12installation manual V4 for thin film PV module For ... · GS-SOLAR thin-film solar module installation manual GS-SOLAR CO.,LTD 6 3 Machinery installation 3.1 Location consideration

Thin-film solar cell 12<1>installation manual V4 for thin

film PV module

For Europe、USA and Canada

GS-SOLAR CO.,LTD

July 2010

Instructions for Installation Personnel

l Read this manual carefully before system installation;

l This manual does not contain all precautions for safety

installation; system installation shall strictly comply with safety

guidance;

l This manual provides guidance for system installation, but does

not guarantee installation quality. Installation shall be taken

seriously； electrical work is operated by professional

electricians;

l This manual is not applicable to BIPV; for BIPV, please contact

PV engineering department of GS-SOLAR；

l Do not dismantle the component or move any label or attached

parts.

GS-SOLAR thin-film solar module installation manual

Contents

1 SAFETY ................................................ 1

2 SPECIFICATION ......................................... 4

2.1 MODULE SPECIFICATION .............................. 4

2.2 MODULE DIAGRAM .................................... 5

3 MACHINERY INSTALLATION ............................. 6

3.1 LOCATION CONSIDERATION ........................... 6

3.2 SUN-SHADING DESIGN CONSIDERATION ............... 7

3.3 INSTALLATION STRUCTURE ........................... 8

3.4 INSTALLATION METHOD ............................... 9

4 CIRCUIT INSTALLATION ................................ 22

4.1 ELECTRIC CONNECTION ............................. 22

4.2 SOLAR MODULE CONNECTION ....................... 23

4.3 RULES............................................... 26

5. MAINTENANCE ........................................ 27

6 DISCLAIMER ........................................... 27


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1 Safety

The manual provides safety information concerning installation and

operation of GS-SOLAR thin-film solar module. Before installation, local

government or relative dept. shall be contacted to confirm authorized rights,

permits, and installation and construction supervision requirements. A

construction (installation) permit shall be made available, if necessary.

GS-SOLAR suggests that installation shall comply with the local latest power

regulations, and that state or international electrical standards shall comply

with the corresponding local regulations. Please keep this manual for checkup.

The manual is compiled on basis of the knowledge and experience gained

by GS-SOLAR personnel, but does not guarantee responsiveness to the

information and proposals contained.

Safety Icon

There are a number of safety icons in the manual. Please make sure to

understand their meanings. These icons are classified according to the level of

consequence on products because of negligence and improper operation.

Please make sure you have read this manual and understood these icon

meanings.

The icon means threat to life safety or possible physical

harm.

The icon means physical harm or threat to property

safety.


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The icon means something is undoable.

Before product installation, wiring, operation and

maintenance, installation personnel shall carefully

read the manual. In a charging circuit in contact with modules, e.g.,

either connected or disconnected, its wire terminal is likely to induce

burn, spark and fatal electric shock, etc.

1) Module installation must abide by some local regulations, permits and

supervision requirements, in additional to the latest power regulations in

USA and Canada.

2) Installation personnel must be very careful and abide by safety

operations, e.g., but not limited to, exposed carrier parts must be insulated,

isolated or short-circuit protected; properly use insulating tools. All

installation personnel must wear insulating gloves, and proper protection

clothes and tools, and remove all metal accessories to reduce risks of

injury or accidental electric shock.

3) Before some electric connection or disconnection is operated, solar

module array shall be fully shaded.

4）If modules are connected in series, module voltage will increase; if

modules are connected in parallel, module current will increase. Hence, an

array module might generate high voltage and high current, a threat to life

safety or a hazard of physical injuries. Please take protective measure in

advance during connection. Do not place conductive objects nearby the

metal pieces of a connector.

Non-professionals are forbidden from electric connection work.


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5) As installation and maintenance of solar modules requires a great deal

of skills, only qualified professionals are allowed.

