Installation manual for PV-Module-Manufacturer SAMKO
Contents
1. the adhesive manufacturer s specifications when working with the adhesive Apply a line of adhesive to the underside of the junction box see Fig 5 When applying the adhesive observe the following points Applythe 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 socket 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 Correct X Incorrect X Incorrect Press the junction box evenly onto the PV module in the prescribed posi tion Make sure to press down precisely vertically otherwise the socket may slip to the side and smear the adhesive The spacer on the rear ensures that the adhesive is at least 1 0 mm thick There may be a larger clearance between the junction box and the PV module if require2. the soldering connection If you wish to establish soldering connections 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 The entire surface of the contact springs must be free of oils greases residues of removed laminate and any other substance that can prevent electrical con tact and impair the contact resistance Coordinate the necessary soldering aid materials with the automation engi neers The already existing tin plating of the contacts is not sufficient on its own 10237070 03en 16 5 Assembly and connection e Solder the surface The temperature profile and the process time must be monitored 5 5 The surface to be soldering must be flat smooth Follow up check e Once the junction boxs have been attached and the soldering connection established check that the following requirements have been fulfilled 5 6 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 soldering connections are properly established and not in contact with one another or short circuited The inside of the socket is free of foreign bodies dirt and moisture There is no silicone at the cover contact points as this can prevent the cover fr
3. INDUSTRIAL ELECTRONICS KOS UAL Installation manual for PV Module Manufacturer SAMKO 100 04 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 an
4. d due to the adhesive or the desired mechanical properties of the joint Make sure that the clearance is kept constant during the drying phase Please note thicker layers of adhesive may prolong the drying phase 10237070 03en 15 Fig 6 tion Soldering connec 5 Assembly and connection 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 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 e Check if the soldering connections touch the contact surfaces and if they are lying flat Several different mounting materials have been certified for this PV module junction box by TUV Rheinland LGA Products GmbH Contact the junction box manufacturer for a list of possible mounting adhesives that have 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 Establish
5. d 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 erorrcccncnnnnonanonanananonnconnnonnnnnnanonanonnnnnnnnonanoncnnncnnnnnnn 1 1 Typographical conventions AAA A 1 2 Scope of validity A A e a lt esa de asadas 1 3 Safety instructions E E KN TT SRK TTL RRA ARRE Proper USE eoerecrrnoncnoncnononononananananannnnononononononononananananana nana rnonononononeneneso Safety instructionS emremnoncncncncnnananoncnoncnonnananancnonononcncarananananonss Product description mmmemmncncncnoncnononanonanonananacanacanncnonononononoso 4 1 Function PEINE AE vee va aaa Dresde ost 4 2 Scope of delivery saa A LA dais e kaas deka sessist ondes 662 4 3 Overview OO pela Tee ae ees viske 44 Identification RO RRE RA RR ARA RA 45 Use A ETE A T A E A TINTE 46 Technical data E TTK TS Assembly and connection 1 w 0vnennenneneonuenneneevennennennennennennenne 5 1 Clearing the contact surfaces a ria 5 2 Preparing the adhesion Surfaces rrerrrerenacnnnananannnnarannananannnnass 5 3 Applying the adhesive and mounting the socket eseese 5 4 Establish the soldering connection RR sed vastate deeds cues 5 5 Follow up check ER RAR RA 5 6 Closing the PV module junction box ENRERE O aial ERATE REEN 5 7 Removing
6. he 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 10237070 03en 18 Fig 9 RemovingEntnah me der Stecker aus dem optionalen Halter 5 Assembly and connection 5 7 Removing the connectors from the holder optional e To remove the connectors from the optional holder proceed as shown in the following figure rene A 1 The holder is only designed for test purposes during the fabrication of the module as well as for the transport and must not be removed from the PV module junction box The use of the holder after the installation of the module e g for testing or maintenance is not allowed by reason of tracking that may occur because of pollution and moisture 5 8 Opening the PV module junction box A DANGER 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 switched back o
