SUNGROW

Installation Manual for G3 Floating System

 Operation Manual

Contents
1 About the Handbook ........................................................................................................................... 2
1.1 Preface ....................................................................................................................................... 2
1.2 Applicable products .................................................................................................................... 2
1.3 Brief introduction ...................................................................................................................... 2
1.4 Applicable personnel ................................................................................................................ 2
1.5 Use of the handbook ................................................................................................................... 2
2 Installation of Floating System Components ........................................................................................ 3
2.1 Safety precautions....................................................................................................................... 3
2.2 Product introduction.................................................................................................................... 3
2.3 Installation of double-glazed module on the main floating body ..................................................... 5
2.4 Installation of aluminum frame module on the main floating body .................................................. 8
2.5 Installation of connection between anchor truss and array edge floating body ................................ 12
2.6 Installation of combiner box bracket........................................................................................... 14
2.7 Installation of cable bracket and cable cover plate ....................................................................... 14
3 Conditions and limits of use ............................................................................................................... 17
4 Mounting instructions ....................................................................................................................... 18
4.1 Key points for a compliant installation ....................................................................................... 18
4.2 Mounting description: floats rows .............................................................................................. 18
4.2.1 Step1: Cap installation ......................................................................................................... 18
4.2.2 Step 2: Installation of the first row of aisle floating body ........................................................ 19
4.2.3 Step 3: Assembly of floats with connection pin...................................................................... 19
4.2.4 Step 4: Mounting the first row of main floating body (Floats without Panels)........................... 20
4.2.5 Step 5: Mounting another row of aisle floating body .............................................................. 21
4.2.6 PV panels mounting following the strings layout ................................................................... 23
4.2.7 Push the unit on to the water ................................................................................................ 24
4.3 Wiring and grounding............................................................................................................... 24
5 Weather conditions and work ............................................................................................................ 25
6 Appendices ........................................................................................................................................ 26
6.1 Quality assurance instructions .................................................................................................... 26
6.2 About Sungrow Floating Module ............................................................................................... 26

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1 About the Handbook

1.1 Preface
Dear customers: thank you very much for choosing Sungrow Floating System and its
accessories. We sincerely hope that this product can meet all your needs, and all your
constructive comments on the product performance and functions are welcome. We will
continue to improve, and constantly improve the quality of the products.
1.2 Applicable products
This manual is applicable for SUNGROW third generation floating system and its accessories.
The major types of accessories include:
Main floating body: SF-M3
Floating corridor: SF-A1
Connect floating body: SF-C1
Floating body of combiner box: SF-H1, SF-H3
Module mounting bracket
Cable bracket
Combiner box bracket
East-west anchoring structural parts
South-north anchoring structural parts
1.3 Brief introduction
The handbook mainly contains the following contents:
Safety Instructions
Precautions of floating system in installation and operation.
Installation and operation methods
It describes the assembly process of each parts of the floating system.
Description of Products
It describes the composition of floating system, the structure, characteristics and technical
characteristics of the main parts.
Others
It introduces the terms of quality assurance and our contact information.
1.4 Applicable personnel
This handbook is applicable to the personnel who carry out the installation, operation,
maintenance and other work of the floating system.
1.5 Use of the handbook
Please read this handbook carefully before using the floating system.
The content of the handbook and the pictures, logos, symbols, etc. contained in this handbook
is the property of Sungrow Power Supply Co., Ltd. The persons other than the employees of
the Company must not public reprint the whole or part of the content without written
authorization.

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In order to facilitate the user to read and use the handbook, a lot of pictures are provided in the handbook.
The pictures are only for illustration purposes. For specific details of the products, please refer to the
actual products received.

2 Installation of Floating System Components

2.1 Safety precautions
1. SUNGROW floating module and supporting products can adapt to the environments as
shown in the following table:

Allowable range of environmental factors

Temperature change °C -40~80

pH value pH value 4~10

Minimum water level m 0.5

Maximum water level m 20

Maximum wind velocity m/s 30

Maximum snow load KN/m2 0.8

2. Note: when the user uses the product in the environment beyond the parameters
specified in the table without the evaluation by our professional personnel, we will not
assume the quality assurance liabilities for the product problems arising therefrom.
2. Prohibition ordinance
(1) Refitting of our products or mixing products of different specifications and models is
prohibited.
(2) Direct contact between sharp objects with the surface of floating body is prohibited.
(3) Rough handling and high-altitude tossing is forbidden.
(4) It is prohibited to smoke, cut, weld or do other operation on the floating arrays that
may generate flame or mechanical damage.
2.2 Product introduction
1. Main floating body

