Aiksolar Aiko Energy PV Module Instruction Manual
- June 12, 2024
- Aiksolar
Table of Contents
Aiksolar Aiko Energy PV Module
Product Information
The Aiko Energy PV module is a solar power module produced by Shenzhen Aiko Digital Energy Technology Co., Ltd. It is designed for electrical and mechanical installation to generate solar energy. The module is made with a single glass structure, ensuring durability and efficiency in converting sunlight into electricity.
The product is available in various models, including:
- AIKO-Pxxx-MAH72Mw
- AIKO-Pxxx-MAH72Mb
- AIKO-Pxxx-MAH54Mw
- AIKO-Pxxx-MAH54Mb
- AIKO-Axxx-MAH72Mw
- AIKO-Axxx-MAH72Mb
- AIKO-Axxx-MAH54Mw
- AIKO-Bxxx-MAH72Mw
- AIKO-Axxx-MAH54Mb
- AIKO-Bxxx-MAH72Mb
- AIKO-Bxxx-MAH54Mw
- AIKO-Bxxx-MAH54Mb
Product Usage Instructions
Important Safety Instructions
Please read and follow the safety precautions specified in this Installation Manual and adhere to local laws before installing and maintaining the Aiko Energy PV module. Only qualified individuals with specialized skills and knowledge should perform the installation and maintenance tasks. Keep this Manual for future reference.
Installation Conditions
Prior to installation, consider the following conditions:
- Location and working environment: Choose an appropriate location for the module installation, considering factors such as sunlight exposure and shading. Ensure the working environment meets safety requirements.
- Tilt angle selection: Select the optimal tilt angle for the module based on the installation location and desired energy output.
Mechanical Installation
Follow these steps for mechanical installation of the single glass modules:
- Ensure general requirements for installation are met.
- Securely install the single glass modules using suitable mounting systems.
Electrical Installation
Perform the following steps for electrical installation:
- Understand the electrical performance requirements of the module.
- Select appropriate cables and make proper connections.
- Use suitable connectors for electrical connections.
Grounding
Proper grounding of the PV module system is essential for safety. Follow the provided grounding instructions to ensure proper installation.
Maintenance of PV Modules
To ensure optimal performance and longevity of the PV modules, perform the following maintenance tasks:
- Clean the modules regularly according to the cleaning instructions.
- Conduct visual checks of the modules to identify any damage or abnormalities.
- Inspect connectors and cables for proper functioning.
Please note that this is a summarized version of the product user manual. For detailed information and specific instructions, refer to the complete Aiko Energy PV module Installation Manual available on the official website: http://www.aikosolar.com/
Aiko Energy PV module Installation Manual
Aiko Energy reserves the right to change this Manual without
prior notice.
Please check the latest version of the Installation Manual on the official
website of Aiko Energy.
Website: http://www.aikosolar.com/
Important safety instructions
- This Installation Manual provides information regarding the installation and safe use of PV power modules (“modules”) produced by Shenzhen Aiko Digital Energy Technology Co., Ltd.(“Aiko Energy”). Installation and day-to-day maintenance of modules shall be in accor-dance with all safety precautions specified in this Manual and local laws.
- Installing module systems requires specialized skills and knowledge, and modules shall be installed and maintained by qualified persons. The installers shall be familiar with the mechanical and electrical requirements of the system. Please keep this Manual for future maintenance or treatment.
Overview
Thank you very much for choosing the products of Aiko Energy. This
Installation Manual con-tains important information regarding electrical and
mechanical installation which you shall know before installing modules. It
also contains some other safety information that you must be familiar with.
This Installation Manual is not intended as any warranty, expressed or
implied. Nor does it in-clude any indemnification plan against loss, module
damage or other expenses directly arising out of or in connection with the
installation, operation, use or maintenance of modules. No responsibility will
be assumed by Aiko Energy for any infringement of patents or other rights of
third parties which may result from the use of PV modules. Aiko Energy
reserves the right to make revisions to the product specification and this
Installation Manual without prior notice. Aiko Energy reserves the right to
make revisions to the product specification and this Installation Manual
without prior notice.
