 143% 149%XC25 94% 102% 111% 119% 128% 137% 145% 154% 162% 171% 179% 188% 197% 205%XC21 87% 95% 104% 112% 121% 130% 138% 147% 155% 164% 172% 181% 190% 198%XC17 78% 87% 96% 105% 114% 123% 132% 141% 150% 160% 169% 178% 187% 196%XC25 110% 122% 135% 148% 160% 173% 186% 198% 211% 224% 236% 249% 261% 274%XC21 103% 116% 128% 141% 153% 166% 179% 191% 204% 217% 229% 242% 255% 267%XC17 95% 108% 122% 135% 148% 162% 175% 189% 202% 216% 229% 242% 256% 269%XC25 158% 183% 208% 232% 257% 282% 307% 331% 356% 381% 405% 430% 455% 480%XC21 151% 176% 201% 225% 250% 275% 300% 324% 349% 374% 399% 423% 448% 473%XC17 146% 172% 199% 225% 251% 277% 304% 330% 356% 382% 409% 435% 461% 487%XC25 216% 255% 294% 334% 373% 412% 451% 490% 530% 569% 608% 647% 686% 726%XC21 209% 248% 288% 327% 366% 405% 444% 484% 523% 562% 601% 640% 680% 719%XC17 208% 249% 291% 332% 374% 416% 457% 499% 540% 582% 624% 665% 707% 749%

Heat Pump Savings

Discover your potential cooling- and heating-cost savings.

Estimated annual operating cost savings* of a 3-ton XP25, XP21 or XP17 heat pump with solar modules,** compared to a 10 SEER/7.0 HSPF heat pump.

© 2013 Lennox Industries Inc. PC74910 06/13 (10N54)www.lennox.com 1-800-9-LENNOX


Climate Regions

Region 1

Region 2

Region 3

Region 4

Region 5

Region 6Includes Canada***

Number of Solar Modules4 5 6 7 8 9 10 11 12 13 14 15 16 17

XP25 68% 72% 76% 79% 83% 87% 91% 95% 98% 102% 106% 110% 113% 117%XP21 60% 63% 67% 71% 75% 78% 82% 86% 90% 94% 97% 101% 105% 109%XP17 53% 57% 60% 64% 68% 72% 75% 79% 83% 86% 90% 94% 97% 101%XP25 69% 73% 78% 83% 87% 92% 96% 101% 105% 110% 115% 119% 124% 128%XP21 60% 64% 69% 73% 78% 83% 87% 92% 96% 101% 105% 110% 115% 119%XP17 54% 59% 63% 68% 72% 77% 81% 86% 90% 95% 99% 104% 108% 113%XP25 64% 68% 73% 77% 81% 86% 90% 95% 99% 103% 108% 112% 117% 121%XP21 55% 59% 63% 68% 72% 77% 81% 85% 90% 94% 99% 103% 108% 112%XP17 51% 55% 59% 64% 68% 72% 77% 81% 86% 90% 94% 99% 103% 107%XP25 52% 55% 59% 63% 67% 70% 74% 78% 82% 85% 89% 93% 96% 100%XP21 46% 49% 53% 57% 61% 64% 68% 72% 75% 79% 83% 87% 90% 94%XP17 43% 47% 51% 54% 58% 62% 65% 69% 73% 76% 80% 84% 87% 91%XP25 38% 42% 45% 48% 52% 55% 59% 62% 65% 69% 72% 76% 79% 82%XP21 34% 38% 41% 45% 48% 51% 55% 58% 62% 65% 68% 72% 75% 79%XP17 34% 37% 41% 44% 47% 51% 54% 58% 61% 64% 68% 71% 75% 78%XP25 62% 67% 72% 77% 82% 87% 92% 97% 102% 107% 112% 117% 122% 127%XP17 48% 53% 58% 63% 68% 73% 78% 83% 88% 93% 98% 103% 109% 114%XP21 50% 55% 60% 65% 70% 75% 80% 85% 90% 96% 101% 106% 111% 116%


**Based on 270 watt solar module from SolarWorld.*** Percent savings for Canada based on 2750 heating load hours (same as U.S.

region 5). Northern regions of Canada may have even higher heating load hours.

SOLADECK JBOX

Composition/Standing Seam/Metal Roof: 10M04 Qty.

Flat Tile/S Tile Roof: 10K57 Qty. INCLUDE ENPHASE ENVOY COMMUNICATIONS GATEWAY?

Yes Y4263 Qty.

NoINCLUDE WEEB DPF’S FOR SOLAR MODULE GROUNDING?NOTE - Order TWICE the amount of WEEB DPFs as Solar Modules!

Yes 10K46 Qty.

NoLENNOX SOLAR SUBPANEL FOR DLSC OUTDOOR UNIT

62E02 Qty.

D

E

F

G

SOLAR MODULES

Solar Modules (Black): 10G11 Qty.

Solar Modules (Silver): 10G01 Qty.

Microinverters: 10G37 Qty.

Installation Package: Catalog No. Qty.

ROOF MOUNT TYPE? NOTE - Order TWICE the amount of Roof Mounts as Solar Modules!

Composition, Black: 10K40 Qty.

Composition, Silver: 10K39 Qty.

Standing Seam, S-5!® S-5-U: 10J43 Qty.

Trapezoid Metal, S-5!® VersaBracket: 10J44 Qty.

Flat Tile, Black: 10K45 Qty.

Flat Tile, Silver: 10K43 Qty.

S Tile, Black: 10J46 Qty.

S Tile, Silver: 10J45 Qty.

B

C

STOP

BLACK FRAME(Quantity) Solar Modules +

(Quantity) Enphase MicroinvertersInstallation

Package(4) 10G11 + (4) 10G37 + (1) 10J08(6) 10G11 + (6) 10G37 + (1) 10J16(8) 10G11 + (8) 10G37 + (1) 10J17

(12) 10G11 + (12) 10G37 + (1) 10J19(16) 10G11 + (16) 10G37 + (1) 10J20

ROOF MOUNT TYPENOTE - Order TWICE the amount of Roof Mounts as Solar Modules!

Catalog No.

Composition Shingle, Black (1 each) 10K40Composition Shingle, Silver (1 each) 10K39Standing Seam Roof, S-5!® S-5-U M8 (1 each) 10J43Trapezoid Metal Roof, S-5!® VersaBracket (1 each) 10J44Flat Tile Roof, Black (1 each) 10K45Flat Tile Roof, Silver (1 each) 10K43S Tile Roof, Black (1 each) 10J46S Tile Roof, Silver (1 each) 10J45

START

1 Include Enphase Envoy Communications

Gateway? (Y4263)

Order one (Y4263)

Yes

No

Include WEEB DPFs

for Solar Module Grounding?

(10K46)

Solar Module Frame

Black or Silver?

B C E

Tile Roof SolaDeck JBOX

(10K57)

No

Yes

F

NOTE - Order TWICE

the amount of WEEBs as

Solar Modules!

SILVER FRAME(Quantity) Solar Modules +

(Quantity) Enphase MicroinvertersInstallation

Package(4) 10G01 + (4) 10G37 + (1) 10K31(6) 10G01 + (6) 10G37 + (1) 10K32(8) 10G01 + (8) 10G37 + (1) 10K33

(12) 10G01 + (12) 10G37 + (1) 10K34(16) 10G01 + (16) 10G37 + (1) 10K38

Composition/Standing Seam/

Metal Roof SolaDeck JBOX

(10M04)

D 1 Enphase Envoy Communications Gateway includes lifetime monitoring.

2 Lennox Solar Subpanel (62E02)

SUNSOURCE® HOME ENERGY SYSTEM - SOLARWORLD® PRE-ENGINEERED KITS - ORDERING PROCESS FOR DEALERS

G

NOTE - The Installation Package contains the appropriate number of required Rails, Cables, Splices, Brackets, Clamps, Clips and assorted hardware (nuts/bolts/washers) for the installation. See next page for Pre-Engineered Kits Components list.

Job:

Location:

Engineer:

Schedule No.:

System Designation:

Architect:

Date:

For: Reference Approval Review ConstructionWO

RK

SH

EE

T

1

2 Order one Lennox Solar Subpanel per Dave Lennox Signature® Collection (DLSC) outdoor unit. Stocked and shipped by Lennox

Bulletin No. 210680 (May 2013)

LENNOX® SOLAR SUB-PANEL

NOTEThe Lennox® Solar Sub-Panel for the outdoor unit must be ordered separately. See below for ordering information.

Order one per outdoor unit. Replaces the outdoor unit piping panel and provides the connection between the solar modules and outdoor unit.

62E02

SOLARWORLD® PRE-ENGINEERED KITS - COMPONENTSDescription No. of Components in Kit

Number of Modules 4 6 8 12 16Solar Modules, Enphase Microinverter and Monitoring Components

Solar Module 270W (Silver) or 265W (Black) Mono

4 6 8 12 16

Enphase Microinverter (M215) 4 6 8 12 16

Enphase Envoy Communications Gateway (Communications Booster Furnished)

1 1 1 1 1

Enphase Engage CableEnphase Engage Cable, 240V Trunk Cable Port, portrait aligned (no. of connectors)

4 7 9 14 18

Enphase Engage Cable Terminator 1 1 1 1 1

Enphase Engage Disconnect Tool 1 1 1 1 1

Enphase Engage Water-tight Sealing Cap

- - - 1 1 2 2

Enphase Microinverter Mounting ComponentsL-Bracket for microinverter, 100 mm, clear anodized aluminum, adjustment slots and serrated mating surfaces

4 6 8 12 16

Flange Nut, 5/16”-16 serrated edge, 18-8 stainless steel

5 7 9 13 18

Truss Screw, HD, 5/16”-18 x 0.75”, 18-8 stainless steel

5 7 9 13 18


Number of Modules 4 6 8 12 16Roof Mounting Components

Composition Shingle Roof Mount Mount/Flashing with base block, hanger bolt and hardware, 12” x 12” (305 x 305 mm), Black or Silver

8 12 16 24 32

Standing Seam Roof Mount, S-5!® S-5-U M8

8 12 16 24 32

Trapezoid Metal Roof Mount, S-5!® VersaBracket

8 12 16 24 32

Flat Tile Roof Mount, 18” x 18”, Quick Mount PV QBase Universal Tile, Black or Silver

8 12 16 24 32

S Tile Roof Mount, 18” x 18”, Quick Mount PV QBase, Black or Silver

8 12 16 24 32

Rail, two modules,122 in. (3099 mm) length

- - - 4 - - - - - - - - -

Rail, three modules, 162 in. (4115 mm) length

2 - - - 4 6 8

Rail Splice Bar Connector - - - - - - 2 4 4

Top Clamp Assembly (M8 bolt with channel nut and bolt positioning retainer), 1-1/4 in. (31 mm), silver or black

14 20 24 34 48

End Clamp Aluminum Spacer, 1-1/4 in. (31 mm), silver or black

6 10 10 14 20

Flange Nut, M8, serrated edge, stainless steel

16 22 28 40 56

T-Bolt M8 x 20, stainless steel 13 19 25 37 50


Number of Modules 4 6 8 12 16Roof Mounting Components (Continued)

L-Bracket, clear anodized aluminum 8 12 16 24 32

Wire Clip, 10AWG, 50-pack 1 1 1 1 1

Cable Ties, 13”, UV resistant, black, 50-pack

1 1 1 1 1

Ground Lug, WEEB 8.0, tin plated, lay-in

5 7 9 13 18

Ground Screw, 10-pack 1 1 1 2 2

Rail-equipment Ground WEEB-lug 8.0 with T-bolt assembly

3 5 5 7 10

WEEB DPF Module Grounding Clip. 8 12 16 24 32

Rail splice ground jumper WEEB 8.0 pre-assembled with T-bolts

- - - - - - 3 5 8

Hex Bit, T40-2”, 1/4” shank 1 1 1 1 1

Rooftop Junction Box, Soladeck JBOX, Composition with flashing or Flat Tile/S Tile

1 1 1 1 1

Soladeck 1 Branch AC Passthru Kit, used with Rooftop Junction Box

1 1 1 1 1

NOTE - Additional items not included that may be required for installation: Lightning arrestors, array marking, or site specific system detail plaques, conduit, conduit fittings, ground/bonding conductor, AC disconnect switch, roof sealant.

5

clearly visible

SunSource® Home Energy SystemPerformance-Monitoring Website

A real-time measure of energy production and environmental benefits

The SunSource® Home Energy System lets you witness solar energy in action. The brilliant innovation that makes the SunSource® Home Energy System such an easy way to go solar is made even better by the addition of a performance-monitoring website that lets you see how it’s working.

Communication module attached to your SunSource system sends performance information for each solar module to a website, where a homeowner can view system status.

Performance-monitoring website allows you to keep track of the system status, energy production and environmental benefits in real time. Monitoring service is provided for free.*

Watch SunSource work! Log onto the website to view accumulated environmental benefits 24/7. (See back cover for details.)

Solar Modules

Future Modules

CondensingUnit

StandardOutlet

CommunicationModule


Website

BroadbandInternet

Connection

ElectricalPanel

* Performance-monitoring website provided by an independent third party, Enphase Energy, Inc.

The overview pane displays current system status, current energy production, the energy produced for the day, the month and the lifetime of your SunSource system.

The performance-monitoring website makes solar’s benefits clearly visible.Providing informative visibility

The performance-monitoring website delivers visible proof of your SunSource® Home Energy System’s reliability, and allows you to better understand its operation. You can log onto the website any time to view an easy-to-interpret display of both real-time and historic performance data and analysis.

Constant monitoring and analysis ensures reliability Not only does the SunSource performance-monitoring website track per-module energy production, it also analyzes production shortfalls, establishes a possible cause and suggests solutions to remedy the situation.

Beyond monitoring and analysis, the website can even notify you and your installing contractor if a problem occurs. At the time of installation, you can instruct the system to send you—or your Lennox Dealer—an alert if a production issue or some other situation warrants attention.

Here you can view time-lapse animation of your solar array to see how power generation is affected by the sun and obstructions such as shade trees or a nearby chimney.

This section displays an aerial view of your roof, showing how the solar modules are physically configured. You can view energy production information for each module on a current, daily, monthly and lifetime basis.

© 2011 Lennox Industries Inc. PC68385 12/11 (72W12)

When you go solar, your world gets greener.

www.lennox.com 1-800-9-LENNOX


The performance-monitoring website automatically calculates the environmental benefits provided by your SunSource® Home Energy System. Log on and watch your carbon footprint shrink, hour by hour, day by day.

Overall Impact of the SunSource® Home Energy System on Annual Reduction of CO2 Emissions (in pounds)*

Based on a 3-ton XC21 air conditioner or XP21 heat pump with solar modules, compared to a 10 SEER A/C or 10 SEER/7.0 HSPF

heat pump.

*Carbon offset estimates based on energy savings provided by an XC/XP21 air conditioner or heat pump with various number of solar modules versus a 10 SEER, 7.0 HSPF air conditioner or heat pump. Calculations based upon EPA egrid2007 version 1.1 and DOE Annual Performance Factor (APF) for heat pumps.

**Percent savings for Canada based on 2750 heating load hours (same as U.S. Region 5). Northern Regions of Canada may have even higher heating load hours.

Climate Regions

Region 1

Region 2

Region 3

Region 4

Region 5

Region 6Includes Canada**

Number of Solar Modules

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

XC21 7932 8302 8673 9043 9414 9784 10154 10525 10895 11266 11636 12006 12377 12747 13118

XP21 7183 7554 7924 8294 8665 9035 9406 9776 10146 10517 10887 11258 11628 11998 12369

XC21 6086 6501 6916 7330 7745 8160 8575 8989 9404 9819 10233 10648 11063 11478 11892

XP21 6267 6681 7096 7511 7926 8340 8755 9170 9584 9999 10414 10829 11243 11658 12073

XC21 4161 4541 4921 5301 5681 6061 6441 6821 7201 7581 7960 8340 8720 9100 9717

XP21 5569 5949 6328 6708 7088 7468 7848 8228 8608 8988 9368 9748 10127 10507 11125

XC21 2908 3296 3683 4071 4459 4847 5235 5622 6010 6398 6786 7174 7562 7949 8337

XP21 5402 5790 6178 6566 6954 7342 7729 8117 8505 8893 9281 9668 10056 10444 10832

XC21 1640 2020 2400 2780 3159 3539 3919 4299 4679 5059 5439 5819 6199 6579 6958

XP21 4021 4400 4780 5160 5540 5920 6300 6680 7060 7440 7820 8199 8579 8959 9339

XC21 931 1231 1532 1833 2134 2435 2735 3036 3337 3638 3938 4239 4540 4841 5141

XP21 3071 3372 3672 3973 4274 4575 4875 5176 5477 5778 6078 6379 6680 6981 7281

2100 Lake Park Boulevard - Richardson, Texas 75080-2254

July 1, 2013

(Revised from May 31, 2012) Dave Lennox Signature Collection® Solar Ready units qualify for the Federal Solar Tax Credit

This note confirms that Dave Lennox Signature Collection® Solar Ready units (XC/XP25, XC/XP21 and XC/XP17) qualify for the Federal Solar Tax Credit (IRC §25D). Here is an example of the impact Estimated retail cost of XC21-060 (outdoor unit only), including labor and installation =

$7000

HVAC Tax Credit (25C)¹ = Solar Tax Credit (25D), 9% of retail installed cost = Total Federal Consumer Tax Credit =

$300 $630 $930

In a private letter ruling*, the IRS confirmed that a portion of the cost of the Solar Ready outdoor units may be allocated to the generation of solar energy and the use of solar energy in the home when attached directly to 1 or more SunSource solar modules and when both the outdoor unit and solar module(s) are installed during the same calendar year. Lennox has determined that 30% of the retail cost of the outdoor unit qualifies for the Solar Tax Credit and would be eligible for the 30% tax credit. The result is that the actual Solar Tax Credit would equal 9% (30% of 30%) of the total retail cost of the outdoor unit. As a reminder, the Federal Solar Tax Credit is available through 2016.

The SunSource® Home Energy System already provides the most innovative, cost effective way to incorporate solar with a high-efficient heating and cooling system. By installing a Solar Ready outdoor unit and attaching at least one solar module, the Solar Ready outdoor unit will qualify for the solar tax credit giving homeowners even more of a compelling reason to buy high efficient outdoor units and the SunSource Home Energy System. If you have any questions, please contact your Territory Manager. ¹The Federal HVAC Tax Credit (IRC §25C) which may be available for the portion of cost of the outdoor unit for which the solar credit is not claimed. The HVAC credit (at 10%) was retroactively reinstated by Congress through the end of 2013. Under that credit, homeowners are eligible for Federal Tax Credits on qualified energy efficiency improvements in HVAC up to the following amounts: - Air Conditioning ($300) - 16 SEER and 13 EER minimum efficiency - Heat Pumps ($300) – 15 SEER and 12.5 EER and 8.5 HSPF minimum efficiency - Advanced main air circulating fan (Variable speed or CT) ($50) – 2% or less of furnace total energy - Furnaces ($150) – 95% minimum efficiency *The IRS private letter ruling was addressed to one of our customers. This represents the IRS’s position, as of the date of the ruling, with respect to the homeowner receiving the private letter ruling and may not be cited as precedent. Customers should consult their own tax advisor regarding their qualification for the Federal Solar Tax Credit in their particular circumstances.

Form 5695Department of the Treasury Internal Revenue Service

Residential Energy Credits Information about Form 5695 and its instructions is at www.irs.gov/form5695.

Attach to Form 1040 or Form 1040NR.

OMB No. 1545-0074

2012Attachment Sequence No. 158

Name(s) shown on return Your social security number

For Paperwork Reduction Act Notice, see your tax return instructions. Cat. No. 13540P Form 5695 (2012)

Note. Skip lines 1 through 11 if you only have a credit carryforward from 2011.

1 Qualified solar electric property costs . . . . . . . . . . . . . . . . . . . . 1

2 Qualified solar water heating property costs . . . . . . . . . . . . . . . . . . 2

3 Qualified small wind energy property costs . . . . . . . . . . . . . . . . . . . 3

4 Qualified geothermal heat pump property costs . . . . . . . . . . . . . . . . . 4

5 Add lines 1 through 4 . . . . . . . . . . . . . . . . . . . . . . . . . . 5

6 Multiply line 5 by 30% (.30) . . . . . . . . . . . . . . . . . . . . . . . . 67 a Qualified fuel cell property. Was qualified fuel cell property installed on or in connection with your

main home located in the United States? (See instructions) . . . . . . . . . . . . 7a Yes NoCaution: If you checked the “No” box, you cannot take a credit for qualified fuel cell property. Skip lines 7b through 11.

b Print the complete address of the main home where you installed the fuel cell property.

Number and street Unit No.

City, State, and ZIP code

8 Qualified fuel cell property costs . . . . . . . . . . . . . 8

9 Multiply line 8 by 30% (.30) . . . . . . . . . . . . . . . 9

10 Kilowatt capacity of property on line 8 above . x $1,000 10

11 Enter the smaller of line 9 or line 10 . . . . . . . . . . . . . . . . . . . . . 11

12 Credit carryforward from 2011. Enter the amount, if any, from your 2011 Form 5695, line 32 . . 12

13 Add lines 6, 11, and 12 . . . . . . . . . . . . . . . . . . . . . . . . . 13

14 Enter the amount from Form 1040, line 46, or Form 1040NR, line 44 . 14

15

1040 filers: Enter the total, if any, of your credits from Form 1040, lines 47 through 50; line 32 of this form; line 12 of the Line 11 Worksheet in Pub. 972 (see instructions); Form 8396, line 9; Form 8839, line 12; Form 8859, line 9; Form 8834, line 23; Form 8910, line 22; Form 8936, line 23; and Schedule R, line 22.

1040NR filers: Enter the amount, if any, from Form 1040NR, lines 45 through 47; line 32 of this form; line 12 of the Line 11 Worksheet in Pub. 972 (see instructions); Form 8396, line 9; Form 8839, line 12; Form 8859, line 9; Form 8834, line 23; Form 8910, line 22; and Form 8936, line 23.

} 15

16 Subtract line 15 from line 14. If zero or less, enter -0- here and on line 17 . . . . . . . . . 1617 Residential energy efficient property credit. Enter the smaller of line 13 or line 16. Also include

this amount on Form 1040, line 52, or Form 1040NR, line 49 . . . . . . . . . . . . . 1718 Credit carryforward to 2013. If line 17 is less than line 13, subtract

line 17 from line 13 . . . . . . . . . . . . . . . . . 18

Part I Residential Energy Efficient Property Credit (See instructions before completing this part.)

Form 5695 (2012) Page 2 Part II Nonbusiness Energy Property Credit

19a Were the qualified energy efficiency improvements or residential energy property costs for your main home located in the United States? (see instructions) . . . . . . . . . . . . 19a Yes NoCaution: If you checked the “No” box, you cannot claim the nonbusiness energy property credit. Do not complete Part II.

b Print the complete address of the main home where you made the qualifying improvements.Caution: You can only have one main home at a time.

Number and street Unit No.

City, State, and ZIP code

c Were any of these improvements related to the construction of this main home? . . . . . 19c Yes No

Caution: If you checked the “Yes” box, you can only claim the nonbusiness energy property credit for qualifying improvements that were not related to the construction of the home. Do not include expenses related to the construction of your main home, even if the improvements were made after you moved into the home.

20 Lifetime limitation. Amounts claimed in 2006, 2007, 2009, 2010, and 2011.

a Amount, if any, from line 12 of your 2006 Form 5695 . . . . . . . 20ab Amount, if any, from line 15 of your 2007 Form 5695 . . . . . . . 20bc Amount, if any, from line 11 of your 2009 Form 5695 . . . . . . . 20cd Amount, if any, from line 11 of your 2010 Form 5695 . . . . . . . 20de Amount, if any, from line 14 of your 2011 Form 5695 . . . . . . . 20ef Add lines 20a through 20e. If $500 or more, stop; you cannot take the nonbusiness energy property credit 20f

21 Qualified energy efficiency improvements (original use must begin with you and the component must reasonably be expected to last for at least 5 years; do not include labor costs) (see instructions).

a Insulation material or system specifically and primarily designed to reduce heat loss or gain of your home that meets the prescriptive criteria established by the 2009 IECC . . . . . . . . 21a

b Exterior doors that meet or exceed the Energy Star program requirements . . . . . . . . 21bc

Metal or asphalt roof that meets or exceeds the Energy Star program requirements and hasappropriate pigmented coatings or cooling granules which are specifically and primarily designed to reduce the heat gain of your home . . . . . . . . . . . . . . . . . . . . 21c

d Exterior windows and skylights that meet or exceed the Energy Star program requirements . . . . . . . . . . . . . . . . . 21d

e Maximum amount of cost on which the credit can be figured . . . . . 21ef

If you claimed window expenses on your Form 5695 for 2006, 2007, 2009, 2010, or 2011, enter the amount from the Window Expense Worksheet (see instructions); otherwise enter -0- . . . . . . . . . . . . . . 21f

g Subtract line 21f from line 21e. If zero or less, enter -0- . . . . . . . 21gh Enter the smaller of line 21d or line 21g . . . . . . . . . . . . . . . . . . . . . 21h

22 Add lines 21a, 21b, 21c, and 21h . . . . . . . . . . . . . . . . . . . . . . 2223 Multiply line 22 by 10% (.10) . . . . . . . . . . . . . . . . . . . . . . . 2324 Residential energy property costs (must be placed in service by you; include labor costs for onsite

preparation, assembly, and original installation) (see instructions).

a Energy-efficient building property. Do not enter more than $300 . . . . . . . . . . . . 24ab Qualified natural gas, propane, or oil furnace or hot water boiler. Do not enter more than $150 . . 24bc Advanced main air circulating fan used in a natural gas, propane, or oil furnace. Do not enter more than $50 . 24c

25 Add lines 24a through 24c . . . . . . . . . . . . . . . . . . . . . . . . 2526 Add lines 23 and 25 . . . . . . . . . . . . . . . . . . . . . . . . . . 2627 Maximum credit amount. (If you jointly occupied the home, see instructions) . . . . . . . . 2728 Enter the amount, if any, from line 20f . . . . . . . . . . . . . . . . . . . . 2829 Subtract line 28 from line 27. If zero or less, stop; you cannot take the nonbusiness energy property credit . 2930 Enter the smaller of line 26 or line 29 . . . . . . . . . . . . . . . . . . . . . 3031 Limitation based on tax liability. Enter the amount from the Credit Limit Worksheet (see instructions) . 3132 Nonbusiness energy property credit. Enter the smaller of line 30 or line 31. Also include this

amount on Form 1040, line 52, or Form 1040NR, line 49 . . . . . . . . . . . . . . 32Form 5695 (2012)

$2,000

$500

Form 5695 (2012) Page 3

General InstructionsSection references are to the Internal Revenue Code.

Future DevelopmentsFor the the latest information about developments related to Form 5695 and its instructions, such as legislation enacted after they were published, go to www.irs.gov/form5695.

What's NewThe nonbusiness energy property credit has been extended through 2013. You figure your nonbusiness energy property credit on Part II of this form.

Purpose of FormUse Form 5695 to figure and take your residential energy credits. The residential energy credits are:

• The residential energy efficient property credit, and

• The nonbusiness energy property credit.

Also use Form 5695 to take any residential energy efficient property credit carryforward from 2011 or to carry the unused portion of the credit to 2013.

Who Can Take the CreditsYou may be able to take the credits if you made energy saving improvements to your home located in the United States in 2012.

Home. A home is where you lived in 2012 and can include a house, houseboat, mobile home, cooperative apartment, condominium, and a manufactured home that conforms to Federal Manufactured Home Construction and Safety Standards.

You must reduce the basis of your home by the amount of any credit allowed.

Main home. Your main home is generally the home where you live most of the time. A temporary absence due to special circumstances, such as illness, education, business, military service, or vacation, will not change your main home.

Costs. For purposes of both credits, costs are treated as being paid when the original installation of the item is completed, or in the case of costs connected with the reconstruction of your home, when your original use of the reconstructed home begins. For purposes of the residential energy efficient property credit only, costs connected with the construction of a home are treated as being paid when your original use of the constructed home begins. If less than 80% of the use of an item is for nonbusiness purposes, only that portion of the costs that is allocable to the nonbusiness use can be used to determine either credit.

!CAUTION

Only the residential energy efficient property credit (Part I) is available for both existing homes and homes being constructed. The nonbusiness energy property credit (Part II) is only available for existing homes.

Association or cooperative costs. If you are a member of a condominium management association for a condominium you own or a tenant-stockholder in a cooperative housing corporation, you are treated as having paid your proportionate share of any costs of such association or corporation.

!CAUTION

If you received a subsidy from a public utility for the purchase or installation of an energy conservation product and that subsidy was not included in your gross income, you must reduce your cost for the

product by the amount of that subsidy before you compute your credit. This rule also applies if a third party (such as a contractor) receives the subsidy on your behalf.

Residential Energy Efficient Property Credit (Part I) If you made energy saving improvements to more than one home that you used as a residence during 2012, enter the total of those costs on the applicable line(s) of one Form 5695. For qualified fuel cell property, see Lines 7a and 7b, later.

