SolarWorld. And EveryDay is a SunDay. www.solarworld.de

March 2008

– GroundMounting System from SolarWorld®Planning and Implementation

Proven quality – simply clever

Status:March 2008

Congratulations,we are pleased that you have chosen the high-quality SolarWorld AGmountingsystems.

All Sunfix® mounting systems are customized to suit the construction environment and staticloading requirements, thus offering an optimal and safe usage of installation space.

To ensure problem-free operation of the photovoltaic (PV) system, all components used are ofhighest quality.

We would like to point out that the following instructions detailing how to install our systems onsite, are only recommendations based on the current level of technology and experience. It is onlynatural that individual exceptions must be accounted for and we recommend professional advicealways to be obtained so that any special features of your roof can be allowed for.

Table of contents

Page 4 The mounting system componentsPage 4 Laying the foundationsPage 6 Pre-assembly of prop supportsPage 7 Installation of the prop supports on the foundationsPage 7 Fixing of profilesPage 8 Clamping on the modulesPage 10 Fixing of cross braces

Page 12 Dimensioning of the foundations and ground anchorsPage 13 Adjusting the prop supportsPage 14 Tilt angle of the modulesPage 15 Setting out a rowPage 16 Distance between two rows

Page 18 General safety informationPage 18 Special safety instructionsPage 19 Warnings

A The mounting systemcomponents

B Design and dimensioningof the mounting system

C Installation advice

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The ground mounting system is a multivariable supporting structure for mounting PV modules on the ground,facilitating modular expansion. It is suitable for mounting the SW 200/210/220 and SW155/165/175 SolarWorld®modules. The height-adjustable prop supports not only allow you to cope with different field situations, they alsomake it possible to change the tilt angle of the modules to suit local conditions.

Laying the foundations

A foundation type appropriate to the terrain must be used. According to the type of foundation, either groundanchors are screwed in, or foundations are cast. The dimensioning and laying of the foundations must be carriedout by a specialist company.

The mounting system componentsA

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This foundation type is suitable for allfree flowing soil types. The screw-inground anchors can be adjusted tomeet the demands of different soiltypes and grain sizes.

A suitable alternative to site-mixed concreteor ready fixed grounds.

Suitable for rubbly or stony soil.

Locally cast individual or strip foundations with cast-in M16thread bolts (anchor screws)

Screwing into prefabricated foundations

Screw-in ground anchors

Type and size of the anchoring parts depend on the soil conditions on site and must be tailored to each project.

Foundations for the prop supports can be constructed in a variety of waysin accordance with the local soil conditions:

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XZ

Y

N

S

1700

Pre-assembly of prop supportsThe supports may be pre-assembled at a single location. First,attach the U-shaped connectors to the rafter profile (2757 mm)using two M10x30 T-head bolts and two M10 toothed lockflange nuts (torque 30 Nm).Then screw the back (1860 mm)and front (880 mm) telescopic bars onto the U-shaped connec-tor, using two DIN 931M10x100 screws for each.Insert an inner telescope (720 mm) into each telescopic bar andfix each one in place with two DIN 931 M10x80 screws. Onlytighten the screws on the telescopic legs and their U-shapedconnectors by hand, thus after installing adjustments can bemade according to the terrain and desired installation angles ofthemodules can be set on site.Next step, attach themiddle telescopic bar (1560 mm) onto thefront U-shaped connector with two DIN 931 M10x100 screws.

Screw the front U-shaped foot to the end of the front telescopicbar with two DIN 931 M10x90 screws (torque 13 Nm). Screw theback U-shaped foot to the back andmiddle telescopic bars inthe sameway. In doing so, screw the telescopic bars into theback/front holes of the U-shaped feet, the middle slotted holesare designed for anchoring to the foundations.

With the help of the U-shaped feet, deviations of up to 20 mmin the X direction, 5 mm in the Y direction, and +/-10° on theX-Z planemay be adjusted for.

When pre-assembling the prop supports consider the desiredinstallation angle of themodules.

M10x100

M10x80

M10x90

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Installation of prop supports on foundations

Screw the prop supports onto the ready-installed ground anchors or foundations on site, each with a clampingplate, a DIN 931 M16x60 screw, and a DIN 125-A 17 washer (torque 50-60 Nm). The distance between the propsupports must be either 5.10 m (SW200/210/220) or 4.965 m (SW 155/165/175). The prop supports of each rowshould be adjusted in order to ensure that the modules can all be installed at the same angle. After the adjust-ment, the screws on the prop supports should be fully tightened (torque 20 Nm).