The customer’s failure to install modules according to the requirements listed
in this Installation Manual will invalidate the limited product warranty
offered to the customer. Recommendations in this Manual are provided to
improve installation safety, and are based on tests and practical experience.
Please provide this Manual to end customers (or consumers) and inform them of
all safety, operation and maintenance requirements and recommendations.
Laws and acts
Mechanical and electrical installations of PV modules shall be executed by referring to the ap-plicable laws and acts, including the electrical act, building act and electrical connection require-ments. These requirements vary from one location to another, such as building rooftop installations and onboard applications. They may also vary with mounting system voltage and current property (DC or AC). Please contact your local authority for further details.
General information
Disclaimer
Aiko Energy reserves the right to change this Manual without prior notice.
This Installation Manual is not a warranty and does not carry the meaning of
any warranty.
Failure to follow the requirements listed in this manual during the operation
of the modules (in-cluding but not limited to product unpackaging/packaging,
loading/unloading, transportation, storage, installation, use, operation or
maintenance, etc.) will result in the product limited warranty void. Aiko
Energy shall not be liable for any loss caused by any improper operation or
fail-ure of the customer to follow the instructions in this Manual, including
but not limited to any product damage, personal injury or other property
damage caused by the failure to follow the in-structions in this Manual during
the operation of the modules.
Module identification
Aiko Energy modules provide two visual labels:
Nameplate
Product type, information regarding the rated power, rated current, rated
voltage, open circuit voltage, short circuit current, certification mark,
maximum system volt-age under standard test conditions (STC).
Serial number
Each individual module is identified with a unique serial number which is
printed on the barcode and placed into the module before lamination such that
it cannot be torn or daubed after lamination. The same serial number can also
be found elsewhere on the module.
Module color
To ensure color consistency when the modules are used by customer, the box of
modules is packed by color by marking the modules with S1, S2, S3, A, or B on
the shipping mark of the box of modules.
Wiring method
The junction box of Aiko Energy modules is located in the middle position. Please refer to the table below for how to connect Aiko Energy modules in series.
General safety
Aiko Energy modules are designed to operate in application to class A according to IEC standards IEC-61215 and IEC-61730. Modules can be used in publicly accessible systems with DC voltage greater than 50 V or power greater than 240 W. Modules are designed with safety class II and fire class rating C.
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Always use appropriate protections such as insulated tools, safety helmets, insulating gloves, safety belts and safety insulating shoes when handling the module whether it is or not connected to the system. Please use the appropriate electrical safety tools when you need to install, ground, connect, clean or otherwise handle the module.
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PV modules will generate direct current while exposed to sunlight whether or not it is connected to the elec-trical system. Touching the live parts of the module (e.g., connectors) can result in casualties. Be sure to avoid direct contact with the module to avoid electrical shock or cut.
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Observe local laws and regulations at the location for module installation and obtain a building license or other qualifications where necessary.
Modules shall be installed by qualified persons who have specialized skills and knowledge and are familiar with the mechanical and electrical requirements of the system. Potentially harmful risks during installation, including electrical shock and cut, shall be identified in advance. -
Rooftop systems can only be installed on roofs having passed the evaluation of construction experts with formal, full structural analysis results.
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Observe the safety rules for all mounting components. For example, wires and cables, connectors, charging controllers, inverters and batteries shall only be installed using equipment, connectors, wires and racks matching with the solar power system. If the PV system is equipped with a battery, the battery manufacturer’s advice shall be followed.
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Only components of the same size and model can be connected together.
Electrical safety
Please strictly follow the electrical safety precautions below to avoid any form of electrical safety accident.
- Do not install or handle modules in periods of humidity or high winds.
- Modules can generate DC voltage exceeding 30 V. Take care to avoid direct contact. Make sure that the connecting cable is secured to the support frame for mounting modules.
- Cables must be protected in conduits in areas where they are accessible by animals or children.
- Do not artificially modify or remove any parts or labels from the module.
- Do not install modules without safety protections.
- Do not make electrical connection by means other than connectors.
- Broken modules have the risk of electric shock and fire and must be replaced immediately.
