AIKO PV Module Installation Manual - Double Glass Module

Structural diagram of double glass modules and component description

The diagram shows a double glass module with the following components:

• 1. Aluminum alloy frame
• 2. Front glass
• 3. EVA (Ethylene Vinyl Acetate)
• 4. ABC cell (All Black Cell)
• 5. Back glass
• 6. Silicone
• 7. Junction Box
• 8. Nameplate
• 9. Cable
• 10. Connector
• 11. Mounting hole
• 12. Grounding hole
• 13. Leak hole
• 14. Barcode

3.1 Module identification

AIKO modules have two visual labels:

• Nameplate: Displays product type, rated power, rated current, rated voltage, open circuit voltage (Voc), short circuit current (Isc) under Standard Test Conditions (STC), maximum system voltage, and certification marks.
• Serial number: Each module has a unique serial number printed on a barcode and embedded before lamination, making it permanent. The serial number is also found on the module frame and back.

Barcode labeling is also present on the module.

Packing List

The packing list includes module type, product serial number, package weight, package dimension, and cell color classification to ensure system color consistency. An example includes:

Serial numbers are listed in a table format for individual modules.

3.2 Wiring method

AIKO modules have the junction box in the middle. Series connections are made as follows, depending on the mounting type:

• Mounting on the long side, single row: Horizontally adjacent modules are connected directly or via secondary beams.
• Mounting on the long side, double rows: Connections between adjacent rows are designed with opposite polarity on the same side. Adjacent modules can be connected via a duct. For vertical installation, connections between vertically adjacent modules are designed with opposite polarities and extension lines can be placed into the secondary beam.
• Mounting on the short side, single row: Similar connection logic applies.
• Mounting on the short side, multiple rows: Vertically adjacent modules are connected directly. Adjacent columns are designed with opposite polarity on the same side.

Diagrams illustrate these connection types.

3.3 General safety

• AIKO modules comply with IEC standards IEC-61215 and IEC-61730, with safety class II and fire class rating C.
• Read and understand this Installation Manual before handling or installing. Contact AIKO (aikosolar.com) for explanations.
• Use appropriate protections: insulated tools, safety helmets ⛑️, insulating gloves ?, safety belts, and safety shoes ?. Use appropriate electrical safety tools.
• PV modules generate DC electrical energy when exposed to sunlight ☀️ or other light sources. Improper contact with live parts (connectors) can result in burns ?, sparks, and lethal shock ⚡.
• Observe local laws and regulations for module installation and obtain necessary qualifications.
• Modules must be installed by qualified persons with specialized skills and knowledge of the system's mechanical and electrical requirements. Identify potential risks like electrical shock in advance.
• Rooftop systems require roofs that have passed structural analysis.
• Observe safety regulations for all mounting components, wires, cables, connectors, inverters, and batteries.
• Artificial concentrated sunlight should not be directed onto the module.

3.4 Electrical safety

• Follow electrical safety precautions strictly to avoid accidents. Modules can generate DC voltage >30V and current >10A (STC). Avoid direct contact. Wear protective helmets ⛑️, insulating gloves ?, and rubber shoes ?. Do not install components without security precautions.
• Do not drill holes in the frame, as this risks module insulation failure.
• Make electrical connections only via connectors.
• Replace broken modules immediately due to risk of electric shock and fire ⚡.
• Install modules only when electrically safe.
• Avoid touching modules as surfaces and frames can be hot, risking burns ?. The series voltage must not exceed the maximum withstand voltage.
• Do not connect or disconnect modules during current leakage or when external current is present. Disconnect faulty modules with safety protection.
• Do not connect the positive and negative anode cables of the same PV module together.
• Do not open the packing box before modules arrive; keep in a ventilated, dry environment.
• Refer to Section 4.0 for Storage and Transportation instructions. Improper handling and storage can cause breakage or loss of electrical property.
• When installing, do not lift modules by the junction box or cable. At least two operators must hold the module edges with both hands.
• Do not attempt to dismantle the module or remove nameplates/components.
• Do not apply paint or other adhesives to the module's top surface.
• Do not damage or scratch the glass on the front or back side.
• Do not drill holes in the frame, as this reduces frame loading capacity, can cause corrosion, and may invalidate the warranty.
• Do not scratch the anodized coating of the aluminum alloy frame, except for grounding connections, as this may lead to corrosion and reduce reliability.
• Do not repair or modify the module yourself.

4.1 Considerations for module turnover and handling

• Upon arrival, check the packaging for good condition and verify module type and quantity against the delivery order. Contact AIKO logistics if there are any issues.
• Crane unloading: Use specialized tooling for the weight and size of the pallet. Adjust sling position for stability. Use wooden sticks or boards on the upper part of the box to prevent the sling from squeezing and damaging the modules. Operate the spreader at a constant speed. Place the box gently on relatively flat ground. Do not unload modules in wind conditions exceeding Beaufort scale 6 ?.
• Forklift unloading: The loading dock should be at the same height as the carrier's underside. Maintain straight line speed within 5 km/h and turning speed within 3 km/h. Avoid sudden stops and rapid starts. If the packing box obstructs the driver's sight, drive in reverse and ensure special supervision to prevent collisions.

