BIFACIAL SOLAR MODULES

(MONO PERC TECHNOLOGY)

INSTALLATION
MANUAL
 TABLE OF CONTENTS

1. Introduction 1

2. Disclaimer of Liability 1

3. General Information 1

4. Safety Instructions
4.1 General Safety ……………………………………………………… 3
4.2 Electrical Safety ……………………………………………………. 3
4.3 Electrical Specifications ……………………………………………. 4
4.4 Fire Safety ………………………………………………………….. 5

5. Unloading, Handling, Storage & Unpacking

5.1 Unloading using Forklift …………………………………………… 6
5.2 Unloading using Hydra …………………………………………….. 6
5.3 Storage Guidelines …………………………………….…………… 7
5.4 Unpacking Guidelines ……………………………………………… 7

6. Environmental Considerations & Site Selection

6.1 Environmental Considerations ……………………………………… 8
6.2 Site Selection ……………………………………………………….. 9
6.3 System Design Guidelines ………………………………………….. 9

7. Installation Guidelines
7.1 General ……………………………………………………………… 10
7.2 Mounting Methods ………………………………………………….. 11
7.3 Grounding …………………………………………………………... 13
7.4 Wiring ………………………………………………………………. 14
7.5 Bypass Diodes ……………………………………………………… 15
7.6 Blocking Diodes ……………………………………………………. 15
7.7 Fuse Rating …………………………………………………………. 16
7.8 Inverter Compatibility & Selection ………………………………… 16

8. Maintenance
8.1 General ……………………………………………………………… 16
8.2 Module Cleaning Guidelines ……………………………………….. 16

9 Notes ………………………………………………………...……………… 17

Annexure 1 List of Applicable Models ………………………………………………….. 18

 LIST OF FIGURES

Figure 1 Cross-section of the solar panel ……………………………………….….. 2

Figure 2 Module schematic for 144 half-cut cell module …………………………….…… 2

Figure 3 Safe handling of pallet using Forklift ……………………………………………. 6

Figure 4 Lifting Support Fixture to be used when lifting using a hydra …………………... 6

Figure 5 Stacking of pallets ………………………………………………………………... 7

Figure 6 Unpacking of pallet ………………………………………………………………. 8

Figure 7 Bolting of the module at the mounting hole ……………………………………... 12

Figure 8 Mounting of modules using 8 mounting holes …………………………………… 12

Figure 9 Recommended mounting positions for bolting …………………………………... 13

Figure 10 Grounding Hole of the PV module ………………………………………………. 13

Figure 11 Grounding mechanism of the PV module ………………………………………... 14

Figure 12 Bending of cable while routing …………………………………………………... 15

1. Introduction
This manual contains information regarding the safe installation and handling of photovoltaic
(PV) modules produced by RAYZON SOLAR. All the instructions given in this manual
should be read carefully and understood before attempting to install the modules. If there are
any questions, please contact RAYZON SOLAR Customer Engineering Service (CES) for
further explanation.

For your safety and the safety of others, please read the entire
Installation, Operation and Maintenance Manual carefully prior to
installing, wiring, operating and performing maintenance of PV
modules. Also, carefully read the Module Data Sheet provided with
this product. Determine local permits, installation and inspection
requirements before installing module(s). If not otherwise specified,
it is recommended that the requirements of the National Electric
Code (NEC) be followed.

2. Disclaimer for Liability

2.1 The use of this manual and the conditions or methods of installation, operation, utilization and
maintenance of PV product are beyond the manufacturer’s control. Therefore, RAYZON
SOLAR will not accept any responsibility and expressly denies any liability for loss, damage,
or expense arising out of or in any way connected with such installation, operation, utilization
or maintenance.
2.2 No responsibility will be assumed by RAYZON SOLAR for any infringement of patents or
other rights of third parties, which may result from use of the PV module. No license is granted
by implication or otherwise under any patent or patent rights.
2.3 The information in this manual is based on RAYZON SOLAR’s knowledge and experience
and it is believed to be reliable. Nevertheless, such information including product specification
(without limitations) and suggestions do not constitute a warranty, expressed or implied.
RAYZON SOLAR reserves the right to change the manual, the PV module, the specifications,
or product information sheets without prior notice.

3. General Information
3.1 The installation of the solar panels should be performed by trained personnel like licensed
contractors and electricians, since there are chances of injury and/or electric shock hazard if the
panels are not handled carefully.

3.2 The flat plate Photovoltaic (PV) module, also referred to as solar panel, converts power of the
visible portion of electromagnetic spectrum to DC electrical power. The construction consists
of laminated assembly of individual solar cells and interconnecting ribbons encapsulated within
an insulating material. This encapsulated assembly is sandwiched between a transparent top
surface (superstrate) and an insulating back surface (substrate). Field wiring connections to the
module are made to output wiring connectors emanating from a weatherproof terminal
assembly.

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3.3 The solar panel is a multi-layered laminate comprising of a top cover of glass (superstrate),
encapsulant, solar cells, a back cover of insulating polymer sheet or glass (substrate) and frame
as indicated in the Figure 1. The solar cells are interconnected using interconnect ribbons. The
cables of the solar panel (one with “positive” and other with “negative” polarity) are attached
to the junction box as shown in Figure 2.

Figure 1: Cross-section of the solar panel

Figure 2: Module schematic (backside) for 144 half-cut cell modules with transparent back cover
(glass/ transparent backsheet). Please refer to the datasheet for the dimensions of the respective
models.

