Sanyo HIP-180BA19 Installation Manual
General Installation Manual
© Jun 2011, Sanyo Electric Co., Ltd. All Rights Reserved. 6/13/11
General Installation Manual for SANYO HIT® Photovoltaic
Modules. Please read this manual carefully before installing
or using HIT Power modules. This manual applies to the
following models:
HIT Power 205
HIT Power 200
HIT Power 195
HIT Power 190 (HIP-190BA19,BA20)
HIT Power 186
HIT Power 180 (HIP-180BA19,BA20)
INTRODUCTION
Thank you for choosing SANYO HIT Power photovoltaic (PV)
modules. With proper operation and maintenance, your solar P V
modules will provide you with clean, renewable solar electricit y for
many years. This manual contains important installation,
maintenance and safety information. The word “module” as used
in this manual refers to one or more PV modules. Retain this
manual for future reference.
Disclaimer of Liability
SANYO does not assume responsibility and expressly disclaims
liability for loss, damage, or expense arising out of, or in any way
connected with installation, operation, use, or maintenance by
using this manual.
SANYO assumes no responsibility for any infringement of patents
or other rights of third parties, which may result from use of
modules.
No license is granted by implication or under an y patent or patent
rights. The information in this manual is believed to be relia ble, but
does not constitute an expressed and/or implied warranty.
SANYO reserves the right to make changes to the product,
specifications, data sheets and this manual without prior notice.
General Information
The installation of solar modules requires a great degree of skill
and should only be performed by qualified licensed profes sionals,
including, without limitation, licensed contractors and electricians.
WARNING
• All instructions should be read and understood before
attempting to install, wire, operate, or maintain a PV
module.
• Contact with electrically active parts of the module such
as terminals can result in sparks, injury, fire, burns, and
lethal shock whether the module is connected or
disconnected.
• The installer assumes the risk of all injury that might
occur during installation.
• PV modules generate direct current (DC) electrical energy
when exposed to sunlight or other light sources.
• Even a single module produces enough voltage and
current to cause shocks and burns if safety precauti ons
are not followed.
• The shock hazard increases as modules are connected in
parallel, producing higher current, and as modules are
connected in series, producing higher voltages.
• To avoid the hazards of electric sparks, shock, fire, burns,
injury, and damage:
• Cover the entire front surface of the PV module with a
dense, opaque material such as a cardboard box or
cloth, during installation and handling.
(HIP-205BA19,BA20)
(HIP-200BA19,BA20)
(HIP-195BA19,BA20)
(HIP-186BA19,BA20)
• Work only in dry conditions, with dry modules and
insulated tools.
• Do not stand or step on modules.
• Do not puncture, cut, scratch or damage the back
sheet of a module. Back sheet damage will void a
module’s Limited Warranty and may cause fire.
Never use modules with a damaged back sheet.
• Do not allow children and unauthorized persons near
the installation or storage site of modules.
• Completely ground all modules.
• Do not disassemble a module, attempt any repair,
open the junction box cover, nor remove any parts
installed by Sanyo. There are no user serviceable
parts within the module or junction box.
• Wear suitable clothing, guards, eye protection and
gloves and remove metallic jewelry to prevent
yourself from direct contact with 30 Volts DC or
greater.
• Wear non-slip gloves and carry modules by its frame
with two or more people.
• Do not carry a module by its wires or junction box.
• Do not drop anything on the surfaces of a module.
• Ensure all system components are compatible, and
they do not subject the module to mechanical or
electrical hazards.
• Sparks may occur; do not install the module where
flammable gases or vapors are present.
• Never rest or leave a module unsupported or
unsecured.
• Do not drop a module.
• Do not use or install broken modules.
• Do not artificially concentrate sunlight on a module.
• Do not touch a PV module unnecessarily. The glass
surface and frames get hot. There is a risk of burn.
CAUTIONS
• Use a module for its intended purpose only.
• Do not treat the back sheet, frame, or front surface with
paint or adhesives, to avoid reducing its’ functionality,
damage, and causing inoperable conditions or other
unknown trouble.
GENERAL SAFETY
Follow all applicable codes, permission, installation and
inspection requirements.
• Before installing modules, contact the appropriate authorities
to determine any codes, permissions, installation and
inspection requirements that apply.
