Packaging for Returns

Stack and pack the modules according to these instructions.

Don’t forget to label the package with the pictograms, affix the stacking protection pyramid, and, for return shipments, attach the return slip.

Materials Needed: Pallet , stacking corners, cardboard liner, stacking discs, edge protectors, strapping bands, cover film, stretch film, packing tape, stacking protection pyramid

Compatible pallets and stacking corners

Pallet:
Use the original Solarwatt pallets appropriate for the module type. These ensure sufficient stability and size to support the weight of the module stack and prevent damage to the modules!

Cardboard pad, 1 piece, flush with the pallet:
Cardboard pad (corrugated cardboard, max. 2-flute; solid cardboard) that prevents direct contact with the wooden pallet and thus prevents scratching of the module frames. A full-surface pad is preferred to prevent the bottom-most module from getting dirty!

Stacking corners, 4 per module, except for end modules:
Color and shape may vary.

Use only corners with no visible prior damage! Use Solarwatt stacking corners; they ensure that the modules do not slip on the pallet.

Foam rubber spacers, 6 per module (4 for SOLARWATT Panel vision GM 3.0), except for end modules:
Elastic, compressible cellular rubber with a minimum thickness of 3 mm (uncompressed), secured by gluing to the frame component, with a minimum surface area of 25x25 mm

Edge protectors, placed under lashing straps on the end module, 8 pieces per package (example shown):
Edge protectors made of plastic or cardboard; edge protector brackets must not extend beyond the base dimensions of the pallet.

Strapping Bands / Strapping Tape, 4 pieces, including corner protectors:
Tensile strength: approx. 400 kg, elongation 15%, recovery 95%

When using other lashing systems, the strength requirement must be met, if necessary by using additional straps (6 instead of 4).

Possible materials: Brühninghaus polyester strapping 12.5x0.7; Kempack PET strapping 12.5x0.7; 15.5x0.7 and larger; Kempack KEMAtex, 16 mm wide)

Or alternative straps: Tension straps with metal ratchets and protective mats, 4 pieces, including fasteners and protective pads

Covering film (PET, PE), 1 piece (approx. 30 cm all around, larger than the module)

Stretch film (PE): When using 25 µm PE film, approximately 35 wraps around the module stack are required for 30 solar panels; for thinner film, a correspondingly higher number of wraps is needed.

Material requirements: PE stretch film; the number of wraps required depends on the film thickness; nominal thickness 25 µm.

Packing tape with pictograms (available from Solarwatt)

Alternatively:

Labeling on 2 sides with the following pictograms:

1. Do not stack!
2. This side up!
3. Protect from moisture!
4. Caution: Fragile!
5. Do not tip!

Stacking Protection Pyramid

• Check the pallet for damage.
• Place the pallet on a stable, level surface (ensure there is sufficient space for removal).
• Place the appropriate cardboard cutout on the pallet.

• Place the module with its front side (sun side) facing the pallet on the cardboard: Make sure to leave an even, all-around border!
• Attach the stacking corners:
  EckPack stacking corners: First, attach 4 pieces to the sides and snap them into place on the back of the module.
  QuickStaxx stacking corners: Place 4 pieces on each of the module corners.
• Attach 6 foam rubber stacking washers per module (4 pieces for SOLARWATT Panel vision GM 3.0) according to the distribution diagram (2 pieces per side on the long sides, 1 piece per side on the short sides).

Maximum stacking height per module type (see table) Please note!

• Place the top module (end module) on the stack with the front side facing up.

• Securing Stacks of Modules

Option 1: Secure with PET strapping (see packaging materials) using a strapping tool

• Apply corner protectors: 2 per corner, or as many as the number of straps used

• Attach 2 straps along the long side and 2 straps along the short side, running vertically upward right next to the outer blocks of the pallet.
• The tension must be adjusted so that the strap is tight but does not damage the solar panels (approx. 2000 N).

When using heat-sealed straps: The area where the two sides of the strap are heat-sealed together must not be less than 90% of the strap’s width. This is achieved by loading the PET strapping into the strapping tool so that the two sides align perfectly.

Option 2: Securing with a ratchet strap

• Apply corner protectors: 2 pieces at each corner, or as many as the number of tie-downs used

• Attach 2 straps across the long side and 2 straps across the short side, running vertically upward right next to the outer blocks of the pallet.
• The ratchet fastener is located on the top of the uppermost module.

We recommend wrapping the secured package in stretch film and using a protective cover. It is absolutely necessary to label it with the following pictograms

Do not stack!

Place on top!

Protect from moisture!

Caution: Fragile!

Do not tip!

The labeling may be printed on the packing tape used or displayed on at least two sides of the package in the form of clearly visible pictograms. To do this, print out the pictogram sheet (LINK!) twice .

• Wrap the stack of modules tightly with stretch film: for 30 modules, use about 35 wraps. If there are fewer modules, use a corresponding number of wraps.

• Position the bottom edge of the film approximately 5–7 cm below the top edge of the pallet.
• Wrap the film up to about 10 cm above the top edge of the last module.
• Secure the cover sheet to the stretch film with packing tape.

• Mark the package on the sides with the required pictograms.
• Affix the stacking protection pyramid.