Installation Guide for GESOLAR Photovoltaic Module

GES-5Mxxx (xxx=170~200) GES-6Mxxx (xxx=205~320) GES-6Pxxx (xxx=180~300)

IssueEN-2011-1

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Content
Content ............................................................................................................................... 1 Introduction ........................................................................................................................ 2 Disclaimer of liability .................................................................................................. 2 General Safety and Warnings ................................................................................... 2 Dimension .......................................................................................................................... 6 Installation .......................................................................................................................... 6 Mechanical installation ............................................................................................. 7 Grounding ................................................................................................................. 10 Wiring ................................................................................................................................ 13 Maintenance & inspection ............................................................................................. 14 Warranty ........................................................................................................................... 14

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Building C, 21 Ruanjian Road, Nanjing 210012, China

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Introduction
Thank you for choosing GESOLAR photovoltaic (PV) modules. This installation manual contains important information about safety, mechanical and electrical installation that you must know before installing GESOLAR PV modules. With proper operation and maintenance, GESOLAR PV modules will provide you with clean, renewable solar electricity for many years.

Disclaimer of Liability
GESOLAR does not assume responsibility and expressly disclaims liability for loss, damage, or expense arising out of or in any way connected with such installation, operation use or maintenance by using this manual. No responsibility is assumed by GESOLAR for any infringement of patents or other rights of third parties, which may result from use of the PV product. No license is granted by implication or otherwise under any patent or patent rights. The information in this manual is believed to be reliable, but does not constitute an expressed and implied warranty. GESOALR reserves the right to make changes to the product, specifications, or manual without prior notice.

General Safety and Warnings

In order to use the modules properly, avoiding property losses or injuring the operator or anyone else, warnings and some other caution signs are printed on the solar modules and manuals. Sign Introduction

Sign

Introduction

Warning

Means Misoperation will cause a risk of lethal or personal serious injury

Caution

MeansMisoperation will cause a risk of injuring or property loss

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Graph Introduction Graph Introduction Prohibited (proceeding not permitted ) The details will be described in the signs, graphs and texts Compulsion (proceeding is compulsory ) The details will be described in the signs ,graphs and texts Caution (Warning included) The details will be described in the signs or graphs and texts General Warnings Solar module installation, maintenance, removal and resetting shall only be done by distributor or professionals If there are defects, there is a risk of electric shock or fire. When installing, wiring, operating, removing and maintaining modules, pay attention to the risk of electric shock. If module is shined by sunlight or other illuminator, the DC electricity will be produced. Artificially concentrated sunlight shall not be directed on the module. Under normal conditions, a photovoltaic module is likely to experience conditions that produce more current and/or voltage than reported at standard test conditions. Accordingly, the values of ISC and VOC marked on this module should be multipled by a factor of 1.25 when determining component voltage ratings, conductor ampacities, fuse size, and size of controls connected to the PV output. Please refer to Section 690-8 of the National Electrical Code for an additional multiplying factor of 125 percent (80 percent derating) which may be applicable. If modules are connected in series or parallel, the voltage and current will increase, the danger will be increased tremendously accordingly. When installing, wiring or maintaining modules, in order to prevent producing the DC electricity, please cover the module surface with sufficiently opaque stuff. When installing, wiring or maintaining modules, please use protective instruments such as rubber gloves. If high reliability is required (the machine is related to person life), please dont use those modules. Output is unstable, serious accidence such as lethal injure may occur. The modules are qualified for application class A: Hazardous voltage (IEC 61730: higher than 50V DC; EN 61730: higher than 120V), hazardous power applications(higher than 240W) where general contact access is anticipated (Modules qualified for safety through EN IEC 61730-1 and -2 within this application class are considered to meet the requirements for Safety Class II)

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Warning for Installation Installing, maintaining, removing and resetting modules shall only be done by distributor or professionals. Dont stand or stamp on the solar modules. Because glass face of the module will be damaged and it is slippery which may make injure to someone. Dont wear steel stuff like rings. There is a risk of electric shock.

