Q.Flat: Installation and Operation Manual

INSTALLATION AND OPERATION MANUAL
Q.FLAT
Valid in Germany
TABLE OF CONTENTS
1 INTRODUCTION 3
2 SAFETY GUIDELINES 5
3 PLANNING 8
3.1 Requirements 8
3.2 Analysis of the Layout Ratio DC-to-AC 10

12
4 INSTALLATION 24
4.1 Preparation for Installation 24
4.2 Laying the Girders 26

27
4.4 Installation of Module Pairs 28
4.5 Securing Module Pairs 29
5 ELECTRICAL CONNECTION 30
5.1 Safety 30
5.2 Connecting Module Pairs 34
5.3 After Installation 35
6 GROUNDING 36
7 FAULTS AND DEFECTS 36
8 CLEANING AND MAINTENANCE 37
9 RECYCLING 39
DOCUMENTREVISION 01
This document is valid in Germany as of October 2012.
Technical parameters and the design are subject to change. The data sheets and customer information valid at the point in time at which
the relevant module was manufactured apply to the installation, mounting, and maintenance procedures for the respective solar modules
2 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

1 INTRODUCTION
With Hanwha Q.CELLS solar modules, you can directly transform the sun's unlimited available energy into environmentally-
friendly solar electricity.

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carefully and observe all the guidelines. Failure to follow these instructions may result in damage and/or physical injury.

Hanwha Q.CELLS.
Ä Please read these instructions carefully before proceeding with installation.
Ä

Ä Please ensure that this installation manual is available to the operator at all times.
Ä

!

Ä All supplements received from the manufacturer should be included.
Ä Please observe all other applicable documents.
Intended Use
This manual is valid in Germany. These instructions contain information regarding the safe handling and use of the

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wiring, and maintenance.
Symbols and Labels

The following symbols and labels are used in the installation manual to make the instructions easier and faster to
understand.
SYMBOL DESCRIPTION
Ä Procedure with one or more steps.
Lists of items
Ensure when carrying out a procedure, check the results of a procedure.
Prohibited procedural method.
Tab. 1: Symbols and Labels
Safety Regulations
The solar module operator is responsible for compliance with all applicable statutory requirements and regulations.
Ä The following regulations and standards must be upheld at all times during the installation, operation, and maintenance
of the solar modules:
Installation and Operation Manual
'

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environmental protection)
/
*

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&
&
&
solar power systems and work on roofs
Valid international, national, and regional regulations governing work with direct current, especially those applicable
to the installation of electrical devices and systems, and regulations issued by the respective energy provider
governing the parallel operation of solar power systems
Accident-prevention regulations
Regulations of the Bau-Berufsgenossenschaft (German institution for statutory accidence insurance and prevention
in the building trade)
FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 3

1 INTRODUCTION
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The operator and installer are responsible for ensuring that installation, maintenance, commissioning, and dismantling

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678 &
VDE regulations, accident-prevention regulations, and the regulations of the local energy provider.
Validity
These instructions are only valid for products from the company Hanwha Q.CELLS. Hanwha Q.CELLS assumes no liability
for damage resulting from failure to observe these instructions.
Ä Please observe the wiring and dimensioning of the system.
The installer of the system is responsible for compliance with all necessary safety regulations during set-up and installation.
Hanwha Q.CELLS assumes no liability on the basis of these instructions. Hanwha Q.CELLS is only liable in the context
of contractual agreements or in the context of accepted guarantees. Hanwha Q.CELLS accepts no other responsibility for
the functionality and safety of the modules.
Ä Please observe the instructions for any other system components that may be part of the complete solar power system.
It may be necessary to carry out a structural analysis for the entire project.
Ä If your questions are not satisfactorily answered in the manual, please contact your system supplier.
Additional information can be found on our website at www.q-cells.com.
Information for the Operator

Ä Register your solar power system immediately!
9*

!

Ä If you have any questions, please contact our Technical Customer Service Department at service@q-cells.com.
Ä Please keep this manual for the entire life of the solar power system.
Ä Please contact your system supplier for information concerning the formal requirements for solar systems.
Ä Please be sure to contact the relevant local authorities and energy providers regarding regulations and permit requirements

!9*

*

Other Applicable Documents

This installation manual is only valid in combination with the following technical information.
DOCUMENT TYPE VERSION
Product data sheet

2 SAFETY GUIDELINES
CAUTION
Risk of injury due to heavy girders with sharp edges!
Ä Ensure that all personnel are aware of and adhere to accident-
prevention and safety regulations.
I D GB
§ § §
Ä Inspect the packaging for damages.

Ä Contact the transport company regarding any damage to the
packaging.
Ä Follow any instructions on the packaging.
Ä Leave modules in their original packaging until installation.

Ä Store the modules securely in cool and dry rooms. The packag-
ing is not weatherproof.
DANGER
Risk of fatal injury due to electric shock!
Ä Do not install damaged modules.
Ä Inform your dealer of any damages immediately.

