Installation manual for PV-Module-Manufacturer SAMKO
Contents
1. 4 3 Overview 4 4 Identification The side of each PV module junction box is market with the article number Fig 3 item 1 type designation 2 revision status 3 Rated Voltage acc UL 1730 UL 3730 for articles with UL regocnition only 4 Rated Current 5 and serial number 7 In addition the serial number 7 is also given as a data ma trix code 2D code 8 The Made in Germany sign 6 will be replaced by UL Recognition Mark and UL File Number for articles with UL recognition 1 8 Cc uE E UN y o 30SLKnnnnnnnn ISNTTTTTYMDXXXXX Maden 410A odid Germany 600V A SAMKO 100 01 tuw wwnoyyzz ee oh 0 ON s y 2 x 180SLKnnnnnnnn ISNTTTTTYMDXXXXX E 10A 3 7 LU SAMKO RRR Sameer HW0000 Gemany soov 7 4 5 Use The SAMKO 01 PV module junction box may only be connected directly or indirectly to structurally identical junction boxes Express approval from KOS TAL is reguired to connect the SAMKO 01 to junction boxes of other types or brands All SAMKO 01 PV module junction boxes are compatible with one another However this may not apply to some customised models certain combinations of plug connectors and connections of panels that are fit with SAMKO 01 10215641 02en Tab 1 Technical data 4 Product description In order to connect the SAMKO 01 PV module junction box to other devices junction boxes inverters etc yo2. The residual adhesive strength after mounting must be sufficient to elas tically compensate for differences in the expansion behaviour of the ma terials involved and to withstand environmental influences wind snow etc over a long period of time After mounting the adhesive must not cross into the four contact points for the cover Hardened adhesive may prevent the cover from being clo sed Itis not permissible to apply the adhesive around the edge of the junc tion box This applies in particular to the areas around the cover contact points Work carefully you will not be able to visually check the adhesion at a later point Fig 4 Application of ad hesive Correct Incorrect right X wrong E C LUJO Oo H p si i D R A F O E i T Lol A 3 8 E F w X wrong A g e Press the junction box evenly onto the PV module in the prescribed posi tion Make sure to press down precisely vertically otherwise the junction box may slip to the side and smear the adhesive The spacer on the rear ensures that the adhesive is at least 0 5 mm thick There may be a larger clearance between the junction box and the PV module if required due to the adhesive or the desired mechanical properties of the joint Make sure that the clearance is kept constant during
3. photographs appearing in this product is not permitted This manual may not be reproduced stored transmitted or translated in any form or by means of any medium in whole or in part without prior written permission Table of contents Table of contents 1 Important notes Reco 4 1 1 Typographical CONVENTIONS 1 1 nnenennenennenennenennenennenenenenneneenet 4 1 2 Scope Of validity rrr rereveernenneneeenenneneeneeneeneneenenneenennennennenne 4 1 3 Safety instructions E KSK KS KN SS RR E RR RR ROS 4 Proper USE eorrrorcnoncnononononanananananaonononononononononanananacnnnononononononanonaanacananass 5 Safety instructions 10 0wmwimenenenenenenensenenenenenensnsenesenenenenenenese 6 Product description 10100010000000nenenenennsennenenensnene vene nenennneenenst 8 4 1 Function RO ETETE TEON EIT NET OEE A R RR RARO 8 4 2 Scope of delivery ASA A POOE I EVENES ACRE EE IVT LIT 8 4 3 Overview SRT A NS 24515 a Ene 9 44 Identification OOO E A OCR TER ROS OTI Rd IO 9 45 Use seisma As LAA A OT IO oui gee setae cote elutes 9 46 Technical data ST KIK A ies ese TTSS 4 0 Assembly and Connection rrrrrornocnnnnnnncnnonnonnonnonnnnnonnnnnnnnnnnnnonnonos 11 5 1 Preparing the contact Strips rrrrremeneenenenenenenenenneneneneenenened 11 5 2 Preparing the adhesion SUrfaGES rrermenernnnnacannnnarannananaanananss 11 5 3 Applying the adhesive and mounting the junction box 12 5 4 C
4. properly The edge of the junction box is free of silicone this will later be used to seat the cover seal 1021564 1 02en 15 Fig 8 Setting the cover in place and pressing it on 5 Assembly and connection 5 6 Closing the PV module junction box Loosely place the cover on the PV module junction box Make sure that the four locking hooks are resting on the clip points of the housing ATTENTION If the adhesive has not yet hardened fully press the cover on carefully Avoid damaging the bond as this may result in the junction box sliding out of position Press the cover onto the junction box All four hooks must audibly click into place If necessary you can use a tool to exert counter pressure at the notches below the locking hooks Check that the following requirements have been met All four locking hooks must be closed The cover must not be askew There must be no gap between the junction box and the cover The cover must be securely seated i e it must be impossible to slide or lift it out of place gt As soon as the adhesive has fully hardened the assembly procedure is complete You can now use the PV module junction box as part of a PV module in accordance with the specifications for said module 10215641 02en 16 5 Assembly and connection 5 7 Opening the PV module junction box DANGER AN During operation there are potentially fatal levels of voltag