6) Non-repairable modules. Damaged modules shall not be repaired but

be replaced (for Junction boxes and external cable in some situations,

simple repairs are allowed).

7) Be careful with installation. Do not bump, scratch, or drop modules. Do

not stand or sit on modules.

Non-professionals are forbidden from operation, as they may

cause electric leak,etc.

8) Broken modules are dangerous. Personnel in touch with module surface

or frame are likely to get an electric shock.

9) Do not install modules in rainy or windy days. Install dry modules in dry

condition, using dry tools.

10) When modules are working, the surface might turn hot, which are

likely to cause skin burn.

11) Do not expose modules to direct artificial sunlight.

12) Keep children and unauthorized personnel away from solar modules to

avoid risks of electric shock and physical injuries.

Do not install modules nearby combustible gas or

explosive objects.

13) As there might be sparks during module installation, do not install

nearby combustible gas or explosive objects.


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2 Specification

2.1 Module specification

Maximum system voltage V 600V（1000V for Europe）

Maximum Source Circuit Fuse A 3

Module type

Amorphous silicon thin-film module

Weight kg Approximately 14.4

Size (LxWxH) mm 1245×635×7.5

Frame material No frame, 10 ± 1mm transparent

edge

Bypass diode number 1

Cable type, diameter, length 2 cables 2.5mm2，400mm or750mm

Front panel 3.2mm glass

Back Cover Sheet 4mm glass

Fire Rating Class C

1) In the first months, module output power is higher than the rated. The

rated power is likely to be 15% higher and the working current 9%

higher.

2) Electric parameters are tested in standard test condition with errors of

short-circuit current, open circuit voltage and rated power within ±5%.

( irradiance 100mW/cm2，AM1.5 spectrum, cell temperature 25℃）

3) The current or voltage produced by a module might be higher than the

report data in standard test condition. Under corresponding conditions,

to calculate the rated voltage, current, fuse carrier of a module and the

electric specification of control parts, the short-circuit current and

open-circuit voltage marked on a module shall be multiplied by 1.25,

respectively for design and installation purpose. Multiplication of

125 %( 80% rated value drop) is appropriate. Please refer to relative

state power regulations.

4) Specification variation, if any, will not otherwise be notified.


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2.2 Module diagram

Please refer the diagram as below (unit: mm)

Front view right view rear view

7.5 635

170 60

145

400

1245


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3 Machinery installation

3.1 Location consideration

1) Fire risk: module array design and installation shall take full consideration of

fire risks. Especially, the rooftop, where a solar farm is erected, must meet

fireproof class C (or higher class). For correct roof selection, please refer to

local construction regulations. Rooftop construction and installation design will

impact architecture fire resistance. For less than 5 inch/feet (127mm/305mm)

slope, if any, fire resistance assessment shall be made. Improper installation

leads to potential fire risks.

2) Ventilation: It is suggested to leave a 4-inch (102mm) or bigger clearance

behind a module for ventilation, especially in extremely hot environment.

Ample clearance can condense or evaporate some moisture. Besides,

sufficient ventilation reduces module temperature and increases module’s

output.

3) Design strength: GS-SOLAR module is designed and tested under the

maximum load (+ / - 2400 Pa) to endure snow or wind attack. Bracket is

designed to have enough strength to support solar module and shall comply

with local specifications. Install module with care. Design strength of 2400 Pa

is equal to the condition of wind speed at 130km/hour (approximately 36m/s),

wind load approximately at + / - 800 Pa and tripled as per safety design

parameter.

4) Architecture construction: The bracket to support solar module shall have

enough strength (bracket design shall consider local wind, snow pressure, and

ice storm, etc.) If a module is installed at rooftop, appropriate installation

method shall be provided for special architecture.

5) Module position: GS-SOLAR module is installed at any horizontal to vertical

angle. Selecting an right tilt angle would cause the module accepted maximum


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direct sunlight.

