Design Guide N V2-3EN

Design Guide
SL100 Series Photovoltaic Panels
DesignGuide_N_V2.3EN English. Version 2.3 Release Date: 2010-04-06
Solyndra, Inc. 47700 Kato Road Fremont, CA www.solyndra.com
Copyright Notice
This document provides information on Solyndra products. By issuance of this document Solyndra assumes no liability. The rights and obligations of Solyndra and any owner of Solyndra panels are governed solely by the express terms and conditions contained in the sale agreement for such panels. Except as provided in Solyndras Terms and Conditions of Sale for such products, Solyndra assumes no liability whatsoever. Copyright (circle logo ) Solyndra Inc. 2009-2010. Printed in the United States of America. All Rights Reserved.
Trademarks & Patents

The following terms are trademarks of Solyndra Inc.: Solyndra; The New Shape of Solar. All other trademarks and registered trademarks are the property of their respective companies. Solyndra products are covered by patents in the US and many other countries.
Disclaimer
Solyndra disclaims any express or implied warranty, relating to sale and/or use of Solyndra products including liability or warranties relating to fitness for a particular purpose, merchantability, or infringement of any patent, copyright, or other intellectual property right. Warranty rights are governed solely by the express terms of the Solyndra warranty provided to the purchaser of Solyndra panels. Solyndra may make changes to specifications, instructions, and product descriptions contained in this document at any time without notice. Contact your local Solyndra Sales Office to obtain the latest specifications before placing your purchase order. Advisory information contained in Solyndra instructions, guides, application notes, or any other document is advisory only. The customer must work with qualified personnel to ensure that all designs are safe and in compliance with all local codes. Solyndra makes no representation that any reference technique or method is necessarily safe, legal, or compliant with application codes. Solyndra assumes no legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by Solyndra. The Energy Yield Forecast Tool leverages past experience, scientific models, and weather data to estimate the expected future performance of Solyndra products. The rights and obligations of Solyndra and any owner of (or investor in) projects containing Solyndra panels are governed solely by the express terms and conditions contained in the sale agreement for such panels. The outputs of this tool shall not represent a departure from the Terms and Conditions of the existing commercial agreements.
Cautions And Warnings

Solyndra panels are typically installed on highly-reflective roof surfaces. The light can be bright enough to affect vision. Sunglasses which filter out ultraviolet light are strongly recommended. Persons who plan to remain on the roof for more than thirty minutes should dress appropriately and wear sunscreen to protect skin from the sun. Cool roof surfaces may promote slippery conditions from water or snow. DO NOT work within 1.6 meters (5 feet) of the edge of a roof without appropriate safety equipment. Solyndra panels are made from glass, and are electrically live whenever light shines on them. If a panel is broken, use insulating, cut-proof gloves to handle debris. Refer to Solyndras safety information for details on clean-up procedures. The Optical Coupling Agent (OCA fluid) is non-toxic, but extremely slippery. Use great care when working around spills.
Contact Information Solyndra Inc. 47700 Kato Road Fremont, CA 95054 USA Tel. (510) 440-2400 http://www.solyndra.com salesinfo@solyndra.com
Solyndra Photovoltaic Panel Design Guide
Solyndra Confidential Doc Number 0920-30006-EN-010
Contents
Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 Chapter 8 Chapter 9 Chapter 10 Designing with Solyndra Array Clearances Sub-Array Wiring Options String Sizing Grounding System Wiring Mechanical Design Solyndra Panel System Site Preparation Tools and Supplies 4 5 27 34 36 38 44 46 56 59 61 62
Appendix A. References Appendix B. Design in Seismic Areas
Version 2.3 Solyndra Confidential
Chapter 1

Designing with Solyndra
The purpose of this document is to provide design rules for Solyndra photovoltaic systems. The target audience is system designers and engineers who are already skilled in photovoltaic design. This guide will highlight the unique properties of the Solyndra technology and the impact on system design, but is not intended to cover all aspects of system design. Solyndra panels have a unique construction. The panels are composed of 40 cylindrical modules with gaps in between each module. Extensive laboratory and real-world testing has confirmed that this form-factor allows the wind to pass through the panels with little resistance and the weight of the panel is enough to keep it in place on the rooftop without attachment. Seismic analysis has been performed to characterize possible array displacement during seismic events and has shown that in seismically active areas no attachment is needed. Solyndra panels are designed be installed on white, high reflectance roofs whenever possible.
Code Compliance & Safety

System installations are subject to a range of codes and standards. These will vary by jurisdiction. In all cases, codes and standards should be followed carefully, but it should be noted that any code or standard provides only a minimum requirement for safety. Codes cannot be comprehensive for all specific system. It is the responsibility of the designer to use her/his judgment and at times go beyond these minimum requirements to ensure the safety of the system. Solyndra panels are made of glass and produce dangerous voltages whenever they are exposed to sunlight. Please refer to the Solyndra Installation Guide for panel handling safety recommendations. In order for an effective design to be produced, the designer needs several pieces of information about the site. A sample site inspection checklist is included but the designer is encouraged to develop their own to cover any unique requirements in their particular jurisdiction. For a preliminary design, you should have: Roofing material type, and age of roof material Roof deck and load bearing capacity Roof dimensions, including height Seismic requirements, if any Locations and dimensions of all roof obstructions Orientation of building Shading considerations Address of site
Required Information

Chapter 2

Array Clearances
Solyndra panels are self-ballasting. A properly-assembled array has sufficient mass to resist windlift without the need for attachment to the roof. The panels are designed to be installed horizontally, parallel to the roof. Because the panels do not need to be tilted for optimum energy production, it is not necessary to leave space between array rows to avoid inter-row shading. This makes it possible to assemble large array blocks of adjacent panels, placing more panels on the roof and maximizing energy yield for the available space. In order to meet wind, fire, safety, access, and seismic requirements its necessary to allow spaces around groups of panels. This chapter will explain the design guidelines for these setbacks and clearances. Any shadow falling across the array will reduce its output, but the unique design and lightgathering technology of Solyndra panels makes them less affected by shading than a silicon panel. However, panels should not be placed in the shadow of roof structures such as HVAC equipment. Fire codes vary, but generally require a minimum number of access paths so that fire crews can fight fires and ventilate the structure. Check with local authorities before designing a project. Safety codes mandate a minimum perimeter clearance in order to provide for worker safety. If panels are installed too close to the edge of a structure, workers may be required to use fallprotection equipment while working. Independent of any code requirement, it may be necessary to provide access to roof-top machinery or skylights for service. Solyndra panels are self-ballasting against wind uplift. The open design of the Solyndra panel reduces wind effects. By mechanically attaching groups of panels, the total weight is increased such that panel lift does not occur. In order to insure that high winds do not lift the panels, certain minimum clearances from building edges and other structures must be maintained. In addition, panels must be grouped into minimum sub-array sizes to ensure adequate selfballasting effect. Seismic conditions and building codes vary widely. Refer to Appendix B for clearance allowances in seismic zones. If you are planning an installation in a seismically active area, contact Solyndra, at Design.Service@Solyndra.com, for design information.
Setbacks and Clearances

Shade Clearances

Fire Clearances

Safety and Access

Wind Clearances

Seismic Clearances

Sub-Array Definition
Note The term sub-array is defined as a group of panels which are physically connected together. The manner of electrical connection(s) is not relevant to this definition. The larger the sub-array, the greater the physical stability of the system. All panels which touch each other should be mechanically connected, using lateral clips, regardless of electrical arrangement. String Blocks Electrical sub-array size is determined by the series string length, which in turn is determined by the chosen inverter. Its important that every series string have the same number of panels. Thus the total number of panels will be a multiple of the series string length. This is usually in the range of 5 to 8 panels. String length is covered in String Sizing in Chapter 3 on page 36. Its preferable to have each mechanical sub-array be a multiple of the string length. This simplifies wiring, by avoiding the need to run conduit across walkways. Thus, you must adjust the number of panels in each mechanical sub-array to obtain an exact multiple of the string length. These areas of omitted panels are sometimes referred to as dead space from stringing.
Design Rules and Examples

The following sections discuss and illustrate clearance requirements and array size restrictions. A Typical Layout Planning Exercise Begin with a plan view of the roof, on which are marked all obstacles, structures, or other features. You will need to know the height as well as the size of all features Next, begin applying the setback and placement rules. Each of the clearance guidelines explained in this chapter is then applied to the sample roof plan. The open area that remains after all the setbacks are established is called the Available Roof Space. 1. Mark the 5-foot (1.52 m) setback line, the Zone A line, and the Zone B line (described later in this document). 2. Mark the shadow path of any roof objects tall enough to cast a shadow. 3. Mark the wind setback of any roof objects taller than the array. 4. Mark the fire-clearance line for access to skylights, hatches, and other roof objects. 5. Mark the seismic setback, if applicable. 6. Place groups of panels in the remaining area. Typically, a designer will place one string block (e.g. 5x3) at a time until the area is mostly filled, then add single stings to fill any remaining area. In the following examples, the setback and clearance rules are first illustrated individually, and then in a combination. Real-world designs must of course meet all rules, but it is easier to understand how the rules apply by examining them individually.
The Example Roof

To illustrate the clearance rules, the example roof shown in Figure 1 is used. This roof has a 24 inch (60 cm) parapet, and several rooftop objects. Figure 1. Example Roof
200 (61 m) 39-4 (12 m) 39-4 HVAC unit (12 m) 6 high (1.82 m) 161-8 (49.3 m)
Skylight 8 high (20 cm) 140 (42.7 m)
265 (80.7 m) 225-8 (68.8 m) DC/AC Inverter Access Hatch 12 high ( 30 cm)
125 (38.1 m)
Skylights 8 high (20 cm) 142 (43.3m) 58 (17.7 m)
Coefficients of Friction
Friction keeps the panels from moving under wind conditions. The standard Solyndra-supplied panel mount has a moderate coefficient of friction. Adding a pad to the foot of the mount can increase this, if required. Solyndra has tested numerous combinations of panel mount materials and roof materials under various conditions, and found that in general, coefficients of friction range from 0.4 to 1.0, sometimes more. You should determine the coefficient of friction of your roof material before proceeding with your design. Solyndra has values for several common roofing materials.
Firefighter Access Clearance

It is beyond the scope of this guide to cover all fire codes for all jurisdictions, however, most fire codes share some principles that will affect panel placement. The Fire Department will require that the designer leave walkways through the array and clearances around hatches and stairways. Check your local fire codes. The example in Figure 2 shows a one-story building with a parapet greater than 19 inches (0.48 m) high. The fire code requires 4 feet (1.2 m) of clearance at the edge. (Note that the wind requirements mandate 5 feet (1.52 m)). Aisles are along structural members, and are 8 feet (2.4 m) wide. In addition, there is aisle access to skylights, and 4 feet (1.2 m) of clearance around roof hatches. The panel arrangement has 1460 panels, and each of the four sub-arrays is a multiple of five, the string length in this example. Figure 2. Fire Clearance Example
39-4 (12 m) Detail B HVAC unit 6 high (1.82 m) 39-4 (12 m) 200 (61 m) 161-8 (49.3 m)
140 (42.7 m)
265 (80.7 m) 225-8 (68.8 m)
Skylight 8 high (20 cm) Access Hatch 12 high ( 30 cm) 125 (38.1 m)
Detail A Fire Clearance Minimum Setback
Color code: Fire) Obstruction Minimum Setback

Skylights 8 high (20 cm) Detail C Detail D 142 (43.3m) Structural Member 58 (17.7 m)
Figure 3. Detail A - Fire Clearances
Access Hatch, 12 (30cm) high 4 (1.2 m) clearance for re
4 (1.2 m) walkway for re
Figure 4. Detail B - Fire Clearances
4 (1.2 m) walkway for re 4 (1.2 m) clearance for re HVAC 6 (1.8 m) high
Figure 5. Detail C - Fire Clearances
Fire Setback Minimum Setback
Figure 6. Detail D - Fire Clearances
Skylight 4 (1.2 m) walkway for re
Color code: Fire (4) Obstruction Minimum Setback ( 5)
Other arrangements are possible. The California Fire Code, and other fire codes, provide alternate arrangements for firefighter access, venting, and other requirements. Study these before planning your layout.
Shade Clearances
To understand the effect shading can have, its helpful to understand how the Solyndra panel is different from conventional flat plate photovoltaic systems. Each Solyndra panel is composed of 40 cylindrical photovoltaic modules, wired in parallel. Each module consists of a number of individual cells, wired in series, as shown in Figure 7. Figure 7. Photovoltaic Cell Structure
np +
n
CIGS Back Contact Substrate Glass Tube
i +
A single cell that is shaded will stop producing current. This blocks current flow from all cells wired in series with it. Thus, shading one cell (fully) blocks output from the entire module. However, since the Solyndra panel has 40 cylindrical modules in parallel, shading one of them causes only a small reduction - 1/40 - in the panels output. Furthermore, because Solyndra panels collect indirect and reflected light as well as direct light, it is very difficult to fully shade a module, much less a full panel. As a result, Solyndra panels are less sensitive to shading than other panel types. By comparison, shading even a small portion of a typical flat-plate PV module can significantly reduce the performance of the entire module. Solyndra panels are less affected by shading than other technologies, so it is possible to place them closer to obstructions than other panels and still maintain good performance. Types of shading and their relative effect are shown in Figure 8. Figure 8. Limited, Moderate, and Severe Shading
Limited Shading SHADE Moderate Shading SHADE Severe Shading
SHADE
SHADE
SH
AD
SHADE
Column 1 shows examples where all or part of a single module is shaded. This slight amount will not significantly affect output. In column 2, several modules are shaded. This could compromise panel output, and may affect system output, depending on the degree and duration of the shadow. Column 3 shows severe shading. Note that in the lower diagram, effective shading is still severe because all of the modules are at least partly shaded.
Solyndra Photovoltaic Panel Design Guide Solyndra Confidential Doc Number 0920-30006-EN-010