3.4 The solar panels produce DC voltage when light falls on the front or back surface of the Bifacial
panels. The open circuit voltage produced by the solar panel is indicated in the name plate (back
label) of the solar panel in addition to the other important electrical parameters like the short
circuit current, and the voltage and current at the maximum power point. Apart from the back
label, two other labels are carried by the solar panel – current grading label (visible on back
side of the panel) and the barcode label (visible from front-side of the panel).
3.5 Each module is provided with a unique serial number for identification, into which is encoded
the date of manufacturing and other details. It is a 19-letter code which is explained below.

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 RS A G 1 M0 02 04 22 000001
RAYZON POWER MODULE LINE CELL MFG. MFG. MFG. SR.NO.
SOLAR CODE CODE NUMBER SIZE DATE MONTH YEAR

The Power Code is related to the nominal power output of the module - "A" for 540 Wp, "B"
for 545 Wp, etc.
The Module Code will depend on type of back cover - “ L ” for regular backsheet, “ G ” for
glass and “ B ” for transparent backsheet.
The Cell Size will be coded as "M0" for M10 cell (182 x 182 mm), "M2" for M12 cells (210 x
210 mm) etc.

4. Safety Instructions

To avoid the hazard of electric shock and injury when installing, wiring,
operating and maintaining the PV modules, below guidelines shall be
strictly followed.

4.1 General safety

a) When lifting the pallets using a forklift, the rated load capacity of the forklift should not be
exceeded. Also ensure that the forks of the forklift are of the sufficient length to move the
pallets.
b) When unpacking the modules, hold the module stack properly when removing the
wrappings so as to prevent the panels from toppling over and causing an injury.
c) When carrying a Module, two or more people should carry it by its frame wearing non-slip
gloves (to avoid injury by slipped module, or by the edge of frame).
d) Do not lift the modules by holding the junction box or the cables.
e) Do not install or handle the modules when wet or during periods of high wind.

4.2 Electrical safety

a) The solar panels have electrical safety class II and fire safety class C rating. The individual
modules/ arrays can have hazardous voltage, current or power levels.
b) The solar panel produces DC voltage (close to 50 Volts) when exposed to sunlight, even if
no load is connected to it. Even if the front side of a bifacial module is covered by opaque
object, the bifacial module will generate voltage if backside is exposed to light (reflected
from surroundings). It is necessary to avoid any contact with the electrically live
conductors (inside the MC4 connectors) to prevent shock hazard.
c) For bifacial modules, the back side is restricted for use with indirect or limited direct
sunlight (less than 300 W/m2).
d) When handling the solar panels or interconnecting the modules in a string, the installers
should wear insulating gloves and use insulated tools.
e) It is recommended to cover the front side of the solar panel (and also the backside in case
of bifacial modules) with an opaque cover during installation and handling of the solar
panels.
f) Do not try to open/break the connections when the solar panel is under load, as it can
lead to sparking and fire hazard.

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 g) Take necessary measures to avoid electric discharges when installation and wiring the solar
panels. Surge protection devices should be installed in the array junction boxes to
safeguard the solar panels from lightning surges.
h) Do not artificially concentrate sunlight on the solar panel.
i) Connectors from different manufacturers should not be used in the same PV system due to
compatibility issues. Ensure that there is no gap between the connectors (as any loose
connection in connectors can cause electrical arcing and lead to fire hazard).
j) Ensure all the connectors are corrosion free and protected from soiling.
k) It is strictly prohibited to remove or cut any connector of PV Module for installation
easiness by the installer/ customer and the modules are deemed out of warranty in such
cases.
l) Ensure that all the modules are grounded properly to avoid any shock hazard.
m) If the front glass or the junction box is broken, there are chances of electric shock from
the module, so such a broken module should be handled only using insulated cut-resistant
gloves.
n) There are no serviceable parts in the module so the user is requested not to try to change
or repair any component of the module.
o) Maximum string voltage must not exceed the allowable system voltage as marked on the
name plate (1500V DC).
p) The top structure and installation may affect the building fire safety - improper installation
may lead to fire hazards. Use of safety devices such as ground fault cut-outs and fuses is
recommended to reduce chances of fire hazard.
q) The grounding method of the frame of arrays shall comply with the NEC, article 250.M.
In Canada, installation should be done in accordance with CSA C22.1, Safety Standard for
Electrical Installations, Canadian Electrical Code, Part 1, and other applicable local
standards.

4.3 Electrical Specifications

a) The electrical parameters are within ±5 % of the rated values (for VOC and ISC) indicated
in the module datasheet (measured at standard test condition of 1000 W/m2, 25 °C module
temperature and AM1.5G spectrum). The tolerance on power output is 0 to 3%. The
electrical parameters are given in Annexure 1.
b) In outside environment, it is possible that under certain conditions, the solar panels will
produce higher voltage or current, depending on the temperature and incident irradiance
levels. The temperature coefficients are as follows:
Dual Glass Transparent Backsheet
Coefficient for short circuit current + 0.0286 %/°C +0.0284 %/°C
Coefficient for open circuit voltage - 0.2488 %/°C -0.2444 %/°C
Coefficient for rated power output - 0.3290 %/°C -0.3210 %/°C

c) Under normal conditions, a photovoltaic module may experience conditions that produce
more current and/or voltage than reported at Standard Test Conditions. Factors to consider
include module temperature and front side irradiance (and, for bifacial modules, ground or
roof albedo, row spacing, and installation height). Accordingly, the values of VOC and ISC
(or for bifacial modules, ISC at BSI) marked on this PV module should be multiplied by a
factor of 1.25 when determining voltage and current ratings for components connected to
the PV output.