You may be able to take a credit of 30% of your costs of qualified solar electric property, solar water heating property, small wind energy property, geothermal heat pump property, and fuel cell property. Include any labor costs properly allocable to the onsite preparation, assembly, or original installation of the residential energy efficient property and for piping or wiring to interconnect such property to the home. The credit amount for costs paid for qualified fuel cell property is limited to $500 for each one-half kilowatt of capacity of the property.

Qualified solar electric property costs. Qualified solar electric property costs are costs for property that uses solar energy to generate electricity for use in your home located in the United States. No costs relating to a solar panel or other property installed as a roof (or portion thereof) will fail to qualify solely because the property constitutes a structural component of the structure on which it is installed. The home does not have to be your main home.

Qualified solar water heating property costs. Qualified solar water heating property costs are costs for property to heat water for use in your home located in the United States if at least half of the energy used by the solar water heating property for such purpose is derived from the sun. No costs relating to a solar panel or other property installed as a roof (or portion thereof) will fail to qualify solely because the property constitutes a structural component of the structure on which it is installed. To qualify for the credit, the property must be certified for performance by the nonprofit Solar Rating Certification Corporation or a comparable entity endorsed by the government of the state in which the property is installed. The home does not have to be your main home.

Qualified small wind energy property costs. Qualified small wind energy property costs are costs for property that uses a wind turbine to generate electricity for use in connection with your home located in the United States. The home does not have to be your main home.

Qualified geothermal heat pump property costs. Qualified geothermal heat pump property costs are costs for qualified geothermal heat pump property installed on or in connection with your home located in the United States. Qualified geothermal heat pump property is any equipment that uses the ground or ground water as a thermal energy source to heat your home or as a thermal energy sink to cool your home. To qualify for the credit, the geothermal heat pump property must meet the requirements of the Energy Star program that are in effect at the time of purchase. The home does not have to be your main home.

Qualified fuel cell property costs. Qualified fuel cell property costs are costs for qualified fuel cell property installed on or in connection with your main home located in the United States. Qualified fuel cell property is an integrated system comprised of a fuel cell stack assembly and associated balance of plant components that converts a fuel into electricity using electrochemical means. To qualify for the credit, the fuel cell property must have a nameplate capacity of at least one-half kilowatt of electricity using an electrochemical process and an electricity-only generation efficiency greater than 30%.

!CAUTION

Costs allocable to a swimming pool, hot tub, or any other energy storage medium which has a function other than the function of such storage do not qualify for the residential energy efficiency credit.

Joint occupancy. If you occupied your home jointly with someone other than your spouse, each occupant must complete his or her own Form 5695. To figure the credit, the maximum qualifying costs that can be taken into account by all occupants for qualified fuel cell property costs is $1,667 for each one-half kilowatt of capacity of the property. The amount allocable to you for qualified fuel cell property costs is the lesser of:

Form 5695 (2012) Page 4

1. The amount you paid, or

2. The maximum qualifying cost of the property multiplied by a fraction. The numerator is the amount you paid and the denominator is the total amount paid by you and all other occupants.

These rules do not apply to married individuals filing a joint return.

Example. Taxpayer A owns a house with Taxpayer B where they both reside. In 2012, they installed qualified fuel cell property at a cost of $20,000 with a kilowatt capacity of 5. Taxpayer A paid $12,000 towards the cost of the property and Taxpayer B paid the remaining $8,000. The amount to be allocated is $16,670 ($1,667 x 10 (kilowatt capacity x 2)). The amount of cost allocable to Taxpayer A is $10,002 ($16,670 x $12,000/$20,000). The amount of cost allocable to Taxpayer B is $6,668 ($16,670 x $8,000/$20,000).

Nonbusiness Energy Property Credit (Part II)You may be able to take a credit equal to the sum of:

1. 10% of the amount paid or incurred for qualified energy efficiency improvements installed during 2012, and

2. Any residential energy property costs paid or incurred in 2012.

However, this credit is limited as follows.

• A total combined credit limit of $500 for all tax years after 2005.

• A combined credit limit of $200 for windows for all tax years after 2005.

• A credit limit for residential energy property costs for 2012 of $50 for any advanced main air circulating fan; $150 for any qualified natural gas, propane, or oil furnace or hot water boiler; and $300 for any item of energy efficient building property.

!CAUTION

If the total of any nonbusiness energy property credits you have taken in previous years (after 2005) is more than $500, you generally cannot take the credit in 2012.

Subsidized energy financing. Any amounts provided for by subsidized energy financing cannot be used to figure the nonbusiness energy property credit. This is financing provided under a federal, state, or local program, the principal purpose of which is to provide subsidized financing for projects designed to conserve or produce energy.

Qualified energy efficiency improvements. Qualified energy efficiency improvements are the following building envelope components installed on or in your main home that you owned during 2012 located in the United States if the original use of the component begins with you, the component can be expected to remain in use at least 5 years, and the component meets certain energy standards.

• Any insulation material or system that is specifically and primarily designed to reduce heat loss or gain of a home when installed in or on such a home.

• Exterior windows and skylights.

• Exterior doors.

• Any metal roof with appropriate pigmented coatings or asphalt roof with appropriate cooling granules that are specifically and primarily designed to reduce the heat gain of your home.

For purposes of figuring the credit, do not include amounts paid for the onsite preparation, assembly, or original installation of the building envelope component.

!CAUTION

To qualify for the credit, qualified energy efficiency improvements must meet certain energy efficiency requirements. See Lines 21a Through 21h, later, for details.

Residential energy property costs. Residential energy property costs are costs of new qualified energy property that is installed on or in connection with your main home that you owned during 2012 located in the United States. Include any labor costs properly allocable to the onsite preparation, assembly, or original installation of the energy property. Qualified residential energy property is any of the following.

• Certain electric heat pump water heaters; electric heat pumps; central air conditioners; natural gas, propane, or oil water heaters; and stoves that use biomass fuel.

• Qualified natural gas, propane, or oil furnaces and qualified natural gas, propane, or oil hot water boilers.

• Certain advanced main air circulating fans used in natural gas, propane, or oil furnaces.

!CAUTION

To qualify for the credit, qualified residential energy property must meet certain energy efficiency requirements. See Lines 24a Through 24c, later, for details.

Joint ownership of qualified property. If you and a neighbor shared the cost of qualifying property to benefit each of your main homes, both of you can take the nonbusiness energy property credit. You figure your credit on the part of the cost you paid. The limit on the amount of the credit applies to each of you separately.

Married taxpayers with more than one home. If both you and your spouse owned and lived apart in separate main homes, the limit on the amount of the credit applies to each of you separately. If you are filing separate returns, both of you would complete a separate Form 5695. If you are filing a joint return, figure your nonbusiness energy property credit as follows.

1. Complete lines 19a through 19c and 21 through 26 of a separate Form 5695 for each main home.

2. Figure the amount to be entered on line 26 of both forms (but not more than $500 for each form) and enter the combined amount on line 26 of one of the forms.

3. On line 27 of the form with the combined amount on line 26, cross out the preprinted $500 and enter $1,000.

4. On the dotted line to the left of line 27, enter “More than one main home.” Then, complete the rest of this form, including lines 20a through 20f. The amount on line 20f can exceed $500.

5. Attach both forms to your return.

Joint occupancy. If you owned your home jointly with someone other than your spouse, each owner must complete his or her own Form 5695. To figure the credit, there are no maximum qualifying costs for insulation, exterior doors, and a metal or asphalt roof. Enter the amounts you paid for these items on the appropriate lines of Form 5695, Part II. For windows and residential energy property costs, the amount allocable to you is the smaller of:

1. The amount you paid, or

2. The maximum qualifying cost* of the property multiplied by a fraction. The numerator is the amount you paid and the denominator is the total amount paid by you and all other owners.

*$2,000 for windows; $300 for energy-efficient building property; $150 for qualified natural gas, propane, or oil furnace or hot water boiler; or $50 for an advanced main air circulating fan.

Specific InstructionsPart IResidential Energy Efficient Property Credit

Before you begin Part I:Figure the amount of any of the following credits you are claiming.

• Credit for the elderly or the disabled.

• Nonbusiness energy property credit (Part II of this form).

• Adoption credit.

• Mortgage interest credit.

• District of Columbia first-time homebuyer credit.

• Alternative motor vehicle credit.

• Qualified plug-in electric vehicle credit.

• Qualified plug-in electric drive motor vehicle credit.

Form 5695 (2012) Page 5

TIPAlso include on lines 1 through 4, and 8, any labor costs properly allocable to the onsite preparation, assembly, or original installation of the property and for piping or wiring to interconnect such property to the home.

Line 1Enter the amounts you paid for qualified solar electric property. See Qualified solar electric property costs, earlier.

Line 2Enter the amounts you paid for qualified solar water heating property. See Qualified solar water heating property costs, earlier.

Line 3Enter the amounts you paid for qualified small wind energy property. See Qualified small wind energy property costs, earlier.

Line 4Enter the amounts you paid for qualified geothermal heat pump property. See Qualified geothermal heat pump property costs, earlier.

Lines 7a and 7bAny qualified fuel cell property costs must have been for your main home located in the United States. See Main home, earlier. If you check the “No” box, you cannot include any fuel property costs on line 8.

If you check the “Yes” box, enter the full address of your main home during 2012 on line 7b.

If you and your spouse are filing jointly and you each have different main homes with qualified fuel cell property costs, provide on line 7b the address of your main home. Add a sheet providing the address of your spouse's main home. You and your spouse should add your qualified fuel cell property costs together on line 8 of one Form 5695.

Line 8Enter the amounts you paid for qualified fuel cell property. See Qualified fuel cell property costs, earlier.

Line 15If you are claiming the child tax credit for 2012, include on this line the amount from line 12 of the Line 11 Worksheet in Pub. 972.

TIPIf you are not claiming the child tax credit for 2012, you do not need Pub. 972.

Manufacturer’s certification. For purposes of taking the credit, you can rely on the manufacturer’s certification in writing that a product is qualifying property for the credit. Do not attach the certification to your return. Keep it for your records.

Line 18If you cannot use all of the credit because of the tax liability limit (line 16 is less than line 13), you can carry the unused portion of the credit to 2013.

File this form even if you cannot use any of your credit in 2012.

Part IINonbusiness Energy Property Credit

Before you begin Part II:Figure the amount of any credit for the elderly or the disabled you are claiming.

Lines 19a Through 19cLine 19a. To qualify for the credit, any qualified energy efficiency improvements or residential energy property costs must have been for your main home located in the United States. See Main home, earlier. If you check the “No” box, you cannot take the nonbusiness energy property credit.

Line 19b. Enter the full address of your main home during 2012.

Line 19c. You may only include expenses for qualified improvements for an existing home or for an addition or renovation to an existing home, and not for a newly constructed home. If you check the “Yes” box, you cannot claim any expenses for qualified improvements that are related to the construction of your home, even if the improvement is installed after you have moved into the home.

Lines 20a Through 20fEnter the nonbusiness energy property credits that you took in 2006, 2007, 2009, 2010, and 2011 on the appropriate lines. If the total of the credits already taken is $500 or more, you generally cannot take this credit in 2012.

Lines 21a Through 21hNote. A reference to the IECC is a reference to the 2009 International Energy Conservation Code as in effect (with supplements) on February 17, 2009.

!CAUTION

Do not include on lines 21a through 21d any amounts paid for the onsite preparation, assembly, or original installation of the components.

Line 21a. Enter the amounts you paid for any insulation material or system (including any vapor retarder or seal to limit infiltration) that is specifically and primarily designed to reduce the heat loss or gain of your home when installed in or on such home and meets the prescriptive criteria established by the IECC.

!CAUTION

A component is not specifically and primarily designed to reduce the heat loss or gain of your home if it provides structural support or a finished surface (such as drywall or siding) or its principal purpose is to serve

any function unrelated to the reduction of heat loss or gain.

Line 21b. Enter the amounts you paid for exterior doors that meet or exceed the Energy Star program requirements.

Line 21c. Enter the amounts you paid for a metal roof with the appropriate pigmented coatings or an asphalt roof with the appropriate cooling granules that are specifically and primarily designed to reduce the heat gain of your home, and the roof meets or exceeds the Energy Star program requirements in effect at the time of purchase or installation.

Line 21d. Enter the amounts you paid for exterior windows and skylights that meet or exceed the Energy Star program requirements.

!CAUTION

If you took the credit for windows in 2006, 2007, 2009, 2010, or 2011, you may not be able to include window expenses this year.

Line 21f. If you reported expenses on your 2006 Form 5695, line 2b; 2007 Form 5695, line 2d; 2009 Form 5695, line 2b; 2010 Form 5695, line 2b; or 2011 Form 5695, line 3d; then use the worksheet next to figure the amount to enter on line 21f.

Form 5695 (2012) Page 6

Window Expense Worksheet—Line 21f1. Enter the amount from your 2006 Form 5695,

line 2b . . . . . . . . . . . . 1.2. Enter the amount from your 2007 Form 5695,

line 2d . . . . . . . . . . . . 2.3. Enter the amount from your 2009 Form 5695,

line 2b . . . . . . . . . . . . 3.4. Enter the amount from your 2010 Form 5695,

line 2b . . . . . . . . . . . . 4.5. Add lines 3 and 4 . . . . . . . . . 5.6. Multiply line 5 by 3.0 . . . . . . . . 6.

7. Enter the amount from your 2011 Form 5695, line 3d . . . . . . . . . . . . 7.

8. Add lines 1, 2, 6, and 7. Also enter this amount on Form 5695, line 21f . . . . . 8.

Manufacturer’s certification. For purposes of taking the credit, you can rely on a manufacturer’s certification in writing that a building envelope component is an eligible building envelope component. Do not attach the certification to your return. Keep it for your records.

Lines 24a Through 24c

TIPAlso include on lines 24a through 24c any labor costs properly allocable to the onsite preparation, assembly, or original installation of the property.

Line 24a. Enter the amounts you paid for energy-efficient building property. Energy-efficient building property is any of the following.

• An electric heat pump water heater that yields an energy factor of at least 2.0 in the standard Department of Energy test procedure.

• An electric heat pump that achieves the highest efficiency tier established by the Consortium for Energy Efficiency (CEE) as in effect on January 1, 2009.

• A central air conditioner that achieves the highest efficiency tier that has been established by the CEE as in effect on January 1, 2009.

• A natural gas, propane, or oil water heater that has an energy factor of at least 0.82 or a thermal efficiency of at least 90%.

• A stove that uses the burning of biomass fuel to heat your home or heat water for your home that has a thermal efficiency rating of at least 75%. Biomass fuel is any plant-derived fuel available on a renewable or recurring basis, including agricultural crops and trees, wood and wood waste and residues (including wood pellets), plants (including aquatic plants), grasses, residues, and fibers.

Do not enter more than $300 on line 24a.

Line 24b. Enter the amounts you paid for a natural gas, propane, or oil furnace or hot water boiler that achieves an annual fuel utilization rate of at least 95.

Do not enter more than $150 on line 24b.

Line 24c. Enter the amounts you paid for an advanced main air circulating fan used in a natural gas, propane, or oil furnace that has an annual electricity use of no more than 2% of the total annual energy use of the furnace (as determined in the standard Department of Energy test procedures).

Do not enter more than $50 on line 24c.

Manufacturer’s certification. For purposes of taking the credit, you can rely on a manufacturer’s certification in writing that a product is qualified residential energy property. Do not attach the certification to your return. Keep it for your records.

Line 27If the rules discussed earlier for joint occupancy apply, cross out the preprinted $500 on line 27 and enter on line 27 the smaller of:

1. The amount on line 26, or

2. $500 multiplied by a fraction. The numerator is the amount on line 26. The denominator is the total amount from line 26 for all owners.

For more details, see Joint occupancy, earlier.

Line 31Complete the worksheet below to figure the amount to enter on line 31.

Credit Limit Worksheet—Line 311. Enter the amount from Form 1040, line 46, or

Form 1040NR, line 44 . . . . . . . 1.

2.

Enter the total, if any, of your credits from Form 1040, lines 47 through 50, and Schedule R, line 22; or Form 1040NR, lines 45 through 47 . . . . . . . . . 2.

3.

Subtract line 2 from line 1. Also enter this amount on Form 5695, line 31. If zero or less, stop; you cannot take the nonbusiness energy property credit . . . . . . . 3.

Section 11: Net Costing SheetsSection 12: Consumer "Incentive Worksheet"Refer to spreadsheets available from your Territory Manager

brilliant selling

How to SCORE with the SunSource® Home Energy System

SCORE big as a home energy consultant.Using the SCORE sales process, you can lay the groundwork for success in selling high-margin, solar-ready products from the Dave Lennox Signature® Collection and establishing yourself as a home energy consultant—a sustainable and profitable point of differentiation for your business.

Setting the Stage

When you arrive at the customer’s home, immediately make them feel comfortable by:

• Showing your photo ID and giving your full name and the name of your company

• Listening attentively to concerns

• Addressing tax credits and financing options early to ease the customer’s mind

Customer Assessment

At this point of the sales process, you can begin to gather information from the customer to find out what they want from their HVAC system.

Ask the customer questions related to:

• The age and performance of their HVAC equipment, particularly their outside condensing unit

• Whether the customer is in the process of changing or enhancing their living environment (planning an addition or remodeling)

• Concerns the customer may have about their home’s comfort and air quality

• How much the customer spends on their utility bills—if the customer thinks their bills are too high, bring up the topic of solar, using the tools provided in the SunSource® Home Energy System folder

Operational Assessment

Also called a technical assessment, this stage is where you show the customer you’re willing to take the time to get the job done right. Important steps include:

• Performing heating/cooling load calculations

• Checking ductwork for air leaks

• Conducting static-pressure tests to ensure the air handler is moving the right amount of air for the size of the system

• Checking the house, particularly the basement and crawlspaces, for correct moisture levels

• Taking accurate room measurements and making grid drawings of each floor

• Assessing the overall energy efficiency of the home through a visual inspection of insulation, windows, HVAC equipment, ductwork, foundation and other structural components

• Reviewing the planning checklist for the SunSource Home Energy System

Sell customers on the SunSource® Home Energy System by telling them:

• All cooling systems from the Dave Lennox Signature® Collection are solar-ready, which means they give customers the flexibility of adding solar modules at the time of installation or later down the line

• DLSC systems are already the most efficient you can buy; integrating them with solar modules makes them even more efficient and friendlier to the environment

• Tax credits, combined with incentives from state governments and utility companies, can significantly reduce the purchase and installation cost of the solar modules

• A complete SunSource® Home Energy System can be easily installed in their home

A chart inside the SunSource® Home Energy System folder can be used to demonstrate the environmental- and cost-savings potential of the system.

Recommending Solutions

Data trends indicate homeowners now see their homes as longer-term investments and are willing to spend money on improvements that enhance livability and efficiency.

Encouraging Sales

When it comes to closing the sale, nothing is more important than simply asking directly, “Mr. and Mrs. Jones, are you ready to approve the recommendation and get started?”

You can give customers extra confidence in your proposal by speaking to Lennox’ long-standing tradition of quality and innovation, with many firsts to its name. You can also play up the warranties on the SunSource® Home Energy System, which offer up to 25 years of performance coverage on the solar modules, and give customers information about financing and promotions. Check DaveNet for complete warranty details.

Adding SunSource to your recommended solutions further enhances the already strong selling message behind the XC/XP21 and XC/XP17 DLSC products.

For additional retail sales training information contact your TM or log on to www.hvacls.com

© 2010 Lennox Industries Inc. PC61955 05/10 (71W90)


SunSource® Home Energy SystemSample Proposal

Best Better Good

XP/XC21 solar-ready heat pump or air conditioner – The most quiet and efficient heat pump and central air conditioner you can buy*

XP/XC17 solar-ready heat pump or air conditioner – The most efficient single-stage heat pump and central air conditioner you can buy***

Solar-ready heat pump (XP21/XP17) or air conditioner (XC21/XC17)

SLP98V/CBX40UHV variable-capacity furnace or air handler • The most efficient and

quietest furnace and air handler you can buy**





SolarSync™ Package–Available exclusively from Lennox• Subpanel for outdoor unit

• Solar modules and mounting kit

• Communication module and online monitoring

SolarSync™ Package–Available exclusively from Lennox• Subpanel for outdoor unit

• Solar modules and mounting kit

• Communication module and online monitoring

Indoor Air Quality System(s)



icomfort by Lennox™ or ComfortSense® Thermostat



*A combination of sound ratings established per AHRI’s test standard: 270; and efficiency ratings established per AHRI’s test standard: ANSI/AHRI 210/240-2008. **Based on sound pressure levels during steady-state, high-fire and low-fire operation of Lennox SLP98UH070V36B and leading competitive units at mid-point

temperature rise and minimum external static pressure when set up per Section 4.5.3 of AHRI 260.***Efficiency claim based on comparison of single-stage air conditioning products’ SEER as published in AHRI (December 2009). Actual system combination efficiency

may vary. Consult a Lennox dealer or AHRI (www.ahridirectory.org) for exact system efficiencies.

November 2012

Pitched roof mounting systemplanning and installation guide

America's Authority on Solar

2 Sunfix plus pitched roof mounting system planning and installation guide November 2012

Proven quality – simply clever – obvious advantage

Congratulations, we are pleased you have chosen one of our high quality Sunfix plus® roof mounting systems from SolarWorld. All Sunfix plus mounting systems offer a value-added engineered design for ease of installation and safety, ensuring trouble free assembly and operation of the photovoltaic (PV) system. All components selected are quality inspected and held to the highest standards.

The instructions and contents of this manual are designed to assist you in planning and installing your Sunfix plus roof mounting system. Building and structural integrity of the installation is ultimately the responsibility of the installing party. Be aware of questionable roof construction conditions and regional wind and snow load exposure effects. Approval by a locally licensed professional engineer may be required.

Sunfix plus pitched roof mounting system planning and installation guide November 2012 3

Table of contents

Safety information 4

Installer responsibility 5

Installer considerations 6

Suitable installation conditions 6

Technical overview of system 8

Component overview 9

Hardware overview 10

System planning 13

Design basics 13

Access, pathways and smoke ventilation 14

Identify roof type 16

Product selection 17

System layout 18

Rail span tables 21

System installation 22

Quick Mount PV composition shingle instructions 23

Quick Mount PV universal tile instructions 26

Installing Sunfix plus racking system 29

PV string wire pull box 31

Wire management 32

Equipment ground-bonding 32

Module installation 38

Top clamp hardware selector guide for other modules 40

Standing seam metal roofing installation 42

Micro-inverter installation 43

Maintenance and cleaning 44

Warranty 45

Appendix 46

Sunfix plus racking system – sample layouts 46


Safety information

In-depth specialist knowledge is necessary to install and service a photovoltaic (PV) system. All work installing the PV system must be carried out by suitably qualified personnel. Carefully read through this manual before installing, operating or servicing the PV system. Store these instructions in an easily accessible place. Failure to follow the safety instructions may result in personal injury and/or damages.

* * * W A R N I N G * * *

Danger of electrocution! Solar modules generate electricity when exposed to sunlight or other light sources and may constitute a danger of electric shock or burn.

Typically an individual module generates voltage less than 50 Vdc. A voltage of 30 Vdc is considered a shock hazard. When multiple modules are series connected the module-string voltage increases; lethal high voltages in excess of 500 Vdc are possible in grid connected PV systems. Although the fully insulated module-plug connectors provide protection against accidental contact, the following points should be observed when handling solar modules in order to avoid damages or arcing, risk of fire, serious injury or a potentially fatal electric shock.

_ Do not insert electrically conductive objects into module-cable plugs or sockets.

_ Do not touch the ends of module cables with bare hands when the module is illuminated.

_ Ensure module cable connections are in good condition-no visible damage.

_ Do not wear jewelry during mechanical and electrical installation work.

_ Keep moisture away from tools and the working environment.

_ Do not dismantle modules or remove parts or labels fitted by the manufacturer.

_ Do not use or install broken modules.

_ Be careful not to drop modules, especially onto hard surfaces.

_ Keep children and unauthorized persons away during installation.

_ Do not scratch or puncture the PV module back sheet; may void warranty.

_ Do not drop objects onto module back sheet, or use as a work surface.

_ Do not stand or walk on modules, avoid bending or twisting the modules.

_ Never leave a module unsupported or unsecured while on roof top.

_ Pay attention to the warning notices on the product packaging!


Installer responsibility_ Ensure the roofing materials are in good condition not requiring repairs within the warranty life of the PV

system.

_ Ensure roof construction is suitable with regard to loading capacity (rafters, connections, other structural sup-port members) determined by the appropriate building codes.

_ Ensure debris shedding and water drainage is not impeded by the solar installation.

_ Ensure adequate ventilation below array to avoid the build-up of heat which may reduce system performance.

_ Ensure the waterproofing integrity of the roof is maintained. Include the use of roof flashing attachments that are appropriate for the roof-covering materials.

_ It is highly recommended to consult a licensed professional engineer if in doubt when performing work in areas subject to high wind and/or snow loads, atypical exposures or seismic conditions.

_ Protect exposed PV cables against atmospheric influences, such as UV light and mechanical damage by suit-able measures.

_ Incorporate appropriate wire management methods restricting module interconnect cables from touching the roof and tangling with debris.

_ Sufficient distance should be kept to roof edges, allowing access for emergency response personnel. Solar modules must never extend beyond the edge of a roof.

_ All applicable local and national code requirements shall be observed and followed, and shall take precedence over information provided in this installation guide.

_ Ensure personal fall protection devices when buildings are greater than 10 ft tall.

_ Protect persons on the ground against falling objects with appropriate barriers.

_ Observe the manufacturer's safety instructions provided with other system components.

_ Ensure all bolted connections are properly torqued to manufacturer recommended values.

_ Record module serial numbers for system documentation and warranty purposes.


Installation considerations

Provide adequate fall protection for yourself and others on roof. Do not perform installation during strong winds or adverse weather conditions. Always work in a team of minimum 2 or more people. Ensure that objects cannot fall down from the work area. Carefully secure the working area to avoid risks of injury to people. Always wear protective head gear and protective shoes with rubber soles. Use insulated tools and wear gloves to prevent risk of shock or burn.

* * * C A U T I O N * * *

Solar modules can weigh in excess of 40lbs (18.2kg). Two persons and proper handling equipment should be em-ployed to safely transport the modules.

Suitable installation conditions

Install the modules in an unshaded location Even slight shading causes a reduced yield from the system. Hence it is particularly important that the modules be installed in a location with the least possible shading. For best performance - there should not be any shading of the PV array surface at any time of the year. The PV array should be exposed to several hours of unobstructed sunlight even during the winter months when sun is lowest in the sky.

Before installationElectric code (NEC), local utility, health and safety standards and accident prevention regulations should be complied with during installation. Ensure that the relevant safety instructions for the installation and operation of the other system components are also followed.

Installation The module must not be installed either as overhead glazing or as vertical glazing (e.g., on a façade). As well as the module itself, the mounting system must also be able to reliably withstand the expected load resulting from the conditions at the installation site (snowfall, wind).

Maximizing yield with optimum orientation and pitchBefore installation, research the appropriate orientation for the modules to enable the system to generate the opti-mum yields. Ideal conditions for power generation occur when the sun’s rays hit the generator surface at a perpen-dicular angle. When the modules are series connected, make sure all modules are installed with the same orientation and pitch to avoid output losses.

Tilt angle selectionInstalling at tilt angles between 9˚ and 45˚ is recommended. The tilt angle of the PV module is measured between the surface of the PV module and horizontal. The minimum recommended roof tilt angle is not less than 9 degrees when installed with Quick Mount PV™ roof flashing systems.

Ensure sufficient ventilationTo ensure sufficient ventilation below a solar array mounted parallel to a roof surface, a clearance from 3” to 6” to the solar modules is recommended.

Do not exceed the maximum mechanical loadEnsure solar mounting system is installed with consideration for local load conditions like wind and snow. The combined wind and snow loads shall not exceed the maximum load rating of the solar module.


Ensure comprehensive fire protectionThe installation of roof-mounted PV systems can affect a building’s fire safety in some cases. Poorly executed installa-tions in particular pose a hazard in the event of a fire. Ensure the system is mounted over a fire resistant roof cover-ing rated for the application. Refer to your local building department for guidelines and requirements for building fire safety. The solar array must not be installed in proximity to highly flammable gases and vapors (e.g., close to gas canisters, paint spraying systems, fuel stations, near naked flames or combustible materials).

Site considerationsMake certain installation site is not exposed to artificially concentrated sunlight or submerged in water or continu-ally exposed to water splashes. If the solar array is exposed to high concentrations of salt or sulphur laden air or any unusual chemical exposure there is a risk of long term corrosion.

