DesignGuide 200series. Solyndra

Design Guide - 200 Series
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English. 0920-30102-002 Release Date: 2011-04-01 Visit http://www.solyndra.com for the mostcurrent version of this document.
Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com
GENERAL DISCLAIMER
The information contained in Solyndras instructions, guides, application notes, or any other document is advisory in nature only. Solyndra makes no representation or warranties that any referenced techniques or methods are necessarily safe, legal, or compliant with applicable codes and regulations. The customer must work with qualified system designers, installers and other professional personnel as required to ensure that all Solyndra photovoltaic system designs and installations are safe and in compliance with all applicable codes and regulations. Solyndra assumes no legal liability or responsibility for the accuracy, completeness, or usefulness of any information or processes disclosed herein. Reference herein to any particular 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.
WARRANTY DISCLAIMER
The warranty terms for Solyndras photovoltaic products are governed solely by the express terms of the Solyndra Limited Warranty provided to the purchaser of Solyndra products as may be transferred there under. Solyndra expressly disclaims any and all other express warranties and any and all implied warranties, including but not limited to those relating to the sale and/or use of Solyndra photovoltaic products, fitness for a particular purpose, merchantability or non-infringement or infringement of any intellectual property right. Solyndra may make changes to specifications, guidelines, and products at any time without notice. Purchasers or potential purchasers, designers and installers should contact their local Solyndra representative or the Solyndra website to ensure that they have and are working with the most up-to-date information and documentation relating to Solyndras photovoltaic products.
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The following terms are trademarks or service marks of Solyndra LLC: 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. Copyright (circle logo ) Solyndra LLC 2011. Printed in the United States of America. All Rights Reserved. UB.EN.20110319.V1-0.
Contact Information
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Design Guide 200 Series
Contents
Chapter 1 Designing with Solyndra Panels 4
1.1. Code Compliance & Safety...............................................................................................................................................4 1.2. Required Information ......................................................................................................................................................4 1.3. Design Sequence ..............................................................................................................................................................4
Chapter 2 Wiring
2.1. The Solyndra Connector System .....................................................................................................................................5 2.2. String Blocks .....................................................................................................................................................................7 2.3. String Wiring .....................................................................................................................................................................8 2.4. Home Run Wiring .............................................................................................................................................................9 2.5. Grounding ....................................................................................................................................................................... 10 2.6. Array Installation around Lightning Grids .................................................................................................................... 10
Chapter 3 Planning the Panel Layout
11
3.1. Designing for Wind ..........................................................................................................................................................11 3.2. Roof Zone Definitions .....................................................................................................................................................12 3.3. Placing Panels Over Roof Objects ................................................................................................................................. 16 3.4. Planning Layouts for Uneven Roofs .............................................................................................................................. 16 3.5. Estimating Energy Yield ................................................................................................................................................. 16
Chapter 4 Design in Seismic Areas
17
4.1. Clearance Tables for Building Site Zones B, C, D ........................................................................................................... 19 4.2. Clearance Tables for Building Site Zone E .....................................................................................................................20 4.3. A Note on Code Compliance ......................................................................................................................................... 22
Chapter 5 Solyndra Panel System
23
5.1. Solyndra Panels & Mounts .............................................................................................................................................23 5.2. Solyndra Cable Management System ...........................................................................................................................24 5.3. Optional Panel Mounting Components ........................................................................................................................24 5.4. Standard Configuration..................................................................................................................................................25 5.5. Roof Loads ......................................................................................................................................................................26
Chapter 6 Optimum Inverter Selection
29
6.1. Inverter Sizing ................................................................................................................................................................29 6.2. Summary .........................................................................................................................................................................30
Chapter 7 Solyndra CAD Toolkit
31
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Solyndra Confidential
Design Guide 200 Series 3
Designing with Solyndra Panels
Chapter 1 Designing with Solyndra Panels

The purpose of this document is to provide design information for Solyndra 200 Series photovoltaic systems. The target audience is system designers and engineers who are already skilled in photovoltaic system design. This guide will highlight the unique properties of the Solyndra 200 Series technology and their impact on system design, but is not intended to cover all aspects of system design. Solyndra panels are designed to deliver optimum performance when installed over white, high reflectance roofs. Projects that do not follow Solyndras design and installation guidelines may not provide the expected energy yield, and will not be covered by Solyndras warranty.
1.1.
Code Compliance & Safety

System installations should be designed by a properly-licensed professional in accordance with all applicable codes and standards. Solyndra panels are made of glass and can be broken. Hazardous voltage is present in photovoltaic cells at all times when they are exposed to any light source. Before handling Solyndra panels, all Solyndra procedure, safety recommendations, and all local safety requirements applicable for working on roofs and around electrical equipment must be read and understood by all personnel. Reference to the Solyndra Installation Guide may be made for safety recommendations.
1.2. Required Information

In order for an effective design to be produced, the designer needs information about the installation site. For a preliminary design, items which are required are as follow: Address of site. Roof diagram with dimensions, including height, and contour if available. Roofing material type. Roof slope. Roof deck and load bearing capacity. Height of nearby structures, if any. Design wind speed, snow-load, and hail exposure. Seismic requirements, if any. Locations and dimensions of all roof obstructions. Orientation of building. Shading analysis.
1.3. Design Sequence

Design begins with the determination of string length using Solyndras Inverter and String Sizing Tool (see 2.3. String Wiring on page 8), or other calculation methods, to achieve proper voltage match for an inverter type. Next, a rooftop layout is prepared. This will allow the most accurate determination of panel count, at which stage an energy yield forecast can be prepared. The final step is the preparation of a complete Bill of Materials for purchase, and an installation plan, including roof loading (structural) design.
Chapter 2 Wiring
2.1. 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 series and parallel connections between panels in an array. The panel and its connectors are shown in Figure 1, along with the CAD tool symbol from the CAD package that Solyndra offers. Refer to Chapter 7 on page 31 for detail of the CAD tool package.
Wiring
Figure 1. Solyndra PV Panel and Power Connections

+ Positive Side
Male + Negative Side Male Female Female +
Female +
Male Female Male -
The preferred orientation for Solyndra panels is with the modules (tubes) oriented north-south. Panels are then wired in series, as shown in Figure 2. This type of connection is commonly referred to as a string.
Figure 2. Two Panels Wired in Series

+ Positive Side
Male + Negative Side Female Male +
Female +
+ Positive Side
Male Female +
Female +
Male -
Negative Side
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Horizontal string connections are also possible, as shown in Figure 3. It is important when connecting panels in horizontal strings, as shown in Figure 3, that only connector pair be connected. Connecting both pairs would create a short circuit between the two panels.
Wiring
Figure 3. Series Connection, End-to-End Panels