Raw material HDPE

Max buoyance force(N) 1380

Weight 7.3±0.5kg

Dimensions（LｘWｘH） 1110ｘ880ｘ190mm

Manufacturing process Blow molding

Function For Supporting

2. Connection floating body

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Raw material HDPE

Max buoyance force(N) 860

Weight 6.3±0.5kg

Dimensions（LｘWｘH） 1212ｘ410ｘ205mm

Manufacturing process Blow molding

Function For Connection

3. Aisle floating body

Raw material HDPE

Max buoyance force(N) 600

Weight 3.8±0.5kg

Dimensions（LｘWｘH） 880ｘ410ｘ205mm

Manufacturing process Blow molding

Function For O&M

4. Mutli-function floating body

Raw material HDPE

Max buoyance force(N) 600

Weight 10.2±0.5kg

Dimensions（LｘWｘH） 1110ｘ880ｘ205mm

Manufacturing process Blow molding

Function For electrical connection

5. Connection pin

Raw material HDPE

Weight(pin) 105±5g

Weight(nut) 51±5g

Dimensions（LｘWｘH） ¢38ｘ155mm

Manufacturing process Injection

Function For connection between

floats

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2.3 Installation of double-glazed module on the main floating body

1. The front leg of the bracket is connected with the reserved bolt hole of the concave
supporting plate at the front end of the floating body by the wrench. Check and ensure the
reliable connection.

2. Similarly, the rear leg of the bracket is connected with the reserved bolt hole of the
concave supporting plate at the rear end of the floating body by the wrench. Check and
ensure the reliable connection.

3. Double-glazed module guide rail is connected with the front leg. The direction of the guide
rail should be checked against the illustration of the diagram to ensure reliable connection.
Similarly double-glazed guide rail is connected with the rear leg. The direction of the
guide rail should be checked against the illustration of the diagram to ensure reliable
connection.

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4. Screw one nut at one end of the tie rod (a nut is screwed to the proper position) to pull the
tie rod through the fixed hole reserved on the low position guide rail before pulling
through the tie rod hole reserved on the high guide rod. Screw one nut at the end of the tie
rod with the socket wrench until it is tightened, in order to ensure the tie rod is straightened
with the required tension. Rubber pads dedicated for double-glazed module shall be
mounted on both ends of the guide rail before insertion into the reserved groove reserved
on the guide rail.

5. Two persons simultaneously lift up the double-glazed module, so that the long side of the
double-glazed module is parallel to the guide rail, and the edge of the module is placed on
the rubber pad. Remember that the edges of the module imposed onto the rubber pad
should be in the same width.

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6. Use the double-glazed module block, slide from the end of the guide rail to the bolt hole
position, tighten the pressing block with bolts and press the double-glazed module.

7. Check the installation of all bolts and parts to ensure the correct and reliable installation of
each part. The double-glazed module and the bracket and connection of the floating body
are completed.

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Overall Diagram of Installation of Double-glazed module

8. Note: the wiring between modules is part of the electrical installation. Please refer to the
manufacturer’s installation instruction. The 4m2 wires between assemblies must be fixed
onto the floating body or bracket guide rail to prevent electric wires from falling into water.
The plastic galvanized wire band or plastic stainless steel band can be used for fixation,
and the bands must be provided by the Owner or the construction company.
2.4 Installation of aluminum frame module on the main floating body
1. Before installation, the central axis of the long side of the aluminum frame module is
drawn out. The jig positioning line should be mapped on the left and right, 210mm from
both sides of the central axis. As shown in the figure below:

2. The bolt hole of the front leg of the bracket is aligned with the reserved bolt hole of the
concave supporting plate in the floating body, and is fastened by bolts.

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Front leg of
the bracket

3. Erect the rear leg of the bracket with the same method.

Leg crimping
groove

Rear leg of the

bracket

4. Two persons lift up the aluminum frame module and put it onto top of the floating body
transversally, and the lower edge of aluminum frame is inserted into the crimping groove
of the front and rear legs. Meanwhile, ensure the positioning lines as described in Step 1
should be aligned with the inner side of the front and rear leg (ensure that module is not
inappropriately installed).

