SOLAR PV SYSTEM

Work Methodology
Contents
1 Purpose..................................................................................................................................................... 3
2 Safety Information.......................................................................................................................................3
a. Personal Safety...........................................................................................................................................3
b. Working at Heights Safety............................................................................................................................3
3 Preparation and Submissions before Installation.............................................................................................5
a. Documentation............................................................................................................................................5
1.1 Tools............................................................................................................Error! Bookmark not defined.
4 Solar PV Mounting Structure Installation........................................................................................................5
5 Installation of Cable Tray, Conduit...............................................................................................................17
6 Installation of Inverters...............................................................................................................................18
1 Purpose
This document formalizes the requirements for the Installation of Solar PV System. The specifications,
procedures, and guidelines contained in this document specify the technical requirements to be followed
and also act as a reference to clearly establish defined standards for work assessment. Moreover, this
document shall provide guidelines to check that specified materials are installed and agreed procedures
are implemented during the execution of work and to define the responsibilities for controlling the
execution.

2 Safety Information
a. Personal Safety
 If there is a probability of personnel injury or equipment damage during operations on the
equipment, immediately stop the operations, report the case to the supervisor, and take
feasible protective measure.

 Use tools correctly to avoid hurting people or damaging the equipment.

 Use correct PPE during the installation of inverter

 Personnel who plan to install should be skilled, understand all necessary safety
precautions, and be able to correctly perform all operations.

 Be cautious to avoid injury when moving/lifting heavy objects.

b. Working at Heights Safety

Each person who could fall more than 1.8m (6ft) shall be protected from falling by means of having
personal fall arrest system. Using of safety harness and lifeline should be strictly implemented.
 Scaffolding and Ladder
 Ensure that the physical and structural integrity of scaffolding and ladders is in good
condition.

 Scaffold components manufactured by different manufacturers should not be intermixed

unless the components are compatible and scaffold’s structural integrity is maintained.

 Every scaffold and scaffold component shall capable of supporting, without failure, its own
weight (dead load) and at least four (4) times the maximum intended load applied or
transmitted before to it (D+4xL).

 Scaffold posts and frames shall be vertically plumb and vertically braced in both directions.

 Supported scaffolds with a height to the uppermost planked level that is over four times
the minimum base dimension (over a 4:1height-to-width ratio) shall be restrained from
tipping by ties, guys, outrigger frames, or equivalent means.

 Ensure that the scaffold and ladders is stable enough to handle intended weight loads
during operation.

 Ensure that there is enough clearances for ease access during operation.

 Use of sacaffolding should be in accordance to Occupational Health and Safety Standards

Rule 1414- Dept. Order No. 128-13.

Hot works and working with machines and sharp objects.

 Always wear correct PPEs during operation such as modification of cable trays, cutting,
bending of conduits and fabrication of supports, fabrication of Inverter structure etc.

 Make sure to wear welding mask and welding gloves when doing welding works.

 Use of fire blanket during hot work activity is necessary.

 Always place a fire extinguisher near the hot works area.

 Make sure to wear safety googles when using grinder and cut off machines.

 Always perform 5S .
 Electrical Works

 Always wear correct PPEs in performing Electrical Works.

 All electrical Works should be performed by a qualified personnel, and should be

supervised by a Professional personnel.

 Always de energize all equipment before performing task.

 Always follow your company’s electrical safety policy and practices.

 Always perform 5S.

3 Preparation and Submissions before Installation

a. Documentation
All materials intended for completion of Solar PV System shall be submitted for approval of the clients
project in harge as per the standard procedure using the notification of permanent material received at
site. Materials shall be checked and apparoved by the clients engineer befor installation. The supervisor
or will complete the inspection checklist and follow the Inspection and Test Plan. The QA/QC Inspectors
should verify the approved procedures are followed and the inspections and testing records are
completed.