Water DrainagePV modules are typically elevated between 3" to 6" above roof, as such, a potential for rain water shedding down the PV array, overshooting the rain gutter exists if installed too close to the eve. A recommended distance from the rain gutter to the lower edge of the PV array is:

Distance Roof Pitch12" 27 degrees or less18" 28 to 45 degrees


Technical overview of system

The Sunfix plus pitched roof mounting system is a versatile support structure for the installation of solar modules onto pitched roofs. The Sunfix plus mounting system has been designed specifically for SolarWorld Sunmodules (2.0 & 2.5 frames). The Sunfix plus mounting system is not approved for use with any other PV module. When Supplied with SolarWorld Sunkits®, the Sunfix plus system is assembled as a complete kit, including all hardware, equipment grounding components and roofing attachments based on the existing roof structure and the site specific load re-quirements (tilt angle, snow, wind loads, etc.).

Every ‘Sunkits’ system is provided with a general racking plan and electrical wiring diagram. These define the ar-rangement of the attachment points and the supporting rail as well as the recommended wiring scheme from the array to the power inverter, all matched to suit your roof construction and PV array layout needs.

Racking Plan

PV STRING FUSE

DC DISCONNECT

Single Line Diagram


Component overview

Sunfix plus rail 2 modules = 82”, 3 modules = 122”, 4 modules = 162”

Top-clamp assembly for 31 mm frame - M8 bolt with channel nut with bolt positioning retainer

End clamp aluminum spacer - 31 mm

Rail splice bar; joins rails together

L-bracket with dual adjustment slots & mating serrations

T-bolt M8 x 20 stainless steel with serrated flange hex nut

Rail splice ground jumper WEEB 8.0 pre-assembled with T-bolts

Rail-equipment ground WEEB-lug 8.0 with T-bolt assembly

Roof attachment/flashing - Quick Mount PV®

Portrait module orientation (single layer) shown with two parallel support rails per row.


Hardware overview

The Sunfix plus mounting system provides a fast, simple and cost effective flush mounting solution for PV modules on pitched roofs. The fasteners are of high quality, corrosion resistant stainless steel for long life. Top clamps insert easily into the Sunfix plus rails. Installation time is reduced by pre-assembled "Top-Clamp" hardware. Top clamps are silver colored, also available in black.

_ Pre-assembled, as shown, Module top clamps are for a Sunmodule frame thickness of 31mm. For attachment of other PV modules other than Sunmodules see page 40. Top clamp bolt assemblies include a channel nut with a plastic retainer which simply inserts into the Sunfix plus rail-slot. This retainer allows the top clamp bolt to stay in place during installation of the modules. The top clamp sets the spacing between modules.

Module clamping washer

Plastic nut retainer

Channel nut

Truss head screw - M8 "TORX" T40

Module top clamp assembly

1/4 turn locks channel nut into rail-slot

1

2

Module mid-clamp

_ The same top clamp bolt for module ‘End-Clamp’ adds a spacer for 31 mm module frame height. Top clamp bolts are with a ‘Torx-T40’ drive head. All fasteners are M8 thread end. Clamp spacer is aluminum.

M8-screw - torx 'T40' drive

Clamping washer - press fitted free-turning

End spacer - not assembled

Slot nut with retainer

Module end clamp assy Module end clamp installation


_ The side slot of Sunfix plus2 rail is designed for insertion of (M8) T-bolts. This slot is used for fastening "L-bracket" brackets and "WEEB" grounding devices with T- bolts. Added confidence in assembly includes alignment indica-tors on end of T-bolts. When the alignment indicator slot is oriented vertically, the bolt is secured in place.

T-BoltAlignment

Indicator Slot

The Sunfix plus2 rail and L-foot bracket have mating serrations to improve alignment and stability of the connection. The L-foot bracket has 1" slots, providing a range of adjustment from 2.5" to 3.5" (as shown). The Quickmount PV flash-ing for composition shingle roofing will add 1.25" below the L-foot bracket.

L-Foot Bracket AssemblyFlashing Assembly

Roof Styles

2.5" Min.3.5" Max.

aa

a

h

Gable Roof

a

Hip Roof

aa

a

ha

Interior ZonesRoofs - Zone 1



ASCE 7-05

1

1111

2

3

5

7

86

9

4

10

18"

4"

18"

9"

L-bracket assembly (shown minimum)


Item No. Description 8 Modules 12 Modules 24 Modules Parts Qty Qty QtyEC0589* Rail, Sunfix plus2, 2 Module - 82" , Clear Anodize 0 0 0EC0591* Rail, Sunfix plus2, 3 Module-122", Clear Anodize 0 8 0EC0592* Rail, Sunfix plus2, 4 Module-162", Clear Anodize 4 0 12EC0421 Plus Connect 2, Splice Bar, Clear Anodize 0 4 8EC0427* L-Bracket, Clear Anodize 16 20 40SA0192* Module Top Clamp Assy M8 -silver 20 28 52SA0177* End Spacer - 31 mm silver 8 8 8SH0001 T-Bolt M8 x 20 S/S 16 20 40EC0496 Hex-nut, M8 serrated flange S/S 16 20 40 Grounding EC0602 Equip. GND Lug Assy - WEEBLug 8.0 4 4 4EC0603 Rail Splice GND Assy - WEEB8.0 Bond Jumper 0 4 8

Required ToolsEC0604 Drive Bit ‘Torx’ T40, 1/4" hex 2" Lg. 1 2 2 Sunfix plus2 Wire ManagementEC0595 Wire Clip #10AWG S/S-50 Pk 1 1 2

Black Top Clamp OptionSA0179 Module Top Clamp Assy M8 - Black 20 28 52SA0181 End Spacer - 31mm Black, Anodize 8 8 8 Roof Attachment ChoicesEC0596 QMSC A, Composition mount, Mill Aluminum 16 20 40EC0217 QMSC B, Composition mount, Bronze Anodize 16 20 40EC0218 QMSC C, Composition mount, Clear Anodize 16 20 40EC0597 QMUTM A, S Tile Mount - Mill alum. 6.5" post 16 20 40EC0598 QMUTM B, S Tile Mount - Bronze ano. 6.5" post 16 20 40EC0034 QMUFTM B, Flat Tile Mount - Mill alum. 4.5" post 16 20 40EC0035 QMUFTM B, Flat Tile Mount - Bronze ano. 4.5" post 16 20 40

This parts list identifies the standard components and hardware items for Sunfix plus2, along with option and acces-sory items. Examples of typical quantities are shown based on the Sunmodule quantity.

The quantity of items listed are based on modules mounted in portrait, two-rail design, with the total number of modules divided into two equal rows.

Item No's Denoted '*' are available in 'Black' as well.

When ordering Sunkits systems that are supplied with SolarWorld Sunmodules in black frames, all racking compo-nents will automatically default to 'Black' to match.


System planningDesign Basics

The Sunfix plus roof mounting system is intended only for flush mounting to sloped roofs, and is not to be used with tilt legs. Flush is defined as parallel to the roof surface. The recommended clearance between solar modules and the roof is 3 to 6 inches. Less than 3” to the roof increases heat build-up which affects power production.

The installer is responsible for ensuring appropriate design parameters were used in determining the design loading considerations for the specific installation. Parameters such as snow ground load, wind speed, exposure category and topographic factors should be confirmed with local building officials or a professional engineer.

Roof zoneAccording to the width and height of the building for the PV system installation, the design wind load will vary based on where the installation is located on a roof. PV arrays may be located in more than one roof zone. The Sunfix plus mounting system is intended for roof types shown herein for roof zone 1; zones 2 and 3 should be avoided. Maintain appropriate distances around the solar array, and pathways for emergency or service personnel. The local building department should be consulted to determine any municipal or county or fire department clearance restrictions.

_ The building construction must be enclosed, not an open or partially enclosed structure.

_ The building is regular shaped with no unusual geometrical irregularity (geodesic dome).

_ The building is not in an extreme geographic location such as a narrow canyon or steep cliff.

_ The building has a gable roof with a pitch not greater than 45 degrees or a hip roof with a pitch less than 27 degrees.


Roof Styles

2.5" Min.3.5" Max.

aa

a

h

Gable Roof

a

Hip Roof

aa

a

ha




ASCE 7-05

1

1111

2

3

5

7

86

9

4

10

18"

4"

18"

9"

a = 10 percent of least horizontal dimension or 0.4 h, which ever is smaller, but not less than either 4% of least hori-zontal dimension or 3 ft. (0.9 meters).

h = Mean roof height, in feet (meters), except that eave height shall be used for roof angles < 10°.


Access, pathways and smoke ventilation

Access and spacing recommendations should be observed in order to:

_ Ensure access to the roof

_ Provide pathways to specific areas of the roof

_ Provide for smoke ventilation opportunities area

_ Provide emergency egress from the roof

Contact the local AHJ for proper roof setback requirements.

Local jurisdictions may create exceptions to this requirement where access, pathway or ventilation requirements are reduced due to:

_ Proximity and type of adjacent exposures

_ Alternative access opportunities (as from adjoining roofs)

_ Ground level access to the roof area in question

_ Adequate ventilation opportunities beneath solar array (as with significantly elevated or widely-spaced arrays)

_ Adequate ventilation opportunities afforded by module set back from other rooftop equipment (example: shading or structural constraints may leave significant areas open for ventilation near HVAC equipment)

_ Automatic ventilation device

_ New technology, methods, or other innovations that ensure adequate fire department access, pathways and ventilation opportunities

Designation of ridge, hip, and valley does not apply to roofs with 2-in-12 or less pitch. All roof dimensions are mea-sured to center lines. Roof access points should be defined as areas where ladders are not placed over openings (i.e., windows or doors) and are located at strong points of building construction and in locations where they will not conflict with overhead obstructions (i.e., tree limbs, wires, or signs).

Residential Buildings with a single ridge: Modules should be located in a manner that provides two (2) three-foot (3’) wide access pathways from the eave to the ridge on each roof slope where modules are located.

3 ft

3 ft

3 ft

Solar Panel

Full Gable Roof

3 ft

Solar Panel3 ft

Cross Gable Roof

Hips and Valleys: Modules should be located no closer than one and one half (1.5) feet to a hip or valley if modules are to be placed on both sides of a hip or valley. If the modules are to be located on only one side of a hip or valley that is of equal length then the modules may be placed directly adjacent to the hip or valley.


Solar Panel

Solar

Panel

3 ft

3 ft

1-1/2 ft

1-1/2 ft

3 ft

3 ft

Cross Gable Roof with Valley

Residential buildings with hip roof layouts: Modules should be located in a manner that provides one (1) three-foot (3’) wide clear access pathway from the eave to the ridge on each roof slope where modules are located. The access pathway should be located at a structurally strong location on the building (such as a bearing wall).

Solar Panel

3 ft3 ft

Full Hip Roof

Location of direct current (DC) conductorsConduit, wiring systems, and raceways for photovoltaic circuits should be located as close as possible to the ridge or hip or valley and from the hip or valley as directly as possible to an outside wall to reduce trip hazards and maximize ventilation opportunities.

Conduit runs between sub arrays and to any DC combiner/pull boxes should use design guidelines that minimize the total amount of conduit on the roof by taking the shortest path from the array to the DC combiner box. The DC combiner boxes are to be located such that conduit runs are minimized in the pathways between arrays.

To limit the hazard of cutting live conduit in venting operations, DC wiring should be run in metallic conduit or race-ways when located within enclosed specs in a building and should be run, to the maximum extent possible, along the bottom of load-bearing members.


Identify roof type

Know Your RoofIt is a good idea to do a thorough roof evaluation prior to your project installation. At this time you should do a layout on the roof confirming everything on the drawing will fit as it is intended. Any irregularities should be noted in ad-vance, so that you can deal with them simply on install day. The quality of the roofing should be determined, so that any repairs or replacement can happen before or in conjunction with the installation. Remove a tile and see what is underneath. On a tile roof it is important to know as much as possible about the manufacturer of the tile, the size of the tile, age of tile, type of substrate (plywood or oriented strand board [OSB]), the rafter size and spacing, age of roof structure, who built it, who roofed it, etc.

The roof covering will dictate the appropriate type of flashing to be incorporated. Installations on composition roof surfaces with flashed components offer the quickest solution. For concrete tile or shake roofs or roofs with cladding that exceeds thickness of 1/8-inch, use taller, female threaded standoffs with approved flashings. Residential building roofs are primarily constructed of three types of coverings:

_ Composition (asphalt) shingles

_ Curved (S) or flat (slate) concrete tile

_ Shake (wood) shingles

Composition (asphalt) shingles Curved (S) concrete tiles

Composition shingle flashing Universal flat tile flashing (Universal) S-tile flashing


Product selection

Quick Mount PV® is an all-in-one waterproof flashing and mount to anchor photovoltaic racking systems to most roofing constructions. The composition flashing fits most asphalt and wood shake roof systems, but not all. Specifi-cally it is sized to fit within a standard 5” to 5-1/2” row or course. To confirm that the composition flashing will match your roof, measure the course exposure of your roof. The “exposed” surface course height should measure no more than 5-3/4”. If it turns out the roof tiles are a non-standard size greater than 5-3/4”, the alternative method is to use a Quick Mount PV® Shake Mount.

3” Offset

Edge of flashing flush with edge

of shingle

Quick Mount — composition flashing

The Quick Mount PV® Composition Flashing is to be installed on composition shingle roofing with the flashing’s lower edge aligned flush with front edge of shingle course, resulting in a 3” offset from this location to where the provided fastener will penetrate the rafter and provide an attachment point for L-foot.

The composition flashing or mount is intended to be attached into a lumber rafter. Mounts are usually laid out based on the location of the rafters. In some cases it is desired to place a mount where there is no rafter. In this case it is possible to install wood blocking between rafters, then lag screw into the block.

The Quick Mount PV® Universal Tile Flashing is intended to fit within most curved tile roof systems, as well as most flat tile systems. Specifically it is sized to fit within a standard 12” wide x 17” tall concrete tile space, flat or curved. It is used on most any flat and curved tile roof and rafter mounted as a standard. Height extensions are not for use with this product. Custom lengths can be ordered.

Pitched Roof Solutions Composition Flat Tile S-Tile Standing SeamSunfix Plus w/quick mount X X XSunfix S-5! (see page 40) X


System layout

Proper layout will reduce the risk of drilling extra holes in the wrong location and possibly having to reposition an installed array. Prior to getting on the roof, the system layout should be defined on paper in the form of a drawing or sketch. This will minimize the number of chalk lines on the roof and speed up the layout process. The drawing should define the overall dimensions of the array as well as the roof plane on which the array is to be installed.

_ Confirm roof rafter size, material, and span to verify that the roof structure is sound and capable of support-ing the additional load of the PV array within local climatic conditions (wind/snow loads).

_ Measure roof surfaces and develop an accurate drawing locating any obstacles such as chimneys, parapets, skylights or roof vents. Look for signs of weak or low-laying roof surfaces which may need repair or additional leveling adjustment of racking.

_ Identify any roof areas requiring access, municipal set-back distances or keep-out areas as required by the local Jurisdiction.

Do NOT Mount on the Short Side

Mounting Area

1/8 Module Length

1/4 Module Length

Mounting Area

1/8 Module Length

1/4 Module Length

Rail Spacing

SolarWorld modules must be securely fastened at a minimum of 4 points on the long-sides between an 1/8 and 1/4 of the module length (from 8.25” to 16.5”) from the edge. Defining overall dimensions of the array, SolarWorld Sun-modules are 39.41” wide x 65.94” long.

The rail spacing is governed by the attachment locations placed on the roof. Rail spacing must fall within the bound-aries of the Sunmodule’s recommended support rail attachment mounting area. Therefore, the minimum rail spacing is 33” and the maximum rail spacing is 49.5”.

For a two-rail assembly, the Sunfix plus rails may be positioned either North/South for modules in landscape, or East/West for modules in portrait (preferred). Installing modules in portrait allows for better positioning of adjacent rows of panel assemblies with closer spacing, not so dependent on rafter locations.


Rail Spacing =Course Spacing

Modules in Portrait34.50 in. at 6 Courses40.25 in. at 7 Courses46.00 in. at 8 Courses

5.75 in. Typ. Course

East / West Rails

North / South Rails

North / SouthRafter Direction

Facia

Peak

Rail Spacing = Rafter Spacing

Modules inLandscape

48.00 in.

65.93 in. Ref.

The “shingled” surface course height should measure not more than 5-3/4”. For East / West rail direction, based on 5-3/4“ typical ‘shingle-course’ spacing, attachment locations for composition shingle flashings would be between either 6, 7 or 8 courses.

34.50 in. at 6 CoursesA = 40.25 in. at 7 Courses 46.00 in. at 8 Courses

The distance between Row 1 toRow 2 Flashing positions are basedon several factors considering:A) Shingle course spacing.B) Module length-distance past rail.C) Gap spacing between rows.

B

Panel Length

Flashings positionedall in same orientation

C1 in. min.

Sunfix Plus rails Row 1

Row 2


First Module

Sunfix plus Rail

Next Module

WEEB 'DPF' (Assembled)

0.875 in. Min.

0.375 in. Typ.

Mid Clamp Bolt

End Cap - Assy

To calculate the assembled Panel Length, the space between the modules needs to be accounted for as well as the rail distance extending beyond the first and last module in a row, allowing for the end-clamp. The minimum rail distance assumed beyond the modules for the end clamp spacer is 7/8". The assumed spacing between the modules is 3/8" when the top clamp bolt is combined with WEEB ‘DPF’ module bonding washer.

Example: The minimum overall design length of a Sunfix Plus assembly of 4 Sunmodules in portrait would be:

39.41 * 4 (Modules) + 0.375 * 3 (mid clamps) + 2 * 0.875 = 160.5” (end clamps)

However, the Sunfix plus2 mounting rail lengths have been predetermined, allowing for installation tolerance and mismatch of positioning roof attachments, these lengths are:

Two (2) module rail = 82” Three (3) module rail = 122” Four (4) module rail = 162”

Refer to Sunfix racking layout drawings for examples of typical combinations from 8 to 24 modules in the Appendix.

Rail Attachment LocationsThere are two key dimensional considerations for the positioning rail attachments, "span" (the center-to-center dis-tance between rail supports (L-feet) and "cantilever" the over-hang distance from the outermost L-foot support to the end of the rail). Rail spans and cantilever distances should not exceed the values listed in the rail span tables on the next page.

Rail Span "L"Per Attachment

Cantilever

Rafter

RoofFlashing

Rail Span "L"Per Attachment

Rail

Outermost L-Foot

For parallel two-rail systems, the installer should take precaution when setting the rail cantilever distance past the L-foot such that the ends of both rails are within +/- 1/4” respectively.


Rail span tables

The following span tables have been engineered to provide the maximum rail attachment span distance (values in inches) for Sunfix plus2 rails. To effectively use the rail span tables, one should consider the wind and snow loads at the site by consulting the local building department. Span calculations utilized design methods or material data from the 2000 AA Specification, ASCE 7-05, 2009 IBC, and 6005-T5 aluminium alloy. The following assumptions were made:

_ Wind exposure category C, zones 1, 2, and (not recommended*) 3

_ Adjustment factor = 1.0

_ Importance factor (occupancy category II) = 1.0

_ Topographic factor = 1.0

_ Maximum deflection limit of L/180

_ Single span condition, building height of 30 feet

_ PV module area is 18 ft2. The dead load including support structure and PV module is 50 lbs

Roof pitch 9 - 27 degreesRail Attachment Span (in)

Rail Cantilever (in)

Wind speed (mph)Snow Load (psf)

0 20 40 50

8566 66 54 48

33 33 27 24

9063 63 54 48

30 30 27 24

10057 57 54 48

27 27 27 24

110*51 51 51 48

24 24 24 24

* Roof zone 3 not recommended at 110 mph.

Roof pitch 28 - 45 degreesRail Attachment Span (in)

Rail Cantilever (in)

Wind speedSnow Load (psf)

0 20 40 50

8578 66 54 51

39 33 27 24

9075 66 54 51

36 30 27 24

10066 60 51 48

33 30 24 24

11060 57 51 48

30 27 24 21

Wind Exposure Category: ASCE 7-05 defines wind exposure categories as follows:

Exposure B: is an urban or suburban area, wooded areas, or other terrain with numerous closely spaced obstructions having the size of single family dwellings upwind for at least a 1/2 mile.

Exposure C: has open terrain with scattered obstructions having heights generally less than 30 feet. This category includes flat open country, grasslands, and all water surfaces in hurricane prone regions.


System installation

This manual primarily covers the installation of the Sunfix plus mounting system and does not address the necessary wiring, conduit, safety disconnects or balance of system components or location thereof conducive to a complete PV system installation.

Planning ahead, ensuring that all necessary plans, instructions, tools, safety equipment, materials and spare parts are gathered prior to arriving at the job site will save time.

Installation Sequence The following pages will illustrate the recommended sequence for racking installation.

_ Install appropriate Quick Mount PV roof flashings per roof type and layout drawing.

_ Attach L-foot brackets to roof flashings, assemble T-bolt and nut onto L-foot top slot.

_ Loosely fasten Sunfix plus rails to L-foot brackets, following layout drawings.

_ Insert rail splice connectors where necessary during rail installation.

_ Adjust L-foot brackets for roof height and rail alignment inconsistencies.

_ Check measurements and alignment of rails before applying torque to fasteners.

_ Attach a roof mounted wiring pull box in a convenient location, preferably below the PV array.

_ Connect PV string home-run cable(s) into wiring pull box.

_ Mount the PV string home-run cables by attaching wire management ties to the rails.

_ Install equipment bonding devices to each rail row-end and rail splice connections.

_ Install a continuous copper ground conductor to all rail-end lugs and along every row (if the modules will also be grounded through this conductor) allowing extra length for the connection into the wiring pull box.

_ Starting at one end of the racking, place the End Clamps and the first module with consideration for position-ing/alignment of the module onto the parallel rails.

_ Install adjacent modules with Mid-Clamp bolts, remembering to electrically interconnect the series cables together. Connect the ground conductor to each module ‘lug’, unless the WEEB "DPF" option is used.

_ Check PV module alignments for aesthetic purposes before applying final torque to top clamps.


Quick Mount PV installation instructions - composition shingle mount

Photos should be taken of all of the roof variables and placed with the job file for any future reference either short term or long. If the roofing manufacturer is known, it is then easy to obtain the written manufacturer’s installation instructions for the roofing materials you are dealing with.

Quick Mount flashings are 100% IBC, UBC compliant, and meet or exceed roofing industry best practices, with the following specifications:

_ 2554 lbs average pullout (Douglas fir)

_ 2203 lbs average shear

_ Stainless steel hardware (included)

_ 10-year warranty

_ 50-year expected life to not void roof manufacturer's warranty

There's no need for trimming shingles to force a fit. Drill one pilot hole into the rafter, backfill it with appropriate sealant, slide the Quick Mount flashing beneath the felt in the course above, drive the bolt home, and it's done. The 12 x 12-inch Composition Mount flashing is designed to fit within a standard 5 to 5.5" course and the exposed course should be no greater than 5.75".

Recommended tools/materials for Quick Mount PV - composition flashings

_ Cordless impact driver (for hanger bolt)

_ Socket wrench with 1/2” hex deep socket (for hanger bolt)

_ Cutoff saw ( for excess rail)

_ Nail pry-bar (enables roof flashing beneath shingle)

_ Drill bit – 7/32” dia. (pilot hole for 5/16” lag screw)

_ Caulk gun-dispenser

_ Approved roof sealant for attachments

_ Digital IR laser stud-finder

_ Tape measure, Level

_ Chalk - plumb line

_ OSHA approved safety glasses and footwear

_ OSHA approved safety harness and anchor


Quick Mount PV installation instructions - composition shingle mount

R

For Questions Call 925-687-6686 www.quickmountpv.com [email protected]©2012 Jan2012

4 of 4

Installation Tools Required: Tape Measure, Roofing Bar, Chalk Line, Stud Finder, Caulking Gun, 1 Tube of Appropriate Sealant, Drill with 7/32” long bit, Drill or Impact Gun with 1/2” Deep Socket.

1 2

Locate, choose, and mark centers of rafters to be mounted. Select each row course of roofing for Mount placement of Quick Mounts.

Lift Composition roof shingle with Roofing Bar, just above placement of Quick Mount.

3

Slide Mount into desired position. Remove any nails that conflict with getting Mount flush with front edge of shingle course. Mark center for drill-ing.

4 5

Using drill with 7/32” long bit, drill pilot hole into roof and rafter, taking care to drill square to the roof. Do not use Mount as a drill guide.

Clean off any saw dust, and fill hole with Sealant.

6

Slide Mount back into position. Prepare Hanger Bolt with 1 Hex Nut and 1 Sealing Washer, insert through Block into hole and drive Hanger Bolt into rafter, tightening to a solid snug fit.

CLASSIC COMPOSITION MOUNTING INSTRUCTIONS - 5/16” - PV -

7 8

Insert EPDM Rubber Washer over Hanger Bolt into Block.

Using the Rack Kit Hardware, secure the rack of your choice (see 9*). Tighten to 13 foot Pounds.

* You are now ready for the rack of your choice. Follow all the directions of the rack manufacturer as well as the module manu-facturer.

All roofing manufacturers’ written instructions must also be followed by anyone modifying a roof system. Please consult the roof manufacturers’ specs and instructions prior to touching the roof.

9

Locate, choose rafters to be mounted and mark centers of rafters with chalk line (N/S). Select each row course of roofing for mount placement of Quick Mounts.

Using drill with 7/32" diameter bit, drill pilot hole into roof and rafter, taking care to drill square to teh roof. Do not use mount as a drill guide.

Insert EPDM rubber washer over hanger bolt into block.

Fasten the L-foot onto hanger bolt, secure the Sunfix plus rails. Tighten to 13 foot pounds.

Clean off any saw dust, and fill hole with sealant. Slide mount back into position. Prepare hanger bolt with (1) hex nut and (1) sealing washer; insert through block into hole and drive hanger bolt into rafter, tightening to a solid, snug fit.

All roofing manufacturers' written instructions must also be followed by anyone modifying a roof system. Please consult the roof manufacturers' specs and instructions prior to touching the roof.

Follow all the directions of the rack manufacturer as well as the module manufacturer.

Lift composition roof shingle with roofing bar, just above placement of Quick Mount.

Slide mount into desired position. Remove any nails that conflict with getting mount flush with front edge of shingle course. Mark center for drilling.


Quick Mount PV - Installation instructions, composition shingle mount

Item No. Description Qty

1 Flashing, 12" x 12" x 0.05" * 1

2 Base block for standard QMSC * 1

3 Hanger bolt, 5/16" x 6" SS 1

4 Washer, sealing 5/16" x 3/4" 1

5 Hex nut, 5/16" - 18 SS 2

6 EPDM washer, 0.125" thick x 0.875" OD 1

7 Washer, fender 5/16" x 1" SS 1

8 Washer, split-lock, 5/16", SS 1

12”

12”

6”

3”

6

8

4

3

5

7

5

2

1

Lag pull-out (withdrawal) capacities (lbs) in typical lumberLag Bolt Specifications

Specific gravity 5/16" shaft per 3" thread depth 5/16" shaft per 1" thread depthDouglas Fir, Larch 0.50 798 266Douglas Fir, South 0.46 705 235Engelmann Spruce, Lodepole Pine (MSR 1650 1 & higher 0.46 705 235

Hem, Fir 0.43 636 212Hem, Fir (North) 0.46 705 235Southern Pine 0.55 921 307Spruce, Pine, Fir 0.42 615 205Spruce, Pine, Fir (E of 2 million psi and higher grades of MSR and WEL)

0.50 798 266

Sources: Uniform Building Code; American Wood Council.Notes:1) Thread must be embedded in a rafter or other structural roof member.2) See IBC for required edge distances.


Quick Mount PV installation instructions – universal flat tile and S-tile mount

The primary flashing at the roof deck forms a waterproof shield isolating all penetrating fasteners from corrosive water intrusion. The top flashing is malleable, so it works equally well for curved and flat tile roofs. Both flashings feature a spun aluminum cone, with no seams to fail in extreme climates. The reinforced QBase makes an extraordi-narily strong foundation.

For concrete tile roofing, typically the tile roof manufacturer puts a stamp of some sort on the back of each tile. This stamp can be defined by the roofing yard, or by a little on-line surfing. The manufacturer’s instructions will spell out exactly what does and does not void the warranty of their roofing product. Officially the roofing manufacturer’s instructions supersede our instructions.

WaterproofingOn a tile roof it is actually the building paper below the tiles that is waterproof. The tiles are considered water resis-tant. It is assumed that water will travel under the tiles. The tiles are there for aesthetics, thermal absorption, and to protect the building paper from U.V. and the elements. It is imperative to follow standard roofing practices with the paper. The Aluminum Primary Flashing that we provide needs to go over our Q Base Mounting Base Plate with the long side of the flashing up-slope, above the mount. On the up-slope side of the mount, the Aluminum Primary Flashing must extend under the existing lap in the paper course directly above the mount.

In the common occurrence that the paper is too far up the roof to reach, you must supply and install another piece of building paper (usually 30 lb.) under the row of paper above, and over the top 2 inches of Aluminum Primary Flash-ing. This paper should be wider than the Aluminum Primary Flashing, and either stapled down or nailed. If a batten board is in the way, pry it up and slip the paper under the batten. Alternatively, three coursing the flashing into the paper is also an acceptable method. Please consult the NRCA’s best practices for material specifics, and methods within your geographic area.

