Page 1
General Installation Manual
© Apr 2010, Sanyo Electric Co., Ltd. All Rights Reserved 4/22/10
General Installation Manual for SANYO
HIT® Photovoltaic Modules. Please read
this manual completely before
installation or use of SANYO modules.
This manual applies to the following
125mm HIT Power products:
HIT Power 215N (HIP-215NKHA5,NKHA6)
HIT Power 210N (HIP-210NKHA5,NKHA6)
HIT Power 205N (HIP-205NKHA5,NKHA6)
HIT Power 200N (HIP-200NKHA5,NKHA6)
INTRODUCTION
Thank you for choosing SANYO HIT
photovoltaic (PV) modules. With proper
operation and maintenance, SANYO HIT
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, and maintain a
photovoltaic module. Contact with
electrically active parts of the
module such as terminals can result
in burns, sparks, and lethal shock
whether the module is connected or
disconnected.
• The installer assumes the risk of all
injury that might occur during
installation, including, without
limitation, the risk of electric shock.
• PV modules generate DC(direct
current) 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 hazard of electric
sparks, shock, fire, burns, damage
and injury:
• Cover the entire front surface of
the PV modules with a dense,
opaque material such as a
cardboard box, during installation
and handling of the modules.
• Work only in dry conditions, with
dry modules and dry tools.
• Do not stand or step on a module.
• Do not puncture, cut, scratch
ordamage 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 the Sanyo.
There are no user serviceable
parts within the module or
junction box.
• Unauthorized persons - except the
qualified licensed professional should not do wiring.
• Wear suitable clothing, guards,
and gloves to prevent you from
direct contact with 30 VDC 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
sunlght on a module.
• Do not touch the junction box
terminals.
• Do not change the wiring of
bypass diodes.
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, and other
unknown troubles.
GENERAL SAFETY
Follow all permission, installation and
inspection requirements.
• Before installing modules, contact the
appropriate authorities to determine
permissions, installation and inspection
requirements, which should be
followed.
• 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
national or international electrical
standards be followed. Refer to “Earth
Ground Wiring” section for more
information.
• Be sure that 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 help 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
specifications in the same system.
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General Installation Manual
Figure 1
Installation
© Apr 2010, Sanyo Electric Co., Ltd. All Rights Reserved 4/22/10
• Follow all safety precautions of other
system components which are used.
UL Listing Information
To satisfy UL requirements, when installing
the modules, be sure to:
1) Use only stranded or solid copper
single–conductor type PV wire or USE2 cable, 12AWG or larger conductors,
rated 600V, 90℃, sunlight resistant, for
modules and interconnect wiring that is
exposed to weather.
2) Observe the requirements described in
sections labeled INSTALLTION and
SPECIFICATIONS.
INSTALLATION
General
Please read this guide completely before
installation or use of the modules. This
section contains electrical and mechanical
specifications needed before using your
SANYO PV modules.
• 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 that are
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 the 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 1 inch of clearance between the
roof and the module frame. If other
mounting means are employed this
may effect the temperature of the panel.
• 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” (38 mm) width
Thickness :not less than 0.12”(3 mm)
Material: aluminum alloy
2
• Recommendation of bolt torque range:
16N.m to 20N.m.
Operating Conditions
SANYO requires that modules be operated
within the following Operating Conditions:
1) Terrestrial applications only—no outer
space or Special Conditions (see
below).
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 or Low of
the installation site.
3) The wind pressure load of the
installation site should be less than
2,880N/m2 (60PSF).
4) Some environmental conditions could
apply. Please refer to Sanyo’s warranty
exclusions.
Installation (reference)
Metal clamp A
(2 places)
Metal clamp A
Metal clamp
SPECIFICATIONS
Notes on Specifications
1) Rated electrical characteristics are
within –5% to +10% of the values
measured at Standard Test Conditions
(STC). STC conditions are; Irradiance
of 1000W/m, 25oC cell temperature,
and solar spectral irradiance per IEC
M8 Nut
38 mm
M8 Bolt
A
End of Module
Metal clamp B
(2 places)
Mounting
Structure Rail
38 mm
Metal clamp B
Mounting Structure Rail
Mounting Structure
60904-3. Note: At the time of
shipment, Sanyo guarantees the output
level of its modules to be -0/+10%
against Rated Power in
SPECIFICATIONS based on Sanyo’s
factory inspection at STC conditions.