Dont touch the terminals. There is a risk of electric shock. Sharp stuff prohibited. It may puncture the back of module. There is a risk of electric shock, electricity leakage and solar modules service life may be shortened. When connecting modules with other controlling device, please entrust distributors or professionals. Grounding If not connected properly, it will cause a risk of electric shock. Please dont connect the cable with any other pipes such as gas pipe, water pipe, thunder-avoiding rod, etc. Each PV module has a hole on each side with a grounding sign. The use of the listed grounding and bonding equipment (KDER), type 1954381-1, by Tyco Electronics Corp (E69905), is in order to provide a reliable grounding connection to the module frame.

Dont put wires between frame and prop. The wire may be damaged and cause electric shock and fire.

Dont damage or process wiring material. It may cause a risk of electric shock.

Dont install solar modules on movable objects such as doors, vehicles. The glass may be damaged and causes injury.

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Warning for Operating Do not open cover of junction box, it may result in electric shock. Do not damage or process wiring material, which may cause a risk of electric shock. Dont let children approach modules. There is a risk of electric shock or injury. Do not prick back of solar module with sharp objects otherwise may result in electric shock, electricity leakage or make solar module damaged.

Warning for Maintenance Dont open cover of junction box and clean inside with liquid, it may result in electric shock. Do not use damaged, abnormal solar module which may cause risk of electric shock. If so, please contact distributor or professionals. Dont immerse the solar modules in liquid, it may result in electric shock.

Dont deform, mend solar Module, it may result in electric shock or be wounded.

Caution

Dont touch solar modules. The module will become high temperature under sunshine, and may cause a risk of scalding.

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Dimension
(Module type: GES-5Mxxx, with Junction box, cable and connector)

Front

Side

Backside

Figure 1

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Installation
Mechanical Installation
Site Selection Please select the site without shadows from trees or buildings, enabling the module to be shined by sun frequently. Especially in very hot weather, please pay attention the modules cant be shadowed partly. Furthermore, in different season, the dimension of shadow caused by plant or any other objects will be changed and may shadow some portions of solar modules, resulting in power generation reducing. Please make sure that there are no obstructions in the surroundings of the installation site. Take proper steps in order to maintain reliability and safety in case the PV modules are installed in areas that have heavy snow, extreme cold, strong winds , installations over or near water and areas where installations are prone to salt water exposure or on small islands or in desert areas. Installation Direction In order to get best power production, PV modules should typically face south in the northern hemisphere, and typically face north in the southern hemisphere. Tilt Angle The tilt angle of the PV module is the angel between PV module surface and horizontal level. There should be 5 cm minimum airspace between the lowest point of PV module and mounting surface. Recommended Tilt Angle for a Fixed System Site Latitude in Degrees 0 to 15 15to 25 25to 30 30to 35 35to 40 40+ Fixed Tilt Angle 15 Same as latitude Latitude + 5 Latitude + 10 Latitude +15 Latitude +20

GESOLAR, Sainty International Group Tel: +86-25-52874084 Fax: +86-25-52875828 21 C 210012

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Building C, 21 Ruanjian Road, Nanjing 210012, China

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Sun light PV module

Tilt angle 5 cm
Figure 2

Horizontal level Mounting ground

Irradiation each day will be different according to different latitudes all over the earth. The optimum angle is equal to latitude but also subject to the design conditions such as site and design angle, etc. Modules are allowed for roof mounting and should be mounted over a fire resistant roof covering rated for the application. But if operating time and operating purpose are limited, the above mentioned design may not be optimum, you can also contact distributor about this. Support Structure Selection In order to make PV modules have a long service life outside please pay attention to the following items: Adopt strong and safety structure. Choose durable, corrosion-resistant and UV-resistant material for support module mounting structure. Follow all kinds of regulations concerned Dont damage any parts of modules for power generation. Be easy to maintenance The foundation shall be done by professional designer or construction company

Mounting Methods 1. Mounting with Bolts The module must be attached and supported by at least four bolts through the indicated mounting holes, as shown in Figure 3. Most installations will use the four inner mounting holes on the module frame. Depending on the local wind and snow loads, additional mounting points may be required.