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Transparent Conductive Layer
Cell 1
Current Flow
Cell 2 ni p +
SHADE
SHAD
Shade Design Recommendations

If there are objects on the roof or near the building, you should determine the amount of shading they will cause. There are tools available for this purpose, including the Solar Pathfinder, from Solar Pathways, and the Sun-Eye, from Solmetric. Either can be used to determine the area and duration of shadows. It is important to make measurements at multiple locations on the roof and around any roof-top objects that will cast a shadow. If you cannot make such measurements, or there are very few potential shade-causing objects, you can estimate the size of the shadow from Table 1. For various latitudes, it shows the maximum angular height of the sun on the winter solstice, and the resulting length of the shadow from an object 10 units (feet, meters, etc) high. Table 1. Shadow Lengths at Winter Solstice
Latitude 25 30 25 40 45 50 55 Sun Angle, Winter Solstice 42.5 37.5 32.5 27.5 22.5 17.5 12.5 Shadow Length per 10 Units of Height 10.9 13.0 15.7 19.2 24.1 31.7 45.1
(The formula for the height of the sun at the winter solstice is 67.5 - Latitude.) On-roof objects will shade panels to the east, west, and north (or south, in the southern hemisphere) of the object. The objects shadow will sweep across a section of roof as the sun transits the sky, as shown in Figure 9. Early in the morning, and late in the afternoon, the shadows are long. At mid-day, the shadow is shorter. Figure 9. Shadow Path Over the Day
Noon Sun Afternoon Sun Morning Shadow Morning Sun Afternoon Shadow
Noon Shadow
Shading effects are most critical at mid-day, because this is peak energy production time. At this time, the shadow falls to the north (or south, in the southern hemisphere). Estimating Shade Many designers estimate shade as the percentage of total panel area that is shaded during any portion of the day. This is a conservative estimate. Either of the test instruments described earlier can be used to give a more precise estimate. You can also refine the estimate by determining the portion of tubes that are shaded, rather that the portion of area.
Solyndra Photovoltaic Panel Design Guide 11
Shade Clearance Example This example adds clearance for the shading caused by the HVAC unit. A rectangular area to the northwest, north, and northeast is kept free of panels. The panel arrangement has 1460 panels, and each of the four sub-arrays is a multiple of five, the string length. Figure 10. Shade Clearance Example
39-4 (12 m) Detail B HVAC unit 6 high (1.82 m) 39-4 (12 m) 200 (61 m) Clearance for shade 161-8 (49.3 m)
140 (42.7 m)
265 (80.7 m) 225-8 (68.8 m)
125 (38.1 m)
142 (43.3m)
58 (17.7 m)
Color code: Obstruction Minimum Setback
Figure 11. Detail B - Shade Clearance
Shade clearance
HVAC 6 (1.8 m) high
12
Wind Clearance
The unique design of Solyndra panels means they withstand wind forces much better than standard flat-plate modules. Solyndra panels have been certified at wind speeds up to 130 mph (208 kph) in wind tunnel studies and in the real world. Wind speeds are defined as a 3-second gust measured at 10 meters, per ASCE 7-05, Figure 6.1. The design wind speed for a site in the United States may be found by consulting ASCE 7-05, Chapter 6. Wind tends to lift panels at the corners and edges of the array, thus, wind clearance rules are defined according to corner, edge, and middle zones of the roof. Following the approach of ASCE 7-05, four roof zones have been defined: The minimum setback zone, a strip 5 feet (1.52 m) wide all around the perimeter. Panels are never permitted here. This zone is based on extensive wind testing and analysis. Zone (A), a strip adjacent to the minimum setback zone. Panels may be placed here, with conditions. Zone (B), an arc segment at each roof corner. Panels may be placed here, with conditions. Zone (C), the portion not included in A or B. Panels may be placed here, with conditions. Slopes and Parapets Roof zone definitions depend on both roof slope and the height of the parapet wall, if any. Solyndra panels are not recommended for use on roof slopes greater than 2:12 (9.5). The building industry typically uses the term low-slope for any roof less than 2:12. For installation purposes, Solyndra divides this into two sub-categories. Flat roofs are those with slopes less than 1:10 (5.7). Roofs with slopes between 1:10 and 2:12 have slightly different rules. Low parapet roofs are those with a parapet height less than 19 inches (0.48 m). Parapets of 19 inches (0.48 m) or more have different zone shapes and less-restrictive rules. Zone definitions for flat, high-parapet roofs are shown in Figure 12 on page 14. Zone definitions for flat, low-parapet roofs are shown in Figure 13 on page 15. Zone definitions for high-parapet roofs with slopes up to 2:12 are shown in Figure 14 on page 15. Zone definitions for low-parapet roofs with slopes up to 2:12 are shown in Figure 15 on page 15. Note that these roofs may have a central ridge line, i.e. a gable roof, and that the clearance rules are slightly different along the ridge In each of the four figures, the red-shaded area represents roof area in which panels may not be placed. Building height is defined as the height above ground of the portion of the roof on which the array is installed. There should be no surrounding buildings taller than 150% of roof height within a distance equal to 200% of roof height. For rectangular buildings, the definitions of length, width, and height are clear. If the building is non-rectangular, consult ASCE 7-05 for definitions.
Roof Zones

Definition of Building Dimensions

Figure 12. Illustration of Roof Zone Definition - Slope <1:10, High Parapet
5 ft (1.52 m) edge setback Zone A Zone B Zone B
5 ft (1.52 m) edge setback Zone A
Dimension A
Zone A
Building Wall 5 ft (1.52 m) edge setback Zone B
Zone C
Dimension B
Zone B
Zone B Zone A 5 ft (1.52 m) edge setback
Zone B
Zone A Zone A is defined as the area of the roof between the 5-foot (1.52 m) setback line and the line defined by Dimension A. To determine Dimension A: Step 1: Calculate two values: 40% of the building height. 10% of the lesser of building length or width. Step 2: Select the smallest of these possible dimensions. Step 3: Compare the result of Step 2 with 5 feet (1.52 m). Dimension A is the largest of these two values. Two examples are shown at right. Note the units are in meters. The Excel MIN() and MAX() functions can be used to calculate the correct width Note
Bldg Height Bldg Width Bldg Height Bldg Length Bldg Width 2.5 40% = 1.00 30 10% = 3.00 30 10% = 3.00
Zone A 5 ft (1.52 m) edge setback
Zone A Calculation Minimum 1.00 Minimum Setback 1.52 Zone A Width 1.52 8 40% = 3.20 130 10% = 13.0
Bldg Length 300 10% = 30.0 Zone A Calculation Minimum 3.20 Minimum Setback 1.52 Zone A Width 3.20
Dimension A is defined as including the 5-foot (1.52 m) setback. This means that if your calculation gives a value of 5 feet (1.52 m), there is no Zone A. In other words, for rectangular buildings less that 12.5 feet (3.8 m) high, or less than 50 feet (15.2 m) wide, the 5-foot (1.52 m) setback is sufficient, and the width of Zone A is zero. Zone B Zone B the intersection of a the pie-shaped section at each exterior corner and Zone A. The pie-section is defined by Dimension B, which is a radius equal to 100% of the building height. The radius is measured from the corner of the building. Note that the shape of Zone B is different for high and low parapet roofs.
14
Figure 13. Illustration of Roof Zone Definition - Slope <1:10, Low Parapet
5 ft (1.52 m) edge setback Zone A Zone B Zone B
5 ft (1.52 m) edge setback Zone A
Dimension A
Zone A
Building Wall 5 ft (1.52 m) edge setback Zone B
Zone C
Dimension B
Zone B
Zone B Zone A 5 ft (1.52 m) edge setback
Zone B
Figure 14. Illustration of Roof Zone Definition - Slope <2:12, High Parapet
5 ft (1.52 m) edge setback Zone B Zone A Zone B Roof Ridge Zone B Zone A Zone B
Dimension B
Zone A Zone A Zone A Zone C
Dimension B
Zone A Zone C
Dimension A (note)
Dimension A
Zone B Zone B
Zone B
Zone A
Zone B
Zone A
Figure 15. Illustration of Roof Zone Definition - Slope <2:12, Low Parapet
5 ft (1.52 m) edge setback Zone A Zone B Zone B Zone B Roof Ridge Zone A Zone B
Dimension B
Zone A Zone A Zone A Zone C
Dimension B
Zone A Zone C
Dimension A (note) Zone B Zone A Zone B Zone B
Dimension A
Zone B Zone A
Note: Dimension A, the width of Zone A at the ridge line, does NOT require the 5 foor (1.52 m) minimum setback. Panels in the Zone A region on each side of the ridge can touch the panels in the other Zone A region. These Zone A panels must still be connected to Zone C panels. If possible, connect panels in the two adjacent Zone A regions together.
Zone A 5 ft (1.52 m) edge setback
Minimum Sub-Array Sizes

Table 2 on page 16 defines the minimum sub-array sizes for roofs up to 60 feet (18.3 m) high and with a slope less than 1:10. It is based on a 100% Load Factor. Table 3 on page 17 defines the minimum sub-array sizes for roofs up to 60 feet high and slopes up to 2:12, at a 100% Load Factor. Table 4 on page 17 defines the minimum sub-array sizes for roofs from 60 feet (18.3 m) to 600 (183 m) high. It applies only to roofs with slopes up to 1:10, at a 100% Load Factor. Design Rules Panels shall only be placed over firmly-attached roof surfaces. Loose-laid membranes or other materials are not acceptable. Panels shall not be raised up higher than the standard height of the supplied Solyndra panel mounts. Do not use blocks, frames, or any other item that will lift the panel. The rules cited here should be considered minimums. When more panels are connected together in an array, the array has more resistance to wind effects. Whenever possible, build arrays larger than the minimum. Height is defined as the height, above the surrounding terrain or ground, of the portion of the roof on which the array is installed. There should be no surrounding buildings taller than 150% of building height within a distance of 200% of building height. A tall parapet is one that is 19 (0.48 m) or more in height. Table 2. Minimum Sub-Array Sizes: Buildings 60 Feet (18.3 m) High Roofs 1:10 Slope 100% Load Factor
Buildings 60 Ft (18.3 m); 1:10 slope
Fc Roof Zone A (Note 2, 3) 85 MPH (137 KPH) 8 35 6 4 1 1 1 1 1 1 1 1 1 1 1 1 95 MPH (153 KPH) 15 50 (Note 5) 25 8 4 8 1 4 1 1 1 1 1 1 1 1 130 MPH (208 KPH) Not allowed Not allowed Not allowed Not allowed 35 (Note 2, 3) Not allowed 49 25 8 15 4 8 8 4 4 8
0.4
Coefficient of Friction
B, short parapet B, tall parapet C A (Note 2, 3) B, short parapet B, tall parapet C A (Note 2, 3) B, short parapet B, tall parapet C A (Note 2, 3) B, short parapet B, tall parapet C
0.58
0.83
1.0
16
Table 3. Minimum Sub-Array Sizes: Buildings 60 Feet (18.3 m) High Roofs 1:10 Slope; 2:10 Slope 100% Load Factor
Buildings 60 Ft (18.3 m); 2:12 slope
Fc Roof Zone A (Note 2, 3) 85 MPH (137 KPH) Not allowed Not allowed 48 75 40 36 36 14 6 6 12 4 5 5 5 1 95 MPH (153 KPH) Not allowed Not allowed 60 Not allowed 56 40 48 21 18 6 27 12 5 5 5 1 130 MPH (208 KPH) Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 96 84 30 30 36 21 25 20 5 10
0.4
B, short parapet B, tall parapet C A (Note 2, 3) B, short parapet B, tall parapet C A (Note 2, 3) B, short parapet B, tall parapet C A (Note 2, 3) B, short parapet B, tall parapet C
0.58
0.83
1.0
Table 4. Minimum Sub-Array Sizes: Taller Buildings 1:10 Slope

