Global Installation Manual for
GCL System Integration Technology
Photovoltaic Module
Version：GCLSI_2016.V1
Purpose of this manual
Disclaimer
Safety and Transport
Mechanical Installation
Electrical Installation
Grounding
Bypass Diodes and Block Diodes
Maintenance
02
02
03
04
10
11
12
13
CONTENTS
GCL System Integration Technology Co.,Ltd
Bringing Green Power to Life
01
Purpose of this manual
Disclaimer
GCL System Integration Technology Co.,Ltd
Bringing Green Power to Life
02
This manual is used for GCL System Integration Technology Co., Ltd. (hereinafter
referred to as GCLSI) solar modules (hereinafter referred to as the Module or Modules)
only. This manual contains installation methods, operation safety and relevant
maintenance information of GCLSI’s Modules.
Modules must be installed by professionals. Please ready this manual carefully before
installation. The installers must follow all the rules described in this manual strictly as
well as local requirements and regulations by law or authorized organizations .
Before installing, the installer must be familiar with their mechanical and electrical
requirements. Please keep this manual in a safe place for future reference (care and
maintenance) and in case of sale or disposal of the Modules.
GCSI shall not be responsible for any loss arising from installation, operation, use or
maintenance of the Modules which is not complying with the guidance of this manual,
including breakdown or damage of the Modules or any other expenses incurred.
Any customer shall not get any patent or authorization of the patent when using the
Modules, expressed or implied. Any infringement of patents or other rights of the third
party, which may result from the use of the Module, is not within the responsibility
scope of GCLSI.
The information in this manual is based on GCLSI’s knowledge and experience and is
believed to be reliable, but such information including product specication (without
limitation) and relevant suggestions do not constitute a warranty, expressed or
implied.
GCLSI reserves the rights to change the manual, the Modules, the specications or any
other information of the Modules without prior notice.
GCL System Integration Technology Co.,Ltd
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03
Modules Carry and Installation Instruction
Both hands when handling Modules Ensure Modu les are xed proper ly Do not use sha rp objects with M odules
Do not pulli ng the wiring cable s
or junction box
Do not stam p on Modules
Do not touch M odules with
bare or dirty hands
Do not pile u p Modules on
uneven ground
Do not drop o r throw Modules
Do not stamp on Modules or put weight on Modules.
Do not disassemble or drop Modules.
Do not use mirrors or magniers 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.
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 .
Unpacking and Storage
SAFETY&TRANSPORT
MECHANICAL INSTALLATION
Location Selection
Installation Angle
Local Latitude
0°~ 15° 15°
Latitude
Latitude
+5°
Latitude+10°
Latitude+15°
Latitude+20°
15°~ 25°
25°~ 30 °
30°~ 35°
35°~ 40°
＞40°
Module installation angle
Tab l e 1
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Select suitable places to install Modules.
Install Modules at the places with sucient sunlight and without shade at any time. If
a module is shaded or even partially shaded, it will result in lower power output. A
permanent or regular shade will cause damage to the module, which will void GCLSI’s
warranty.
Do not place, install or use Modules at the places where combustible gas is easily
generated or gathering.
The straight-line distance between the installation site and coastline shall not be
shorter than 1 km unless there is a written approval from GCLSI or an engagement
specied in the contract.
Modules in the same string should be installed at the same angle. Modules installed in
dierent angles will receive dierent irradiation, which will cause current dierent. As
a result, it will decrease the operation eciency of the system.
Please refer to Table 1 for the recommended installation angles of the Modules.
Module Installation
General Installtion
The mounting structure must be made of durable, corrosion-resistant and UV-resistant
materials. Always use a tested and certied mounting structure for the system.
Make sure Modules are securely fastened to the mounting structure to withstand
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 ying
sands.
As for the system installed on the ground, the minimum distance GCLSI recommends
between the bottom of Modules and the ground should be 24 inches (60 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 GCLSI and not subjected to excessive force due to the thermal expansion
of the mounting system. 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 surface and the Module is GCLSI generally
recommended.
To prevent the linear thermal expansion of the Module frames, GCLSI suggests that the
minimum distance between two Modules should not be shorter than 2cm.
Always follow the guidance and safety rules specied in the mounting system.
Do not drill holes on the glass surface or the frames of the Module, which will void the
warranty.
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M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
安装夹
组件
安装支架
图 2
M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
组件
安装支架
图 1
Installation Method
Insertion system: Insert the whole Module into the rail, as shown in Figure 3
.
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.
Clamping system: Use suitable clamps to x the Module on the support frame, as
shown in Figure 2.
Figure 1
Figure 2
Figure
3
M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
安装夹
组件
安装支架
M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
安装夹
组件
安装支架
图 2
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Module
Module
Mounting
Structure
Mounting
Structure
Nut(M8,SS)
Nut(M8,SS)
Spring washer
Spring washer
Flat washer
Flat washer
Bolt(M8,SS)
Bolt(M8,SS)
Clamp
Select a suitable installation method depending on the load requirements. More
detailed information is shown in Figure 4.