2 SAFETY GUIDELINES
DANGER
Ä Cover the modules with an opaque material during installation.
WARNING
Fire hazard!
Ä Do not install modules indoors.
Ä Do not install modules on moving objects.
NOTE
Damage to the modules!
Ä Never lift or move the module with the connection cables or
junction box.
Ä #
+
!
NOTE
Ä Do not let modules fall.

2 SAFETY GUIDELINES
NOTE
Ä Do not stack modules.
NOTE
Ä Never step on modules.
Ä Do not subject modules to any mechanical stress.
Ä Do not allow any objects to fall onto modules
NOTE
Ä '
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NOTE
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vapors.

3 PLANNING 3.1 Requirements
By using this document in conjunction with the Hanwha Q.CELLS design tool, you can plan your roof system with Q.FLAT. Please
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3.1.1 General Requirements
Installation Site
Please note the following guidelines that apply to the installation site:
The modules have been tested according to IEC 61215 for operation in a temperate climate.
Solar modules are not explosion-proof operating equipment.
Ä 6

( & >
Ä Do not install modules in enclosed spaces.
Ä Do not install modules in locations where water may collect.
Prevention of Shadowing Effects

Optimal solar irradiation leads to maximum energy output:
Ä Set up the modules so that the sun side points towards the sky.
Ä Avoid shadowing (due to objects such as buildings, chimneys, or trees).
Ä Avoid partial shading (for example through overhead lines, dirt, or snow).
Limitations
The solar modules are designed for the following applications:
Operating temperatures from –40 °C to +85 °C (–40 °F to +185 °F).
Wind dynamic pressure up to 0.85 58;X&!
YZ 58;X
Ä Make sure that the frames are open. Do not seal them.
3.1.2 Electrical Layout
Module Selection
Ä Detailed electrical parameters are provided in the product data sheet.
Ä Only connect modules of the same type and the same power class.
Fuses and Line Cross-Sections

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DIN VDE 0100-712.
Series Connection
Connection of modules in series is only permitted up to the maximum system voltage as listed in the current applicable
data sheet.
Ä Ensure that the system voltage is not exceeded in any operating situation.
Ä Take the voltage limit of the inverter into account when determining the string length.

3 PLANNING 3.1 Requirements
Parallel Connection
Under unfavorable conditions (e. g. due to faults), reverse currents may occur in a solar power system.
7
* &!
!

connection options:
1) Layout with a limited number of parallel connected strings :

Without undertaking further current blocking measures, a maximum of two module strings may be operated in parallel on
an inverter or MPP tracker.
2) Layout with string fuses :

Each module string must be protected on the plus and minus ends with a fuse. Take into account the reverse current
resistance of the modules and the layout guidelines provided by the fuse manufacturer when selecting the fuse value.
NOTE
When using different product versions (e. g. Q.PRO and Q.PRO - G2), the smaller reverse current load capacity value
applies.
3.1.3 System Description

The Q.FLAT system is designed so that the module frame is built into the module or mounting structure. This means that
in addition to the module, only four other components are required.
108 1955
55
2 3
2010
140
4
60
160
1630
Fig. 1: Components of the Q.FLAT SYSTEM

c Module d Girder e;

f Ridge connector g Ballast beam

3 PLANNING 3.2 Analysis of the Layout Ratio DC-to-AC
3.2.1 Analysis of the Layout Ratio DC to AC
NOTE
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+! ]`z % per year. The inverters were
connected identically during these tests.
When installing Q.FLAT with an east-west orientation, a DC-AC ratio of 1.35 applies under certain conditions. The DC-AC

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In Fig. 2, instantaneous values for Freiburg (in Breisgau) were used to calculate the ratio of generator power to the AC

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in this case due to the power limitation of the inverter as a limit value for the layout ratio (Fraunhofer Institute for Solar
Energy Systems – ISE).
90°
Inclination
1.6
1.5 1.55
1.35 1.4 1.45
75°
1.3
1.25
1.2
60°
Neigung
45°
1.15
30°
15°
0°
90° 120° 150° 180° 210° 240° 270°
East
Ost South
Süd West
West
Fig. 2: / 6#))# !

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! 5`&! 6#))#

Y~]!

Y]^ +

of 90° (east orientation) or, respectively, 270° (west orientation). This layout ratio only applies when each inverter is only
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(

west), this results in a feasible DC-to-AC ratio of 1.35 due to the lower average irradiation total via both orientations (see
Fig. 3, p. 11).

