Gamko Photovoltaic Module Installation Guide

Photovoltaic Module

7FSTJPO(AMKO@97
AUTHORITY FOR GAMKO USE
Global Installation Manual for GAMKO Photovoltaic Module

CONTENTS

Purpose of this manual

02

Disclaimer

02

Safety and Transport

03

Mechanical Installation

04

Electrical Installation

10

AUTHORITY FOR GAMKO USE Grounding
Bypass Diodes and Block Diodes Maintenance

11 12 13

01

Purpose of this manual
This manual is used for GAMKO solar modules (here in after referred to as the Module or Modules) only. This manual contains installation methods, operation safety and relevant maintenance information of Gamko’s Modules . Modules mus t b e installed by professionals . Please ready this manual carefully before installation. T he ins taller s mus t follow all the rules describe d in this manual strictly as well as local requirement s and regulations by law or authorized organiz
SE ations . U B e fore ins t alling, th e ins t aller mus t b e f amiliar w ith th eir m e chanic al and e le c tric al O re quirem ent s . Pleas e ke ep this manual in a s afe p lace for f uture re ference (c are and K maintenance) and in c ase of s ale or disp os al of the M o dules . D i s c l a i m e r Y FOR GAM Gamko shall not be responsible for any loss arising from installation, operation, use IT or maintenance of the Modules which is not complying with the guidance of this R manual, including breakdown or damage of the Modules or any other expenses O i n c u r r e d .
Any cus tomer shall not get any patent or authoriz ation of the patent when using the
TH M o dules , e xpresse d or imp lie d. Any inf ringem ent of p atent s or other right s of the third U par t y, which may result f rom the use of the Module, is not within the responsibilit A y scope of Gamko.
The information in this manual is based on Gamko’s knowledge and experience and is believe d to b e reliable, but such information including product specification (without limitation) and relevant suggestions do not constitute a warrant y, e xpressed or implied. Gamko reserves the right s to change the manual, the Modules, the specifications or any other information of the Modules without prior notice.
02

SA F E T Y&T R A N S P O R T
Unpacking and Storage
Keep all the Modules and electrical connectors clean and dry before installation. Use dry and ventilated room when storing uninstalled modules. Use both hands to carry Modules. Do not overlap Modules. Be cautious when carrying Modules. Slip-proof gloves are necessary. Use supportive disassembling tools when unpacking .
AUTHORITY FOR GAMKO USE Do not stamp on Modules or put weight on Modules.
Do not disassemble or drop Modules. Do not use mirrors or magnifiers concentrated sunlight onto Modules. Do not lift the module by grasping the junction box. Do not use any sharp object with Modules. Do not directly apply pressure on the glass surface or backsheet of Modules. Must use both hands to carry Modules. Do not touch the surface of the coated glass with bare hands. Ensure all contacts and the operating environment are clean and dry.
Modules Carry and Installation Instruction

Both hands when handling Modules

Ensure Modules are fixed properly

Do not use sharp objects with Modules

Do not pulling the wiring cables or junction box

Do not stamp on Modules

Do not touch Modules with bare or dirty hands

Do not pile up Modules on uneven ground

Do not drop or throw Modules

03

MECHANICAL INSTALLATION

Location Selection

Select suit able places to ins t all Modules .

Ins t all Modules at the places with sufficient sunlight and without shade at any time.

If a module is shaded or even partially shade d, it will result in lower power

output. A permanent or regular shade will cause damage to the module, which will

void GAMKO ‘s warrant y. Do not place, install or use Modules at the places where combustible gas is easily
SE generated or gathering. U The straight- line distance between the installation site and coastline shall not KO be shorter than 1 km unless there is a writ ten approval from GAMKO or an M engagement specified in the contract.

I n s t a l l a t i o n A n g l e FOR GA Modules in the same string should be installed at the same angle. Modules installed in Y different angles w ill re ceive different ir r adiation, w hich w ill c aus e cur rent different . A s IT a result, it will de crease the op eration efficienc y of the s ystem. OR Please refer to Table 1 for the re commende d ins tallation angles of the Mo dules.