5. stated intended purpose is con sidered inappropriate The manufacturer accepts no liability for any damage resulting from such use It is forbidden to make alterations to the PV module junction box The PV module junction box may only be used if safe to operate and in tech nically perfect condition Any instance of misuse will void the warranty guaran tee and general liability of the manufacturer In particular the following actions constitute improper use The electrical connection with non structurally identical PV module junction boxes of other types or brands without the express approval of KOSTAL Contacting using cables or wires other than those specified within the inte rior of the junction box instead of the prescribed contact strips Unfastening the cable fittings on the junction box Shortening or replacing the cable attached at the factory Replacing the plug regardless of type or manufacturer without the express approval of KOSTAL Applying force to the attached PV module junction box during transport assembly or operation This also applies to both open or closed junction box bodies and the attached cables and plug connectors Removing or covering safety notices 10215641 02en 3 Safety instructions 3 Safety instructions DANGER Improper handling during installation and while operating the PV module junction box can lead to potentially fatal electric shock Always obser
6. 0664 1 Flammability class 5 VA UL 94 Max dimensions L x W x H 132 mm x 125 mm x 27 mm Certification T V Rheinland certification in acc with EN 50548 2011 A1 2013 certification number R60091059 Certification to UL 1703 UL 3730 UL File Number E328235 Other properties RoHS compliant Halogen free acc to DIN VDE 0472 Part 815 Vapour pressure balancing via breathable membrane with IP 65 protection 10215641 02en 10 5 Assembly and connection 5 Assembly and connection ATTENTION Risk of damage due to electrostatic discharge ESD The PV module junction box contains electric components that can be dam aged or destroyed by electrostatic discharge e Implement measures to prevent ESD damage cf DIN EN 61340 5 1 2 In order to ensure that the adhesion surfaces of the PV module junction box and the PV module are not contaminated by oils especially silicone oils greases dust dirt moisture etc only touch and handle the junction box with clean gloves or using clean tools Work carefully and keep all tools and components clean no dirt contaminant or moisture must be allowed to penetrate the junction box Some assembly aids such as oils and greases may be chemically incompatible with the plastic of the junction box Consult KOSTAL before using any assembly aids 5 1 Preparing the contact strips Before mounting the PV module junction box place th
7. INDUSTRIAL ELECTRONICS KOS UAL Installation manual for PV Module Manufacturer SAMKO 100 01 About us KOSTAL Industrie Elektrik GmbH An der Bellmerei 10 58513 L denscheid Germany Telephone 49 2351 16 O Fax 49 2351 16 2400 info industrie kostal com Postal address KOSTAL Industrie Elektrik GmbH Lange Eck 11 58099 Hagen Germany Telephone 49 2331 8040 4800 Fax 49 2331 8040 4601 Exclusion of liability All names of usage trade names product names or other designations given in this manual may be legally protected even without special labelling e g as a trademark The KOSTAL company assumes no liability for their free usage The illustrations and texts have been compiled with great care However the possibility of errors cannot be ruled out There is no guarantee of the correct ness of the illustrations and texts in this compilation General note on non discrimination The KOSTAL company publishers are aware of the meaning of language with regard to the equality of women and men and always make an effort to reflect this in the documentation Nevertheless for the sake of readability we are un able to use non gender specific terms throughout and have used the mascu line form as a rule 2013 KOSTAL Industrie Elektrik GmbH All rights reserved by KOSTAL including those of reproduction by photocopy and storage in electronic media Commercial use or distribution of the texts models diagrams and