4 Solar PV Mounting Structure Installation

ROOFTOP and FLAT SURFACE ROOF INSTALLATION

1. Before Installation of Mounting Structure

 Mounting systems will be installed as per local safety specifications and
relevant operation regulations. Safety precautions indicated in this document
are only supplementary information to local safety specifications;
 Berde Renewables Inc. will install mounting systems carefully, so as to
prevent damage to the PV system, avoid any injuries and accidents, and
guarantee the maximum service life of the mounting systems and the
maximum generating capacity of the PV system;
  Berde Renewables Inc. will make sure that bolts and connectors of mounting
systems are reliably fastened during installation, following the specifications
recommended by the equipment manufacturer;
 Maintenance personnel will have professional skills corresponding to
assigned responsibilities. Only qualified professionals will be allowed to install
and maintain mounting systems;
 Personnel must wear sufficient safety equipment before entering the
construction area and attach lifelines to permanent anchor points wherever
necessary;
 Installation will be carried out in sequence according to the procedures
specified in the User Manuals/Installation Guides provided by equipment
manufacturers and suppliers.
 Any procedure will be checked and confirmed to fully comply with the
manuals/guides before moving on to the next procedure; and
 All construction procedures for any equipment or component must be
completed and accepted as compliant to established standards before the
installation and commissioning for the next equipment or component will be
carried out.

COMPONENTS OVERVIEW (ROOFTOP)

LFEET / INTERFACE KIT RAILS RAIL CONNECTOR

with EPMD RUBBER
 END CLAMP MIDDLE CLAMP / GROUND LUGS AND
INTER CLAMP KIT GROUND CLIP
Figure 1. Mounting Structure Main Components

FLAT SURFACE ROOF MOUNTING COMPONENTS

Figure 1.1. Mounting Structure for Flat Surface Roof Main Components
2. INSTALLATION OVERVIEW
(ROOFTOP)

Figure 2. Installation of Mounting Structure (Side View)

L-Feet

Splice Kit / Rail Connector

Rail

Figure 2.1. Installation of Mounting Structure (Top View)

 3. INSTALLATION OVERVIEW (FLAT
SURFACE ROOF)

BALLASTED

CONCRETE
SOLAR
Figure 2.2. Installation of Mounting Structure (ISO View)
 4. INSTALLATION OF PV MOUNTING STRUCTURE (ROOFTOP)

1. Mark the locations of L-feet to be attached on roof based on design.

(See Figure 2.1)
2. Mount the L-feet on Metal Roof with a self-tapping screw / Tek screw.
(See Figure 2)
3. Make sure the screw of L-feet is secured and tightened properly.
4. After installation of L-feet, Place the MA rail on the side of the L Feet support
and fasten them with the M8 bolt assembly. The rail connectors are on the
same side, as shown on the Figure 2.1. (Recommended torque: 8 N·m)
5. Install the planned location according to the engineering plan and install all
the rails and ensure that the bolts are locked.
6. If the rail is not long enough, connect the MA Rail with the Splice / Rail
Connector for MA Rail as shown on the right, and lock it on each side. (See
Figure 2.1)
7. Make sure all bolt of rails and rail connectors are all secured and properly
tightened before installing Solar PV Module.

5. INSTALLATION OF PV MOUNTING STRUCTURE (FLAT SURFACE ROOF)

1. Mark the location of mounting structure for Flat Surface Mounting Structure
2. Concrete Ballast should be done according to the design, its dimension etc.
3. Make sure to make enough concrete ballast as per the quantity on design.
4. Install the planned location according to the engineering plan and install all
the rails and ensure that the bolts are locked.
5. If the rail is not long enough, connect the MA Rail with the Splice / Rail
Connector for MA Rail as shown on the right, and lock it on each side
6. Make sure all bolt of rails and rail connectors are all secured and properly
tightened before installing Solar PV Module.
Installation of Solar PV Modules onto the Solar PV Mounting Structure
(ROOFTOP)