7. 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 ATTENTION can cause damage to property 10237070 03en 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 The SAMKO 04 PV module junction box enables assembly under especially space saving conditions 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 stated intended purpose is con sidered inappropriate The manufacturer accepts no liability for any damage re
8. n 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 10237070 03en 19 5 Assembly and connection A DANGER 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 if the tool slips e Move the tool in a levering motion towards the PV module to release the locking hook The seal is destroyed on opening to indicate that the cover has been opened Fig 10 Releasing the locking hook e Repeat this process for each locking hook e Remove the cover ATTENTION Immediately replace covers with broken seals with new undamaged covers You can order new covers Please get in contact with KOSTAL 10237070 03en 20 KOSTAL 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 DOC01109369 0019 01 2014 MA EN
9. om being closed properly The edge of the socket onto which the seal of the cover will later be set is free of silicon Closing the PV module junction box Setting the cover in place can also be done automatically because the cover is constructed correspondingly The SAMKO 04 PV module junction box is constructed to enable assembly under especially space saving conditions An example of closing the junction box in such conditions is shown in the following diagram Fig 7 Setting the cover in place under space saving conditions 10237070 03en 17 5 Assembly and connection Fig 8 Setting the cover in place and pressing it on e 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 The higher sealing lip on the cover should be on the smoother housing side when setting in place ATTENTION If the adhesive has not yet hardened fully press the cover on carefully Avoid damaging the bond as this may result in the socket sliding out of position e Press the cover onto the socket 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 e 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 socket and t
10. ot become de formed Under certain circumstances a deformation of the contacts may lead to premature ageing of the contact or to insufficient defective soldering Some assembly aids such as oils and greases may be incompatible with the plastic of the junction box Consult KOSTAL before using any assembly aids 5 1 Clearing the contact surfaces It must be ensured that the contact surfaces on which the contact springs lie are metallically bright The contact surfaces must therefore be cleaned before the PV module junction box is attached 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 10237070 03en 14 Fig 5 Application of adhesive Correct Incorrect 5 Assembly and connection 5 3 Applying the adhesive and mounting the socket ATTENTION Always observe
11. r may affect the connection equipment 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 4 Warning high voltage I A rs a a Do not disconnect under load ETV gt E 0 Electrical protection class II acc to DIN EN 61140 600V 1000V Peted voltage in ace with UL 1703 UL 3730 IP65 Protection class acc to DIN EN 60529 1000V Rated voltage in acc with EN 50548 Opening the unit A DANGER 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 switched 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 connector and contact strips must not be removed while still live 10237070 03en 3 Safety instructions Usage in the field In order to prevent damage and p
12. remature failure observe the following points when laying cables between the individual PV modules inverters and parts of a PV module group 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 ageing Do not leave cables or plug connectors exposed across transport and trav el 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 socket connectors to be subjected to ten sion Take into account possible causes of expansion due to fluctuations in temperature Cables may not be routed 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 04 PV module junction box is built Care must also be taken to ensure that the PV module junction box and its electrical and mechanical connections are not subjected to permanent pres sure tension or torque from any direction e g due to supports or other com ponents 10237070 03en 4 Product description 4 Product descrip
13. ressly tested and approved before use 10237070 03en 12 Tab 1 Technical data 4 6 Technical data 4 Product description The SAMKO 04 PV module junction box is available with certification from the T V Rheinland and UL The rated voltage for UL certified junction boxs is 600 V 1000 V in accordance with UL 1703 UL 3730 This does not affect the stan dard rated voltage of 1000 V in accordance with european standards UL certi fied junction boxs bear the recognition mark and the corresponding file number E328235 SAMKO 04 Manufacturer KOSTAL Industrie Elektrik GmbH Designation SAMKO 100 04 Rated current 10A SAMKO 100 04 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 1000 V in acc with UL 1703 UL 3730 Max permitted operating voltage 100V SAMKO 100 04 in acc with EN 50548 2011 A1 2013 Comnectible cable cross sections 4 mm AWG 12 assembled at factory Comnectible contact strips Recommendation 5 x 0 5 mm Tin plated surface special testing by the PV module manufacturer required for other surfaces The soldering must be done automatically The temperature and time of the soldering process must be monitored The joining parts must be smooth Number of diodes max 3 Degree of p