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5. After the module is adjusted, the lateral pressure block of the module is installed. Firstly,
the lateral pressure block at the lower part should be installed first (south side).

lateral pressure
block of module

6. And then, the lateral pressure block should be installed at the upper part of the module
(north side).

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lateral pressure
block of module

7. Complete the installation of the whole module, check the installation reliability of each
module, and the installation of aluminum frame module is completed.

Overall Diagram of Installation of Aluminum Frame Module

Note: the wiring between modules is part of the electrical installation. Please refer to the
manufacturer’s installation instructions. The 4 square wires between modules should be fixed onto
the floating body or the bracket guide rail to prevent the electric wires from falling into water.
Suggestions: the male plug wire of the module connecting wire is 1250mm long, female plug wire
is 1120mm long, and the male plug wire connects the cable-stayed part of two modules. The plastic
galvanized wire band or plastic stainless steel band can be used for fixation, and the bands must be
provided by the Owner or the construction company. We recommend specific installation as shown
below:

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2.5 Installation of connection between anchor truss and array edge floating
body
The east-west anchor truss and south-north anchor truss are installed basically in the same
manner. Here is the installation process of south-north anchor truss as an example.
1. After the floating array is installed, the position of the anchoring point should be found out
according to the requirements of the drawings.

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2. Place the anchor truss flatly onto the surface of the floating body and ensure the U-shaped
ring is towards the outward of the array, so that the bolt hole of the truss is aligned with the
lug position of the floating body. Steel casing should be added between the support bottom
board of the truss and lug of the floating body, and inserted downward into the lug bolt hole.

3. The steel casing and steel bolt should be inserted through from the lower part of the lug, so
that the steel bolt can get through three layers, lug, top steel casing – truss leg bottom board.
Lock with nuts, so that the truss is compressed with the lug.
4. Complete the connection of four truss angle legs with the lug of the floating body, and
check the installation reliability.

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5. Then, the installation of anchor truss is completed.

2.6 Installation of combiner box bracket
1. Installation of combiner box floating box (SF-H3) bracket with concave supporting plate
on the side.
2. During the installation process, find out the positioning floating body of the combiner box
(remember: during the installation process, the combiner box bracket is connected to the
floating body of the combiner box; otherwise, once the overall array is formed, it will
largely make the installation of combiner box bracket more difficult).
3. Align the leg bolt hole of U-shaped supporting on the combiner box bracket with the
reserved bolt hole on the concave supporting plate of the combiner box floating body. The
bolts (enlarged pad) get through the supporting plate and leg bolt hole, and tighten the
bolts with nuts (enlarged pad) at the upper part of the leg bottom plate.

4. Check the installation of U-shaped supporting to ensure the reliability.

5. Then, the installation work of combiner box bracket (the installation of combiner box is
described in the operation manual).
2.7 Installation of cable bracket and cable cover plate
1. I. Installation of floating box (SF-H3) cable bracket with concave supporting plate on the
side.
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2. In the array installation process, according to the requirements of the design drawings, find
out a floating body which should be equipped with the cable bracket. (Remember: when
installing the combiner box floating body, the cable bracket should be mounted onto the
combiner box floating body; otherwise, once an entire array is formed, the installation of
cable bracket will become more difficult).
3. Align the bolt hole of the cable leg with the reserved bolt hole on the concave supporting
plate of the floating body. The bolts (enlarged pad) get through the supporting plate and
leg bolt hole, and tighten the bolts with nuts (enlarged pad) at the upper part of the leg
bottom plate. Also install another cable leg in the same row.

4. Align the bolt holes on both ends of the first layer of cable supporting steel plate with thee
bolt holes of the cable leg, and tighten with bolts. Also install the second layer of cable
supporting steel plate.

5. Repeat Step 2 and Step 3 to complete the installation of another cable bracket.

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6. Mount the cable cover plate after the cables are laid.
7. Firstly, install the cable cover plate at the upper part of the combiner box floating body.
Put the cable cover plate onto the upper part of the floating body, so that the reserved bolt
hole is aligned with the reserved bolt hole at the side of the cable leg before connection
and fixation with bolts. The floating body cover plate of combiner box shall be completed
one by one.

8. After all cover plates are installed at the upper part of the floating body of two adjacent
combiner boxes, floating corridor cover plate should be mounted between two cover plates.
Firstly, the floating corridor cover plate is placed above the floating corridor, and the
reserved bolt hole should be aligned with that of the combiner box floating body cover
plate before being tightened with bolts.

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9. Repeat the above steps until the entire cable bracket and cover plate is completely installed.

