Sanyo HIP-205BA3 User manual

General Installation Manual
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
products: HIP-205BA3, HIP-200BA3, HIP-195BA3, HIP-190BA3, HIP-186BA3, HIP-180BA3, HIP-
175BA3 and HIP-205BA5, HIP-200BA5, HIP-195BA5, HIP-190BA5, HIP-186BA5, HIP-180BA5
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, or
manual without prior notice.
General Information
The installation of solar modules requires
a great degree of skill and should only be
performed by a qualified licensed
professional, including, without limitation,
licensed contractors and licensed
electricians.
1
■ All instructions should be read
and understood before attempting to
install, wire, operate, and maintain the
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.
© Sept. 2006 Sanyo Electric Co., Ltd.
All Rights Reserved
■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 electrical
energy when exposed to sunlight or
other light sources. Although single
modules produce only a low voltage
and current, shocks and burns are still
a potential hazard.
■Do not carry a module by its
wires or junction box, to avoid the
hazard of electric shock, injury or
damage to the module.
■Do not drop anything on the
surfaces of a module, to avoid the
hazard of electric shock, injury, and
damage.
■To avoid the hazard of electric
shock and fire, be sure that all
other system components are
compatible, and they do not
subject the module to mechanical
or electrical hazards.
■To avoid the hazard of electric
shock and injury, cover all of the front
surface of the PV modules with a
dense, opaque material such as the
cardboard box, during installation and
handling of the modules.
■The shock hazard increases as
modules are connected in parallel
producing higher current. The
shock hazard increases as modules
are connected in series producing
higher voltages.
■To avoid the hazard of electric
shock, work only under dry
conditions, with dry modules and
tools.
■Do not stand or step on a
module to avoid the hazard of injury
and damage to a module.
■Do not puncture or damage the
back-sheet of a module, to avoid the
hazard of electric shock and fire.
■To avoid the hazard of electric
shock and injury, children and
unauthorized persons should not be
allowed near the installation of PV
modules.
■To avoid the hazard of electric
shock and injury, be sure to
completely ground all modules.
■To avoid the hazard of electric
shock, fire, and injury, do not
disassemble the module, or remove
any part installed by the
manufacturer.
■Unauthorized persons--except
the qualified licensed professional--
should not open the cover of the
junction box to avoid the hazard of
electric shock.
Provide suitable guards to prevent
yourself from direct contact with 30
VDC or greater to avoid the hazard
of electric shock or injury.
■When carrying a module, two
or more people should carry it by
its frame and wear non-slip gloves
(to avoid injury by a slipping
module, to a foot, or cuts by the
edge of a frame, and so on).
■Since sparks may occur, do not
install the module where flammable
gases or vapors are present.
■Never leave a module unsupported
or unsecured.
■Do not drop a module.
■Do not use or install broken
modules to avoid the hazard of
fire, electric shock, and injury.
■Do not artificially concentrate
sunlight on a module to avoid the
hazard of fire or damage.
■Do not touch the junction box
terminals to avoid the hazard of
electric shock and injury.
■Do not change the wiring of
bypass diodes to avoid the hazard
of electric shock and injury.
■Use a module for its intended
purpose only.
■Do not treat the back sheet and
front surface with paint or adhesives
to avoid reducing its’functionality,
damage, inoperable conditions, and
other unknown troubles.
CAUTIONS
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！
WARNING
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2
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 used.
●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. 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.
●Follow all safety precautions of other
system components 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 UF cable or USE
cable, rated sunlight resistant, for
modules and interconnect wiring that is
exposed to weather.
2) Observe the requirements described in
sections labeled INSTALLTION and
SPECIFICATIONS.
3) Grounding of the module frame is
required. When ground wires greater
than 6mm2(No.10 AWG) are required,
the installer will need to provide suitable
terminal connectors.
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.
●The appropriate material should be
used for mounting hardware to prevent
the module frame, mounting structure,
and hardware itself from 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.
●Please contact your SANYO
authorized representative with
questions regarding mounting profiles
for modules.
Notes on Installation
●Clearance between the module
frame and the mounting surface is
required to allow cooling air to circulate
around the back of the module. This
also allows any condensation or
moisture to dissipate. The module
should never be sealed to the mounting
surface with sealant that prevents air
from circulating under the module.