Before Installation of Solar PV Modules

1. Solar PV Modules will be installed as per local safety specifications and

relevant operation regulations. Safety precautions indicated in this document
are only supplementary information to local safety specifications;
2. Solar modules should be installed at the optimized tilt angle to maximize the
energy output;
3. When installing solar modules on a roof always leave a safe working area
between the edge of the roof and the external edge of the solar array;
4. Position the modules to minimize the chances of shading at any time of the
day;
5. Do not install PV modules in a location where they will be immersed in water
or continually exposed to water from a sprinkler or fountain;
6. Avoid using a mounting method that will block the drainage holes in the
module frame;
7. In cases wherein the solar modules (except for smart module) on the same
installation will be mounted at different angles or orientations, energy
production can normally be optimized by connecting the strings/arrays of
different orientations to different inverters or different MPPT terminals on the
same inverter with reference to recommendations and guidelines set by the
inverter manufacturers;
8. DC wiring connections and grounding for the solar PV modules will be done in
parallel with the installation of solar PV modules onto the mounting system;
9. Berde Renewables Inc. will make sure that bolts and connectors of solar PV
modules are reliably fastened during installation, following the specifications
recommended by the equipment manufacturer;
10.Maintenance personnel will have professional skills corresponding to
assigned responsibilities. Only qualified professionals will be allowed to install
and maintain solar PV modules;
 11.Personnel must wear sufficient safety equipment before entering the
construction area and attach lifelines to permanent anchor points wherever
necessary
12.Installation will be carried out in sequence according to the procedures
specified in the User Manuals/Installation Guides provided by equipment
manufacturers and suppliers. Any procedure shall be checked and confirmed
to fully comply with the manuals/guides before moving on to the next
procedure; and
13.All construction procedures for any equipment or component must be
completed and accepted as compliant to established standards before the
installation and commissioning for the next equipment or component will be
carried out.

INSTALLATION OVERVIEW

MIDDLE CLAMP w/
GROUND CLIP
ALUMINUM RAIL
END CLAMP

C- PURLIN

CORRUGATED
ROOF
LFEET

Figure 3. Installation of Clamps and PV Module to Rails

Installation of Solar PV Modules onto the Solar PV Mounting Structure

1 To install the solar PV Modules onto the mounting system, each solar module
will be successively installed end-to-end for each array (Figure 3.1).

Figure 3.1 Installation and configuration of solar PV modules on the mounting system
2 Place the first solar module (of the row) on the end of the installed mounting
rails and slide the end clamp tightly against the solar module and fasten using
using a torque wrench (manufacturer recommends tightening the bolt to a
torque of 10 Nm to 12 Nm).

Figure 3.2. Installation of solar PV modules - Side Clamps

3 Slide pre-assembled inter clamps into the mounting rails beside the first solar
module, then position the next solar module in the row. Tighten the pre-
assembled clamp using a torque wrench (manufacturer recommends
tightening the bolt to a torque of 10 Nm to 12 Nm). Use the same procedure
for each succeeding solar module in the row.

Figure 3.3. Installation of solar PV modules - Middle Clamps

4 For the last solar module, use the end clamp to fasten the last solar module in
the row through the same procedure carried out for the first solar module in
the row. (Back to Figure 3.2)
PV Module Connection and its Pre-requisites

● All wiring should be performed, by qualified installers, in accordance with the

local codes and regulations.

● Modules can be connected in series to increase the operating voltage by

plugging the positive MC4 connector of one module into the negative MC4
socket of the next. Before connecting modules always ensure that the
contacts are corrosion free, clean and dry;

● Product can be irreparably damaged if the array string is inadvertently

connected in reverse polarity. Always verify the voltage and polarity of each
individual string before making a parallel connection. If you measure a
reversed polarity or a difference of more than 10V between strings then check
the string configuration before making the connection.

● The minimum and maximum outer diameters of the cable are 5 to 7mm.

● For field connections, use at least 4mm 2 copper wires insulated for a minimum
of 90°C and sunlight resistance with insulation designated as PV Wire.