3.2 Sun-shading design consideration

In inclined installation, generally, array pitch is designed as per local

non-sun-shading from 9:00 a.m. to 15:00 p.m. on winter solstice. GS-SOLAR

has realized that amorphous silicon module has good weak-light optical effect,

and that partial sun-shading has less influence on outputoutput. Therefore,

sun-shading design of amorphous silicon PV system is optimized by

comprehensively taking all factors such as system floor space, cost, climate

and output.

Sun-shading of a module or a series of module array will decrease array

output. Bracket installed, adjacent modules and plant, or architecture nearby

might overshadow modules. In the optimized design of amorphous silicon PV

system, the short side of a module shall be shaded from sunlight as below

picture. This method can effectively reduce and avoid module overheating.

Sun-shading of long side (for transversal installation): this method may

lead to one or more complete PIN junction failure, current disfunction and

internal resistance increase. Power loss is substantial. This method requires

for avoiding sun-shading as much as possible. If necessary, an array pitch

shall be multiplied by 1.1~1.2 as safety design allowance. It is not

recommended for sun-shading optimized design.

Sun-shading of short side (for vertical installation): this method

overshadows the lower part of PIN junction. For upper part without

sun-shading, the output is normal. Power loss is low.


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Optimized sun-shading design principles:

1. In areas of abundant rainfall and snow, in order not to abate

self-cleaning ability, it is suggested not to substantially change array tilt

angle. The design is optimized by shortening pitch. (In this situation, only

the lower part is shaded in the winter. As this area often has snow

residue in winter, sun-shading has minor impact on outputoutput. )

2. In areas of scarce rain, module self-cleaning is not required. The

design is optimized by properly reducing module array tilt angle.

3. In areas of low radiant exposure in winter, sun-shading is optimized by

shortening pitch.

3.3 Installation structure

Installation structure must be solid enough to securely bear module

weight and some other external force (e.g. wind, snow, ice). For some glass

panels, their modules and bracket may be destroyed by strong winds.


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Therefore, bracket structure is designed to support their weight at maximum

wind speed (also by considering uplift and down force).

Installation structure (installation with proper force) shall prevent module

from deformation or distortion. Even if the environment is terrible, excessive

move or vibration shall be avoided.

The clearance between a module and a mounting surface is ample

enough to prevent both from contact with cables, which are likely to be

damaged due to squeeze and friction. The module is not designed as part of

entire rooftop or wall installation.

3.4 Installation method

3.4.1 Operation

GS-SOLAR modules are solidly packed with glass, however, any

improper installation and operation might destroy modules. When installing

GS-SOLAR modules, one shall wear protective gloves to avoid cut by sharp

glasses or burn. Modules are transported and stored in open vehicles or

containers. These modules are protected from bumping and knocking during

the whole transportation, hauling and installation process until installation

finishes.

In order not to break glass, which may crack modules, modules shall

not sit on unstable concrete or one corner shall not sit on concrete or any

other solid or coarse surface. Before taking out modules from the container or

other conveyance, please check module surface. Carefully move modules.

Do not hit other modules or hard object. Do not touch any object which might

cause scratches on glass.

To avoid electric shock, injuries or module damage, do

not drag module cables and Junction boxs during moving

and installation.


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3.4.2 Fastening position for installation

A module is fastened with special clamp (4 fastening points every one

module) as below. The clamps are symmetrically laid out on a plane with

deviation no bigger than 1mm. D1 is the distance between two clamp

centerline points along 1245mm side, 760±10 mm long.

Contact surface width (D2) is 9±1mm. Contact surface length (D3) is

80±2mm at the clamp. A clamp contains EPDM material to protect module

glass.

1) The four clamps on the bracket are on a plane

with levelness no bigger than 2mm.

2) The roughness of clamp contact surface is no

bigger than 12.5 RMS.

3) The contact surface of clamps is flat without deformation.

