Flexsolar G Series Connection Instructions

The Flexsolar G Series is a high-efficiency solar panel system designed for residential and commercial applications, featuring monocrystalline silicon cells, IP68 waterproof rating, MC4 connectors, and compatibility with most grid-tie and off-grid inverters. Below are key sections for safety, components, installation, electrical connection, commissioning, and maintenance.

System Components

Key components: Solar panels, MC4 connectors, mounting brackets, grounding lugs, junction box, and connection cables.

Safety Precautions

Always follow electrical safety standards. Panels generate DC voltage when exposed to light.

1. Wear insulated gloves and safety glasses during installation.
2. Disconnect all power sources before making connections.
3. Install during low-light conditions (early morning or cloudy days).
4. Ensure proper grounding to prevent electric shock.
5. Keep panels covered with opaque material during wiring.

WARNING! DC voltage can be lethal. Only qualified electricians should perform electrical work.

Installation Preparation

Site assessment and tool preparation.

1. Check roof structure: Ensure it can support panel weight (approx. 22kg per panel).
2. Verify orientation: South-facing (Northern Hemisphere) with 15-40° tilt angle.
3. Clear shading: Remove obstructions (trees, vents, etc.).
4. Gather tools: Drill, wrench set, torque wrench, cable cutter, multimeter.
5. Review local codes: Obtain permits if required.

CAUTION! Never walk on panels. Use proper fall protection on roofs.

Mounting Instructions

Secure mounting to roof or ground structure.

1. Attach rails: Secure mounting rails to roof rafters using brackets.
2. Place panels: Lift panels onto rails (two-person job).
3. Clamp panels: Use end and mid clamps to secure panels to rails.
4. Ground panels: Connect grounding lugs between panels and to grounding wire.
5. Check alignment: Ensure panels are evenly spaced and level.

Tip: Leave minimum 10mm gap between panels for thermal expansion.

Electrical Connection

Series or parallel configuration based on system design.

• Series Connection: Connect positive (+) of one panel to negative (-) of next. Increases voltage.
• Parallel Connection: Connect all positives together, all negatives together. Increases current.
• Combination: Series-parallel for optimal inverter matching.

Connection steps:

1. Connect MC4 connectors: Push until click (male to female).
2. Route cables: Use cable clips, avoid sharp edges.
3. Waterproof connections: Ensure seals are tight; use junction box for multiple strings.
4. Label cables: Mark positive and negative ends.

Inverter Connection

Connect solar array to inverter input.

1. Check voltage: Ensure array open-circuit voltage (Voc) is below inverter maximum.
2. Connect DC cables: Positive to inverter PV+, negative to PV-.
3. Install DC disconnect: Between array and inverter for safety.
4. Connect AC output: Inverter AC to grid/load via circuit breaker.
5. Ground inverter: Connect grounding terminal to earth ground.

WARNING! Polarity must be correct. Reversed polarity can damage inverter.

Commissioning & Testing

Final checks before system activation.

1. Visual inspection: Verify all connections are tight and waterproof.
2. Continuity test: Check for short circuits with multimeter.
3. Voltage test: Measure array voltage (should match calculated series/parallel sum).
4. Insulation test: Ensure no current leakage to ground.
5. Inverter startup: Follow manufacturer's power-up sequence.
6. Performance check: Monitor inverter display for power generation.

Note: Record initial readings for future reference.

Monitoring Setup

Connect monitoring device to track system performance.

1. Install monitoring module: Connect to inverter communication port.
2. Power module: Use provided power adapter or PoE.
3. Connect to network: Via Wi-Fi or Ethernet to router.
4. Register online: Create account on monitoring platform.
5. Pair device: Scan QR code or enter serial number.
6. Verify data: Check real-time power, energy, and alerts.

Tip: Set up email/SMS alerts for fault notifications.

Maintenance Guidelines

Regular maintenance ensures optimal performance.

• Monthly: Visual inspection for debris, bird droppings, or shading.
• Quarterly: Clean panels with water and soft brush (early morning).
• Biannual: Check cable connections, grounding, and mounting hardware.
• Annual: Professional inspection including thermal imaging.

CAUTION! Do not use abrasive cleaners or high-pressure water.

Technical Specifications

• Panel Type: Monocrystalline silicon
• Power Output: 400W, 450W, 500W, 550W models
• Efficiency: 20.5% - 22.3%
• Voltage: Voc 41.2V - 49.8V, Vmp 34.8V - 42.1V
• Current: Isc 10.8A - 12.5A, Imp 10.2A - 11.8A
• Dimensions: 1722×1134×35 mm (standard 550W)
• Weight: 22 kg per panel
• Temperature Range: -40°C to +85°C
• Warranty: 25-year linear power output, 12-year product

Troubleshooting

Support: 1-800-FLEXSOLAR; www.flexsolar.com/support

Emergency: In case of fire, use Class C extinguisher. Disconnect all power immediately.