Joule Navitas In-roof Installation Manual

The Joule Navitas In-roof system is a premium integrated solar panel solution designed for seamless roof integration, featuring high-efficiency monocrystalline cells, waterproof flashing system, aluminum alloy frame, integrated cable management, and compatibility with standard mounting rails. Below are key sections for safety, components, installation steps, electrical connections, commissioning, and maintenance.

System Overview & Components

Key components: Navitas solar panels, integrated flashing kits, mounting brackets, cable harnesses, junction boxes, and sealant.

Safety Precautions

Always prioritize safety during installation.

1. Use proper fall protection: Harness, anchor points, and guardrails required.
2. Electrical safety: Disconnect all power sources before wiring; use insulated tools.
3. Weather conditions: Do not install during rain, snow, or high winds.
4. Personal protective equipment: Wear gloves, safety glasses, and non-slip footwear.
5. Roof integrity: Verify roof structure can support system weight (≥25kg/m²).

WARNING! Solar panels generate DC voltage when exposed to light. Cover panels during electrical work. Never work on wet surfaces.

Pre-Installation Checklist

Complete these steps before beginning installation.

1. Verify delivery: Check all components against packing list.
2. Roof inspection: Ensure roof deck is sound, dry, and clean.
3. Measurements: Confirm roof dimensions and panel layout.
4. Tool preparation: Have drill, torque wrench, sealant gun, multimeter ready.
5. Permits: Ensure local building and electrical permits are obtained.

CAUTION! Only qualified installers should perform installation. Check local regulations.

Roof Preparation

• Roof Type: Compatible with tile, metal, and asphalt shingle roofs.
• Flashing Placement: Position flashing under existing roofing material.
• Rail Alignment: Install rails parallel to roof ridge with ≤1° deviation.
• Penetration Sealing: Apply sealant around all roof penetrations.
• Water Drainage: Ensure integrated drainage channels are clear.
• Spacing: Maintain 10mm gap between panels for thermal expansion.
• Roof Pitch: Minimum 15° for optimal water runoff.
• Load Capacity: Verify roof structure meets 1.5x system weight safety factor.

Panel Installation

Install panels according to layout plan.

Step-by-step:

1. Position flashing: Slide under existing roof layer, secure with screws.
2. Mount rails: Attach to roof structure through flashing using brackets.
3. Install panels: Lift panel onto rails, secure with mid clamps (torque: 15-20 Nm).
4. Connect cables: Route cables through integrated channels, connect MC4 connectors.
5. Ground system: Attach grounding lugs to each panel frame and rail.
6. Final check: Verify all clamps are tight, cables are secure.

Tip: Use two installers for panel handling. Never step on panels.

Electrical Wiring

Follow electrical codes and manufacturer guidelines.

1. String configuration: Connect panels in series (check inverter specifications).
2. Cable management: Route cables through designated channels, secure with clips.
3. Junction boxes: Connect strings to junction boxes, ensure IP67 seals are tight.
4. DC isolator: Install DC isolator within 1m of array (readily accessible).
5. Inverter connection: Connect DC cables to inverter, observing polarity.
6. Testing: Use multimeter to verify open-circuit voltage and short-circuit current.

WARNING! DC voltages can exceed 600V. Use appropriate PPE and follow lock-out/tag-out procedures.

Waterproofing & Sealing

Ensure complete waterproof integrity.

1. Flashing seals: Verify butyl rubber seals are compressed evenly.
2. Penetration points: Apply polyurethane sealant around all screw penetrations.
3. Panel edges: Check drainage channels are unobstructed.
4. Roof interface: Ensure flashing overlaps existing roofing by ≥100mm.
5. Final inspection: Conduct water test with hose (low pressure) after installation.

CAUTION! Improper sealing can cause roof leaks. Follow sealing instructions precisely.

System Commissioning

Final checks before system activation.

1. Visual inspection: Verify all components are properly installed and secured.
2. Electrical tests: Measure insulation resistance (>1MΩ) and continuity.
3. Inverter setup: Configure inverter parameters per system design.
4. Grid connection: Have utility representative verify connection (if required).
5. Monitoring: Activate monitoring system, verify data transmission.
6. Documentation: Complete installation certificate, provide to customer.

Maintenance Guidelines

Regular maintenance ensures optimal performance.

Quarterly: Inspect for debris, clean panels with water and soft brush. Annually: Check electrical connections, sealant condition, and mounting hardware torque. After severe weather: Inspect for damage.

CAUTION! Do not use abrasive cleaners or high-pressure water. Disconnect system before maintenance.

Troubleshooting

Reset: Inverter may need reset after fault clearance.

Support: Contact Joule Technical Support: 1-800-555-NAVITAS; www.joulesolar.com/navitas-support

Technical Specifications

• Panel Type: Monocrystalline silicon, 144 cells
• Rated Power: 400W (STC)
• Dimensions: 1756 × 1038 × 35 mm
• Weight: 22.5 kg
• Frame: Anodized aluminum alloy
• Max System Voltage: 1000V DC
• Operating Temperature: -40°C to +85°C
• Power Tolerance: 0 to +5W
• Warranty: 25 years linear power output, 10 years product
• Fire Rating: Class A
• Wind Load: Up to 2400 Pa
• Snow Load: Up to 5400 Pa