D1

D2 D3


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4) Recommended GS-SOLAR torque : 4 N·m ～6 N·m. 5 N·m torque

wrench is used so that modules will not fall off and the clamp will not

break module glass. The guarantee does not cover any module damage

because of improper installation.

5) During installation, personnel shall operate cautiously to avoid

module bumping, scratches, and drop and prevent personnel from

standing or sitting on modules.

3.4.3 Module positioning

Modules are mounted vertically or transversally.

A. Transversal installation as below:

B. Vertical installation (as below).

GS-Solar recommends the vertical method for ground installation,

and the advantages are as below:

1. Effectively reduce sun-shading loss and increase system

outputoutput. For reasons, please refer to 3.2 Sun-shading

Consideration.

2. Easily optimize sun-shading design as per local climate and

effectively reduce system floor area.

3. Easily conduct electric connection. The upper and lower rows

Transverse


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are connected in series respectively as per the description in 4.2.3.

No need for extra cable, which saves system cost.

4. Effectively reduce the loss arising from system mismatching and

increase system output.

Disadvantages of vertical installation:

1. If clamps are not tightened, modules are likely to fall off.

2. If clamps are locked too tight, it is likely to cause stress and

break modules.

Hence, GS-SOLAR introduces torque wrench（5 N•m）to control

locking force, which effectively avoid above disadvantages.

3.4.4 Installation of mounting clamps

1) Specification of clamps

A. End clamps

Vertical


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B. Middle clamps

2) Position and size of clamps

A. End and middle clamp size

B. Middle clamps and middle clamps size

662

662


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3) Installation of end clamps

Mount a bolt, an end clamp, a flat washer, a spring washer, and a

nut, respectively onto a bracket, but not tighten.

4) Installation of middle clamps

Mount a bolt, a middle clamp, a flat washer, a spring washer and a

nut, respectively onto a bracket, but not tighten.

3.4.5 Installation process

1) Before installation, please confirm if the bracket of solar module

unit satisfies design size (bracket in good order without obvious

deviation) and if the bracket assembled is solid and reliable.


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2） Please confirm if the distance from the mounting hole center of the

first rail (eg: C-type steel) to the second rail is 662mm, and if the

distance between mounting holes of other two rails is 662mm.

3) Measure with a tape the corresponding position of a module edge on

the bracket after the module is installed as below (taking example of

vertical installation of 2 modules, the module edge is 15mm away from

the centerline of the bracket long side), make a mark (point A), and

adjust a laser level to the same height as the mark (point A), and beam

out a horizontal laser ray. Make a mark (point B) on the last rail along

662mm

662mm 662mm

662mm

Rails qty as per

actual design. In

the illustration,

other rails are

ignored.

1st rail

Last rail

Bracket support legs Note：this is an illustration.

Design as per specific

site

Bracket rails

For module fastening


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the laser ray (ensure point B and point A's level deviation on the bracket

within 15mm)

4) Pull a horizontal plumb line from point A to B and fix it at two points.

Personnel fixing a horizontal plumb line must

wear laser protection glasses ( to avoid eye burn)

B

A

Plumb line

30mm 15mm

B

A

Bracing

centerline along

long side Laser ray

Module edge


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5) For the first module installation, the lower edge of a module is along

the horizontal line (line AB). The first row of modules are installed

along this base line (if tilt angel, GS-SOLAR recommends top to

bottom installation solution).

6) Mount the end clamps on the bracket and fasten nuts so that clamps

will not slide (end clamps are applicable for fastening modules along

the edge. )

Makes sure clamps and the parts in contact with

clamps are clean without foreign matter, which

might casue stress and break modules.

12th

module

Arrow shows mounting sequence


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7) Insert a module into EPDM pad of an end clamp and fasten nuts so

that the module will not slide.

8) Insert a module to a middle clamp and mount it onto the bracket.