3 PLANNING 3.2 Analysis of the Layout Ratio DC-to-AC
950 210
$ *=)>?
Irradiance E (W/m2)
900 EE 10°
10°East
Ost 200
1 EE 10°
10°West
West
850 EE 10°
10°Middle
Mitte 190
800 PP 10° Ost

10° East 180
PP 10° West
10° West
170
750 PP Gesamt
Total
160
700
150
650
140
Energieertrag P (kW)
600
Einstrahlung E (W/m2)
130
550 120
500 110
450 100
400 90
350 80
70
300
60
250
50
200
40
150
30
100 20
50 10
0 0
03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00
TimeZeit t (h:m)
t (h:m)
Fig. 3: Irradiation levels on the module surface and power produced for east and west orientations on June 20th
in Berlin
c: East - west systems with 10° inclination angles
Inverter AC total nominal power 200 kW
2 symmetrical trackers with > 100 kW per tracker
DC to AC ratio: 1.35
'
*z %
WR loses inverter power - as function of the Module plane direction

1 1,05 1,1 1,15 1,2 1,25 1,3 1,35 1,4 1,45 1,5 1,55 1,6 1,65 1,7
-0,1
30° South
10° East
10° West-East
-0,3
-0,5
WR loses over inverter power (%)
-0,7
-0,9
-1,1
-1,3
-1,5
DC/AC Ratio
Fig. 4: Inverter losses due to power limitation at high DC to AC ratios

3 PLANNING 3.3 Technical Specifications
3.3.1 Q.FLAT Applications
Layout Grid

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(with sliding blocks). The fronts of the girders lie next to each other in the direction of orientation (gaps generally 5 mm,
max. 10 > ``]zYYX
95
195
5
Fig. 5: Top view
3.3.2 Usage Limits in Wind and Snow Load Zones (GER)

The Q.FLAT system was rated using the computational calculation for wind and snow loads on structures in accordance with
DIN 1055-4 & 5. The characteristic value for the snow load on the ground "sk" depends on the geographical location and

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++
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intensities. The snow load intensity increases from Zone 1 to Zone 3.
Wind loads are variable, free and independent factors. Photovoltaic systems are subjected to wind pressure and wind forces.
These pressures and forces should be calculated for each area subjected to the wind. Parameters for determining the wind
load include, among others, the topographical and climatological conditions. The wind dynamic pressure on the structure

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wind tunnel tests (model test).

DESCRIPTION VALUE
Max. snow load (ground) 5`]]58;X
Max. snow load (roof) Y5]`]]58;XYZ]58;X
Max. wind dynamic pressure Y`z58;X
(roof type 1 and roof type 2)
Roof type 3 Yz58;X
Tab. 2: !

*
TYPE OF ROOF ROOF EDGE WIDTH FASCIA HEIGHT

1 20-100 cm <50 cm
2 >100 cm <50 cm
3 >100 cm >50 cm
Tab. 3: Roof edge width and fascia height

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77)777( *

> 77( > 7 5
7 77)777( *

>
NOTE
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SNOW LOAD ZONES ALTITUDE ABOVE SEA ILLUSTRATION

LEVEL
SLZ1 d 930 m
SLZ 1a d 805 m
SLZ2 d 585 m
SLZ2a d 498 m
SLZ3 d 438 m
Fig. 6: %!
+ _
Tab. 4:
!
+(_ >

TERRAIN CATEGORY II – III (INLAND)

WIND LOAD ZONES BUILDING HEIGHT ILLUSTRATION
Roof type 1 and roof type 2
WLZ1 d 132 m
WLZ2 d 58 m
WLZ3 d 33 m
WLZ4 d 20 m
Roof type 3
WLZ1 d 283 m
WLZ2 d 124 m
WLZ3 d 57 m
WLZ4 d 34 m
Abb. 7:
+ _
Tab. 5:
!
+(_ >
TERRAIN CATEGORY II (COAST)

WIND LOAD ZONES BUILDING HEIGHT ILLUSTRATION
Roof type 1 and roof type 2
WLZ1 d 85 m
WLZ2 d 34 m
WLZ3 d 17 m
WLZ4 d8m
Roof type 3
WLZ1 d 222 m
WLZ2 d 78 m
WLZ3 d 33 m
WLZ4 d 17 m
Abb. 8:
+ _
Tab. 6:
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+(_ >

3.3.3 Ballast Distribution
NOTE
7
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( )
west = eaves side). The distribution of the color gradations is based on this. These should be taken into account if the
Q.FLAT system will be used as a north-south system, for example.
The weight and weight distribution of the ballast elements is determined by the geographical position of the installation

create the compulsory ballast plan, please contact your Hanwha Q.CELLS contact person.

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c in Fig. 9 to Fig.
Y` *
!9
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areas with the lowest ballast levels. There is no ballast in the white areas!
N
N
W
W OE
SS
Fig. 9: %
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c Module pair
N
N N
N
WW OE WW OE
S
S SS
Fig. 10: %

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left: for roof type 2 in accordance with [4]
right: for roof type 3 in accordance with [4]

Special notes for the individual roof types in accordance with [4]
+
+ !Z

7
&

+
Smaller system layouts are possible, but they must be approved in writing by Hanwha Q.CELLS. Please contact us in
these cases.
Larger than 14 rows x 12 module pairs:

If the system is larger than 14 rows x 12 module pairs, the loads on the corners and edges do not change.

+
!