8. e contact strips in a suitable position for the assembly process in order to ensure that the joint is not subjected to any application of force before it has reached its full adhe sive force 5 2 Preparing the adhesion surfaces The adhesion surfaces of the PV module junction box and the PV module must fulfil the requirements of the adhesive manufacturer Usually this means at least that the surface must be clean dry and free of dust oil grease and silicone residue Perfectly prepared adhesion surfaces are key to ensuring a strong bond e Treat the adhesion surfaces of the junction box and the PV module in ac cordance with the adhesive manufacturer s specifications The adhesive manufacturer may specify that the surfaces of the joining parts must be treated specially to prepare them for adhesion If you are unsure about any part of this process please consult the adhesive manufacturer 10215641 02en 11 5 Assembly and connection 5 3 Applying the adhesive and mounting the junction box ATTENTION Always observe the adhesive manufacturer s specifications when working with the adhesive e Apply a line of adhesive to the underside of the junction box see Fig 4 When applying the adhesive observe the following points Apply the adhesive with an even thickness There must be no gaps or bubbles in the line The adhesive must surround all openings that lead to the inside of the junction box
9. e in the PV module junction box Touching live parts and even opening the junction box while it is still connected to the power supply may induce a fatal electric shock Perform the following steps before opening the PV module junc tion box e Disconnect the device from the power supply at all sides e Secure the power supply from being unintentionally swit ched back on e Check the device and cables to make certain that they are voltage free e Insert a suitable tool e g flat headed screwdriver at least 30 mm shaft length and maximum 3 mm blade width into one of the four side openings on the cover DANGER AN Risk of death by electric shock Risk of damage to the PV module There are electric wires beneath the panel laminate e Insert the tool gently so as to avoid touching live parts and to prevent the PV module from being damaged ifthe tool slips e Move the tool in a levering motion towards the PV module to release the locking hook Fig 9 Releasing the locking hook e Repeat this process for each locking hook e Remove the cover 5 8 Instructions for semi automatic assembly The junction box can be attached and connected automatically With the ex ception of the section on connecting the contact strips the procedure outlined in these instructions is transferrable for such a purpose A semi automatic handling and working concept is subject to special re quirem
10. ents for ESD conformity 10215641 02en 17 KOSVAL KOSTAL Industrie Elektrik GmbH KOSTAL Industrial Electronics Lange Eck 11 58099 Hagen Germany Phone 49 2331 8040 4800 Fax 49 2331 8040 4811 www kostal com industrie DOC01117245 0008 01 2014 MA EN
11. hanical connections are not subjected to permanent pres sure tension or torque from any direction e g due to supports or other com ponents 10215641 02en Fig 1 Scope of delivery 4 Product description 4 Product description 4 1 Function The PV module junction box is used to provide an electrical connection to a PV module Usually up to three of a PV modules cell strings are connected in the PV mod ule junction box via up to four contact strips one per cell string plus one ex tra Pressure spring contacts are used for the contacting The PV module junction box uses special semi conductors to protect the solar cells from damage in cases of shadowing The sealed design with an IP65 protection rating protects the electrical con nections from penetration by water or contaminant A pressure balancing ele ment is used to guarantee the defined ventilation for the junction box interior The PV module junction box is used either to connect multiple PV modules with each other or to connect a PV module to an inverter or to other compo nents of a PV module network 4 2 Scope of delivery Junction box Fig 1 Item 4 with cables ready for use 2 and plug con nectors 3 Cover 1 Documentation 10215641 02en Fig 2 SAMKO01 PV module junction box Housing Clamp springs Diodes Cable fittings Ah ON a Fig 3 ldentification of the PV module junction box 4 Product description
12. lding or using other joining processes 10215641 02en 14 Fig 7 Inserting the contact strip and closing the clamp 5 Assembly and connection e Release the lever to relieve the clamp springs so that the contact strip is fixed in place e Remove the tool ATTENTION Ensure that the polarity is correct when connecting the contact strips Implement suitable measures to ensure that the contact strips do not come into contact with one another and short circuit DANGER Risk of death by electric shock Exposed contact strips coming into contact with each other can create potentially fatal electric arcs If it is not possible to prevent the contact strips from crossing one another e g due to the wiring of the PV module they must be insulated in a suitable manner e g using shrinkage tubing 5 5 Follow up check e Once the junction boxes have been attached and the contact strips con nected check that the following requirements have been fulfilled The junction box is in the prescribed position The junction box is lying flat on the laminate The junction box is undamaged The connections and cables are free of defects The contact strips are securely connected and not in contact with one another or short circuited The inside of the junction box is free of contaminant dirt and moisture There is no silicone at the cover contact points this can prevent the co ver from being closed
