Installation and Safety Guide MIPV Leisure Series safety ... · MiPV (BIPV Ltd.) does not assume...

Installation and Safety Guide

MIPV Leisure Series safety and

installation guide for Multiple

module photovoltaic systems for

Motorhomes & Caravans.

Products Codes:

MIPV 013A (480W)

MIPV 016A (330W)

Contents

2

MIPV Installation Manual v2.3.1

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1. Introduction ................................................................................................................................................... 3

2. Scope ............................................................................................................................................................. 3

3. Package Contents .......................................................................................................................................... 3

4. Packaging ....................................................................................................................................................... 3

5. Disclaimer of liability ..................................................................................................................................... 4

6. General Safety ............................................................................................................................................... 4

7. Handling Safety ............................................................................................................................................. 4

8. Technical Specification .................................................................................................................................. 5

9. Installation Safety .......................................................................................................................................... 6

10. Required Tools ............................................................................................................................................... 6

11. Bonding MIPV module to the roof of a motorhome or a caravan. ............................................................... 7

12. Preparing the Roof ........................................................................................................................................ 8

13. Laying the panel ............................................................................................................................................ 9

14. Installing the Cabling ................................................................................................................................... 11

15. Position the Entry Gland Cowl ..................................................................................................................... 11

16. Installation wiring diagram for four module series-parallel system ......................................................... 12

17. Installation wiring diagram for three module parallel connection system ................................................. 13

18. Installing the Charge Controller .................................................................................................................. 14

19. Connecting to the battery ........................................................................................................................... 14

20. Connecting the solar modules ..................................................................................................................... 15

21. Maintenance of MiPV solar modules .......................................................................................................... 15

22. Accessories .................................................................................................................................................. 16

3


Introduction

3

PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING OR USING THE MODULES. PLEASE PASS ALONG THE MANUAL TO YOUR CUSTOMER.

1. Introduction The MIPV leisure series module is a truly flexible peel and stick PV module manufactured specifically for the leisure vehicle market. Our Powerful, lightweight and flexible module is ideal for direct application onto motorhome and caravan roofs.

2. Scope This manual is for the installation of MiPV leisure series kits comprising of either three or four MIPV solar modules, a charge controller and ancillaries for installing on a caravan or motorhome.

Applicable Products: Product Codes: MIPV 013A (480W)

MIPV 016A (220W)

For other MiPV products please refer to the relevant instructions.

3. Package Contents The MIPV Leisure series kit will contain the following items:

Product Reference: MIPV013A MIPV016A

MIPV solar module 4 3

Charge controller P1500B - 1

Charge controller PC164015 1 -

Twin gland entry cowl 1 1

Red 4mm solar cable with MC4 connector 20m 15m

Black 4mm solar cable MC4 connector 20m 15m

Jumper cable MC4 connector 1 x 500mm 4 x 750mm

10A In-line Fuse - -

2 into 1 ’Y’ Connector (FF-M & MM-F) 2 -

3 into 1 ’Y’ Connector (FFF-M & MMM-F) - 2

50ml Isopropanol cleaner (Aktivator) 8 3

290ml white adhesive / sealant 1 1

Twin gland entry cowl 1 1

Gloves 1 1

Installation and safety instruction 1 1

Warranty Card 1 1

4. Packaging Modules will be shipped to retail customers rolled up in cardboard boxes. Boxes should be kept upright and stacked no more than 2 boxes high. DO NOT use any sharp objects to open the packaging

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Safety

4

5. Disclaimer of liability This document does not constitute a guarantee, expressed or implied. MiPV (BIPV Ltd.) does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected with installation, operation, use or maintenance of the PV modules. No responsibility is assumed by MiPV (BIPV Ltd.) for any infringement of patents or other rights of third parties that may result from use of PV module. MiPV (BIPV Ltd.) reserves the right to make changes to the product, specifications or installation manual without prior notice. All the information described in this manual is the intellectual property of MiPV (BIPV Ltd.)