3 Conditions and limits of use

Floating system of Sungrow Floating is designed to resist the following conditions:
 Waves: up to 0.9m.
 Ambient temperature: between -40℃and 85℃.
 Snow load: limited to 1.0KN/m2.
 Wind velocity: limited to 60m/s.
Warning: If the Floating system is not properly constructed, it may not withstand the
conditions listed above and the entire floating solar plant may be damaged!

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4 Mounting instructions
4.1 Key points for a compliant installation
 The solar island shall be built following the designs and specifications of Sungrow Floating

 Comply with the connection Tabs/Ears order of alignment

 Check that PV panels have not shifted and are correctly fixed

 Check that all the float caps are correctly installed and tightened

4.2 Mounting description: floats rows

Recommendations:

 The floating system should be installed on a flat mounting platform.

 We recommend dividing the power plant into smaller units in order to simplify the construction.
The small units are assembled separately on the mounting platform and then linked together while
on the water .

 The mounting platform should be long enough for at least the length of a full string of panels.
This way it is easier to install the cables on the platform.

 Make sure you don’t assemble too many strings at once on the platform, it will be difficult to pull
the island on the water.

 We recommend to build as much as possible on the bank and not on the water.

4.2.1 Step1: Cap installation

The cap needs to be completely screwed-in and checked before pushing the floats onto water,
otherwise the water tightness and buoyancy of the float is compromised. These caps must be
screwed-in using a torque wrench (as shown on the below picture), to ensure that the cap is
completely and correctly tightened and marked.

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4.2.2 Step 2: Installation of the first row of aisle floating body

The aim of this step is to install a complete row of aisle floating body. The caps of the floats shall
always be oriented to the left. Moreover, it is important that the ears are fitted correctly. When the
floats are laid on a flat ground, the ears will fit together perfectly. The left and right ears of the
aisle floating body are not at the same height. The height difference between the ears of the
left float and the right one in the vertical direction is 36mm. The thickness of ears of floating
body is 18mm. We recommend starting with the row’s rightmost float.

Caps orientated to the left Ears of the left float go on top of

the ears of the right one.

4.2.3 Step 3: Assembly of floats with connection pin

The connection pins should be fastened-in on the side of the row which corresponds to the external
side of the unit.

Connection pins

The operator shall repeat this process until they have completed a full row of aisle floating body,
following the working drawings of the solar island they have to mount.

When connecting this first row of aisle floating body, there are two mounting options for
connection pins:

•  Three superimposed ears

•  Only two superimposed ears

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* The color difference on the secondary floats gives a better understanding (SSF
and SLF). In reality, the floats have the same color.

For both options, the mounting technique is the same. After installing the pins, the order of all the
floats’ ears shall be checked.

Step 1: Connection pin positioning Step 2: Connection pin plugging

The pin is first placed under the ears, The pin is inserted into the hole until

aligned with the holes. the pin head reaches the lower ear.

Step 3: Nut positioning Step 4: Nut tightening

Once the pin is correctly plugged into The nut is tightened until it reaches

the hole, the nut is screwed on top. the upper ear.

4.2.4 Step 4: Mounting the first row of main floating body (Floats without
Panels)
Once the row of aisle floating body is assembled, the operator is able to mount the corresponding
row of main floating body and connect it on the aisle floating body row, on the side without
connection pins. First, the operator puts a main floating body in front of the aisle floating body and
fixes it using two connection pins. The ears of the main floating body shall be between the two
ears of the adjacent aisle floating body.
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Top of the main floating body

Connection pins inserted

The ears of the main floating body
between the ears of aisle floating body .

Bottom of the main floating

body

Using the same method, the operator can add other main floating body and fix them with
connection pins.

This method is repeated in order to complete the row.

4.2.5 Step 5: Mounting another row of aisle floating body

After having completed the first row of aisle floating body and the first row of main floating body,
the operator shall mount the second row of aisle floating body, but this step may be slightly
different from step 2 due to the solar island design.
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First, an aisle floating body is placed in front of the first main floating body of its row, and is fixed
thanks to a connection pin.

Connection pins inserted

Ears of the main floating body
between the two ears of the
aisle floating body .

Another aisle floating body can be then mounted and fixed with 2 connection pins.

The operator can then complete the row following the working drawings, provided showing the
solar island’s design. It is really important to follow the instructions of these drawings, as aisle
floating body are not needed in some places (but they can be installed to make a good maintenance
path).

No need of aisle floating body

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The operator completes the row as illustrated on the solar island design working drawings, and the
row’s last float is locked using a connection pin.