60-120 Feet (18.3 m); 1:10 slope Fc Roof Zone A (Note 2, 3) 0.4 B, tall parapet C Coefficient of Friction A (Note 2, 3) 0.58 B, tall parapet C A (Note 2, 3) 0.83 B, tall parapet C A (Note 2, 3) 1.0 B, tall parapet C 85 MPH (137 KPH) 30 95 MPH (153 KPH) 55 130 MPH (208 KPH) Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 36 36 36 55 4 25 120-180 Feet (36.6-54.9 m); 1:10 slope 85 MPH (137 KPH) 95 MPH (153 KPH) Not allowed 130 MPH (208 KPH) Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 55 45 Not allowed 20 35
Not allowed 45
B, short parapet Not allowed Not allowed Not allowed Not allowed 20 9 1 7 1 1 1 1 1 1 30 15 55 9 9 6 4 4 6 4 4 4 4
Not allowed Not allowed Not allowed Not allowed 25 9 36 4 7 4 4 4 4 4 4 4 49 25 Not allowed 25 20 9 4 4 8 5 4 4 5
B, short parapet 16
49 (Note 2, 3) 4
B, short parapet 1
B, short parapet 1
Table 4, continued.
180-240 Feet (54.9-73.2 m); 1:10 slope Fc Roof Zone A (Note 2, 3) 0.4 B, tall parapet C Coefficient of Friction A (Note 2, 3) 0.58 B, tall parapet C A (Note 2, 3) 0.83 B, tall parapet C A (Note 2, 3) 1.0 B, tall parapet C 85 MPH (137 KPH) 55 95 MPH (153 KPH) Not allowed 130 MPH (208 KPH) 240-300 Feet (73.2-91.4 m); 1:10 slope 85 MPH (137 KPH) 95 MPH (153 KPH) 130 MPH (208 KPH) Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 49 Not allowed 36 40
Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 30 Not allowed 16 Not allowed 55 Not allowed 7 Not allowed 9 Not allowed 6 Not allowed 4 Not allowed 4 Not allowed 5 49 36 40 4 4 4 Not allowed 4 Not allowed 40 Not allowed 49 23 12 9 4 9 6 4 4 7
B, short parapet Not allowed Not allowed Not allowed Not allowed 30 12 7 9 5 4 5 4 4 4 Not allowed 32 Not allowed 49 23 9 9 4 9 6 4 4 7
B, short parapet 55
B, short parapet 4
B, short parapet 4
Table 4, continued.
300-400 Feet (91.4-122 m) Fc Roof Zone A (Note 2, 3) 0.4 B, tall parapet C Coefficient of Friction A (Note 2, 3) 0.58 B, tall parapet C A (Note 2, 3) 0.83 B, tall parapet C A (Note 2, 3) 1.0 B, tall parapet C 85 MPH (137 KPH) 95 MPH (153 KPH) 400-500 Feet (122-152 m) 85 MPH (137 KPH) 95 MPH (153 KPH) 500-600 Feet (152-183 m) 85 MPH (137 KPH) 95 MPH (153 KPH)
Not allowed Not allowed Not allowed Not allowed 49 25 25 20 8 4 7 5 4 5 Not allowed 55 Not allowed 36 16 42 4 16 9 4 4 9
Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 32 49 24 9 16 4 9 7 4 4 7 Not allowed Not allowed 45 22 49 4 20 12 16 4 12 Not allowed Not allowed
Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed Not allowed 35 55 25 9 25 4 9 8 4 4 7 Not allowed Not allowed 49 25 Not allowed 9 24 15 25 4 15 Not allowed Not allowed
B, short parapet Not allowed Not allowed
B, short parapet Not allowed Not allowed
B, short parapet 4
B, short parapet 4
* Installation is not permitted on buildings over 300 feet (91.4 m) high in wind zones over 95 MPH (153 KPH).
18
Notes on Tables The following notes apply to Table 2, Table 3, and Table 4. 1. Powder coat refers to the paint finish on the panel mount, i.e. no pad required. 2. Number of panels in direction towards center of roof must equal or exceed number of panels along perimeter. 3. No array can be fully inside Zone A. Array shall have at least two times as many panels in Zone C as in Zone A (see Figure 16 on page 20). 4. Zone B is defined by either Figure 13 on page 15 (with parapet < 19) or Figure 12 on page 14 (with parapet 19) 5. This array size cannot be fully inside Zone B. Array shall have at least as many panels in Zone C as in Zone B. 6. Wind regions are defined by 3-second gust measured at 10 m (ASCE 7-05, Figure 6.1). Special wind regions are excluded. Tornadoes have not been considered in developing this specification. 7. Wind speed-up due to local topography must be considered when establishing design wind speed. Consult ASCE 7-05, Section 6.5.7. 8. This specification can be used for roof slopes of up to 2:12 on roofs up to 60 feet (18.3 m) high, and for roof slopes up to 1:10 on roofs up to 600 feet (183 m) high. 9. Any building steps or obstructions such as overruns, HVAC units or skylights shall have a minimum clearance equal to the lesser of said obstructions width or twice its height. 10. For objects less than 3 inches (7.5 cm), either flush to roof surface or elevated, arrays may be placed over them if: a. Said object is below no more that two panels on the exterior of the array, AND b. Said object is below no more than 20% of the panels in the array. For objects between 3 and 8 inches (7.5 and 20 cm), comply with rules (a) and (b), AND double the array sizes as defined in the tables. 11. No surrounding buildings greater than 150% of subject roof height high within 200% of subject building. 12. The weight of a single panel with support is assumed to be 68 lb. The friction coefficients used are as shown. Each roof should be measured individually. Contact Solyndra for details. Any excursion from these assumptions will change this specification.
Panel Placement at Edges and Over Obstacles

Panels placed at the edge of an array - that is in Zone A or B - must be connected to a minimim number of panels in Zone C. No sub-array can be fully inside Zone A. All arrays shall have at least two times as many panels in Zone C as in Zone A (see Figure 16). Likewise, no sub-array can be fully inside Zone B. All arrays shall have at least as many panels in Zone C as in Zone B. In addition, the array must be as deep (or deeper) than it is wide, That is, the number of panels in the direction toward the center of the roof must equal or exceed the number of panels along perimeter. If you are setting up a small array for evaluation purposes, place it in the center of the roof; well away from Zone A and Zone B. Figure 16. Rules for Panel Placement at Edges
Not Acceptable Zone A Zone C Roof Edge Not Acceptable Acceptable
Placing Panels over Roof Objects

There are several rules that must be followed when placing panels around or over any obstructions, conduit, or other items on the surface of the roof. First, never place panels over objects more than 8 inches (20 cm) tall. Never block up panels to clear objects. Roof Object Height & Size For the purposes of clearance, roof object height and size are not the same. Objects such as conduit runs are sized according to the diameter of the conduit (or any type of pipe, etc), not the height of the top of the conduit. Thus, a one-inch conduit whose top edge is six inches above the roof surface is treated as a one-inch object, not a six-inch object. When several pipes are run together, each one is treated as an independent object. Several examples are shown in Figure 17 on page 21.
20
Figure 17. Examples of Roof Object Height Measurements

(a) (b) (c) (d) (e)
8 (20 cm)
1 (2.5 cm)
3 4 (7.5 cm) (10 cm)
6 (15 cm) 2 (5 cm)
Objects which rest directly on the roof, with no gap, are defined by their height. Object (a) in Figure 17 is an example. In Figure 17, objects (b), (c), (d), and (e) do not rest directly on the roof. They are, respectively, 1 inch (2.5 cm), 3 (7.5 cm) inches, 4 (10 cm) inches, and 6 (15 cm) inches high. They are NOT 3 inches (7.5 cm), 5 inches (12.5 cm), 6 inches (15 cm), and 8 inches (20 cm) - it is not necessary to include the space under the object when determining height. Panel arrays may be placed over objects less than 3 inches (7.5 cm), provided: (a) the objects length OR the objects width does not exceed 12 inches (30 cm), OR (b) the object is under the arrays interior panels and either the objects length or width does not exceed 25% of the arrays length or width, respectively.
Note that these rules do not prevent panels from being placed over conduit, etc, because each conduit is less than 12 inches (30 cm) across. Thus, rule (a) exempts conduit and other piping in almost all cases. In general, rule (b) permits panels to be placed over other rooftop items as long as the items are in the interior of the array. Panel arrays may be placed over objects between 3 inches (7.5 cm) and 8 inches (20 cm), provided: the object is below no more than two panels on the exterior of the array, AND the object is below no more than 20% of the panels in the array, AND the sub-array size is at least twice the minimum defined in the tables.
Taller Objects Objects taller than 8 inches (20 cm) should not be covered by panels. Any building steps or obstructions more than 8 inches (20 cm) high, such as overruns, HVAC units or skylights, shall have a minimum clearance equal to the lesser of the obstructions width or twice its height.
Wind Clearance Example

Solyndra arrays are held down by their own weight. On buildings with low or no parapet, you must maintain a minimum setback from the building edge, and at corners make sure there are enough panels hooked together to provide adequate mass. In addition, you must allow for clearance around large obstacles on roofs, due to wind eddies. Figure 18 shows a two-story building, 30 feet (9 m) tall, with a parapet less than 19 inches (0.48 m). There are 1295 panels total. Figure 18. Wind Clearance Example
39-4 (12 m) 200 (61 m) 161-8 (49.3 m) Wind clearance around HVAC Detail B HVAC unit 6 high (1.82 m) Zone B Zone A Zone B
39-4 (12 m)
Zone B
Zone A 140 (42.7 m)
Zone A 265 (80.7 m) 225-8 (68.8 m) Zone A Zone B
Skylight 8 high (20 cm)
Access Hatch 12 high ( 30 cm) Detail A Zone A Fire Clearance Minimum Setback Wind Zone A Border
125 (38.1 m)
Zone B Detail C
Zone A Detail D 142 (43.3m)
Zone B Structural Member
Skylights 8 high (20 cm)
58 (17.7 m)
Color code: Obstruction Wind Minimum Setback 22 Solyndra Photovoltaic Panel Design Guide Solyndra Confidential Doc Number 0920-30006-EN-010
Figure 19. Detail A - Wind Clearance Example
Access Hatch, 12 (30cm) high Clearance for wind
Figure 20. Detail B - Wind Clearance Example
Clearance for wind HVAC 6 (1.8 m) high
Figure 21. Detail C - Wind Clearance Example
Zone B restricted area Array > 15 panels
Wind clearance
Figure 22. Detail D - Wind Clearance Example
Wind clearance Skylight
Color code: Obstruction Wind Minimum Setback
All Clearances
Some designs must meet fire, wind, and seismic rules at the same time. It might seem that this would seriously reduce panel count, but Figure 23 shows otherwise. It shows the same twostory building, 30 feet (9 m) tall, with a parapet less than 19 inches (0.48 m). There are 1265 panels in all. Figure 23. All Clearances Example
39-4 (12 m) Seismic, wind clearance around HVAC Shade clearance around HVAC Detail B HVAC unit 6 high 39-4 (1.82 m) (12 m) Zone B Zone A Zone B 200 (61 m) 161-8 (49.3 m)
Zone B
Zone A 140 (42.7 m)
Zone A 265 (80.7 m) 225-8 (68.8 m) Zone A Zone B Skylight 8 high (20 cm) Access Hatch 12 high ( 30 cm) Detail A Zone A Seismic Clearance Fire Clearance Wind Zone A Border Minimum Setback 125 (38.1 m)
Zone B Zone A Detail C Detail D 142 (43.3m) Zone B Structural Member
Skylights 8 high (20 cm) 58 (17.7 m)
Color code: Fire Obstruction Seismic Wind Minimum Setback 24 Solyndra Photovoltaic Panel Design Guide Solyndra Confidential Doc Number 0920-30006-EN-010
Figure 24. All Clearances - Detail A

Seismic clearance Access Hatch, 12 (30cm) high Clearance for wind 4 (1.2 m) clearance for re 4 (1.2 m) walkway for re
Figure 25. All Clearances - Detail B

4 (1.2 m) walkway for re Clearance for shade Clearance for wind Clearance for seismic HVAC 6 (1.8 m) high
Figure 26. All Clearances - Detail C
Zone B restricted area Array > 15 panels Fire clearance Minimum clearance Seismic clearance Wind clearance
Figure 27. All Clearances - Detail D
Wind clearance Skylight Seismic clearance

Color code: Fire Obstruction Seismic Wind Minimum Setback
4 (1.2 m) walkway for re
Estimating Energy Yield

Once you have completed your layout, you can use Solyndras on-line energy yield modeling tool to determine hourly, daily, monthly, and total energy yield. Figure 28 shows a screen shot of the data entry portion of the tool. Refer to Forecasting Energy Yield for instructions in the use of this program. Contact your Solyndra representative to obtain access to the tool. Figure 28. Example Screen Shot from Solyndra Energy Yield Tool
Detailed results are available on-screen, in a downloadable report, and in a downloadable Excel-compatible spreadsheet.
Solyndra Photovoltaic Panel Design Guide Solyndra Confidential Doc Number 0920-30006-EN-010
26
Chapter 3
Sub-Array Wiring Options
The Solyndra Connector System