- Module arrays shall be installed when it is electrically safe to do so.
- During installation, the voltage of modules connected in series shall not exceed the maximum system voltage.
- Do not mate connectors from different manufacturers or of different models.
- Do not use conventional modules as a substitute for roof or wall materials.
- Do not connect or disconnect the module when there is current in the module or when an external current is present.
- Do not coat module surfaces with corrosive chemicals.
- Do not access modules while they are wet.
Handling safety
Standing, stepping, sitting, walking or jumping directly on the module package
or module is prohibited.
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Do not pile heavy objects on the module.
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Do not connect the positive and negative anode cables of the same PV module together; Do not open the packing box before the modules arrive at the location.
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Keep the packing box in a ventilated, dry environment. Be sure to avoid exposing modules to major vibration in all handling processes. Inappropriate handling and placement can result in breakage of glass or loss of electrical property, consequently the use value of the modules.
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Do not step, stand or sit on modules. This will damage the module and potentially cause injury.
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Do not place any heavy objects on the front or back of the module. Do not place the module on the surface of a sharp object.
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Do not attempt to dissemble the module, and do not remove any attached nameplates or components from the module.
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Do not apply paint or other adhesives to module top surface.
Avoid scratching the back cover or glass surface of the module. -
Do not drill holes on the module frame. This will lead to degraded frame load handling capaci-ties and frame corrosion, which will invalidate the limited warranty of the module.
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Do not scratch the anodized layer on the surface of the aluminum alloy frame. Scratching will lead to frame corrosion and deteriorate the load handling capacities and long-term reliability of the frame.
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Do not repair or modify the module by yourself.
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Accessible PV module surfaces shall be smooth and free of sharp edges or burrs.
Fire safety
- Please refer to local laws and regulations before installing any module and observe their building fire safety requirements.
- Rooftop installations shall be placed over fire-resistant roof coverings appropriate for this rating, and adequate ventilation shall be provided between the back cover and the mounting surface. The roof structure and module mounting method will affect the fire safety performance of the building. Inappropriate installation can lead to fire risks.
- To guarantee the fire rating on roof, the module frame shall be sited a minimum of 10 cm from the roof surface.
- Please use the appropriate module accessories, e.g., fuses, circuit breakers and ground connectors, according to local laws and regulations.
- Do not use modules if there is an exposed combustible gas in the vicinity.
Storage and transportation instructions
Considerations for module turnover and transportation
When the modules arrive, please timely check whether the outer box of the package is in good condition, and check whether the module model and quantity on the outer package are consis-tent with the delivery note. If any abnormality is found, please contact the logistics personnel and Aiko Energy sales personnel immediately before unpacking.
Crane unloading
When unloading by crane, please use special tooling. Please select the lifting
tool with sufficient tension according to the weight and size of the module
before hoisting. When hoisting, please adjust the position of the sling to
keep the center of gravity of the module stable, which should be on the top of
the packing box.
Use wooden boards or other fixtures of the same width to prevent the slings
from squeezing the case and causing the components to break. Please operate
the spreader at a constant speed, when the lifting is close to the ground,
place the box gently in a relatively flat position.
It is strictly prohibited to install photovoltaic modules under meteorological conditions with wind force greater than 6 (Beaufort wind scale), heavy rain or heavy snow.
Forklift unloading
- The height of the loading and unloading platform should be the same as the bottom of the transportation vehicle.
- Keep the straight line speed of forklift within 5km/h and the turning speed within 3km/h. Please avoid sudden stop and rapid start.
- If the packing box blocks the sight of the forklift driver, it is recommended to drive the forklift in reverse during transport, and arrange special supervision and command to prevent the collision of personnel or items resulting in the occurrence of personnel injury accident or module damage due to the falling of package box.
- After transportation to the installation site, choose a flat hard ground for placement.
Considerations for module turnover and Transportation
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When using forklift to transport modules, please ensure that the fork length meets the requirements to avoid module tilting due to uneven force.
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When opening the packing box, please place the modules to be unpacked at a distance of 20-30cm from the wall or another torr of modules, and then remove the torr. After removing the cable tie of the fixed modules, slowly lean the modules against the wall or another torr of modules to prevent them from falling.