+
+
Smaller than 14 rows x 12 module pairs (at least 4 x 6 module pairs):

If the system is smaller than 14 rows x 12 module pairs, the loads on the corners and edges do not change.
7 &
+ (YY>
Roof type 2 (Fig. 10 left):

The ballast is reduced by one color gradation if there are 16 or more module pairs (Fig. 11 left). This occurs in the
east-west direction in the north-south middle axis on the second row.
Roof type 3 (Fig. 10 right):

The ballast is reduced by one color gradation if there are 16 or more module pairs (Fig. 11 right). This occurs in the
north-south direction in the east-west middle axis.
Special note: The non-ballasted area (white color elements) expands if there are 12 or more module pairs in the
north-south direction.
NN
N
N
W
W O
E WW OE
S
S
SS
Fig. 11: %

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left: for roof type 2 with 18 (16 or over) module pairs in the east-west direction
right: for roof type 3 with 14 x 24 module pairs

3.3.4 Spacing
Spacing (e. g. for maintenance access) between the modules: These may measure up to 150cm without having to be
5 7! Yz]&

+
for the edge area must be adjusted. Please contact Hanwha Q.CELLS.
Spacings in the module array (e. g. for skylights) are permitted to a limited extent: The color gradations of the wind loads
in relation to one row around the spacing (not diagonal) must be increased by one color gradation (see Fig. 14). The color
gradation yellow remains unchanged as it indicates the maximum load.
N
N N
N
W
W EO W
W EO
S
S S
S
Fig. 12: %

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! Y

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*

right: with skylight on the edge
7
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*

! (Y`
right) then
either the girders have to be connected in the east-west direction with girder connectors (can be obtained from Hanwha
Q.CELLS),
or the four module pairs must be able to carry a higher ballast. If the latter is the case, please send the modules to
Hanwha Q.CELLS.
NOTE
Ä
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5 " ! #$%
This also applies for ballasting modules that are part of rows with less than three pairs (E-W or N-S) (in Fig. 12 on the
right, this applies to the two rows N-S on the east edge of the array).

3.3.5 Static of the Roof

Ä Ensure that the additional load from the Q.FLAT system (PVS + ballast) is covered by the bearing load reserves of the
roof structure.
NOTE
Damage to the girders!
Ä Ensure that no load concentrations can occur under the girders.
Ä Roof constructions without adequate lateral load distribution (e. g. corrugated sheet) should be inspected separately
by your structural engineer.
Ä 7

; &

)
distributing measures must be used. Please contact your structural engineer in this case!
)

(system dead loads including ballast and snow loads, which are dependant on the installation site) distributed over the
contact area of the girder (2.2 m * 0.14 m).
The distribution of the compression, starting from the girder, adapts to the stiffness of the roof construction including
roof structure (e. g. insulation).
max σ
2,20
Fig. 13: c Girder, d Compression stress distribution
Ä Ensure that the increased compression applied locally due to the distribution of the existing compression (tension
peaks in the edge area) are taken into account in the structural analysis of the roof. The exact calculation and load
distribution test should be done by your structural engineer.
3.3.6 Suitability and Protection of the Roof

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system.
NOTE
Damage to the roof cladding!
Ä Ensure that there is suitable separation between the bottom edge of the girder and the roof cladding.
We recommend laying a protective mat underneath the system. Select the appropriate type of mat for the roof cladding in
order to prevent damage. The protective mat used should be approved by the roof cladding manufacturer. Some protective
* !
NOTE
*]z]!

Ä If this value cannot be reached with the existing roof surface, please contact Hanwha Q.CELLS.
Notes on the ballooning effect of the roof membrane under wind suction loads: Vacuum pressure in areas subjected
!

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7 &
Ä Relevant securing measures should be implemented in order to prevent this from occuring.

3.3.7 Selecting the Ballast Elements

The following details should be taken into account when selecting the ballast elements to ensure that they can be
positioned under the module pair without damage:
Max. height = 150 mm
Max. width = 250 mm
max.
250 mm
max.
150 mm
Fig. 14: Max. ballast height
NOTE

!

*
the module pair.
Ä Ensure that at least 10 mm are left at the lowest point of the lower edge of the ridge frame.

!

( >

*
NOTE
Some other manufacturers work with different weights for the same dimensions.
NOTE
In order to achieve maximum ballasting in regions with extremely high wind loads, it may be necessary to arrange the
bottom ballast level transversely to the ballast girders.
Ä The weights of the ballast distribution in accordance with the ballast plan from Hanwha Q.CELLS must be complied with.
BALLAST ELEMENT DIMENSIONS IN WEIGHT

MM/MM/MM IN KG
Kerb edge (EF) DIN EN 1340 ;`z];z] 26
Kerb edge (EF) DIN EN 1340 ;`z];z] 13
Kerb edge (EF) DIN EN 1340 ;~]];z] 35
Trough (EF) DIN EN 1340 ;`z];] 48
Trough (EF) DIN EN 1340 ;~]];] 58
Trough (EF) DIN EN 1340 ;~]];Y]] 70
½ trough (TB) DIN EN 1340 ½(;~]];Y]]> ½ x 70
Tab. 7: Standard Concrete Ballasts