Fixing of profiles

After installing the prop supports, attach the purlin sections. It is advisable to begin with themiddle purlin and thenposition the lower and upper purlins at a distance of 1263 mm (dimension between the axes) from themiddle purlin.

Layout of purlins

SW200/210/220:Depending on the installation planned, alternate the purlin section of the 14er table (7112mm)with the one of the 6er hang-in (3072 mm) (for how to set up the tables see parttwo of the installation instructions: B Design and dimensioning of themounting system).At the start and the end of a row, alternatives to the standard set-up of a 14er table and a6er hang-in are also possible. An alternative can be for example a 16er table instead of a14er table, and a 10er extension instead of a 6er hang-in. Attach the appropriate purlinsections for your chosen layout – 5092 mm for a 10er extension and 8122 mm for a 16ertable.

SW155/165/175:Depending on the installation planned, alternate the purlin section of the 16er table(6603 mm)with that of the 8er hang-in (3327 mm). Alternatively, an 18er table (7422mm) can be selected instead of a 16er table, and a 12er extension (4965 mm) can beused instead of a 6er hang-in.

The purlin sections are joined on the underside using a U-shaped butt connector, fourM10x30 T-head bolts and four M10 toothed lock flange nuts (torque30 Nm).

outer purlin

middle purlin

Clamp the purlin sections and the rafter section of the prop support to the frame profiles using two M10x30T-head bolts and two M10 toothed lock flange nuts (torque 30 Nm).

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Clamping onthe modules

Themodules are secured using M8shear nuts, which serve as theft protec-tion. The modules are clamped onto theprofiles using M8x53 T-head bolts, lockwashers, and shear nuts. The short sidesof two vertically adjacent modules areclamped to the middle purlin section.On the long sides, the horizontally adja-cent modules are clamped to the upperor lower purlin section. A spacer withT-head bolt, lock washer, and shear nutis placed at the end of each rack.

The breakway torque of the nut liesbetween 13 and 25 Nm. If this value isexceeded or not reached, the shear nutwill have to be replaced with a new one.

B

C

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A module frameB purlin sectionC clamp connectorD prop supportE prop base

A

B

D

E

E

BCC

C

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Fixing of cross bracesA ø8 mm stainless steel cross brace with a turnbuckle must be attached lengthways on every fourth array (everysecond array without a hinge joint). Tables which stand alone always require a cross brace.

The first cross brace must be attached to the first 14er or 16er (resp. 16er or 18er) table, and then another one toevery fourth table. 10er (12er) extensions and 6er (8er) hang-ins never have cross braces.

After having assembled the prop supports,measure the required length of cables, cut the cables and attach them.When attaching the cables, the following criteria must be fulfilled:

The first steel cable clamp is attached closely to the cable eye stiffener.

The steel cable clamps must be attached with a distance between them of at least the width of another steelcable clamp.

The clamp straps must always be placed on the end of the cable with the least stress.

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The components are assembled in the following order, starting with the U-shaped foot and working towards theU-shaped connector: First, the eye bolt is fixed with its nut to the U-shaped foot through the central borehole.Then the shackle is fed through the eye bolt, and the steel cable loop with cable eye stiffener and four steel cableclamps is attached to the shackle. Another shackle is hooked into the eye of the steel cable, and then the turnbuck-le is attached to it. A further shackle is then hooked into the eye of the turnbuckle. Another eye bolt is attached tothis shackle. The bolt and its nut establish the connection to the borehole of the U-shaped connector.

Tighten the cross braces securely with the help of the turnbuckle.Make sure that the brace is neither sagging norso tight as to bend the frame.

A eye bolt with nutB shackleC steel cable loop with stiffener

D steel cable clampsE turnbuckle

A B C D E

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Design and dimensioningof the mounting system

BDimensioning of the foundationsand ground anchorsThe foundations must be able to bear the following loads safely:

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Adjusting the prop supports

The aluminummounting sections allows distances between the prop supports of 5.10 m (SW 200/210/220) or4.965 m (SW155/165/175) with an assumed wind load of 160 km/h (135 km/h is hurricane force) and a snow loadof 0.75 kN/m2 for a module tilt angle of 30°.