Each Solyndra panel has four connectors; two for positive and two for negative. The connectors are arranged to make it possible to implement almost any desired series, parallel, or seriesparallel. The panel and its connectors are shown in Figure 29. Figure 29. Solyndra PV Panel and Power Connections
+ Positive Side
Male, Positive
Female, Positive
Negative Side Female, Negative Male, Negative
A series connection is shown in Figure 30. Figure 30. Two Panels Wired in Series
+ Positive Side
Male, Positive
Female, Positive
Negative Side Female Male +
Male Female +
+ Positive Side
Female, Negative
Negative Side
Male, Negative
Figure 31 shows how two panels can be connected in parallel. Figure 31. Two Panels Wired in Parallel
+ Positive Side Male, + Female, + Male, Negative Side Female, Negative Side + Positive Side
Male, Positive
Female, Positive
Female, Negative
Male, Negative
These are the two most common panel-to-panel connections. There is a third possible arrangement; a series connection of panels which are physically end-to-end. This is shown in Figure 32. Figure 32. Series Connection, End-to-End Panels
Do not connect! + Positive Side Male, Negative Side
Male, Positive
Female, +
Female, Negative
Female, Negative
Negative Side
Male, Female, +
+ Positive Side
Male, Positive
It is important when connecting panels in series, as shown in Figure 32, that you NOT connect the other connector pair. This creates a short circuit. A correct five-panel string is shown in Figure 33. You may wish to place caps on the unused connectors, to avoid inadvertent use. Figure 33. Five-Panel Series Connection, End-to-End + No Inter-panel Connections
Figure 34 shows series connections between panels, and a typical view, from underneath the array, of several series connection in a string of panels. Panel wiring uses USE-2 AWG #12 conductors. To connect panels in series, take the positive connector and snap into the negative connector of the adjacent panel. Figure 34. Interpanel Connection of Positive and Negative Pigtails
28
Jumper Types
Most connections can be directly between panels, using the panel pigtails. This type of connection is shown as a black line in the following diagrams. In certain cases, you will need longer jumper connection, for both positive and negative connectors. These are shown as red or blue lines in the following diagrams. Figure 35 shows the types of jumpers. Figure 35. Jumper Types
Male, Positive
Positive Jumpers
Negative Jumpers
Female, Positive
Male, Negative
Female, Negative
Electrical Sub-Arrays
Panels are grouped in series strings to produce sufficient voltage to drive the inverter. A series string is a group of panels whose electrical connections are in series. These series strings are then connected in parallel to increase the total current and reduce the number of inverters needed. The number of panels needed in the series string depends on the inverter chosen for the design, but five is a typical number, and will be used for the following examples. (Refer to page 36 for details on string sizing.) Similarly, most designs have three such strings in parallel, for a total of 15 panels per stringblock. A series string and a 5 by 3 array are shown in Figure 36. Figure 36. A Typical Series String, and a 5 by 3 Array
Home-run Connection
Home-run Connection
In all of these examples, the location of the home-run connection can vary. In general, the home-run connection should be made to minimize the length of wire required.
More Complex Sub-Array Arrangements

In some cases, the standard 5 by 3 string-block arrangement may not be mechanically convenient for a given roof location due to shape, obstacles, or other factors. Figure 37 shows an alternate method of creating a 5 by 3 string-block. Note the places where connections should NOT be made. Figure 37. Alternate 5 by 3 Sub-Array Configuration No Inter-panel Connections Home-run Connection
Home-run Connection
Roof obstructions may make it necessary to arrange panels in arbitrary ways. Figure 38 shows a method of arranging panels to clear such obstructions. (No-connects omitted for clarity.) Figure 38. Panel Arrangement to Clear Obstructions
Home-run Connection Home-run Connection
Obstruction
Obstruction
30
It is occasionally necessary to place panels along a diagonal or curved boundary. Figure 39 shows a method of wiring a 5 by 3 string-block to fit a diagonal edge. (No-connects omitted for clarity.) Figure 39. Panel Arrangement for a Diagonal Boundary
Home-run Connection Home-run Connection
Panel Matching
Every panel has a maximum power point, the unique combination of voltage and current that delivers the most energy. These values are called Vmp and Imp. Each panels maximum power point is at a slightly different point, and will vary with temperature and insolation. For a single panel, this is not an issue, because the inverter will keep the panel at its maximum power point. However, there is a small loss of efficiency when multiple panels are connected to the same inverter. When two or more panels are wired in series, the current in each panel is the same, but that value of current cannot be the optimum load current (Imp) for all panels in the string. Likewise, when two or more panels (or series strings) are wired in parallel, all must operate at the same voltage, but this voltage cannot be the optimum load voltage (Vmp) for all elements. For Solyndra panels, it is not necessary to attempt to match panels closely within an array. The mismatch loss can be kept under 0.4%. Solyndra panels are very insensitive to operation at non-optimum current, and reasonably insensitive to operation at non-optimum voltage. This means that panels of different power ratings do very well when wired in series, but slightly less well when wired in parallel. Panels from as many as three different power ratings may be mixed, as long as the power ratings are adjacent ones. Thus, with nameplate values of 150, 157, 165, 173, and 182 watts, 157-165-173 is permissible, but 150-165-173 is not. When installing panels, the guidelines illustrated in Figure 40 should be followed. In this illustration, panels of three different power ratings are represented by the three different colors. In each sub-array, there are five panels per series string, and three strings in parallel. Figure 40. Panel Matching and Panel Arrangements
Example (a) shows an installation of Solyndra panels entirely of the same power rating. This is the best-case installation practice, but may not be applicable to very large arrays. In Example (b) the panels are pulled from crates so that each series string contains a similar mix of panels, and all parallel strings contains the same panel arrangements. This is the optimum combination when mixing. This arrangement will keep mismatch loss below 0.4%. In Example (c) the installers used the contents of one crate of 16 panels, then proceeded to the next crate, and continued. There is no loss in most strings because they are matched, but the loss in the non-matched strings brings the total mismatch loss to 0.8%. Example (d) is the worst-case arrangement. By confining the mismatch across parallel strings, the loss exceeds 1% . This arrangement would not occur during a normal installation process. It is shown here to indicate that it is the one arrangement that should not be used.
Inverter Inverter Inverter
Panel Matching Recommendations

32
Planning Recommendations
You should develop a specific wiring and placement plan for each electrical sub-array in the overall layout, and have it available during installation. Installers will need to know which way to orient each panel as it is placed, so that wiring connections can be made conveniently. If you are using panels of more than one power rating, you should indicate the correct power rating for each panel on the layout. Note that while it is necessary that all strings connected to a given inverter be the same length, it is not necessary to have the same number of strings in parallel for every inverter. It is electrically and mechanically feasible to hook groups of panels in parallel first, and then combine the parallel blocks in series. However, this configuration will slightly increase panel mismatch loss, and is not recommended. For details on the physical wiring and handling of panels, please refer to the Solyndra Photovoltaic Panel Installation Manual.
Chapter 4
String Sizing
Series String Length

Optimum series string length is a balance between the highest safe voltage and the lowest workable operating voltage. The highest voltage occurs when the temperature is cold and the inverter is off. The inverter then sees the open-circuit voltage of the panels. The lowest voltage occurs on hot days, typically late in the afternoon, when light levels are falling but the temperature remains hot. The number of panels that can be wired in series is determined by the maximum safe voltage of the electrical system and the worst-case open-circuit voltage of the panels. The maximum safe voltage is limited by either the voltage rating of the inverter, or the rated working voltage of the wiring. In the US, most wiring is rated for 600 volts maximum; in Europe the maximum rating is 1000 volts. To determine the maximum number of panels you can wire in series, compute the worst-case panel open-circuit voltage at the coldest temperature the system will experience. This is commonly taken as the record 30-year low. This voltage, times the number of panels in series, must not exceed the maximum safe voltage of the system The minimum number of panels in series is set by the panels peak power voltage (Vmp), its temperature coefficient, the minimum voltage at which the inverter will operate, and the highest temperature at the site. If there is a wide range between the hottest and coldest temperatures, it may be difficult to select a string series length that avoids excessively high open-circuit voltages, yet maintains sufficient voltage during hot weather so that the string operating voltage will remain in the inverters power tracking window. All of the strings connected to an inverter must have the same number of panels in series. This ensures that paralleled strings have similar output voltages. It is not necessary to performancematch panels within an array for voltage or current. Inverter sizing for Solyndra panels is the same as for other types of PV panels. Tools are available on Solyndras website to select the number of panels for a given inverter.
34
Parallel Strings
The number of strings which can be wired in parallel is limited by the series fuse rating. The number of sub-array strings in a system is limited by the maximum input current rating of the inverter. In order to determine the sub-array string size limit, use the Fault Current Equation. (A full discussion may be found in Reference Document 5.) Eqn 4. I fault = 1.56 n Isc + ( n 1) 1.25 Isc where n is the number of single strings. The first term is the NEC required overcurrent protection device rating on a single string, and must be rounded up to the next available fuse size. The second term is the current from any other series string in the same sub-array. They are added because the strings are combined in parallel. Equation 4 simplified is: Eqn 5. I fault = (2.81 n -1.25) Isc For example, if the panel series fuse rating is 22 A, how many single strings in parallel can be combined without violating the rating and destroying a panel during a fault? Solve for n. Eqn 6. I 1 n = fault + 1.25 Isc 2.81 Plug in the series fuse rating for Ifault and the panel short circuit for Isc (lets say 2.60A). This gives 3.46. But n must be an integer, so we round down to 3. Notice that an increase in Isc at constant Ifault leads to smaller n. What happens if we try and use more than three strings in parallel? Plug 4 into Eqn. 4 or 5 for n. Ifault is 25.97Aslightly over the series fuse rating. Note that electrically it is safe to have sub-array strings of fewer than three single strings in parallel, however this is more costly in terms of labor and materials. At times, the geometry of a roof layout may necessitate smaller sub-array strings than the maximum, but the number of these strings should be minimized.
Chapter 5

Grounding
Solyndra recommends grounding the frames of all panels. Safety requires that Solyndra panel arrays be properly grounded. Correct grounding protects personnel in the event of a panel failure due to breakage, and it protects personnel and equipment from lightning-related effects. To avoid electrical shock, ground the panel as soon as it is placed, before doing any other wiring. As the array is built, the first panel of each column should be connected to earth ground as soon as it is placed, using the supplied ground lug or equivalent. As each panel is added, connect a ground strap between it and the previous panel. These connections ensure that the aluminum frame is grounded. Use a grounding method that meets applicable national and local code requirements. For the US and Canada, these include NEC or CSA C22.1 Safety Standard for Electrical Installations, Canadian Electrical Code Part 1. You may also wish to refer to NEC Article 690 on grounding photovoltaic arrays for specific requirements. Grounding in the Solyndra system is accomplished by three primary elements: 1) system ground lugs (ILSCO GBL4-DBT), 2) a ground wire, and 3) ground straps. One ground lug is installed on the first panel in every column, and every 15 rows thereafter. Each of these rows of lugs is connected together and then to ground via 10 AWG solid copper ground wire to system (earth) ground. The design goal is to keep resistance to ground below 0.1 ohm, per UL 1703. In addition, ground lugs must be installed whenever an obstruction creates a hole in an array. When building around obstructions, the first row after the obstruction requires a ground wire and lugs to connect the obstructed column to either one of the neighboring columns. If local codes require a larger ground wire, you may need to use a different ground lug. The third component of the ground system is the panel ground strap. To complete the ground path, ground straps are used to ensure that panels in each column are a grounded unit. Equipment ground conductors must be connected with stainless steel hardware. Make sure that there is no copper-to-aluminum contact; this will cause rapid galvanic corrosion. A stainless steel washer must be used to isolate copper wire from the aluminum frame. Solyndra panels can be grounded using a grounding washer or clip system, provided such system has been tested and certified to meet UL467 requirements for bonding and grounding systems, and are installed according to the manufacturers specifications. All threaded holes in a Solyndra panel are ground connections, regardless of labeling. Figure 41. Grounding Connections for Solyndra Array
Ground Lugs Ground Bus Wire - 10AWG or Equivalent
Ground Strap
Grounding Holes 4 per Frame
Roof Obstruction
Additional Ground Bus & Lugs

36 Solyndra Photovoltaic Panel Design Guide Solyndra Confidential Doc Number 0920-30006-EN-010
Array Installation over Lightning Grids

A Solyndra Array is not a Lightning Grid Some rooftops are fitted with a grid of conductors to deal with lightning. A Solyndra array, when installed, may be placed over these conductors. Certain guidelines should be followed. Background A lightning grid is an array of wires running horizontally in both directions across a roof. Dimensions vary, but typically the wires are space a few meters apart. The entire grid is carefully grounded to earth. These grids are occasionally fitted with vertical conductors as well, commonly called lightning rods. 1. In all cases, a qualified lightning-grid designer shall be consulted during the design and installation phase. 2. In all cases, a qualified electrical engineer shall be engaged to design system lead-ins to the inverter, equipping them with high-voltage shunts or other safety equipment as appropriate. 3. No part of any Solyndra panel, including the panel mount, shall be in contact with any part of the lightning grid. 4. The Solyndra panel grounding system shall not be connected to the lightning grid anywhere; and: 5. The Solyndra panel ground shall have its own dedicated conductor directly to earth ground. It shall not be connected to building electrical ground. 6. No lightning rods shall be placed, or allowed to remain, anywhere under the Solyndra array. 7. No lightning rods shall be placed, or allowed to remain, within one meter of the Solyndra array. 8. All remaining lightning rods shall be increased in height by a distance equal to the height of the top of the Solyndra array above the roof; i.e. approximately 25 cm in most installations.
Array Placement Guidelines
Chapter 6
System Wiring
Home-Run Wiring
Sub-array strings are connected in parallel inside a combiner box. Just as each panel has four connections, each of the four corners of a sub-array string will have a plus or minus pigtail available. Run a positive home run cable and a negative home run cable from the corners in such a way that minimizes cable length. Along edges of panels, you may use either the Solyndra-offered cable trays or UV-rated cable ties to keep wires organized and prevent them from dangling. Solyndra recommends the use of cable trays, as they reduce the possibility of snagging a wire and offer greater UV protection than cable ties. Cable trays are available for both the short side and the long side of the array. Figure 42 shows a sub-array with cable trays installed. Figure 42. Long and Short Cable Trays
Connectors and Dust Caps