6. General Safety The following guidelines are to be followed to ensure the safe storage, handling and installation of the MiPV modules. Failure to follow these instructions may result in serious bodily injury, damage to the equipment or property. Failure to follow these instructions may invalidate the MiPV warranty

Electrical and mechanical installation of the MiPV Leisure Series PV system should be carried out by a qualified vehicle technician. MiPV has a network of authorised installers across the UK. For details of the nearest authorised installer please contact [email protected].

The installation must comply with the administrative and technical provisions of the respective country in which it is used. National regulations and law must be observed.

Under normal conditions, a photovoltaic module is likely to experience conditions that produce more current and/or voltage than reported at standard test conditions. Accordingly, the values of Isc and Voc marked on this module should be multiplied by a factor of 1.25 when determining component voltage ratings, conductor current ratings, fuse sizes, and size of controls connected to the PV output.

When the modules are connected in series, voltage is cumulative. When the modules are connected in parallel, current is cumulative, this will result in higher currents or voltages being present in a multi module system.

The solar module generates electricity and is hazardous when exposed to light even in very low light conditions; always treat the MiPV module as live. Avoid contact with any live parts and ensure all live circuits have been isolated before making or breaking any connection.

Before installing the modules, we recommend you cover the front of the module to prevent any electricity being produced.

DO NOT shade part of the MIPV module surface from the sunlight for a long time. A shaded cell may become hot and will cause a drop in generated power and could cause failure

DO NOT artificially concentrate sunlight on the module.

ALWAYS use the correct tools when installing the PV module including insulated tools and appropriate personal protective equipment (PPE).

TURN OFF charge controllers and circuit breakers immediately, should a problem occur.

7. Handling Safety DO NOT lift or pull the module by the connection cables this can cause irreversible damage to the module and invalidate the warranty.

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Safety

5

Keep the MIPV modules packed in the carton until installation.

Static may be present in the MIPV module, e.g. after friction of the modules over the surfaces (electrostatic loading). This can discharge through the edge on the module, to avoid discomfort always handle modules with polymeric gloves (e.g. nitrile or nitrile coated knitted gloves).

Do NOT place MiPV modules directly on top of each other.

The front surface of the MiPV module is susceptible to scratching, avoid scraping with sharp edges.

Do NOT stand or step on the MiPV module.

Do NOT place or allow hard objects to fall onto MiPV modules

Do NOT cause the MiPV module to flex or twist excessively. A bending radius in excess of 225mm can damage the module.

Technical Specification

8. Technical Specification There are no user serviceable parts in the MIPV Leisure Series solar kits. DO NOT attempt to repair, alter or remove any part of the equipment included in the kit.

MiPV PHOTOVOLTAIC MODULE SPECIFICATIONS

F11F-110BM F13F-120B1

Nominal Power (W) 110 120

Open Circuit Voltage (V) 35.4 38.6

Open Circuit Current (A) 4.39 4.43

Maximum Series Fuse Rating (A) 10 10

Length (mm) 1293 2609

Width 674 358

Thickness 2.5mm – (17mm at Junction Box)

Solar cell type CIGS (Copper, Indium, Gallium, Selenide)

MIPV modules meet the requirements of IEC 61730 & 61646 MIPV CHARGE CONTROLLER SPECIFICATIONS

P1500A PC164015

Battery Voltage (V) 12 12

Maximum PV input voltage (V) 50 145

Rated Current (A) 30 40

Max PV Input Power (W) 390 600

Weight (kg) 0.35 2.5

6


Mechanical Installation

6

READ CAREFULLY AND STRICTLY OBSERVE THE ASSEMEBLY INSTRUCTIONS BEFORE STARTING WORK.

9. Installation Safety DO NOT install MiPV modules in wet or windy conditions to avoid risk of personal injury or damage to property.

When working at height follow all national guidelines. Always use appropriate safety equipment.

DO NOT walk on MiPV leisure series solar modules.

MiPV modules are designed to be applied on to subtlety curved structures such as those found on the bulkhead of a motorhome. They are not intended to be applied to sharp curves.

DO NOT apply paint, adhesives or solvents to the top surface of the MiPV module. Keep all electrical contacts clean and dry.