The prop supports adjust telescopically to adapt to different module tilt angles, local conditions and to compensateuneven terrain.

The prop supports may be adjusted to thefollowing lengths:

A 1.32 m to 1.68 m (adjustment with tele-scopic bar, breadboard 10 mm)

B 2.30 m to 2.46 m (adjustment with tele-scopic bar, breadboard 10 mm)

A B

Position

A

Dead weight+ snow load

Dead weight+ snow load

+ 1/2 wind load fromthe left

Dead weight+ 1/2 snow load

+ wind loadfrom the left

Dead weight+ wind load

from the right

7,4 kN 6,6 kN 2,7 kN 3,3 kN

B 6,7 kN 16,7 kN 24,1 kN

C 5,3 kN 10,5 kN

D 10,5 kN

E 18,6 kN

Load case

The loads shown are pure loads which do not take additional safety factors into consideration.

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The U-shaped connectors allow acompensation for slanted terrain of+/- 10° on the X-Z plane and of +/- 6°on the Y-Z plane.

Tilt angle of the modules

The tilt angle of the modules can be varied from 20° to 40° in order to adjust it to local irradiation conditions andrequirements. The optimal set-up may be reached by extending or shortening the telescopic bars.

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Setting out a row

SW 200/210/220The standard set-up of a row of SW 200/210/220 SolarWorld® modules consists of tables with 14 and hang-inswith 6 modules. A hang-in (B) with 6 modules is placed between the 14er tables (A). This hang-in (B) does notrequire a separate prop support. The distance between two prop supports is always 5.10 m for this set-up. Themodules are arranged in double rows.

At the start and end of a row, various possibilities to arrange the tables are available in order to make optimal useof the space available.

One possibility is to have a 10er extension (D) joined onto a 14er table. This requires an extra prop support at adistance of 5.1 m. Another option for the start or end of a row is to have two further protruding modules addedonto a 14er table,making it a 16er table (C). This does not require an extra prop support.

A table with 14 SW 200/210/220 modulesB hang-in with 6 SW 200/210/220 modules

C table with 16 SW 200/210/220 modulesD extension with 10 SW 200/210/220 modules

9 60 60

3030

1001

10101010 5101

7121 3081 3081

5101 5101

1675

9 60

3030

1001

10102020

51018131

51015101

1675

SW 155/165/175SolarWorld® SW 155/165/175 modules are installed on tables of 16 and hang-ins with 8 modules. A hang-in with8 modules (B) is placed between these 16er tables (A). The distance between two prop supports should alwaysbe 4.965 m.

At the start and end of a row it is possible to join a 12er extension (D) onto a 16er table. This requires an extra propsupport at a distance of 4.965 m. Another option for the start or end of a row is to have two further protrudingmodules added onto a 16er table,making it an 18er table (C). This does not require an extra prop support.

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A table with 16 SW 155/165/175 modulesB hang-in with 8 SW 155/165/175 modules

C table with 18 SW 155/165/175 modulesD extension with 12 SW 155/165/175 modules

9 60 60

3030

810

819819 4965

6603 3327 6603

4965 4964

1610

3030

8191638

49657422

49654965

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Distance between two rows

A certain minimum distance between the rows must be adhered to. This ensures that modules do not blockeach other’s sunlight throughout the whole year. The distance between the rows depends on the sun’s irradia-tion angle and can be calculated using the latitude of the location. For this calculation, the following formulais used:

Minimum distance between rows: dmín = htot / tan (66.5°-latitude)

For a mounting frame of the SW200/210/220 modules with an installation angle of 30°, the height (h1)of the upper edge of the module over that of the lower edge of the module is h1 = 3367 mm • sin 30° = 1683.5mm. For the SW155/165/175 modules h1= 3237 mm • sin 30°= 1618.5 mm. If the modules are set-up on one plane,h1 = htot. If, due to uneven terrain, there is a height difference (h2) between the two rows, the total height (htot)is calculated from h1 + h2, as long as the back row is the lower of the two. If the back row is higher than thefront row, the total height is calculated using h1 - h2.