When connected together, the Solarlok connectors used on Solyndra panels form a weathertight seal designed to last the life of the panel. However, open connectors are not weatherresistant. Therefore, Solyndra strongly recommends that all unused connectors be covered with dustcaps when the panel is installed. This helps to maintain connector quality. There are two options for this: Connect both wires to the next panel. This increases redundancy in the wiring as well. Use the available Solyndra dustcap (male or female as appropriate) to cover the unused connector. Secure any dangling pigtails to the panel.
DC Conduit Design and Placement

Conductors that connect each array combiner box to the inverter should be designed and installed per applicable codes. Homerun wire should be grade USE-2, of 12 gauge or larger, and properly protected against mechanical damage.
38
Inverters for Solyndra Arrays

Solyndra panels are designed to operate with a wide range of inverters. Strings of panels may be configured for both 500V and 600V inverters in the US and for 1000V strings in Europe. The types of inverters that have been investigated for proper operation are: Centralized inverters: Solyndra panels have been verified for operation with standard 300-600V DC input centralized inverters with 3-phase, 480V output. Some central inverters may require a low voltage setting (also known as a center tap) in order to operate within the input voltage range during bright warm days. Distributed or string inverters: Solyndra panels have been tested with a wide range of distributed inverters. Contact Solyndra for details and recommendations. Micro-inverters: At the time of publication no micro-inverters were commercially available that can operate with a Solyndra panel, due to their low input-voltage design. Solyndra anticipates that its panels will operate satisfactorily on micro-inverters when they do become available for the higher input voltages necessary Solyndra panels. Transformerless inverters Inverter manufacturers have introduced various inverter designs that employ transformerless topologies. These transformerless inverters have the potential to result in higher system efficiency by eliminating the output transformer, which is a source of loss. Solyndra panels have extremely low capacitance (500-600 pF) from terminal to frame; since the measured leakage capacitance is orders of magnitude lower than that required for a transformerless inverter it may be adequate for ungrounded operation when connected to such an inverter. While ungrounded arrays are more prevalent in Europe, NEC690-2008 has addressed the issue in 690.35. Nevertheless, many utility jurisdictions may still require PV arrays to be electrically grounded via the grounding electrode in the inverter per UL-1741; accordingly, systems may not be designed with transformerless inverters that do not allow the array to be grounded.
Optimum Inverter Sizing

Inverters represent about 5% to 8% of the total system cost of a PV project investment. System designers must understand the difference between the panels nameplate power rating, Wp, and the actual energy yield in the field. All too often, PV system designers size inverters to match the nameplate Wp rating of the PV array. This is a wasteful practice. An inverter almost never needs to be rated at the same Wp as the array. Figure 43 shows how the power output varies over the course of the year, from the best (summer) days to the worst (winter) days. Figure 43. Power Output Variation over a Year
100
80 Percentage of Wp Intermediate Panel Power Outputs
Panel Power Output; Brightest Days
60
40
Panel Power Output; Darkest Days
20
6 AM
9 AM
Noon
3 PM
6 PM
This hour-by-hour variation in power output over the year can be plotted as a histogram, showing the number of hours in each year which reach a given power level. This is shown in Figure 44. Figure 44. Histogram of Power Output per Hour
100
80 Percentage of Wp
60
40
20
Hourly Data
4000
Figure 44 shows that only on a few days of the year is the output power close to the Wp value; on most days it is significantly less. This section will explain how to size the inverter for the maximum economic return. Furthermore, it will explain why the unique energy delivery curve of Solyndra panels allows the use of an even smaller inverter, typically 5% to 15% smaller than the flat-panel array requirement.
40
Actual Power vs Wp Rating

The actual power produced by a panel is usually less than the Wp rated power for three reasons: The sun is usually not as intense as the 1000W/m2 used for measuring Wp. Power decreases as temperature increases, and the panel is usually warmer than the 25C temperature used for measuring Wp. This is especially likely to be the case in the summer. The panel is not aimed directly at the sun; that is, it is not perpendicular to the sunlight. Geometry & Tracking The angle of the panel with respect to the direction of sunshine affects the amount of solar energy which strikes the panel. For example, tilting a conventional solar panel 45 degrees away from the sun reduces the amount of direct solar radiation that strikes the panel, as shown in Figure 45. The panel only captures about 70% (1 meter out of 1.41 meters, in this example) of the sun when the angle of incidence is 45 degrees. Non-tracking designs are subject to this intensity-reduction throughout the day. Solyndras unique self-tracking geometry reduces this effect, as illustrated. A Solyndra panel is a one-axis tracking panel; as the sun moves across the sky from morning until evening, the panel passively tracks this motion. Solyndra panels are thus able to produce more energy than conventional flat plate panels in the morning and afternoon hours when the sun is not directly overhead. Figure 45. Geometry Effect & Solyndra Self-Tracking Effect
Morning Noon Afternoon
1-meter panel
1-meter panel
1.0 meter
1.41 meters
Solyndra modules
This self-tracking feature means that Solyndra panels deliver more energy in the morning and evening, compared to conventional flat panels, even though the peak is lower. Figure 46 shows measured output of a Solyndra panel and a flat panel. The Solyndra panel produces more total energy during the day. This is why a Solyndra panel does not require as much inverter capacity as conventional panels. Put differently, for the same energy output, a Solyndra system works well with a smaller inverter size than a conventional flat panel PV system, significantly reducing costs. Figure 46. Solyndra Energy Yield Curve
140 120 100 80 60 40 20 0 Instantaneous Power Solyndra SL001-157 Sharp NT180U1
6 AM
9 AM
Noon
3 PM
6 PM
Inverter Sizing
Because of the factors described above, a typical solar array will never generate the nominal Wp rated power. The inverter can and should be smaller. The amount depends on both technical factors and economic factors. Technical Factors Solyndras solar-energy modeling program produces an hour-by-hour forecast of energy production. From this, the peak power produced by the array can be determined. An inverter sized to this value will be sufficient. As an example, a nominal 250 kW array installed in Sacramento, California will produce, for a few days around June 22nd, a maximum of 206 kW. This is the peak output, so an inverter of 210 kWp is more than sufficient for this array. Economic Factors It may make economic sense to use an even smaller inverter than the technical factor alone suggest. Inverters are not harmed by being connected to an array which produces more watts than the inverter rating. The inverter simply ignores the extra power (if any), an effect known as clipping. In the above example, a 200 kW or even a 180 kW inverter will result in a small amount of energy loss, but the cost savings will justify it. The Levelized Cost of Energy (LCOE) metric is an useful indicator of the optimum inverter size, as it accounts for both the cost benefit and the lost energy penalty. In the example array, a 200 kW inverter will sacrifice only 0.2% of total energy. A 180 kW inverter will sacrifice only 3.6%. The system designer can compute the LCOE for different inverter sizes, given the cost of inverters. Figure 5 shows the LCOE for different inverter sizes for the nominal-250 kW example system. At the specified ratio of 1.45, the inverter size is 172.4 kW, for a loss of only 8.4%. Solyndra offers an Excel spreadsheet tool that will automatically import the hourly data from the energy yield model and evaluate the performance of various inverter sizes. Figure 47. LCOE vs DC:AC Ratio
$0.256 $0.254 $0.252 LCOE $0.250 $0.248 $0.246 $0.244 $0.242 1.00 1.20 1.45 1.40 1.60 DC:AC Ratio 1.80 2.00
42
Maximizing Value for AC-Limited Incentive Applications

In the previous section, we determined the optimum inverter size for a given DC project size to yield the lowest LCOE. The calculation is based on a fixed feed-in tariff (FIT). However, some feed-in tariffs are tied to the AC rating of the inverter, rather than the DC output of the array. There are breakpoints in the FIT at various AC sizes. This incentive system means that the economic goal is to determine the most cost-effective DC array size for a given AC inverter rating. This DC-to-AC ratio is called the oversize ratio. There is an optimum oversize ratio which will maximize the net present value (NPV) of the project to the investor. The higher capital cost for the larger DC array is balanced by the gain in revenue from the extra energy produced by the oversized DC array, and sold at the higher FIT rate. Figure 48 shows the economically-optimum oversize ratio for an array installed where there is a change in FIT rates for a 250 kW-rated inverter. At a 1.75 ratio, the array is 437.5 kWp. Figure 48. NPV vs DC:AC Ratio
$700 1.75 $600 $500 $400 $300 $200 $100 $0 1.00 1.20 1.40 1.60 1.80 2.00 DC:AC Ratio
A 250 kWp array at this location will yield 302 MWh of energy. By increasing the array size to 437.5 kWp, the total energy yield increases to 392 MWh. This is illustrated in Figure 49. The area in red is the energy lost; the area in green is the energy gained due to the oversize array. Figure 49. Energy-Cost Trade-off for Oversized Array
400 350 300 250 200 150 100 50 0
400 350 300 250 200 150 100 50 0
Clipped Optimized 1.2 DC:AC Ratio
NPV
kW Output
1 218 435 652 869 1086 1303 1520 1737 1954 2171 2388 2605 2822 3039 3256 3473 3690 3907 4124 4341
kW Output
1.2 DC:AC Ratio
Histogram of Hourly Energy Output
Summary
In all cases, it makes sense to determine the actual power output of the array, and size the inverter accordingly. In most cases, it will make economic sense to select an inverter somewhat smaller than the actual peak power output of the array. The precise oversize ratio will depend on the tariff regimen, actual insolation, and inverter cost. Regardless of your tariff model, you can use Solyndras Excel tool, or the Solyndra Design Services team will be happy to assist you in determining the optimum inverter size for your array and your economic situation.
1 218 435 652 869 1086 1303 1520 1737 1954 2171 2388 2605 2822 3039 3256 3473 3690 3907 4124 4341 Histogram of Hourly Energy Output
Chapter 7
Roof Loads

Mechanical Design
The roof deck may be made of any material as long as it is covered by a securely fastened lightcolored cool-roof membrane, has a slope of 2:12 or less, and can support the load. Other roofing materials and colors may be used, but lower-reflectivity roofs will reduce array output. Solyndra has a modeling tool and an extensive collection of reflectivity data; contact Solyndra if you wish to install panels on a non-white roof. Each panel covers 1.97 m2 (21.2 ft2) and weighs, with mounts, 70 pounds (32 kg). Table 5. Roof Loading
Item Panels with mounts and home run wiring Dead Load (US units) 3.3 pounds/square foot Dead Load (Metric) 16 kg/ square meter
From a design viewpoint, adding an array to a roof adds 3.3 lbs/ft2 (16 kg/m2) of loading to the roof. However, the roof s live load allowance of 20 lbs/ft2 (100 kg/m2) may be eliminated because it will no longer be possible to place materials in areas occupied by the array. Therefore, most building and permitting authorities will accept the argument that adding an array will actually reduce the calculated load on the roof. All roof-top photovoltaic installations should be reviewed by a qualified structural engineer. The following data should be considered as advisory only. Some roof materials, such as mineral wool and certain types of foam insulation, have a specific local pressure loading limit. These soft roofs may required the use of a panel mount with a larger footprint to reduce localized pressure. Solyndra offers a Load Distribution Foot (LDF) for installation situations which must meet a local pressure loading limit. The LDF attaches to the standard panel mount. The attachment allows the LDF to tilt slightly to accommodate uneven roof surfaces. When used in accordance with Solyndras installation guidelines (see next page), the LDF limits roof compression to less than 3 mm. Table 6. Standard Panel Mount and Load-Distribution Foot
Standard Mount Material Area of Foot Weight, each Powder-coated aluminum 0.0138 m2 0.48 Kg Load-Distribution Foot Powder-coated aluminum 0.123 m2 0.6 Kg
Panel Mount
Structural Engineering

Roof Mount Pressure Loads

LDF
44
Determining Panel Mount Pressure

The maximum pressure at the foot of each mount is shown in Table 7. These are worst-case values, based on an average of two mounts per panel. Table 7. Standard Panel Mount Maximum Loading
Snow Load paskg/m2 cals 0 0 500 51.0 1000 102 1500 153 2000 204 2500 255 2800 286 Total Weight psf 0 10.4 20.9 31.3 41.8 52.2 58.5 kg 31.9 132.1 232.3 332.6 432.8 533.0 593.1 lbs 70.3 291.3 512.2 733.2 954.1 1175 1308 Pressure per Mount, Standard psi 1.69 6.86 12.0 17.2 22.4 27.5 30.6 psf 244 988 1732 2476 3220 3965 4411 kg/m2 1189 4823 8457 12090 15724 19357 21538 pascals 11662 47296 82930 118564 154197 189831 211211 psi 0.20 0.79 1.37 1.95 2.53 3.11 3.46 Pressure per Mount, LDF psf 29 113 197 281 365 448 499 kg/m2 144 553 962 1371 1780 2189 2434 pascals 1409 5420 9432 13443 17455 21466 23873
Minimum Pressure Rating for Roofing Material