DO NOT cut, drill or penetrated or modify MiPV modules in anyway. Cutting the modules will result in exposed conductors and will void the warranty and could result in injury.

MiPV Leisure Series (with adhesive backing) has a minimum shelf life of one year prior to installation when stored at temperatures below 24°C

Leave all protective packing on the module until they have been installed on the roof.

Modules should be installed in a location where the wind uplift is at its minimum (see figure 1 for example).

The ambient temperature at the time of installation should be between 4 °C and 40°C

If the temperature is greater than 40°C, the polymer release liner may be difficult to remove from the adhesive backing and the adhesive may exceed the adhesive application temperature. If the temperature is lower than 4°C the module may not adhere to the roof structure.

Before applying the module to the roof, ensure they are stored in a dry and cool location to avoid issues with adhesion to the roof.

Modules should only be applied to a dry, clean roof prepared as per this manual. Do not apply on a wet/damp roof.

10. Required Tools Screwdriver

Drill Bit 10mm

Meter Ruler

Adhesive

Tape Marking Pen / Pencil

Clean Lint Free Cloth

Cartridge Gun

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7

11. Bonding MIPV module to the roof of a motorhome or a caravan. The bonding and application guidelines listed below are provided as an outline only and apply only to the application of the module onto polymeric motorhome or caravan roofs. For instructions on the application of the modules to other roof types please contact your supplier.

Failure to follow these guidelines when installing the modules on the roof could invalidate the warranty. For full warranty details please consult the warranty documentation.

We recommend that all roofs are cleaned prior to application of the solar panel. The roof should be cleaned using warm water and proprietary cleaners. Please ensure the roof is fully dry before beginning the installation process.

Once the roof surface is dry, use a pencil or a marker pen to mark out the four corners of the panel. To ensure the panel is mounted squarely on the roof, measure the distance from each corner of the panel to the edge of the vehicle roof. We suggest the location such that the MiPV module junction boxes are as close as possible to any trunking or service ducting within the vehicle. We would also strongly advise against installing the panel with its leading edge in position A (figure 1) which is the area of maximum aerodynamic uplift/peel force when the vehicle is in motion. Moving the panel backwards from this point to position B is strongly advised. Ensure any curved surface the module is fitted to has a radius greater than 225mm (Please note the maximum diameter of a rolled module must be greater than 450mm)

Figure 1

A

B

mailto:[email protected]

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12. Preparing the Roof WARNING: Please refer to the safety data sheet included in the kit for the isopropanol activator. Ensure that when preparing the roof you do so in a well-ventilated area away from naked flame and always use the safety gloves provided.

Before applying the activator to the desired location on the roof, we advise that firstly you test a small area of the roof to ensure that the activator has no adverse impact on the roof structure. Once you are satisfied that there has been no adverse impact, clean the area where the module is going to be located using the activator. Ensure you extend the clean area to 10cm beyond the perimeter of the module (figure 2).

After cleaning the roof and applying the activator, lay the panel in position ensuring the release liner is still in place and secure it to the roof using tape leaving one end of the panel free for at least the end half of the module (figures 3 & 4). Only when you are fully satisfied with the position of the module proceed to the next stage.

IMPORTANT NOTE: Extreme care should be taken before beginning to lay the module. Once you begin the laying of the module you are committed to its positioning which cannot be later changed.

Clean Area - Clean this area with the

activator Remember to extend beyond the module perimeter by at least 10cm

Figure 2

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9

Figure 3 Figure 4

13. Laying the panel

Bend back the connector end of the module and carefully peel back a single section of 300mm of the white backing and fold it back over the still protected area (figure 5). Carefully lay down this exposed section of the black adhesive adhering it to the roof, ensure the module alignment does not change. Press down firmly using a dry cloth to ensure that the adhesive backing makes full and even contact with the vehicle roof (figure 6)

Figure 5 Figure 6

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10

Now the module is secure by one end remove the tape and lift the other end of the module and roll back ensuring you do not crease the module. Find the folded back section of the release liner (figure 7) and carefully pull back the release liner laying down the module as you proceed. Press down using a dry cloth as you go working towards the free end of the module (figure 8). When the module has been applied to the roof, use a clean and dry soft cloth to work along the entire panel to ensure all parts of the panel are in full contact with the roof surface.