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 d) The safety factor of 1.25 given for the minimum voltage rating of the components in the
example statement above may be modified during the design of a system according to the
minimum temperature of the location of the installation and the temperature coefficient for
VOC. The safety factor of 1.25 given for conductor current ratings values for ISC (or for
bifacial modules, ISC at BSI) may be adjusted based on the maximum values of irradiance
incident on the front side of the module (and the rear side for bifacial modules). To this
purpose, a full simulation for the specific location and module orientation (and for bifacial
modules, ground albedo, row spacing and installation height) is required. Further guidance
for the choice of a safety factor other than 1.25 is given in the National Electrical Code.
e) Please refer to Section 690-8 of the National Electric Code for an additional multiplying
factor of 1.25 which may be applicable. Please also consider the backside power gain of
bifacial modules (which will increase the module current) when deciding the component
electrical ratings.
f) It is also necessary to refer to the local electricity codes and standards while determining
the ratings of the electrical components.

4.4 Fire Safety

a) Rayzon Solar modules have a Class B Type 22 fire resistance rating in accordance with UL
61730 certification. The fire rating of the module is valid only when mounted in the manner
specified in the mechanical mounting instructions in this manual. Rooftop installations
should be placed over fire resistant roof coverings only. Roof constructions and
installations may affect the fire safety of a building, and improper installation may create
hazards in the event of a fire.
b) The modules with the specified construction in below table, when used with a UL Listed
mounting system that has been rated as a Class B System, when installed with type 22
modules, is suitable to maintain the System Class B Fire Rating.
Module Series Specific construction Marking
RSG525WC to RSG560WC Superstrate: 2 mm thick; Module Fire
Performance:
RSG485WC to RSG500WC Top encapsulant: 0.5 mm thick
Type 22
RSG440WC to RSG480WC Bottom encapsulant: 0.5 mm thick;
RSG395WC to RSG420WC Substrate: 2 mm thick;

RSG350WC to RSG370WC Frame: Yes

RSG265WC to RSG280WC

c) A minimum slope of 5 inch/feet is necessary when mounting on a roof in order to ensure

the Class B fire rating of the modules. It is recommended that the height of the module
from the roof should be minimum 1 meter for achieving bifacial power gain.
d) In the event of a fire, PV modules may continue to produce a dangerous voltage, even if
they have been disconnected from the inverter, have been partly destroyed, or the system
wiring has been compromised or destroyed. In the event of a fire, inform the fire crew about
the particular hazards from the PV system, and stay away from all components of the PV
system during and after a fire until the necessary steps have been taken to make the PV
system safe.

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5. Unloading, Handling, Storage & Unpacking
5.1 Unloading using Forklift
a) Forklift should be used for loading/unloading of modules (and not pallet trucks, which are
useful for positioning of modules only). Forklift should be selected according to the size
of the pallets. When unloading, please ensure that suitable aids (front loader, forklift, or
similar) with the following minimum requirements are used:
Fork length: > 1.20 m
Lifting height: > 1.30 m
Load capacity: > 2.0 tonne (for handling 2 pallets)
b) If fork length is less than the size of pallet, then extension sleeves should be fitted on the
forks before the assembly is lifted.
c) It is recommended to upload the pallets from the rear side of the trailer, using an unloading
ramp. In case unloading ramp is not available, the pallets may be unloaded from the long
side of the trailer.
d) When unloading to the side, ensure that the front pallets are first unloaded from the truck
trailer.
e) The spacing between the two forks should be adjusted as required, such that the load on
the forks is balanced.
f) When lifting double stacked pallets with forklift, first ensure that the pallets are properly
aligned.
g) One side of the pallets should be close to the forklift retainer (do not keep any space).
h) The lifting and lowering of the pallets using forklift should be done slowly and steadily
without any jerks.
i) Unload the pallets on a flat and dry place at the project site.
j) Do not stack more than 2 pallets at the project site.

Figure 3: Safe handling of pallet using Forklift

5.2 Unloading using Hydra

a) A Lifting Support Fixture should be used when lifting the pallets using a hydra.
b) The length of the fixture should be greater than 80% of length of pallet and the width of
fixture should be about 132 mm greater than the width of pallet.
c) The fixture should be placed on top of the pallet (longer side aligning with the pallet
length).
d) Nylon lifting belts should be used for lifting the pallets (and not wire ropes).
e) The lifting belts should pass through the gaps between the blocks in the bottom of the pallet.

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 f) Before lifting, please confirm the pallet are not damaged and the lifting belt is firm and
solid.
g) Before lowering the pallet back on the ground, two persons should support the two sides
of the pallet gently to put it on a relatively flat place.

Figure 4: Lifting Support Fixture to be used when lifting using a hydra.

5.3 Storage guidelines

a) The pallets should be placed in on a dry and flat ground (horizontal slope should be less
than 10°).
b) Do not stack more than 2 pallets at the project site.
c) Place a waterproof cover on the pallets if they are stored in open area at the site for long
periods.
d) There should be at least 30 cm distance between two rows of pallets for easy movement of
pallets.

Figure 5: Stacking of pallets. Maximum allowable stacking is 2 pallets per stack.

5.4 Unpacking Guidelines

a) For unpacking the pallets, arrange wire cutting pliers and an empty pallet for keeping the
panels.
b) Follow the step-by-step procedure detailed below:
i. Place the pallet to be opened in a dry and clean space.
ii. Place an empty pallet in front of the loaded pallet.
iii. Cut the outermost vertical straps on all sides using a wire cutter (refer Fig. 6a).
iv. Remove the top surface corner guards by hand (refer Fig. 6b).
v. Cut the horizontal straps using wire cutter (refer Fig. 6c).
vi. Remove the vertical corner guards on four corners by hand (refer Fig. 6d).