2) 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. USA:
Refer to Section 690-7 and Section
690-8 of the U.S. National Electrical
Code for an additional multiplying
factor of 1.25, w hich may be
applicable.
Solar Module
Solar Module
Metal clamp B
Module
Between Modules
3) The current output for the modules
shown in the SPECIFICATIONS
section is measured at Standard Test
Conditions. These conditions may not
be frequently observed in actual
practice.
M8 Bolt
M8 Nut
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General Installation Manual
Figure 3.
1
© Apr 2010, Sanyo Electric Co., Ltd. All Rights Reserved 4/22/10
Mechanical Loading
• The modules should be mounted at the
four (4) quarter points by the means
shown in Figure 2.
• This method offers a maximum load of
2,880N/m2 (60PSF) in a static state on
the module surface.
Note: This mechanical loading value
was tested using the following
mounting device.
> Provider: UniRac, Inc.
> Part number: SolarMount®
TOP MOUNTING CLAMPS
Mid clamp and End clamp, F size,
Part No.320029, 320102
WIRING
General
• All wiring should be done in
accordance with applicable electrical
codes.
• 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 ten
(10) or fewer. If connecting eleven (11)
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 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
3
the maximum possible system open
circuit voltage.
• Check local codes for requirements.
Earth Ground Wiring
• Grounding should be carried out by
attachment to the module or array
frame, 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, or 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 be 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. It
can also be caused when two
dissimilar metals are in contact
(galvanic action).
Note that 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 screw or bolt
should not be more than 0.78’’(20
mm) 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 (0.165’‘ diameter (4.2 mm))
and two larger holes for bolts
(0.205’‘ diameter (5.2 mm)). 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
metal frame at one of these location.
• There are two methods available to
ground modules. Select one method.
>Wire connection using cup washers
(see Figures 3.2 and 3.3)
・ The use of cup washers is to prevent
wire from slipping out from under the
screw head (and/or the flat washer).
・ Make sure that the cup washer is
placed between the wire and the
module frame.
・ Choose an adequate size for the cup
washer and the flat washer so that the
wire is fully clamped between them.
・ Note: Cup washers are also called as
terminal cup washers.
・ The cup washers should be stainless
steel, or a cup washer made of brass
may be used only if a large flat washer
made of stainless steel is inserted
between the module frame and the cup
washer.
・ Choose the adequate size for the large
flat washer (between the module frame
and the cup washer) so that the cup
washer doesn’t contact the module
frame and is fixed stably to the module
frame.
Ground Location
(smaller holes for self-tapping screw)
PVU- B50. 2
IP65
600V
PVU- B50 .2
Label
Junction Box
Backside
The ground holes
are on the backside of
the module frame.
Ground Location
(larger holes for bolt and nut )
Module Ground Position
Page 4
General Installation Manual
Figure
4
Configuration of
© Apr 2010, Sanyo Electric Co., Ltd. All Rights Reserved 4/22/10
Method 1- Use a self tapping screw (see
Figures 3.1 and 3.2)
• If using this method, use one of the
smaller holes with diameter of
0.165’‘ (4.2 mm)
• 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.
Note: Self-tapping screws are also
called as thread cutting screws.
Method 2- Use a bolt and nut (see
Figures 3.1 and 3.3)
• If using this method, use one of the
larger holes with diameter of
0.205’‘ (5.2 mm)
The bolt and nut size should be No.8
(0.164’‘ diameter (4.16 mm)), or No.10
(0.190’‘ diameter (4.83 mm)) or M5
(0.197’‘ diameter (5.0 mm)).
• 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.
Module Terminations
• A junction box as a terminal enclosure
is equipped for electrical connections.
• Modules are equipped with MCTM plugs
as a terminal enclosure. Use these
MCTM plugs for electrical connections.
Junction Box and Terminals
• Modules equipped with one junction
box 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)
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.
