Kyocera KC-120-1 User Manual

INSTALLATION MANUAL

FOR THE

KC-SERIES

OF

SOLAR PHOTOVOLTAIC POWER MODULES

Please read this manual carefully before installing the modules.

KYOCERA CORPORATION

1. INTRODUCTION

As the world leader in development and application of high technology ceramic/silica materials, Kyocera Corporation
(KC) offers a wide range of highly efficient and reliable crystalline silicon solar photovoltaic (PV) power modules.
Kyocera began to extensively research PV technology in 1975 and commenced manufacturing operations in 1978.
Since then, Kyocera has supplied millions of cells and modules throughout the world. With years of experience and
state-of-the-art technology, Kyocera provides the highest quality PV power modules in a range of sizes designed to
meet the requirements of the most demanding energy and power users worldwide.

2. POWER MODULES

Kyocera power modules consist of a series of electrically interconnected crystalline silicon solar cells. Which are
permanently laminated within an ethylene-vinyl-acetate (EVA) pottant and encapsulated between a tempered glass
cover plate and a poly-vinyl-flouride (PVF) back sheet. The entire laminate is secured within an anodized aluminum
frame for structural strength, ease of installation, and to protect the cells from the most severe environmental
conditions.

3. APPLICATIONS

Kyocera modules are a reliable, virtually maintenance-free direct current (DC) power source, designed to operate most
efficiently in sunlight. Kyocera modules are ideal to power remote homes, recreational vehicles, water pumps,
telecommunication systems and many other applications either with or without the use of storage batteries.

4. WARNINGS

Solar modules generate electricity when exposed to light. Arrays of many modules can cause lethal shock and burn
hazards. Only authorized and trained personnel should have access to these modules. To reduce the risk of electrical
shock or burns, modules may be covered with an opaque material during installation to avoid shocks or burns. Do not
touch live terminals with bare hands. Use insulated tools for electrical connections.

PERMIT

・ Before installing your solar system, contact local authorities to determine the necessary permit, installation and

inspection requirements.

INSTALLATION AND OPERATION

・ Systems should be installed by qualified personnel only. The system involves electricity, and can be dangerous if

the personnel are not familiar with the appropriate safety procedures.

・ Do not step on the module.
・ Although KYOCERA modules are quite rugged, the glass can be broken (and the module will no longer work

properly) if it is dropped or hit by tools or other objects.

・ Sunlight shall not be concentrated on the module.

・ The module frame is made of anodized aluminum, and therefore corrosion can occur if the module is subject to a

salt water environment with contact to a rack of another type of metal.(Electrolysis Corrosion) If required,
stainless steel washers can be placed between the solar module frame and support structure to prevent this type of

PVC or

corrosion.

・ The solar module frame must be attached to a support structure using ¼” or M6 stainless steel hardware in a

minimum of four (4) places symmetrical on the solar module. The stainless steel hardware used for securing the
module frame should secured with an applied torque of 6 foot-pounds (8 Newton-meters).

・ Module support structures that are to be used to support Kyocera Solar modules should be wind rated and

approved for use by the appropriate local and civil codes prior to installation.

GROUNDING

・ All module frames and mounting racks must be properly grounded in accordance with local and national electrical

codes.

INSPECTION

・ Follow the requirements of applicable local and national electrical codes.

BATTERY

・ When solar modules are used to charge batteries, the battery must be installed in a manner which will protect the

performance of the system and the safety of its users. Follow the battery manufacturer’s guidelines concerning
installation, operation and maintenance recommendations. In general, the battery (or battery bank) should be
away from the main flow of people and animal traffic. Select a battery site that is protected from sunlight, rain,
snow, debris, and is well ventilated. Most batteries generate hydrogen gas when charging, which can be explosive.
Do not light matches or create sparks near the battery bank. When a battery is installed outdoors, it should be
placed in an insulated and ventilated battery case specifically designed for the purpose.

5. SITE SELECTION

In most applications, KC modules should be installed in a location where they will receive maximum sunlight throughout
the year. In the Northern Hemisphere, the modules should typically face south, and in the Southern Hemisphere, the
modules should typically face north. Modules facing 30 degrees away from true South (or North) will lose approximately
10 to 15 per cent of their power output. If the module faces 60 degrees away from true South (or North), the power loss
will be 20 to 30 per cent. When choosing a site, avoid trees, buildings or obstructions which could cast shadows on the
solar modules especially during the winter months when the arc of the sun is lowest over the horizon.

6. MODULE TILT ANGLE

Kyocera solar modules produce the most power when they are pointed directly at the sun. For installations where the
solar modules are attached to a permanent structure, the solar modules should be tilted for optimum winter
performance. As a rule, if the system power production is adequate in the winter, it will be satisfactory during the rest of
the year. The module tilt angle is measured between the solar modules and the ground (Figure 1). Refer to Table 1 for
the recommended module tilt angle your site.

MODULE

SUNLIGHT

TILT ANGLE

HORIZONTAL

Table 1. Recommended Tilt Angles for Fixed
Systems—Based on Winter Performance

SITE

LATITUDE IN

DEGREES

0°TO 15
15°TO 25°
25°TO 30°
30°TO 35°
35°TO 40°
40°+

FIXED TILT ANGLE

15°

SAME AS LATITUDE

LATITUDE + 5°
LATITUDE + 10°
LATITUDE + 15°
LATITUDE + 20°

Figure 1. Module Tilt Angle

7. INSTALLING KC MODULES

The frame of each module has 0.28”φ diameter (7 mm) mounting holes (Refer to Module Mounting Specifications).
These are used to secure the modules to the supporting structure. An example of a ground mounted structure is shown
in Figure 3. The four holes close to the corners of the module are most often used for attachment. Refer to the
Mounting Specification Specifications for the position of these holes. Clearance between the module frame and the
mounting surface may be required to prevent the junction box from touching the surface, and to circulate cooling air
around the back of the module. If the modules are to be installed on the roof or wall of a building, the standoff method
or the rack method is recommended.

STAND-OFF METHOD: The modules are supported
parallel to the surface of the building wall or roof.
Clearance between the module frames and surface of
the wall or roof is required to prevent wiring damage
and to allow air to circulate behind the module.
The recommended stand-off height is 4.5 in. (about 115
mm) If other mounting means are employed, this may
affect the Listing For Fire Class Ratings.

RACK: The supporting frame is used to mount
modules at correct tilt angles. The modules are not
designed for integral mounting as part of a roof or wall.
The mounting design may have an impact on the fire
resistance.

SUPPORT

LEGS

Figure 2. Basic Rack or Standoff Mounting Structure

MOUNTING HOLE

FOOT ANGLE

ARRAY FRAME

MODULE

8. MODULE WIRING

As shown in Module Mounting Specifications, all of the KC modules utilize the Type G junction box except the KC-70,
KC-80 and KC-120-1 modules which utilize the Type M junction box (see J-box details). This junction box, located on
the back side of the module, is weatherproof and is designed to be used with standard wiring or conduit connections.
Kyocera recommends that all wiring and electrical connections comply with the 1999 National Electrical Code (NEC).
Bypass diodes and cable clamps are included with each module when shipped from the factory.

Figure 3. Standard Wiring Examples

To wire Kyocera modules:
A Determine the nominal system array voltage of your system. Each panel is equivalent to a 12 VDC nominal block.

Standard array voltages 12, 24 and 48 volt are shown as examples in Figure 3.

B. Open the "G" or "M" box cover by loosening the screws in the cover.