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Please handle the installation modules gently.
Do not lift the modules by pulling the junction box or cables under any circumstances. Two or more people must hold the edges of the modules with both hands.
Considerations for module storage and placement
Please store the packing box of modules in a clean, dry place with relative
humidity below 85%. The storage temperature should be between -20 °C and 50
°C.
In any circumstances, keep the junction box and cables of the modules clean and dry.
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Please store the modules in a ventilated, rain-proof, dry area. When stored outdoors, the modules must be protected from rain or mois-ture using relevant rainproof materials.
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For the storage of scattered modules, please stack the vertical modules flat on the empty torr. The first module should be placed with the glass side up, and the following ones placed with the glass side down. A maximum of 25 modules can be stacked together.
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If the modules need to be transported for long distances or stored for long periods, do not open the original packaging. Please keep the wrapping film and packaging carton intact.
It’s recommended to place modules in a standard warehouse for long-term storage and conduct regular inspections. Once there is an abnormal tilt, please take enforcement measures in time under the precondition of ensuring personal safety.
Installation conditions
Location and working environment
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Aiko Energy modules are recommended to be installed in a -20°C~50°C environment, with an extreme working ambient temperature of -40°C~85°C and a humidity less than 85%RH.
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Aiko Energy modules are designed to operate up to 2000 m above sea level.
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Do not artificially concentrate sunlight on PV modules.
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When installing solar modules on the roof, always leave a safe working area between the edge of the roof and the external edge of the PV module array.
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When stacking modules on the roof, double check the roof loads and make a construction organization plan meeting the applicable standards.
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Modules shall be positioned to receive adequate sunlight and avoid shading the module surfaces in part or in whole (by trees, buildings, clothes, tools or packing materials).
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Modules shall be installed in a well-ventilated position to ensure adequate air circulation on the back and sides of the module and allow immediate dissipation of heat produced during module operation.
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When modules are used in areas exposed to high wind or snow pressure, supports and fixings shall be designed according to local design standards to keep external loads within the maximum mechanical strength that modules can withstand.
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In areas (coastal areas, factories, volcanic areas, farmlands) exposed to salt fog, sulfide or ammonia gas, corrosion can occur at the connection between the module and the racking or at the ground connection. Anticorrosive materials (e.g., stainless steel or aluminum materials) must be used in contact with PV modules and the mounting position must be protected against rust.
Tilt angle selection
- The tilt angle of PV modules is the angle between the PV module and the horizontal ground. Different tilt angles shall be selected for different projects according to local conditions.
- All modules in the same array shall be of the same orientation and angle. Different orientations and angles will result in different total solar irradiation absorbed by modules, leading to output mismatch that degrades system operating efficiency.
- In order for the modules to reach their maximum annual power generation capacity, it is important to choose the optimal orientation and tilt angle of the modules at the location so that the sunlight can still shine on the modules between 9am and 15pm even in the shortest day of sunlight of the year. The optimal tilt angle of PV arrays shall be designed by taking into account the multi-year mean monthly irradiance, direct irradiance, scattering irradiance, wind speed and other climate conditions at the location. PV modules should be tilted at an angle to receive the maximal annual irradiance. Angles shall be selected by considering natural conditions such as local wind load, snow load and avoidance of water and dust collection on module surfaces.
Mechanical installation
General requirements
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Make sure that the modules are properly installed and the racking systems are adequately fastened. Module mounting rackings shall be constructed of anticorrosive, ultraviolet-resistant materials.
Modules shall be firmly secured to the rackings. -
Higher racking systems are used in areas exposed to heavy snowfalls. This prevents long-time snow coverage at the lowest point of modules. The lowest point of modules shall be kept at a height to prevent shading by weeds or trees.
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When modules are installed parallel to the roof, a clearance of at least 10 cm is provided between the module frame and the surface of the roof.
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The minimum mounting distance between adjacent modules is 10 mm.
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The module loads described herein are test values. According to the installation requirements of IEC 61215-2, maximum design load shall be calculated with a safety coefficient of at least 1.5 times. Project design loads must be based on project location, climate, racking structure and applicable standards. Design loads are determined by racking suppliers and engineers. Please observe both the local laws and regulations and the instructions of structural engineers.
Mechanical installation of single glass modules
Aiko Energy single glass modules can be connected to the racking system using pressure clamps. Modules must be mounted as recommended and illustrated below. Other mounting con-figurations may be used provided that consultation is made with, and prior written consent is received from, Aiko Energy. Failure to do so will invalidate our warranty.
Mounting pressure clamps
Specialized pressure clamps are used to mount modules as shown below.
Pressure clamps should not come into contact with the glass surface of the
module and must not deform the frame. Be sure to avoid shadowing effect from
the pressure clamp.
Be sure that pressure clamps will not fail due to deformation or corrosion
while the entire module is under load. Pressure clamps ≥ 50 mm in length and ≥
3 mm in thickness are recommended. The overlapped distance between the
pressure clamp and the module frame, D, shall be at least 7 mm but no more
than 10 mm.
Installation diagram of single glass modules and corresponding loads
Single glass modules can be installed using pressure clamps. Following are the
installation diagram and corresponding loads.
Here, distance and length are provided in mm; pressure is provided in Pa.
Mounting pressure clamps on the long side, with crossbeam perpendicular to the
long side frame
Note: The installation method below is based on the experiment.
Electrical installation
Electrical performance
The electrical performance parameters of Aiko Energy PV modules are detailed
in the product specification of PV modules. There is a ±3% error between
nominal electrical parameters of PV modules (e.g., Isc and Voc) and
measurements under standard test conditions. Standard test conditions (STC)
for PV modules: irradiance 1000 W/m2; battery temperature 25℃; air quality
AM1.5. The maximum system voltage of Aiko Energy PV modules is 1500 V.
When modules are connected into a string, the final voltage is the sum of the
voltages of individual modules; when they are connected in parallel, the final
current is the sum of the currents of individual modules, as shown below.
Modules with different electrical parameters cannot be connected into a
string.
If the module is passed through by a reverse current greater than the maximum
fuse current of the module, the module shall be protected with an overcurrent
protector of the same specification. If more than two strings are connected in
parallel, each module string shall be protected with an overcurrent protector
as shown above.
The string voltage must not exceed the maximum voltage that the system can
withstand or the maximum input power of the inverter or other electrical
devices installed in the system. To ensure this, the open circuit voltage of
the array shall be calculated at the minimum expected ambient temperature at
that location. The following formula may be used:
Cables and connections
- The junction box for modules is designed for IP68 and is composed of connected cables and IP68 connectors. The module has a positive and a negative PV cable connected into the junction box and a plug-and-play connector connected at the other end. Using the positive connector of the module to connect the negative connector of the adjacent module connects the two modules in series.
- Use specialized solar cables and appropriate connectors according to local electrical and installa-tion standards, codes and regulations at the location, and make sure that the cables are electrically and mechanically sound.
- Aiko Energy modules use specialized PV cables which have a cross-sectional area of 4 mm² and are ultraviolet-resistant. All other cables used to connect the DC system shall be of similar (or better) specifications. Aiko Energy recommends that all cables are run
- inappropriate conduits and sited away from areas prone to water collection.
- In field connection, copper cables with a minimum cross-sectional area of 4 mm² which are rated for 90°C and are UV resistant shall be used as PV connecting lines.
- The minimum bending radius of the cable is 43mm.
Connector
- Take care to keep the connectors dry and clean. Make sure that the connector nuts are tightened before making any connection. Do not connect while the connectors are wet or otherwise abnor-mal. As connectors provide IP68 protection only when the positive and negative poles are fully mated, please connect modules as soon as possible after installation or take proper steps to prevent water vapor and dust from coming into the connector.
- Avoid exposing the connector to direct sunlight and water. Avoid exposing the connector directly to ground surface or roof.
- Make sure that all electrical connections are secure. Incorrect connection can result in electrical arcing and shocks.
- Do not mate different models of connectors together.
Grounding
Modules are designed with an anodized anticorrosive aluminum alloy frame as a
rigid support. Module frames must be grounded to ensure safe use and protect
the module against lightning and electrostatic damage. Grounding must be made
with the grounding device in full contact with the interior of the aluminum
alloy and penetrating the oxide film on the frame surface.
Grounding hardware items include grounding screws, flat washers, puncture
gaskets and ground-ing wires. All these hardware items shall be constructed of
stainless steel except grounding wires. Grounding conductors or grounding
wires shall be copper wires. Grounding conductors shall be connected to the
ground through an appropriate grounding electrode. Third-party grounding
devices meeting local electrical installation standards at the location may be
used for grounding Aiko Energy modules. Grounding device shall be installed
according to the operation manual provided by the manufacturer.
Following is the recommended grounding method
There are Ф4.2 mm grounding holes on surface C of the module frame. Use a separate grounding wire and accessories to connect the aluminum alloy frame of PV modules and connect the grounding wire to the ground. We recommend using M4×12 mm grounding bolts accompanied by M4 nuts, star washers and flat washers.
We recommend torquing grounding bolts to 3~7 Nm and using 4 mm2 copper wires as grounding wires.
Unused module mounting holes on the frame may also be used for grounding purposes.
Maintenance of PV modules
Modules shall be inspected and maintained on a regular basis, especially within the warranty period, which is an obligatory responsibility of the user. Any damage or other visible abnormalities of the module shall be reported to Aiko Energy customer service upon discovery.
Cleaning
- The power output of modules is related to incident light intensity and can be reduced by dust collection or other shadings. Dirt on modules must be cleaned up immediately.
- The cleaning frequency depends on the degree of dirt collection. Modules installed at an ade-quate tilt angle will allow rainwater to clean the module surfaces, thereby reducing the cleaning frequency.
- We recommend cleaning the glass surface of the module with a clear water-wetted sponge. Do not clean modules with a detergent containing acid or alkali. Do not clean modules with a hair brush or other rough surface tools.
- We recommend cleaning modules in the early morning or late afternoon or other periods of time when the light is weak and the module temperature is comparatively lower.
Cleaning methods
Method A: High-pressure water cleaning
Water quality requirement
- PH:6-8;
- Water hardness – calcium carbonate concentration: ≤600mg/L;
- Recommended use of soft water cleaning;
- Recommended maximum water pressure is 4MPa(40bar)
Method B: Compressed air cleaning
Air pressure cleaning is recommended when cleaning soft stains (like dust) on
modules. This technique can be applied as long as the on-site cleaning effect
is good enough.
Method C: Wet test cleaning
If there is too much stain on the surface of the module, it’s recommended
to carefully use an insulating brush, sponge or other soft cleaning tools.
Ensure that any brushes or agitating tools are made of insulating material to
minimize the risk of electric shock and that they do not scratch the glass or
aluminum frame.
For oil stains, it’s recommended to use an environmentally friendly cleaner.
Method D: Robot cleaning
If the cleaning robot is used for dry cleaning, the brush material is required
to be soft plastic, so that the glass surface and aluminum alloy frame of the
module will not be scratched during and after cleaning. The cleaning robot
should not be too heavy. The module damage and power degradation caused by
improper cleaning of the cleaning robot are not covered by Aiko Energy
warranty.
Visual checks of the modules
Visually checks for visual defects on modules, such as:
- Whether the module glass is broken;
- Whether the back cover of the module is cracked or otherwise abnormal;
- Whether the junction box is damaged or the cable is broken;
- Whether the module is shaded by foreign matter or shadows;
- Check whether the bolts fixing the module to the racking are loose or corroded and adjust or replace them if necessary;
- Check whether the modules are well-grounded;
Checks of connectors and cables
It is recommended to perform preventive examinations every six months, such as:
whether the connectors are properly sealed and the cables are properly fastened; whether the sealant of the junction box is cracked.
Shenzhen Aiko Digital Energy Technology Co., Ltd.
16-28 floor, Building A, Terra City Building, Terra 4 Road No. 66, Futian
District, Shenzhen Tel: 400-0099-366
Website: http://www.aikosolar.com/