AUTH Local Latitude

Module installation angle

0°~ 15°

15°

15°~ 25°

Latitude

25°~ 30°

L atitude+5°

30°~ 35°

L atitude+10°

35°~ 40°

L atitude+15°

40°

L atitude+20°

Table 1

04

Module Installation
General Installtion
The mounting structure must be made of durable, corrosion-resistant and UV- resistant materials. Always use a tested and certified mounting structure for the system.
Make sure Modules are securely fastened to the mounting structure to withstand
AUTHORITY FOR GAMKO USE corresponding wind load and snow load.
Select a suitable height for the mounting system to prevent the lowest portion of the Module covered by snow in winter. In addition, ensure the bottom of the Module is high enough so that the Module will not be shaded by plants or damaged by flying sands. A s for the system installed on the ground, the minimum distance Gamko recommends between the bot tom of Modules and the ground should b e 24 inches (6 0 cm). Before installing Modules onto a rooftop, make sure the roof construction is suitable and the installed Modules will not exceed the roof area. Besides, the roof must be properly sealed to prevent leaks.
When installing Modules to a pole, the selected mounting structure and pole shall be able to withstand the expected wind load and snow load in the area.
Make sure Modules are not subject to wind or snow loads exceeding the maximum load permitted by GAMKO and not subjected to excessive force due to the thermal e xpansion of the mounting sys tem. It is not allowed to overlap the Modules .
Provide adequate ventilation to the back of the Module for cooling. A minimum distance of 10cm between the installation surf ace and the Module is GAMKO generally recommended. To prevent the linear thermal expansion of the Module frames, GAMKO sugges t s that the minimum distance between two Modules should not b e shorter than 2cm.
Always follow the guidance and safety rules specified in the mounting system. Do not drill holes on the glass sur f ace or the frames of the Module, which will void the warrant y.
05

Installation Method
Modules can be installed on the frame in the following 3 methods.
Mounting hole system: Use anticorrosive M8 bolts to install the Module on the support frame through the installation holes on its own frame, as shown in Figure 1.

AUTHORITY FOR GAMKO USE Module Mounting Structure

NM8ut(M8,SS) Springwasher Flat washer

Figure 1

1

MB8olt(M8,SS)

Clamping system: Use suitable clamps to fix the Module on the support frame, as shown in Figure 2.

M8

MN8ut(M8,SS) Springwasher
Flat washer Clamp
MB8olt(M8,SS)

Module

MS tor uu nctt

in ur

g e

2

M8

Figure 2

I n s e r t i o n s ys t e m : Ins e r t th e w h ol e2M o dul e into th e r ail, as sh ow n in Figure 3.

3
3 Figure 3
06

Mounting hole system

Select a suit able installation method depending on the load requirement s. More detailed information is shown in Figure 4.

It has been tested that Gamko’s Modules can withs t and the loads of 240 0 Pa, 380 0 Pa and 540 0 Pa (IEC 61215 Standard), which are respectively equivalent to 160 0 Pa (0. 232 psi), 250 0 Pa (0. 363 psi) and 360 0 Pa (0. 522 psi) under UL1703 Standard, when different installation methods are used.

AUTHORITY FOR GAMKO USE 2400Pa

3800Pa

5400PaSnow Loads Only

Permissible clamp

Use 4 mounting holes Permissible clamp

Use 8 mounting holes

Permissible clamp

Permissible clamp

Use 4 mounting clips Permissible clamp

Use 4 mounting clips

Use 4 mounting clips Permissible clamp

Use 6 mounting clips

Clamping system Attachment to the long frame

Clamping system Attachment to the short frame

Insertion system

Use 4 mounting clips Insertion system Insertion system

Use 4 mounting clips on short frame Use 2 mounting clips on long frame Permissible clamp
Insertion system
Insertion system

07

2400Pa

3800Pa

5400PaSnow Loads Only

Mounting hole system

Clamping system Attachment to the long frame

Clamping system Attachment to the short frame

AUTHORITY FOR GAMKO USE Permissibleclamp

Use 4 mounting holes Permissible clamp

Use 8 mounting holes

Permissible clamp

Permissible clamp

Use 4 mounting clips Permissible clamp

Use 4 mounting clips

Use 4 mounting clips Permissible clamp

Use 6 mounting clips

Use 4 mounting clips

Use 4 mounting clips on short frame Use 2 mounting clips on long frame

Permissible clamp

Insertion system Insertion system

Figure 4

08

Insertion system

Module Specification (as shown in Figure 5 and Table 2)

Barcode

8-9X14Mounting hole

No.

AUTHORITY FOR GAMKO USE Groundinghole

Front View

Side View
Figure 5

Back View

Module Type A

B

C

D

E

F

G

H

GK60P-XXX

Frame Section
Unite:mm
We ight(kg)

1 GK60M-XXX

992 1640 35 941 990 1350 11

35

18.5

GK60MH-XXX

GK72P-XXX

2 GK72M-XXX

992 1956 35 941 1176 1676 11

35

22.5

GK72MH-XXX

3

GK96P-XXX

1008 2568 40 958 1428 1928 11

35

36.5

4

GK72PH-XXX 1020 1945 40 970 1176 1676 11

35

21.5

5 GK60DG-XXX 992 1658 6

NA NA NA NA NA

23

6 GK72DG-XXX

992 1968 6

NA NA NA NA NA

27

*”XXX”refers to Module Power Index. Table 2
09

ELECTRICAL INSTALLATION
DC power generated by the photovoltaic system can be converted into AC power and fed into the grid. Policies on connecting renewable energy system to the grid vary from region to region. Consult senior system designer before designing the system. Generally, the system installation shall be formally approved by the local public sector.
General Installation
AUTHORITY FOR GAMKO USE Installation structure should be compatible with aluminum frame of module, in order
to avoid galvanic corrosion. Any defects caused by such corrosion will void the w a r r a n t y. Negative grounding is recommended during installation of Modules to prevent PID effect. Positive and negative part of the module should use the same type of connector for electrical connection. It is forbidden for non-professionals to open the lock nuts of the connector. Make sure that the connectors are clean, dry and fully connected (A click sound should be heard when fully connected), otherwise it may lead to electric arc sparks which will damage the connector or cause a fire. All electrical components should have ratings equal or greater to the system rating. Do not exceed the maximum of system voltage marked on the module label. Under normal conditions, a Module may produce more current and/or voltage than reported at standard test conditions. Accordingly, the values of ISC and Voc marked on the Module should be multiplied by a factor of 1.25 when determining component voltage ratings, current ratings, fuse sizes, and size of controls connected to the PV output. Completely cover the Modules with an opaque material to prevent electricity from being generated during disassembling the conductors.
10