At the maximum rated snow load of 2800 Pascals, the minimum roof load pressure specification must be 8300 Pascals. For applications with less snow or softer roofing materials, contact Solyndra. Solyndra panels have been tested per Section 10.16 of IEC 61646. They can withstand 58 pounds per square foot (283 kg/m2, or 2800 Pascals) of snow load. In many cases, snow will accumulate on the tubes, although light snow sometimes falls through. Solyndra panels do not increase the amount of snow that will accumulate on the roof. Snow on the tubes should be brushed off to enhance electrical yield. Snow on the roof has excellent albedo, and will not decrease panel output. The historical snow loading in a particular region and the details of the job site should be examined to assess the risk of exceeding this value on the roof in a given year. In addition to dead loads, the roof must withstand live loads during installation. Solyndra panels are packed horizontally onto pallets for shipment. The pallet weighs approximately 1100 lbs (500 kg). (Refer to Solyndras shipping documentation for exact weight and size.) Make sure that the roof surface is not overloaded when pallets are placed on the roof.
Snow Loads

Construction Materials Placement

Chapter 8

Solyndra Panel System
This section details the parts involved in a Solyndra PV installation.
Part Definitions and Identification

Figure 50 shows the major components of a Solyndra PV panel and their names. Fasteners and other small parts are listed in Table 8. Figure 50. Panel Parts and Assemblies
Ground Lug Hole (underside) Ground Strap Hole SolarLok Male, Positive Lateral Clip Hole SolarLok Female, Negative Ground Strap Hole Panel Mount Ground Lug Hole (underside) Ground Strap Hole SolarLok Female, Positive Lateral Clip Hole SolarLok Male, Negative Ground Strap Hole
Panel Installation Rates

Panel installations are typically done with a five-person crew. A team of two people assemble the panels; a second two-person team carries them into position. The fifth person makes the electrical connections. An experienced crew can install up to 300 panels per day under good conditions. However, if the panel layout is complex, or the distance to carry the panels from the staging area is long, it may only be possible to install around 100 panels per day.
46
Solyndra Provided Parts and Ancillary Recommended Parts

General Recommendations
The following is a list of general recommendations to help the installer choose the right materials, equipment, and installation methods that will help ensure that the system will provide many years of reliable service. These recommendations can be used to evaluate pre-engineered system designs and compare system features from one supplier to another. Do not substitute any Solyndra-specified parts without the express written consent of Solyndra. Materials used outdoors should be sunlight/UV resistant. Follow roof manufacturers guidelines for sealants. If no guidelines are provided, urethane sealants should be used for all non-flashed roof penetrations. Materials such as wire insulation and other components should be certified to withstand the temperatures to which they are exposed. Dissimilar metals (such as steel and aluminum) should be isolated from each other using non-conductive shims, washers, or other methods. Aluminum should not be placed in direct contact with concrete materials. Only high quality stainless steel fasteners should be used. Structural members should be either: corrosion resistant aluminum, 6061 or 6063. hot dip galvanized steel per ASTM A 123. coated or painted steel (only in low corrosion environments such as deserts). stainless steel (particularly for corrosive marine environments).
Materials Recommendations
Equipment Recommendations and Installation Methods

All electrical equipment should be listed for the voltage and current ratings necessary for the application. Inverters should be listed to UL 1741. All required over-current protection should be included in the system and should be accessible for maintenance. All electrical terminations should be fully tightened, secured, and strain relieved per NEC. All roof penetrations should be sealed with an sealing method approved by the roofing material vendor, and that does not adversely impact the roof warranty. If possible, have the roofing contractor seal all roof penetrations. Integral roofing products should be properly rated (e.g., class A roofing materials). All cables, conduit, exposed conductors and electrical boxes should be secured and supported according to code requirements.
Solyndra Parts
Table 8 lists the parts which are a standard part of the Balance of System (BOS) in Solyndra systems. Table 9 and Table 10 list the optional BOS parts. Table 8. Panel Installation Hardware - Provided as Balance of System
Item Panel Picture Part Number Description SL001-XXX Solyndra photovoltaic panel. -XXX represents the power rating of the panel.
Panel Mount
0040-30175
Panel mount for Solyndra photovoltaic panel. Attached using 1/4-20 screw. Because panels share panel mounts, the number of panel mounts required will vary with each installation. 1/4-20 x 3/4 Phillips head with star washer, stainless steel, for attaching panel mounts. One needed per panel mount. 10-32 x 1/2 Phillips head with star washer, stainless steel. Used for ground strap (2), lateral clip (2), and ground lug (1). Total number required will vary with installation. In mid-2009, Solyndra upgraded all fasteners to ISO-standard metric screws. The M5-0.8 x14 mm stainless steel screw replaces 0520-30011 and 0520-00689 for all holes. 10 AWG tinned stranded wire with lugs at each end. UL, green jacket. Used between the long side of adjacent panels. Total number required will vary with installation. Used to connect frames together with 10-32 screws. Has teeth on one side; these go against aluminum frame to insure a good connection. Total number required will vary with installation. Used to support the panel while installing panel mounts onto panel. Clean up kit in case of panel breakage. One kit needed per building or installation site
Panel Mount Screw (obsolete) General Purpose Screw (obsolete) M5 Screw
0520-30011
0520-00689
0520-30658
Ground Strap
0011-30029
Lateral Clip
0020-30213
Panel Prep Block OCA Clean-up Kit
0205-30029
0240-30833
48
Table 9. Panel Installation Hardware - Optional, from Solyndra

Item Long Cable Tray Short Cable Tray Load-Distributing Foot Cable Tray Clip Dust Cap for Female Solyndra Connectors Dust Cap for Male Solarlok Connectors Ground Lug Pad, Panel Mount, TPO Pad, Panel Mount, PVC Pad, Panel Mount, EPDM 0020-30225 0048-30094 Picture Part Number Description 0020-30198 0020-30199 0024-31632 Used for routing the home-run cables around the array. Used on mineral-wool or other soft roofs.
0020-30205
Cable tray clips are installed on the short side of the panel. They support the cable tray that contains the home-run power connections. May be used to cover unused Solarlok female connectors. Not required.
0048-30100
May be used to cover unused Solarlok male connectors. Not required. Also available from Tyco . Attaches to panel with a screw. The wireclamping portion is open-jawed; permits the use of a continuous length of grounding wire. Also available as ILSCO GBL-4DBT. Pad for panel mount - TPO type roof membrane junction, at the option of end user. Pad for panel mount - PVC type roof membrane junction, at the option of end user. Pad for panel mount - EPDM type roof membrane junction, at the option of end user.
0700-30198
0020-30226
0020-30227
Table 10. Panel Installation Hardware - Optional, from Third-Party Suppliers

Item Solarlok female connector Solarlok female connector Solarlok male connector 0710-00379 0710-00077 Picture Part Number Description 0710-00075 Keyed positive. For positive lead, marked Red. Used to connect the home-run cables to the output connection of the strings of the array. Keyed negative. For negative lead, marked Blue. Used to connect the home-run cables to the output connection of the strings of the array. Unkeyed. Can be used or positive or negative lead. Used to connect the home-run cables to the output connection of the strings of the array. Dust Cap for Male Solarlok Connectors Ground Lug 0048-30100 May be used to cover unused Solarlok male connectors. Not required. Attaches to panel with a screw. The wireclamping portion is open-jawed; permits the use of a continuous length of grounding wire. Also available as ILSCO GBL-4DBT.
0700-30198
For your convenience, part numbers for Tyco Solarlok connectors are shown in Table 11. These connectors are sized for 12 AWG (4 mm2) wire. Table 11. Tyco Solarlok Connector Part Numbers
Female Cable Connector Plus Keyed Plus Coupler Minus Coupler Male Coupler, Neutral 1394462-3 Minus Keyed 1394462-4 Male Cable Connector Plus Keyed 1394461-3 Minus Keyed 1394461-3 Unkeyed 6-1394461-2
50
Quantities of Parts
Solyndra panels share mounts and certain other components. Therefore the number of parts needed is determined by both the number of panels and the arrangement of the arrays, i.e. the number of rows and columns of panels. Spreadsheet tools are available from Solyndra that can calculate a bill of materials for a project. To aid the designer, the equations used to calculate the required number of each type of part are discussed below. Figure 51 shows a detailed view of the placement of each part and helps to illustrate how to calculate the required number of parts. Figure 51. Parts Arrangement in a Typical Sub-Array
Wiring Polarity + Panel Row + Panel Row + Panel Row + Panel Row + Panel Row -
Ground Lugs
Ground Bus Wire
Ground Strap
Grounding Holes 4 per Frame
Lateral Clip
Panel Column (String)
A Note on Panel Terminology

Note that in most installations, panels are grouped electrically by column first, then row. That is, a columns represents a series string of panels, as shown in Figure 51. Columns are then wired in parallel with other columns. Of course, other arrangement are possible in consultation with your qualified solar system designer.
Calculating Parts Counts

Panels are held up by panel mounts, and tied together by ground straps and lateral clips. Panel Mounts: Panel mounts are shared between panels. The number of panel mounts needed is the number of panels in the array times 2, plus another pair to start the first row, or: Eqn 1. N mounts = 2 N columns ( N rows + 1)
Ground Straps: Ground straps connect panels in each row together. The panel at the end of the row doesnt need a ground strap. Therefore, the number of ground straps needed is the number of panels in the array minus the number of panels in the last row, or: Eqn 2. N straps = N columns ( N rows 1)
Lateral Clips: Lateral clips connect panels in adjacent columns together, The final column needs no ground strap. The number of lateral clips needed is the number of panels in the subarray minus the panels in the last column, given by: Eqn 3. N clips = ( N columns 1) ( N rows )
Ground Lugs: The number needed is the number of columns in a sub-array, plus any opening in the array must have ground lugs that run along the north end of the exposed panels. Fasteners: Each panel mount requires one fastener 0520-30011. Each ground lug, lateral clip, and cable tray clip requires one fastener 0520-00689. Each ground strap requires two fastener 0520-00689. Cable Trays: The required number of long cable trays is two times the number of columns. The necessary number of short cable trays is the number of rows if wires are run on only one side of the array. Cable Tray Clips: Two per short cable tray. Long cable trays do not require clips; they fit into tabs on the panel mounts. Tyco Solarlok Connectors: The number of male and female connectors needed is the total number of panels divided by the number of panels in a sub-array string. For example, 1500 panels in a 5 series by 3 parallel arrangement would require 100 female and 100 male connectors. However, extra connectors will be required if the same 1500 panels are not all connected 3 in parallel, or where roof obstructions prevent close packing of panels and extra jumpers are required to connect panels that are not adjacent.
52
A Sample BOM Calculation

Table 12 shows a sample of the spreadsheet available from Solyndra to aid the system designer. This spreadsheet is available at the Solyndra website. This tool allows the designer to input the number of rows and columns of each sub-array in the system, and the equations discussed in the previous section will calculate the quantities of the ancillary parts required. Assuming that sub-array A-1 in the above example corresponds to the sub-array shown in Figure 51 on page 51, a 3 is placed under columns and a 5 is placed under rows. The rest of the row in the worksheet is calculated based on this geometry. The worksheet comes with a few example lines filled in. Edit the columns and rows as necessary, and copy and paste the lines for a larger system as needed. Edit the column USE-2 12 AWG as necessary to get the correct amount of wire for each sub-array. For irregular subarrays, input the total number of columns and rows, and then edit the equations for panels, panel mounts, ground straps, and lateral clips to get the correct amount. Table 12. Sample BOM
Subarray Columns Rows Panels Panel Fastener Ground Fastener Ground Lateral Cable Cable Clip, Name Mounts 0520- straps 0520lug clip tray, tray, cable 30011 00689 long short tray A-1 3 5 15 36 36 12 57 3 10 6 5 10 A-2 A-3 A-4 A-5 A-6 A-7 A-8 A-9 B-1 Totals 15 15 15 15 15 15 15 15 12 135 10 10 10 10 10 10 10 10 5 90 150 150 150 150 150 150 150 150 50 1275 330 330 330 330 330 330 330 330 144 2820 330 330 330 330 330 330 330 330 144 2820 135 135 135 135 135 135 135 135 48 1140 585 585 585 585 585 585 585 585 228 4965 15 15 15 15 15 15 15 15 12 135 140 140 140 140 140 140 140 140 55 1185 30 30 30 30 30 30 30 30 24 270 10 10 10 10 10 10 10 10 5 90 20 20 20 20 20 20 20 20 10 180
For larger installations, you may wish to include a few extra screws, lateral clips, ground lugs, and ground straps.
Mounting on Uneven Roofs

Panel mounts should not be placed wholly or partially on raised areas such that the surface contact area between the mount and roof is reduced, or that there is a large height disparity between panels. For stability, it is recommended that the mounts be placed in the valleys of a non-flat patterned roof, versus the peaks. It is also recommended that the roof structures loadbearing capability be assessed wherever the mounts are placed. Figure 52. Right and Wrong Ways to Place Panels on Uneven Roofs
Acceptable
Unacceptable
Unacceptable
Use of the Multi-Hole Mount