Figure 7 Figure 8

11


Electrical installation

11

14. Installing the Cabling Prior to finally connecting the module, ensure all connectors and cabling is in good working order. Ensure the connector plugs properly secured and no cuts to the cable insulation. Do not install the module if any components or parts supplied by MiPV are not in good working condition.

IMPORTANT NOTE: Do not connect the leads to the MiPV solar module. This must be done later in the installation process (see section 20).

You will need to install the cabling which will connect the module to the solar charge controller. Once you’ve decided on the location of the cable entry point, you will need to drill through the vehicle roof. MiPV recommend that this is done from within the vehicle and where possible by utilising the cable service/trunking to avoid miss drilling (See figure 4). These service points are usually be found in the overhead lockers in most caravans and motorhomes. A 10mm clearance hole will be required to accommodate the two connection leads.

IMPORTANT NOTE: If in doubt about the positioning of the holes or the suitability of the roof for drilling check with the vehicle supplier.

The connection leads are provided in two colours. The RED lead has a female connector; this will connect to the male + (positive) plug of the module.

Each MiPV module has two junction boxes marked (+) for positive and (-) for negative. Connect the RED lead to the positive (+) terminal and the black lead to the (-) terminal.

Feed the cable tails through the two glands fitted in the supplied roof entry cowl non-plugged end first.

DO NOT tighten the glands on the cable until the installation is complete. Ensure you leave ‘free play’ in the cable to connect to the module and thread the tails through the 10mm hole you have previously drilled.

15. Position the Entry Gland Cowl Once you’ve fed a sufficient length of the connection cables through the roof you now need to apply a generous bead of the sealant into the hole and cables.

Apply a bead of sealant to the bottom of the entry gland cowl.

Position the roof entry gland cowl in the desired location and then gently slide the connection cables through the glands. Ensure the remaining portion of free cable is sufficient to reach the module plugs.

Once you are satisfied that all is in the correct order, place the roof entry cowl over the tail lead entry point.

It is important to ensure that the roof entry gland maintains good contact with the roof surface. Firmly press the roof entry box down and fasten in position using masking tape and/or weight if necessary.

Once all the above steps are complete, whilst holding the entry gland cowl, securely, tighten the entry glands (do not over tighten) on the entry cowl and remove all tape and ‘holding down’ implements.

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16. Installation wiring diagram for four module series-parallel connection systems (Product MIPV 013A only)

(*)Fuse (not required for MIPV 013A product)

Figure 9

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17. Installation wiring diagram for three module parallel connection systems (Product MIPV 016A only)

(*)Fuse (not required for MIPV 016A product)

Figure 10

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18. Installing the Charge Controller Choose a suitable position in the vehicle to mount the charge controller. This should be away from combustible, materials with suitable air flow to allow cooling.

When a suitable position for the charge controller has been identified mount the controller to the vehicle securely using suitable fixings.

Route the cables from the roof of the vehicle to the location of the charge controller. An in-line fuse is supplied for kits MiPV 010A) this should be connected to the positive (red) connection cable see figure 9. Connect the cables to the correct input terminals (red +ve, black –ve) ensuring the all securing screws are tight.

Negative output to Battery Positive output to Battery

Negative Input from Module Positive Input from Module

Charge controller P1500B Charge controller PC164015

Figure 11

19. Connecting to the battery The MiPV Leisure solar products must be connected the leisure battery system only and MUST NEVER be connected to the main vehicle battery.

The connection to the vehicle leisure battery is outside the scope of these instructions. Connection should be carried out by a qualified vehicle technician.

IMPORTANT – If the vehicle contains an intelligent battery management system, be sure to connect the MiPV charge controller according to the vehicle manufacturer’s instructions.

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15

When connecting the charge controller to the vehicle ensure you use the correct polarity. The connection leads should be of sufficient cross section to carry the charging current (Note: longer cables will require a larger cross section). If the connection is directly to the leisure battery the connection cable should be protected by a suitability rated fuse positioned as close to the battery as possible on the positive battery lead.

