Sanyo HIT POWER 180, HIT POWER 195, HIT POWER 186, HIT POWER 190, HIT POWER 205 User Manual

General Installation Manual

© January 21, 2009. SANYO Energy (USA) Corp. All Rights Reserved.

General Installation Manual for SANYO
HIT® Photovoltaic Modules. Please read
this manual completely before use of, or
installation of HIT Power modules. This
manual applies to the following models:

HIT Power 205
HIT Power 200
HIT Power 195
HIT Power 190
HIT Power 186
HIT Power 180

INTRODUCTION
Thank you for choosing SANYO HIT Power
photovoltaic (PV) modules. With proper
operation and maintenance, your solar PV
modules will provide you with clean,
renewable solar electricity 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 any patent or patent rights. The
information in this manual is believed to be
reliable, 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
professionals, 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.

(HIP-205BA19)
(HIP-200BA19)
(HIP-195BA19)
(HIP-190BA19)
(HIP-186BA19)
(HIP-180BA19)

1

• 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
precautions 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.

• Work only in dry conditions,

with dry modules and insulated
tools.

• Do not stand or step on a

module.

• 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 part installed by Sanyo.
There are no user serviceable
parts within the module or
junction box.

• Wear suitable clothing, guards,

and gloves and remove metallic
jewelry to prevent yourself from
direct contact with 30 Volts DC
or greater.

• Wear non-slip gloves and carry

a module 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.

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 construction or structure
(roof, façade, etc.) where the modules
are being installed has enough
strength.

• For modules mounted on roofs, special
construction or 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 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 type UF cable or

General Installation Manual

Figure 1.

Installation

© January 21, 2009. SANYO Energy (USA) Corp. All Rights Reserved.

USE cable, rated sunlight resistant, for
modules and interconnect wiring that is
exposed to weather.

• Observe the requirements described in
sections labeled INSTALLTION and
SPECIFICATIONS.

INSTALLATION

Please read this guide completely before
installation or use of the PV modules. This
section contains electrical and mechanical
specifications needed before use.

• 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. Especially pay attention to avoid
partially shading modules by objects
during the daytime.

• Contact an Authorized Representative
with questions regarding mounting
profiles for modules if needed.

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 so that air can circulate
between the roof and the module.

• Leave 4 inches of clearance between
the roof and the module frame.

• 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 metal
clamps. The metal clamp must fulfill
the following specifications:
Size: not less than 1.5” (38mm) width
Thickness: not less than 0.12” (3mm)

Material: aluminum alloy

• Recommendation of bolt torque range:
16N.m to 20N.m.

Operating Conditions

SANYO requires that modules be operated
within the following conditions:

• Modules are intended for use in
terrestrial applications only—no outer
space use.

• Modules must not be installed nor
operated in areas where, salt, hail,
snow, sand, dust, air pollution,
chemically active vapors, acid rain,
soot, etc., are excessive.

2

• 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 less than
2,880N/m2 (60PSF).

Installation (reference)

Metal clamp A
(2 places)

Metal clamp A

M8 Bolt

Metal clamp A

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. 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

M8 Nut

38mm

Metal clamp B
(2 places)

Mounting
Structure Rail

Mounting Structure Rail

End of Module

multiplying factor of 1.25 which may
be applicable.

• The current output for modules shown
in the SPECIFICATIONS section is
measured at Standard Test Conditions.
These conditions may not be frequently
observed in actual practice.

38mm

Metal clamp B Solar Module

Metal clamp B

Module

Mounting Structure

Between Modules

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 the following mounting devices:
SolarMount® by UniRac®; top mounting
clamps; mid clamp and end clamp size
F; part no. 320029, 320102.

WIRING

• All wiring should be done in
accordance with applicable electrical
codes.

Solar Module

M8 Bolt

M8 Nut

General Installation Manual

Figure 3.

1

The ground holes are

on the backside of the

for bolt and nut

© January 21, 2009. SANYO Energy (USA) Corp. All Rights Reserved.

• Wiring methods should be in
accordance with the NEC in USA or
CEC in Canada.

• A qualified, licensed professional
should do all wiring.

• Wiring should be protected to help
ensure personal safety and to prevent
its damage.

• All modules connected in series should
be of the same model number and/or
type.

• Do not connect modules in parallel
without using a connection box.

Module Wiring

•

The number of modules that can
be wired in series is 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.