Do not connect! + Positive Side Negative Side Male,
Female, +
Male + Negative Side
Female + Positive Side
Male, Female, +
Female +
Male +
Correct four-panel strings are shown in Figure 4. Notice how positive connectors are connected to negative connectors starting at the tail end of the string arrow (in green) and going towards the head of the arrow, increasing the total voltage with each panel.
Figure 4. Four-Panel Series Connections
Figure 5 shows connections between panels in a typical view from underneath the array.
Figure 5. Interpanel Connection of Positive and Negative Pigtails
2.2. String Blocks

A string is a group of panels whose electrical connections are in series. The number of panels needed in each string depends on the inverter chosen. Strings can be connected in parallel within an array to reduce home run wiring costs. A typical 4 by 4 array is shown in Figure 6. Note the parallel connections, indicated by the red jumper symbols at the top of the array, and the blue jumper symbols at the bottom of the array.
Wiring
Figure 6. A 4 by 4 String Block

Home Run Connection
Home Run Connection
Some designs use strings six panels long. An example is shown in Figure 7. Note that in Figure 6 and Figure 7 all series and parallel connections can be made using only the built-in panel connectors.

Home Run Connection
Home Run Connection
In some cases, the standard string-block arrangement may not be convenient for a roof location due to obstacles or other factors. Figure 8 shows a 24-panel horizontal string block. In this design, short jumper cables (shown in red and blue) will be required to make the parallel connections on the positive and negative ends of the string block. Note that the string blocks shown in Figure 7 and Figure 8, while physically different, are electrically equivalent.
Home Run Connection

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Negative Jumpers
Positive Jumpers
Home Run Connection
Wiring
2.3. String Wiring

An inverter and string sizing tool is offered by Solyndra to assist in determining the optimum string length and the correct inverter size for the array. The tool is available in two versions, one for North American systems (up to 600V) and one for EU systems (up to 1000V). These tools are Excel spreadsheets named Inverter_and_StringSizing-200Series-EU and Inverter_and_StringSizing-200Series-NA. These tools may be obtained from Solyndra or an authorized distributor.
2.3.1. Determining String Length

The number of panels placed in series determines the system voltage. The system voltage must stay below the smallest of: the maximum voltage rating of the inverter the rated working voltage of the wiring all applicable electrical codes In the US, electrical equipment and wiring is rated for 600 volts maximum; in Europe the maximum rating can be as high as 1000 volts. Because panel voltage varies with temperature, the maximum voltage occurs when the temperature is cold and the inverter is off. Similarly, array voltage should be designed to stay above the minimum inverter tracking voltage when the temperature is hot and the array is operating at its maximum power point voltage, Vmp. Refer to the panel data sheet for specific temperature coefficients.
2.3.2. Parallel Strings

Connecting strings in parallel within the array reduces the amount of home-run wiring needed, saving time and cost. First, the series fuse size for each string block must be determined. The equation is: Eqn 1. I fuse = 1.56 (N : I sc) Where N is the number of strings to be connected in parallel and Isc is taken from the panel data sheet. The calculated value must be rounded up to the next larger size. Values are listed in Table 1.
Table 1.
I5 One String Two Strings
Ifuse, Minimum Series Fuse Size for Multiple Strings in Parallel

182 2.33 4 8 11 15 191 2.34 4 8 11 15 200 2.35 4 8 11 15 210 2.36 4 8 11 15 220 2.37 4 8 11 15 Watts Amps Amps Amps Amps Amps
Panel Power Rating
Three Strings Four Strings
2.3.3. Maximum Number of Parallel Strings

The maximum number of strings which can be wired in parallel is limited by the series fuse rating of the panel. In order to determine the number of strings, the Fault Current Equation as specified by the controlling code authority must be used. As an example, the IEC Fault Current Equation is shown in Eqn 2: Eqn 2.
where N is the number of strings to be connected in parallel while still keeping the maximum fault current (Ifault) less than the series fuse rating, as specified in the data sheet. This can be solved for N, the number of strings, as: Eqn 3. N = ( I fault - I fuse ) + 1
I fault = I fuse + 1.25 ^N - 1 h I sc
1.25I sc
The series fuse rating for 200 Series Panels is 24.4 Amps. Substituting this into Eqn 3 this for the fault current, and using the short-circuit current rating as specified in the data sheet, the maximum number of strings can be calculated. The results are shown in Table 2. It is permissible to have string blocks of fewer than the maximum number of strings in parallel.
Wiring
Table 2.
Isc
Maximum Number of Parallel Strings per Fused Home Run

182 2.33 4.17 4 191 2.34 4.16 4 200 2.35 4.14 4 210 2.36 4.13 4 220 2.37 4.11 4 Watts Amps strings strings
Panel Power Rating N, calculated N, rounded down
2.4. Home Run Wiring

Home run wires from string blocks are connected in parallel inside combiner boxes. Just as each panel has four connections, each of the four corners of a string block will have a positive or negative pigtail available. Run a positive home run cable and a negative home run cable from the corners in a way that minimizes cable length. Use the Solyndra Cable Management System to keep wires organized and prevent them from dangling. It is shown in Figure 9, and it includes long and short channels, hangers and pegs, and panelmount cable channels.
Figure 9. Cable Management System and Close-up View of Corner
The Solyndra cable management system makes it easy to efficiently route home run wiring. An example for 4 by 4 systems is shown in Figure 10; one for 6 by 4 systems is shown in Figure 11.
Figure 10. Typical Home Run Wiring - 4 by 4 String Blocks
4x4 string block Standard 8 x 12 (96 panels) equals 6 4x4 blocks Double-wide (192 panels) equals 12 4x4 blocks Home run wiring
Figure 11. Typical Home Run Wiring - 6 by 4 String Blocks
4x6 string block Standard 8 x 12 (96 panels) equals 4 4x6 blocks Double-wide (192 panels) equals 8 4x6 blocks Home run wiring
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Wiring
2.5. Grounding
Solyndra 200 Series Panels and mounts meet the requirements for IEC Protection Class II . It is not necessary to ground the array, or to ground any particular lead of the array at the inverter (unless required by code) when installing a Solyndra system. Due to the hermetic seals used in the construction of each Solyndra module, they are not susceptible to corrosion damage from voltage offsets with respect to ground.
2.6. Array Installation around Lightning Grids

Some rooftops are fitted with a lightning grid. A lightning grid is an array of wires running horizontally in both directions across a roof. Dimensions vary, but typically the wires are spaced a few meters apart, and the entire grid is carefully grounded to earth. These grids are occasionally fitted with vertical conductors called air terminals, or lightning rods. A Solyndra system, when installed, may be placed over a lightning grid. Certain guidelines must be followed, but Solyndra panels do not impact the function of lightning systems or make the building more likely to have a lightning event.
Array Placement Guidelines with Lightning Grids