SealantsIt is important to put a compatible sealant into any and all holes drilled into a roof. Most roofing manufactures list a suggested, approved sealant in their specifications. In the freeze-thaw zones, it is important to follow the manufac-turers’ rules for freeze-thaw conditions. Use the properly rated sealant for each specific application and condition. Some that may be more appropriate for asphalt/composition roofs include Geocell 2300 and ChemLink M-1.

PlywoodSheathing

5/16" x 3" Zinc Lag Bolts

Racking of Choice

Field Applied Appropriate Sealant

Cast Aluminum Base Plate (Q Base)

Aluminum Primary Flashing

5/16"x 1-1/4" EPDM Washerwith Flat Washer (Stainless Steel)

5/16" Lock Washer (Stainless Steel)

5/16" Washer (Stainless Steel)

5/16"x 1" Machine Bolt (Stainless Steel)for Rack Attachment

5/16"x 3/4"Machine Bolt(Grade B)

Flexable Aluminum Flashing12" x 17"Curved Tile

EPDM Counter Flashing

Batten

6-5/8"Lip of Tile to

Center of Post

Tar Paper

2X Rafter

Batten

Installation Tools Required:1) Tape Measure.2) Drill with 7/32 in. wood bit.3) Ratchet withn 1/2 in. Socket.4) Caulking Gun.5) 1 Tube of Appropriate Sealent.6) 30 lb. Felt Paper.7) Wisk Broom / Vacuum.8) Roofers Bar / Shingle Ripper.


Quick Mount PV installation instructions - universal tile mount*

R

For Questions Call 925-687-6686 www.quickmountpv.com [email protected]©2011 Aug 20114

Remove Tile at selected location of Mount. Locate center of rafter and Mark with a felt pen. Use a straight edge and measure up 6 5/8” from bottom of tiles to center of the Mount, over the center of Rafter.

Align Q Base over rafter center and drill 2 each 7/32” pilot holes. Place grade 8 Machine Bolt un-der Q Base in hex slot, threads pointing up. Lag Q Base into Rafter on Marks.

Carefully clean the building paper then install Pri-mary Flashing in either a three course method, or properly lapped paper method. Now is a good time to apply sealant to the flashing opening.

Take care to do a quality installation – when us-ing the paper method, cut a piece of paper 18” wide to slide under the course above, and over the Primary Flashing of the Mount.

Cut a hole in the tile removed, with room to get the post through. Replace tile in position. Insert post and tighten into place. install the 18” x 18” flashing, and apply sealant around the opening.

Pre bend the flashing to follow the contour of the tile if curved. Install counter flashing collar.

You are now ready for the rack of your choice. Follow all the directions of the rack manufacturer as well as the module manufacturer.


UNIVERSAL TILE MOUNTING INSTRUCTIONSRAFTER INSTALLATION

1 2 3

54 6

87You are now ready for the Sunfix plus rack. Follow all the directions of the Sunfix plus instructions as well as the Sunmodule instructions.


*Note: SolarWorld offers a universal 'flat' tile mount (4.5" post) in addition to an "S"-curved tile mount (6.5" post). Both versions, show above, are otherwise identical.

If tile is curved, pre-bend the flashing to follow the contour of the tile. Install counter flashing collar.

Cut a hole in the tile removed, with room to get the post through. Replace tile in position, Insert post and tighten into place. Install the 18" x 18" flashing, and apply sealant around the opening.


Quick Mount PV installation instructions - universal tile mount

Lag bolt specifications (lbs)

Specific gravity2 ea. 5/16" shaft

2.5" thread depth5/16" shaft

1" thread depthDouglas fir, larch 0.50 1330 266Douglas fir, South 0.46 1175 235Engelmann spruce(MSR 1650 f & higher) 0.46 1175 235

Hem, fir 0.43 1060 212Hem, fir (North) 0.46 1175 235Southern pine 0.55 1535 307Spruce, pine, fir 0.42 1025 205Spruce, pine, fir (E of 2 million psi and higher grades of MSR and MEL) 0.50 1330 266

Sources: Uniform Building Code; American Wood Council


Roof Styles

2.5" Min.3.5" Max.

aa

a

h

Gable Roof

a

Hip Roof

aa

a

ha




ASCE 7-05

1

1111

2

3

5

7

86

9

4

10

18"

4"

18"

9"

Item No. Description Qty1 QBase 12 QBase primary flashing 13 Tile flashing (bronze or mill finish) 14 Cut post 1.25" OD x 6.5" aluminum* 15 1" EPDM pipe collar 16 Hex bolt 5/16" x 1" SS 17 Sealing Washer 5/16" x 1.25" SS 18 Split lock washer 5/16" SS 19 Fender washer 5/16" x 1" SS 110 Hex bolt 5/16" x 3/4" grade 8 111 Hex lag bolt 5/16" x 3" zinc 2

Flashing assembly


Installing Sunfix plus racking system

Tools for Sunfix plus Mounting System:

_ 13 mm open end wrench

_ Socket wrench - 3/8” drive

_ 7/16” and 13 mm hex socket - 3/8” drive

_ ‘Torx’ T40 drive bit (supplied with Sunkits)

_ ‘Torx’ T40 socket x 3/8” drive (for torque wrench)

_ Torque wrench 0-30 ft-lbs x 3/8” drive (for top clamp bolts)

_ OSHA approved safety glasses and footwear

_ OSHA approved safety harness and anchors

Sunfix plus rail assemblyOnce the roof attachments and L-foot brackets are in position as per the layout drawing, working from left to right, measure the distance of the first rail overhang to the center of the L-foot and secure the T-bolt(s) on the L-foot into the side of the rail profile (13 mm wrench). Refer to Appendix A for examples of typical rack layout drawings.

MECHANICAL NOTES:1. TYPICAL ATTACHMENT SPANS AT 4 FT ON CENTER. REFER TO SPAN TABLES IN THIS INSTALLATION GUIDE TO EXCEED 4FT.

2. DO NOT EXCEED CANTILEVER VALUES LISTED IN SPAN TABLES. ADDITIONAL FLASHINGS MAY BE NEEDED, ADJUSTMENTS MAY BE REQUIRED.

3. MAX MODULE DIMENSIONS: 65.94" x 39.41"

4. ROOF MEMBER N-S RAFTERS MIN 2" X 4".

5. TOTAL RACKING SYSTEM LOAD W/O MODULES BUT INCLUDING FLASHING, TOP CLAMPS, AND GROUNDINGS: 0.40 PSF

6. CONTRACTOR SHALL TAKE ALL NECESSARY PRECAUTIONS WHEN PREPARING ROOF FOR ANCHOR POINT LOCATIONS. BUILDING STRUCTURE INTEGRITY IS THE RESPONSIBILITY OF THE INSTALLER.

7. LAYOUT BASED ON INSTALLING MODULES ONTO RAIL FROM LEFT TO RIGHT.

8. ENSURE INTERSECTION OF ADJACENT MODULES IS AT LEAST 1" AWAY FROM THE END OF THE RAIL AT THE SPLICE JOINT (SEE TOP OF PAGE 31 IN THE INSTALLATION GUIDE).

Typical racking layout drawing.


Place the other rows of parallel rails onto the roof attachments in the same manner. Do not torque the T-bolts con-necting the L-brackets to the rails until all rails have been placed, aligned and spaced off the roof surface (if neces-sary). Torque all M8 T-bolts to 12 ft-lbs.

Adjust L-foot to varied roof surface

M8 T-bolt & flange nut

To join rails on a given row, attach rails together using the rail splice connector. Once all of the rails are connected together and fastened to L-foot brackets, check the flatness of the support rails along the length and correct any bowing by adjusting the upper L-foot slot.

The individual rail sections are connected to each other by a fastener-free rail splice connector. One rail splice connec-tor is used at each rail connection.

A pin on the center of the splice connector separates the rails leaving a gap of 1/4” inch between the rail sections to accommodate thermal expansion.


WEEB DPF (Optional)

3/8” (Ref.)

Sunmodule Frame

1” Minimum

Sunfix Plus Mid Clamp

Sunfix Plus Rail Rail Splice

When placing solar modules onto Sunfix plus rails, it is important to keep the intersection of adjacent modules at least 1” away from the end of the rail at the splice joint, preventing the module frame from resting directly over the gap between spliced rails.

PV string wire pull box

A PV-string wire transition pull box rated for the intended use is located either below the PV array (if space allows) or along side the PV array onto the roof surface with the appropriate sealing considered. The pull box facilitates transi-tion for open PV array wiring to wiring in conduit and should not be attached to the support rail unless it is specifi-cally designed to do so and may only be attached onto the side rail slot with M8 T-bolts.

Modules in Series

Equipment Ground Conductor Lay-In Lug on Module

PressureTerminals

OutdoorPull Box

3/4” Conduit: (6) #10 THWN-2 Conductors, (2) #10 THWN-2 Ground

PV String Home Run Wiring Exposed to Free-Air:(4) #10 PV Wire or USE-2 Conductors, Rated for Outdoor Use,

(1) Bare Copper Ground, Shown.

Install the PV-String Home Run cables and route cables to their respective locations at each end of the ‘modules in series’ string.


Wire management

The PV string cables and module series interconnects should not be allowed to hang much below the support struc-ture of the solar array. Sufficient wire management devices are to be incorporated to prevent any wiring from near-ing the roof surface. PV array wiring can be neatly attached to the supporting rails by black cable ties (supplied with Sunkits)—outdoor rated for UV resistance and high-temperature services.

Wire clips/ties should be spaced approximately 12" apart - along the rail.

Equipment ground-bonding

Tools for Rail Grounding Devices (with Lay-in Lugs)

_ Socket wrench - 3/8” drive

_ 13 mm & 7/16” hex socket - 3/8” drive

_ Torque wrench 0-30 ft-lbs x 3/8” drive

_ Torque screwdriver 0-30 in-lbs

Equipment Grounding Grounding is required by the National Electric Code (NEC) for module frames and equipment racking (2008NEC 690.43). Therefore, it is necessary to use the provided grounding devices to connect all non-current carrying electri-cally conducting components to the Earth (ground) with wire sized per NEC 250.122. The contractor is responsible for ensuring professional grounding of the system and components.

Grounding method should result in an electrically continuous wire to each PV module and supporting metal struc-ture. However, if WEEB-DPFs are used, then only rails need to be bonded. Requirement in the NEC is to make a grounding connection first and break it last (250.124(A)). Consider a module with an internal ground fault to the frame. If WEEBs are used and the circuit conductors are left connected, and the module is unbolted from the ground-ed rack—disconnecting the frame grounding first rather than last—the module frame may be energized with up to 600 volts to the grounded rack.

Devices identified and listed for bonding the metallic frames of PV modules shall be permitted to bond the exposed metallic frames of PV modules to the metallic frames of adjacent PV modules. The equipment grounding conduc-tors shall be no smaller than #14AWG. Equipment grounding conductors for PV modules smaller than #6AWG shall comply with NEC art. 250.120C. If lay-in lugs are used for PV module grounding, it is recommended to attach these lugs onto each PV module prior to installation onto the racking system. Follow the SolarWorld Sunmodule installa-tion instructions for module grounding device attachment.


(CONTINUOUS)

PV array equipment grounding – example

1

2

Module corner ground (2.0/2.5 frame) detail "A"

4

3

5

2

1

Module frame (2.5) ground detail "B"

Item Description1) Grounding lay-in lug GBL-4EDBT (or Equivalent)2) Bolt #10-24 x 0.5", S/S

Item Description 3) Serrated lock washer #10, S/S1) Grounding lay-in lug GBL-4EDBT (or Equivalent) 4) Flat washer #10 S/S2) Socket head cap screw #10-24, 5/8", S/S 5) Nut #10-24, S/S

Sunkits are supplied with rail splice ground jumpers WEEB 8.0 and WEEB 8.0 lay-in lugs (Burndy LLC) for equipment


ground-bonding of all support rails. One WEEB lug 8.0 is needed at one end of each rail-row. Also, every rail splice con-nection will need the rail splice ground jumpers WEEB 8.0 attached as shown. WEEB "DPF" module grounding clips are supplied (as option with Sunkits) as an accessory item. Burndy LLC recommends that the sufficient details of the installation be submitted to the AHJ for approval before any work is started.

WEEB-DPF

SolarWorldPlastic Bolt Guide

SolarWorld M8 Bolt

SolarWorldMid-Clamp

Washer

SolarWorldChannel Nut

Pre-assemble WEEB-DPF to mid-clamp assembly as shown. Pre-assembling WEEB-DPF to mid-clamp assembly will contain the small individual parts, reducing the possibility of losing parts during installation.

Slightly lift solar module and slide it over theWEEB-DPF teeth and under the mid-clampassembly, ensuring the module frame isflush against the mid-clamp. WEEB teeth willautomatically be aligned under the edge ofthe module when mid-clamp assembly iscorrectly installed.


When position of solar modulesare finalized, torque fasteners to12ft-lb / 16.3 N-m using generalpurpose anti-seize compoundon threads.

Assemble WEEB 8.0 lay-in lug assembly and torque fasteners to 12 ft-lb / 16.3 N-m using general purpose anti-seize compound on threads.

WEEB teeth towards rail


WEEB 8.0 bonding strap


Even number of modules in a row

X Denotes Places to Install WEEB-DPF

XXXX

XXXX

X denotes places to install WEEB-DPF

Odd number of modules in a row

X Denotes Places to Install WEEB-DPF

XX XXXX

XX XXXX

X denotes places to install WEEB-DPF


Module installation

The modules are fastened to the support rails using the top clamps. A torque wrench is required to ensure the correct pressure of the clamp against the module frame. Remember to plug the modules together in series during mechani-cal installation. Warning: modules connected in series may result in dangerously high voltages! Wear insulating gloves when handling module interconnect cables.

_ Wire the modules using the approved electrical diagram.

_ Make sure to strictly observe the wiring diagram instructions (string size, AC/DC disconnects, wire size, etc.). Incorrect wiring may cause damage to or even destroy the grid connected inverter and/or modules.

_ In order to keep inductive coupling as low as possible in case of lightning strike, the home run cables (+/-) of the string shall be laid as closely to each other as possible (avoid loops).

_ The minimum bend radius of cables (5x cable diameter) must be observed in all situations.

_ Keep all plugs and sockets dry during installation.

_ Attach the cable to the rails using UV-resistant cable ties.

Note: in some cases tightly fastened stainless steel screws cannot be unscrewed without causing damage due to galling. Therefore, SolarWorld recommends the following steps to minimize these problems:

_ Keep the stainless hardware shaded, especially on hot days.

_ Use an anti-seize product.

_ Use lower speed settings on installation tools to reduce the applied heat.

_ Tighten all fasteners with a torque wrench to the recommended setting.


Mechanical Assembly

Step 1. Start at end, insert top clamp-bolt assembly into rail, add spacer.

Step 2. Position bolt end-spacer against first module frame, tighten end-clamp bolt to 15 ft-lbs torque.

Step 3. Insert mid-clamp bolt(s) into rail(s) then 1/4 turn CW to lock the ‘channel-nut’.

Step 4. Slide bolt firmly into position against module frame so that the plastic retainer touches.

Step 5. Place adjacent module firmly against bolt; torque all mid-clamp bolts to 15 ft-lbs (12 ft-lbs with WEEB-DPFs).

Step 6. Position bolt end-spacer against last module frame, tighten end-bolt to 15 ft-lbs torque.

Routinely check the bolt and connecting parts to make sure they do not become loose. SolarWorld recommends checking a minimum of every two years, to ensure that the required torque is maintained.


Sunfix® Plus 2 Top Clamp Selector Guide for Other Modules

The following top clamps for the Sunfix Plus2 roof mounting system are compatible with other PV modules with a frame thickness of 40, 42, 45, 46 and 50 mm.Make every solar installation the best it can be by starting with the right hardware. The Sunfix Plus 2 Top Clamp hardware for ‘end-clamp’ and ‘mid-clamp’ bolt assemblies is illustrated below. Determine the M8 T-Bolt (length) and End Spacer (height) requirements by selecting the appropriate item numbers, based on PV frame height, in the Top Clamp Selection table. The M8 Flange Nut and Clamping Washer are universal fits every top clamp bolt assembly, and are listed separately in the Common Parts table. All Sunfix Plus 2 Top Clamp hardware components are ordered as individual items in package increments of 100 pieces.

For installation compatibility, PV modules should be listed to UL1703 and conform to the following criteria:

Weight not to exceed 46.7 lbs (21.2 kg) Clamping surface not to exceed 1.38” width

Dimensions not to exceed 39.41” W x 65.94” L Module area not to exceed 18 ft2

Sunfix Plus 2 Top Clamp SelectionPV Frame Top Clamp T-Bolt M8 End Clamp - Spacer

Height (mm) * Item no. Description Item no. Description

40.00 SH0015 M8 x 60 mm SA5190 Spacer - 39.5 mm



46.00 SH0005 M8 x 65 mm SK5115 Spacer - 45.5 mm

50.00 SH0006 M8 x 70 mm SK5222 Spacer - 49.5 mm

End-Clamp Assembly

M8 flange nut (EC0496)

Clamping washer (SA5079)

End spacer (see table) alum.

T-bolt M8 (see table)




Mid-Clamp Assembly

* Standard tolerance on PV frame height not to exceed +/- 0.25 mm.


Sunfix® Plus 2 Top Clamp Selector Guide for Other ModulesAccessory PV module grounding, as shown as the WEEB-‘DPF’ option below, is available for PV module frames that fit within the dimensional guidelines of acceptable frame cross-sections listed by (Wiley) Burndy Corp. Please review the particular PV module MFR’s installation instructions for any restrictions pertaining to allowable grounding devices or minimum top clamping surface area requirements. Refer to the Sunfix Plus 2 installation instructions for WEEB placement locations for even or odd numbers of PV modules in a row.



WEEB “DPF” (option)


Common PartsItem no. DescriptionEC0496 M8 flange nut

SA5079 Clamping washer

Accessory ItemsItem no. DescriptionEC0534 WEEB DPF

NOTE:

Fasteners are grade A2 stainless steel.

Top clamps require 15 ft-lbs (20 nm) applied torque. If used with WEEB-DPF, recommend 12-ft-lbs.

T-bolts feature a directional slot indicating proper installation when slot is parallel to module frame.

Top Clamp Hardware Quantity EstimatorArray total qty of PV modules

T-bolt clamp assembly End clamp spacerPV-one row PV-two rows PV-one row PV-two rows

8 18 20 4 810 22 24 4 812 26 28 4 814 30 32 4 816 34 36 4 818 38 40 4 820 42 44 4 822 46 48 4 824 50 52 4 8

First Module

Sunfix plus Rail

Next Module

WEEB 'DPF' (Assembled)

0.875” Minimum

0.31” Minimum, 0.38” Maximum

Clamp Washer

M8 T-Bolt

End Clamp - Spacer

M8 Flange Nut


Standing seam metal roof installation

For metal standing seam roofs, the Sunfix plus rails, L-foot brackets and roof flashings are replaced with an S-5-U Mini clamp solution incorporating the Sunfix top clamp bolt as shown below. The top clamp spacer is only needed on the ends of rows. Module ground-bonding can be accomplished as described in the previous section with lay-in lugs. Grounding of the metal roof will be as governed by the local AHJ.

The S-5-U Mini is a medium-duty, non-penetrating seam clamp. Installation is as simple as placing the clamp on the seam and tightening the patented round-point setscrew to the specified tension. Then, affix ancillary items using the bolt pro-vided. S-5! ® clamps do not pierce metal roof paneling, thereby protecting roof coatings and preventing water intrusion.

A structural aluminum attachment clamp, the S-5-U Mini is compatible with most common metal roofing materials excluding copper. All included hardware is stainless steel.S-5-U Mini clamps are furnished with set screws, and a bit tip for tightening using an electric screw gun.

1.5” (38 mm)

0.9”(23 mm)

1.5”(38 mm)

1.18”(30 mm)

0.4” (10 mm)

0.54”(14 mm)

M8 HolesCenteredon Part

EC0181 S-5-UMini Clamp (M8 Thread)

M8 Bolt with TopWasher Attached.

SK0166 Silveror

SK0165 Black

SK0164 Silver Spaceror

SK0163 Black Spacer

EC0548 Flat Washer


Micro-inverter installation

Incorporate the following method for Sunfix plus rail mounting of micro-inverters. Install the hardware and L-bracket shown below to facilitate mounting from the side of the rail profile using the M8 T-bolt. This location does not pro-vide sufficient clearance between the back of the Sunmodule frame and inverter mounting hardware when exposed to heavy ice/snow loads.

1

3 2

4

5

Sunfix Plus 2 Rail(Note 1) Grounding Clamp

(REF)Enphase M215 Micro Inverter

Item No. Part No. Qty Description1 EC0605 1 Screw-truss HD, 5/16"- 18 x 0.75" S/S2 EC0606 1 Flange nut, 5/16" - 16 serrated S/S3 SH0001 1 T-bolt M8 x 20 S/S4 EC0496 1 Flange nut M8 serrated S/S5 EC0058 1 L-bracket, clear anodized

Notes:

1. Do not attach any hardware on top of rail directly under the solar module. Doing so may void module warranty.

2. Install Enphase inverter with 5/16" hardware as shown. Torque M8 and 5/16" bolts to a minumum of 10 ft-lbs.

3. Use M8 T-bolt and nut to attach the L-bracket to the rail as shown.

4. Micro-inverters or other components should not be installed onto the Sunmodule 2.5 frame without prior written consent from SolarWorld.


Maintenance and cleaning

Maintenance – annual

_ Electrical connections at pressure terminals set to proper torque.

_ Wiring conductors are properly & securely dressed with cable clips/ties to support structure, not dangling near roof surface or trapping debris.

_ Wiring conductors not damaged or rubbing against sharp metal edges which may cause removal or penetration of insulation.

_ Visually inspect solar modules for signs of damage to front glass surface or metal framework.

_ Visually check all hardware connection points for signs of loose or missing parts.

_ Mechanically check fasteners at connection points, insuring torque valves are per manufacturer's recommendations.

_ Visually inspect the solar array for signs of modules shifting.

Cleaning – semi annual

_ Cleaning schedules are dependent upon your system location, tilt angle, and weather patterns.

_ In general, the greater the roof inclination and yearly rainfall, the less cleaning a system will require.

_ It is advisable to clean your system with water (no cleaning agents) two times per year after initial installation, and then subsequently as needed.

_ In cases of heavy dirt and/or debris, more frequent cleanings and the use of an appropriate microfiber brush or sponge may be required.

_ Dirt must never be scraped or rubbed away when the modules are dry as this may cause micro-scratches, which have a negative effect on the module performance.

_ The condition of the PV array connections and plugs should be visually inspected at regular intervals.


Warranty

SolarWorld Americas LLC (“SolarWorld”) warrants to the original buyer (“Buyer”) at the original installation site, that any of the – ‘Sunfix plus®’ components (the “Product”) purchased from SolarWorld shall be free from defects in materials and workmanship for a period of ten (10) years from the date of shipment, except for the anodized finish which fin-ish shall be free from visible peeling, or cracking or chalking under normal atmospheric conditions for a period of five (5) years from the date of shipment (each, as appropriate, the "Warranty Period"). The warranty for the anodized Finish does not apply to any foreign residue deposited on the finish. All installations in corrosive atmospheric conditions are excluded. Buyer may transfer this Warranty to subsequent owners, or if Buyer is a contractor to the property owner, any subsequent transferee of which SolarWorld has advance notice, proof of purchase is required.

This Warranty covers only the Product, and not photovoltaic or PV modules, electrical components or wiring used in con-nection with the Product, or other products of SolarWorld. This Warranty shall be void if A) installation of the Product is not performed in accordance with the SolarWorld Product information, B) the Product has been modified, repaired, or reworked in a manner not previously authorized by SolarWorld in writing, or C) the Product is installed in an environ-ment for which it was not designed, each as determined in SolarWorld’s sole discretion.

If, within the Warranty Period, the Product shall be proven in SolarWorld’s sole discretion to be defective, then Buyer’s sole and exclusive remedy, and SolarWorld's only obligation for breach of warranty for Products hereunder, shall be, at SolarWorld's option in its sole discretion, to either repair or replace the defective Product, or any part thereof.Any such repair or replacement does not constitute a new Warranty Period, nor shall the Warranty Period of this Lim-ited Warranty be extended by any such repair or replacement. Buyer shall bear all costs of shipment or transportation related to the repair or replacement of the defective Product. Such repair or replacement shall be Buyer’s sole remedy under this Limited Warranty, and does not include on-site physical installation of repaired or replaced product and shall fulfill SolarWorld’s obligations with respect to this Limited Warranty. The provision of the above remedy shall be condi-tioned upon notification and substantiation as may be required by SolarWorld.

Warranty Limitations. The warranties and remedies for breach of warranty provided for herein extend only to use of Products at their site of original end user installation and do not cover, and SolarWorld shall not be liable for, (i) damage to the Product that occurs during its shipment, storage, and installation, (ii) any product, component, accessory or part not supplied by SolarWorld, (iii) abnormal wear and tear or damage, (iv) any cause beyond or not contemplated by the warranty and outside the reasonable control of SolarWorld, including conditions caused by movement, settlement or structural defects of the environment or other components in which the Products are installed, any conditions proxi-mately caused by intentional misconduct of others, improper use or third party negligence, or (v) damage proximately caused by anyone except SolarWorld employees, contractors or agents. If any provision of this Limited Warranty is held unenforceable or illegal by a court or other body of competent jurisdiction, such provisions shall be modified to the minimum extent required such that the rest of this Limited Warranty will continue in full force and effect.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES ARISING BY OPERATION OF LAW, TRADE OR COURSE OF DEALING INCLUDING, WITHOUT LIMITATION, IMPLIED WARRANTIES OR CONDITIONS OF TITLE, NON-INFRINGEMENT, MERCHANTABILITY, FITNESS OR SUITABILITY FOR A PARTICULAR PURPOSE, USE OR APPLICATION. SOLARWORLD SHALL HAVE NO RESPONSIBILITY OR LIABILITY WHATSOEVER FOR DAMAGE OR INJURY TO PERSONS OR PROPERTY OR FOR OTHER LOSS OR INJURY RESULTING FROM ANY CAUSE WHATSOEVER ARIS-ING OUT OF OR RELATED TO THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ANY DEFECTS IN PRODUCT, OR FROM USE OR INSTALLATION. SOLARWORLD'S TOTAL LIABILITY TO BUYER (REGARDLESS OF THE NATURE OF THE CLAIM) SHALL BE LIMITED TO THE TOTAL PURCHASE PRICE OF THE PRODUCTS PURCHASED FROM SOLARWORLD BY BUYER. UNDER NO CIRCUMSTANCES SHALL SOLARWORLD BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY TYPE, INCLUDING WITHOUT LIMITATION RELATING TO LOSS OF USE, LOSS OF PROFITS, LOSS OF PRODUCTION OR LOSS OF REVENUES.


Appendix

Sunfix plus racking system – sample layouts

Recommended module layoutsThe following drawings illustrate typical racking layout plans with SolarWorld ‘Sunmodules’. These layout drawings identify:

_ Where to start the first module

_ Approximate length of assembled rows

_ How much rail overhang is expected

_ Approximate location of rail splice connectors

_ Quantity of roof attachments recommended

_ How much rail cut-off may be needed-post install

The following module layouts are:

_ Sunfix plus2 Sample Layout 8 Modules, 1 Row of 8, 030025-A

_ Sunfix plus2 Sample Layout 8 Modules, 2 Rows of 4, 030026-A

_ Sunfix plus2 Sample Layout 10 Modules, 1 Row of 10, 030027-A





_ Sunfix plus2 Sample Layout 24 Module, 2 Rows of 12, 030032-A


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Sunfix plus2 Sample Layout 8 Modules, 2 Rows of 4, 030026-A.


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Sunfix plus2 Sample Layout 24 Module, 2 Rows of 12, 030032-A.

This page intentionally left blank.