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between summer and winter. To prevent damage to the roof sealing, expansion joints of 5 mm should be placed between
the girders (axis grid in east-west direction 2.205 m).
In the north-south direction, tensions in the system caused by constructional tolerances are absorbed in the substructure.
Erosion Forces in the East–West Direction

In unfavorable load conditions (brief gusts of wind occurring once in 50 kJ), difference thrusts may be generated that
come from the edge modules subjected to higher wind loads in the east-west direction. These difference thrusts have
a force of approx. 0.1 kN. If the friction between the girder – protective mat – roof surface does not safely absorb this
force, then the force is absorbed in the so-called unsteady load condition by the pressure contact of the girders on the
front sides.
3.3.9 Lightning Protection and Potential Equalization

%

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`
connection of the modules, s Fig. 15b. 15, is a "general ground connection". The ground connection can take over
functional grounding tasks (PID effects). This connection is not a protective grounding connection, but rather a
functional grounding.
Abb. 15: Ground connection
Ä 7

+

Ä

+ 5

NOTE

+

protection specialist in accordance with DIN VDE 0185 305 3 Supplement 5 (DIN EN 62305 3 Supplement 5) and set
*

3.3.10 Modules
The current valid data sheet applies. The current valid electrical and mechanical data can be found in the data sheets
at www.q-cells.com. The Q.FLAT system is designed for use with Hanwha Q.CELLS modules with the dimension
1670 mm x 1000 mm x 50 mm (including frame).

3.3.11 Inverters
Tab. 9 lists inverters that work optimally with the circuits of solar modules. The table is not a complete listing. Hanwha
Q.CELLS cannot guarantee the correct function or quality of the inverters. The table shows connection options with the
Q.PRO-G2 250 module. The layout of the inverter must be checked in individual cases.
The inverter layout is done as follows:
INVERTER LAYOUT 22X XX3
223 22 - number of modules in a row 3 - number of parallel strings
Tab. 8: Explanation of the numbers in the inverter layout
Notes to Tab. 9, p. 22:
Columns 1 and 2: Inverters

Number and type of MPP trackers
Inverter manufacturer and type
Column 3: Modules in row per string

Minimum and maximum string length
Column 4:
Possible layout of the inverter

NUMBER / INVERTER MANU- MODULE IN Q.PRO - G2 250 WP 3
TYPE OF MPP FACTURER/TYPE ROW PER
TRACKERS STRING NUMBER OF 42 42 48 51 54 63 64 66 68 80 88 92 102 105 108
MODULES/IN-
VERTERS
MIN MAX OUTPUT 11 11 12 13 14 16 16 17 17 20 22 23 26 26 27
PLANNING
[KWP]
Ø ROOF SUR- 96 96 110 116 123 144 146 151 155 183 201 210 233 240 247
FACE [M²]
3 symmetrical Danfoss TLX Pro 22 22 223
MPP trackers 12.5k
2 symmetrical KACO Powador 12.0 17 17 173

MPP trackers TL3
Tab. 9: Inverter layout (no liability accepted)

KACO Powador 14.0 16 22 164 223 174
TL3
Danfoss TLX Pro 8k 21 21 212

Power One TRIO- 17 21 176 215 186
20.0-TL-OUTD
3.3 Technical Specifications
2 asymmetrical SMA Sunny Trip- 14 21 212 143

MPP trackers ower 8000 TL
SMA Sunny Trip- 17 17 173
ower 10000 TL
ower 12000 TL
ower 17000 TL
PPV / PINVERTER
128 % -132 % Modules of an inverter all face in the same compass direction.
133 %-135 % In the symmetrical assignment of the inverter, all modules face east and west.
136 %-137 % See light green. On sunny days, the inverter can reach the power limitation for a short period in the middle of the day.
3.3.12 Notes on using inverters in east-west systems

The inverters mainly differ in the number and type of the MPP tracker and the output of the inverter. Depending on the
type of the MPP tracker, a DC to AC ratio of 1.30 or 1.35 can be expected.
Conditions for a DC-to-AC ratio of 1.35:

Using an inverter with 2 MPP trackers
Both MPP trackers are loaded symmetrically
One MPP tracker can temporarily track slightly more than half of the installed output
If these three requirements are met, the inverter can be set up so that a DC-to-AC ratio of 1.35 is achieved. Ensure the
following:
Ä Connect the strings of the modules with east orientation to 1 MPP tracker.
Ä Symmetrically to this, connect the string of the modules with west orientation to the other MPP tracker of the same
inverter.
Ä Do not exceed the maximum input current and the maximum system voltage.
Conditions for a DC-to-AC ratio of 1.30:

Use of an inverter with 1 MPP tracker.
Use of an inverter with 1 MPP tracker and string connections with two orientations (east and west).
Use of an inverter with 2 MPP trackers that are only loaded asymmetrically.
210
Irradiance E (W/m2)
200 PP 10° East

Ost
1 PP 10° West
West
190
PP 10°
TotalGesamt
180
170
160
150
140
130
Einstrahlung E (W/m2)
120
110
100
90
80
70
60
50
40
30
20
10
0
03:00 04:00 05:00 06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00
Time
Zeit tt (h:m)
(h:m)
Abb. 16: Exemplary distribution of the produced output for east and west orientations
c: East - west systems, each with a 10° inclination angle
]];X

Inverter AC total nominal power 200 kW
2 symmetrical trackers with > 100 kW per tracker
DC-to-AC ratio: 1.35
'
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*!