4.2 Considerations for module turnover and transportation

• When using a forklift, ensure fork length meets requirements to avoid module tilting.
• When opening the packing box, place modules to be unpacked at a distance of 20-30cm from the wall or other modules. Remove the torr (stack). After removing cable ties, slowly lean modules against the wall or torr to prevent falling.
• Handle modules gently during transportation. Do not lift by the junction box or cables. Two or more people must hold the module edges with both hands.

4.3 Considerations for module storage and placement

• Store modules in a clean, dry place with relative humidity below 85% ?. Storage temperature should be between -20°C and 50°C.
• Do not stack two boxes of modules on top of each other for long-term storage.
• Keep the junction box and cables clean and dry.
• Store in a ventilated, rainproof, dry place. If stored outdoors, fully cover modules and pallets with rain protection and take moisture-proof measures to prevent collapse and moisture ingress.
• For scattered modules, stack vertically with the glass side up for the first module, followed by modules with the glass side down. Maximum stack: 22 pieces for 54 types, 16 pieces for 72 types.
• For long-term storage, keep the original package. It is recommended to store modules in a standard warehouse and conduct regular inspections. Address any abnormal tilt immediately.

5.1 Location and working environment

• Install modules in an environment between -20°C and 50°C (extreme working temperature -40°C to 85°C) with humidity less than 85%RH ?.
• Modules are designed to operate up to 2000 m above sea level.
• Do not install in locations at risk of flooding, near open flames ?, or flammable materials.
• Install modules at least 50m away from the seashore. For installations between 50m and 500m, frames and components need anti-corrosion treatment.
• For rooftop installations, ensure a safe working area between the roof edge and the PV module array. Check roof loads and create a construction organization plan.
• Position modules to receive adequate sunlight ☀️ and avoid shading from trees or buildings.
• Ensure modules are installed in a well-ventilated position for adequate air circulation on the back and sides to dissipate heat. Poor heat dissipation reduces output power.
• For areas with high wind ? or snow ❄️ pressure, design supports and fixings according to local standards to withstand external loads.
• In areas prone to salt fog, sulfide, or ammonia gas (coastal, factories, volcanic, farmlands), use anticorrosive materials for module-to-racking connections and ground connections.
• After installation, ensure modules are protected against lightning strikes ⚡ via grounding.

5.2 Tilt angle selection

The tilt angle is the angle between the PV module and the horizontal ground. Different projects require different installation angles based on local conditions. All modules in the same array should have the same orientation and angle to avoid output mismatch and ensure system efficiency. For maximum annual energy generation, select the optimal orientation and inclination. When the module surface is perpendicular to sunlight ☀️, output power is maximized. AIKO recommends a tilt angle of not less than 10 degrees. The optimal tilt angle should consider multi-year mean irradiance, direct/scattering irradiance, wind speed, snow load, and water/dust collection. Consult a reliable local solar system installation company for details.

6.1 General requirements

• Ensure modules are properly installed and the mounting structure is adequately fastened. Use anticorrosive, UV-resistant materials.
• Installation bracket systems should be tested by a third party according to local or international standards.
• In regions with heavy snowfall ❄️, adjust mounting system height so the module's lower edge is not covered by snow and is not in the shadow of plants/trees.
• For rooftop installations, maintain a minimum gap of 10cm between the module frame and the roof for air circulation.
• The minimum mounting distance between adjacent modules is 10 mm.
• Ensure the module's backside does not contact piercing structures, especially under pressure.
• Modules can be installed horizontally or vertically. Be cautious not to block drain holes.
• Module loads described are test values. According to IEC 61215-2016, a safety factor of 1.5 is required for maximum design load calculations, complying with local laws. Project design loads must be based on location, climate, mounting structure, and standards. Consult mounting suppliers and structural engineers.

6.2 Mechanical installation of double glass modules

AIKO double glass modules can be mounted using pressure clamps and bolts. Follow recommendations below. Other configurations require AIKO Energy's prior written consent, otherwise the warranty will be invalidated.

06 Mechanical installation (continued)

07 Electrical installation

08 Grounding

Module frames are made of anodized anticorrosive aluminum alloy and must be grounded for safety, lightning ⚡, and electrostatic protection. Grounding must ensure full contact with the interior of the aluminum alloy frame, penetrating the oxide film. Grounding devices include grounding screws, flat washers, puncture gaskets, and grounding wires (stainless steel except for wires, which are copper). Connect to the ground through an appropriate grounding electrode. Third-party grounding devices meeting local electrical installation standards may be used. Install grounding devices according to the manufacturer's manual.

Recommended grounding method: Use the grounding holes (Ø 4.2 mm) on surface C of the module frame. Connect the aluminum alloy frame to the ground using a separate grounding wire and accessories. AIKO recommends M4×12 mm grounding bolts with M4 nuts, star washers, and flat washers. Torque grounding bolts to 3~7 N•m and use 4 mm² copper wires. Unused module mounting holes can also be used for grounding. The connection sequence is: star washer, flat washer, ground wire, screw, tightened.

A diagram illustrates the grounding components and method.

09 Maintenance of PV modules

Modules shall be inspected and maintained regularly, especially within the warranty period. Report any damage or visible abnormalities to AIKO Energy customer service. Any damage or abnormalities of the module shall be reported to AIKO Energy customer service upon discovery.