4.2.6 PV panels mounting following the strings layout

In order to facilitate the PV panel mounting, PV panels shall be mounted following the strings’
layout. The installation process is the same whether there is a panel on the float or not. When there
is a PV panel on it, the first float (with panel on it) of the row shall be installed, then the second one
just next to the first one, and then the 2 PV panels can be connected to one another via MC4
connectors (or equivalent). It is easier to unwind the DC feedback cable at the same time.

The same process is repeated with all the PV panels of this row, in order to finish the first string.

The example below shows a string of 8 panels. On the outsides of the island or sometimes in the
middle, some floats are installed without panels, depending on the island design.

Then previous steps can be repeated to get all complete rows of PV panels (or a few rows,
depending on the mounting area or the size of the unit).

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4.2.7 Push the unit on to the water

Every two or three rows, you will have to push the unit onto water to be able to build the next rows.

Once you have completed enough strings, the unit shall be pushed onto water and then towed from
the mounting platform to its final location.

To do so, we recommend using a boat(s) and ropes. It can be difficult to tow a unit if you are
against the wind. The location of the mounting platform should be selected correctly in order to
avoid this problem. As well, we do not recommend to tow a unit in case of extreme winds.

4.3 Wiring and grounding

Please refer to your country recommendations and standards for the cables sizing and grounding
method.

We recommend using cables ties or wire management clips to secure the cables or to protect them
to avoid any contact with the water.

The openings between the panels and main floats have been designed to allow of the good
management of DC string and grounding cables.

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The main DC cables shall be water resistant or be protected with cables conduits.

The cables can be installed on floating pontoon or float by themselves using plastic conduits.

Be careful with the weight of the cables, make sure that the island’s buoyancy is sufficient.

5 Weather conditions and work

The contractor must consider the local codes regarding outside construction. In addition, some
weather conditions are not suitable for the installation and maintenance of the floating PV plant.

1. Thunderstorms

Lightning makes it highly dangerous for the operator to connect electric cables during
thunderstorms.

2. High Wind Speed and Waves

When the wind speed is higher than 40 km/h (25 mph), it will to be difficult to carry and install the
panels. The wind will also generate waves on the water surface; walking on the solar island near to
the water becomes difficult, or even dangerous.

3. Temperature

When temperatures drop below -5°C (23°F), installation and maintenance have to be avoided.
The lake could have a frozen layer of ice which will obstruct the construction site.

4. Snow and Hail

When there is snowfall or hail, it is not possible to carry out installation or maintenance activities.

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6 Appendices
6.1 Quality assurance instructions
Any defective product during the quality assurance period will be repaired or replaced free of
charge by Huainan Sungrow Floating Module Sci. & Tech. Co., Ltd. (hereinafter referred to as
the Company).
Evidence
In the warranty period, the Company requires customers to present the purchase invoices. At
the same time, the label on the product shall be clearly visible, or the quality assurance may not
be granted.
Condition
• The replaced nonconforming products shall be disposed of by the Company.
• Customers should grant reasonably adequate time to the Company for repairing faulty
equipment.
Immunity from liabilities
The Company has the right to reject to provide quality assurance in any of the following
circumstances:
• The whole unit and components have been beyond the warranty period.
• Damage to goods in the secondary handling and storage after the receipt and acceptance
• Incorrect installation, modification or use
• Operating in a harsh environment beyond the conditions described in this handbook
• Damage caused by abnormal natural environment
• Whole system injury caused by force majeure factors
• Damage to floating body caused by design defect of floating power plant system
Where customers request maintenance and services for product failure caused by the above
situation, after the determination by the Company’s service agent, the maintenance services can
be provided for value.
In order to continuously improve customer satisfaction, the Company's products and product
manuals are in continuous improvement and upgrading. In case of any difference between the
handbook and the product, the version is to blame, and the specific product shall prevail. In
case of any doubt, please contact the Company.
6.2 About Sungrow Floating Module
If you have any questions about this product, please get in touch with us. Please remember the
following contact information:

Name HuainanSungrow Floating Module Sci. & Tech. Co., Ltd.

Address No.1688, Xiyou Road, Hefei Hi-tech Zone, Hefei, Anhui Province

Post code 230088

Sales hotline 0551-65327879

After-sale service 400-880-5578

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hotline:

Website www.sungrowpower.com

Sales@sungrowpower.com (sales)
Mailbox
Service@sungrow.com (after-sales service)

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