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Building C, 21 Ruanjian Road, Nanjing 210012, China

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Component Bolt Nut Washer Flexible washer

Quantity 4 4 8 4

Dimention M8 M8 M8 M8

Material Stainless steel Stainless steel Stainless steel Stainless steel

Back View of PV Module

PV Module Bolt Washer Support Element

Washer Flexible Washer Nut

Figure 3

2. Mounting with Clamping Hardware

Figure4
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If module clamps are used to secure the module, the torque on the clamp bolt should be around 810 Nm. Four module clamps should be used at least two on each long frame side. Depending on the local wind and snow loads, additional module clamps may be required.

Grounding
Introduction All the modules should be ground-connected with the ground holes of the modules. Size of earth and the equipment grounding conductor are in accordance with local requirements. Attach the equipment grounding conductor to the module frame using the grounding hole and hardware provided. The grounding clip assembly consists of a slider, base, and a 8-32 screw and hex nut. The screw is used to mount the grounding clip to the frame of the solar module. The slider is used to hold the wire. The slider features a multidimensional curved wire slot that provides enhanced wire retention. The base is used to terminate the wire. The base features pointed lances that provide four points of contact to the frame for high reliability and antirotation of the grounding clip. The removal slot accepts the tip of a flathead screwdriver which is used to disengage the slider. When the slider is disengaged, the wire can be removed, and the screw is exposed for removal.

Figure 5

Installation The grounding clip must be placed onto the frame so that the screw straddles a predrilled 4.09mm diameter hole. The screw should be tightened to a torque of 2.3 and 2.8 Nm. The head of the screw must be flush with the base and the base must be flush with the frame. The hex nut must be tight.

GESOLAR, Sainty International Group Tel: +86-25-52874084 Fax: +86-25-52875828 21 C 210012

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Building C, 21 Ruanjian Road, Nanjing 210012, China

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Figure 6

Removal The wire can be removed from the grounding clip when the slider is disengaged (slider and screw are exposed). The screw must be loosened before the grounding clip can be removed from the frame. The grounding clip can be reused up to 5 times after proper removals (the 8 32 screw and hex nut can be reused). Repair The grounding clip is not repairable. Discard any defective or damaged grounding clips.

GESOLAR, Sainty International Group Tel: +86-25-52874084 Fax: +86-25-52875828 21 C 210012

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Building C, 21 Ruanjian Road, Nanjing 210012, China

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Wiring
Please notice the correct cable connection polarity when installing the modules. If not connected properly, the bypass diode would be destroyed. For bypass diode, rated current of 15A and Maximum reversing voltage of 45V are chosen for Junction box. Maximum Series fuse rating: 8A for GES-5Mxxx (xxx=170~200); 13A for GES-6Mxxx (xxx=205~320) and GES-6Pxxx (xxx=180~300). Modules are equipped with Multi-contact connector as electrical connections. Use the National Electric Code to determine system wiring size (refer to NEC clause 310), type and temperature rating of conductors to be connected to the module's connectors. Wiring connected to the module's wiring should be 1X4.0mm2 (minimum) and rated at 90 (minimum). PV modules can be wired in series to increase voltage as shown in figure 7. In this case, the maximum open circuit voltage must not be greater than the specified maximum system voltage. The voltage is proportional to the number of series. PV modules can be wired in parallel to in increase the current as shown in figure 8. In case of parallel connection, please take proper measure to block the reverse current flow. Otherwise, the current may easily flow in a reverse direction.

Figure 7

Figure 8

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Maintenance & inspection

Solar modules require very little maintenance. It is not uncommon for a remote site to be checked but once per year. Under most conditions, normal rainfall is sufficient to keep the module glass clean. If dirt build-up becomes excessive, clean the glass with a soft cloth using mild detergent and water. Modules that are mounted, flat (0 tilt angle) should be cleaned more often, as they wont "self clean" as effectively as modules mounted at 15 or a greater tilt. Once a year, check the tightness of terminal screws and the general condition of the wiring. Also, check to be sure that mounting hardware is tight. Loose bolts could result in a damaged module or array.

Warranty
Detailed warranty terms please refer to Limited Power Warranty for PV Modules.

GESOLAR, Sainty International Group Tel: +86-25-52874084 Fax: +86-25-52875828 21 C 210012

www.gesolar-power.com

Building C, 21 Ruanjian Road, Nanjing 210012, China