Solyndra offers a panel mount with multiple holes, shown in Figure 53. This allows the mount to be moved slightly toward the middle, or the end, of the panel. This feature is useful when installing on standing seam metal roofs or other roofs that have a regular pattern of high and low places. It is also useful on conventional flat roofs in cases where there is a small projection or bump of some sort, right where the regular mount would normally sit. Figure 53. Multi-Hole Panel Mount
[993.39] 39.110 (POR) [917.19] 36.110 (POR) [839.72] 33.060
[1069.59] 42.110 [1147.06] 45.160 [1083.33] 43.635 [1070.23] 42.135 [1032.13] 42.135 [993.39] 39.110 [954.66] [916.56] 37.585 36.085 [878.46] 34.585
[917.19] [955.29] 36.110 [1031.49] 37.610 40.610
54
Mount Spacing Options

Depending on the mounting hole locations selected, a number of possible spacings are available. These are listed in Table 13. The Panel Mount Pitch columns show the center-to-center spacing of mounts. The intra-panel dimension refers to mounts on the same panel, and the inter-panel dimension refers to mounts on adjacent panels. Note that the total pitch is always 1819 mm, or 68-13/16 inches. The intra-panel spacing column shows the clear space between the mounts, that is, it allows for the width of the mount. The inter-panel spacing column shows the clear space between the mounts for mounts on adjacent panels. The highlighted line is the standard spacing. Table 13. Possible Panel Mount Pitches
Mount Position mm +76.8 +63.5 +38.0 0.0 -38.0 -63.5 -76.8 inches +3 +2-1/2 +1-1/2 0 -1-1/2 -2-1/2 -3 mm 1147 1120 1070 993 917 866 840 Panel Mount Pitch intra-panel inches 45-3/16 44-1/8 42-1/8 39-1/8 36-1/8 34-1/8 33-1/16 mm 672 699 749 826 902 953 979 inter-panel inches 23-5/8 24-11/16 26-11/16 29-11/16 32-11/16 34-11/16 35-3/4 mm 1076 1049 999 922 846 795 769 inches 42-3/8 41-5/16 39-5/16 36-5/16 33-5/16 31-5/16 30-1/4 mm 601 628 678 755 831 882 908 inches 23-21/32 24-23/32 26-23/32 29-23/32 32-23/32 34-23/32 35-1/4 Intra-panel Spacing Inter-panel Spacing
Chapter 9

Site Preparation
This chapter addresses key steps you should take before the panels arrive at the site. While it is beyond the scope of this manual to provide a complete guide to planning your photovoltaic installation, its important to understand the basic principles of installation. These include: Scope Safety. Installation of conduit and electrical equipment boxes. Planning installation of grounding wires. Roof preparation and cleaning. Planning panel placement and clearances. Planning panel wiring. Tools, supplies, and techniques.
Scope
The installation of Solyndra panels must take place in compliance with national and local electrical and building codes. These are too numerous to describe here. The use of qualified and experienced local professionals is the best way to ensure compliance with such codes as well as optimum system design, installation, and performance. A Solyndra panel is part of a complete photovoltaic installation. A properly-engineered installation will meet all applicable fire codes, electrical codes, building codes, and other safety codes. In most cases compliance with these codes involves many components in addition to the Solyndra panels. Your installation plan should include a detailed description of the wiring methods to be used and a detailed description of the mechanical mounting. These plans should specify, at a minimum: Size, type, and temperature rating of all wiring components. Wire should be type USE2, 12 AWG (4 mm2), or better if required by local codes. Note that this is a UV-resistant grade rated for 90C operation (North America) or 120C (Europe). Identification and wiring orientation of each electrical sub-array within the system. Subarray wiring options are described on page 36. Use of materials such that fire rating of the roof is maintained. Solyndra-supplied panels and hardware will preserve fire ratings.
Safety
A pre-installation safety survey should be completed prior to any on-site construction. This should include a full inspection, with photographs. This process allows the integrator to note any existing damage to any areas in which they will be working, while also noting all possible hazards.
56
Safety & Preparation Checklist

Before the panels arrive, you should complete all of the items in the list in Table 14. Table 14. Site Preparation Checklist
Item
Fall protection equipment Ladders and scaffolding Safety equipment Description Safety harness or other fall-protection equipment, and locations on roof where its use is required. This will be governed by local codes. As required for the job, but all must meet application safety standards. At a minimum, all personnel must have sunglasses and protection form the sun, including some type of hat, and suntan lotion. Other equipment may be required by local codes. Locations on the roof strong enough to support the weight of a Solyndra crate must be clearly marked. Roof edges and other no-go areas, as defined by local codes, must also be marked. Site-specific blueprints, wiring diagrams, and BOS for the installation. Conduit and boxes for AC wiring, DC wiring, inverters, monitoring equipment, and all other work, per designer plans. All equipment must be locked out and tagged out until all work is complete. Panels clear 9 in (23 cm) fixtures; check roof against designed layout. Provide a ground conductor, per local codes. Repair any problem roof areas; repair any rooftop fixtures. Clean the roof to insure maximum reflected light.
Hazard warnings
System Design Electrical installation
Check clearances Insure adequate ground Repair roof and roof fixtures Clean roof
Arrange for rooftop panel delivery Crates are heavy; a lift or crane is required. All lifting must be done by trained personnel, using equipment and techniques rated for the load.
Electrical Equipment Installation

Detailed electrical specifications for Solyndra panels are contained in the corresponding data sheet. The electrical characteristics are within 10% of the indicated values of ISC, VOC, and 4% of the indicated values of Pmax under standard test conditions (Irradiance of 1000 W/m2, AM 1.5 spectrum, a cell temperature of 25C, and with panel mounted above a roofing material with a reflective index of 70% or greater). Even under normal operating 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 ampacities, fuse sizes, and size of controls connected to the PV output. Refer to Section 690-8 of the National Electrical Code for an additional multiplying factor of 125 percent (80 percent derating) which may be applicable. While not necessary, most installers have the conduit, electrical equipment, and inverters installed prior to panel installation. Its easier to do this work before the roof is covered with panels. Electrical equipment should be placed at the northeast or northwest corner of the array. (This, and all installation instructions in this manual, assume a northern hemisphere installation.) This minimizes cable runs and avoids shadow problems. Other locations are permissible if shade and cable-run calculations have been completed. In all cases, follow your photovoltaic design teams plans as well as all local and national building and electrical codes. Be sure to have the electrical equipment tested after installation.
Ground Wires
Solyndra recommends that all panels be adequately grounded in order to assure safety in the event of a lightning strike or electrical malfunction. Refer to Chapter 5 on page 36 for complete details on grounding.
Roof Preparation
Your panels will cover most of your roof. Solyndra panels are designed to fit over items less than nine inches above the roof. The panels can be removed to allow service access to the roof or any fixtures. Inspect your roof and all fixtures well before the panels arrive, and fix or replace any potential problems, as required. Solyndra panels perform optimally when placed over high-reflectivity roofs. You may wish to have the roof cleaned or the reflectivity tested before installation. No other artificially concentrated sunlight shall be directed onto the panel.
Planning Panel Placement & Clearance

There are four basic guidelines for Solyndra panel installation: First and foremost: Follow the plans prepared by the installation designer! This installation manual cannot anticipate every design circumstance, but the installation designer has. Follow the plans, even if they contradict this manual. Orient the panels correctly, per the sub-array wiring plan. Test for correct installation as you go, using a voltmeter. Panels are installed parallel to the roof. Panels should not be installed on any roof with a slope greater than 2:12 (9.5 degrees). Where possible, panels should be installed with the tubes aligned on the north-south axis. This optimizes output by optimizing incident sunlight. If panels are otherwise oriented, there can be a slight loss of power. Panels may require service or cleaning. Allow for access. To reduce the risk of falls, keep the panels a minimum of five feet (1.52 m) away from the roof edge, or more if local safety codes require.
58
Chapter 10 Tools and Supplies

For panel installation, you will need a torque-limiting electric screwdriver with a range of 0 to 24 inch-pounds (2.7 N-m). Fasteners must not be overtorqued during the installation process. The frame material on Solyndra panels is aluminum, so it is not necessary to apply excessive torque to the screws. You will need a phillips driver bit as well. You should also have a standard screwdriver, for tightening the screw in the ground lug. You may wish to have an extra phillips screwdriver as well. It is convenient, though not necessary, to have a pouch for small parts. This ensures that the installer(s) have the parts they need at hand. Typical examples of these items are shown in Figure 54. Figure 54. Tools Needed for Panel Assembly
Panel installation requires a two-person crew. It is common practice to have two such crews assemble and place panels, especially for larger installation. If this is the case, you will need two sets of tools. Items to Avoid Solyndra recommends that installers NOT wear tool belts equipped with hammers or any other object heavy enough to break a panel.
Cable Fabrication Tools

You will need tools for fabricating Tyco Solarlok connector cables. These include hand crimpers and extraction tools. Tyco Solarlok connectors are attached by stripping the insulation, crimping a pin onto the wire, and assembling the connector. This is shown in Figure 56. Figure 55. Tyco Solarlok Connector Tools
Cable Stripping Tool Tyco #1-1579002-2
Crimping Tool Tyco #1-1579004-2
Extraction Tool Tyco # 1102855-3
Figure 56. Tyco Solarlok Assembly Steps

8.0 mm
(a)
(b)
(c)
(d)
(e)
(f)
1. Strip the insulation back 8 mm (5/16 in). 2. Insert the stripped wired into the crimp barrel until it stops. Hold it in place while squeezing the crimp tool until the ratchet releases. 3. Place the seal/pinch ring combination into the connector housing until it stops. 4. Place the backshell onto the connector housing. 5. Push the pin & wire assembly into the connector housing until you hear it click into place. 6. Tighten the backshell nut to 1.5 N-m.
60
Appendix A. References
1. NEC 2008 2. SOLAR PHOTOVOLTAIC INSTALLATION GUIDELINE, CALIFORNIA DEPARTMENT of FORESTRY and FIRE PROTECTION OFFICE OF THE STATE FIRE MARSHAL. 3. Planning and Installing Photovoltaic Systems, A guide for installers, architects, and engineers. Published in German by DGS. Translated to English by Ecofys. Published by James & James 4. A GUIDE TO PHOTOVOLTAIC (PV) SYSTEM DESIGN AND INSTALLATION, for California Energy Commission, by Endecon Engineering, Version 1.0, June 14, 2001; http://www.energy.ca.gov/reports/2001-09-04_500-01-020.PDF 5. Photovoltaic Power Systems and the 2005 National Electrical Code: Suggested Practices, John Wiles, Southwest Technology Development Institute, Electronic Version 1.6, March 22, 2007 6. Non-Anchored Rooftop Solar Arrays Structural Permitting Submittal, Forell/Elsesser Engineers, August 19, 2008
Appendix B.Design in Seismic Areas

A Solyndra array installed on a rooftop functions as a seismically-isolated system. It is intended to slip or slide slightly as the building sways underneath it. When designing systems for seismically active areas, a clearance zone must be maintained around the array so that it cannot slide into rooftop objects. In order to determine the amount of clearance required, the design engineer must determine the parameters listed below. Solyndra recommends that system designers work with a qualified seismic engineer who is familiar with seismic conditions in the region where the array will be installed.
Seismic Hazard Zone
The seismic hazard zone is defined based on California state standards. In areas outside of California, the seismic engineer must determine the sites hazard zone using the metrics defined by the State of California.
Site Class
The site class must be determined per ASCE 7-05. Possible site classes are B, C, D, and E.
Building Period.
Consult the original building plans or a competent structural engineer to determine the period of oscillation of the building.
Roof Slope.
Slopes greater than 1:12 (4.76 degrees) should not have arrays installed on them.
The coefficient of friction between the roof surface and the chosen panel mount must be known. Appendix C lists values for several common roof materials. If your roof material is not listed, contact Solyndra. Typical coefficients range from 0.4 to over 1.0. A number of common roofing materials, when used with the correct Solyndra panel mount, produce coefficients in excess of 0.8, and these higher-value combinations are preferred in seismic areas. When you have determined the five required parameters, the required clearance can be looked up in the tables. Home-run wiring must be long enough not to restrict any possible movement of the panels in a seismic event. After you have determined the required clearance, plan all home-run wiring with sufficient extra length to permit movement.
Determining Required Clearance

Wiring

62
Clearance Tables for Building Site Zones B, C, D

Table 15. Clearance for Coefficient of Friction 0.4; Site Classes B, C, D
Seismic Hazard Building Level Period 1 0.1 0.2 0.3 0.4 0.5 2 0.1 0.2 0.3 0.4 0.5 3, 4 Clearance, 1/4:12 slope inches cm 4 10 1 2.5 2 5 4 10 4 10 4 10 7 17.5 12 30 21 52.5 Clearance, 1/2:12 slope Clearance, 1:12 slope inches cm inches cm 1 2.5 1 2.5 0 0 2 5 3 7.5 4 10 5 12.5 9 22.5 5 12.5 9 22.5 4 10 5 12.5 7 17.5 9 22.5 14 35 Not Recommended Not Recommended Not Recommended Not Recommended
Table 16. Clearance for 0.6 Coefficient of Friction 0.4; Site Classes B, C, D
Seismic Hazard Building Level Period 1 0.1 0.2 0.3 0.4 0.5 2 0.1 0.2 0.3 0.4 0.5 3 0.1 0.2 0.3 0.4 0.5 4 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 1 2.5 2 5 3 7.5 2 5 5 12.5 9 22.5 17 42.5 18 45 4 10 7 17.5 11 26.5 17 42.5 20 50 10 25 15 37.5 20 50 30 75 31 77.5 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 2 55 3 7.5 3 7.5 2 5 6 15 11 26.5 20 50 21 52.5 4 10 8 20 13 32.5 20 50 25 62.5 10 25 17 42.5 26 65 34 95 Not Recommended Clearance, 1:12 slope inches cm 1 2.5 1 2.5 2 5 5 12.5 5 12.5 2 5 8 20 18 45 26 65 32 80 5 12.5 10 25 19 47.5 28 70 Not Recommended 12 30 18 45 35 87.5 Not Recommended Not Recommended