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 vii.Cut the inner horizontal straps using cutter (refer Fig. 6e).
viii.Unwrap the plastic wrapping on top of the cardboards (refer Fig. 6f).
ix. Remove the cardboards from all sides (refer Fig. 6g).
x. Two persons should now hold the panels from two ends, while two other
persons can proceed to remove the panels as follows.
xi. Remove the plastic wrapping using cutter or by hand. Do not use any sharp
object like blade, as it can scratch the panel glass/backsheet (refer Fig. 6h).
xii. While two workmen are supporting the panels vertically, other two workmen
can lift one panel at a time and place on the other pallet (refer Fig. 6i).
xiii. While laying the solar panel on the pallet, ensure that the panel glass side is
facing down, and panels should be stacked on top of each other in perfect
alignment (refer Fig. 6j).
c) Do not place more than 27 panels in one stack.
d) Cover the modules with a waterproof cover to prevent water from accumulating on the
modules.

(a) (b) (c) (d)

(e) (f) (g)

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 (h) (i) (j)
Figure 6: Unpacking of pallet

6. Environmental Considerations and Site Selection

6.1 Environmental Considerations
a) RAYZON SOLAR panels have passed the IEC 61215 and IEC 61730 certification tests
which indicates that the modules are suitable for use in terrestrial applications in open air
environments.
b) The solar panels can be used in locations where the ambient temperature is within -40 °C
and +50 °C, such that the module operating temperatures are between -40 °C and +85 °C.
The annual average ambient humidity should be less than 85% RH.
c) The solar panels have been designed considering a design load of 3600 Pa on front side
and 1600 Pa on back side and tested with factor of safety = 1.5 (hence tested at 5400 Pa
load from frontside and 2400 Pa from backside, as per IEC 61215 standard). However, the
ultimate load bearing ability will depend on the mounting method and mounting structure
design.
d) The maximum altitude is up to 2000 m above sea level.
e) The panels that have passed the Ammonia corrosion test (as per IEC 62716 standard) can
be used in farmlands or over animal shelters.
f) The panels that have passed the Salt Mist corrosion test (as per IEC 61701 standard) can
be used in coastal areas near the sea shore.

6.2 Site Selection

a) Do not install the panels in areas having inflammable or corrosive gases, or areas where
the panels can get submerged under water for extended periods of time.
b) Flood prone areas and areas with high frequency of cyclonic winds should be avoided (if
possible) in order to reduce the chances of damage to the PV system due to extreme weather
events (which are not covered under warranty clause).
c) Care should be taken to select a shade-free site so that there are less chances of hot spot
creation in the solar panel due to partial shading.
d) The solar panels have been evaluated by UL considering a maximum positive design load
of 3600 Pa on front side and negative design load of 1600 Pa (for bolt mounting method).
It is recommended that the site selection and mounting system design should be done such
as to ensure that these design loads are not exceeded.

6.3 System Design Guidelines

a) The panels should be placed with south facing orientation (in Northern hemisphere) with a
tilt angle close to the latitude of the site for maximum annual energy generation. Higher tilt
angles will also reduce the rate of soiling on the modules, so usually “latitude + 5°” is a
close estimation for the optimum tilt angle (for latitudes up to 35°).
b) Modules should have direct access to sunlight between 9 AM and 3 PM even on the shortest
day of the year. The site-specific tilt angle can be calculated based on this requirement,
which will ensure sufficient power generation throughout the year.
c) For bifacial modules, the optimum orientation and tilt angle will depend on the site
conditions and plant design. Also, in order to ensure rear side power gain in bifacial
modules, it is recommended that the height of the lowest edge of module from ground