• Electrically ground modules for all systems of any voltage. If
not otherwise specified, it is recommended that requirements
of the latest National Electrical Code (USA) or Canadian
Electric Code (Canada) or other applicable local, national, or
international electrical standards be followed. Refer to
“System Grounding” section for more information.
• Be sure the building or structure (roof, façade, etc.) where the
modules are being installed has enough strength to support
the load of the modules.
• For modules mounted on roofs, special structures may be
required to provide proper installation support.
• Both roof construction and module installation design have an
effect on the fire resistance of a building. Improper installation
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General Installation Manual
© Jun 2011, Sanyo Electric Co., Ltd. All Rights Reserved. 6/13/11
may contribute to fire hazards. Additional devices such as
ground fault, fuses, and disconnects may be required.
• Do not use modules of different power specifications, in the
same string.
• Follow all safety precautions of other system components and
BOS parts.
UL Listing Information
To satisfy UL requirements, when installing a module, be sure to:
• Use only stranded or solid copper single–conductor su nlight-
resistant cable rated for outdoor use (e.g. type UF or USE) ,
for all wiring that is exposed to weather.
• Observe the requirements described in sections labeled
INSTALLTION
INSTALLATION
Please read this guide completely before installing or using your
Sanyo PV modules. This section contains important electrical and
mechanical specifications.
• Modules should be firmly fixed in place in a manner suitable to
withstand all expected loads, including wind and snow loads.
• Metals used in locations exposed to moisture shall not be
employed alone or in combinations that could result in
deterioration or corrosion.
• Install modules where they are not shaded by obstacles like
buildings and trees. Pay special attention to avoid p artially
shading modules by objects during the daytime.
• If needed, contact an Authorized Representative with
questions regarding mounting profiles for Sanyo modules.
Notes on Installation
• Clearance between the roof surface and module
frame is required to allow cooling air to circulate
around the back of the module. This also allows
any condensation or moisture to dissipate. Install
modules with a minimum of 1 inch clearance
between the roof surface and the modules so that
air can circulate.SANYO recommends the
installation method and mounting profile shown in
Figure 1.
A module should be attached on a mount or
•
support structure rail by corrosive-resistant
metal clamps.
•
The clamps should be made of aluminum
alloy or other material that will reasonably
protect against the a risk of electrolytic
corrosion.
• Recommendation of bolt torque range: 16N.m to
20N.m
•
The module was tested using Unirac clamps
with the specifications below; if a different
clamp is used it must have a design load
capacity equivalent to or greater than the
load specified in this Manual.
¾ Provider: UniRac, Inc.
¾ Part number: SolarMount®
¾ Clamps type: Top Mounting Clamps
¾ Clamp size:Mid clamp and End clamp, F
size,
¾ Unirac Part No.320029, 320102
¾ Width: 1.5” (38 mm)
and SPECIFICATIONS.
Installation (reference)
Metal clamp A
(2 places)
Metal clamp A
Metal clamp A
¾ Thickness : 0.12”(3 mm)
¾ Torque range: 16N.m to 20N.
¾ Material: Aluminum Alloy
Sanyo does not provide a warranty for clamps. The module
warranty Sanyo provides shall be voided if clamps selected by the
customer are of an improper material or size.
Operating Conditions
SANYO requires that modules be operated within the following
conditions:
• Modules are i ntended for use in terrestrial applications only—
no outer space use.
• Modules must not be installed or operated in areas where, salt,
hail, snow, sand, dust, air pollution, chemically active vapors,
acid rain, soot, etc., are excessive.
• The ambient temperature must be within –20°C (-4°F) to 46°C
(115°F). The temperature limits are defined as the monthly
average high and low of the installation site.
• The wind pressure load of the installation site should be le ss
than 2,880N/m
SPECIFICATIONS
• Rated electrical characteristics are within –5% to +10% of the
values measured at Standard Test Conditions (STC). STC
conditions are; Irradiance of 1000W/m2, 25oC cell temp., solar
spectral irradiance per IEC 60904-3.
• Under normal conditions, a photovoltaic module may
experience conditions that produce more current and/or
voltage than reported at Standard Test Conditions.
38mm
Mounting
Structure Rail
M8 Bolt
End of Module Between Modules
2
(60PSF).