• Modules are not designed for “off-grid”
or battery charging systems, because
of their operating voltage. Therefore, it
is not recommended to use them to
charge batteries.

• These modules contain four (4) factory
installed bypass diodes. If these
modules are incorrectly connected to
each other, the bypass diodes, cable,
or junction box may be damaged.

Array Wiring

• The term “array” is used to describe
the assembly of several modules on a
support structure with associated
wiring.

• Use copper wire that is sunlight
resistant and is insulated to withstand
the maximum possible system open
circuit voltage.

• Check local codes for requirements.

System Grounding

• 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.

• The ground wire must be No.12 AWG

(3.5mm2).

• Recommended torque value is

2.3N.m (20in-lb).

• 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).

• These ground holes are marked with a

“G” adjacent to their location on the
frame rail (see Figure 3.1).

• Ground wires must be connected to

the module’s frame at one of these
locations.

• There are two methods available to

ground a module. Select one method.

Wire Connection Using Cup Washers

(see Figures 3.2 and 3.3)

• The use of cup washers, also called
terminal cup washers, is to prevent the
wire from slipping out from under the
screw head (and/or the flat washer).

• Make sure the cup washer is placed
between the wire and module frame.

• Choose an adequate size for the cup
washer and flat washer so the wire is
fully clamped between them.

• The cup washers should be stainless
steel, or cup washers may be brass
only if a large flat washer made of
stainless steel is inserted between the
module frame and the cup washer.

• Choose an adequate size for the large
flat washer (between the module frame
and cup washer) so the cup washer
doesn’t contact the module frame and
is fixed firmly to the module frame.

Method 1 (See Figure 3.2)

• Use a self-tapping screw, also called a

Ground Locations

(Smaller holes for self-tapping screw method)

Label

module frame.



Ground Locations

(Larger holes

Junction Box

Backside

method)

Module Ground Locations

thread cutting screw.

• If using this method, use one of the
smaller holes with a diameter of 0.165”
(4.2mm).

• The self-tapping screw size must be No.
10 (0.190” diameter (4.83mm)).

• This method requires aminimum number
of threads-per-inch to achieve an
adequate electrical connection. For a
single screw, the thread pitch must be at
least 32 threads per inch (TPI). A single
screw less than 32 TPI does not provide
sufficient thread contact.

Method 2 (See Figure 3.3)

• Use a bolt and nut.

• If using this method, use one of the larger

holes with a diameter of 0.205” (5.2mm).

• The bolt and nut size should be No. 8
(0.164” diameter (4.16mm)), or No. 10
(0.190” diameter (4.83mm)), or M5
(0.197” diameter (5.0mm)).

• Star washers must be used to make
contact through the anodization of the
module for this method.

• In this case, the screw threads are not
providing the electrical ground contact.



3

General Installation Manual

If using a brass cup washer,

a flat washer must be inserted between the cup washer and

If using

a brass cup washer, a flat washer must be inserted between the cup washer and

Figure

3.2 (Method 1)

© January 21, 2009. SANYO Energy (USA) Corp. All Rights Reserved.

Glass

Back sheet

Frame (Longer side)

Ground hole
(0.165” diameter (4.2 mm)

*Flat washer (Stainless steel)

Cup washer (Terminal cup)
(Stainless steel or *brass)

Flat washer (Stainless steel)

Spring washer (Stainless steel)

Length

Self-tapping screw (Stainless steel)
#10-32

*

module frame, and the flat washer diameter must be greater than the cup washer diameter.

Frame (Longer side)

(not less than 0.47” (12 mm)
not more than 0.78” (20 mm))

Nut (Stainless steel)

Flat washer (Stainless steel)

Star washer (Stainless steel)

Ground wire (#12AWG)
(wound around the screw)

Glass

Backsheet

Ground hole

0.205” diameter
(5.2mm)

Ground using a self-tapping
screw. Note: Use the smaller
ground holes illustrated in
Figure 3.1.

Figure 3.3 (Method 2)

Ground using a bolt and nut.
Note: Use the larger ground
holes illustrated in Figure 3.1.

*Flat washer (Stainless steel)

Cup washer (Terminal cup)
(Stainless steel or *brass)

Flat washer (Stainless steel)

Spring washer (Stainless steel)

Length

Bolt (Stainless steel)
#8, #10, M5

*

module frame, and the flat washer diameter must be greater than the cup washer diameter.