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 should be at least 1 meter. The bifacial power gain will also depend on the type of ground
(sand, grass, white concrete, etc.).
d) It is recommended to check the optimum tilt angle for the site in professional PV system
design software like PVSyst or online available tools like PVGIS.
e) When selecting a site in a flood prone region, the structures should be designed with
sufficient height such that the lowest edge of the solar panels are above the flood water
level based on historical records (in order to avoid damage to panels due to submergence
in water during floods).
f) In areas having high wind speeds, the mounting structures should be suitably designed to
withstand the high wind forces, and the panels should be mounted on at least 8 bolting
points. The tilt angle may need to be adjusted (reduced) in such areas to avoid wind induced
damage to the panels. In case of trackers, the tracker should be orientated such that the
panels are almost horizontal during storms, so as to reduce the wind load on the solar
panels.
g) The maximum irradiance and ambient temperatures during sunshine hours at the site need
to be considered during system design. The panel’s current will depend on the maximum
irradiance and module temperature, and the current ratings of the balance of system
components need to be selected accordingly. Also, the panel voltage will increase with
decrease in the panel temperature.
h) It is recommended to multiply the current and voltage ratings of the panel by suitable safety
factor (1.25 for weather related enhancement x 1.25 for equipment derating = 1.56) to
calculate the electrical ratings of balance of system components. In case of bifacial
modules, the backside power gain should also be factored in.
i) The safety factor of 1.25 for the minimum voltage of the components can be modified
during the system design according to the minimum temperature of the location of
installation and the temperature coefficient for Voc. Similarly, the ISC can be adjusted based
on the maximum temperature, irradiance and orientation of the module. For this purpose,
it would be necessary to perform a full simulation of the PV system using long term weather
data, for which specialised software like PVSyst (or other alternatives) may be used.
j) PV modules may be connected in series in order to increase the system voltage, but
maximum modules that can be connected in a series string is limited by the maximum
system voltage or the maximum input voltage rating of the inverter (whichever is lower).
Maximum number of series connected modules
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑜𝑓 𝐼𝑛𝑣𝑒𝑟𝑡𝑒𝑟 𝑖𝑛𝑝𝑢𝑡 𝑟𝑎𝑡𝑖𝑛𝑔 𝑎𝑛𝑑 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑆𝑦𝑠𝑡𝑒𝑚 𝑣𝑜𝑙𝑡𝑎𝑔𝑒
= 1.25 𝑥 𝑀𝑜𝑑𝑢𝑙𝑒 𝑂𝑝𝑒𝑛 𝐶𝑖𝑟𝑐𝑢𝑖𝑡 𝑉𝑜𝑙𝑡𝑎𝑔𝑒
k) PV modules (series connected module strings) may be connected in parallel to increase the
current. Maximum number of parallel connected strings
𝐹𝑢𝑠𝑒 𝑟𝑎𝑡𝑖𝑛𝑔
=
1.25 𝑥 𝑀𝑜𝑑𝑢𝑙𝑒 𝑆ℎ𝑜𝑟𝑡 𝐶𝑖𝑟𝑐𝑢𝑖𝑡 𝐶𝑢𝑟𝑟𝑒𝑛𝑡
l) Module connected in series should have same orientation and tilt angle so that there are no
mismatch losses in the modules.
m) The modules can be connected in series to increase the array voltage, but care should be
taken to keep the array voltage below the maximum system voltage rating of the modules
(considering the module temperature in the coldest day of the year).
n) The recommended standoff height is 150 mm. If other mounting means are employed this
may affect the UL Listing or the fire class ratings.
o) A minimum slope of 5 inch/feet is necessary when mounting on a roof in order to ensure
the Class C fire rating of the modules.

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7. Installation Guidelines
7.1 General
a) The outer packaging of the pallets should be opened only when the installation starts.
b) Do not expose the Backsheet directly to sunlight for long period of time.
c) Do not damage or scratch the glass/ backsheet of the Module.
d) Installation should be done in dry environment using insulated gloves.
e) Do not transport the panels by resting them on the head, to avoid generating micro-cracks
in the panels.
f) Do not stand or step on the modules.
g) Do not drop Module or allow objects to fall on the Module.
h) Only PV modules with the same cell type and in same current bin should be connected in
series. Intermixing modules from different current bins in a series string will lead to
mismatch loss in the string.
i) Do not drill holes in the frame or glass of the module. It may compromise the frame
strength and cause corrosion of the frame and also voids the warranty.
j) The solar panels should not be used as overhead glazing.
k) Avoid forming wiring loops in the PV system in order to prevent surge currents during
lightning.
l) We recommend leaving a space of at least 10 mm between two modules considering linear
thermal expansion of the module frames.
m) Modules shall be mounted so that the junction box remains in the uppermost position to
minimize the ingress of moisture/water.
n) Avoid the direct contact of the aluminium frame of modules with steel or copper as this
may result in galvanic corrosion of the module frame.
o) Clearance between the module frame and the mounting surface is required to allow cooling
air to circulate around the back of the module. The module should never be sealed to the
mounting surface with sealant that prevents air from circulating under the module. For roof
mounted systems, adequate rear ventilation (minimum 100 mm gap) should be provided.
p) The mounting structure and all hardware like bolts, nuts and washers should be of stainless
steel so as to eliminate the possibility of rust.
q) Avoid using a mounting method that will block the drainage holes in the module frame.
Do not drill additional mounting holes on the frame & glass surface of the
Module. Doing so will void the warranty.

In any case DO NOT STAND OR STEP on the modules. Do not drop

or place objects on the module(s) (such as tools), do not thump / give
extra pressure on the surface of the module(s) as localized high loads
can induce severe micro-cracks at the cell level, which in turn may
compromise module reliability. Failure to comply with above caution
will void RAYZON’s warranty.

7.2 Mounting Methods - Bolting

a) The module is considered to be in compliance with the UL standard only when the module
is either mounted in the manner specified in this manual, or when the mounting means has
been evaluated with the module to UL 2703.

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b) The module frame is provided with mounting holes as indicated in Figure 2. The position
of the holes (X-pitch and Y-pitch) is indicated in the module datasheet.
c) The PV module has been evaluated by UL for mounting using this bolting method for a
maximum positive design load of 3600 Pa and negative design load of 1600 Pa, with a
safety factor of 1.5.
d) The module design has been tested with 8 mounting holes and it is the recommended
mounting configuration if the maximum design load has to be achieved. Mounting the
module on only 4 bolts will partly reduce the load bearing capacity of the modules.
e) Mounting should be done using M8 stainless steel nut, stainless steel bolt (8 mm), flat
stainless steel flat washer (8 mm), and stainless steel spring washer (8 mm).
f) Mounting should be done using the pre-drilled holes in the frame, and no new holes should
be drilled in the frame as it will reduce the strength of the frame and hence void the
warranty.
g) The length of the mounting screw should be selected such that there is a gap of at least 5
mm between the screw’s face and the module backside, to avoid any scratches in the
module while tightening.
h) The nuts should be tightened using torque wrench, with a torque of 15 – 20 Nm for M8
stainless steel bolts with washer and nut.
i) There should be sufficient clearance (at least 10 cm) below the module for free circulation
of air so that the module can be cooled naturally.

