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General Installation Manual
© July 1, 2008. SANYO Energy (USA) Corp. All Rights Reserved.
Wiring
methods
should
accordance with the NEC in USA or
CEC in Canada.
A
qualified,
licensed
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.
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
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 requirements for
grounding solar electrical systems.
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.
be
in
Great care should be exercised to
ensure that corrosion caused by the
grounding means is avoided.
professional
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
(3.5mm
Recommended
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).
If
these
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.
associated
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
2
).
torque
value
3
Ground Locations
(Smaller holes for self-tapping screw method)
Label
Backside
The ground holes are
on the backside of the
module frame.
Ground Locations
(Larger holes for bolt and nut
is
Figure 3.1
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
adequate electrical connection.
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
(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.
Junction Box
method)
to
achieve
an
For a
(4.83mm)),
or
M5
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