(not less than 0.63’‘(16 mm)
not more than 0.78’‘(20 mm))

Ground wire (#12AWG)
(wound around the bolt)

4

General Installation Manual

S

afety lock clip

Figur

e 4 Configuration of

© January 21, 2009. SANYO Energy (USA) Corp. All Rights Reserved.

Module Terminations

• A junction box as a terminal enclosure
is equipped for electrical connections.

• Modules are equipped with MC4TM
locking plugs as a terminal enclosure.
Use these MC4TM locking plugs for
electrical connections.

Junction Box and Terminals

• Modules are equipped with one
junction box and contain terminals for
both positive and negative polarity, and
bypass diodes.

• One terminal is dedicated to each
polarity; with the polarity symbols
engraved onto the body of the junction
box (see Figure 4).

Cable

Connector

TM

MC

Plug

Option :

negative ( - ) positive ( + )

Bypass Diodes

• When modules in series strings are
partially shaded, it may cause reverse
voltage across the cells or modules,
because the current from other cells in
the same series is forced to flow
through the shaded area. This may
cause undesirable heating to occur.

• The use of a diode to bypass the
shaded area can minimize both heating
and array current reduction.

• Modules are equipped with factory
installed bypass diodes. The factory
installed diodes provide proper circuit
protection for the systems within the
specified system voltage, so that you
do not need any other additional
bypass diodes.

MAINTENANCE

• Some maintenance is recommended to
maintain optimal output performance of
the solar modules.

• If the module surface becomes dirty, it
may reduce output power.

• It is recommended to clean the surface
of the module with water and a soft
cloth or sponge, twice or more per year.

• A mild non-abrasive detergent may be
applied for persistent dirt.

• It is also recommended to inspect the
electrical and mechanical connections
annually.

• If you need electrical or mechanical
inspection or maintenance, have a
licensed authorized professional carry
out the inspection or maintenance to
avoid the hazards of electric shock or
injury.

As part of SANYO’s policy of continuous
improvement, SANYO reserves the right to
change product specifications at any time
without prior notice.

For further information, please visit

sanyo.com/solar or contact your SANYO

Authorized Representative.

Junction Box

Conduit

• For applications where wire conduits
are used, follow the applicable codes
for outdoor installation of wires in
conduits.

• Verify that all fittings are properly
installed to protect wires against
damage and prevent moisture intrusion.

5

General Installation Manual

Figure 2

.

Dimensions

Dimensions

© January 21, 2009. SANYO Energy (USA) Corp. All Rights Reserved.

SPECIFICATIONS

Electrical Specifications

Model HIT Power 205 HIT Power 200 HI T Power 195 HIT Power 190 HI T Power 186 HIT Power 180

Number of Cells in Series 96 96 96 96 96 96
Rated Power, Watts (Pmax) 205.0 200.0 195.0 190.0 186.0 180.0
Maximum Power Voltage (Vpm) 56.7 55.8 55.3 54.8 54.4 54.0
Maximum Power Current (Ipm) 3.62 3.59 3.53 3.47 3.42 3.33
Open Circuit Voltage (Voc) 6 8.8 68.7 6 8.1 67.5 67.0 6 6.4
Short Circuit Current (Isc) 3.84 3.83 3.79 3.75 3.71 3.65
Temp. Coefficient (Pmax) %/oC -0.29 -0.29 -0.30 -0.30 -0.30 -0.33
Temp. Coefficient (Voc) V/oC -0.172 -0.172 -0.170 -0.169 -0.168 -0.173
Temp. Coefficient (Isc) mA/oC 0.88 0.88 0 .87 0. 86 0.85 1 .10
Maximum System Voltage (Voc) 600 6 00 600 600 600 600
Factory Installed Bypass Diodes 4 4 4 4 4 4

Mechanical Specifications

Length

Width

Depth
Weight

(HIP-205BA19) (HIP-200BA19) (HIP-195BA19) (HIP-190BA19) (HIP-186BA19) (HIP-180BA19)

51.9in (1319mm)

34.6in (880mm)

1.8in (46mm)

33.07 Lbs. (15kg)

Dimensions in mm

All HIT Power Models

Mount Locations

(

HIP-xxxBA19)

Junction Box

Label

Negative (-)

Positive (+)

63cm (24.8in) 78cm (30.7in)

Connector (MC TM Plug)

Ground (4 places)

Section A-A’

6

Front Side Backside

Note: A module should be installed on a mounting structure
rail, using four (4) symmetrical mounting points within Range A.

Range A

Section B-B’