7
&

tracked is 200 kW. The maximum output on a tracker is 115 kW and not half of the total output.

4 INSTALLATION 4.1 Preparation for Installation
DANGER
Ä
5
+
Ä ¡
+
!
solar power system.
DANGER
Ä Only use dry, insulated tools.
DANGER
Ä Ensure that modules and tools are not subject to moisture or
rain at any time during installation.
WARNING
Risk of injury due to falling modules!
Ä Secure modules during installation.
Ä Do not install modules in windy or wet weather.

4 INSTALLATION 4.1 Preparation for Installation
Ä Do not carry out the installation alone.
Ä Only install undamaged modules and components.

Ä Do not drill any other holes.

4 INSTALLATION 4.2 Laying the Girders
1 Ä *
%~~ Y
Ä Take the distances to the fascia into account (if present).
Ä Take edge spacings and roof structures into account.
Ä Maintain dimensional chains (risk of shadowing).
Ä Compare measurements with project documents.
Ä If you have any questions, please consult with Hanwha
Q.CELLS employees.
Resources, tools:
Project documents
Layout plan
Tape measure
2 Ä Position the protective mats according to the layout plan.
NOTE
Damage to the roof cladding!
Ä Use protective mats that are suitable for the roof cladding
material.
Resources, tools:
Project documents
Layout plan
Tape measure
3 Ä Arrange the girders according to the layout plan.
CAUTION
Risk of injury from heavy girders with sharp edges!
Ä Wear protective gloves.
Ä Align the girders in the center of the protective mats.

Ä Ensure that the load is distributed evenly.
Ä 7 &*

4 Ä Hang two ballast beams in each girder.

centred on the girder
orthogonal to the girder
190
Ä Maintain the inner interval between 2 ballast beams.
The interval should be 19 cm

4 INSTALLATION

5
Ballast clamps may be used if desired:
Ä use two ballast clamps on two ballast beams.
6 Ä Align the girders and ballast beams precisely along the

longitudinal and transverse direction of the roof.
Resources, tools:
Tape measure
Measuring gauge
Guide
7 *
Ä Position the ballast elements in accordance with the ballast
plan.
NOTE
Damage to the roof!
Ä Do not let ballast elements fall onto the roof cladding.
Ä 7
&
!*
Ä Take the geometric limits of the ballast height into account.
Resources, tools:
Layout plan
Ballast elements, ballast plan
8 Laying the return conductor strings:

Ä Lay the return conductors from the east or the west string
transverse to the girder.
Ä Ensure that the return conductors run in the direction of the
outer edges of the girder.

4 INSTALLATION 4.4 Installation of Module Pairs
9 Pre-mount the module pairs:

Ä Align the modules so that all connection boxes in one string
are facing in the same direction.
c Module
d Junction box
10 Ä Insert two modulesc*

NOTE
Pay attention to the alignment of the junction box!
Ä Align the junction boxes in the same direction. See next
illustration.
Resources, tools:
*
11 Ä Screw in the push-pull rod on both sides.
NOTE
Risk of material damage due to incorrect tightening torques!
Ä Ensure that the correct tightening torque of 8 Nm is used.
Resources, tools:
*
Screwdriver
Bit-TORX TX 30
Torque wrench
12 Ä Screw in the ridge plate on both sides.
NOTE
Resources, tools:
Screwdriver
Bit-TORX TX 30
Torque wrench

4 MOUNTING 4.5 Securing Module Pairs
13 Ä Check the assembled module pair for dimensional accuracy

and
quality.
Ä Check the tightening torque of 8 Nm.
Resources, tools:
Tape measure
Torque wrench
14 Ä Push the cable out of the holder under the modules to make
connecting the modules easier.
NOTE
Unreachable module pairs!
Ä Mount and connect the cables on modules one after the other
because it will be impossible to reach the inner module pairs
if the cables are connected at a later point. See the section
"Installation Step 17" (Section 5.2, p. 35).
15 Ä Transport the module pair to the installation site.

Ä Position the spacer plates and place the module pair on top.
Ä Place the module pair on the shoulder area of the girders.
Ä Align the module, girders, and ballast beam
with each other.
NOTE
Stepping on the modules could cause microcracks!
Ä Never step on modules.
Ä Do not subject modules to any mechanical stress.
Ä Do not allow any objects to fall onto modules
16 Ä Insert the sliding block into the girder.