20. Connecting the solar modules The MiPV solar modules can now be connected to the cables you have installed into the vehicle. The solar modules should be connected together according to the appropriate circuit diagram.

For product code: MiPV 013A use the circuit diagram shown in figure 9 For product code: MiPV 016A use the circuit diagram shown in figure 10

IMPORTANT NOTE: Ensure the correct circuit is being used. Incorrect connection will result in incorrect voltages or currents being present. This can be hazardous and will cause damage to the charge controller and invalidate the warranty.

WARNING: The system is now energised and hazardous voltages may be present.

Use an appropriate cable management method to ensure all cables and plugs on the roof are fully secure and unable to move or vibrate when the vehicle is in motion.

Maintenance

21. Maintenance of MiPV solar modules Keeping MIPV Leisure Series Modules clean and unsoiled is critical to achieving maximum power output. Whilst rain will clean off dust and soil, we recommend that owners inspect and clean the modules regularly, particularly after visiting desert, urban and rural locations.

Observe all safety guidelines when working at height.

Be cautious when on motorhome/caravan roof. Roof surfaces can be extremely slippery when wet.

DO NOT walk on the surface of the module.

Wear protective gloves when cleaning the module.

When cleaning MiPV Leisure Series Module use a clean, damp, soft, non-abrasive micro-fibre cloth or sponge to wipe soil and dust off the module. Wipe with a gentle motion, and do not use excessive force.

Visually inspect the MiPV module, wiring and connections for any visible signs of damage.

DO NOT spray high pressure water directly onto the MiPV Leisure series modules, junction boxes or wiring as it will damage the module and will void the warranty

DO NOT use solvents or acetone when cleaning the module.

DO NOT use brushes and power cleaners on the module.

Do not use automatic car / van cleaners (car washes).

DO NOT attempt to repair solar modules or charge controller in the event of failure contact your supplier.

16


Accessories

16

22. Accessories

Accessory Part Code

MiPV Module 1293 * 358 (55W) F11F-055BM



MiPV Module 2609 * 358 (120W) F13F-120B1

MiPV Module 2609 * 990 (360W) F33F-360B1

Charge Controller PC1500A

Charge controller PC164015A

MC4 connector male LEADR0302SHOT1

MC4 connector female LEADR0303SHOT1

In-line Blocking diode c/w MC4 connections LEADR0304SHOT1

10A In-line fuse c/w MC4 connections LEADER0312SHOT1

In line fuse carrier c/w screw connections FUSEA0301SHOT1

2 into 1 MC4 connector LEADR0306SHOT1

Isopropanol cleaner 50ml ACPPU0301SHOT1

White adhesive white 290ml DEKAS0301SHOT1

5m x 4.0mm solar cable Red LEADR0310SHOT1

5m x 4.0mm solar cable Black LEADR0311SHOT1

500 mm jumper connection c/w MC4 connectors (Black) MULTI0308SHOT1




2 into 1 ’Y’ Connector (FF-M) LEADR0305SHOT1

2 into 1 ’Y’ Connector (MM-F) LEADR0307SHOT1

3 into 1 Connector (FFF-M) LEADR0308SHOT1

3 into 1 Connector (MMM-F) LEADR0309SHOT1

Crimping tool for MC4 connectors MULTI0315SHOT1

Cable Stripper MULTI0316SHOT1

Solar Spanner Set MULTI0317SHOT1


MIPV LEISURE SOLAR

PV ACCELERATOR SHOTTON WORKS, DEESIDE, FLINTSHIRE CH5 2NH WALES, UNITED KINGDOM

TELEPHONE: +44 (0) 1244 892069 EMAIL: [email protected] WEBSITE: WWW.MIPV.CO.UK

FOR FURTHER SUPPORT AND GUIDANCE ON INSTALLING MIPV MODULES CONTACT [email protected] OR TELEPHONE 01244 892069 FOR FREE ADVICE AND GUIDANCE.


http://www.mipv.co.uk/


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