Please fasten an end clamps at the front , and lock the middle clamp

but not tighten before the next module insert to EPDM of this middle

clamp，then lock the nuts. (Middle clamps are used to tighten two

neighboring modules.)


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9) Lock the nuts on the left side of the clamps as per above method.

10) Repeat Step 7） and 8）till the last 2 modules in one row are to be

installed. (GS-SOLAR suggests no more than 12 modules each row

unless one row of modules can stay level.


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11) The last module of the row is mounted with end clamps. (If more

than 12 modules each row, please use middle clamps to install the 12th

module to enable module mounting afterwards.)


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12) After the first row of 12 modules are installed, check the levelness

and make adjustment if necessary. If no problem with levelness, move

down a horizontal drop cord from the horizontal line (line AB) fixed as

per Step 3) by 30mm [module row pitch at 30mm (in view to palm

thickness) for easy mount], and then start mounting row 2 and 3

modules (the module top edge shall be along the horizontal line), other

installation steps are the same as the 1st row. (Unless the inclination

angle of the bracket is 0 or modules are installed on a sloped rooftop,

GS-SOLAR suggests no more than 3 rows of modules).


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13) Finish installing 3 rows of modules. (If modules each row are

designed to exceed 12 and more than 24 modules, GS-SOLAR

recommends the installation sequence as below to ensure levelness of

each row installed.)

4 Electric installation

4.1 Electric connection

Module connection can choose series, paralleling or series and

paralleling connection to achieve the required output. During installation, the

same type of modules string uses the same inverter.

1st module

12th module

24th

module

30mm


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Series connection: modules with series connection generate required output

voltage. The voltage shall not exceed maximum system voltage of the

module and maximum direct voltage of the inverter. Maximum system

voltage of the module is shown on the module product information list,

and maximum direct voltage of the inverter is shown on the inverter

electric data.

Paralleling connection: modules with paralleling connection generate

required current output. When connecting one array with the other,

current return, which might destroy modules, is must considered. For

maximum return current value, please refer to the module product

information list.

4.2 Solar module connection

1. Cable requirements: Modules are connected with cables of insulation grade

above 1000v, 2. 5 mm2 in size and ultra-violet resistant. If exposed in air,

high-temperature endurable insulating cables (minimum high-temperature

resistance at 90℃) are used.

2. Connector connection: there is one positive and one negative wire at the

back of a solar module. When connecting two terminals of a waterproof

connector, tighten the connector till the terminal reaches the bottom. (The

picture below shows one type of connector. The connector to be used for the

product may be different.)


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A connector must be tightened. Loose connection

might lead to overheat, burn or other damage.

3. Module series connection: the negative wire of the first solar panel is

connected with the positive wire of the second solar panel. The negative wire

of the second solar panel is connected with the positive wire of the third solar

panel, and vice versa, till the sequence satisfies module string number in the

design.

4. Connection test: test open-circuit voltage of a module string with a

multi-meter and auxiliary cable. If no voltage is shown on the multimeter

(direct current), check this string of modules one by one till abnormal module

and reason is found. Fix it before next process. If the test shows voltage is

abnormal, the positive wire of the first solar panel and the negative wire of the

last panel shall be connected to the module string output cable.

Voltage testers must wear insulating gloves to avoid

electric shock.

5. Cable clear-up: If module cables are tangled, clear it up and make a mark ，

fix it behind the module.

Wrap cable end with insulating tape. In direct sunlight,

solar module will generate high voltage. Be careful of

electric shock.


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6. Cable identification: Cable output terminal of each set of solar modules shall

bear an identification card (plate). The card shows the number of solar

modules, the polarity of solar array output cable (e.g. positive or negative) so

that an electrician can understand output terminal’s location of at the system

electric structure.

7. Connector protection: timely finish electric connection after module

installation. If electric connection is not finished in time or wind and snow

weather is forecast soon, lock positive and negative connectors of output cable,

or wrap connector terminals with insulating tape, which can effectively protect

metal pieces of a connector.