When connected in series, the maximum number of the Modules are determined by the system design, inverter type and environment. ( shown in Figure 6).
When connected in parallel, the current output is equal to the sum of each string’s current ( shown in Figure 7). Fuse is necessary for each module string. Please take reference to the local regulation. Recommended maximum parallel Modules configurations: Fuse rating/Isc+1.

AUTHORITY FOR GAMKO USE Figure 6

Figure 7

Please refer to the local regulations to determine the system wire size, types and temperatures.
The cross section of the cables and the capacity of the connectors must be selected to suit the maximum system short circuit current (The

recommended section area for a single piece of Module is 4 mm , and the

recommended rated current for the connector is greater than 10A),

otherwise the cables and connectors shall be overheated under large

current. Caution: The maximal temperature of the cable is 85 C while the

upper limited temperature of the connector is 105 C.

Make sure the electric components such as the connectors and inverters are off-state during the installation.

To reduce lightning damage, the loop area should be kept as small as possible when laying cables. It is recommended to use fuses in each string.

11

GROUNDING

All the module frames and mounting structures shall be grounded according to regional and national electricity regulations. Use recommended hardware to connect grounding cables and fasten to the Module frames. While using the metal structure, make sure the surface of the system have been electroplated to keep a good conducting circuit. Use suitable grounding conductors to connect the Module frame to the mounting
AUTHORITY FOR GAMKO USE structure. This can achieve proper grounding effects.
The grounding conductor must be connected to ground via an appropriate grounding electrode. It is recommended to use lugs to connect the grounding cables. If it is only mechanically connected to a grounded module without bolts and nuts, the mounting system should be grounded as well.
Grounding by lugs
First, peel the grounding cable to a proper length withot damage to the metal core. Then insert the peeled cable into the lug, tighten the screw. As shown in Figure 8, connect the lug to the aluminum frame with stainless steel bolts and connection components. The recommended tightening torque for M3 bolts is 2.3 N·m.
Nut (M3,SS) Spring washer Flat washer

Frame
Grounding Lug Grounding cable

Star washer Bolt (M3,SS)

Figure 8

12

Grounding by cable

The grounding bolts must be made of stainless steel and be used in the specified

grounding holes. First, make the M3.5 stainless steel bolt pass through the spring washer,

flat washer, cup washer (copper conductor with a diameter of 2.1 mm) and star washer,

and then insert through the grounding hole, flat washer and spring washer on the frame.

Finally, tighten with a M3.5 nut. Caution: The upper limited temperature of the conductor

USE is 85. As for the installation, refer to Figure 9.

Nut (M3.5,SS)
Spring washer Flat washer

GAMKO Frame B y p ass ADUiToHdOReIsTYaFnORd B l o c k D io de s Copperwire

Figure 9

Star washer
Flat washer Cup washer Spring washer
Bolt (M3.5,SS)

In a system with two or more Modules connected in series, if part of a Module is shaded while the other part is exposed to the sun, a very high reverse current will go through the cells which have been partly or entirely covered and it will cause overheat on the cells, which may damage the Module. Using bypass diodes can protect Modules from this kind of risk. There are bypass diodes in junction boxes, which can reduce the effects of partial shadows. Do not privately disassemble the junction box to replace the diodes, even when the diodes are broken. This should be processed by the professionals.
In a system with batteries, if the controller doesn’t have the function of backswing protection, block diodes installed between the battery and the Module can prevent the reverse current from damaging the Module.

13

MAINTENANCE
Normally, the Modules don’t need repair. Follow the maintenance methods below to ensure the best performance of the Modules:
In most conditions, the normal rainwater can keep the module glass clean. Clean the glass surfaces with wet soft sponge or cloth if necessary. Use mild non-abrasive cleaning agent to remove stubborn dirt. Do not try to clean a Module with broken glass or perforated backsheet. It will cause
AUTHORITY FOR GAMKO USE serious electrical shock.
Take a regular inspection on grounding, mechanical and electrical connections every 6 months. Make sure all the Module connectors are connected, clean and without damage or corrosion. When disassembling the connectors, must make sure all the components are working well; otherwise the connectors shall be replaced. Damage on the connector will cause water leakage. The tightening torque of the nut should be 1.5 N·m – 3 N·m. Use opaque material to completely cover the modules during repair to avoid electric shock. When exposed to the sunshine, the Modules will produce high voltage. The repair work must be carried out by professionals.
Warning: Shut down the system before any electric repair. Improper maintenance may cause electric shock or fire.
14

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