SolarWorld France SASHôtel de l‘Entreprise, Petite Halle, Bouchayer-Viallet31, rue Gustave Eiffel38000 GrenobleFrance

SolarWorld Africa Pty. Ltd.20th Floor1 Thibault SquareKapstadt, 8001South Africa [email protected] solarworld-africa.co.za

SolarWorld Asia Pacific Pte. Ltd.72 Bendemeer Road#07-01, LuzerneSingapore 339941Singapore

Production and sales locations of the SolarWorld group

SolarWorld Ibérica, S.L.C/La Granja 15, Bloque B-1°B28108 Alcobendas, MadridSpain

SolarWorld Americas LLC4650 Adohr LaneCamarillo, CA [email protected]

SolarWorld AGMartin-Luther-King-Str. 2453175 BonnGermanyPhone: +49 228 55920 0Fax: +49 228 55920 [email protected]

solarworld.comSW-0

4-51

22U

S 11

-201

2

Location Distributor

Rheinfelden Freidberg

Bonn

Grenoble

Madrid

Cape Town

Singapore

Boca Raton

Hillsboro

Camarillo

February 2012

Installation Best Practices

America’s largest solar manufacturer since 1975

2 Installation best practices February 2012

Table of Contents

Purpose 4

Scope 4

Distribution list 4

Terms 5

PV 101 6

Basics of electricity 6

Series and Parallel 6

PV Basics 6

Types of PV Systems 6

Solar Resource 11

Qualifications 16

Customer qualifications 16

Site qualifications 17

Site upgrades/cost adders 17

Other considerations 17

Site assessment 18

Solar resource 18

Site demand 22

Area limitations 23

Site details/location questionnaire 26

System location information 26

System installer information 26

Pricing information 27

Utility bill information 27

System characteristics 28

Roof characteristics 28

Rafter information 29

Structure information 29

Loading requirements 30

Wiring requirements 31

Specific request/adders 31

Additional information 32

Array layout 32

Signature 33

Installation best practices February 2012 3

Table of Contents (cont'd)

Design rules 34

Safety 34

Financial investment 35

System efficiency 35

Aesthetics 36

Mounting solutions 37

SolarWorld provided designs 38

Mechanical integration 39

Safety 39

Tools (general) 40

Tools (Sunfix plus) 40

Layout 41

Penetrations 44

Composition 45

UNIRAC SolarMount 53

Solar module handling/installation 53

Electrical integration 54

Electrical safety 54

Electrical components 55

SMA 64

PVPowered 64

Enphase 65

Suntrol system monitoring 65

Operation & maintenance 68

Introduction 68

Major system & component list & definitions 69

System specifications 70

System startup & testing 70

System verification 70

Inverter start-up & shut-down procedures (energizing/decommissioning) 71

Safety considerations 71

Routine maintenance schedule 72

Recommended maintenance tools 72

Warranty 73

Troubleshooting 74

Audit form - example 79


Purpose

Define the rules, guidelines, best practices and instructions for successful evaluation, design, installation and mainte-nance of a SolarWorld Sunkit.

Scope

SolarWorld is committed to providing high quality products and the best solutions for system owners – including modules, projects and Sunkits® systems. These solutions begin with accurate and detailed site assessment and evaluation. A quality system design must incorporate safety first and foremost, followed by a balance of financial re-turn, system efficiency, and aesthetics. As with any building component, it must be understood that there is as much art as there is engineering in the design of a quality solar electric system. Sunkits is a SolarWorld brand solution and while there may be many opinions on best practices for solar installations, systems that are approved or certified with a SolarWorld Sunkits brand should adhere to SolarWorld standards of system design and installation practices to ensure quality for current and future system owners. A Sunkits, and any PV system, is intended to last a minimum of 25 years. In reality, SolarWorld anticipates the solar array may produce valuable energy for twice as long. Such a term of operation must be understood during system design and installation process.

Disclaimer of LiabilitySince the use of this guide and the conditions or methods of installation, operation, use and maintenance of the module are beyond SolarWorld control, SolarWorld does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected with such installation, operation, use or mainte-nance. The information in this guide is based on SolarWorld’s knowledge and experience and is believed to be reli-able; but such information including product specifications (without limitations) and suggestions do not constitute a warranty, expressed or implied. SolarWorld reserves the right to make changes to the product, specifications, or guide without prior notice.

Distribution list

Sunkits sales, customer service, marketing, engineering teams, and contractors.


Terms

Solar Module/Solar Panel – These are interchangeable terms as they have come to mean the same thing. Historically groups of smaller solar modules were pre assembled on rails or into a larger panel assembly. (a solar panel referred to panelized modules)

kWh per kw – kiloWatt hours produced per kilowatt of solar. This is a benchmark that indicates how much power a system produces for a given unit of its size. (This is sort of like miles per gallon) Generally this is a better comparison of solar products as it better accounts for real world performance where lesser products may appear similar in lab tests but given time will produce less.

Load - This is a device that consumes energy. Examples: Toaster/AC unit/Microwave/Lights/Water Heater.

Battery - An energy storage device. Typically lead acid but newer chemistries are gaining traction.

Note: Most PV systems do not need or include any batteries.

Generator - A device that converts one form of energy into another, typically electricity. Sometimes we refer to solar systems as power generators. Commonly gasoline, natural gas or diesel generators consume fuel to generate electric-ity for loads when not connected to the grid or when the grid is down.

Solar Noon - when the sun is perpendicular to a solar array such that the most intense sunlight is striking the array.

Efficiency - This is measurement of energy generated from (potentially) available light as compared to the surface area of your solar module/s. With crystalline silicon solar modules it is about 14-16%. Typically crystalline silicon mod-ules produce nearly 50% more energy than comparably sized thin film modules. Be sure to compare solar systems by overall performance, reliability and value.

STC - This stands for Standard Test Conditions which is a set of specifications that solar manufacturers use to test and compare products.

1,000W/m², 25°C, AM 1.5. Most PV systems are bought or sold based on STC DC wattage but actual PV system AC out-put is reduced due to site variables, wiring and conversion losses.


PV 101

Basics of electricity

AC stands for alternating current and refers to electrical systems where the voltage and current are constantly chang-ing between a positive and negative value. Common residential electrical service is 240 volts AC split phase to 120 volts AC.

DC stands for direct current and refers to electrical systems where the voltage and current are steady over time. PV modules produce DC electricity.

Voltage is electrical potential, in units of volts (V). Analogous to hydraulic pressure (current multiplied by resistance = I x R).

Current is the flow of electrical charge, in units of amperes (I). Analogous to hydraulic flow (wattage divided by volts = W/V).

Power is an instantaneous quantity, the rate of transferring work or energy. Electrical power is expressed in units of watts (W) or kilowatts (kW) (current (amps) multiplied by voltabe - I x V).

Energy is the total amount of work performed, accumulated over time.

_ Electrical energy is expressed in units of watt-hours (Wh) or kilowatt-hours (kWh).

_ Energy (Wh) = Avg. Power (W) x Time (h).

Example (power consumption):A 100 watt light bulb on for 10 hours would consume a total amount of energy of 100 watts x 10 hours = 1,000 watt-hours or 1 kWh (kilo - 1,000).

Example (power generation):A solar array producing 1,000 watts and operating at this rate for 5 hours would generate a total amount of energy of 1,000 watts x 5 hours = 5,000 watt-hours or 5 kWh.

Summary:V = I x RP = I x V = I2 x R = V2 / RE = P X T


Series and parallel

SeriesWhen connecting devices in series the positive of one source is connected to the negative of another. The voltage of each component adds to the next while the current flow is constant through all of the components (voltage increas-es, current remains the same).

ParallelWhen connecting devices in parallel the positives of all sources are connected together and the negatives are all connected together. The current of each component adds to the next while the voltage remains constant (current increases, voltage remains the same).


PV basics

Photovoltaic (PV) technology is a method of generating electrical power by converting solar radiation into direct cur-rent electricity using semiconductors that exhibit the photovoltaic effect.

The building blocks that make up a photovoltaic system start at the cell level and build to an array.

Cell

The photovoltaic cell generates DC electricity when exposed to sun light. A typical silicon solar cell produces about 0.5 volts and up to 8 amps. These devices are the basic building block of a PV module.

Module (Panel)

The PV module is the smallest practical unit that can do work in real world applications. SolarWorld mod-ules come in 36 cell and 60 cell versions.

Array

A mechanical integrated assembly of modules with a support structure, foundation, and other compo-nents, as required, to form a direct-current power-producing unit.


Types of PV systems

Stand-alone or off-grid systems operate independent of the utility grid. These systems are commonly used when the costs of extending utility service and other power generating means are not practical such as for a recreational vehicles, temporary traffic signs and/or cost-prohibitive as in remote locations such as telecommunications or oil and gas pipeline monitoring. These systems may or may not use energy storage devices, such as batteries, and may power DC and/or AC loads.

Grid tied or utility-interactive systemsThese systems are interconnected, in parallel, with the utility grid.


Residential Commercial Utility

Bi-modal systems These systems may operate in either utility-interactive or stand-alone mode, but not concurrently.


Solar resource

Irradiance is the intensity of solar power and is commonly expressed in units of watts per square meter (W/m2). Typi-cal peak value is 1000 W/m2 on a surface facing the sun at solar noon and is referred to as “Peak Sun.” This value is used to rate PV modules and arrays.

Irradiation is the total amount of solar energy accumulated on an area over time and is commonly expressed in units of watt-hours per square meter (Wh/m2). Insulation is the measure of energy collected over the period of the day.

Peak sun hours are a tool for solar production extimation purposes. Actual system performance increases and de-creases in response to solar intensity, (increasing from sunrise to noon and then decreasing to sunset) this amount of energy is reformatted to imagine a system at full production for a given amount of hours at a given site. To estimate a given solar systems output, several resources list each regions historical measurement of solar resources expressed as sun hours, this can be used along with specific design factors to estimate production.


Example:The solar power incident on a surface averages 400 W/m2 for 12 hours. How much solar energy is accumulated?400 W/m2 x 12 hours = 4800 Wh/m2 = 4.8 kWh/m2 = 4.8 PSH

A PV system produces 6 kW AC output at peak sun and average operating temperatures. How much energy is produced from this system per day if the solar energy received on the array averages 4.8 Peak Sun Hours?6 kW x 4.8 hours/day = 28.8 kWh/day

I-V characteristicsThe current-voltage (I-V) curve defines the electrical performance characteristics of a photovoltaic device. The curve repre-sents an infinite number of current-voltage operating points, and varies with solar radiation and cell temperature.

PV device performance is given by the following IV parameters:

_ Voc open-circuit voltage_ Isc short-circuit current_ Vmp maximum power voltage_ Imp maximum power current_ Pmp maximum power

SW‑02‑5002US 05‑2011

SW 245 mono / Version 2.0PERFORMANCE UNDER STANDARD TEST CONDITIONS (STC)* PERFORMANCE AT 800 W/m², NOCT, AM 1.5

Maximum power Pmax

Open circuit voltage Voc

Maximum power point voltage Vmpp

Short circuit current Isc

Maximum power point current Impp

SW 245245 Wp

37.7 V30.8 V8.25 A7.96 A

Maximum power Pmax

Open circuit voltage Voc

Maximum power point voltage Vmpp

Short circuit current Isc

Maximum power point current Impp

SW 245179.1 Wp

34.4 V28.1 V

6.65 A6.37 A

COMPONENT MATERIALS

Cells per module 60Cell type Mono crystallineCell dimensions 6.14 in x 6.14 in (156 mm x 156 mm)Front tempered glass (EN 12150)Frame Clear anodized aluminumWeight 46.7 lbs (21.2 kg)UL Maximum Test Load** 50 psf (2.4kN/m²)IEC Maximum Snow Test Load** 113 psf (5.4kN/m²)

*STC: 1000W/m², 25°C, AM 1.5

THERMAL CHARACTERISTICS

NOCT 47 °CTC Isc 0.042 %/KTC Voc ‑0.33 %/KTC Pmpp ‑0.45 %/K

SYSTEM INTEGRATION PARAMETERS

Maximum system voltage SC II 1000 VMax. system voltage USA NEC 600 VMaximum reverse current 16 AMax. mechanical load 5.4 kN/m²Number of bypass diodes 3

ADDITIONAL DATA

Measuring tolerance2) +/‑ 3 %SolarWorld Plus‑Sorting3) PFlash ≥ Pmax

Junction box IP65Connector MC4Module efficiency 14,6 %Fire rating (UL 790) Class C

65.94 (1675)

39.41 (1001) 1.22 (31)

41.34(1050)

1) Sunmodules dedicated for the United States and Canada are tested to UL 1703 Standard and listed by a third party laboratory. The laboratory may vary by product and region. Check with your SolarWorld representative to confirm which laboratory has a listing for the product.2) Measuring tolerance is used conjunctions with the SolarWorld Limited Warranty. SolarWorld AG reserves the right to make specification changes without notice.3) The output identified by SolarWorld (PFlash) is always higher than the nominal output (Pmax) of the module. PFlash is the power rating flashed at a SolarWorld manufacturing facility.4) All units provided are imperial. SI units provided in parentheses.

0.6 (15.3)

0.6 (15.3)

0.5(12.65)

Minor reduction in efficiency under partial load conditions at 25°C: at 200W/m², 95% (+/‑3%) of the STC efficiency (1000 W/m²) is achieved.

**Please apply the appropriate factors of safety according to the test standard and local building code requirements when designing a PV system.


Response to solar irradiance

Example:Q: The Sunmodule SW245 produces 245 watts maximum power at 1,000 W/m2. What would the maximum power

output be under 600 W/m2 irradiance?

A: Power output is generally proportional to irradiance, therefore the maximum power at 600 W/m2 irradiance would be:

245 W x 600 / 1,000 = 147 Watts

Response to temperatureSolar module voltage has an inverse relationship to temperature changes. This means an increase in temperature results in a decrease of voltage where as a decrease in temperature results in an increase in voltage. Solar module current changes as well, but not very much. Current increases as temperature increases and decreases as tempera-ture drops.


Example:_ Q: What would the open-circuit voltage be for the SW245 module operating at 0°C?_ A: The open-circuit voltage at 0°C is calculated by:

= 37.7 V + [-0.0033/°C x (0 - 25)°C x 37.7 V] = 37.7 V + 3.11V = 40.81 V

I-V curve for similar PV devices in series

I-V curve for similar PV devices in parallel


Qualifications

Accurately qualifying a site is the best way to increase sales per sales call and avoid time delays proposing systems that are doomed from the start. The below questions can help determine if the customer is a prime candidate for a new solar system. By answering “yes” to the majority of the questions in this section would be a good indication that the customer has the best chances of being a qualified solar customer.

Customer qualifications

Solar electric systems have can have very high initial costs. An average residential system (5 kW) cost is about $25,000 prior to rebates and incentives, larger commercial systems (> 25 kW) can be $100,000 and above.

Does the customer have a clear financial solution for the installation (cash or credit)?

Is the average monthly electric bill greater than $ 100+ per month?

Is the customer expecting utility rates to increase significantly in the future?

Is the customer willing to install solar strictly from an environmental benefit perspective?

Site qualifications

Solar electric systems require maximum sun exposure for best performance (southern exposure with little or no obstructions).

Is the customer willing to put solar panels on the optimum solar exposure roof, even if that means the front of the house?

Is the area free from trees, utility poles, chimneys, satellite dishes, antennae or other buildings invading the solar view?

Is the customer willing to move or remove any obstructing objects?

Will the current roofing material last at least 15 years before requiring replacement?

Is the roofing material tough enough to handle the installation process (e.g., Spanish tile roofs are easily breakable)If either of the two above responses are “no,” is the customer willing to pay for the re-roof of the array area and/or entire roof?

Is the building structure substantial enough to handle the added loads of the solar modules?

*Most pre-fabricated structures are not designed to have added loads retrofitted to the structure.

If the roof structure is not sufficient, is there satisfactory area available for a ground mounted system?

*Flat roof and metal structures often require additional structural engineering, particularly when joist spacing is greater than 4 ft.

If flat roof installation requires bracing, are the joists easily accessible?


Site upgrades/cost adders

Main panel source circuits can be equal up to 120% of the rated Amps of the buss bar.

Is there sufficient space in the existing breaker panel to add the required system breaker?

If no to the question above, is there room and funding available for a panel upgrade or line or load side tap?

Is there a clear solution for roof access if required?

Is there a clear solution for terrain modification if required?

Is there room on site, and in the budget, for large equipment if required?

Other considerations

Metal roofing, particularly corrugated metal roofs, are very difficult to waterproof during retrofits.

The customer should be aware that grid connected solar electric systems DO NOT provide power if the utility power goes out.


Site assessment

Once the site has been generally qualified as a potential installation deeper assessment is required to help determine what size system is best for that location. The key factors for site assessment are:

_ Solar resource – how much sun?_ Site demand – current energy consumption and rates_ Area limitations – roof or ground area

Solar resource

There are a number of ways to determine Solar Resources below are three of the most common solar resource solu-tions in increasing detail.

PV Watts

“PV Watts” is a program developed by the National Renewable Energies Laboratory (NREL) to help determine solar re-sources throughout the United States. There are 2 versions of the tool Version 1 and 2. Version 1 is the simplest to use and is generally fairly accurate. Version 2 extrapolates more detail for specific areas based on the same data found in Version 1, but is more complicated to work with and doesn’t give significantly more detail. Version 1 can be found here: http://rredc.nrel.gov/solar/calculators/PVWATTS/version1/.

For general estimating in your area it is good to look at a 1 kW system with a tilt equal to the latitude facing due south. PV Watts defaults to a 77% derate factor but for SolarWorld systems we would recommend entering 85% sys-tem efficiency for the reasons below.


PV Watts defaultCalculator for Overall DC to AC Derate Factor

Benefits of SolarWorld's Sunmodule Plus sorting Adjustments due to actual module and

system performanceCalculator for Overall DC to AC Derate Factor

Component Derate Factors

Component Derate Values

Range of Acceptable Values

Component Derate Factors

Component Derate Values

Range of Acceptable Values

PV module name-plate DC rating

0.950 0.80-1.05 Due to Plus sorting, minimum is 100 %

PV module name-plate DC rating

1.000 0.80-1.05

Inverter and Transformer

0.920 0.97-0.98 CEC average inverter efficiency is 94.62 %. Current SMA inverters average is 99 %

Inverter and Transformer

0.950 0.88-0.98

Mismatch 0.980 0.97-0.995 Due to Plus sorting, average is > 99 % Mismatch 0.990 0.97-0.995

Diodes and connections

0.995 0.99-0.997 Diodes and connections

0.995 0.99-0.997

DC wiring 0.980 0.97-0.99 1.5 % voltage drop standard DC wiring 0.980 0.97-0.99

AC wiring 0.990 0.98-0.993 AC wiring 0.990 0.98-0.993

Soiling 0.950 0.30-0.995 This can vary by site; high rain = less issue Soiling 0.950 0.30-0.995

System availability 0.980 0.00-0.995 System availability 0.980 0.00-0.995

Shading 1.000 0.00-1.00 Site specific Shading 1.000 0.00-1.00

Sun-tracking 1.000 0.95-1.00 Sun-tracking 1.000 0.95-1.00

Age 1.000 0.70-1.00 Linear Guaranty is 7 % per year Age 1.00 0.70-1.00

Overall DC to AC derate factor

76.979 % Overall DC to AC derate factor

84.523 %

The output will give general information of how many kWh/kW a SolarWorld PV system will produce over 1 year and can be used as a rule of thumb for your area. Below is an example of Colorado Springs, Colorado.

Station Identification ResultsCity: Colorado Springs

MonthSolar Radiation (kWh/m2/day) AC Energy (kWh) Energy Value ($)

State: Colorado 1 4.81 131 11.0Latitude: 38.82° N 2 5.30 128 10.75Longitude: 104.72° W 3 5.84 152 12.77Elevation: 1,881 m 4 6.09 149 12.77PV System Specifications 5 5.94 146 12.26DC Rating: 1.0 kW 6 6.18 141 11.84DC to AC Derate Factor: 0.850 7 5.97 139 11.68AC Rating: 0.9 kW 8 6.23 147 12.35Array Type: Fixed Tilt 9 6.32 147 12.35Array Tilt: 38.8° 10 6.03 150 12.60Array Azimuth: 180.0° 11 5.15 130 10.92Energy Specifications 12 4.44 118 9.91Cost of Electricity: 8.4 /kW Year 5.69 1679 141.04

The PV Watts table shows that in Colorado Springs, an optimum system would produce about 1,700 kWh/kW which can be used as a good rule of thumb for system production in that area.

Energy production may decline slightly from the basic estimate when micro climates, shading, orientation and tilt angle are actually assessed. Often the decrease is not as much as would be expected for orientation and array tilt adjustments. These are worth investigating through the PV Watts calculator for deeper knowledge of those impacts. Below is the same location and system size facing Southeast at a 22.5 degree tilt (5-12 pitch roof) and only shows a decrease of ~100 kWh/kW.


Station Identification ResultsCity: Colorado Springs

MonthSolar Radiation (kWh/m2/day) AC Energy (kWh) Energy Value ($)

State: Colorado 1 3.64 98 8.23Latitude: 38.82° N 2 4.34 104 8.74Longitude: 104.72° W 3 5.31 139 11.68Elevation: 1,881 m 4 6.12 152 12.77PV System Specifications 5 6.46 161 13.52DC Rating: 1.0 kW 6 7.15 166 13.52DC to AC Derate Factor: 0.850 7 6.66 157 13.19AC Rating: 0.9 kW 8 6.51 155 13.02Array Type: Fixed Tilt 9 5.96 140 11.76Array Tilt: 22.5° 10 5.10 128 10.75Array Azimuth: 135.0° 11 3.96 99 8.32Energy Specifications 12 3.23 84 7.06Cost of Electricity: 8.4 /kW Year 5.37 1583 132.97

Significant shading can have a much greater impact on performance and is harder to estimate without the proper tools.

Solar pathfinderMany rebate incentives require a detailed shade analysis to approve the rebates for the system. The Solar Pathfinder is one tool for determining solar resources at a site. While it tends to be a more manual process, it has the ability to provide real time feedback and help with array location choices.

The solar pathfinder:

_ Set-it-and-forget-it magnetic declination correction_ Equipped with a compass and bubble level for orientation calculations_ Allows for continual shading percentage calculations for a specific location_ Provides you with a hard copy of each skyline taken immediately_ Instantaneous read outs of time of shading issues

Optional software that calculates all your solar needs just by uploading a picture.


_ Provides before-and-after shading contrast for obstacles_ Solar insolation (in kWh/m2/day)_ Percentage of sunlight_ Altitude and azimuth (orientation)_ AC energy (kWh)_ California rebate compliant

Solmetric SunEye™The Solmetric SunEye™ uses a digital camera to automatically provide shading analysis for an installation. The out-puts are compatible with many rebate programs.

_ A compass and bubble level for orientation calculations_ A fish eye camera lens incorporated with a PDA_ Software that overlays the picture you’ve taken with the sun path chart for your location _ Multiple, instantaneous shade results


Software is computer compatible

_ Usage is simple_ Large storage and ease of edit ability. _ Straightforward calculating and report generation _ As well as basic computations:_ Tilt or pitch_ Azimuth_ Magnetic declination

Site demand

Utility rate structures can be extremely complicated but there are 3 basic forms of rate structure that can have differ-ent impacts on PV system payback.

_ Tiered rates_ Time of use (TOU)_ Demand based

Tiered rate

Tiered rate structures are the most common residential rate structure. Some utilities use them differently. In many states, the more energy consumed above a set base rate are charged higher $/kWh. These tend to be the most cost effective rate structures for PV systems. By offsetting the more expensive power in the higher tiers, the payback time for the PV system can be accelerated.

Time of use (TOU)

Time of use rate structures generally vary the $/kW cost by time of day and time of year usage. This is also very common among both residential and commercial billing. Close attention should be paid to these types of rates and can be very difficult to predict payback value since the site generated energy will vary in value based on the time of production.

Demand based

Demand based utility charges actually charge more for the kW and only very little for the kWh. These do not gener-ally work as well for direct payback, since the PV provides kWh and may not significantly affect the kW demand of a site. This rate schedule is most common for commercial and industrial customers since the rate schedule allows for a more leveled monthly bill for ongoing business.


Correlation between demand charges and potential savings from PV. NREL Technical Report, NREL/TP-6A2-46782, June 2010. The Impacts of Commercial Electric Utility Rate Structure Elements on the Economics of Photovoltaic Systems.

For both TOU and Demand based rate schedules, it may be worth investigating alternative rate schedules that the local Utility might provide. Many utilities have adopted Solar Rate schedules for these customers to help balance out the inefficiencies of those rates for payback on PV systems that overall help the Utility provide power to their custom-ers. The goal would be to reduce the percentage of the bill that is attributed to demand and shift that percentage to the energy (kWh) usage.

Area limitations

Limitation of available space for mounting the PV modules can be a major limiting factor. In each of the three basic types of installation, pitched roof, flat roof, and ground mount, there are space limiting factors that need to be considered and can reduce the options for installation. These can be in addition to the external shade structures like trees and other buildings avoided in the shade analysis.

Pitched roof limitations

Avoid minimum of 3 ft around edges, eaves, and ridges for fire safety and access. Be aware of site shading concerns that may not be obvious like vent pipes, chimneys, higher roofs satellite dishes, and antennae. Even small shading of these can have greater detrimental impact on system performance than a shade analysis will determine.

Rafter locations and faux rafters can limit the area of penetrations and therefore the array size as well.

Flat roof limitations

For commercial flat roofs, the edge spacing may need to be greater due to parapet walls shading and local access requirements.

Be aware of roof top obstructions that can cause large shading arcs to avoid, like skylights, air-conditioning and com-pressor units.

Note water shed points and drains to be sure the array will not impede the water flow off of the structure.

Many jurisdictions require maintenance paths of 6 ft for every 50 ft of array area, these should be considered wheth-er required by local code or not.


Ground mounted limitations

Due to the low height of ground mounted arrays, tall obstructions will have greater impact on performance. Note tree lines and buildings. A good rule of thumb is to keep the array a distance of 2x the height of an object away from that object.

Be aware of underground utility concerns like water, gas, sewer, and power lines before assessing array size optionsWater management needs to be considered for ground mount installations as well; how water will drain and how it will be managed.

Many ground mount installations require barriers to entry for safety and security of the system. This should be noted during assessment as well since any fence will need to be a certain distance away from the array to avoid shading.

Array layout for all situations is best started by choosing rectangular areas and maximizing the array sizes based on simple geometry. Once a rectangle is determined, use the dimensions of a module plus mid clamps as a simple rectangle dimension.

For pitched roof installations, how many module rectangles will fit in the available array rectangle is the easiest way to determine maximum potential array size.

For flat roof and ground installations, it is important to size the array in conjunction with the mounting solution choice. Since tilted modules in consecutive rows may cause shading from row to row, some basic trigonometry can help evaluate the unit rectangle. The safest assumption is that a tilted module will cast a shadow straight back, elongating the “module rectangle” used for array size calculation. Worst case scenarios for row to row shading will be determined by the Sun angle in the sky on the shortest day of the year at the time of day you want to be sure the modules will be receiving full Sun. 10 AM is an acceptable time of day but many will use 9 AM as a worst case scenar-io. Sun angle can be determined via web based tools like www.nrel.gov/midc/solpos/solpos.html. Once determined, the Sun angle can be used in a local area with general confidence on all layout estimates.


Latitude (°N) 49.3 47.0 44.8 42.5 40.3 38.0 35.8 33.5 31.3 29.0 26.8 24.5 22.3 20

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Distance from front of 1 row of modules to the front of the next row of modules (inches, d)

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Altitude angle of the Sun at 10 AM at sea level on December 21st, (degrees, b)

12 14 16 18 20 22 24 26 28 30 32 34 36 38

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Site details/location questionnaire

Once the site is assessed as a viable solar installation site documenting and recording key bits of information is ex-tremely important. Below is a review of the SolarWorld Location Questionnaire and it’s contents.

Instructions:

All fields must be filled in by a certified and bonded contractor. Extra information relating to Sunkits System Installa-tion is welcome. Appropriate design is based upon accurate information provided. If you are unsure of an appropriate response, please refer to the Location Questionnaire Guide for more details and training. Enter “DNK” (Do Not Know) or “NA” (Not Applicable), for item not related to this specific installation. SolarWorld America will only respond to requests submitted via approved Sunkits distributors and that are responsive to the instructions or requests herein.

System location information

1. System Location Information

Please submit to [email protected]

Project/Homeowner Name:

Location Type:

Address: City: State: Zip:

County:

Email:

Phone:

Form # : 1-12.30.2011Page 1

Location Questionnaire

All fields must be filled in by a certified and bonded contractor. Extra information relating to the Sunkits® System Installation is welcome. Appropriate design is based upon accurate information provided. If you are unsure of an appropriate response, please refer to the location Questionnaire Guide for more details and training. Enter “DNK” (Do Not Know) or “NA” (Not Applicable) for items not related to this specific installation. SolarWorld Americas will only respond to requests submitted via approved Sunkits® distributors and that are responsive to the instructions or requests herein.

Federal Income Tax Rate:

State Income Tax Rate:

Defaut to 28%

Default to 9%

Customer tax rate information is usedfor accurate financial analysis only

Residential* Commercial* Municipal Non Profit

4. Utility Bill Information - for Return On Investment / Payback Proposal

2. System Installer Information

Installer Contact Name:

Installer Company Name:

Address: State: Zip:

Phone:

Contractor License Number:

Distributor Name:

Branch/Location:

SolarWorld Sales Representative:

Distributor Contact Name:

Phone #:

Email:

Installation Price of ($/DC Watt): Default ($7.25) Total Installed Price:

3. Pricing Information

Kwh Total $ KW (demand)

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Supply as much usage information as possible for each month. At least 1 full year of information preferred. If only one month supplied, enter in correct month of the year. Demand infomation for Commercial billing only (required for Proposal).


This Year Last Year

Utility/Provider (required for Proposal):

Current Rate Schedule (required for Proposal):

Rate Type (found on your electric bill or statement, i.e., “domestic,” TOU-1?); (required for Proposal):

City:

* See page 3 for sample sketch (3a for Residential; 3b for Ground Mount; 3c for Commercial)

This contact information is used by SolarWorld to communicate warranty, productupdates, o©ers and other information related to the Sunkits system installed.