●Leave 4 inches of clearance between
the roof and the module frame.
Standard Operating Condition
SANYO recommends that modules be
operated under Standard Operating
Conditions (SOC).
An installation location with conditions
exceeding SOC or with other Special
Conditions (see below) should be avoided.
SOC of SANYO modules is as follows:
2. Special Conditions
1. Standard Operating Conditions
(1) The modules should be operated only
in terrestrial applications. No space or
other Special Conditions (see below).
(2) The measured ambient temperature
of the installation location should be
within –20℃(-4°F) to 40℃(104°F).
The lower and upper temperature limit
is defined as the monthly average low
or high of the installation location.
(3) The relative humidity should be within
45% to 95%.
(4)The installation place should be less
than 1,000m (3,280ft) above sea level.
Installations more than 1,000m (3,280ft)
are allowed only if the wind pressure
load for a module is less than
2,400N/m2(50PSF).
Metal fitting
Spring washer
Flat washer
Module
Mounting Structure Rail
M6 Bolt/setscrew
M6 Nut
Metal fitting
(4 places)
Mounting
Structure Rail
Solar Module
Between Modules
Mounting Structure Rail
Solar Module
Metal fitting
End of Module
f
8
27 27
14
Installation (reference)
Figure 1. Installation
This referential figure is for HIP-xxxBA3
modules.
●The drilling and addition of ground holes is
permitted, but should be avoided whenever possible
to avoid damage to the module. When additional
ground holes are necessary, they must not penetrate
the inner side of the aluminum frame. Caution is
advised to avoid accidentally drilling, scratching, or
penetrating the back surface of the module.
( 1 ) The ambient temperature of the
installation place exceeds SOC.
(2) The salt damage is heavy at the
installation place.
(3) The hail and snow damage is heavy
at the installation place.
(4) The sand and dust damage is heavy
at the installation place.
(5) The air pollution, chemically active
vapors, acid rain, and/or soot, etc. are
heavy at the installation place.
If required, it is recommended to add
additional ground holes to the outer
aluminum lip area of the module. In such
case, additional ground holes must be at
least 65㎜away from any frame corner.

Mechanical / Electrical Specifications
*HIT = Hetero junction with Intrinsic Thin-layer
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 maximum number of modules
that can be wired in series is seven (7).
The SANYO solar modules are not
designed for “off-grid”or battery charging
systems. 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, cables, 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 your local codes for
requirements.
Figure 2.
Module Ground Position
The ground hole is
on the inside of the
module frame.
Ground Location (1 place)
Ground hole
Label
Backside
Junction Box
Earth Ground Wiring
Grounding should be carried out by
the securement 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.
Each framed module has a hole in the
shorter side frame rail, to connect a
grounding conductor to the module
metal frame (see Figure 2).
Elec tric a l Spe c ific atio n All HIP -xxxB A3 M o de ls (xxx = o utput po we r)
All HIP -xxxB A5 M o de ls (xxx = o utput po wer)
Mo de l 2 0 5 2 0 0 19 5 19 0 18 6 18 0 17 5 2 0 5 2 0 0 19 5 19 0 18 6 18 0
C e ll Num be r in S e rie s 96 96 96 96 96 96 96 96 96 96 96 96 96
R a te d P o we r, Wa tts (P ma x) 205 200 195 190 186 180 175 205 200 195 190 186 180
Ma xim um P o we r Vo lta ge (Vpm ) 56.7 55.8 55.3 54.8 54.4 54.0 52.9 56.7 55.8 55.3 54.8 54.4 54
Ma xim um P o we r Curre nt (Ipm ) 3.62 3.59 3.53 3.47 3.42 3.33 3.31 3.62 3.59 3.53 3.47 3.42 3.33
Ope n C ircuit Vo lta ge (Voc ) 68.8 68.7 68.1 67.5 67.0 66.4 65.7 68.8 68.7 68.1 67.5 67.0 66.4
S ho rt Circ uit Curre nt (Is c) 3.84 3.83 3.79 3.75 3.71 3.65 3.64 3.84 3.83 3.79 3.75 3.71 3.65
C e ll Type HIT* HIT* HIT* HIT* HIT* HIT* HIT* HIT* HIT* HIT* HIT* HIT* HIT*
Ma xim um S ys te m Vo lta ge (Voc ) 600 600 600 600 600 600 600 600 600 600 600 600 600
F a c to ry Ins talle d B ypa s s Dio des
4
4
4
4
4
4
4
4
4
4
4
4
4
Mo de l 205 200 195 190 186 180 175 205 200 195 190 186 180
Le ngth, m m (inc he s )
Width, mm (inc he s )
F ra m e De pth , mm (inc hes )
Weight, kg (po unds )
60(2.4)
Me c hanica l Spe c ific a tio n
1319 (51.9)
894 (35.2)
35 (1.4)
14 (30.9)
SPECIFICATIONS
Notes on Specification
(1) Rated electrical characteristics are
within 10% of the values measured at
Standard Test Conditions (STC). STC are:
Irradiance of 1000W/m, 25℃cell
temperature, and solar spectral irradiance
per IEC 60904-3.