Without proper protection, electrode wires and

connectors are likely to be damaged.

If a wire is installed outdoor or through wall, please use metal tube, soft

metal tube or apply other protective measures, otherwise it might cause

electric shock or short-circuit.

8. Special situation requirements: If solar module output cable is under direct

sunlight, do use tubes to avoid electric shock.


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4.3 Rules

Electric installation and wiring method shall strictly comply with the latest

local power regulations and some local regulations, permits and inspection

requirements.

In Canada the installation shall be in accordance with CSA C22.1, Safety

Standard for Electrical Installations, Canadian Electric Code, Part1. .

The system is designed by professionals familiar with solar system.

Carefully confirm voltage limit and overcurrent specification. Module

performance and safety relies on intact design and installation of electric

system.

Maximum system return current: In system design, one external return

current resistant diode can be mounted to one module or

array. It can be combined with a module or a series of

modules.

Return current: In special situations, if a module is shaded, it is likely to cause

extreme temperature, which is out of working range for a module.

It is likely to break glass, and cause temporary electric arch (if

conductive material is damaged) and smoke. If a big array is

considered in the design, the designer is suggested to contact

GS-SOLAR for design assistance.

Grounding: As modules have no frame or exposed conductive part (except

wire pins), grounding of module external surface is not required.

According to state electric regulations, conductive parts of any

non-carrier mounting structure must be grounded in compliant

with local standards. A correct grounding system must ensure that

under a lightening stroke, the electric system has the lowest loss,

and that the current protection device is easy to start under


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electric failure.

Negative electrode of a module can be grounded or not grounded, which

is decided by inverter condition. If an inverter is electrically isolated without

transformer, the negative or positive electrode of a module is not grounded; if

an inverter is electrically isolated with a transformer, the negative or positive

electrode of a module can be grounded or not; for large-capacity(≥100KWp),

an inverter is electrically isolated with a transformer and the negative

electrode of a module is grounded by groundeding protection module made

by inverter supplier ,or PV module output terminals not grounded.

GS-SOLAR suggests that system design shall give priority to good

grounding measures to achieve safety. The design includes, but not limited to,

complete grounding to ensure low resistance of electrode grounding, and

potential failure treatment ability developed in the entire electric system.

5. Maintenance

Daily module maintenance is not required. But it is recommended to

regularly check if module glass is broken and if electric connection is loose or

corroded. Please refer to Thin-film Solar Module Maintenance Manual for

details.

6 Disclaimer

GS-SOLAR is not liable for this manual use and condition, or system

design installation, operation, use method, and module maintenance, which

is out of GS-SOLAR control, and declares that GS-SOLAR is not liable for

any loss or injury fee arising from improper installation, operation, use or

maintenance and connecting method, not compliant with this manual,

GS-SOLAR is not liable for any consequences arising from infringement of

some patents or other third party rights because of module use. GS-SOLAR's

liability of defective products is solely limited to replacement of defective


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products.

Customers shall not utilize any patent or authorized patent use of

GS-SOLAR products, whatever expressed or implied. The manual is compiled

by GS-SOLAR personnel according to their own knowledge and experience,

but does not guarantee responsiveness to the information and proposals

contained, and shall not constitute any warranty expressed or implied.

GS-SOLAR reserves rights to change product and specification. Content

renewal, is any, will not otherwise be notified.

GS-SOLAR CO.,LTD

Address: Jiangnan High-tech Electronic

Industrial Zone, Nanhuan Road, Quanzhou,

Fujian,GHINA

Tel：086-0595-22412383

Fax：086-0595-22412393

E-mail：[email protected]

Website：http://www.gs-solar.com

Documents

12installation manual V4 for thin film PV module For ... · GS-SOLAR thin-film solar module installation manual GS-SOLAR CO.,LTD 6 3 Machinery installation 3.1 Location consideration