● The minimum bending radius cables should be approximately 43mm.

the module-to-module wiring for each string will utilize using the daisy chain
configuration (Figure 3.4) for module-to-module wiring, leapfrog wiring minimizes
excess wire lead length often left just coiled up and organized using some type of PV
cable clip or conduit under the string/array

Figure 3.4. Standard module-to-module wiring - Daisy Chain Configuration

5 Installation of Cable Tray, Conduit

a. Installation Prerequisites

 Approved site fabricated trays, conduits and support shall be used as per site condition.

 Only approved brand cable conduits shall be allowed to be used.

 Manufacturer’s standard fittings shall be used and where manufacturer’s fittings are
inadequate as per site requirements site fabricated fittings shall be used as per client’s
approval.

 Mark the location of installation and install the approved ladders and conduits as per
specifications, shop drawings and site requirements for individual cases like slab or wall etc.

 In case of hollow block expansion bolts (unifix) will be drilled and brackets will be installed at
the regular intervals. Trays and conduits shall be fixed on the fabricated supports/bracket using
suitable bolts sized as per load of the tray and conduit size and as per approved mock-up.
Supports shall be installed as per specifications.

 Ensure conduits are installed neatly on the surface and underground and be truly vertical,
horizontal or parallel with the features of the building.
  Wherever the
accessories like Tees, flat elbows,
reducers & the jointing of two straight runs are required it should be provided with support or
300mm distance from the point.

 Sets and bends shall be sized to allow for the minimum permissible radius of the largest cable
on the tray.

 Earth continuity strips shall be installed at all joints and fitting connections.

 Burs and sharp edges shall be removed prior the installation of the conduits. Approved
galvanized paint shall be applied on the cut edges to protect from rusting.

 Joints shall kept as closed as possible to the supports.

 A minimum space of 75mm shall be maintained between installations and building structure in
order to secure the cables and for general maintenance.

 All conduits shall be secure with proper clamps or screws fixed with supports.

b. Installation Procedure

Step 1 Marking all the locations of supports/brackets and determine the actual
Measurements.
Step 2 Fabricate all supports/brackets base on gathered measurements.
Step 3 Install brackets/supports.
Step 4 Install cable trays/conduits and secure with bolts and clamps.

6 Installation of Inverters

 Mounting of Inverter Brackets to wall or Fabricated Mounting Structure on approved inverter

location.

 Inverter location and Inverter structure or Wall mounted are all coordinated and should be
approved by the client before proceeding on installation.
  Make sure to comply
spacing of inverter in its location.

 Use Proper tools for the installation of Inverters.

 Proper handling should be done when installing inverter to Inverter bracket.

 Make sure all inverter brackets are secured with bolts and properly tightened.

 Opening Cable compartment

 Electrical connection: DC cables and AC Cables wiring connection, should be performed by

qualified personnel.

 Wiring connection of Network Cable for online monitoring

7 Miscellaneous List

7.1 Tools

Allen key 6mm Socket Wrench

Pliers RJ45 Crimper
Long Nose Aluminum Ladder
Cutter Pliers Open and Close Wrench
Mc4 Crimper Level Bar
10mm Tekscrew Adaptor Wire Stripper
8mm Tekscrew Adaptor Sheet Cutter
Riveter Jack Pallet
Sealant Gun Electrician Knife
Iron Saw Rope
Wood Saw Extension wire/cord
Hammer Coring Machine
Cutter blade Hydraulic Cutter
 Allen Keys Hydraulic Crimper
Precision Tools Fish tape
Knockout Puncher Screwdriver (+) (-)
Long Tape (50m) L-Square
Steel Tape Adjustable Wrench

7.2 PPE’s

Hardhat Welding Mask

Full Body Harness Welding Gloves
Safety Gloves Fire Extinguisher
Safety Goggles Fire Blanket
Safety Mask Safety Shoes