(2) The current output for the modules
shown in the Specifications is
measured at Standard Test Conditions.
These conditions may not be frequently
observed in actual practice.
(3) Under normal conditions, a
photovoltaic module may experience
conditions that produce more current
and/or voltage than reported at
standard component 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 690-8 of the
U.S. National Electrical Code for an
additional multiplying factor of 1.25
which may be applicable.
Mechanical Loading
The modules should be mounted at the
four quarter points by the means shown
in Figure 3.1 and 3.2. This method offers
a maximum loading of 2400N/m2(50PSF,
in a static state) on the module surface.
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.
•All wiring should be done by a
qualified, licensed professional.
3

4
Dimensions
Models (Standard): HIP-205BA3, HIP-200BA3, HIP-195BA3, HIP-190BA3,
HIP-186BA3, HIP-180BA3, HIP-175BA3
Dimensions in mm
Side
Front Backside
Note: A module is installed on a
platform
with standard setting range
(shaded)
Figure 3.1 Standard Model
Dimensions
Note: A module should be attached
on a mount or support structure rail
within the shaded range.
Connector (MCTM Plug)
Junction Box
Label
Mount Locations (4 places)
Section A-A’
negative ( - )
78cm (30.7in)
positive ( + )
63cm (24.8in)
Ground (1 place)
Module Terminations
A junction box as a terminal enclosure is equipped for
electrical connections on SANYO modules. Modules are
equipped with MCTM plugs as a terminal enclosure. Use
these MCTM plugs for electrical connections.
Please contact your SANYO authorized representative with
questions regarding other electrical connections for
modules.
negative ( - ) positive ( + )
Figure 4. Configuration of
Junction Box
Connector
MCTM Plug
Cable
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 the modules in series strings are shaded partially,
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.
All SANYO 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. Contact your authorized
SANYO representative for proper diode type, if it is
necessary to add or change diodes due to system
specifications.
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).

5
MAINTAINENCE
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. A mild non-abrasive
detergent may be applied for persistent
dirt. It is also recommended to inspect
the module’s electrical and mechanical
connections annually.
If you need electrical and mechanical
inspection or maintenance, it is
recommended to have an authorized
professional carry out the inspection or
maintenance to avoid the hazard of
electric shock and/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 our policy of continuous
improvement SANYO reserves the right
to change product specifications at any
time without prior notice.
Figure 3.2 Deep-Frame Model
Dimensions
For More Information,
Please Contact SANYO
Authorized Representatives
at:
www.sanyo.com/industrial/sol
ar/representatives.cfm
Dimensions
Models (deep-frame): HIP-205BA5,HIP-200BA5, HIP-195BA5,
HIP-190BA5, HIP-186BA5, HIP-180BA5
Dimensions in mm
Side
Front
Backside
Note: A module should be installed on a support structure in
accordance with the following:
Use four (4) symmetrical mounting points within set range A.
Section A-A’
Ground (1 place)
Label
Junction Box
Mount Locations
negative (－)
78cm (30.7in)
positive ( + )
63cm (24.8in)
Connector (MCTM Plug)
For further information, please
contact: