AIKO PV Module Digital Energy Technology Instruction Manual
- May 15, 2024
- AIKO
Table of Contents
AIKO PV Module Digital Energy Technology Instruction Manual
⚠ Important Safety Information
- This installation manual provides information on the installation and safe use of photovoltaic modules (hereinafter referred to as “Modules”) from Shenzhen Aiko Digital Energy Technology Co., Ltd. (hereinafter referred to as ” Aiko “). During module installation and routine maintenance, please comply with all safety precautions and local laws and regulations specified in this manual.
- Professional skills and knowledge are required to install and maintain module systems. Only qualified personnel can install and maintain module systems. Installation personnel should be familiar with the mechanical and electrical requirements of the system. Please keep this manual for future maintenance or treatment.
1 Overview
First of all, thank you for choosing AIKO’s products. This installation manual
contains important electrical and mechanical installation information. Please
understand this information before you install modules. In addition, the
manual also contains some other safety information that you must be familiar
with.
This installation manual does not have the meaning of any warranty, whether
express or implied. There is no provision on the compensation scheme for the
loss, module damage or other expenses directly caused by or related to the
installation, operation, use or maintenance of modules. If the patent right or
the rights of a third party are infringed due to the use of modules, AIKO will
not bear any relevant responsibilities. AIKO reserves the right to change the
product manual and this installation manual without prior notice.
If the customer fails to follow the requirements listed in this manual during
the installation of modules, the limited warranty provided to the customer
will be invalid. At the same time, the recommendations in this manual are to
improve the safety of modules during installation, and have been tested and
verified by practice. Please provide this manual to the owners of photovoltaic
system for reference, and inform them of all relevant safety, operation and
maintenance requirements and suggestions.
2 Regulation and rules
The mechanical installation and electrical installation of PV modules shall refer to corresponding regulations, including electrical law, building law and power connection requirements. These regulations vary from installation site to installation site, such as building roof installation, vehicle mounted applications, etc. Requirements may also vary depending on the voltage and current nature (DC or AC) of the installed system. Please contact the local authority for specific terms.
3 General information
3.1 Module identification
Three kinds of visual labels provided by AIKO’s modules:
Nameplate Product type, rated power under standard test conditions (STC),
rated current, rated voltage, open circuit voltage, short circuit current
under STC, certification mark, maximum system voltage and other information
Serial number Each module has a unique serial number. This serial number is
printed on the bar code and placed in the assembly before lamination, and
cannot be torn or coated after lamination. In addition, an identical serial
number can be found on or next to the module nameplate. Current grading
label(if necessary): The modules of the same gear are second graded by rated
current and marked for differentiation on the modules.
3.2 Wiring mode
The junction box of AIKO ABC photovoltaic module is located in the middle.
Please refer to the
following table for the series connection mode of various modules.
3.3 General safety
The design of AIKO PV module complies with IEC-61215IEC-61730CSA C22.2 No.
61730
and UL 61730 international standards. The application level is class A. the
module can be used for systems with DC 50V or above 240W that the public may
contact. The safety level of the module is class II and the fire protection
level is class C. Fire type can be classified as Type 4 based on the
construction and fire performance.
No matter whether the PV module is connected to the system or not, appropriate
protective measures shall be taken when contacting the module, such as
insulating tools, safety helmets, insulating gloves, safety belts and safety
insulating shoes. When you need to install, ground, wire and clean modules,
please be sure to use appropriate electrical safety protection tools.
Under the sunlight, whether the module is connected with the electrical system
or not, it can generate direct current, and touching the live parts of the
module (such as connectors) may cause casualties. Avoid direct contact with
photovoltaic modules, which may cause electric shock or cuts.
The installation of PV modules shall comply with the laws and regulations
clearly stipulated by the relevant regions and countries where the PV modules
are installed. If necessary, the construction permit and other certificates
shall be obtained first.
The installation of PV modules shall be carried out by qualified professionals
who have professional skills and knowledge and are familiar with the
mechanical and electrical requirements of the system. The risk of possible
injury during installation, including electric shock or cuts, shall be known
in advance.
The roof system can only be installed on the roof with formal and complete
structural analysis results after evaluation by construction experts.
Observe the safety rules for all installed modules. For example, wires and
cables, connectors, charging controllers, inverters, batteries, etc., only
equipment, connectors, wires and supports matching the solar power system can
be used. If the photovoltaic system uses batteries, it shall follow the
opinions of the battery manufacturer.
PV modules of the same size and model can be interconnected. Please do not
artificially focus light on modules.
3.4 Electrical safety
Please strictly follow the following electrical safety provisions to avoid any
form of electrical safety accidents.
Please do not install or operate PV modules when it is wet or windy. The DC
voltage of photovoltaic modules may exceed 30V, and direct contact shall be
avoided. It is necessary to ensure that the connecting cable is fixed on the
support frame for the installation of PV modules. Where animals and children
can reach, cables must be protected with conduits. Please do not artificially
modify or remove any modules and labels of PV modules. Please do not install
PV modules without safety precautions. Do not use any means other than
connectors for electrical connection. The damaged PV module has the risk of
electric shock and fire and should be replaced immediately.
The installation of PV module array must be carried out under the condition of electrical safety. During installation, the voltage of PV modules in series shall not exceed the maximum system voltage. It is forbidden to plug connectors of different manufacturers and models into each other. Please do not use conventional PV modules to replace roof and wall materials. When there is current or external current in the PV module, the PV module shall not be connected or disconnected. Please do not use corrosive chemicals to coat the surface of photovoltaic modules. Please do not touch the PV module when it is wet.
3.5 Operational safety
Before the PV modules arrive at the installation site, please do not open the
packaging box. Please put the packaging box in a ventilated and dry
environment.
During all handling, please ensure that the PV module will not be subject to
large vibration. Improper handling and placement may cause the glass of
photovoltaic modules to break or lose electrical performance, and lose the use
value of photovoltaic modules.
Handle and install PV modules with care. In any case, it is forbidden to lift
the PV module by pulling the junction box or cable. Two or more people must
hold the edge of the PV module with both hands.
It is forbidden to step on, stand on or sit on the PV module, which will
damage the PV module and pose a risk of injury to people.
It is forbidden to place any heavy object on the front and back of the PV
module, and do not place the PV module on the sharp object surface.
It is forbidden to attempt to disassemble the PV module, remove the nameplate
of the PV module or the modules on the PV module.
It is strictly prohibited to brush paint or apply any other adhesive on the
surface of photovoltaic modules.
Avoid scratching the back plate and glass surface of PV module. It is strictly
prohibited to drill holes on the frame of PV modules, which will reduce the
load resistance of the frame and lead to the corrosion of the frame, which
will lead to the invalidation of the limited warranty of PV modules. Except
for grounding, it is forbidden to scratch the anodic oxide layer on the
surface of the aluminum alloy frame, which may lead to frame corrosion and
affect the load resistance and longterm reliability of the frame.
It is strictly prohibited to repair or refit PV modules by yourself. The
surface of the touching photovoltaic module should be smooth, without sharp
edges, burrs, etc.
Do not dispose of electrical appliances as unsorted municipal waste, use
separate collection facilities.
Contact your local government for information regarding the collection systems
available. If electrical appliances are disposed of in landfills or dumps,
hazardous substances can leak into the groundwater and get into the food
chain, damaging your health and well-being.
When replacing old appliances with new ones, the retailer is legally obligated
to take back your old appliance for disposals at least free of charge.
3.6 Fire safety
Please consult local laws and regulations before installing PV modules, and comply with the requirements on building fire resistance. When installing on the roof, the roof must be covered with a layer of fireproof materials suitable for this grade, and sufficient ventilation between the back plate and the installation surface must be ensured. Different roof structures and installation methods will affect the fire safety performance of buildings. Improper installation may cause fire. In order to ensure the fire rating on the roof, the minimum distance between the PV module frame and the roof surface is 10cm. Please use appropriate PV module accessories such as fuse, circuit breaker and grounding connector according to local regulations. Do not use PV modules if exposed flammable gases are present nearby.
4 Installation conditions
4.1 Installation site and working environment
AIKO PV modules are recommended to be installed in an environment where the
operating ambient temperature is -20 ° C ~ 50 ° C. the limiting operating
ambient temperature of PV modules is -40 ° C ~ 85 ° C and the humidity is
lower than 85%rh.
AIKO PV modules are applicable to the operating environment below 2000m above
sea level. Do not directly irradiate the artificial spotlight on the solar PV
module. When installing solar PV modules on the roof, a safe working area must
be reserved between the edge of the roof and the outer edge of the PV module
array. When photovoltaic modules are stacked on the roof, the load of the roof
shall be rechecked and the construction organization plan meeting the
specification requirements shall be formulated. When selecting the
installation position of PV modules, the position where the sun can fully
shine shall be selected to avoid partial or total shielding (trees, buildings,
clothes, tools, packaging materials and other obstacles) on the surface of PV
modules. A safety factor (1.25) regarding the open circuit voltage (Voc) and
short circuit current (Isc) needs to be set, considering that the irradiance
of the installation site can sometimes be higher than 1000W/m² and the
temperature may be lower than 25. The PV module shall be installed in a well
ventilated position to ensure sufficient air circulation at the back and side
of the PV module, so that the heat generated during the working state of the
PV module can be dissipated in time. When used in areas with high wind
pressure and snow pressure, the support and fixed structure shall be designed
in strict accordance with local design codes to ensure that the external load
does not exceed the mechanical strength limit that the PV module can
withstand. In salt spray, sulfide and ammonia environments (coastal, factory,
volcanic and farm), corrosion may occur at the connection between modules and
supports, or at the position where the grounding is connected. Corrosion
resistant materials (stainless steel or aluminum materials, etc.) must be used
to contact the PV module, and the installation position shall be subject to
anti-corrosion treatment.
4.2 Inclination angle selection
The inclination angle of PV module refers to the included angle between PV
module and horizontal ground.
Different projects choose different installation inclination angles according
to local conditions.
Each PV module of the same array must have the same direction and angle.
Different installation directions and angles will lead to the difference in
the total amount of solar radiation absorbed by photovoltaic modules,
resulting in the mismatch loss of output power, thus reducing the operating
efficiency of the system.
In order to achieve the maximum annual power generation of PV modules, the
optimal orientation and inclination of PV modules in the installed area shall
be selected to ensure that even on the day with the shortest sunshine
throughout the year, the sunlight can still shine on the PV modules during the
period from 9:00 to 15:00. The optimal inclination design of photovoltaic
array shall comprehensively consider the climatic conditions such as monthly
average irradiance, direct irradiance, scattering irradiance, wind speed, etc.
of the installation site for many years. The inclination of photovoltaic
modules shall maximize the annual radiation received on the photovoltaic
modules. The selection of angle shall also consider the influence of natural
conditions, such as local wind load, snow load, avoiding ponding and ash
deposition on the surface of photovoltaic modules, etc.
5 Mechanical installation
5.1 General requirements
Ensure that the PV module installation method and support system are firm
enough. The PV module mounting bracket must be made of corrosion-resistant and
UV resistant materials.
The PV module must be firmly fixed to the bracket. In areas with heavy
snowfall, a higher support system shall be selected to avoid the lowest point
of PV module being covered by snow for a long time. The lowest point of the PV
module shall be at a certain height to prevent the PV module from being
covered by weeds and trees on the ground.
When the PV module is installed parallel to the roof, the minimum gap between
the PV module frame and the roof is 10cm.
The minimum installation distance between two adjacent PV modules is 10mm. The
maximum static test load passed by the PV module is front 3600/ back 1600 with
Safety factor 1.5. The specific load depends on the installation mode of the
PV module (please refer to the following). All load values mentioned in this
manual are static test loads. Note: according to IEC 61215-2, 1.5 times of
safety factor shall be considered when calculating the maximum design load;
When calculating the wind load, the design maximum instantaneous gust load
shall consider 3 times the safety factor. The loads of the modules described
in this manual are test loads. According to the installation requirements of
IEC 61215-2, the corresponding maximum design load should be divided by at
least with safety factor 1.5. The design load of the project needs to depend
on the project location, climate, support structure, and relevant
specifications. The support supplier and professional engineers are
responsible for determining the design load, in accordance with local laws and
regulations and the instructions of the structural engineer.
5.2 Mechanical installation
The connection between AIKO single glass photovoltaic modules and the support system can be installed by pressing blocks. PV modules must be installed according to the following suggestions and examples. If there are other installation methods, please consult Shenzhen AIKO digital energy in advance and obtain written consent, otherwise the warranty will be invalid.
