Mounting Instructions

ManualsBrandsSunman ManualsNew Products!EArc 2 x 175W Flexible Solar Panel

FLEXIBLE SOLAR PANEL MOUNTING INSTRUCTION GUIDE

Please read this document in full before commencing installation.

To maximise the efficiency and longevity of your new solar panels, please ensure you follow the

instructions in this guide carefully. Failure to do so WILL result in shortened panel lifespan AND void

your warranty.

While it seems simple to mount a flexible solar panel, common installations such as sealing around

the edges of the solar panel and direct adhesion of the solar panel to a surface using Sikaflex and

most other adhesives WILL damage the solar panel AND void your warranty, please continue reading

the guide for more details.

Whilst due care has been taken to ensure these methods provide a secure and permanent mounting

connection, we cannot guarantee these methods will be suitable in every scenario due to variations in

substrate materials, environment, and installation technique. It is the duty of the purchaser to

regularly inspect and maintain the solar panel installation.

It is normal for solar panels to heat up to above 85°C in operation or higher in fault conditions. In

some cases, this can damage the substrate. The vented gap kit is recommended to avoid this.

Exotronic will not be liable for any damage to the substrate the panels are installed onto.

If you need clarification on any of the instructions, please contact your distributor.

Summary of content (19 pages)

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FLEXIBLE SOLAR PANEL MOUNTING INSTRUCTION GUIDE Please read this document in full before commencing installation. To maximise the efficiency and longevity of your new solar panels, please ensure you follow the instructions in this guide carefully. Failure to do so WILL result in shortened panel lifespan AND void your warranty.
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Contents Protecting the panels during installation ...................................................................................... 3 Safety .......................................................................................................................................... 3 Panel Curvature (Flexibility) ......................................................................................................... 3 Handling the Panel ...................................................................
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Protecting the panels during installation IMPORTANT: • All work should be carried out in shade or inside out of direct sunlight. Use a towel or blanket on top of the panel to reduce light exposure; • Do not install the panels in windy or gusty conditions.
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Longitudinal axis The longitudinal bend can be convex as shown below. ü Transverse axis The image below shows a panel with multiple radii with all axis of rotation having the same direction, i.e. transverse with respect to the panel.
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Panels cannot accommodate multiple radii with different directions without being stressed. For example, a longitudinal bend and a transverse bend.
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INSTALLATION ONTO A RIGID SURFACE If mounting your panel(s) onto a rigid surface such as a RV roof, you will need to take into consideration the thermal expansion and contraction of both the panel, the surface it’s being mounted to and the product used to adhere the two together. It is unlikely both the panel and surface will expand and contract at the same rate, therefore an adhesive with some ‘give’ will be required to absorb the difference.
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STEP 1 Clean and degrease the surface area To ensure proper adhesion, all surfaces (mounting surface, back of panel and strips if being used) must be cleaned and degreased. Not doing so will weaken the bond and can cause the bond to fail. • • • Clean the surfaces with slightly soapy water to remove excess grime/dirt. Check the surface for any loose paint or blemishes, if required rub the mounting surface with a fine or medium grit emery.
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STEP 3 Mount the panels using one of the following methods Method 1 – Vented Gap Kit (Sunman eArc panels ONLY) The Vented Gap Kit is available exclusively from Exotronic and consists of pre-cut strips of twin-wall polycarbonate sheeting & VHB Tape. How To: Lay the panel face down on a soft surface (carpet, towel, etc.) and then line the strips into position.
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Bottom of panel (regardless of junction box position). Side view of panel with panel, showing double strips at top. If your panel has the Junction Box on Top - Apply double-sided acrylic high bond foam tape to both sides of the strips and attach to the panel (leave the top layer of red plastic intact for now). Finger pressure must be used to push the tape into the surface to make sure that it has sufficient grip on the surface for adequate bond strength.
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Double layer of tape. Once the strips are attached to the panel, proceed to carefully lay the panel into position and remove the red plastic layer. Gently apply pressure in between the cells, along the strips, ideally with a roller. Ensure you do not apply excessive force or push on the cells where there is no strip behind as this will damage the cell. Wait time of tape to full strength: 20 minutes – 50% strength 1 hour – 75% strength 1 day – 90% strength 3 days – 100% strength Method 2 – Exotronic 2.
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Method 5 – Bi-Adhesive Backing Bi-Adhesive backing is available for purchase with your panels. This method is required if you plan to walk on your panel (please read Walking on the panels for greater detail). This method is an easy ‘peel and stick’ method, however, be mindful not to over-flex the panel in the process.
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The bond area of the roof should be well drained, i.e. panels should not be bonded where water can puddle. Any droops in the surface should be fixed first. Other textured surfaces may not be suitable for tape and require the use of this method.
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INSTALLATION ONTO CANVAS Panels can be attached to canvas providing the following guidelines are carefully adhered to: • • • • • • • • • • The canvas must provide continuous support to the panel Shallow radius, i.e. do not bend panel excessively The panel is not laid over irregularities such as structural elements, e.g. ridges/beams/tubes. These will result in the panel creasing over the structure causing premature failure.
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Method 2 – Velcro (hook & loop) Velcro must be attached under and over the panel so that the panel is in the “middle of a Velcro sandwich”. Velcro is not recommended as on removal of the panel, excessive force may damage the cells compared to Zips where to force is put onto the cells during removal. Method 3 – 3M Dual Lock Dual lock can be used as an alternative to Velcro using the same instructions. Method 4 - Loxx Fasteners Loxx fasteners can be used to attach panels to canvas or other material.
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Method 5 – Eyelets Exotronic can punch stainless steel eyelets into the panel at various intervals (please advise at time of purchase) along the panel. Rope or similar material can then be used to tie the panel down to a supported surface. Enough eyelets must be attached alongside each panel edge to fully support the panel. The size of panel will determine the adequate number of eyelets. Speak to our technicians to confirm based on the panel you’ve purchased. Combination of eyelets & Rope.
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Example of good installs ü Panels are well supported by the canvas over the entire back surface of the panel ü Panels are well clear of the transverse beams ü Slight bending of panel in one axis ü Similar sun strength on all cells and panels as curvature is slight ü Cables are not applying any lifting, shear or twisting force on the junction box, i.e. ü cables are laid neatly, level and are gently radiused.
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ü Custom pocket houses a polycarbonate enclosure containing 3 fuses ü Underside location avoids rain/seawater directly on the IP67 solar connectors ü Panels can be easily removed as connectors are used Example of bad installs  Panels have an obvious crease which will cause stress on the cells  Plastic cover over panels traps excess heat and moisture © Exotronic, 2022 - not to be used or distributed without permission Page 17 of 19
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In this example, the bending over the tube lead to fracturing of the cells and produced a hot spot within months of installation.
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 Panels have an obvious crease which will cause stress on the cells  Panels are flexing in multiple directions causing increased stress on the cells Walking on the panels (Solbian anti-slip panels ONLY) Solbian anti-slip surface panels are the only panels sold by Exotronic that allow the panel to be walked on, provided they are installed in the following manner: • • using bi-adhesive backing; onto flat, smooth, continuous surface (no bumps, hollows or irregularities).