DIODES
Bypass Diodes
• When modules in series strings are
partially shaded, it may cause reverse
voltage across 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 factoryinstalled diodes provide proper circuit
protection for the systems within the
specified system voltage, so that you
do not need any other additional
bypass diodes.
• Contact your SANYO Authorized
Representative for proper diode type, if
it is necessary to add or change diodes
due to system specifications.
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, it is
recommended to have a licensed
authorized professional carry out the
inspection or maintenance to avoid the
hazards of electric shock or injury.
The return of any modules will not be
accepted by SANYO unless prior written
authorization has been given by SANYO.
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.
P V U - B 5 0 . 2
I P 6 5
6 0 0 V
P V U - B 5 0 . 2
Cable
Connector
TM
MC
Plug
Option :
Safety lock clip
negative ( - ) positive ( + )
Junction Box
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General Installation Manual
Figure
3.2 (Method 1
)
ground
holes illustrated in Figure
*
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 3.3
(
Method 2)
d
holes illustrated in Figure
© Apr 2010, Sanyo Electric Co., Ltd. All Rights Reserved 4/22/10
Cup washer (Terminal cup)
(Stainless steel or *brass)
Flat washer (Stainless steel)
Spring washer (Stainless steel)
Frame (Longer side)
Grounding hole
(0.165’‘ diameter (4.2 mm) )
Glass
Backsheet
*Flat washer (Stainless steel)
Ground wire (#12AWG)
(wound around the screw)
Grounding method
using self-tapping screw
Note: Use the smaller
3.1.
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)
Cup washer (Terminal cup)
(Stainless steel or *brass)
Flat washer (Stainless steel)
Spring washer (Stainless steel)
Length
(not less than 0.47’‘(12 mm)
not more than 0.78’‘(20 mm))
Glass
Backsheet
Nut (Stainless steel)
Flat washer (Stainless steel)
Star washer (Stainless steel)
Grounding hole
0.205’‘ diameter
(5.2 mm))
*Flat washer (Stainless steel)
Ground wire (#12AWG)
(wound around the bolt)
Grounding method
using bolt and nut
Note: Use the larger groun
3.1.
Bolt (Stainless steel)
#8, #10, M5
module frame, and the flat washer diameter must be greater than the cup washer diameter.
Length
(not less than 0.63’‘(16 mm)
not more than 0.78’‘(20 mm))
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General Installation Manual
Mechanical Specifications
Dimensions
© Apr 2010, Sanyo Electric Co., Ltd. All Rights Reserved 4/22/10
SPECIFICATIONS
Electrical Specifications
Model HIT Power 215N HIT Power 210N HIT Power 205N HIT Power 200N
(HIP-215NKHA5,6) (HIP-210NK HA5,6) (HIP-205NKH A5,6) (HIP-200NKHA5,6)
Cell Number in Series 72 72 72 72
Rated Power, Watts (Pmax) 215 210 205 200
Maxi mum Power Voltage (Vpm) 42.0 41.3 40.7 40.0
Maxi mum Power Current (Ipm) 5.13 5.09 5.05 5.00
Open Circuit Voltage (Voc) 51.6 50.9 50.3 49.6
Short Circuit Current (Isc) 5.61 5.57 5.54 5.50
Cell Type HIT HIT HIT HIT
Maxi mum System Voltage (Voc) 600 600 600 600
Factory Installed Bypass Diodes 3 3 3 3
Maxi mum series fuse (A) 15 15 15 15
Length, mm (inches)
Width, mm (inches)
Frame Depth, mm (inches)
Weight, kg (pounds)
Dimensions in mm
1580 (62.2)
798 (31.4)
46 (1.8)
16 (35.3)
All HIT Power N Models (HIP-xxxNKHA5,HIP-xxxNKHA6)
Mount Locations
PVU -B5 0.2
IP6 5
600 V
PVU -B5 0.2
Junction Box
Label
negative (-)
88cm
(34.6 in)
positive (+)
103cm
(40.6 in)
Connector (MC TM Plug)
Section A-A’
6
Ground (4 places)
Front
Note : A module should be installed on a mounting structure rail in accordance with the following
＞Use four (4) symmetrical mounting within setting range A.
: range A
Side Backside
Figure 2 Dimensions
Section B-B’
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