13. onnecting the contact strips RAR ERA RRA 3 3 5 5 Follow up check RAR IO IPOTI EENEN T S OILI PENE IOE O 15 5 6 Closing the PV module junction box EAEN O AEN ERENER EAE 3 6 5 7 Opening the PV module junction DOX nenenevnenenenenenened 17 5 8 Instructions for Semi automatic assembly 0errerererenenanananananan os 17 10215641 02en 1 Important notes 1 Important notes This manual contains important information regarding the features and handling of the SAMKO 01 photovoltaic module junction box by KOSTAL Read this manual carefully in its entirety KOSTAL assumes no liability for any damage resulting from the non observance of this manual 1 1 Typographical conventions The following typographical conventions are used in this manual Lists are marked with a dash e Instruction steps are marked with a dot gt This arrow indicates the result of an action 1 2 Scope of validity This manual is an integral part of the product It applies exclusively to the photovoltaic module junction box SAMKO 01 whereby to simplify matters the designation SAMKO 01 covers the variant SAMKO 100 01 Please send any questions concerning the validity of this manual to KOSTAL Industrie Elektrik GmbH Lange Eck 11 58099 Hagen Germany Telephone 49 2331 8040 4800 Fax 49 2331 8040 4601 1 3 Safety instructions Information concerning your safety or that of the unit is specially highlighted DANGER Non obser
14. or and contact strips must not be removed while still live 10215641 02en 3 Safety instructions Usage in the field In order to prevent damages and premature failure observe the following points when laying cables between the individual PV modules and between the PV modules the inverters and other parts of the PV module combination Wear the prescribed protective clothing Do not leave cables or plug connectors lying in dirt or water make drainage holes in cable ducts Do not leave cables hanging by their own weight or in positions where they are susceptible to long term movement by the wind increased mechanical aging Do not leave cables or plug connectors exposed across transport and tra vel routes or areas where things may be put down Do not allow cables or cable ends in particular the cable inputs to the PV module junction box or the PV plug connector to be subjected to tension Take into account possible causes of expansion due to fluctuations in tem perature Do not allow cables to be guided over sharp edges Work carefully taking particular care not to damage the PV plug connector its seals contact elements or other parts when using it to establish the electrical connection Allow sufficient ventilation at the rear of all PV modules into which the SAMKO 01 PV module junction box is built Care must also be taken to ensure that the PV module junction box and its electrical and mec
15. or use with the clamp springs If you wish to connect contact strips while the adhesive is still drying take care to ensure that you do not impair the quality of the joint For example it may be advisable to use an adhesive pad to fix the joint in place temporarily e A suitable tool is required to open the clamp springs Please contact KOSTAL regarding this issue A flat headed screwdriver with a shaft length of at least 30 mm and a maximum blade width of 4 mm is also suitable for this purpose e Insert the tool into the square opening of the clamp spring 10215641 02en 13 5 Assembly and connection ATTENTION Pulling on the clamp springs may exert forces and moments that could damage the adhesive bond with the PV module Fix the junction box in place e g by hand in order to keep such forces to a minimum e Pull the lever until the clamp spring is open sufficiently wide Fig 6 Inserting the contact strip e Insert the contact strips Fig 6 Item 1 vertically into the gap between the clamp spring 2 and the diode plate 3 as far as it will go The area of the contact strip that is to be clamped must not be deformed contaminated or kinked in any way The entire surface of the contact strip must be free of oils greases and any other substances that can prevent electrical contact and impair the contact resistance There is no need to strengthen the connection by soldering we