Ä Place the spacer between the girders and the pull-push rod
Ä Fasten the module pair with a rounded head screw M8 x 20.
NOTE
Ä A sleeve to compensate for expansion can be inserted (not
shown) between the head of the rounded head screw and the
pull-push rod.
Resources, tools:
Screwdriver, Bit IS5, rounded head screw M8 x 20

5 ELECTRICAL CONNECTION 5.1 Safety
DANGER!
When disconnecting an electric circuit carrying direct current, electric arcs can occur that may result in life-threatening
injuries.
Ä Do not unplug the cable when under load.
Ä Do not connect any exposed cable ends.
Ä Do not touch the poles at the same time.
A solar module generates electrical current and voltage even at a low intensity of illumination. Sparks and electric arcs
may result from the separation of a closed circuit. These can result in life-threatening injuries. The danger increases when
several modules are connected in series.
Ä Please ensure that the entire open circuit voltage is present even at low levels of solar irradiation.
Ä Please follow the valid national regulations and safety guidelines for the installation of electrical devices and systems.
Ä Please make sure to take all necessary safety precautions. With module or phase voltages of more than 120 V, the
extra-low voltage range is exceeded.
Ä Carry out work on the inverter and the wiring with extreme caution.
Ä Ensure that the modules are disconnected at the inverter prior to separation.
Ä
* ! ")

components need time to discharge.
DANGER
Ä Only use dry, insulated tools for electrical work.
DANGER
Ä Never open the junction box.
Ä Do not remove bypass diodes.

DANGER
Ä Never touch live contacts with bare hands.
Ä Do not touch the poles at the same time.
DANGER
Ä Insulate any exposed cable ends.
Ä '
5*
!
*!" ! #$%
DANGER
Ä Ensure for correct polarity.
DANGER
Ä
*!
switching off the inverter and beginning any further work.

1
OFF DANGER
Ä Never unplug the cable when under load.
Ä Switch off the inverter.
2
Ä Cover the modules to be disconnected.
3
Ä Unplug the DC supply.

Ä Use solar cables for the connection at the junction box outlet.
Ä Use the same, inverter-compatible plugs.
SOLAR
DANGER
Ä Ensure that all electrical components are in a proper, dry, and
safe condition.
Ä Ensure for a tight connection between the plugs.

click
Plugs click together audibly.
NOTE
Ä Ensure that the cabling is not under stress.

5 ELECTRICAL CONNECTION 5.2 Connecting Module Pairs
17 Ä Mount and connect the cables on modules one after the other.
Ä Lift the module pair on one side (long module frame side) and
plug the cables together.
Ä Pull the cable between the pull-push rod and the girders.
Ä Fix the cable in place on the short module frame side with a
cable clip so that the cable does not lie on the roof cladding.
18 Ä Only connect cables in the same string.
CAUTION
Risk of material damage due to a closed circuit!
Ä Ensure that the circuit is open.
19 Ä Ensure that the cables and plugs do not lie in a water-channel-

ing layer, do not lie on the roof cladding, and do not rub.
20 Ä Check the installation dimensions against the project documents.

Ä Implement correction measures.
Ä Connect the system in accordance with the project documents.
Resources, tools:
Project documents
Layout plan
Tape measure

5 ELECTRICAL CONNECTION 5.3 After Installation
Ä Ensure that all necessary safety and functional tests have been
carried out according to current industry standards.
Ä Integrate the system into the existing lightening protection

system in accordance with the applicable local regulations.
Ä Ensure that the cables are not exposed or hanging down.

Ä Protect the cables from dirt and moisture.
WARNING
Fire hazard!
Ä Do not use light concentrators (e.g., mirrors or lenses).

6 GROUNDING
Ä The modules must be grounded in accordance with the local

statutory regulations.
Ä 5!
!678Y&
`&+
5.5 mm x 16 mm.
c c Stainless Parker screw
d
e dStainless washer (cable lug)
f e Stainless serrated lock washer
c
f Module frame
Ä Fasten the protective grounding to the grounding points with a
Parker screw.
7 FAULTS AND DEFECTS
DANGER
Ä 6 *

(&
5&
>
Ä Please contact an installer or Hanwha Q.CELLS Technical Customer Service Department.

8 CLEANING AND MAINTENANCE
!"#$%%

J

usually washed away by rain. If the module is fully or partially shaded by dirt or debris (e.g., plants, bird droppings), it needs to
be cleaned to prevent a loss of performance.
Maintenance
Ä The system should be inspected by an installer annually to check the following:
all system components sit securely and are corrosion free
the connection is secure and all electrical components are clean and undamaged
transfer resistances of the grounding
Cleaning
WARNING
Risk of injury due to hot and live modules!
Ä Only clean modules that have cooled down.

Ä Do not carry or wear any electrically conductive parts.
WARNING
Risk of falls due to unsecured access!
Ä Never access the installation area alone or without taking adequate safety precautions.
Ä Please commission a trade specialist.
Clean the modules as follows:

Ä Remove snow and ice without force (e.g., with a broom).
Ä Do not scratch off dirt.
Ä Rinse dirt off with lukewarm water (dust, leaves, etc.).
Ä Use a soft wet cloth or sponge to carefully wipe away stubborn dirt.
Ä Do not use abrasive detergents or tensides.
Isopropyl alcohol (IPA) can be used selectively to remove stubborn dirt and stains.
Ä Please follow the safety guidelines provided by the IPA manufacturer.
Ä Do not let IPA run down between the module and the frame or into the module edges.
NOTE
0°
Ä Do not clean modules with water if there is a risk of frost.