5.2.1 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.
When choosing clamp-mounting, please be sure to use at least four clamps on
each module. Depending on the local wind and snow loads, if excessive pressure
load is expected, at least six clamps should be required to ensure the module
can bear the load (more details, please contact AIKO technical personnal)
The applied value of torque should refer to mechanical design standard and the
bolt type customer is using, for example: M8: 16-20 N·m.
5.2.2 Clamp mounting diagram and corresponding loads
Single glass modules can be installed by clamps base on rails. Following are
the installation diagram and corresponding
loads. Here, L stand for long side of module, W stand for short side of
module, black shadowing area stand for the installation area of the middle of
clamp. Distance and length are provided in mm; pressure is provided in Pa.
Note: The installation method shown in the above table is based on the test results.
5.2.3 Bolts mounting
Single glass modules can be installed by bolts base on rails. Using bolts to fix the module on the bracket through the mounting holes at the back of module’s frame. Modules come standard with 4 or 8 mounting holes, matching M8 bolts, as figure below:
Be sure that the bolts will not fail due to deformation or corrosion while the assembly is under full load. It is recommended that the thickness of the gasket be at least 1.7mm and that the bolts and nuts of the M8 be installed. For the M8 coarse teeth bolts, the fastening torque should be between 16 nm and 20Nm according to the bolt class.
5.2.4 Single glass module bolt installation diagram and corresponding
load
Single glass modules bolt mounting diagram and corresponding loads as below diagram, pressure unit is Pa.
6 Electrical installation
6.1 Electrical performance
Please see the PV module product specifications for the electrical performance
parameters of PV modules of AIKO digital energy. There is ± 3% tolerance
between the nominal values of the electrical performance parameters of
photovoltaic modules such as Isc, Voc and Pmax at the standard test
conditions. Standard test conditions (STC) for photovoltaic modules:
irradiance 1000w/m2, cell temperature 25 , air quality AM1.5. The maximum
system voltage of AIKO digital energy photovoltaic modules is 1500V
When the PV modules are connected in a series, the final voltage is the sum of
the single PV modules.
When the PV modules are connected in parallel, the final current is the sum of
the single PV modules, as shown in the figure below. Photovoltaic modules of
different electrical performance models cannot be connected in a string.
When the PV modules are connected in a series, the final voltage is the sum of
the single PV modules.
When the PV modules are connected in parallel, the final current is the sum of
the single PV modules, as shown in the figure below. Photovoltaic modules of
different electrical performance models cannot be connected in a string.
If there is a reverse current exceeding the maximum fuse current of the PV
module passing through the PV module, an overcurrent protector of the same
specification must be used to protect the PV module. If the number of parallel
connection is greater than two strings, each string of PV module must have an
overcurrent protector, as shown in the above figure.
The voltage of the string shall not be higher than the maximum voltage that
the system can withstand and the maximum input voltage of the inverter and
other electrical equipment installed in the system. To ensure this, the open
circuit voltage of the array needs to be calculated at the lowest expected
ambient temperature at that location. The following formula can be used for
calculation
Maximum system voltage N V 1 T 25 Of which: N—-Number of PV modules in series.
Voc—-Indicates the open circuit voltage of each PV module (refer to the
product label or data sheet). TCvoc—-Temperature coefficient indicating open
circuit voltage of PV module (see data sheet). Tmin—-Indicates the minimum
ambient temperature.
6.2 Cables and wiring
The protection grade of junction box of PV module is IP68, which is composed
of connected cable and connector with IP68 protection grade. The PV module has
a dedicated PV output cable with a positive pole and a negative pole connected
to the inside of the junction box, and the other end is connected with a plug
and play connector. The two PV modules can be connected in series by
connecting the positive connector of the
PV module with the negative connector of the adjacent PV module.
According to the electrical design and construction specifications,
regulations and corresponding regulatory requirements of the installation
site, special solar cables and appropriate connector models shall be used to
ensure good electrical and mechanical properties of the cables.
The solar PV module of AIKO adopts special PV cables with a cross-sectional
area of 4mm2 or more and UV protection. All other cables used to connect the
DC system shall have similar (or higher) specifications. AIKO recommends that
all cables should be laid in appropriate pipelines or trucking and away from
places prone to ponding.
For field wiring, PV special copper core cable with a minimum temperature
resistance of 90 ° C, light resistance and a cross section of not less than
4mm2 shall be used as the PV connecting wire.
6.3 Connector
Please ensure that the connector is dry and clean. Confirm that the connector
nut is tightened before wiring.
Do not connect when the connector is wet or in other abnormal conditions. The
premise that the connector meets the IP68 protection grade is that the
positive and negative poles are fully inserted, so the PV modules need to be
connected as soon as possible after installation, or appropriate measures
should be taken to avoid water vapor and dust infiltration inside the
connector.
Avoid direct sunlight and immersion in water. Avoid direct contact between the
connector and the ground or roof.
Please ensure that all electrical connections are secure. Incorrect
connections may cause arc and electric shock risks.
It is forbidden to plug connectors of different models into each other.
7 Grounding
In the design of PV modules, anodized corrosion-resistant aluminum alloy frame
is used as a rigid support. In order to use safely and avoid lightning and
electrostatic damage to PV modules, the PV module frame must be grounded. When
grounding, the grounding device must be in full contact with the interior of
the aluminum alloy to penetrate the oxide film on the frame surface.
The grounding hardware includes: grounding screw, flat washer, puncture gasket
and grounding wire.
Except for the grounding wire, other related hardware shall be made of
stainless steel. The grounding conductor or grounding wire adopts copper core
wire, and the grounding conductor must be connected to the earth through a
suitable grounding electrode. The third-party grounding device that meets the
requirements of the installation ground electrical equipment specification can
be used for the grounding of AIKO digital energy photovoltaic modules. The
grounding device shall be installed and operated in accordance with the
operation manual specified by the manufacturer.
The following are the recommended grounding methods: On side C of PV module
frame, there are 4.2mm grounding hole, use separate grounding wire and
relevant accessories to connect the aluminum alloy frame of the solar
photovoltaic module and connect the grounding wire to the earth. It is
recommended to use m4x12mm grounding bolt and M4 nut, star washer and flat
washer. The recommended torque value of grounding bolt is 3~7n · m, and the
grounding wire adopts 4mm2 copper core wire. Unused PV module mounting holes
on the frame can also be used for grounding.
8 PV module maintenance
The PV modules must be regularly inspected and maintained, especially within the warranty period, which is the responsibility of the user. And notify AIKO’ customer service personnel as soon as possible in case of any damage or other significant abnormalities of PV modules.
8.1 Clean
The power output of photovoltaic modules is related to the incident light
intensity. Dust accumulation or other obstructions will reduce the power
output of photovoltaic modules. The dirt on the PV module shall be cleaned in
time.
As for cleaning frequency, it depends on the accumulation rate of dirt. If the
PV module has enough inclination angle, the rainwater will clean the surface
of the PV module, which can reduce the cleaning frequency.
It is recommended to use a sponge moistened with clean water to wipe the glass
surface of photovoltaic modules. It is strictly prohibited to use cleaning
agents containing acid or alkali to clean PV modules. It is forbidden to use
brush and other tools with rough surface for cleaning.
It is recommended to clean PV modules in the early morning or evening when the
light is weak and the temperature of PV modules is relatively low.
8.2 Visual inspection
Visually inspect the PV module for appearance defects, such as: Whether the
photovoltaic module glass is broken; Whether the photovoltaic module backplane
is cracked or otherwise abnormal; Whether the junction box is damaged and
whether the cable is damaged; Whether the PV module is covered by foreign
matters and shadows; Check whether the bolts fixing PV module and bracket are
loose or rusted, and adjust or replace
them in time; Check whether the PV module is well grounded.
8.3 Connector and cable inspection
It is recommended to carry out preventive inspection once every six months, such as: Check the tightness of the connector and the firmness of the cable; Check the junction box sealant for cracks.
9 Revision version and date
Rev 1.0, issued in May 2022;
Rev 1.1, revised in November 2022;
Rev 1.2, revised in December 2022;
Rev 1.3, revised in February 2023;
Rev 1.4, revised in March 2023;
Rev 1.5, revised in April 2023；
Rev 1.6, revised in July 2023；
Rev 1.7, revised in Sep 2023;
Rev 1.8, revised in Nov 2023.
Appendix: Electrical performance parameters of modules
  
References
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