38mm
Metal clamp B
(2 places)
Metal clamp B Solar Module
Mounting Structure Rail
Metal clamp B
Mounting Structure M8 Nut
Figure 1. Installation
Module
Solar Module
M8 Bolt
M8 Nut
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General Installation Manual
© Jun 2011, Sanyo Electric Co., Ltd. All Rights Reserved. 6/13/11
Accordingly, the values of Isc and Voc marked on UL listed
modules should be multiplied by a factor of 1.25 when
determining voltage ratings, conductor capacities, fuse sizes,
and size of controls connected to the module output. Refer to
Section 690 of the National Electrical Code for an
additional multiplying factor of 1.25 which may be
applicable.
• The current output for modules shown in the
SPECIFICATIONS
Conditions. These conditions may not be frequently observed
in actual practice.
Mechanical Loading
• Modules should be mounted at four (4) symmetrical quarter
points by the means shown in Figures 1 and 2.
• This method offers a maximum load of 2,880N/m2 (60PSF) in
a static state on the module surface. Note: This 60PSF
mechanical loading value was tested with mouting device
specified in section “Notes on Installation”.
WIRING
• All wiring should be done in accordance with applicable
• Wiring methods should be in accordance with the NEC in U SA
• A qualified, licensed professional should do all wiring.
• Wiring should be protected to help ensure personal safet y and
• All modules connected in series should be of the same model
• Do not connect modules in parallel without using a connection
• Do not disconnect terminals while PV modules generate
• To avoid the hazard of electric shock and sparks, please
• Cable conduits should be used in locations where the wiring is
Module Wiring
• The number of modules that can be wired in series is
• Modules are not designed for “off-grid” or battery charging
• These modules contain four (4) factory installed bypass
• The term “array” is used to describe the assembly of several
• Use copper wire that is sunlight resistant and is insulated to
• Check local codes for requirements.
System Grounding
electrical codes.
or CEC in Canada.
to prevent its damage.
number and/or type.
box that connects appropriate FUSE for each series string or
each module.
electricity and connect electrical load to avoid the hazard of
electrical shock.
connect each cable after confirming the polarity of them is
correct.
inaccessible to children or small animals.
recommended at seven (7) or fewer. If connecting eight (8)
modules in series, check local temperature conditions and
follow the National Electric Code (690.7) to ensure
compliance with maximum voltage limitations.
systems, because of their operating voltage. Therefore, it is
not recommended to use them to charge batteries.
diodes. If these modules are incorrectly connected to each
other, the bypass diodes, cable, or junction box may be
damaged.Array Wiring
modules on a support structure with associated wiring.
withstand the maximum possible system open circuit voltage.
section is measured at Standard Test
Ground Locations
(Smaller holes for self-tapping screw method)
Label
The ground holes are
on the backside of the
module frame.
Ground Locations
(Larger holes for bolt and nut
Junction Box
Backside
method)
Figure 3.1
Module Ground Locations
• Ground the frame of the module or array to avoid the hazards
of electric shock or fire.
• The array frame shall be grounded in accordance with NEC
Article 250 (USA) or CEC in Canada.
• Bonding shall be by a positive means, such as clamping,
riveting, bolted or screwed connectors, welding, soldering or
brazing. If the bonding means depends upon screw threads,
two or more screws, or two full threads of a single screw must
engage the metal.
• All the washers illustrated in Figures 3.2 and 3.3 are required
as part of the grounding connection.
• Great care should be exercised to ensure that corrosion
caused by the grounding means is avoided.
• Corrosion can increase the resistance of the grounding
connection on the module, or can even cause the grounding
connection to fail entirely.
• Corrosion can be caused by the effects of weather, humidity,
dirt and so on. Corrosion can also be caused when two
dissimilar metals contact each other (galvanic action).
• The module frame material is aluminum/magnesium alloy.
• All fasteners (nuts, bolts, washers, screws, etc.) must be
stainless steel unless otherwise specified.
• Length of self-tapping screws or bolts should not be more
than 0.78in (20mm) in order to avoid contacting the back
sheet of the module.
• Acceptable grounding wire is following.
Ilsco Corp. GBL-4DBT 10-14AWG-Solid, 4-6, 8, 10-14AWGStrand
Burndy L L C CL501TN 14AWG-Solid, 14-4AWG-Strand
Tyco Electronics Corp. 1954381-1/1954381-2 10-12AWG
Solid
• Each ledge on the module frame has two smaller holes for
self-tapping screws of 0.165” diameter (4.2mm) and two
larger holes for bolts of 0.205” diameter (5.2mm).
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