The system location information is required for general information. This is the actual site of the proposed solar array. It is specifically used for design calculations and to allow SolarWorld to use satellite map data to assist in the design of the system tax rate are important to most accurately determine the rebates and tax credits. SolarWorld will always default to the best financial solution.

System installer information




Location Type:


County:

Email:

Phone:

Form # : 1-12.30.2011Page 1





Defaut to 28%

Default to 9%








Phone:


Distributor Name:

Branch/Location:



Phone #:

Email:




Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec



This Year Last Year




City:



The installer information is required in order for SolarWorld to use as a primary contact and to accurately assign job numbers and shipping information. An active contractor license and approved classification or type is required for SolarWorld to proceed. The type of license required may vary by region so check with your local building department. The distributor information is required for pricing, shipping, etc.


Pricing information




Location Type:


County:

Email:

Phone:

Form # : 1-12.30.2011Page 1





Defaut to 28%

Default to 9%








Phone:


Distributor Name:

Branch/Location:



Phone #:

Email:




Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec



This Year Last Year




City:



This is the price per watt or the total installed amount the installer is intending to charge for the full installation of the Sunkit. This price will be used to calculate financial information for any Return on Investment/Payback Proposals supplied by SolarWorld.

_ The default amount will be $7.25/W if no alternative is provided_ Sample: 3,185 W x $7.25/W = $23,091.25 installed system price_ Or 13 modules x 245 W/module x $7.25/W = $23,091.25

Tax rates are important to most accurately determine the rebates and tax credits. SolarWorld will always default to the best financial solution.

Utility bill information




Location Type:


County:

Email:

Phone:

Form # : 1-12.30.2011Page 1





Defaut to 28%

Default to 9%








Phone:


Distributor Name:

Branch/Location:



Phone #:

Email:




Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec



This Year Last Year




City:



This information is required for any return on investment/proposals supplied by SolarWorld, in addition to accurate sizing and designing of the system to offset the customer’s utility bill. Generally, the prospective system owner can obtain a year-long historical data from their utility website. Filling in the table makes for expedited processing and sending a copy of an electric bill to accompany the questionnaire is helpful.

A. Utility/Provider – Found on Utility BillB. Current Rate Schedule – Found on Utility BillC. Rate Type – Found on Utility Bill, i.e., “Domestic,” “TOU-1”

This information is used to determine current rates and rebates available.


System characteristics

Form # : 2-12.30.2010


5. System Characteristics

6. Roof Characteristics

Roof Pitch (i.e., 5-12) or Tilt Angle (22.6º): True Orientation (in degrees 0˚-360˚):

Module Mounting: (For ground mounted, enter requested angle, defaultto 20, and use true N-S direction, not compass reading)Roof Ground* Tilt Angle: Orientation:

Asphalt/Composition Shingle

7. Rafter Information

Rafter Spacing (inches on center):

Rafter Cross Cut Dimensions (2 x 4, 2 x 6, 2 x 8):

Horizontal RaftersVertical Rafters

10. Wiring Requirements

Grid Voltage (required): 240 V 208 V 277 V 480 V Other:

Existing Panel Size:

Distance from Array to Inverter (ft): Distance from Inverter to Main Panel (ft): Wire routing distance (ft):

Bus Bar Rating: Main Breaker Size:

9. Loading Requirements (per ASCE 7-05, IBC)

Wind Loading Class: Max Wind Speed (mph):C D Wind and Snow DataB

Seismic Loading

Average High Temperature (ºF):

Temperature information is available at www.weather.com.

Record Low Temperature (ºF): Record High Temperature (ºF):

Zone: Snow Load (lbs/ft2):0 2A 2B 3 4 5 Seismic Map1

Concrete S-TileConcrete Flat Tile Spanish Tile Other:

Metal (Standing Seam)

Flat Roof

Gauge: Manufacturer:

Material:

8. Structure Information

Base Elevation in feet (above sea level):

Maximum Building Height in feet (ground level to highest ridge):

Proposed System Size: DC Watts (Total number of modules multiplied by the module STC Watts; see LQ Guide for suggested system sizes)

Requested Number of Modules:

11. Specific Requests/Adders (specific requests may e�ect pricing, and may be adjusted to ensure appropriate system, mounting, or availability requirements)

Module: Black Mono Poly

Mounting: ProSolar® UniRac®Sunfix® Other

Stando¦ Height: 3 Inches 4.5 Inches 6 Inches 7.5 Inches

Inverter Request: SMA® PV Powered® EnPhase® Quantity:

Monitoring: SMA Web Box PVM 1010 EnvoySMA Sunny BeamSuntrol®

12. Additional Information

In the area below, please enter any information regarding the structure relevant to the Sunkits® installation, concerns, special requirements, or special requests. Please print clearly in order to avoid delays in processing.


Page 2 Form # : 1-12.30.2011

Module MountingThis information is used to determine if the arrays will be roof or ground mounted. For ground mounted solutions enter this information (i.e., 20°, 180°) and skip questions 6, and 7.

Requested Number of ModulesThis information ensures that all of the expectations are consistent and provides the opportunity to request multiple systems at one site.

Proposed System SizeThe DC Watts expected. See Appendix A and use the table in order to calculate best solutions using standard 245 W modules for total DC watts in a specific region. Availability of module types may change from request to final delivery, but modules will be in the same class as requested.

Roof characteristics

Form # : 2-12.30.2010


















Seismic Loading







Flat Roof


Material:















Page 2 Form # : 1-12.30.2011

Roof pitch: Roof Pitch is the slope of the roof. In the U.S. this is typically given in inches of rise per 12 inches of span. For example, a 4:12 pitch is 4” of rise for every 12” of span. See graph below for standard pitches. For more information on Roof Pitch, see Appendix B of the Location Questionnaire Guide.

Slope Angle (degrees) Pitch0.25 14° 3:120.33 18.4° 4:120.42 22.6° 5:120.50 26.6° 6:120.58 30.3° 7:120.67 33.7° 8:120.75 36.9° 9:120.83 39.8° 10:120.92 42.5° 11:121.00 45° 12:12

True orientation

Orientation refers to the compass direction the roof the solar array will be mounted on faces (North = 0°, East = 90°, South = 180°, West = 270°). For maximum performance in the Northern Hemisphere, solar arrays should face a south-erly direction. See Appendix C of the Location Questionnaire Guide for accurate compass reading and other methods.


Note: Satellite TV dishes point to the southern sky, and most online mapping sites default with true north up, and true south down.

Roofing materialThe existing roofing material is important to determine the type of roof mounting solution for the solar array. It is also important to note the age and condition of the roof material. If the roof is in poor condition, it is recommended to repair or replace the roof prior to installing a solar array.

Metal (standing seam)The gauge and manufacturer are required to ensure the mounting solution has been approved by the manufactures. Panel seams must have sufficient flexural strength to carry these loads when clamp is used mid-span. Panel attach-ment and building structure must also be sufficient to carry these loads. It is the responsibility of the user to verify this information, or seek assistance from a qualified design professional, if necessary.

Rafter information

Form # : 2-12.30.2010


















Seismic Loading







Flat Roof


Material:















Page 2 Form # : 1-12.30.2011

The rafter spacing is required for loading calculations and mounting hardware. Most residential roof systems utilize vertical rafters installed either as stick framing or truss systems. Stick framed rafters consist of dimensional lumber (2 x 6, 2 x 8, 4 x 6, etc.) sized appropriately for spanning from the top plate to the ridge. Truss systems consist of a pre-engineered 2 x 4 truss that spans from top plate to top plate. The easiest way to determine the rafter spacing is to measure the rafter tails that extend past the exterior wall. Note: This will not work with faux rafter tails. Although less common in the U.S. some structures are built with horizontal rafters that span from gable to gable.

Stick Framing Truss System

Structure information

Form # : 2-12.30.2010


















Seismic Loading







Flat Roof


Material:















Page 2 Form # : 1-12.30.2011

The basic structure information is used in equations for IBC load calculations. Inaccurate or incomplete data can lead to inspection failure.


Loading requirements

Form # : 2-12.30.2010


















Seismic Loading







Flat Roof


Material:















Page 2 Form # : 1-12.30.2011

Loading requirements are important to confirm the roof structure can withstand the additional weight and loads possible with the addition of the solar array, as well as to be sure the solar array can handle the local structural de-mands, i.e., wind, snow and seismic loading. This data is especially important in areas with high wind, snow, or seis-mic loads. If the solar array is to be installed in one of these high load areas, contact the local building department for the required load data. SolarWorld will use default data based on zip code and the IBC unless noted otherwise. The ultimate responsibility is on the installer to ensure that all building requirements are satisfied. See links and maps on the following page for general information. Contact your local permit office for more accurate local requirements in your area.

Links: site map

Wind data

Snow data


Seismic zone map

Wiring requirements Grid voltage is of paramount importance for appropriate inverter choices and string sizing. Wiring requirements are important to properly determine the type, size, and length of the wiring. The distance from the array to the inverter location, junction box, or combiner box is important to determine the length of the PV wire. If routing the wire through the building, the PV wire is only required for the environmentally exposed portion of the run. From a junc-tion box and metallic conduit, standard THWN, 90o C wiring can be generally be used.

Note: NEC code requires that all DC wiring be in METALIC conduit inside of structures for fire safety.

Temperatures are important to properly determine the type and size of wire. Temperature is also a key variable to determine module string sizing. While low temperatures can permanently damage the inverter and void warranties, high temperatures can cause the inverter to shut down at peak production times. There are a variety of inverter tech-nologies and sizes which can be leveraged to produce the most efficient system for the lowest long-term cost.

Specific request/adders

Form # : 2-12.30.2010


















Seismic Loading







Flat Roof


Material:















Page 2 Form # : 1-12.30.2011

If there are specific requests associated with the system that are requested or required, please note them. Although unlikely, SolarWorld reserves the right to refuse the request based on safety and system functionality requirements. Some specific requests may create longer lead and delivery times due to product availability. Without specific input, SolarWorld will default to the “standard” solution using SolarWorld standard modules, SMA inverters, and Sunfix mounting solutions, defaulting to the appropriate Sunfix penetration solution for the roofing material indicated. Monitoring equipment is not included in the price of a Sunkit and will be added. Check with your local distributor or dealer for pricing.


Additional information

Form # : 2-12.30.2010


















Seismic Loading







Flat Roof


Material:















Page 2 Form # : 1-12.30.2011Additional information is any information unique to the installation location that can affect the sizing, mounting, performance of the solar array. Use this section for any comments or requests. Our highest priority is to provide the system owner with the best possible solution meeting their needs.

Array layout

The sketch of the roof layout is important for SolarWorld to provide an accurate proposal and include the correct mounting hardware and wire lengths, etc. It is also important to make sure there are not shading issues that will seriously affect the performance of the system. See Appendix D of the LQ Guide for appropriate and accurate di-mensioning. Digital photos of the roof and surrounding area can be the most useful tool to help SolarWorld or your system designer understands the installation location.


13a. RESIDENTIAL layout. See sample below, then submit your layout on page 4

• Roof measurements

• Requested array layout and configuration

• Location and size of existing obstructions on the roof (for example: Dormers, vent pipes, chimneys, vents, skylights, hips, valleys, electrical boxes, etc.)

• Expected mounting layout, and other variable mounting requirements

• All potentially useful dimensions

• Include which direction is North

• Include approximate location of the Inverter, Circuit Panel, and the Utility Meter

QUESTIONS

• What is the location of combiner/junction box?

• Are there any shading issues? If so, Please identify any external obstructions like trees, branches, and other buildings.

• Are there any site-specific spacing requirements?

• Are there any local jurisdiction requirements?

SAMPLE

Information is gathered for purposes of providing Products and Services to SolarWorld Americas Customers and for our system records. While most information is required for the appropriate structure and physical installation of the Sunkits® system, some information is collected to provide the best possible electrical solution for your location and specific needs. SolarWorld will not supply or share any information provided with any entity except certain SolarWorld California a�liates dedicated to making your purchase operate at maximum e�ciency and durability.

The tests performed on the materials included in the Sunkits® are standard testing for such materials. There is no specific testing done for your individual system and location. Designs are based on the provided information and SolarWorld accepts no risk due to faulty or false information provided in this document. The system installer is finally responsible for supplying any uncommon factors in the system requirements. The System Installer is ultimately responsible for installing the system according to all state and local codes and regulations.

It is possible that after examining the information provided, SolarWorld Americas, LLC may conclude that your specific location is inappropriate or not conducive to installing a Sunkits® Solar Electric System. Part of our commitment to our customers is high quality products, and if the location specified is not appropriate for solar installation due to the structure, direction, angle, external obstructions or other variable, we may recommend finding an alternate location or solution to satisfy the customers energy needs.

I hereby certify that all information provided is complete and accurate to the best of my knowledge. Further, I hereby absolutely, irrevocably and unconditionally release and hold harmless SolarWorld Americas LLC and its a�liates, partners, and/or subsidiaries, and each of their successors, assigns, directors, o�cers, shareholders, employees and agents, from any and all claims, demands, actions, suits, damages and expenses of any and every nature whatsoever, known and unknown, that arise out of or relate to this document, subsequent documents, the information provided in this document and/or subsequent documents that may be provided in the course of this Sunkits® system design process.

Date:

N

E

S

W

Signature:14.

Page 3a Form # : 1-12.30.2011

Pitched Roof


13b. GROUND MOUNT layout. See sample below, then submit your layout on page 4

SAMPLE

Information is gathered for purposes of providing Products and Services to SolarWorld Americas Customers and for our system records. While most information is required for the appropriate structure and physical installation of the Sunkits® system, some information is collected to provide the best possible electrical solution for your location and specific needs. SolarWorld will not supply or share any information provided with any entity except certain SolarWorld California a liates dedicated to making your purchase operate at maximum e ciency and durability.



I hereby certify that all information provided is complete and accurate to the best of my knowledge. Further, I hereby absolutely, irrevocably and unconditionally release and hold harmless SolarWorld Americas LLC and its a liates, partners, and/or subsidiaries, and each of their successors, assigns, directors, o cers, shareholders, employees and agents, from any and all claims, demands, actions, suits, damages and expenses of any and every nature whatsoever, known and unknown, that arise out of or relate to this document, subsequent documents, the information provided in this document and/or subsequent documents that may be provided in the course of this Sunkits® system design process.

Date:

• Proposed array layout and configuration with dimensions

• Location and size of existing obstructions (ex. Buildings, trees, play structures, etc.)

• Contour lines or the North-South and East-West slope under the array

• Show proposed path of wiring from array to inverter and provide a dimension

• Include location of Circuit Panel and Utility Meter

• Include frost line depth for your local area (this will affect your racking)


QUESTIONS


• How many rows and columns will be in each array?

• Are there any shading issues? If so, Please identifyany external obstructions like trees, branches, andother buildings. Include the height.


• Are there any local jurisdiction requirements (i.e., setbacks)?

Signature:14.

Page 3b Form # : 1-12.30.2011

Ground Mounted


13c. COMMERCIAL layout. See sample below, then submit your layout on page 4

SAMPLE





Date:

• Roof measurements and other potentially useful dimensions

• Proposed array layout and configuration

• Location and size of existing obstructions on the roof (ex. Ducting, compressors, skylights, vents, access doors, parapet walls, etc.)

• Include approximate location of the Inverter, Circuit panel and utility meter.

• Indicate which direction the support structure is oriented

• Indicate any slopes or pitch to the roof

• Indicate finished elevation of roof sections


QUESTIONS


• Are there any shading issues? If so, Please identify any external obstructions like trees, billboards, and other buildings. Include the height.


• Are there any local jurisdiction requirements (i.e. 3’ clearance from perimeter walls)?

Signature:14.

Page 3c Form # : 1-12.30.2011

Flat Roof


Signature


13c. COMMERCIAL layout. See sample below, then submit your layout on page 4

SAMPLE





Date:

• Roof measurements and other potentially useful dimensions

• Proposed array layout and configuration

• Location and size of existing obstructions on the roof (ex. Ducting, compressors, skylights, vents, access doors, parapet walls, etc.)

• Include approximate location of the Inverter, Circuit panel and utility meter.

• Indicate which direction the support structure is oriented

• Indicate any slopes or pitch to the roof

• Indicate finished elevation of roof sections


QUESTIONS


• Are there any shading issues? If so, Please identify any external obstructions like trees, billboards, and other buildings. Include the height.


• Are there any local jurisdiction requirements (i.e. 3’ clearance from perimeter walls)?

Signature:14.

Page 3c Form # : 1-12.30.2011Signature of licensed contractor is required to process documents.


Design rules

Safety

Safety is of paramount importance for SolarWorld in all facets of system integration. SolarWorld may adhere to requirements adopted in some locations and affect them throughout the nation as they may be deemed as a best practice. California, Oregon, New Jersey, Colorado, and Florida for example have had considerable experience with PV installations and have adopted new requirements for system safety above and beyond the latest National Codes. It is understandable that Snow load requirements in Colorado, should not be required in Florida, or wind load require-ments in Florida be adopted for Colorado market. But some additions make universal sense when it comes to system designs and safety of all parties involved.

NEC and ICC codesFirst default for system design safety begins with the latest national code requirements. All systems use the latest published NEC and ICC code requirements as a basis for electrical and mechanical system design, even if the local adopted code is still only requiring an older revision.

Local codesLocal codes must also be considered for details above and beyond those considered in the model codes. In many installations, this may require a local professional engineering approval and stamp for local code compliance. While it is difficult for SolarWorld to categorize local code requirements for PV systems, systems will be adjusted to meet local requirements based on input from the installing company, and local AHJs. SolarWorld will keep a record of local requirements, but as those requirements change and since PV is far reaching to every corner of the US, it is ultimately the responsibility of the Sunkit Installer to ensure that local requirements are followed and communicated to Solar-World for key issues to be recorded.

SolarWorld non-standard requirementsSolarWorld may adopt some non-standard requirements in an effort to support safe practices. Examples of adopted design requirements:

_ Much of California and Oregon currently require a 3 ft accessible area around residential rooftop arrays. (fire safety, access and pathways).

_ 4 ft walkways for every 50 linear ft of array section on flat roof installations. (fire safety, access and pathways)Minimum of 3 ft. radius from any exhaust vent opening.

Suitable materialsSolarWorld will only supply designs and materials that are approved for the installation method defined by the man-ufacturers. Using components in an unintended or untested manor is wholly inappropriate without prior stamped engineering approval.

Installation guidesInstallation guides and manuals must be read, understood, and followed. Any contradicting instructions or instruc-tions incongruent with local codes should immediately be brought to SolarWorld technical support’s attention prior to installation.

At risk structuresSome structures (i.e., many pre-fabricated metal buildings) are not suitable for system installations. If for any reason there is concern for structural and safety integrity, SolarWorld reserves the right to refuse design and sale of that Sunkit.

GroundingWhile there are several methods in the marketplace for grounding a PV system, Sunkits defaults to the generally ac-cepted method of incorporating tin plated grounding lugs approved for outdoor use as noted in the module installa-tion guide.


Financial investment

SolarWorld asserts that it is in the best interest of the system owners to have the best financial return and most effective system for their money. Sunkits are priced on a $/W basis, so adjustments to balance of system costs are incorporated in the price of the Sunkit and wholly reliant on the number and type of modules provided.

System size impactA Sunkit solution is intended to provide the system owner with what they need, rather than how much they can fit. Offsetting 100% or more of the system owner’s energy demand is not generally the best practice for the financial investment. In many cases, particularly with tiered utility rate structures, a smaller system will provide a better finan-cial offering and return on investment than a larger system.

Array tracker optionsTracking options are often considered to increase energy generation, however, in many cases, that equivalent money spent on a larger system with more PV modules will generate more kWh/$ spent and require little to no ongoing maintenance costs.

Rebates and incentivesSystem designs that void a rebate or incentive program should be avoided. A system that does not meet rebate requirements is considered a poor design. SolarWorld reserves the right to refuse design and sale of system that increases payback time due to decreased efficiency of the design when there are more efficient and cost effective op-tions.

System efficiency

System efficiency is a look at all of the components of a system design and their lifetime effect on energy production. Choosing the right components to work together appropriately is of importance, not only for code requirements, but for lifetime energy production of the system.

SolarWorld modulesSolarWorld modules are plus sorted and have very tight tolerances. This ensures when modules are connected to-gether in a system, they work optimally with each other.

Array configurationArray configuration is important to the effective lifetime operation and efficiency of the inverters. Connecting mod-ules in significantly different orientations in a single series string of modules to a string inverter is considered bad system design since the lower performing orientation will drag down the potential of the higher performing orienta-tion, and reduce overall energy performance.

String sizingString sizing is important for safety and inverter integrity. The number of modules connected together in series to generate the appropriate voltage required by the inverter is tricky. Local factors must be considered to maximize inverter uptime and efficient production. Temperature ranges tend to have the largest impact on the electrical design of the system and may limit sizing options in a specific area. Oregon’s ETO (Energy Trust of Oregon), for example, ads up to 30° C to the average local high temperature for pitched roof installation. The design factor adjustment accounts for higher temperatures that can arise due to a smaller gap for cooling airflow behind the module. Additionally, Oregon requires the inverter low voltage window to be increased by 15% to avoid potential future degradation in the module voltages which could reduce inverter daily uptime down the road. While SolarWorld may not hold the rest of the nation to the stringent requirements of Oregon, particularly due to the quality of the modules being used in a Sunkit system and the limited impact on voltage due to degradation, the concept is sound and SolarWorld and many inverter manufacturers have generated similar guides to efficient system design.

Note: This is not intended to limit choices. Much of this is the art of system design. The first question is will it work. Then, will it work efficiently for a long time. Customers should understand the impacts of different system designs that may influence their decision on system size.


Array orientationOrientation of the array should be considered. Choosing the best location for the system can be tricky, but in general the most southern facing orientation at an angle close to the latitude is the goal. However, there are always caveats to this rule and in > 99% of systems installed are NOT installed at this optimum angle and orientation. There are many other factors that go into the system design that effect the ability to meet this goal and peak optimum orien-tation but SolarWorld system designers strive to get as close as possible without detrimentally effecting the other criteria.

Array shadingShading is of considerable importance to Sunkit systems. In some cases, if shading is significant enough, there are some clear options.

_ Limit the size of the system to reduce or eliminate the impact of the shading

_ Remove the object(s) causing the shade.

_ Use the micro-inverter solution available to limit the shade impact on individual modules, rather than an entire series string of modules.

_ Choose a different location for the system, either ground mounted or and alternate roof location (often a non-ideal roof orientation is preferred to a shaded roof in a more ideal orientation).

_ Choose not to go solar for that customer, offer energy efficiency upgrades and appliances to reduce the en-ergy consumption of the customer.

_ In reality, this should be done first anyway. The most valuable kWh is the one not needed.

Row spacingRow spacing on flat roofs (generally commercial buildings) can be tricky. It requires a balance of optimum tilt to maxi-mum rows (minimize row spaces) for maximum performance. This is a bit of the art of system design and is a func-tion of each site. In general, maximizing inverter efficiencies often becomes the deciding factor. If a 5 degree reduc-tion in tilt can add another row of modules, but require an additional non-maximized inverter, it may not be the right choice. Similarly, if the 5 degree reduction does not allow for more rows, perhaps it is possible to increase the tilt by 5 degrees, use the same inverter, and increase system performance. This “requirement” is more subjective but should be investigated during system design.

Aesthetics

While aesthetics is generally a subjective portion of system design, there are some simple design parameters that have proven to be more beneficial in the long run. SolarWorld wants to be sure not to unduly sacrifice aesthetic value in pursuit of the maximum performance. It is important to keep in mind that most homes will be resold prior to the life of the solar electric system runs out. A Sunkit solar electric system should add value and not inhibit the resale of a home, and of course, customers should be happy with their system, including the appearance, so they will recom-mend systems to others in the community. The following are some basic guidelines to system design aesthetics that SolarWorld follows in the Sunkit program.

Compound tiltsNo tilted modules on pitched roof slopes greater than 2-12 pitch. This is what is known as a compound tilt angle. It is understandable that one might make an effort to tilt modules on an eastern or western facing roof to face more south and closer to the optimum tilt. Tilting the array to the south on a north facing roof should NEVER be consid-ered. There are a number of reasons why these are considered a poor design.

Aesthetic impactFirst and foremost, it has been generally accepted that the saw tooth appearance of tilted modules on pitched roofs is very unattractive. This same phenomenon was noted in the 80s with solar hot water panels that have to be tilted due south, and the general consensus was that the aesthetics where unsightly. SolarWorld and installing companies alike will want the potential customers driving by to like what they see.


Aesthetic impactThese tilts will require that multiple rows be spaced very far apart to avoid shading concerns, so may only be using 1/3 to 1/4 of the available roof space with large gaps between rows.

Safety impactMost tilted mounting solutions are not designed to be mounted on an angled plane (non-level); this changes the loads on the components and can put the system in danger of not being safe or secure.

Financial impactBy titling the modules, it is creating a much higher wind loading on the array (like a sail on the roof), and more mate-rials and installation expense will likely be required to meet the new loads.

Efficiency impactWhile theoretically the “more” due south facing modules will receive more of the Sun’s energy, the cost increase to the system and the detrimental aesthetics outweigh the increase in efficiency. In many cases choosing the east or western facing roof will only reduce the energy performance from the optimum performance by a maximum of 20%. It could be as little as 5% performance reduction from optimum.

Protruding modulesSunkits will always avoid modules overhanging ridges, eves and roof edges (not to include specially designed and en-gineered window awnings and shade structures). While this may reduce system sizes for individual customers, there are significant impacts of designing systems with such characteristics.

Aesthetics impactOverhangs outside of the general building envelope or protruding from the apex of a roof tend to draw the eye un-necessarily and can take away from the overall look of a building.

Safety impactInstalling systems with overhanging components makes it difficult or impossible for the homeowner to perform basic home maintenance safely.

Safety impactIf the structure were to have a fire, the safety of the fire fighters trying to secure the home could be in jeopardy when trying to traverse the overhanging portions of the solar array.

Safety impactThe penetrations would tend to be very close to the edge of the roof in order to meet mounting requirements of the live loads (wind and snow), and will likely not be mounted to structural components, but faux rafter tail or façade edging.

Design impactOver hanging edges of arrays tend to have a minimum of 3x the wind loading requirements of array portions located centrally on a roof. This will require more penetrations, or not strong enough penetrations.

Mounting solutions

Not all Sunkits are supplied with all of the structural materials required for installation. In fact, a no mounting option is available and the structural and material supply responsibility lies with the installer. SolarWorld recognizes that there can be uncommon situations where the standard mounting components supplied by SolarWorld are not suffi-cient for a specific installation, or not cost effective due to solutions commercial availability. In such cases, SolarWorld will not be able to provide engineering or design support for the structural portion of that system. There are some guidelines SolarWorld adheres to for our own structure designs and that our long experience and quality requirements recommend for constructing such systems. Safety and system life should be a priority for any structural solution.


Approved materialsOnly use designs and materials approved by qualified professional engineers and approved by local building code requirements for specific installation.

EngineeringA qualified engineer providing stamps for the structure should have all qualifications required for permitting and stamping in the local area of the installation.

StructureStructural elements should be constructed with suitable materials for the environment. The below are not strict limi-tations but will offer the best chance of success for successfully navigating the structural engineering requirements.

Examples:

_ Anodized Aluminum and Stainless steel hardware should be used whenever possible to reduce material fatigue over the long life of the system in harsh environments. In particular those locations close to corrosive environments like salt and byproducts of industrial processes.

_ If steel is used it is recommended to use hot dipped galvanized coating; ASTM A123, which can be mainte-nance free for 75 years.

_ Do not use “standard” galvanized metal strut materials for structural mounting. These prefabricated compo-nents tend to be weaker as individual units and require considerably more material, as well as thinner mate-rial that can corrode at key intersecting points that have lost the galvanized coating, significantly reducing integrity and increasing the potential safety hazard over the life of the system.

SolarWorld provided designs

Electrical single line and mechanical layout drawings can be provided by SolarWorld for systems that include the purchase of the mounting components and inverter and are supplied with a fully completed questionnaire. Part of the customer benefit of SolarWorld Sunkits is that SolarWorld will have a record of the system in our data base for future inquiries, trouble shooting, or technical support. If SolarWorld does not supply the designs for the system and the system is based off of system designs by alternate sources, SolarWorld requires that the designs submitted and approved for permitting are supplied to SolarWorld for our records and meet the design criteria set forth in this docu-ment.

No mounting optionSolarWorld recognizes that there are many different mounting solutions available, or required by a customer, which is not provided by SolarWorld. If a Sunkit is purchased with a “No mounting” option, SolarWorld requires that the Mechanical plans submitted for permitting and/or inspection are supplied to SolarWorld for approval.

SolarWorld will not provide mechanical layout drawings for Sunkit systems which SolarWorld does not supply the full mounting solution.