It has been tested that GCLSI’s Modules can withstand the loads of 2400 Pa, 3800 Pa
and 5400 Pa (IEC 61215 Standard), which are respectively equivalent to 1600 Pa (0.232
psi), 2500 Pa (0.363 psi) and 3600 Pa (0.522 psi) under UL1703 Standard, when dierent
installation methods are used.
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2400Pa
Permissible clamp Permissible clamp
Use 4 mounti ng holes
Use 4 mounti ng clips Use 4 mounti ng clips Use 4 mounti ng clips Use 6 mounti ng clips
Use 8 mounti ng holes
Permissible clamp
Permissible clamp
Permissible clamp Permissible clamp
Permissible clamp
3800Pa 5400Pa（Snow Loads Only）
Mounting hole system
Clamping system
Attachment to the long frame
Clamping system
Attachment to the short frame
Insertion system
Insertion system
Insertion system
Insertion system
Insertion system
Use 4 mounti ng clips
Use 4 mounti ng clips on short f rame
Use 2 mounti ng clips on long fra me
Figure 4
Use 4 mounti ng clips
Use 4 mounti ng clips on short f rame
Use 2 mounti ng clips on long fra me
Use 4 mounti ng holes Use 8 mounti ng holes
Permissible clamp
Permissible clamp Permissible clamp
Permissible clamp Permissible clamp
Use 4 mounti ng clips Use 4 mounti ng clips Use 4 mounti ng clips Use 6 mo unting clips
孔
Permissible clamp Permissible clamp
2400Pa 3800Pa 5400Pa（Snow Loads Only）
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Mounting hole system
Clamping system
Attachment to the long frame
Clamping system
Attachment to the short frame
Insertion system
Insertion system
Insertion system
Module Specication (as shown in Figure 5 and Table 2)
Module Type A
1
GCL-P6/60-XXX
GCL-C6/60-XXX
GCL-M6/60-XXX
GCL-P6/72-XXX
GCL-C6/72-XXX
GCL-M6/72-XXX
992
992
992
992
100 8
1020
GCL-P6/96-XXX
GCL-P3/72-XXX
GCL-SP6/60-XXX
GCL-SP6/72-XXX
164 0
1658
1945
1956
196 8
2568
40
40
40
40
6
6
941
941
958
970
NA NA NA NA NA
NANANANANA
990
1176
1176
1428
1350
1676
1928
1676
11
11
11
11
35
35
35
35
22.5
21.5
27
23
36.5
18. 5
2
3
4
5
6
B C D E F G HNo. Weight(kg)
Figure 5
Front View Side View Frame Section
Tab le 2
*
“XXX”refers to Module Power Index.
Unite:mm
Barcode
Grounding hole
8-9X14
Mounting hole
Back View
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M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
安装夹
组件
安装支架
图 2
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
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
warranty.
Negative grounding is recommended during installation of Modules to prevent PID
eect.
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 re.
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.
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ELECTRICAL INSTALLATION
M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
安装夹
组件
安装支架
M8不锈钢螺栓
M8不锈钢螺母
弹簧垫圈
平垫圈
安装夹
组件
安装支架
图 2
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 f or a single piece of Mo dule 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
o-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.
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
congurations: Fuse rating/Isc+1.
Figure 6 Figure 7
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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
structure. This can achieve proper grounding eects.
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.
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.
Grounding by lugs
Frame
Grounding Lug
Grounding cable
Nut (M3,SS)
Bolt (M3,SS)
Spring washer
Flat washer
Star washe r
Figure 8
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GROUNDING
Grounding by cable
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 eects 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.
Bypass Diodes and Block Diodes
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The grounding bolts must be made of stainless steel and be used in the specied
grounding holes. First, make the M3.5 stainless steel bolt pass through the spring washer,
at washer, cup washer (copper conductor with a diameter of 2.1 mm) and star washer,
and then insert through the grounding hole, at washer and spring washer on the frame.
Finally, tighten with a M3.5 nut. Caution: The upper limited temperature of the conductor
is 85℃. As for the installation, refer to Figure 9.
Figure 9
Frame
Nut (M3.5,SS)
Spring washer
Flat washer
Star washe r
Flat washer
Spring washer
Bolt (M3.5, SS)
Copper wire
Cup washer
Warning: Shut down the system before any electric repair.
Improper maintenance may cause electric shock or fire.
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
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.
Normally, the Modules don’t need repair. Follow the maintenance methods below to
ensure the best performance of the Modules:
MAINTENANCE
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GCL System Integration Technology Co., Ltd
Add: 3F, GCL Energy Center, No.28 Xinqing Road, SIP Suzhou, Jiangsu, China
Tel: +86-512-6983 2860
Fax: +86-512-6983 2777
Web: www.gclsi.com
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