Figure 7: Bolting of the module at the mounting hole provided in the module frame.

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 Figure 8: Mounting of modules using 8 mounting holes. Values of Y1 and Y2 are as per the Y-
pitch mentioned in the module datasheet.

Figure 9: Recommended mounting positions for bolting

7.3 Grounding
a) The module frame should be grounded to prevent any shock hazards due to failure of
insulation from the internal circuitry or lightning induced voltages.
b) The aluminum frame of the modules is anodised to generate a corrosion resistant layer
on the frame which, however, is non-conductive in nature and cannot provide grounding
to the module. So, separate grounding holes are provided in the module (marked with the
earthing symbol).

Figure 10: Grounding hole of the PV module

c) The grounding method of the frame of arrays shall comply with the NEC NFPA 70, issue
date 2017, article 250. In Canada, installation should be done in accordance with CSA
C22.1, Safety Standard for Electrical Installations, Canadian Electrical Code, Part 1, and
other applicable local standards.
d) The aluminum frame should not come in direct contact with any copper wire, so special
grounding device should be used (such as Tyco grounding bolt #2058729-1, UL listed
KDER E69905) as shown in Figure 12 below.
e) The Tyco grounding bolt comprises of wire bolt & slot, Hex washer nut (with star washer)
and Hex nut. The Hex washer nut shall be 8.73 mm thick, made of stainless steel. The
grounding device should fully conduct between frame, structure and earthing wire.
Tightening torque shall be 16-20 Nm.

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 Figure 11: Grounding mechanism of the PV module, using Tyco grounding bolt

7.4 Wiring
a) The junction box is pre-fitted with UV-resistant, halogen-free, low smoke, flame
retardant photovoltaic cable (4 sq.mm. size, rated for 1500 V), suitable for operation up
to 90 °C ambient temperature.
b) The cables come pre-fitted with PV connectors (rated 1500V DC, 35A, conforming to
IEC 62852) which have been evaluated to UL 6703 Standard. Further details of the
connector is available from the manufacturer website.
PV Connector Male Connector Female Connector Mating
Manufactured by Model No. Model No. Connector

Dhash PV Technologies Same

Private Limited DS-01 DS-01 manufacturer and
(https://dhashtec.com/) model of connector

c) The wiring of the system should be done in accordance with the National Electricity Code
(NEC) and all other relevant local regulations.
d) The junction box comes pre-fitted with bypass diodes and their wiring/connections
should not be changed under any circumstance.
e) When wiring the PV system, avoid forming loops to minimize risk in the event of an
indirect lighting strike.
f) Modules can be connected in series to increase the operating voltage by plugging the
positive plug of one module into the negative socket of the next module. Before
connecting modules always ensure that the contacts are corrosion free, clean and dry.
g) Module may get damaged if an array string is connected in reverse polarity to another, so
always verify the voltage and polarity of each individual string before making a parallel
connection. Do not connect two strings in parallel if their voltages differ by more than 10
V.
h) When connecting the modules in series using the MC4 connectors, ensure that the
connection is tight and the mating connectors are locked. There should not be any outside
stress/load on the cables and connectors.
i) PV modules may be connected in parallel to increase the array current, but the maximum
array current should be less than the Inverter specification for maximum input current. In
case of parallel connection, each series string of modules should be provided with a series
fuse (fuse rating shall be as specified in the module datasheet).
j) Do not cut/remove any connector when connecting the cables, and always use compatible
MC4 connector, of the same manufacturer as provided with the PV module. Use of

Page | 14
 different connector can lead to lose connections which can result in sparking and fire
hazards.
k) Use UV-resistant cable ties to tie the cables to the purlin or other support structure.
l) For extension of the cables to the DCJB or inverter, use single core extension cables that
are UV resistant, fire retardant and can operate up to 90 °C ambient temperature. The
cable should be rated for 1500 V insulation capacity, and have compatible male & female
MC4 connectors.
m) The extension cable should be sized to ensure that the voltage drop in the DC side should
not exceed 2% (minimum recommended cable size is 4 sq.mm.).
n) In case bending of the cable cannot be avoided when routing the cables, the minimum
allowable bending radius is 4 x cable diameter.

Figure 12: Bending of cable while routing

o) It is recommended to place the cables inside plastic conduits to prevent any direct
exposure to sunlight and rainfall.
p) The cable routing should be done in such a way there is no tensile stress in the cable.
q) Ensure that the cable is not passed through low lying sections/potholes where water may
accumulate after rainfall.
r) When disconnecting wires under load, an electric arc may result, which can cause fire.
To disconnect the PV system while under load, turn off the inverter first and then switch
off the DC-circuit breaker, before opening the module connections.

7.5 Bypass Diodes

a) When modules are partially shaded, it may produce reverse voltage across the shaded cell,
which can lead to heating in the cell and generate hot spot.
b) The Bypass diodes are provided in the junction box, in order to bypass any shaded sub-
string and thereby ensure that the array continues to generate power, and any chances of
hot spots are avoided.
c) In case of failure of a bypass diode in the field during operation, the corresponding sub-
string will appear hot in thermal imaging. In such case, the user should not try to repair the
panel on their own but instead contact us for corrective action.
d) All RAYZON Modules are equipped with factory installed bypass diodes, so that the user
need not install any diodes on their own. However, if the intended application of the
modules requires additional diodes to be installed, the user should contact authorized
RAYZON representative for the necessary changes.