No inverter optionSolarWorld recognizes that there are many different inverter options available or specifically requested by a customer. SolarWorld has teamed with the highest quality inverter manufacturers in the industry and there is frequently an alternate solution with an inverter available through SolarWorld. However, if an inverter has been procured through a different route or is no available through SolarWorld, the “No inverter” option is available. If a Sunkit is purchased with a “No inverter” option, SolarWorld requires that the Electrical plans submitted for permitting and or inspection are supplied to SolarWorld for our approval.

SolarWorld will not provide electrical drawings for systems which SolarWorld does not supply the inverters.


Mechanical integration

PV modules have a 25 year performance warranty but can be expected to produce energy for 30 plus years and the system components should be designed to last as long. The workmanship of the installation should not only meet local and national code requirements but should exceed the customer’s aesthetic requirements.

SW Installation Best Practice: The condition of the roofing material should be checked during the site evaluation and is a critical factor in minimizing the potential for leaks during the 30-40 year life of the system. Repair or replace any damaged areas where the array will be installed prior to installing the modules as this area will become inaccessible.

Be sure to review the documentation provided with the racking system and solar modules.

Steps_ Layout_ Roof Penetrations_ Racking Installation

Safety

Fall protectionStandard measures to protect against falling from roofs should be followed, including wearing fall restraint equip-ment. An anchor system needs to be put in place on the roof peak or other suitable point, and each person working on the roof needs to be trained in the proper use of the equipment and should always utilize it.

ExposurePersons working on exposed rooftops for many hours must drink water and wear sun protection, and take adequate breaks.

LaddersFrequent use of ladders can lead to carelessness and improper climbing technique. Have both hands free to grip the ladder and secure tools to a proper tool belt instead of carrying by hand. Ladders should be secured at the top to the surface they are resting against. Proper tilt angles must be used as well.

Working in enclosed spacesIt is sometimes necessary to work in attic spaces that can be confined, dark and hot. Follow proper procedures for a buddy system and install adequate lighting. Lay down plywood or other materials to protect against stepping through ceiling areas. Wear proper breathing equipment when working around dust or insulation.

Falling objectsHard hats should be worn by all persons working on a solar installation. Tools and other heavy and sharp objects can be dropped from the roof on people working or walking below. The area immediately below the roof should be taped off or in some equivalent way made accessible only to the installation crew. The homeowner and family and friends should not be allowed to walk or stand near the roof edge while work is being conducted on the roof.


Tools (general)

Item CommentsTape measureChalk line Roof layoutLumber crayon Marking standoff locationsDrill Impact DriverDrill bitsSocket drivers set Racking installationMulti-meter with DC current clampOSHA approved safety glasses and footwearOSHA approved safety fall protection Ex. harness and anchorRoofing bar Pulling nails from roofing materialRoof sealant/caulking Seal penetrationsAdjustable Pliers 1-1/2” jaw capacityUtility knife with hook blade For cutting comp shinglesFirst aid kit Keep stocked regularly

Tools (Sunfix plus)

Item Comments7/32” long drill bit QM pilot holes1/2” and 9/16” socket drivers Racking installationMulti-meter with DC current clamp3/8” carbide masonry drill bit Breaking through comp shingle surface only, not pilot

hole


Bolt table

Bolt DiameterFraction Decimal Socket#6 / #8 1/4#10 / #12 5/161/4 0.25 7/165/16 0.3125 1/23/8 0.375 9/167/16 0.4375 5/81/2 0.5 3/49/16 0.5625 13/165/8 0.625 15/163/4 0.75 1-1/87/8 0.875 1-5/161 1 1-1/2

Layout

Review the system design and installation documents when measure and mark the jobsiteProper layout will reduce drilling extra holes and having to reposition an installed array. Prior to getting on the roof, the system layout should be defined on paper in the form of a drawing or sketch. This will minimize the number of chalk lines on the roof and speed up the layout process. The drawing or sketch should define the overall dimensions of the array as well as the roof plane the array is to be installed on. To define the overall dimensions of the array, So-larWorld modules are 39.4” wide x 66” tall. The space between the modules needs to be accounted for and this varies depending on the racking manufacturer.

Pitched roof

Manufacturer Mid Clamp End ClampSolarWorld Sunfix Plus 0.315” 2”Pro Solar 0.6” 2”Unirac 1.0” 2”

Therefore the overall dimensions of an array of 4 modules in portrait by 2 rows using Sunfix Plus would be:

Width = 2” + 39.4” + .315” + 39.4:” + .315” + 39.4”+ .315” + 39.4” = 162.545” (includes end clamps)

Height = 66” + .315” + 66” = 132.315

Note: A clamp is not used between rows, but a matching space is recommended.


158.55"

132.32"

The next step will be to layout the array on the roof plane. The required clearances between the edge of the roof and the array vary by AHJ and should be understood for the particular market. The default is to leave a minimum 36” on the sides of the array as well as from the ridge to provide access for firefighters to vent the roof. In most applications, centering the array on the roof plane is the best for aesthetics. Subtract the array width from the total roof plane width and divide by two. This will give you the clearance on either side of the array. Using the chalk line, mark these dimensions on the roof. Repeat these similar steps for the top and bottom of the array. Subtract the array height from the total roof plane height and divide by two. This will give you the clearance on the top and bottom of the array, be sure to maintain ridge clearances.

For example:The roof plane measures 16’ x 20’. Center the array on the roof measuring 36” from the ridge.Change feet to inches (20’ x 12”) – 158.55” (solar array width) = 244” – 158.55 = 81.45 (unused space)81.45 ÷ 2 = 40.725 = clearance between array and edges of roof plane.

The next step is to find the rafters and mark them on the roof. Stand-offs used to support the array racking must be attached to structural members. Typical rafter spacing is 24” on center and most racking systems are designed to span 48” o.c. maximum.

SW Installation Best Practice: For aesthetics try to avoid installing penetrations outside of the array.


The next step is to layout where the penetrations for the rails will be located. Mark the rafters that will be used, standard spacing for the penetrations is 48” o.c. Also do not make penetrations outside of the array envelope. Then measure out the rail spacing on the edge rafters. Small adjustments may be made to help position flashings or foot-ings for a smoother more reliable install. For example: it may be useful to move a row of penetrations up an inch so that they better fit in line with roof shingles.

SolarWorld modules must be securely fastened at a minimum of 4 points on the long sides between ¼ and 1/8 of the module length or between 8.25” and 16.5” from the edge.

Using the middle of this range, layout the rails at 12” from the edge and 42” apart. Where the rows of modules meet, add the width the modules are spaced. This will provide a uniform appearance of vertical and horizontal spacing. This is a good time to review the positioning of the array on the roof!


Penetrations

Once approved and the layout on the roof matches the drawings the next step is to install the mounting system to the roof.

SolarWorld recommends that all roof penetrations are properly flashed.

SW Installation Best Practice: It is important to make sure that the penetrations are properly attached to structural members. If possible, from the attic confirm the penetrations did not miss the rafters or blow out the side. The op-tions are to reposition the penetration or add blocking between the rafters.

Once the locations of the mounting system have been marked, follow the manufacturer’s installation guidelines. The type of roofing material will determine the proper roof penetration. There are many racking manufacturer options, but SolarWorld has selected key partners whose quality, performance, and value compliment the SolarWorld brand. Table 1.0 shows the roof type and the racking manufacturer used in SolarWorld systems. Always read and follow the manufacturer’s installation guidelines prior to installing on the roof.

Pitched Roof SolutionsComposition Flat Tile S-Tile Standing Seam

Sunfix Plus w/ QuickMount

X X X

ProSolar X X XUnirac X X XS-5! X


Composition

QuickMountPV®

R

For Questions Call 925-687-6686 www.quickmountpv.com [email protected]©2012 Jan2012

4 of 4

Installation Tools Required: Tape Measure, Roofing Bar, Chalk Line, Stud Finder, Caulking Gun, 1 Tube of Appropriate Sealant, Drill with 7/32” long bit, Drill or Impact Gun with 1/2” Deep Socket.

1 2

Locate, choose, and mark centers of rafters to be mounted. Select each row course of roofing for Mount placement of Quick Mounts.

Lift Composition roof shingle with Roofing Bar, just above placement of Quick Mount.

3

Slide Mount into desired position. Remove any nails that conflict with getting Mount flush with front edge of shingle course. Mark center for drill-ing.

4 5

Using drill with 7/32” long bit, drill pilot hole into roof and rafter, taking care to drill square to the roof. Do not use Mount as a drill guide.

Clean off any saw dust, and fill hole with Sealant.

6

Slide Mount back into position. Prepare Hanger Bolt with 1 Hex Nut and 1 Sealing Washer, insert through Block into hole and drive Hanger Bolt into rafter, tightening to a solid snug fit.

CLASSIC COMPOSITION MOUNTING INSTRUCTIONS - 5/16” - PV -

7 8

Insert EPDM Rubber Washer over Hanger Bolt into Block.

Using the Rack Kit Hardware, secure the rack of your choice (see 9*). Tighten to 13 foot Pounds.

* You are now ready for the rack of your choice. Follow all the directions of the rack manufacturer as well as the module manu-facturer.


9

Locate, choose rafters to be mounted and mark centers of rafters with chalk line (N/S). Select each row course of roofing for mount placement of Quick Mounts.

Using drill with 7/32" diameter bit, drill pilot hole into roof and rafter, taking care to drill square to teh roof. Do not use mount as a drill guide.

Insert EPDM rubber washer over hanger bolt into block.

Fasten the L-foot onto hanger bolt, secure the Sunfix plus rails. Tighten to 13 foot pounds.

Clean off any saw dust, and fill hole with sealant. Slide mount back into position. Prepare hanger bolt with (1) hex nut and (1) sealing washer; insert through block into hole and drive hanger bolt into rafter, tightening to a solid, snug fit.


Follow all the directions of the rack manufacturer as well as the module manufacturer.

Lift composition roof shingle with roofing bar, just above placement of Quick Mount.

Slide mount into desired position. Remove any nails that conflict with getting mount flush with front edge of shingle course. Mark center for drilling.

Professional solar Fast-Jack®

SW Installation Best Practice: The ProSolar Fast-Jack system does not include roof flashings and the type of flashing is selected by the installer. Use the best flashing for the roofing type ad region.


SW Installation Best Practice: One popular method is the no-caulk flashing (Oatey is one manufacturer). A common mistake is to allow the neoprene seal to become inverted around the penetration, resulting in a source for pooling water and eventually leaks.

Make sure roof is clean and free from any major protrusion before roof covering is installed:

No tar, asphalt-based roof cement or “pitch” should be applied to the collar portion of any metallic No-Calk flashing or the base or collar portion of any Thermoplastic or Flexible No-Calk flashing. At the discretion of the installer, flexible roofing sealant can be applied over all exposed nails or staples. Sealant can also be applied to the underside of the base to increase sealing power to the roof and is recommended in areas where frequent or heavy precipitation is common.

Place correct size No-Calk flashing over stand-offs with angle facing down slope of the roof. Push firmly to base of stack until flashing lies flat on the roof. Flashing size should be equivalent to pipe diameter size (e.g., 1 ½” flashing for 1 ½” pipe, 2” flashing for 2” pipe size, etc.). The Oatey logo printed on the flashing represents the front or down slope side of the flashing.

The top of the flashing will be covered one-quarter to one-half of the way down with roofing shingles. The bottom edge of the flashing should overlap the shingles beneath it so it sheds, not traps, water.

Oatey thermoplastic base flashings are designed to fit roof angles from flat to 45 degrees. Flexible, galvanized, alu-minum and copper base flashings are designed to fit roof angles from flat to 38 degrees. Oatey All-Flash High-Rise Thermoplastic Roof Flashings are designed to fit roof angles from flat to 60 degrees.


Tile

QuickmountPV® - universal tile mounts

Tile roofs present unique challenges during the installation of roof mounts. Depending on the condition of the tiles and the number of required penetrations, an alternative is to remove the tiles where the array is to be installed, in-stall composition roofing, and then replace tiles around the perimeter.


Professional solar Tile Trac®


Sunfix standing seam metal roof

The Sunfix SSMR allows the modules to be mounted directly to the roof in landscape or can be used with rails to install the modules in portrait.

SW Installation Best Practice: In many cases S-5 and SolarWorld recommend utilizing clamps on nearly every seam that the modules cross.

When installing directly to the roof there are two layout methods:

1) Seam Alignment: Modules are aligned on the roof so that the seams support the modules at the recom-mended quarter points. Depending on the spacing of the seams, this typically results in a larger spacing between modules.

2) Module Alignment: Modules are aligned on the roof so that the module spacing is approximately 3/8” apart. As a result the seams may not land at the quarter points. The solution is to install additional clamps the module to meet the loading requirements.

SW Installation Best Practice: SolarWorld does not endorse the S-5! PV Kit as it requires field adjustment of a jamb nut to achieve proper clamping force on the modules. We recommend using SolarWorld Sunfix clamping hardware with S-5 clamps.

CAUTION

Metal roofs can be HOT! Common practice is to place a piece of cardboard or carpet on the surface to prevent getting burned while working on roof.


Racking installation

It is important that the racking system is designed and installed to meet the site specific conditions, including load-ing and environmental conditions. Areas with higher wind or snow loads may require additional roof mounts or rails. More corrosive environments, such as coastal installations, require all hardware to be anodized aluminum or stain-less steel. SolarWorld supplies racking that has been specifically designed for PV installations.

SW Installation Best Practice: PV modules will last 25 plus years and it is important that all components of the sys-tems be designed to last as long.


Sunfix plus®

February 2012

Pitched roof mounting systemplanning and installation guide

America’s largest solar manufacturer since 1975


UNIRAC SolarMount

UNIRAC SolarMount Prosolar

Solar module handling/installation

_ Do not drop module or allow objects to fall on module.

_ Do not stand or step on module.

_ It must be assured that other system components do not generate any hazard of any mechanical or electrical nature to the module.

_ Never leave a module unsupported or unsecured. If a module should fall, the glass can break. A module with broken glass cannot be repaired and must not be used.

_ Work only under dry conditions, with dry module and tools.

_ Module installation and operation should be performed by qualified personnel only. Children should not be allowed near the solar electric installation.

_ If not otherwise specified, it is recommended that requirements of the latest local, national and/or regional electric codes be followed.

_ Use module for its intended function only. Follow all module manufacturer´s instructions. Do not disassem-ble the module, or remove any part or label installed by the manufacturer. Do not treat the back sheet with paint or adhesives.


Electrical integration

Electrical integration involves connecting the PV modules to each other, creating PV source circuits, and wiring the balance of system electrical components such as J-boxes, combiner boxes, AC/DC disconnects, inverters and a util-ity interconnection. As the scope of this document covers residential and small commercial systems, the maximum system voltage is 600 V DC. Since PV systems involve working with DC and AC systems, most jurisdictions require the electrical portion of a PV installation to be performed by a licensed electrician or contractor. The system is also inspected by the local authority having jurisdiction (AHJ) for code compliance as well as the utility. The majority of the regulations governing electrical installations, including PV systems, are found in NFPA 70: National Electrical Code (NEC). Article 690, “Solar Photovoltaic Systems,” specifically addresses the requirements for all PV installations covered under the scope of the NEC.

PV circuits diagram

Steps_ Electrical component installation_ Array installation_ Final Inspection_ System Activation

Electrical safety

The installation & testing of solar modules requires a great degree of skill and should only be performed by qualified licensed professionals. The installer assumes the risk of all injury that might occur to persons or damage to property including, without limitation, the risk of electric shock when working with live electrical components. All instructions should be read and understood before attempting to install, wire, operate and maintain the photovoltaic module.

Be sure to refer to documentation provided with your solar equipment BEFORE TAKING ANY ACTION.


* * * W A R N I N G * * *

Contact with electrically active parts of the module can result in burns, sparks, and lethal shock whether the module is connected or disconnected.Photovoltaic modules produce DC electricity when exposed to sunlight or other light sources. When modules are connected in series, voltages are additive. When modules are connected in parallel, current is additive. Con-sequently, a multi-module system can produce high voltages and current which constitute an increased hazard and could cause serious injury or death.

CAUTIONS

_ Avoid electrical hazards when installing, wiring, operating and maintaining the module.

_ When installing or working with module or wiring, cover module face completely with opaque material to halt production of electricity.

_ Do not touch terminals while module is exposed to light or during installation. Provide suitable guards to prevent contact with 30VDC or greater

_ Always use proper PPE (Personal Protective Equipment) including but not limited to gloves, eye protection, hard hat, fall protection, boots etc…

_ Electrical arcing may occur when connecting or disconnecting module circuits under load. An arc may emit intense light that can damage vision and can cause burns or sparks.


_ Since sparks may be produced, do not install module where flammable gases or vapors are present.


_ Use properly insulated electrical tools


_ If not otherwise specified, it is recommended that requirements of the latest local, national and / or regional electric codes be followed.

_ Use module for its intended function only. Follow all module manufacturer´s instructions. Do not disassem-ble the module, or remove any part or label installed by the manufacturer. Do not treat the back sheet with paint or adhesives.

_ Always measure conductors and terminals BEFORE working with them, to insure there is no voltage on the line when making connections. Do not pull apart module MC connectors under load. Ensure there is no current flowing in an array circuit before working with MC connections. Cover the solar array with an opaque blanket or other material to de-energize them.

Electrical components

This section describes how to install the BOS electrical components, including the inverter, disconnects, J-boxes, and connection to service panel.

Note: Before getting started, please read over all component guides/manuals for all the equipment used in installing your system.

Array installationThis section describes how to install the solar modules to the racking. Connecting the modules electrically to each other, the use of an array (rooftop) junction box, and grounding.


Planning/layout grounding & “homerun” circuitsNow that the racking material are in place you are ready to install your modules. However, before doing so you will want to plan the paths for your grounding and homerun circuits. This includes at the array and from the roof array through the attic, to the DC disconnect, etc. Typically you should use a mechanical or accurate layout drawing of the site and:

_ Mark where you want to place your (rooftop) junction box, this will vary site to site. Often it is located nearest to the ridge and under a module secured to solar mounting rail.

_ Mark your Equipment Grounding Conductor (EGC) wire run with consideration for both grounding and aiding in wire management.

_ Mark any needed homerun or jumper wires. After completing the above assessments you are now ready to mount your modules.

Note: If using micro inverters they will be installed and grounded prior to modules..

Junction box/combiner box installationAn array (rooftop or other location) junction box is used to transition from “free air” PV Wire or USE-2 conductors to more common conductors that can be easily run in conduit, such as THHN orTHWN-2. A combiner box is a junction box (J-box) used to combine or parallel source circuits into fewer larger output circuits, reduce the number of conduc-tors that must be run to the disconnect and inverter.

Transitioning to standard PV electrical wire (THHN or THWN-2)Transitioning from PV Wire to THHN or THWN-2 can be done a number of ways.

_ Using a J-box attached to a mounting rail or

_ Through the use of a SolaDeck that is flashed into the roof.

Proper wire colors/labelingFrom the solar array each wire will transition into its respective standard electrical wire (THHN or THWN-2) or be run the whole way with PV cable. Proper wire color and or labeling is essential.

SW Installation Best Practice: The standard for PV cabling colors/labeling is generally similar to household wiring standards and should not be confused with automotive or other basic low voltage DC standards.

_ Grounding / Bonding wires should be green or bare copper

_ Negative (DC) wire should be white (or taped white) as most systems are Negative Grounded (this is a grounded current carrying conductor)

_ Positive (DC) wire should be black

_ (this is an ungrounded current carrying conductor)

_ Additional positive DC wires may be Red or other colors not including green, grey or white

_ Often additional DC wires are the above colors and labeled with a number or letter to indicate an additional string circuit

Note: The appropriate transitional wire gauge should be used and will be listed on your electrical line drawing, it should always be double checked by the appropriate licensed electrician in charge of the job. The transitional wires are also recommended to be course stranded instead of solid copper for easier workability in relation to pulling wire through conduit.

Proper wiring sequenceIt is recommend that the first and last module string connectors to the “homerun” circuits are left OPEN or discon-nected until after the wiring runs are completed.


1. The bare copper grounding/bonding wire should be installed first and usually attaches to the grounding con-duit lock nuts and grounding / din rail itself or a terminal bars. attached to the SolaDeck unit followed by

2. Next the PV negative/white wires

3. and lLast the PV positive black or /red wires.

This wiring order is always recommended

_ SolaDeck

When using a SolaDeck the grounding bare copper wire, along with the positive and negative homerun cir-cuits from the array, should be brought into the SolaDeck, inside you will transition from the array grounding and PV cabling via a terminal block or insulated lugs to the appropriate colored THHN or THWN-2 wires.

_ All weather box

When using an all weather box (AKA junction or bell-box) the grounding wire, along with the positive and negative homerun circuits from the array, should be brought into the J-box, through the appropriately sized gland/compression fittings or (strain reliefs). Inside you will transition from the array grounding and PV ca-bling via an insulated terminal strip/block or insulated lugs to the appropriate colored THHN or THWN-2 wires (the Polaris lug is a common brand/item) or equivalent.

SW Installation Best Practice: Wire nuts may be allowed by code, however due to the nature of the outdoor conditions, SolarWorld does not recommend them. Terminal strips and insulated lugs can be torqued and wired with confidence. Exceeding code minimums for material used throughout the PV array will only in-crease the safety and longevity of the system.

Note: Depending on where the J-box is located and how it is mounted it should be NEMA rated appropriately. For example: J-boxes in an outdoor environment should have at least a NEMA 3 rating.

_ Weather head

In certain PV systems no transition from PV wire to standard electrical wire is needed (no complex jumpers when the wire is short) if the DC disconnect and inverter is nearby. When using a weather-head you can sim-ply pull the PV wire “homerun” circuits – as well as the EGC – through the weather-head and down to the DC disconnect.

Note: Once solar circuits leave the solar array they must be run in proper conduit. For rooftop systems the conduit must be metallic. Ground mount systems may utilize PVC or appropriate conduit materials.

When metallic conduit is run through an attic, be sure to follow code for the appropriate distance from the rafters if out from under the location of the array (10 inches; NEC 690.31E1). If run directly under the array, mounting directly to the rafters is fine.

An additional option to the attic is to run the wires in conduit through the eave and out along the wall/home to the DC disconnect.

Note: Remember to properly mark or label the conduit as required by NEC code (690.31E3 and 4) and go no more than 10 ft. in between a label and/or a marking.

Grounding

Note: Depending on your jurisdiction, additional Grounding Electrode Conductors (GEC) may be required at the array (i.e., ground mounted system) and/or at the inverter.


_ Modules

Functional grounding of the solar module metal frame is essential. If an exterior lightning protection system is present, the PV system must be integrated into the protection concept against a direct lightning strike. Local building code requirements shall be observed. For grounding in the US and Canada the modules with a “2.0” and “2.5” frame can be grounded to by using any one of the four grounding holes in the corners of the frame. A lay-in lug and a socket head cap screw shown below are the recommended hardware (Fig. 1). For the “2.5” framed modules, grounding can be achieved by either the corners of the frame, as listed above, or through the four additional grounding holes located in the frame flange.

The hardware needed for the grounding in the flange are:

_ A lay-in lug

_ A bolt

_ A serrated washer

_ A washer

_ A nut (Fig. 2)

We recommend using the components as listed below. However, any compatible UL approved PV grounding method and components are also acceptable in the US and Canada.

Fig 1. Lay-in lug.

Item Manufacturer/Description Tightening torqueLay-in lug Ilsco GBL-4DB (E34440) 35 lbf-in, 4-6 AWG str

25 lbf-in, 8 AWG str20 lbf-in, 10-14 AWG sol/str

Socket head cap screw 10-24, 5/8”, SS 18-8 62 lbf-in (7.0 Nm)


Figure 2.

Item Description Manufacturer/Distributor Manufacturer Part NumberGrounding lug Lay-in lug Ilsco GBL-4DBTBolt #6-32, SSSerrated washer M5, SSWasher ID 9/64”, OD 3/8”, SSNut #6-32, SS

See: www.ilsco.com; www.mcmaster.com

Once you have located all the modules in place onto the racking system, with the appropriate grounding/bonding mechanisms (tin plated copper lugs/grounding clips), then you can proceed to bond and electrically connect the modules.

_ Method (module grounding)

While you place each module onto the racking/mounting system, using one continuous bare copper wire (known as the Equipment Grounding Conductor (EGC) or Protected Earth (PE), connect the copper wire into the grounding lugs and tighten the set screw to the proper torque rating, then proceed to mount the mod-ule and hardware (clamps, bolts etc.) using the appropriate method the racking system calls for. Next, reach under and plug the modules together with the provided wires and connectors. Continue the said steps for the next module until you get your appropriate numbers of modules in a series string.

_ Grounding clip alternatives (WEEBs or equivalent)

Instead of using lugs for each module, place the grounding clips as the modules are installed; ground the rails/racking as usual.

Note: Always check with your AHJ and local inspector/s to see if grounding clips are acceptable in your area. The grounding clps used for the job will depend on the racking system.

Note: Follow all instructions for the WEEBs themselves on proper use on them.

_ Microinverters

The grounding location of the micro inverter is located on the top side of the micro inverter itself and will need to be tied into the continuous EGC/GEC being run from module to module, module to rail and rail to rail if using the bare copper and lugs method. If using the WEEB method, then the micro inverters will have to be incorporated in to the bare copper wire used to run/ground rail to rail on the array. Please consult the micro in-verter installation guide below for the exact means and torque values to use in grounding them appropriately.


After fully grounding/bonding the modules and rails/racking system, you will then connect the modules into series strings. Some sites may need jumper (extension) cables, which are outdoor rated cabling that has the proper solar connectors on the ends. Next to run the PV circuits to the DC disconnect and inverter you will need “homerun” cabling to get to the (rooftop) transition J-box/weather-head. “Homerun” cables are outdoor rated PV cables with an MC4 connector that will connect to the end of the module series string and the other stripped wire end connects to either the (rooftop) transition J-box or all the way to the DC disconnect.

Module mountingThe modules must be securely at a minimum of 4 locations on the substructure. Mounting is only allowed in desig-nated areas located on the long sides of the module frame. They are located between 1/9 of the module length and 1/4 of the module length (8 ¼” to 16 ½”), measured from the module corner. Mounting the module on its short sides is not permissible. In regards to clamping the modules from the front/top, the clamping area on the module frame must be at least 130 mm2 for each mounting point. The required clamping force is 20 N/m 14 lb/ft. Do not drill any holes into the module or modify them in any way. Use corrosion-resistant mounting materials. Some sites with high loads may require additional support.

Cable managementIn order to secure, protect and organize the solar cabling you will need to utilize tie wraps (zip ties) or cable clips. Loop the cables in a bow shape remembering not to make the bends too tight. Keep the MC4 connections up towards the top off the racking and under a module. This will help provide protection from the elements.

For installations using the Sunmodule 2.5 frame, the flange on the long sides of the frame can also be used to secure the wires.

1. SolarWorld recommends securing all solar (including module) cabling to the arrays support structure (mod-ule frame, racking or rails). Securing cabling to mounting structure is typically faster and more effective than other means. In some systems you may be able to place cabling within the rails.

2. Multiple accessories can be used to secure cabling depending on the site and materials used, these include:


Tie wraps (aka zip ties) must be outdoor/UV rated in composite or stainless steel versions available from your local SolarWorld distributor.

Examples from manufacturer: stainless steel & composites nylon listed from Thomas & Betts

http://www.tnb.com/ps/endeca/index.cgi?a=nav&N=511+961+2661&Ntthttp://www.tnb.com/ps/endeca/index.cgi?a=nav&N=511+958+4294955757+4294954317+1324&Ntt

Cable clips must be outdoor rated and compatible with your rails/support materials. Available from your local SolarWorld distributor.

Example from manufacturer link: stainless steel listed from Wiley Tech. http://we-llc.com/ACC.html

3. When wrapping cables be sure to maintain a minimum bending radius of 4x cable width. For example: If the cable width is 7.1 mm, then the minumum bending radius is 28.4 mm or 1.12”.

_ In diameter a loop of cable would measure at least (56.8 mm) or 2.24” across.

_ A 90° bend of cable would use at least (44.68 mm) or 1.76” in length.

_ A 180° bend of cable would use at least (89.35 mm) or 3.52” in length.

_ A full loop of cable would use at least (178.69 mm) or 7.04” in length.


PV output circuit wiring

_ Splices: lugs, terminal strips, wire nuts

_ Conduit: attic (10”)

_ Wire THHN or THWN-2

_ DC disconnect: additional or supplied with inverter

Inverter installation SolarWorld carries SMA, PV Powered, and Enphase inverters. Always refer to the manufacturer’s installation guide prior to installing these components.

String inverters should be handled by two people and mounted to at least one stud.

Wiring of a separate DC disconnectIf a separate DC disconnect is required by Code for the specific AHJ of the job site, separate from the one attached to the inverter, then it should be wired as listed below.

It is recommended that the first and last module string connectors to the “homerun” circuits are left OPEN or discon-nected until after the wiring runs are completed.

1. The bare copper grounding/bonding wire should be installed first and usually attaches to the grounding con-duit lock nuts and grounding / terminal bars.


3. Last the PV positive black or red wires.

This wiring order is always recommended.