1. Engineering for a photovoltaic system on roofs with lightning grids requires obtaining the S dimension required by code, either from the original designer or by re-calculating it. The S dimension is the minimum separation distance from the lightning grid required if additional precautions are not taken. 2. If panels are to be installed within distance S of the lightning grid components there are certain applicable electrical code requirements. These may include a requirement to connect exposed metal components to the lightning grid and a recommendation that conductors coming into the building be protected by voltage shunt devices. 3. Solyndra 200 Series Panels and mounts are IEC certified Class II devices. They are not considered to have exposed metal parts and therefore do not have a requirement to be attached to the lightning grid, even if placed within the S distance. 4. Because Solyndra 200 Series Panels are IEC certified Class II devices, voltage shunt devices are not required, but are recommended, for building lead-ins and inverter protection. Use of such devices is a design decision that should be based on sensitivity of building use, or an inverter protection risk versus cost analysis. 5. Solyndra panels should never be placed over air terminals. Any air terminals that are under the array must be moved. 6. Modifying the lightning protection system to protect the Solyndra array is not necessary.
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Chapter 3 Planning the Panel Layout

This chapter explains the rules for placing Solyndra 200 Series panels on a building roof. Solyndra panels are designed to be installed flat, elevated above the roof surface by Solyndra panel mounts. The open design of the Solyndra panel reduces wind effects, so they are self-ballasted against sliding and uplift. By attaching groups of panels together, mass is increased such that panel movement does not occur. A properly-assembled array has sufficient mass to resist movement without the need for attachment to the roof. In order to insure that high winds do not lift the panels, certain minimum clearances from building edges and other structures must be maintained. Panels shall only be placed over firmly-attached roof surfaces. Loose-laid membranes or other materials are not acceptable. As with any rooftop solar system, the design must also meet fire, safety, and access clearance requirements, as dictated by applicable codes.
Planning the Panel Layout
3.1. Designing for Wind

The Solyndra panel-and-mount system, when installed according to Solyndra guidelines, has been certified at wind speeds up to 130 MPH (208 KPH) in wind tunnel and outdoor studies. Wind speeds are defined as a 3-second gust measured at 10 meters, per ASCE 7-05, Figure 6.1. Wind speed-up due to local topography must be considered when establishing design wind speed. Consult ASCE 7-05, Section 6.5.7. Tornadoes have not been considered in developing this specification.
3.1.1.
Physical Sub-Array Definition

For purposes of wind analysis, 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.
3.1.2. Coefficients of Friction

Friction between the Panel Mount and the roof makes the panels resist movement. Solyndra has tested various combinations of Panel Mount materials and roof materials. The results are shown in Table 3. Pads are available from Solyndra. The designer is responsible for ensuring that proper friction assumptions are used.
Table 3.
Coefficients of Static Friction (Fc) for Common Roofing Materials

Panel Mount (bare) Panel Mount with EPDM pad 0.8 1.2 1.6 1.0 1.0 0.6 1.2 Not recommended Not recommended 1.0 Panel Mount with PVC pad Panel Mount with TPO pad 1.2 Not recommended Not recommended 0.8
Roof material TPO membrane Elastomeric coatings EVA membrane PVC membrane EPDM membrane Hard coatings
Not recommended Not recommended 1.4 0.8
Not recommended Not recommended
Not recommended means that the combination is not chemically compatible. Care should be taken during installation on icy or dirty surfaces as these can reduce friction below measured values.
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3.2. Roof Zone Definitions

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 rooftop perimeter. Panels are never permitted here. This zone is based on extensive wind testing and analysis. Zone A, a strip adjacent to the 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. Roof slopes can be less than 1:10 (5.7), or up to 2:12 (9.6). Solyndra panels using Solyndra-supplied mounts are not permitted on roof slopes greater than 2:12 (9.6).
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. Dimension A is defined as including the 5-foot (1.52 m) setback. This means that if the 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 effectively zero, that is, there is no Zone A.
Determining 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 with 5 feet (1.52 m). Dimension A is the largest of these values.
Zone B
Zone B is 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, from the corner of the building, equal to 100% of the building height. The shape of Zone B is different for high and low parapet roofs. For high-parapet roofs, the intersection of Zone A and Zone B is defined as Zone B. For low-parapet roofs, the intersection of Zone A and Zone B is a forbidden area.
Definition of Building Dimensions

Building height is defined as the height above ground of the portion of the roof on which the array is installed. For rectangular buildings, the definitions of length, width, and height are clear. If the building is non-rectangular, consult ASCE 7-05 for definitions. 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 roof height within a distance equal to 200% of roof height. The rules cited herein 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. If a small array is being erected for evaluation purposes, place it in the center of the roof; well away from Zone A and Zone B.
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3.2.1. Roof Zone Defintions

Zone definitions depend on roof slope, parapet height, and whether there is a roof ridge. Zone definition drawings are shown in Table 4. A high parapet is one that is 19 (48 cm) or more in height. For slopes less than 1:10, no distinction is made between monoslope and ridged.
Table 4.
Roof Slope
Zone Definition Drawing Key

High Parapet Monoslope or Ridged Monoslope Ridged Figure 12 Figure 14 Low Parapet Figure 13 Figure 15
Less than 1:10 (5.7) Between 1:10 and 2:12 (5.7-9.6) Between 1:10 and 2:12 (5.7-9.6)
In each of the figures, red represents roof area in which panels may never be placed.
Figure 12. Roof Zone Definition - High Parapet; Monoslope 2:12; Ridged 1:10
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 13. Roof Zone Definition - Low Parapet; Monoslope 2:12; Ridged 1:10
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
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Zone A 5 ft (1.52 m) edge setback
Zone A 5 ft (1.52 m) edge setback
Figure 14. Ridged Roof, 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 B Zone B Zone B Zone A Zone A Zone C
Dimension A (*)
Dimension A
Zone B
Zone B
Zone A
Zone B
Zone A
Figure 15. Ridged Roof, Slope 2:12, Low Parapet

5 ft (1.52 m) edge setback Zone A Zone B Zone B Zone B Roof Ridge Zone A
Dimension B
Zone A Zone A Zone A Zone C
Dimension B
Zone C
Dimension A (*) Zone B Zone A Zone B Zone B
Dimension A
* Dimension A does not require the minimum 5-foot (1.52 m) setback.
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3.2.2. Minimum Sub-Array Sizes

Table 5 defines the minimum sub-array sizes for roofs up to 60 feet (18.3 m) high, with slope less than 1:10. Table 6 defines the minimum sub-array sizes for roofs up to 60 feet (18.3 m) high, with slope less than 2:12.
Table 5.
Fc (1)
Minimum Sub-Array Sizes: Buildings 60 Ft (18.3 m) High, 1:10 Slope