8 CLEANING AND MAINTENANCE
Ä Remove dirt with lukewarm water, a broom, or a soft cloth.

Ä Do not use tensides, scrapers, or any high-pressure water
cleaning equipment.
Ä Free the substructure from any dirt and debris (leaves, bird
nests, etc.).

9 RECYCLING
Ä Do not disconnect modules yourself.

Ä Please commission a trade specialist.
Ä Please ask your installer whether your modules are eligible for the PV Cycle (www.pvcycle.com) disposal program.
Ä Dispose of modules in accordance with the local disposal regulations.
Sources
Y6)7
6
¢+5
)
&
Fraunhofer Institute for Solar Energy Systems ISE
[2] Klaus-Jürgen Schneider: "Bautabellen für Ingenieure," Werner Verlag
[3] Matthias Knorr: "Typenstatik Q.CELLS Flachdachsystem," Knorr Ingenieure
6)7"/!5
+
#$%&/#/!#

[5] Dr. Thomas Straub: "Auslegung von PV-Anlagen im Polystring-Betrieb," SMA Solar Technology AG

KONTAKT
HANWHA Q.CELLS GMBH TEL +49 (0)3494 66 99 - 23222

OT Thalheim FAX +49 (0)3494 66 99 -23002
Sonnenallee 17–21 EMAIL service@q-cells.com
06766 Bitterfeld-Wolfen WEB www.q-cells.com
Germany
Subject to change without notice. © Hanwha Q.CELLS GmbH installation Instructions Q.FLAT_2012-10_Rev01_EN

Q.Flat: Installation and Operation Manual

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INSTALLATION AND OPERATION MANUAL

3.2 Analysis of the Layout Ratio DC-to-AC 10

4.1 Preparation for Installation 24

4.2 Laying the Girders 26

4.4 Installation of Module Pairs 28

4.5 Securing Module Pairs 29

5.2 Connecting Module Pairs 34

5.3 After Installation 35

7 FAULTS AND DEFECTS 36

8 CLEANING AND MAINTENANCE 37

2 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

 !    

Symbols and Labels

Ensure when carrying out a procedure, check the results of a procedure.

Prohibited procedural method.

Tab. 1: Symbols and Labels

FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 3

*       !

Ä Please observe the wiring and dimensioning of the system.

Information for the Operator

9    * 

Other Applicable Documents

DOCUMENT TYPE VERSION

Product data sheet

4 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

Ä Inspect the packaging for damages.

Ä Leave modules in their original packaging until installation.

FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 5

6 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 7

3.1.1 General Requirements

Prevention of Shadowing Effects

3.1.2 Electrical Layout

Fuses and Line Cross-Sections

8 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

1) Layout with a limited number of parallel connected strings :

2) Layout with string fuses :

3.1.3 System Description

Fig. 1: Components of the Q.FLAT SYSTEM

FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 9

3.2.1 Analysis of the Layout Ratio DC to AC

Fig. 2: /   6#) )# !    

!  5`& ! 6#) )#

       (   

10 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

800 PP 10° Ost

WR loses inverter power - as function of the Module plane direction

Fig. 4: Inverter losses due to power limitation at high DC to AC ratios

FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 11

3.3.1 Q.FLAT Applications

       * 

Fig. 5: Top view

3.3.2 Usage Limits in Wind and Snow Load Zones (GER)

12 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

Tab. 2:     !

TYPE OF ROOF ROOF EDGE WIDTH FASCIA HEIGHT

Tab. 3: Roof edge width and fascia height

SNOW LOAD ZONES ALTITUDE ABOVE SEA ILLUSTRATION

FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN 13

TERRAIN CATEGORY II – III (INLAND)

TERRAIN CATEGORY II (COAST)

14 FLAT ROOF SYSTEMS Q.FLAT HANWHA Q.CELLS GMBH – EN

3.3.3 Ballast Distribution

!

* !

9*

Fig. 2: / 6#))# !

! 5`&! 6#))#

(

*

Tab. 2: !

! !

!) Y ! [4]

Fig. 10: %

!

&

Fig. 11: %

! !

Fig. 12: %

! Y

* !

Kerb edge (EF) DIN EN 1340 ;`z];z] 13

Kerb edge (EF) DIN EN 1340 ;~]];z] 35

Trough (EF) DIN EN 1340 ;`z];] 48

Trough (EF) DIN EN 1340 ;~]];] 58

Trough (EF) DIN EN 1340 ;~]];Y]] 70

½ trough (TB) DIN EN 1340 ½(;~]];Y]]> ½ x 70

*!

10 Ä Insert two modulesc*