14. rotection IP65 IP67 DIN EN 60529 Pollution degree Housing interior 2 acc to EN 60664 1 Housing exterior 3 acc to EN 60664 1 Over voltage category III EN 60664 1 Flammability class 5 VA UL 94 Max dimensions L x W x H 138 mm x 125 mm x 26 mm Certification T V Rheinland certification acc to EN 50548 2011 A1 2013 certification number R60090667 Certification acc 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 IP65 and IP67 protection 10237070 03en 13 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 Handle the solder contacts with particular care They may n
15. sulting 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 boxs of other types or brands without the express approval of KOSTAL Contacting of cables or wires other than those specified within the interior of the socket instead of the prescribed soldering joints Unfastening the cable fittings on the socket 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 socket bodies and the attached cables and plug connectors Removing or covering safety notices 10237070 03en 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 observe all the safety instructions in this manual Risk of damage due to excessive application of force forces and torques that affect o
16. the connectors from the holder optional 5 8 Opening the PV module junction box nenenenneneneneenenend 10237070 03en 1 Important notes 1 Important notes This manual contains important information regarding the features and handling of the SAMKO 04 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 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 04 whereby to simplify matters the designation SAMKO 04 covers the variant SAMKO 100 04 Please send any questions concerning the validity of this manual to KOSTAL Industrie Elektrik GmbH Lange Eck 11 58099 Hagen Telephone 49 2331 8040 4800 Telefax 49 2331 8040 4601 1 3 Safety instructions Information concerning your safety or that of the unit is specially highlighted DANGER Non observance 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
17. tion 4 1 Function The PV module junction box is used to provide an electrical connection to a PV module It is intended for fully automatic assembly Mechanical calibration of the joining parts e g Vision system is displayed for correct positioning Usually up to three of a PV modules cell strings are connected in the PV mod ule junction box via up to four soldering joints one per cell string plus one extra Soldering joints are used for contacting These soldering joints are laid out on smooth surfaces for an automatic and monitored soldering 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 and IP67 protection rating protects the electrical connections from penetration by water or foreign bodies A pressure equalisation element is used to guarantee the defined ventilation for the socket 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 10237070 03en 4 Product description 4 2 Scope of delivery Junction box Fig 1 Item 2 with cables ready for use 3 and plug con nectors 4 optional fixed in a holder 5 Cover 1 Documentation Fig 1 Scope of delivery 10237070 03en Fig 2 Scope of delivery with optional holder 4 Prod
18. uct description 5 10237070 03en 10 4 Product description 4 3 Overview Fig 3 SAMKO04 PV module junction box Housing Soldering connections Diodes Cable fittings Retainer for handling system NDAOND 4 4 Identification The side of each PV module junction box is market with the article number Fig 4 item 1 type designation 2 serial number 3 and revision status 4 In addition the serial number 3 is also given as a data matrix code 2D code 5 Fig 4 Identification of the PV module junction box 1 2 Made in Germany 30SLKnnnnnnnn SAMKO RRR SStt wwwxxyyzz ISNTTTTTYMDXXXXX HW0000 K00 3 10237070 03en 17 4 Product description 4 5 Use The SAMKO 04 PV module junction box may only be connected to structurally identical junction boxs directly or indirectly Express approval from KOSTAL is reguired to connect the SAMKO 04 to junction boxs of other types or brands All SAMKO 04 PV module junction boxs are compatible with one another However this may not apply to some customised models and certain combi nations of plug connectors and connections of panels onto which the SAMKO 04 is attached In order to connect the SAMKO 04 PV module junction box to other devices junction boxs inverters etc you must use the same type and brand of plug connector as supplied Ensure that all third party plug connectors are exp
Download Pdf Manuals
Related Search