Wind 85 mph 90 mph 95 mph 100 mph 105 mph 110 mph 115 mph 120 mph 125 mph 130 mph Speed 137 kph 145 kph 153 kph 161 kph 169 kph 177 kph 185 kph 193 kph 201 kph 208 kph
Roof Zone A (2, 3) 0.6 B, low (4) B, high (4) C A (2, 3) 0.8 B, low (4) B, high (4) C A (2, 3) 1.0 B, low (4) B, high (4) C 4 4 4 4 4 4 4 4 4 4 4 1 4 9 4 4 4 4 4 4 4 4 4 1 9 16 9 9 4 4 4 4 4 4 4 4 9 36 4 9 4 4 4 4 4 4 4 4 16 64 9 9 9 4 4 9 4 4 4 4 25 100 16 16 9 16 9 9 9 9 9 9 25 NA 36 25 9 25 9 9 9 9 9 9 36 NA 49 25 16 36 16 16 9 9 9 9 49 NA 81 36 25 49 16 16 9 9 9 9 100 NA NA 49 25 64 25 25 16 25 16 16
Table 6.
Fc (1)
Minimum Sub-Array Sizes: Buildings 60 Ft (18.3 m) High, 2:12 Slope

Wind Speed 85 mph 137 kph 95 mph 153 kph 130 mph 208 kph
Roof Zone A (2, 3) 0.6 B, low (4) B, high (4) C A (2, 3) 0.8 B, low (4) B, high (4) C A (2, 3) 1.0 B, low (4) B, high (4) C 54 40 40 18 12 8 12 9 8 8 8 8 63 63 60 32 20 8 27 12 8 8 8 8 NA NA 108 98 45 60 44 40 40 40 15 24
Figure 16. Notes for Table 5 and Table 6.

1. Fc is the coefficient of friction, from Table 3. 2. The array must be as deep, or deeper, than it is wide, that is, the number of panels in direction towards center of roof must equal or exceed number of panels along perimeter (see drawing at right). 3. No array can be fully inside Zone A. An array shall have at least two times as many panels in Zone C as in Zone A (see drawing at right. 4. Zone B is defined by Figure 12, Figure 13, Figure 14, or Figure 15, based on low or high parapet. 5. NA is Not Allowed.
Building Wall Zone A
5 ft (1.52 m) edge setback
Zone C Not Acceptable Not Acceptable Acceptable
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3.3. Placing Panels Over Roof Objects

Never place panels over objects more than 10 inches (25 cm) tall, or elevate panels to clear objects. Any building steps or obstructions more than 10 inches (25 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.
3.4. Planning Layouts for 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 such that there is a large height disparity between panels. For stability, it is recommended that the mounts not be placed on the peaks of a non-flat patterned roofs. It is also recommended that the roof structures load-bearing capability be assessed wherever the mounts are placed. Many roofs have local ridges and valleys for drainage. Layouts should be designed such that Panel Mounts rest solidly on the roof. Figure 17 shows several placements. When peaks and valleys are present, as in (b), do not place mounts on peaks. This places excess localized pressure on the roof. Avoid valleys if possible, as the mount can affect drainage.
Figure 17. Right and Wrong Ways to Place Panels on Uneven Roofs
Acceptable
Acceptable (a)
Unacceptable
Avoid if possible (b)
Unacceptable
Angles at Panel Joints

200 Series Panel Mounts form flexible joints, and can generally be placed on any roof surface that varies less than 10 degrees from surface to surface. Under certain circumstances it may be possible to bridge differences of roof slope up to 18 degrees provided that the following rules are adhered to: Panels can bridge either parallel or perpendicular to a ridge or valley, but the center axis of the panel must be within 10 inches (25 cm) of the ridge peak. Panels which use Snow Mounts cannot bridge perpendicularly across a ridge or valley because this may interfere with Snow Mount locations, unless additional Snow Mounts are used. While it is possible to bridge valleys, accessibility and local requirements to keep drainages clear may recommend against this design.
3.5. Estimating Energy Yield

When the layout is completed, Solyndras on-line energy yield forecast tool can be used to estimate hourly, daily, monthly, and annual energy yield. Detailed results are available on-screen, in a downloadable report, and in a downloadable Excel spreadsheet. For instructions in the use of this tool, refer to the Energy Yield Forecast Tool User Guide. Contact a Solyndra representative to obtain access to the tool.
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Chapter 4 Design in Seismic Areas

A Solyndra array, properly installed on a rooftop, functions as a seismically-isolated system. It is designed to have some movement in the largest seismic events. When designing systems for seismically-active areas, clearances must be maintained around the array to allow for maximum possible displacements in a worstcase seismic event. In order to determine the amount of clearance required, the engineer must determine the parameters listed below. Solyndra recommends that designers work with a qualified seismic engineer who is familiar with seismic conditions in the region where the array will be installed, and can determine the building period of the structure where the array will be installed.
Design in Seismic Areas
Understanding Seismic Hazard Levels

This chapter uses a method to determine expected earthquake-induced array displacements for locations with a varying intensity of seismic hazard. The seismic hazard at a given location can be defined by two parameters: the short period Maximum Considered Earthquake (MCE*) spectral response acceleration (SS), and the 1-second MCE spectral response acceleration (S1). The levels of seismic hazard are defined by maximum spectral response acceleration parameters. Four levels are defined: Low (Level 1), Moderate (Level 2), High (Level 3), and Very High (Level 4) seismic activity. Any site with spectral response parameters equal to or lower than the maximum values for a seismic hazard level are within that level. The expected seismically-induced array displacements for any Solyndra installation can be determined from the seismic hazard level of the site. The spectral response parameters that define the four seismic hazard levels are shown in Table 7.
Table 7.
Seismic Level Spectral Parameters

Seismic Hazard Description Low Medium High Very High Maximum SS 0.533 1.500 2.000 2.893 Maximum S1 0.210 0.600 0.940 1.237 Units G G G G 1 2 3 4
Seismic Hazard Level
Multiple soil conditions are also considered for each of the four levels in this study by adjusting the SS and S1 values by site soil coefficients (Fa and Fv) per ASCE 7-05. Only site Classes B, C, D, and E (as defined by ASCE 7-05) are considered in this study. Site Class A is not considered as it is rarely encountered in occupied areas. The adjusted values are then used to define the MCE response spectra for each soil type considered.
* The MCE is defined as an earthquake of such intensity that there is a 2% probability that it would be exceeded in a time period of 50 years (or equivalently with a return period of 2,475 years). 0920-30102-002 Solyndra Confidential Design Guide 200 Series 17
Roof Slope.
Arrays should not be installed on roofs with slopes greater than 1:12 (4.76 degrees) in seismically-active areas
Coefficient of Friction
For seismic purposes, the coefficient of friction is the dynamic friction between the roof surface and the chosen panel mount. Refer to Table 8 for values.
Table 8.
Dynamic Coefficients of Friction for Common Roofing Materials