16. the drying phase Please note thicker layers of adhesive may prolong the drying phase While the adhesive is hardening the subsequent operational steps contacting transport storage must be carried out with the utmost care so as not to impair 10215641 02en 12 Fig 5 tool and opening the clamp spring Inserting the 5 Assembly and connection the adhesive result For example the PV module should only be transported and stored in a horizontal position otherwise the junction box may slip Make a note of the weight and rigidity of the cable harness In unfavourable conditions e g during transportation of the PV module and in particular before the adhesive has fully hardened the junction box may be lifted off the module by the cable harness Several different mounting materials have been certified for this PV module junction box by T V Rheinland LGA Products GmbH Contact the junction box manufacturer for a list of possible mounting adhesives that habe been certified for this junction box Contact the junction box manufacturer for a list of possible PV module back sheet materials material groups PVF PVDF PA ETFE Glas that have already been certified with this junction box for the use as mounting adhesives 5 4 Connecting the contact strips ATTENTION The clamp springs on the PV module junction box are only suit able for use with contact strips cf Section 4 6 Cables and other wires are not suitable f
17. u must use the same type and brand of plug connector as supplied Ensure that all third party plug connectors are expressly tested and certified before use 4 6 Technical data The SAMKO 01 PV module junction box is available with certification from the T V Rheinland and UL The rated voltage for UL certified PV junction boxes is 600 V according to UL 1703 UL 3730 This does not affect the European standard rated voltage of 1000 V UL certified junction boxes bear the recog nition mark and the corresponding file number E328235 SAMKO 01 Manufacturer KOSTAL Industrie Elektrik GmbH Designation SAMKO 100 01 Rated current 10A SAMKO 100 01 Schottky Diode acc to EN 50548 2011 A1 2013 and UL 1703 UL 3730 Rated surge voltage 8 kV in acc with EN 50548 2011 A1 2013 Rated voltage 1000 V in acc with EN 50548 2011 A1 2013 600 V in acc with UL 1703 UL 3730 Max permitted operating voltage 100V SAMKO 100 01 in acc with EN 50548 2011 A1 2013 Connectable cable cross sections 4 mm AWG 12 werkseitig montiert Connectable contact strips Width 3 5 10 mm Thickness 0 3 0 75 mm Tin plated surface special testing reguired for other surfaces Number of diodes max 3 Protection rating IP 65 DIN EN 60529 Pollution degree housing interior 2 acc to EN 60664 1 housing exterior 3 acc to EN 60664 1 Overvoltage category Ill EN 6
18. vance of safety warnings marked with the signal word DANGER can cause fatal injuries WARNING Non observance of safety warnings marked with the signal word WARNING can cause serious and or permanent injuries CAUTION Non observance of safety warnings marked with the signal word CAUTION can cause minor and or reversible injuries ATTENTION Non observance of safety warnings marked with the signal word ATTEN TION can cause damage to property 10215641 02en 2 Proper use 2 Proper use The PV module junction box enables a PV module to be electrically connected to other suitable components The electrical specifications of the PV module and the PV module junction box must match The PV module junction box is attached to the back of the PV module using adhesive In order to do this there must be sufficient installation space on the PV module Where necessary the method of attachment joining parts to be used adhe sives and rear side and how to combine them are explained in the applicable certificates Contact must only be made with the components described here and in the way described here Inappropriate use can be hazardous and lead to injury or even death of the operator or third parties Material damage to the unit and other equipment can also occur The PV module junction box may therefore only be used for its intended purpose Exclusion of liability Any use that differs from or goes beyond the
19. ve all the safety instructions in this manual Risk of damage due to excessive application of force forces and torgues that affect or may affect the connection eguipment must be kept to a minimum at all times regardless of the standards assessed characteristics in order to pre vent damages and premature failure Markings The labels and markings applied to the housing by the manufacturer may not be changed or removed The unit bears the following markings f Warning high voltage 210 Do not disconnect while live Electrical protection class II acc to a DIN EN 61140 1000V Rated voltage acc with EN 50548 IP65 Protection class acc to DIN EN 60529 600V Rated voltage acc to UL 1703 UL 3730 E Instructions on opening the cover 2 Opening the unit DANGER AN During operation there are potentially fatal levels of voltage in the PV module junction box Touching live parts and even opening the junction box while it is still connected to the power supply may induce a fatal electric shock Perform the following steps before opening the PV module junc tion box e Disconnect the device from the power supply at all sides e Secure the power supply from being unintentionally swit ched back on e Check the device and cables to make certain that they are voltage free Disconnecting cables The plug connector and contact strips may only be disconnected by a qualified electrician The plug connect
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