Note: Depending on the inverter you will be installing, “string” or “micro” inverter/s, there will be a slight differences in the wiring process. In this section we will be talking strictly about string inverters, micro inverters will be revisited later.

Wiring of the DC disconnect attached to the inverter

Note: Depending on the string inverter specified for the job you may have to wire and attach the DC disconnect prior to continuing with your wiring of the inverter disconnect (i.e., SMA). However, the inverter manuals will provide you with all the information you need to wire the disconnect properly.

It is recommend that the first and last module string connectors to the “homerun” circuits are left OPEN or discon-nected until after the wiring runs are completed.

1. The bare copper grounding/bonding wire should be installed first and usually attaches to the grounding con-duit lock nuts and to the grounding terminal designated as the PE or Protected Earth ground located on what is sometimes referred to as the AC side of the disconnect.


3. Last the PV positive black or red wires.

This wiring order is always recommended.

Note: Some string inverter disconnect switches are both DC and AC combined (PVPowered) however, depending on your jurisdiction you may need a separate AC disconnect switch independent from the inverter or the breaker in the main/sub-panel.


Some inverters require an AC neutral wire (Enphase) and some don’t (PVPowered). SMA inverters can typically be wired with or without neutral (there are some exceptions).

AC with no neutralIf there is no neutral used on the AC side of the inverter, the AC disconnect terminals will be labeled “Ground/PE, L1, and L2.” You will use a grounding conductor (green wire) then L1 is for line 1 (typically a black wire) and L2 is for line 2 (typically a red wire) (PVPowered, SMA optional).

Note: the “grounded DC” terminal is not the same as grounding/bonding; it refers to an inverter ground fault detec-tion system that uses the negative wire connected to the grounding system via a fuse or other device to look for faults (GFDI).

AC with neutralIf there is a neutral on the AC side of the inverter, then the AC disconnect terminals will be labeled “Ground/PE, N, L1, and L2. You will use a grounding conductor Ground/PE (green wire). N stands for neutral (white) wire; L1 is for line 1 (typically a black wire); L2 is for line 2 (typically a red wire).

Wiring of a separate AC disconnectIf the jurisdiction of the job site requires a separate AC disconnect, then the wiring of it will be similar to that of the previously mentioned items. The output from the inverter should be connected to the (touch protected) load side of the disconnect as the inverter will shut down when the service or grid is down.

Wiring to the main panelYou will bring the AC wiring, either from the disconnect connected to the inverter or from a separate AC disconnect, to the main panel and into the appropriate breakers. The back-fed PV-sourced breakers shall be positioned as far away from the main breaker as possible to reduce loads on panel bus bars.

Note: For new home construction you will have to continue out of the main panel from the grounding terminal in the main panel with an additional piece of bare copper wire in another slot on the grounding terminal bar that connects to a grounding rod.


SMA

PVPowered


Enphase

Suntrol system monitoring

_ SolarWorld offers an effective solar monitoring system

_ Easy install and configuration

_ Has no monthly or annual fee

_ Mobile version available for all Android smart phones, iPhones and iPads

_ Can handle 48 different inverter manufactures

_ Can record data for a 30-year period with updates every 5 minutes


_ Suntrol STL 200 data logger with 2 line lcd readout and can track 2 devices

_ Suntrol STL 400 data logger with 2 line lcd readout and can track 10 devices

_ Suntrol STL 800 data logger with large graphic LCD display and can track 100 devices

_ RS485 or wireless Bluetooth versions available for each model

_ (Bluetooth adds BT to the name: ex STL400BT)

_ Separate Suntrol documentation and trainings are available


With Suntrol products, you can always keep an eye on the current output of your solar power system and regularly monitor its performance—on your house wall, in your living room, on your computer, or at all times on your iPad, iPod touch, or portable smart phone.


Operation & maintenanceIntroduction

Sunkit solar electric systems are designed to operate reliably in a wide range of environments while providing unat-tended conversion of sunlight into electricity from daily startup to daily shutdown.

The Sunkit solar photovoltaic (PV) system consists of SolarWorld Sunmodules, appropriately chosen inverter(s) with compatible electrical components, and the module mounting solution and hardware.

The Sunkit has been designed to operate most efficiently in the location specified. We have taken into account many variables to ensure the Sunkit operates efficiently for many years with minimal maintenance requirements. Among the variables are 30 year historical data for wind speeds, temperatures, and the angle and orientation of the installed module array.

The DC photovoltaic circuits from all Sunmodules are electrically connected in combinations of series and parallel for appropriate electrical output characteristics required for superior operation of the provided inverter. The inverter converts the DC power into utility matched AC power and delivers it to the electrical grid via a connection point at or near the sites utility meter (generally the main service panel). Multiple inverters may be in operation at your site, act-ing independently, but have combined output for appropriate system performance.

DC disconnects are in your system for electric isolation of components for safety in the event that maintenance is required. Note: The PV array and DC circuits may still be energized when light is present. AC disconnects, where re-quired, or AC breakers may be used to isolate AC components or circuits. Make note of where all disconnects for your specific system are located.

With limited maintenance, your solar system will operate at peak performance for many years. Cleaning and inspec-tion intervals will vary depending on site specific factors like rain and soiling. It is best to consult your installer for a (or create a site appropriate) schedule and site specific methods to clean your modules. We recommend an annual inspection of the system to make sure it is operating properly and be sure to inspect all of the electrical and mechani-cal connections for cleanliness, tightness and damage, too.

When cleaning solar modules we recommend that you avoid using chemical cleaning products as they can damage the solar modules.

To reduce the chances of thermal damage, it is best to clean modules early in the morning or late in the day. We rec-ommend the use of water with a soft cloth or sponge and a squeegee. Pressure washers should not be used as they may damage modules, wiring, glass or injure people.

In some cases certain stains or deposits may need extra attention. In these cases use a mild non-abrasive deter-gent with a soft cloth or sponge. Be sure to avoid chemicals like ammonia or lye. Some recent VINEGAR based glass cleaning products have worked well. They are dilute and formulated to be gentle. PLEASE ALWAYS DO A SPOT TEST FIRST. Car wash soaps tend to be very gentle, as well. To avoid mineral spotting, better results may be achieved with a nozzle that aids in a careful final rinse so that water “sheets” away. This is when larger droplets or a large stream of water is applied to the modules and the water runs off without leaving behind minerals, etc. (as opposed to fine droplets that quickly evaporate).

SnowSites that have substantial snowfalls need to be designed to support additional loads. It is important that large masses of ice or snow do not move suddenly as they can hurt people or damage the system. Each site will vary, so please consult your (design team, engineers or installer) for proper maintenance or service. On some sites where safety and access are a challenge it may be best to leave ice and snow alone until they shed or melt away on their own… DO NOT APPLY MELTING SALTS or other chemicals on the solar modules. When safe, snow can be gently brushed off of the solar modules.


Major system component list & definitions

The solar array consists of the following components:(Reference site drawings, installation guides and manuals for details on components used)

_ SolarWorld Sunmodules

_ DC to AC grid-tied inverter(s)

_ Module mounting components and hardware

_ Electrical wires and connections

_ Disconnecting switches

_ DC fused combiner boxes (not always required)

The above components are defined below:

SolarWorld SunmodulesThe Sunmodule leads the PV industry in quality, output and reliability. The fully automated production process at SolarWorld factories ensures consistent high quality and enables tight power tolerances.

The glass is set deep into the module frame and secured with silicone adhesive, which provides exceptional rigidity for the entire module and prevents frame loosening from handling or sliding snow and ice.

The Sunmodule patented low-profile junction box provides exceptional protection against corrosion and features integral heat sinks that help maintain a lower temperature if and when any of the 25 amp Schottky bypass diodes are conducting. The junction box is connected by a solid welded bond to maximize reliability and performance life. In ad-dition, the integrated high-quality robust cables are factory equipped with NEC 2008 code compliant locking connec-tors. Each Sunmodule is covered by a 25-year performance warranty and is recyclable.

DC to AC grid tied inverter(s)The inverter is the transition device from the DC energy generated by the solar electric modules and the AC power provided from the electric utility grid. The inverter is specifically sized and chosen to match both the electrical out-put of the PV array (the DC input of the inverter) and the grid characteristics for the site. The inverter also provides the main data access point for the current and historical production and performance of the system. See included manual and installation guide for details on inverter characteristics for this specific site.

Module mounting componentsThe modules are mechanically mounted to a structure designed for the physical load based on site and location specific information. The components and hardware are designed from aluminum or stainless steel to ensure the longevity and reliability of the mechanical connections.

Electrical wires and connectionsThe electrical wires and module interconnections are designed to specifically operate for the life of the system in the harsh environments where solar PV modules are generally installed (e.g., rooftops, fields, and carports). Integrated high-quality robust cables are factory equipped with NEC 2008 code compliant locking connectors.

Disconnecting switchesNEC code requires that all PV systems have disconnecting means for both the AC and the DC side of the inverter. While the specific location of the switches will often depend on the local inspector and code requirements, the location should be noted and marked clearly. The inverters will have a switch (or breaker) associated which will shut down the inverter, but may or may not disconnect the conductors. Care should be taken when troubleshooting an inverter and should only be done by a trained professional (portions of the solar DC circuits remain energized when light is present).


DC fused combiner boxesA circuit combiner box serves to collect the DC power of the source (string) circuits of the PV array. The combiner boxes are minimum NEMA 3R in construction. There are fuses in each combiner box; combiner boxes can be daisy-chained in parallel to create a branch circuit that feeds to the Inverter.

System specifications

Refer to the provided system drawings for electrical specifications for the system.

System startup & testing/commissioning

Before commissioning a PV system or operating any components within the solar system it is imperative that the in-staller verifies the wiring and measurements at each connection. With proper labeling and the use of a multi-meter the installer should take electrical readings and compare them to the designed specifications.

_ Ensure that measured voltages are as expected

_ Look for reversed polarity (as DC circuits can be wired backwards, showing a minus sign)

_ Test for ground faults

After measurements are confirmed you may refer to the inverter or system manual and specifications for proper system startup sequence.

_ It may be useful to measure individual solar string output with a DC clamp meter to verify proper function.

System verification

Verifying that a system is performing as expected for site conditions is needed to ensure that the system is operating properly.

It is important to note that the PV system performance is directly related to site conditions including:

_ Light intensity on the solar array (clouds and time of day are major factors)

_ Temperature (which is impacted by sunlight intensity and wind)

_ Shade and Soiling of the solar array

_ Wiring, breaker and switch losses (energy lost due to resistance)

_ Conversion efficiency of the inverter (DC to AC and transformers)

To gauge if a system is performing as expected it is useful to compare the sites performance at a given moment to the expected peak AC output. PV systems have a calculated site specific DC to AC de-rate or anticipated peak AC out-put for a given site. We can measure site conditions and PV system operation and then compare them to the antici-pated peak AC output.

1. Ensure that the solar array is clean, free of damage and not shaded in any way.

2. Position a light intensity meter along the same plane as the solar array (same tilt and heading) Irradiance = ___________W/m²

3. Measure Solar Array Temperature (you may estimate array temperature if not easily accessible typically 20-30F above ambient temp)

4. Read AC output from inverter/s. __________Watts

5. Adjust your (previously calculated) expected peak AC output number ________AC Watts to reflect the impact of the actual site irradiance and temperature at the given moment.


A. Increase or decrease the number it as corresponds to your recent irradiance measurement. (Equation)

B. Increase or decrease the number it as corresponds to your recent temperature measurement. (Equation)

6. Compare recorded AC output _________Watts AC from the inverter at the site to your adjusted expected AC output number__________Watts AC (DC to AC watts adjusted to site conditions), if they are close it appears that the system is functioning properly.

Inverter start-up & shut-down procedures (energizing/decommissioning)

Refer to the provided Inverter Manual for additional information as required.

* * * W A R N I N G * * *

Start-up and shut-down procedures for this grid connected PV system shall only be performed by authorized per-sonnel. Operation of the system with any enclosure access doors open is discouraged. Lethal levels of current and voltage may be present in all compartments at all times regardless of whether the PV array is exposed to sunlight. A minimum of two qualified personnel equipped with appropriate safety attire shall perform these procedures.

Automatic operationIf the system is performing normally after a successful start-up, no activity by the operator is necessary. In the course of a 24-hour cycle, the unit will automatically connect and disconnect from the grid as a function of the time of day, amount of insolation, and other operational parameters as required by the NEC codes.

Routine Maintenance

WARRANTY NOTICEWhile the solar array system is under the warranty, only qualified personnel shall perform maintenance. Any maintenance procedures other than those expressly defined in the paragraphs below or in the included product guides and manuals are discouraged and may result in damage to the system.

Safety considerations

* * * W A R N I N G * * *

Lethal levels of voltage may be present at all times. Extreme caution should be used in all maintenance ac-tivities. All product guides and manuals must be read and understood before maintenance procedures are performed. It is recommended that at least two qualified personnel, attired appropriately for safety, perform any maintenance. All mandated safety precautions for the local and national region should be followed.


Routine maintenance schedule

The SolarWorld Sunkit solar electric system is designed for unattended operation and very low maintenance. Mini-mum required routine maintenance must be done on a scheduled basis, unless a significant reduction in system output is discovered.

EVERY FOUR MONTHS

PV PANELSVisually inspect the front surface of each PV modules for cracked glass, blown debris, dust, any opaque sub-stances or vandalism. A simple rinse with pure water is all that is required for removal of any obstructions on the face of the modules, rain will most often suffice. Do not use ANY additives like soap, abrasives or power washers to clean the surface of the modules. Some cleansers may harm the modules through chemical reactions. This can permanently damage the modules and void power warranties. Follow module guides for appropriate cleaning techniques. Inspect the back of the panel for environmental debris such as bird nests and insect hives. The debris may be carefully removed by hand without the removal of the PV module

INVERTERSCheck the display on each inverter to ensure that the system is operating as expected. Fans should be checked for debris and obstructions.

YEARLY

STANDARD MAINTENANCEWe recommend that the system be inspected at regular intervals to ensure:

_ All mounting points are tight and secure and free of corrosion._ All cable connections are secure, tight, clean and free of corrosion._ Cables are not damaged in any way. _ The conductivity of module frame to earth ground.

INVERTERSFollow the inverter installation guide for trouble shooting and maintenance.

COMBINER OR FUSE BOXESOpen the front panel and carefully remove any debris by hand.

SUPPORT STRUCTURESight down the length of each array row from either end. The continuous array should appear to be relatively straight. Some settling, shifting or shrinking can be expected over time.

Check hardware and connection points for tightness and security. Appropriately tighten, to installation guide torque specifications, any connections that may have loosened due to settling and expansion and contraction of components due to temperature.

Recommended maintenance tools

Tools Required QuantityVarious hand tools A/RFuse puller 1Volt Meter (600 VDC min) 1Amp meter (minimum 10 A, varies by installation 1


Troubleshooting faults

Inverter faultsRefer to the inverter installation guide for trouble shooting of inverter faults.

Module faultsModules are designed for a MINIMUM of 25 years of low maintenance operation. If in the course of troubleshooting the inverter, it is believed that the modules or installation are causing the fault, it is recommended to contact the installing company or a comparable certified solar installer.

Warranty

Warranties are held by individual major component manufacturers and providers; modules, Inverters, and the instal-lation company of record as required by state and local codes.


Troubleshooting

Field test/troubleshoot for grid-tied solar module applications (CreDHaprRC rev 120117)

The installation & testing of solar modules requires a great degree of skill and should (if DC voltage exceeds 30V: must) only be performed by qualified licensed professionals. The installer assumes the risk of all injury that might occur to persons or damage to property including, without limitation, the risk of electric shock when working with live electrical components.

PLEASE READ THIS GUIDE COMPLETELY BEFORE TAKING ANY ACTION. Be sure to refer to documentation provided with your solar equipment. Your authorized SolarWorld Solar distributor or dealer can provide additional sizing and system design information if necessary.

Disclaimer of LiabilitySince the use of this guide and the conditions or methods of installation, operation, use and maintenance of the module are beyond SolarWorld control, SolarWorld does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected with such installation, operation, use or mainte-nance. The information in this guide is based on SolarWorld’s knowledge and experience and is believed to be reli-able; but such information including product specifications (without limitations) and suggestions do not constitute a warranty, expressed or implied. SolarWorld reserves the right to make changes to the product, specifications, or guide without prior notice.

* * * W A R N I N G * * *

All instructions should be read and understood before attempting to install, wire, operate and maintain the photovoltaic module. Contact with electrically active parts of the module can result in burns, sparks, and lethal shock whether the module is connected or disconnected.Photovoltaic modules produce DC electricity when exposed to sunlight or other light sources. When modules are connected in series, voltages are additive. When modules are connected in parallel, current is additive. Con-sequently, a multi-module system can produce high voltages and current which constitute an increased hazard and could cause serious injury or death.

CAUTIONS

_ Avoid electrical hazards when installing, wiring, operating and maintaining the module.

_ When installing or working with module or wiring, cover module face completely with opaque material to halt production of electricity.

_ It is recommended that the module remain secured in original packaging until time of installation.

_ Do not touch terminals while module is exposed to light or during installation. Provide suitable guards to prevent contact with 30VDC or greater. As an added precaution, use properly insulated tools only.

_ Always use proper PPE (Personal Protective Equipment) including but not limited to gloves, eye protection, hard hat, fall protection, boots etc.

_ Electrical arcing may occur when connecting or disconnecting module circuits under load. An arc may emit intense light that can damage vision and can cause burns or sparks.

_ Do not drop module or allow objects to fall on module.

_ Do not stand or step on module.


_ Since sparks may be produced, do not install module where flammable gases or vapors are present.


_ Never leave a module unsupported or unsecured. If a module should fall, the glass can break. A module with broken glass cannot be repaired and must not be used.



_ If not otherwise specified, it is recommended that requirements of the latest local, national and / or regional electric codes be followed.

_ Use module for its intended function only. Follow all module manufacturer´s instructions. Do not disassemble the module, or remove any part or label installed by the manufacturer. Do not treat the back sheet with paint or adhesives.

_ Do not artificially concentrate sunlight on the module.

Note: The word “module” as used in this guide refers to one or more photovoltaic modules.

You may use this document as a worksheet to help troubleshoot an issue. If an issue is found or resolved not all tests are needed. Please take notes as you test. All electrical tests are in DC voltage only.

□ 1. Visually inspect the system for visible damage. Please take several pictures (close-up and wider shots) then email them to SolarWorld for review (contact info follows below).

□ Broken Glass □ Hotspot (brown marks) □ Damaged Cabling □ Other:

□ 2. Document how system wiring is connected.

Take pictures, make a drawing or label the wires so you can properly reassemble everything after testing.

□ 3. Check wiring connections and protection devices. Make sure connections are tight and secured properly. Fuses may be enclosed in a disconnect or in a combiner box. Ground Faults as indicated by inverters are commonly caused due to pinched, frayed or damaged wiring such as module cabling OR string circuits ( jumpers and homeruns).

□ Loose Solar Connectors □ Fuses / Breakers □ Damaged Cabling □ Wiring Terminals

□ Splices / Junctions □ Burn Marks □ Corrosion □ Other:

□ 4. Test solar module voltage Voc (Voltage open circuit / no load):

Be sure to isolate the solar module, and test it with no other items connected. This means that only the electrical meter is electrically connected to the solar module. Testing the module alone is essential because other parts of the system may have failed and can impact the measurements.

Turn off all loads and open appropriate disconnects. For additional safety it is recommended that you de-energize the solar modules by covering them with an opaque material, then carefully disconnect the solar module connec-tors from the string / circuit then test the module Voc. Now use a trusted multi-meter set to DC volts and be sure to place the solar module in full sunlight.

220 to 260 watt (60 cell) modules should test between 32 - 39 volts Voc (weather and sunlight impact voltage).

140 to 185 watt (72 cell) modules should test between 38 - 46 volts Voc (weather and sunlight impact voltage).


(Example)Module 1, top right

(Model)SW245 mono

(Serial)408201234

(Measurement) 35 Voc(Notes) Tested good

If you get voltage, that is below the above numbers please contact your local distributor or SolarWorld customer service for additional support (contact info follows below).

□ 5. Comparative analysis: If you have additional solar modules or inverters on site be sure to measure them and compare them to your suspected solar hardware. Small differences are normal so look for larger or meaningful differences. Please compare or swap devices when appropriate to verify your suspected conclusions. Examples follow:

Solar module- Module “A” measures 36 Voc. Module “B” an identical unit, measures 28 Voc. This would indicate that module “B” is likely a defective module.

Micro Inverter- If a micro inverter will not operate correctly, in full daylight swap EITHER the micro inverter or a mod-ule within the system and trace what component the problem follows.

If a micro inverter won’t work with several solar modules it is likely that the issue is with the micro inverter. If several inverters won’t work with the same solar module, the solar module is likely the problem.

□ 6. Short Circuit Current Test (Isc): SAFETY NOTE: THIS CAN GENERATE A SPARK OR ELECTRIC ARC AND DAMAGE METAL SURFACES. IT CAN ALSO DESTROY YOUR METER or FUSE. BE SURE YOUR METER CAN HANDLE ABOVE THE MODULE’S CURRENT (Isc) OUTPUT RATING.

Be sure to isolate the solar module, and test it with no other items connected. This means that only the electrical meter is electrically connected to the solar module. Testing the module alone is essential because other parts of the system may have failed and can impact the measurements. Testing should be carried out in bright noon time / full sun / good weather conditions.

A. Turn off all loads and open disconnects.

B. De-energize the solar module by covering it with an opaque material (or if removed, face module away from sunlight)

C. Carefully disconnect the solar module connectors from the string / circuit.

D. Using a trusted multi-meter set to DC amps (Isc) carefully make meter probe to solar wiring connections and expose the solar module to full sunlight, note your measurement.

E. Cover module (or face module away) from sunlight, then remove meter connections.

Your measurement WILL VARY depending on your module, light intensity, location, weather, tilt angle, etc

For field test quick estimation, if you get 75% of the labeled short circuit current (Isc) rating the solar module appears good.


Refer to solar module label / data sheet short circuit current (Isc) →

( ___ ) Isc

x .75x 75%

= ( ____ )Calculated number

Is (Isc) test measure-ment equal to or above

calculated number?

(example) module 1, top right (model) SW245 mono (serial) 408201234

(measurement) 7amps (Isc) (notes) tested good

8.25 (Isc) x 75% = 6.19 amps

If the module doesn’t improve with any of the above troubleshooting and if the module is still under warranty please contact your local installer / distributor. You may also contact SolarWorld to obtain a RMA (Return Merchandise Au-thorization) from us in order to send in the module. We will diagnose it and make our determination.

Contact:

SolarWorld Customer Service 805-388-6590 [email protected]

SolarWorld Technical Support 805-388-6587 [email protected]


SolarWorld return Merchandise Authorization form RMA#: (issued by SolarWorld).

Customer information Project name: Date:

Contact name:


County/misc:

Phone: Email:

Purchase Information Distributor company name: Purchase/install date:

Distributor contact name: Installer contact name:


County/misc:

Phone: Email:

Return shipping information RMA number must be issued before products are returned. All shipments with no RMA number will be refused. SolarWorld will specify return address along with RMA number.

Shipping notes:

Return classification Reason for return

□ New Product Return (no damage/no defect) □ Defective upon arrival/install □ Wrong item/s

□ Damaged/Defective Product □ Damaged/refused Shipment

□ Other □ Defective from existing/commissioned system

□ Other

Conditions of items:

□ Unopened new □ Opened new □ Damaged/defective product

Item information

Item brand & model: Quantity: Serial:



Notes:

Contact:

SolarWorld Customer Service 805-388-6590 [email protected]

SolarWorld Technical Support 805-388-6587 [email protected]


Audit form – example

1 Confidential Installation Audit Form 110930

PV System Installation Audit

Date: ___________

Installer Information Company Name

Address

Primary Phone # Other

E-mail

Distributor Contact

SW Account Manager

Project Information Project Name SK #

Project Address

System Owner Contact Phone #

Utility Rate Schedule

Annual Usage (kWh) Proposed System Size

Inspector Information Name

Signature

Date of inspection

Inspection Status




Interconnection Information Make & Model # of main service panel

Meter number

Main breaker size

Buss bar rating

Sub-panel model and buss rating

Sub –panel feeder breaker

Other POI-supply side connection, load side tap, etc.

Other electrical sources (batteries, wind, generators, etc.

Electrical concerns & Code Violations (690.64; 705.12)

Other Article 230 Considerations (6 handle rule, service disconnect rules, etc.

Comments

Roof Information Roofing Type (comp, masonry tile, ssmr, membrane)

Method of sealing penetrations

If DC conductors run through the house identify method used to address protection issues.

Roof condition

Roof damage

Inspect penetrations and stand-off installation

Comments




Racking System Racking System Mfr & Model

Confirm installed per Mfr instructions

Visually inspect and use “pull test” to confirm installation to structural member

Confirm module properly secured at ¼ points - between 8-16 inches

Confirm non current carrying metal parts are grounded properly. (frames, racking, boxes, etc.

Type of lugs or WEEBS

Comments

Photovoltaic Module/Array Information

Module Model Number Array #1 Array #2

Number of modules

Number of modules per string

Number of strings

Confirm modules are grounded properly

Confirm connections are fully engaged

Cable management

Wire Clips/Zip ties (black are UV resistant)

Visually inspect for damaged modules

Stand-off height

Confirm strings properly configured (all modules are facing same pitch and azimuth)

Comments




Inverter Information Number of Inverters

Inverter Make & Model

Inverter Installation-Confirm properly mounted

Verify ground installation to inverter (UFER, ground rod, GEC)

Confirm Input String Voltage within Operating Voltage (use table 690.7 correction factors)

Confirm NEC Compliant Disconnects (pyhisically-separable disconnect and wiring box from actual inverter unit

Comments

Wiring and overcurrent protection Wire type is 90°C wet rated (USE-2, THWN-2)

Electrical boxes and conduit bodies on roof reasonbly accessible?

Electrical connections suitable for the environment?

Confirm conductor ampacities are sufficient?

Inspect combiner or j-boxes (confirm weep hole or other drainage)

Verify source circuit overcurrent protection is sufficient

Verify overcurrent protection on inverter output circuit is sufficient

Verify point of connection meets provisions of NEC 690.64, 705.12 & verify Article 230 has not been violated

Check that all cable and conduit is properly supported

Verify complete system bonding to main UFER/Grounding Rod at location

Comments

PV system signs and labeling Do signs have sufficient durability? Sign IDing PV power source (at DC disconnect) Sign IDing AC point of connection Sign at main electrical service disconnect




Performance/Site evaluation Is the system in operation? If no turn on.

Has a “smart” meter been installed?

Azimuth direction of array-True Array #1 Array #2

Tilt angle of array

Time of day

Ambient Temperature

Module Temperature

Irradiance (W/m2)

Watts ouput on inverter display (measured immediately after irradiance measurement)

Voltage output on inverter display

Total Energy production (kWh)

Verify shading conditions-attach shade report

Look for any environmental variables that may affect system performance (Dusty conditions, trees, animals, etc.

Comments




1. Attach a copy of the customer usage data. 2. Visually inspect the installation at all structure entry points to insure they are

properly weather sealed. (Attach Photos) 3. Visually inspect the installation for proper module and system grounding.

(Attach Photo)

4. Visually inspect all external wires and connectors for damage and proper connection. (Attach Photo)

5. Verify modules are mounted on proper quarter points

6. Verify proper system labeling of all components . (Attach Photos)

7. Verify that all DC system grounding is installed correctly

8. Measure ambient temperature (degrees C) and irradiance (W/M2) and record on the Worksheet

9. Take the following photos:

• DC switchgear / combiner(s) overall

• Close-ups of the DC switchgear / combiner(s) nameplates(s)

• Close-ups and overall photos of the monitoring equipment

• All accessible conduit runs

• Tape measure showing the height of the array from the roof to the

• bottom of the modules

• Close-ups of module nameplates




Notes/Comments

Date: Project:

SolarWorld France SASHôtel de l‘Entreprise, Petite Halle, Bouchayer-Viallet31, rue Gustave Eiffel38000 GrenobleFrance

SolarWorld Africa Pty. Ltd.20th Floor1 Thibault SquareKapstadt, 8001South Africa [email protected] solarworld-africa.co.za

SolarWorld Asia Pacific Pte. Ltd.72 Bendemeer Road#07-01, LuzerneSingapore 339941Singapore

Production and sales locations of the SolarWorld group

SolarWorld Ibérica, S.L.C/La Granja 15, Bloque B-1°B28108 Alcobendas, MadridSpain

SolarWorld Americas LLC4650 Adohr LaneCamarillo, CA [email protected]

SolarWorld AGMartin-Luther-King-Str. 2453175 BonnGermanyPhone: +49 228 55920 0Fax: +49 228 55920 [email protected]

solarworld.comSW-0

4-51

21U

S 02

-201

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Location Distributor

Rheinfelden Freidberg

Bonn

Grenoble

Madrid

Cape Town

Singapore

Boca Raton

Hillsboro

Camarillo

Lennox SunSource Home Energy Retail Book July 2013

Documents

Transcript of Lennox SunSource Home Energy Retail Book July 2013