Seismic Hazard Building Level Period 1 0.1 0.2 0.3 0.4 0.5 2 0.1 0.2 0.3 0.4 0.5 3 0.1 0.2 0.3 0.4 0.5 4 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 0 0 1 2.5 1 2.5 2 5 2 5 1 2.5 3 4.5 8 20 10 25 14 35 2 5 6 15 8 20 13 32.5 17 42.5 6 15 11 26.5 16 40 26 65 27 67.5 Clearance, 1/2:12 slope inches cm 0 0 1 2.5 1 2.5 2 5 2 5 1 2.5 4 10 8 20 12 30 16 40 2 5 6 15 10 25 15 37.5 19 47.5 7 17.5 13 32.5 19 47.5 28 70 32 80 Clearance, 1:12 slope inches cm 0 0 1 2.5 1 2.5 3 4.5 3 4.5 1 2.5 5 12.5 12 30 17 42.5 23 57.5 3 4.5 8 20 13 32.5 21 52.5 27 67.5 7 17.5 14 35 25 62.5 34 85 Not Recommended

Seismic Level 1 Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 0 0 0 0 1 2.5 1 2.5 1 2.5 1 2.5 3 4.5 6 15 8 20 11 26.5 2 5 4 10 7 17.5 12 30 13 32.5 4 10 9 22.5 14 35 22 55 26 65 Clearance, 1/2:12 slope inches cm 0 0 0 0 1 2.5 1 2.5 1 2.5 1 2.5 3 4.5 7 17.5 9 22.5 13 32.5 2 5 5 12.5 7 17.5 13 32.5 14 35 4 10 10 25 15 37.5 24 60 28 70 Clearance, 1:12 slope inches cm 0 0 0 0 1 2.5 2 5 1 2.5 1 2.5 3 4.5 8 20 11 26.5 18 45 2 5 5 12.5 10 25 16 40 20 50 5 12.5 12 30 19 47.5 29 73.5 36 90
64
Clearance Tables for Building Site Zone E

Table 19. Clearance for Coefficient of Friction 0.4; Site Class E
Seismic Hazard Building Level Period 1 0.1 0.2 0.3 0.4 0.5 2 0.1 0.2 0.3 0.4 0.5 3, 4 Clearance, 1/4:12 slope inches cm 1 2.5 2 5 3 4.5 5 12.5 9 3 4.5 5 12.5 10 25 16 40 18 45 Clearance, 1/2:12 slope inches cm 1 2.5 2 5 4 10 6 15 12 30 3 4.5 6 15 11 26.5 19 47.5 Not Recommended Not Recommended Clearance, 1:12 slope inches cm 1 2.5 3 4.5 5 12.5 11 26.5 20 50 3 4.5 7 17.5 Not Recommended Not Recommended Not Recommended

Seismic Level 1 Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 2 5 3 4.5 6 15 1 2.5 4 10 7 17.5 12 30 16 40 3 4.5 6 15 9 22.5 14 35 18 45 7 17.5 12 30 16 40 25 62.5 26 65 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 2 5 4 10 7 17.5 1 2.5 5 12.5 9 22.5 15 37.5 18 45 3 4.5 7 17.5 11 26.5 16 40 21 52.5 7 17.5 12 15 19 47.5 28 70 34 85 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 3 4.5 6 15 10 25 2 5 6 15 15 37.5 20 50 26 65 4 10 9 22.5 16 40 24 60 33 82.5 9 22.5 14 35 27 67.5 Not Recommended Not Recommended

Seismic Level 1 Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 2 5 2 5 5 12.5 1 2.5 3 4.5 6 15 8 20 11 26.5 3 4.5 4 10 7 17.5 11 26.5 13 32.5 5 12.5 9 22.5 13 32.5 21 52.5 25 62.5 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 2 5 3 4.5 5 12.5 1 2.5 3 4.5 6 15 9 22.5 13 32.5 2 5 5 12.5 8 20 13 32.5 15 37.5 5 12.5 9 22.5 15 37.5 23 57.5 28 70 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 2 5 4 10 7 17.5 1 2.5 4 10 9 22.5 12 30 19 47.5 2 5 6 15 11 26.5 17 42.5 22 55 5 12.5 11 26.5 20 50 30 75 Not Recommended

Seismic Level 1 Building Period 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5 Clearance, 1/4:12 slope inches cm 1 2.5 1 2.5 1 2.5 1 2.5 3 4.5 1 2.5 2 5 5 12.5 6 15 9 22.5 1 2.5 3 4.5 6 15 10 25 10 25 3 4.5 8 20 11 26.5 17 42.5 21 52.5 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 1 2.5 2 5 4 10 1 2.5 2 5 5 12.5 7 17.5 11 26.5 1 2.5 3 4.5 6 15 11 26.5 11 26.5 3 4.5 8 20 12 30 19 47.5 23 57.5 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 1 2.5 3 4.5 5 12.5 1 2.5 2 5 6 15 8 20 15 37.5 1 2.5 4 10 8 20 13 32.5 15 37.5 3 4.5 9 22.5 15 37.5 24 60 30 75
66
A Note on Code Compliance

A non-anchored array of Solyndra panels complies with the 2007 edition of the California Building Code. Article 13.4 of ASCE 7-05, first paragraph, states : Component attachments shall be bolted, welded, or otherwise positively fastened without consideration of frictional resistance produced by the effects of gravity. This requirement is mediated by the Recommended Lateral Force Requirements and Commentary, Seismology Committee, Structural Engineers Association of California (SEAOC), 1999, as referenced by the ASCE 7-05 commentary Chapter C11, first page, together with the recommendations contained herein. The SEAONC Commentary article C107.1.1, second paragraph, states: It is not the intent of [building code requirements] to prohibit unrestrained components and equipment. Unrestrained components and equipment may be permitted [] provided the safety of the occupants and the public will not be compromised. Items with low ratios of height-to-base width or length that are inherently stable against overturning may be unrestrained. In such cases, lateral movement may be limited by friction forces based on gravity forces with reductions due to vertical earthquake accelerations, as considered appropriate by the design engineer. Accordingly, Building Code restrictions are not universal, as the Code authors can neither anticipate nor address all possible conditions. It has long been recognized that systems not identified in the code may be used, provided they are developed using well-established engineering principles. Note that the use of friction to resist lateral loads is permitted elsewhere in the Code. For instance, shallow foundation systems rely in good part on friction between the foundation and the soil to resist the lateral forces in the building. In addition, newer high-performance structures utilize various friction-generating devices to resist lateral forces. In each of these cases, the force of friction is a reliable quantity and its benefit is the reliable dissipation of energy generated within the structure during an earthquake or windstorm. The same approach is used with the Solyndra systems. The frictional forces used are reliable and are based on testing. The panel will slide horizontally, disallowing sufficient force to develop. Uplift caused by vertical seismic accelerations has been explicitly addressed by Solyndra. The recommended clearance values reflect the range of responses that may occur under severe events. Provided that adequate clearance is made available around the installation, neither occupant safety nor public safety will be compromised by a non-anchored Solyndra installation.
Notes
68
Revision History
File Name DesignGuide_N_V2.3EN Revision History
Revision 1.0 1.1D 1.1 1.2 1.3 2.0 2.1 2.2 Part Number 0920-30006-EN-001 0920-30006-EN-002 0920-30006-EN-003 0920-30006-EN-004 0920-30006-EN-005 0920-30006-EN-007 0920-30006-EN-008 0920-30006-EN-009 Date 2 Nov 2008 7 Jan 2009 27 Jan 2008 5 Feb 2009 2 Mar 2009 15 Jun 2009 8 July 2009 4 March 2010 Notes Initial Release. Updated with new wind clearances rules. Modified drawings to clarify setback rules. Added rules for placing panels over conduit, etc. Added rules for tall buildings. Added 2:12, string wiring, mount-pressure data. Added new cover, corrected BOS tables, incl. dustcaps Add text describing dustcap use Add text about inverter sizing . Add new seismic section as Appendix B. Add new wind tables. Fixed string wiring drawings. Add multi-hole metal mount option. Revised roof loading section. Clarify panel install rate, up to 300 per day. Correct ground wire drawing to show redundant connection where needed. Added uneven mount information. Added lightning information. Split into separate Design and Installation documents. Clarified friction. Corrected part number for M5 screw.
2.3
0920-30006-EN-010
6 April 2010
Safety First
DANGER! You will be working on a rooftop. Even a 4 to 6 meter fall can cripple or kill.
Be careful.
You can be electrocuted. Unlike regular electrical work, where power can be switched off, a photovoltaic panel produces voltage whenever there is light. Even at modest levels of illumination, there is enough voltage to kill.
WARNING! Solyndra panels are made from glass tubes. The tubes can be broken. If they are,
there are two hazards you must deal with: 1. Broken glass.
2. Leaking OCA fluid. While this fluid is not toxic, it is EXTREMELY slippery. Any spill should be cleaned up immediately. Your shipment includes a clean-up kit. Instructions can be found on page 66.
Safety Rules
Two people are required to move each panel. DO NOT carry more that one panel at a time. Carry and lift panels from edge of metal frame. NEVER carry or move panels by grabbing the glass tubes. NEVER lean or sit on panels. DO NOT place anything on panels. This could damage the glass tubes or shade the panels, causing improper operation. DO NOT place panels in areas where persons may walk on or trip over them. DO NOT carry objects that might obstruct your view of the floor while in the vicinity of the panels.
Solyndra panels are intended to be used over highly reflective surfaces, but no other artificially concentrated sunlight should be directed onto the panel.

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Design Guide

SL100 Series Photovoltaic Panels

DesignGuide_N_V2.3EN English. Version 2.3 Release Date: 2010-04-06

Solyndra, Inc. 47700 Kato Road Fremont, CA www.solyndra.com

Trademarks & Patents

Cautions And Warnings

Solyndra Photovoltaic Panel Design Guide

Solyndra Confidential Doc Number 0920-30006-EN-010

Appendix A. References Appendix B. Design in Seismic Areas

Version 2.3 Solyndra Confidential

Solyndra Photovoltaic Panel Design Guide

Designing with Solyndra

Code Compliance & Safety

Solyndra Photovoltaic Panel Design Guide

Solyndra Confidential Doc Number 0920-30006-EN-010

Setbacks and Clearances

Safety and Access

Version 2.3 Solyndra Confidential

Solyndra Photovoltaic Panel Design Guide

Design Rules and Examples

Solyndra Photovoltaic Panel Design Guide

Solyndra Confidential Doc Number 0920-30006-EN-010

The Example Roof

Skylight 8 high (20 cm) 140 (42.7 m)

Skylights 8 high (20 cm) 142 (43.3m) 58 (17.7 m)

Version 2.3 Solyndra Confidential

Solyndra Photovoltaic Panel Design Guide

Firefighter Access Clearance

265 (80.7 m) 225-8 (68.8 m)

Detail A Fire Clearance Minimum Setback

Color code: Fire) Obstruction Minimum Setback

Solyndra Photovoltaic Panel Design Guide

Solyndra Confidential Doc Number 0920-30006-EN-010

Figure 3. Detail A - Fire Clearances

Access Hatch, 12 (30cm) high 4 (1.2 m) clearance for re

4 (1.2 m) walkway for re

Figure 4. Detail B - Fire Clearances

4 (1.2 m) walkway for re 4 (1.2 m) clearance for re HVAC 6 (1.8 m) high

Figure 5. Detail C - Fire Clearances

Fire Setback Minimum Setback

Figure 6. Detail D - Fire Clearances

Skylight 4 (1.2 m) walkway for re

Color code: Fire (4) Obstruction Minimum Setback ( 5)

Version 2.3 Solyndra Confidential

Solyndra Photovoltaic Panel Design Guide

CIGS Back Contact Substrate Glass Tube

Transparent Conductive Layer

Shade Design Recommendations

Version 2.3 Solyndra Confidential

Solyndra Photovoltaic Panel Design Guide 11

265 (80.7 m) 225-8 (68.8 m)

Color code: Obstruction Minimum Setback

Figure 11. Detail B - Shade Clearance

HVAC 6 (1.8 m) high

Solyndra Photovoltaic Panel Design Guide

Solyndra Confidential Doc Number 0920-30006-EN-010

Definition of Building Dimensions

Version 2.3 Solyndra Confidential

Solyndra Photovoltaic Panel Design Guide 13

5 ft (1.52 m) edge setback Zone A

Building Wall 5 ft (1.52 m) edge setback Zone B

Zone B Zone A 5 ft (1.52 m) edge setback

Zone A 5 ft (1.52 m) edge setback