Panel Mount (bare) Panel Mount with EPDM pad 0.6 0.6 0.8 0.6 1.0 Not recommended 1.0 1.0 Not recommended 0.8 0.6 Panel Mount with PVC pad Not recommended 1.0 Panel Mount with TPO pad 0.8 Not recommended 0.6
Roof material
TPO membrane Elastomeric coatings EVA membrane PVC membrane EPDM membrane Hard coatings
Not recommended Not recommended Not recommended Not recommended
Not recommended means that the combination is not chemically compatible. Care should be taken during installation on icy or dirty surfaces as these can reduce friction below measured values.
Wiring
Combiner boxes must be set back from the array a distance greater that the specified displacement. Homerun wiring must be flexible and include strain-reliefs. It must be long enough not to restrict any possible movement of the panels in a seismic event.
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4.1. Clearance Tables for Building Site Zones B, C, D

Table 9. Clearance for Coefficient of Friction 0.6; Site Classes B, C, D
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 2 5.1 3 6 8 12 12 6 7 9 13 15 10 13 16 21 26 7.6 15.2 20.3 30.5 30.5 15.2 17.8 22.9 33 38.1 25.4 33 40.6 53.3 66 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 1 2.5 2 5.1 2 5.1 4 8 12 15 18 5 9 13 16 20 10 16 22 27 36 10.2 20.3 30.5 38.1 45.7 12.7 22.9 33 40.6 50.8 25.4 40.6 55.9 68.6 91.4 Clearance, 1:12 slope inches cm 1 2.5 2 5.1 2 5.1 3 7.6 2 5.1 7 14 22 25 30 7 15 23 17 34 17.8 35.6 55.9 63.5 76.2 17.8 38.1 58.4 43.2 86.4 Seismic Hazard Level
15 38.1 27 68.6 Not Recommended Not Recommended Not Recommended
Table 10. Clearance for Coefficient of Friction 0.8; Site Classes B, C, D

Seismic Hazard Level 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 1 2.5 2 4 6 10 10 3 6 9 11 12 8 11 14 19 22 5.1 10.2 15.2 25.4 25.4 7.6 15.2 22.9 27.9 30.5 20.3 27.9 35.6 48.3 55.9 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 1 2.5 1 2.5 1 2.5 3 6 8 12 14 4 7 10 13 15 8 13 17 23 30 7.6 15.2 20.8 30.5 35.6 10.2 17.8 25.4 33 38.1 20.3 33 43.2 58.4 76.2 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 1 2.5 2 5.1 1 2.5 5 9 15 18 23 4 10 17 20 25 12.7 22.9 38.1 45.7 58.4 10.2 25.4 43.2 50.8 63.5
9 22.9 20 50.8 31 78.7 Not Recommended Not Recommended
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Table 11.
Clearance for Coefficient of Friction 1.0; Site Classes B, C, D

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 1 2.5 2 3 5 9 9 3 5 7 10 10 6 10 13 16 19 5.1 7.6 12.7 22.9 22.9 7.6 12.7 17.8 25.4 25.4 15.2 25.4 33 40.6 48.3 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 1 2.5 1 2.5 1 2.5 2 4 7 10 12 3 6 8 11 12 6 11 15 20 24 5.1 10.2 17.8 25.4 30.5 7.6 15.2 20.3 27.9 30.5 15.2 27.9 38.1 50.8 61 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 1 2.5 1 2.5 1 2.5 3 6 11 15 19 3 8 13 16 19 7.6 15.2 27.9 38.1 48.3 7.6 20.3 33 40.6 48.3
Seismic Hazard Level
7 17.8 16 40.6 25 63.5 31 78.7 Not Recommended
4.2. Clearance Tables for Building Site Zone E

Table 12. Clearance for Coefficient of Friction 0.6; Site Class E
Seismic Hazard Level 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 5.1 3 7.6 5 12.7 3 5 6 10 10 4 6 8 10 12 8 10 13 17 22 7.6 12.7 15.2 25.4 25.4 10.2 15.2 20.3 25.4 30.5 20.3 25.4 33 43.2 55.9 Clearance, 1/2:12 slope inches cm 1 2.5 2 5.1 2 5.1 3 7.6 6 15.2 4 6 10 12 14 4 7 10 13 17 8 13 18 23 30 10.2 15.2 225 30.5 35.6 10.2 17.8 25.4 33 43.2 20.3 33 45.7 58.4 76.2 Clearance, 1:12 slope inches cm 2 5.1 3 7.6 3 7.6 5 12.7 10 25.4 6 11 17 20 24 6 13 19 23 28 15.2 27.9 43.2 50.8 61 15.2 33 48.3 58.4 71.1
12 30.5 22 55.9 33 83.8 Not Recommended Not Recommended
20

Seismic Hazard Level 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 5.1 2 5.1 5 12.7 2 3 5 8 8 3 5 7 9 10 6 9 12 15 17 5.1 7.6 12.7 20.3 20.3 7.6 12.7 17.8 22.9 25.4 15.2 22.9 30.5 38.1 43.2 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 2 5.1 2 5.1 5 12.7 2 4 7 10 11 3 6 8 11 12 6 10 14 19 23 5.1 10.2 17.8 25.4 27.9 7.6 15.2 20.3 27.9 30.5 15.2 25.4 35.6 48.3 58.4 Clearance, 1:12 slope inches cm 1 2.5 2 5.1 2 5.1 3 7.6 7 17.8 4 7 11 15 18 3 9 13 16 20 10.2 17.8 27.9 38.1 45.7 7.6 22.9 33 40.6 50.8
7 17.8 15 38.1 25 63.5 30 76.2 Not Recommended

Seismic Hazard Level 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 2 5.1 4 10.2 2 3 4 7 7 2 4 6 8 8 4 8 11 14 16 5.1 7.6 10.2 17.8 17.8 5.1 10 15.2 20.3 20.3 10.2 20.3 27.9 35.6 40.6 Clearance, 1/2:12 slope inches cm 1 2.5 1 2.5 1 2.5 2 5.1 4 10.2 2 3 5 8 9 2 4 7 9 9 5 9 12 16 19 5.1 7.6 12.7 20.3 22.9 5.1 10.2 17.8 22.9 22.9 12.7 22.9 30.5 40.6 48.3 Clearance, 1:12 slope inches cm 1 2.5 1 2.5 2 5.1 3 7.6 6 15.2 3 5 8 11 14 3 6 10 12 14 5 12 20 24 30 7.6 12.7 20.3 27.9 35.6 7.6 15.2 25.4 30.5 35.6 12.7 30.5 50.8 61 76.2
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4.3. A Note on Code Compliance