Example:

Frankfurt is at 50° latitude. The modules are tilted at an angle of 30°. The distance between the rows for aproject on a site in the Frankfurt area must be at least:

dmin = (3367 mm • sin 30°) / tan (66.5°-50°) (SW200/210/220 modules)

dmin

= 1683.5 mm / tan (66.5°-50°) = 5683 mm

The distance between the rows should be at least 5.7 m, in order to minimize any mutual blocking of sunlightover the course of the year.

h2

dmín

h1

l 1=3367 m

m

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Installation adviceCGeneral safety information

All work on a PV system (installation, commissioning,maintenance, repairs) may only be performed by appropri-ately qualified and authorized persons. The relevant regulation and technical standards of the country where theinstallation takes place must be observed.

The systemmay only be connected to the public mains grid by a qualified electrician who is authorized by the dis-tribution network operator (DNO) to carry out such work.

Special safety instructions

Attention must be paid to the module installation guide as well as the inverter installation instructions and theplanning examples provided with the delivered system.We recommend that the Sunfix® System is installed by aspecialized company.

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Danger of life• Ensure that the permitted wind and snow loads are not exceeded on site.• Make sure that all screw connections are securely fastened, and that the given torque values are adhered to.

Danger of life from electric shockSolar modules generate electricity as soon as they are exposed to light. There is always a voltage present. Onemodule on its own is below the safety extra low voltage (SELV) level, but multiple modules connected in series(summation of the voltage) or in parallel (summation of the current) represent a danger. Although touchprotection is provided in the form of the fully insulated plug contacts, the following points must be observedwhen handling the solar modules to avoid the risk of fire, sparking and fatal electric shock:• Do not insert electrically conducting parts into the plugs or sockets!• Do not install solar modules and wiring using wet plugs and sockets! Tools and working conditions must be

dry.• Exercise utmost caution when carrying out work on wiring and use the appropriate safety equipment

(insulated tools, insulated gloves, etc.)!• Do not use damaged modules!• Do not dismantle the modules!• Do not remove any part or type plate fitted by the manufacturer!• Do not treat the rear side of the module with paint, adhesives or mark it using sharp objects!

The inverter can produce high touch voltages, even when not connected:• Exercise utmost caution when working on the wiring and inverter!• After switching off the inverter, it is essential to wait for the time interval specified by the manufacturer

before beginning any further work. This allows the high voltage components time to discharge.• Be sure to carefully follow the inverter manufacturer’s installation instructions!

Danger of life from electric arcsModules generate direct current (DC) when light shines on them.When opening a connected string(e.g. when disconnecting the DC line from the inverter under load), a potentially lethal electric arc can occur:• Never remove the solar generator from the inverter while it is still connected to the mains grid!• Ensure that the cable connections are in perfect condition (no splitting, soiling or other contamination)!

Warnings!

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SolarWorld. And EveryDay is a SunDay. www.solarworld.de

SolarWorld AGKurt-Schumacher-Straße 12-1453113 Bonn, GermanyTelephone: +49 - 228 - 55920 - 0Fax: +49 - 228 - 55920 - 99service@solarworld.dewww.solarworld.de

Production and distribution sites of the SolarWorldGroup

SolarWorld AGKurt-Schumacher-Str. 12-1453113 BonnGermany

SolarWorld Ibérica, S.L.C/La Granja 15,Bloque B-1º B28108 Alcobendas,MadridSpain

SolarWorld California Inc.4650 Adohr LaneCamarillo, CA 93012USA

SolarWorld Africa Pty. Ltd.20th Floor1 Thibault SquareCape Town, 8001South Africa

SolarWorld Asia Pacific Pte. Ltd.72 Bendemeer Road#07-01, LuzerneSingapore 339941Singapore

Production

Deutsche Solar/Freiberg, GermanyDeutsche Cell/Freiberg, GermanySolar Factory/Freiberg, GermanySunicon/Freiberg, GermanySolarWorld Innovations/Freiberg, GermanySolarWorld Industries Germany/Munich, GermanySolarWorld Industries America/Camarillo,USASolarWorld Industries America/Vancouver,USASolarWorld Industries America/Hillsboro,USA

Distribution

SolarWorld Head Office/Bonn, GermanySolarWorld Ibérica/Madrid, SpainSolarWorld Africa/Cape Town, South AfricaSolarWorld Asia Pacific/Singapore, SingaporeSolarWorld California/Camarillo, USA