7.6 Blocking Diodes

a) Blocking diodes are typically placed between the battery and the PV Module output to
prevent battery discharge at night.

Page | 15
 b) RAYZON Modules do not contain a blocking diode when shipped from the factory. It is
recommended that a charge controller be used to prevent the batteries from being
overcharged and discharged at night.
c) In battery-based PV systems, it is mandatory to use a blocking diode or reverse current
protection device. If such a device is not used, the warranty on the panels is void.

7.7 Fuse Rating

a) Fuses should be rated for the maximum DC voltage and connected in each, non-grounded
pole of the array (i.e., if the system is not grounded then fuses should be connected in both
the positive and negative poles).
b) The maximum rating of fuse connected in series with a module string should be as per
information given in Annexure 1. Guidelines provided in IEC 60269-6 standard for fuses
for PV systems should be followed when deciding the type of fuse and its rating.
c) The number of strings that can be connected in parallel will depend on the fuse rating.

7.8 Inverter Selection and Compatibility

a) The RAYZON modules can be used with both galvanically isolated (transformer-based)
inverters and transformer-less inverters.
b) The maximum allowable number of modules connected in series string will depend on the
maximum input voltage specifications of the inverter.
c) In Hot & Humid locations, it is mandatory to use galvanically isolated transformer-based
inverters and connect the negative pole of the array to ground, in order to prevent
Potential Induced Degradation (PID) in the modules. If a transformer-less Inverter is used
in Hot & Humid climatic location, the installer should ensure that the right active negative
earthing kit is installed as per recommendations of the inverter supplier.

8. Maintenance
8.1 General
a) Annual inspection of the PV system should be performed by trained professionals to
check for damage to glass, backsheet, frame, junction box, loose connections and
corrosion.
b) Module having critical damage (like broken glass or junction box damage) and should be
removed from the array circuit for the safety of the plant and personnel.
c) There should not be any shading on the module. Tree branches which cast shadow on the
panels should be cut off at regular intervals.

8.2 Module Cleaning Guidelines

a) Accumulation of dust on the solar panels reduces the power generation from the panels.
Normally the dust will get washed away with rain water, but during dry spells, it is
necessary to clean the modules at weekly intervals. To assist in cleaning by rainwater, the
panels should be installed with a slope (tilt angle) greater than 15°.
b) Always wear rubber gloves for electrical insulation while maintaining, washing or
cleaning modules.

Page | 16
 c) Cleaning of modules with water should be done either in early morning or late evening,
and never when the module surface is hot. The temperature difference between the
module glass and the cleaning water should be less than 20 °C.
d) It is recommended to use fresh water with Total Dissolved Solids (TDS) < 1500 mg/L
and total hardness < 75 mg/L. If low mineral water is not available in some regions, it
is advisable to add sodium chloride (< 2% by weight) in water to avoid depositing the
dried minerals on glass.
e) If needed, a mild, non-abrasive, non-caustic detergent may be mixed in water such that
the pH level of the solution is within 6.5 – 8.5.
f) Abrasive cleaners, acid or alkali detergents must not be used. Do not use solutions
containing hydrochloric acid, D-Limonene, ammonia or sodium hydroxide.
g) Water pressure at the nozzle should not exceed 35 bar (500 Psi) when cleaning the front
side glass.
h) The module backsheet does not need any cleaning in the conventional (monofacial)
modules. In bifacial modules with transparent backsheet, it is preferable to clean the
backsheet gently with cotton cloth or with compressed air (at pressure less than 2.4 kPa).
Water should not be sprinkled on the backside of the modules to avoid water ingress
inside the junction box.
i) If excessive soiling is present, a non-conductive soft brush, non-abrasive sponge, or
other mild agitating method may be used before using water. Ensure brushes or agitating
tools are not abrasive to glass.
j) Do not let water stay on the glass surfaces of PV modules for a long time. This creates a
risk of permanent damage to the glass, such as white efflorescence, otherwise known as
“glass disease,” which may cause reduced power output.

9. Notes

9.1 Installation of the modules should be done by trained professions, in accordance with the
provisions of the installation manual (latest updated version at the time of sales).

9.2 The applicable models and electrical parameters are given in Annexure 1.

9.3 After PV module has reached its end of life, the customer is advised to hand over the module
to nearby E-Waste recycling centre, as per the local re-cycling regulations.

9.4 The installer/system owner may contact Rayzon Solar at the following address for further
clarifications regarding the safe installation and maintenance of the solar panels.

RAYZON SOLAR PRIVATE LIMITED

8th FLOOR, BLUE POINT, opp. D-MART,
Sarthana Jakat Naka, Nirmal Nagar Society,
Nana Varachha, Khadsad, Gujarat 395006, India.

Page | 17
 ANNEXURE 1: LIST OF APPLICABLE MODELS

Open Maximu Short Rated Maxi

Rated Rated Protection
Circuit m Circuit Maximum mum
Condit Voltage Current Class
Model Voltage System Current Power at Series
ion at STC, at STC, (IEC
at STC, Voltage, at STC, STC, Fuse,
(Vdc) (Adc) 61140)
(Vdc) (Vdc) (Adc) (Watts) (A)

144 Half-cut cell series

STC 50.34 42.42 1500 13.21 13.77 560

RSG560WC 25 II
BNPI 50.34 42.42 1500 14.55 15.16 615

STC 50.20 42.28 1500 13.13 13.71 555

RSG555WC 25 II
BNPI 50.20 42.28 1500 14.46 15.10 610

STC 50.06 42.14 1500 13.06 13.65 550

RSG550WC 25 II
BNPI 50.06 42.14 1500 14.38 15.03 605

STC 49.91 42.01 1500 12.98 13.59 545

RSG545WC 25 II
BNPI 49.91 42.01 1500 14.29 14.97 600

STC 49.78 41.86 1500 12.91 13.53 540

RSG540WC 25 II
BNPI 49.78 41.86 1500 14.22 14.90 595

STC 49.64 41.72 1500 12.83 13.47 535

RSG535WC 25 II
BNPI 49.64 41.72 1500 14.15 14.83 590

STC 49.50 41.58 1500 12.76 13.41 530

RSG530WC 25 II
BNPI 49.50 41.58 1500 14.07 14.77 585

STC 49.36 41.44 1500 12.68 13.35 525

RSG525WC 25 II
BNPI 49.36 41.44 1500 14.00 14.70 580

132 Half-cut cell series

STC 45.89 39.4 1500 12.95 13.66 510

RSG510WC 25 II
BNPI 45.89 39.4 1500 14.26 15.04 560

STC 45.69 39.12 1500 12.92 13.62 505

RSG505WC 25 II
BNPI 45.69 39.12 1500 14.23 15.00 555

STC 45.48 38.84 1500 12.89 13.57 500

RSG500WC 25 II
BNPI 45.48 38.84 1500 14.19 14.95 551

STC 45.3 38.55 1500 12.85 13.54 495 25 II

RSG495WC
BNPI 45.3 38.55 1500 14.15 14.91 545

Page | 18
 STC 45.06 38.23 1500 12.83 13.49 490
RSG490WC 25 II
BNPI 45.06 38.23 1500 14.13 14.86 540

STC 44.89 37.99 1500 12.79 13.45 485

RSG485WC 25 II
BNPI 44.89 37.99 1500 14.08 14.81 535

120 Half-cut cell series

STC 42.02 36.02 1500 12.94 13.64 465

RSG465WC 25 II
BNPI 42.02 36.02 1500 14.25 15.02 510

STC 41.78 35.71 1500 12.91 13.60 460

RSG460WC 25 II
BNPI 41.78 35.71 1500 14.22 14.98 505

STC 41.54 35.41 1500 12.88 13.57 455

RSG455WC 25 II
BNPI 41.54 35.41 1500 14.18 14.94 500

STC 41.30 35.10 1500 12.85 13.53 450

RSG450WC 25 II
BNPI 41.30 35.10 1500 14.15 14.90 495

STC 41.07 34.79 1500 12.81 13.49 445

RSG445WC 25 II
BNPI 41.07 34.79 1500 14.11 14.86 490

STC 40.83 34.48 1500 12.79 13.45 440

RSG440WC 25 II
BNPI 40.83 34.48 1500 14.08 14.81 485

108 Half-cut cell series

STC 37.79 32.48 1500 12.95 13.68 420

RSG420WC 25 II
BNPI 37.79 32.48 1500 14.27 15.07 460

STC 37.56 32.18 1500 12.92 13.63 415

RSG415WC 25 II
BNPI 37.56 32.18 1500 14.23 15.01 455

STC 37.34 31.88 1500 12.88 13.58 410

RSG410WC 25 II
BNPI 37.34 31.88 1500 14.18 14.96 450

STC 37.07 31.57 1500 12.85 13.54 405

RSG405WC 25 II
BNPI 37.07 31.57 1500 14.15 14.91 445

STC 36.87 31.28 1500 12.8 13.49 400

RSG400WC 25 II
BNPI 36.87 31.28 1500 14.1 14.86 440

STC 36.63 30.97 1500 12.77 13.44 395 II

RSG395WC 25
BNPI 36.63 30.97 1500 14.06 14.80 435

Page | 19
 96 Half-cut cell series

STC 33.38 28.61 1500 12.96 13.62 370

RSG370WC 25 II
BNPI 33.38 28.61 1500 14.27 15.00 405

STC 33.17 28.33 1500 12.91 13.58 365

RSG365WC 25 II
BNPI 33.17 28.33 1500 14.22 14.95 400

STC 32.95 28.07 1500 12.86 13.54 360

RSG360WC 25 II
BNPI 32.95 28.07 1500 14.16 14.91 395

STC 32.73 27.72 1500 12.81 13.47 355

RSG355WC 25 II
BNPI 32.73 27.72 1500 14.11 14.83 390

STC 32.55 27.44 1500 12.77 13.42 350

RSG350WC 25 II
BNPI 32.55 27.44 1500 14.06 14.78 385

72 Half-cut cell series

STC 25.08 21.72 1500 12.9 13.57 280

RSG280WC 25 II
BNPI 25.08 21.72 1500 14.21 14.94 305

STC 24.88 21.4 1500 12.86 13.53 275

RSG275WC 25 II
BNPI 24.88 21.4 1500 14.16 14.90 300

STC 24.67 21.04 1500 12.84 13.5 270

RSG270WC 25 II
BNPI 24.67 21.04 1500 14.14 14.87 295

STC 24.48 20.74 1500 12.79 13.45 265

RSG265WC 25 II
BNPI 24.48 20.74 1500 14.08 14.81 290

Note: Backside irradiance at BNPI condition = 135 W/m2

Bifaciality Coefficient:
φIsc=[Isc(back)]/[Isc(front)] = 75 ±10 %
φVoc=[Voc(back)]/[Voc(front)] = 100 ±5 %
φPmmp=[Pmmp(back)]/[Pmmp(front)] = 75 ±10 %

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