The Solyndra system is designed to not be attached and to minimize lateral forces on the roof diaphragm as it acts as an isolation system. It is exempt from the prescribed requirements described in Section 1613 of the 2007 CBC (California Building Code) and Section 13.1.4 of ASCE 7- 05, under specific exemption for non-structural electrical components with weights of less than 400 pounds (182 Kg), mounted less than 4 feet (1.22 m) above floor level, provided that flexible connections are provided and testing has been done. The applicable code sections are shown in Table 15 for reference.
Table 15. A Selection of Applicable Seismic Codes

2007 CBC, Section 1613 EARTHQUAKE LOADS 1613.1 Scope. Every structure and portion thereof, including nonstructural components that are permanently attached to structures and their supports and attachments, shall be designed and constructed to resist the effects of earthquake motions in accordance with ASCE 7, excluding Chapter 14 and Appendix 11A. The seismic design category for a structure is permitted to be determined in accordance with section 1613 or ASCE 7. ASCE 7-05, Chapter 13 SEISMIC DESIGN REQUIREMENTS FOR NONSTRUCTURAL COMPONENTS 13.1.4 Exemptions. The following nonstructural components are exempt from the requirements of this section: 4. Mechanical and electrical components in Seismic Design Categories D, E, or F, where the component importance factor, Ip, is equal to 1.0 and both of the following conditions apply: a. Flexible connections between the components and associated ductwork, piping, and conduit are provided, and b. Components are mounted at 4 ft (1.22 m) or less above a floor level and weigh 400 lb (1780 N) or less. 2007 CBC, Section 1708.5 1708.5 Seismic qualification of mechanical and electrical equipment. The registered design professional in responsible charge shall state the applicable seismic qualification requirements for designated seismic systems on the construction documents. Each manufacturer of designated seismic system components shall test or analyze the component and its mounting system or anchorage and submit a certificate of compliance for review and acceptance by the registered design professional in responsible charge of the design of the designated seismic system and for approval by the building official. Qualification shall be by an actual test on a shake table, by three-dimensional shock tests, by an analytical method using dynamic characteristics and forces, by the use of experience data (i.e., historical data demonstrating acceptable seismic performance) or by a more rigorous analysis providing for equivalent safety.
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Chapter 5 Solyndra Panel System

5.1. Solyndra Panels & Mounts
The Solyndra 200 Series Panel System is a tool-less panel installation system requiring no fasteners; it simply snaps together. It consists only of Panels and Panel Mounts. The 200 Series Cable Management System simplifies wiring and requires no tools for assembly. Solyndra offers optional Snow Mounts and Load Distribution Feet (LDF). Figure 18 shows a six-panel system with Panel Mounts, optional Snow Mounts, and the Cable Management System.
Solyndra Panel System
Figure 18. Solyndra Panel Mount System
Panel
Snow Mount
Panel Mount Cable Trough Clip Cable Trough
Table 16 lists the standard parts in Solyndra systems.
Table 16. Panel Installation Hardware - Provided as Balance of System

Item Panel Panel Mount Order Number SL200-XXX SLN-230 Description Solyndra photovoltaic panel. -XXX represents the power rating. Panel Mount for Solyndra 200 Series photovoltaic panel.
Dust Cap for Male Solarlok Connectors
0048-30100
May be used to cover unused Solarlok male connectors. Dust Cap for Female Solyndra Connectors 0048-30094
May be used to cover unused Solarlok female connectors
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5.2. Solyndra Cable Management System

Table 17 lists the components in the Solyndra Cable Management System. Refer to 2.2. String Blocks on page 7 for information on routing home run cables within arrays.
Table 17. Solyndra Cable Management System

Item Long Cable Channel Order Number SLC-2TE Illustration
Used for routing the home-run cables around and within the array. Short Cable Channel SLC-2TN
Used for routing the home-run cables around and within the array. Cable Channel Peg SLC-2CN
Cable Channel Pegs are installed on the sides of the array. They support the Short Cable Channels that contain the home-run connections. Cable Channel Hanger SLC-2CE Cable Channel Hangers are installed on the sides of the array. They support the Long Cable Channels that contain the home-run connections. Panel Mount Cable Channel SLC-2DE
Used in corner wiring and certain other cases.
5.3. Optional Panel Mounting Components

Solyndra offers a Snow Mount for use in high snowfall areas. It increases the snow rating from 1200 Pascals (25 PSF) to 1850 Pascals (38.6 PSF). A Load Distribution Foot (LDF) is available for mineral wool roofs and other applications which require a more distributed load. Refer to 5.5.1. Snow Loads on page 26 for details.
Table 18. Optional Snow Mount and Load Distribution Foot

Item Snow Mount Part Number SLM-2DS Illustration
Used at the center of the Panel side rails to increase the snow load rating.
Load Distribution Foot
SLL-340
Used on mineral-wool or other soft roofs. The standard Panel Mount rests on the LDF, which allows the LDF to tilt slightly to accommodate uneven roof surfaces.
5.3.1. Determining the Required BOS Parts Quantities

The Solyndra CAD Tool has attributes that allow part counts to be extracted from designs. See Chapter 7 Solyndra CAD Toolkit on page 31 for details.
24 Design Guide 200 Series Solyndra LLC 47488 Kato Road Fremont CA 94538 www.solyndra.com
5.4. Standard Configuration

A certain number of panel mounts, cable management components, and dust caps are included with each panel at no additional charge. The quantities are based on a typical 8 x 12 panel rectangular sub-array. Table 19 lists the standard ratios. Note that the exact quantities shipped will vary due to the standard packaged quantity of each component. For example, Long Cable Channels are shipped in minimum quantities of 15 per box. The actual quantities required will depend on sub-array size and shape, and therefore will vary by project. For small or irregularly-shaped sub-arrays, additional components may be ordered separately.
Table 19. Standard Configuration BOS Component Ratios

BOS Component Panel Mount Dust cap for male connectors Dust cap for female connectors Long Cable Channel Short Cable Channel Cable Channel Hanger Cable Channel Peg Panel Mount Cable Channel Snow Mount Load Distribution Foot (LDF Order Number SLN-230 SLC-2TE SLC-2TN SLC-2CE SLC-2CN SLC-2DE SLM-2DS SLL-340 Units per Panel 5 mounts to 4 panels 1 cap to 1 panel 1 cap to 1 panel 1 channel to 20 panels 7 channels to 50 panels 3 hangers to 20 panels 7 clips to 25 panels 1 protector to 20 panels 0 0 Ratio 1.25 1 1 0.05 0.14 0.15 0.28 0.05 0 0
Use of Non-Approved Hardware

Do not substitute for Solyndra-specified parts without the express written consent of Solyndra. Use of nonSolyndra-specified parts will void the warranty. Materials used outdoors should be sunlight/UV resistant. Materials such as wire insulation and other components should be certified to withstand the temperatures to which they are exposed.
Tyco Solarlok Connector Information

Table 20 lists part numbers for Tyco Solarlok connectors for 10 AWG (5.3 mm2) wire, commonly used for home run connections. Table 21 lists part numbers for Tyco Solarlok connectors for 12 AWG (4 mm2). These should be used if it is necessary to replace a connector on a Solyndra panel.
Table 20. Tyco Solarlok Connector Part Numbers, 10 ga (5.3 mm2) Wire
Female Cable Connector Plus Keyed Plus Coupler Minus Coupler Male Coupler, Neutral 5-1394462-5 Minus Keyed 5-1394462-5 Male Cable Connector Plus Keyed 1394461-7 Minus Keyed 1394461-8 Unkeyed 6-1394461-3
Table 21. Tyco Solarlok Connector Part Numbers, 12 ga (4 mm2) Wire

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 1394461-4 Unkeyed 6-1394461-2
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5.5. Roof Loads

All roof-top photovoltaic designs should be reviewed by a qualified structural engineer. The following data should be considered as advisory only. The roof deck may be made of any material as long as it is securely fastened, has a slope of 2:12 or less, can support the load, and provides proper friction. High-reflectivity white material is preferred; lower-reflectivity roofs will reduce energy output. Solyndra offers a Load Distribution Foot (LDF) for installation situations which must meet a local pressure loading limit.
Figure 19. Solyndra LDF with Mount on Top
Table 22. Distributed Roof Load, Standard Panel Mount and LDF Mount
Panel Wt. 31.8 Kg 70 lbs Panel Area 2.49 m2 26.8 ft
2
Standard Mount Distributed Load Wt. 2.3 Kg 5 lbs 13.9 Kg/m2 2.84 psf
LDF Wt. 2.05 Kg 4.5 lbs
Distributed Load w/ 4 LDF 14.9 Kg/m2 3.05 psf metric imperial
The values in Table 22 assume an average of 1.22 panel mounts per panel; correct for an 8 by 12 array. From a design viewpoint, adding an array to a roof adds 2.84 lbs/ft2 (13.9 kg/m2) of distributed load to the roof. However, in some cases the roof s live load allowance of 20 lbs/ft2 (100 kg/m2) may be eliminated in those areas covered by panels because it will no longer be possible to walk in areas occupied by the array.
5.5.1. Snow Loads

Solyndra 200 Series Panels have been tested per Section 10.16 of IEC 61646. They can withstand 25 pounds per square foot (122 kg/m2, or 1200 Pascals) of snow load when mounted on the standard fourcorner mount system. For locations that require snow load ratings between 1200 and 1850 Pascals (25 and 38.6 PSF), two Snow Mounts mounts can be placed under the panel rails, at the mid-point. These Snow Mounts increase the rating to 38.6 pounds per square foot (189 kg/m2, or 1850 Pascals). Note that each Snow Mount is supporting two panels.
26
5.5.2. Roof Mount Point Loads Table 23. Snow Load Contact Pressure Metric Units
Snow Load Total Weight Kg 0 76.0 175 228 304 384 469 Pressure per Mount Panel Mounts at corners only KPa 9.43 30.1 57.1 71.6 92.3 Kg/m2 962 3073 5819 7297 9409 Panel Mounts + Snow Mounts KPa 4.76 15.1 28.6 35.8 46.2 57.0 68.6 Kg/m2 485 1541 2914 3653 4709 5817 6996 Pressure per Mount, with LDF Panel Mounts at corners only KPa 1.06 3.25 6.10 7.64 9.83 Kg/m2 108 331 622 779 1002 Panel Mounts + Snow Mounts KPa .563 1.66 3.08 3.85 4.95 6.10 7.32 Kg/m2 57 169 315 393 505 622 747
Pascals 0 300 690 900 1200 1515 1850
Kg/m2 0 30.6 70.4 91.8 122 154 189
Not permitted
Not permitted
Table 24. Snow Load Contact Pressure Imperial Units

Snow Load Total Weight lbs 0 168 385 503 670 846 1006 Pressure per Mount Panel Mounts at corners only psf 197 629 1191 1494 1927 psi 1.36 4.37 8.27 10.4 13.4 Panel Mounts + Snow Mounts psf 99.1 315 597 748 964 1191 1433 psi 0.688 2.19 4.14 5.19 6.70 8.27 9.95 Pressure per Mount, with LDF Panel Mounts at corners only psf 22.0 67.8 127 159 205 psi 0.153 0.471 0.885 1.11 1.43 Panel Mounts + Snow Mounts psf 11.7 34.6 64.4 80.4 103 127 153 psi 0.081 0.240 0.447 0.559 0.718 0.885 1.06
psf 0 6.27 14.4 18.8 25.1 31.6 38.6
psi 0 0.044 0.100 0.131 0.174 0.220 0.268
Not permitted
Not permitted
Snow Loads for Mineral Wool Insulated Roofs

Mineral wool insulated roofs have a maximum pressure rating in order to insure that the material is not crushed. When installing with the LDF on a mineral wool insulated roof, determine the pressure rating of the insulation. Table 25 shows the maximum snow loads for Rockwool roofs in good condition, and other lesser mineral wools.
Table 25. Maximum Snow Loads on Mineral Wool Insulated Roofs

Mount Arrangement Panel Mounts with LDF Panel Mounts + Snow Mounts. all with LDF Roof Type Rockwool Lesser Mineral Wools Rockwool Lesser Mineral Wools Maximum Snow Load Pascals 1200 650 1850 1500 Kg/m 122 66.3 189 153 psf 25.1 13.5 38.6 31.3 psi 0.174 0.094 0.268 0.218
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5.5.3. Hail
Solyndra panel hail specifications are shown in Table 26. When planning installations, check historical weather data to determine the possibility of receiving hail in excess of the panels hail specification.
Table 26. Hail Specification

Specification Hail Size 25 mm Mass 7.53 g Velocity 23 m/s
5.5.4. Construction Materials Placement

In addition to combined loads, the roof must withstand live loads during installation. Solyndra panels are packed horizontally onto pallets for shipment. A full crate of 13 panels weighs approximately 1150 lbs (520 kg). Refer to Solyndras shipping documentation for exact weight and size. Have a qualified structural engineer verify that the roof structure will not be overloaded from the combination of live loads and pallets on the roof.
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Chapter 6 Optimum Inverter Selection

An inverter never needs to be rated at the same Wp as the array. Figure 20 shows how the power output varies over the course of the year, from the best (summer) days to the worst (winter) days. The hour-byhour 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. The histogram 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 is especially true at more northern latitudes.
Optimum Inverter Selection
Figure 20. Annual Power Output Variation & Histogram

100
100
Percentage of Wp
60 40 20 0
Intermediate Panel Power Outputs Panel Power Output; Darkest Days

6 AM 9 AM Noon 3 PM 6 PM
Percentage of Wp
80
Panel Power Output; Brightest Days
80 60 40 20 0
Hourly Data
4000
Actual Power versus 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.
6.1. Inverter Sizing

A typical solar array will seldom generate the STC-rated power. The inverter can and should be smaller. The amount depends on both technical factors and economic factors.
Technical Factors
Solyndras energy yield forecast tool 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 sufficient for this array.
Economic Factors
It may make economic sense to use an even smaller inverter than the technical factors alone suggest. Inverters are not harmed by being connected to an array which produces more watts than the inverter rating. The inverter simply de-tunes the array, an effect known as clipping. In the above example, a 200 kW inverter will sacrifice only 0.2% of total energy; a 180 kW inverter will sacrifice only 3.6%. 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. Figure 21 shows the LCOE for different inverter sizes for the nominal-250 kW example system. At the ratio of 1.45, the inverter size is 172.4 kW, for a loss of only 8.4%.
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Optimum Inverter Selection
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 21. LCOE vs DC:AC Ratio & NPV 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
$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
6.1.1. Maximizing Value for AC-Limited Incentive Applications

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. Figure 22 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. 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 22. The area in red is the energy lost; the area in green is the energy gained due to the oversize array.
Figure 22. 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
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
NPV
Histogram of Hourly Energy Output
6.2. 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, especially at more-northern latitudes. The precise oversize ratio will depend on the tariff regimen, actual insolation, and inverter cost. Regardless of the tariff, Solyndras Excel tool can be used to evaluate inverter size options. Solyndras Design Team can also assist in determining the optimum inverter size.
30
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 Solyndra CAD Toolkit

The Solyndra CAD Toolkit is an AutoCAD .DWG file with blocks representing Solyndra panels and mounting system components. The blocks have been assigned attributes that make it possible to extract parts counts from a drawing. Additional files in the CAD tools folder are provided to assist with this extraction process. The toolkit includes two AutoCAD .DWG files. One is based on U.S. standard units and the other is based on SI (metric) units.
Solyndra CAD Toolkit
Layers
Layers have been assigned to drawing elements to allow the designer to control the desired level of visible detail in a drawing. The defined layers are:
SOL-PANEL CONNECTIONS SOL-BLOCK DESCRIPTIONS SOL-SHEET OBJECTS SOL-PANEL MOUNTS SOL-PROOFING SOL-COMPONENT HANDLES SOL-CABLE CHANNELS SOL-STRING BRANCHES SOL-PANELS SOL-ATTRIBUTES
The SOL-PROOFING layer displays colored indicators of the different panel assembly blocks. There are four color coded panels in the CAD Toolkit. This color coding provides visual cues that allow the designer to quickly verify that the correct panel and array blocks were used in creating an array design. The yellow (TL) panel is always in the upper left corner of the sub-array. The light blue (T) panel is the top row of the sub-array, excluding the upper left corner panel. The pink panel (L) is the left edge of the sub-array, excluding the upper left corner panel. And the dark blue (F) panel is the remaining fill of the sub-array.
Blocks
The parts required for a Solyndra installation are drawn as blocks in the Model space. The panel block contains handles for attaching the other mounting system parts. The Model space also contains blocks containing pre-built sub-arrays for typical stringing configurations. These sub-array blocks have been built up from the individual parts blocks and can be used as building blocks for assembling larger arrays. Where an array section calls for a configuration not provided in the pre-built sub-arrays, the designer can build up that array section from detailed panel and parts blocks. Each block may be copied from the example already inserted in the Model space or accessed from the Insert Block menu.
Panel Details
The Panel Details sheet contains blocks for individual parts and single panel assemblies. Panels are drawn to scale; panel dimensions have been increased slightly to allow for typical spacing between panels when installed. Panel Mounts (feet only) are drawn to scale and positioned accurately on the panel. All other parts are symbolic representations and are not drawn to scale.
Vertical String Blocks & Horizontal String Blocks

The Vertical String Blocks sheet contains blocks of pre-built strings and sub-arrays with panels arranged in typical vertical (or horizontal) stringing configuration.
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Solyndra CAD Toolkit
Attributes
Each individual part block has text attributes attached to it, which allow parts counts to be extracted from a drawing. The attributes assigned to each part block are as follows:
Block Name PANEL_W_ANCHOR PANEL_MNT CABLE_CHANNEL_LONG CABLE_CHANNEL_SHORT Attributes PANELS PANEL_MOUNT CABLE_CHANNEL_LONG CABLE_CHANNEL_SHORT Description Panel Panel Mounts Long cable channel Short cable channel Default qty 1 1 1 1
Important Note: To avoid clutter in the drawing, the attributes are set as Invisible and Constant. If the blocks are exploded, the attributes will appear in the model space, and they will no longer be attached to a block and will prevent counting of parts.
Mounting BOS Extraction (ATTEXT)

The attribute extraction command, ATTEXT,* can be used to extract Solyndra mounting system parts counts for a completed array layout design. After entering the ATTEXT command a dialogue box will appear. Follow these instructions to extract attributes to a comma-delimited file which can be used to get a total parts count for the Solyndra mounting system. 1. Choose Comma Delimited File. 2. Click on Select Objects, and select the portion of the drawing for which it is desired to determine the parts count. 3. If the template file field is blank, click the button and locate SOL_BOM_NOTEPAD_TEMPLATE.TXT on the computer. (This file is in the Solyndra CAD Toolkit folder.) 4. Click the Output File button to select the location for the output text file. The default file name is the name of the drawing file. Note that in order to ensure the template file is not overwritten, name the output file differently from the template file, and click OK. 5. There is now a text file with a line for each block instance, and values for the associated attributes separated by commas. 6. Locate and change its file extension to .csv; open the file with Excel, select all and copy. 7. Open the Solyndra BOS summary template Excel file ([Solyndra] bos summary template.xls). 8. Paste the copied data from the extract file into the location in the BOS summary template spreadsheet. The spreadsheet will total the number of panels and the parts counts extracted from the drawing. The spreadsheet will also compute an average parts per panel value for each mounting system component. 9. Save and close the BOS summary template file. Note that if it is desired to keep the original for later use, the working copy must be saved to a different directory and/or file name from the master copy. *The spelling of the attribute extraction command differs depending on the language in which AutoCAD is used. English ATTEXT Czech ATREXT German ATTEXT French ATTEXTR Spanish ATREXT Italian ESTRATT Portuguese EXTRATRIB Russian
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Revision History
Revision 1.0 1.1 Part Number 0920-30102-001 0920-30102-002 Date 2010-08-10 2 011-04-01 Notes Initial Version Updated for LLC
0920-30102-002
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Design Guide 200 Series Solyndra LLC 47488 Kato Road Fremont CA 94538

DesignGuide 200series. Solyndra

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