General Installation Manual
© Apr 2012, SANYO Electric Co., Ltd. All Rights Reserved
4
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 Figure 4.1
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).
¾
Note that the module frame material
is aluminum/magnesium alloy.
¾
All fasteners (nuts, bolts, washers,
etc.) must be stainless steel
unless
otherwise specified.
•
Length of bolt should not be more than
1.26’’(32 mm).
•
Acceptable grounding wire is following.
Ilsco Corp. GBL-4DBT 10-14AWG-
Solid, 4-6, 8, 10-14AWG-Strand
Burndy L L C CL501TN 14AWG-Solid,
14-4AWG-Strand
Tyco Electronics Corp. 1954381-2 10-
12AWG Solid
•
Each framed module has a hole for a
bolt (0.205” diameter (5.2 mm)). This
ground hole is marked with a “G”
adjacent to the location on the frame
rail (see Figure 2). Ground wires must
be connected to the module’s metal
frame at this location.
Grounding Locations (or grounding
holes)
•
If using this method, use one of the
larger holes with diameter of
0.205’‘ (5.2 mm)
¾
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 frame.
•
In this case, the screw threads are not
providing the electrical ground contact.
Grounding Method
Wire connection using cup washers
(see Figures 4.1)
・
Use a bolt and nut (see Figures 2
Figures 4.1)
・
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.
•
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.
•
Recommended torque value in
tightening bolt and nut is 2.3N.m
(20in-lb).
Using “grounding lug . (see Figures 4.2)
Use a bolt and nut
(see Figures 2 and
4.2)
•
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.
As shown in Figures 4.2, tighten the
set screw (stainless steel) to ground
wire at the torque specified by lug
manufacturer.
The specified torque is following.
Ilsco Corp. GBL-4DBT 10-14AWG-
Solid -> 20 in-lbs, 4-6AWG-Strand ->
35 in-lbs, 8AWG-Strand -> 25 in-lbs,
10-14AWG-Strand -> 20 in-lbs
Burndy L L C CL501TN 14AWG-Solid -
> 35 in-lbs, 14AWG-Strand -> 35 in-lbs,
4AWG-Strand -> 45 in-lbs
•
Recommended torque value in
tightening bolt and nut is 2.3N.m (20in-
lb).
•
Use a grounding tin plated solid copper
lay-in lug rated for direct burial and
outdoor use. Lug must be used
ILSCO
GBL-4DBT, Burndy CL501TN.
Using a Grounding Clip with bolt and
nut
Use a bolt and nut
(see Figures 2 and
4.2)
•
Use Tyco Electronics 1954381-2 as
grounding clip.
•
As shown in figure2, place the
grounding clip onto the module frame.
•
Thread the hex nut onto the end of the
screw, then using a 3/8-in. wrench,
tighten the nut.
Recommended torque value in
tightening bolt and nut is between 1.7
and 2.2 Nm.
•
Insert the wire into the wire slot. Press
down on both ends of the wire.
•
Manually, or using channel lock pliers,
push the slider over the base until it
covers the base. This will terminate
the wire.
•
For more information, please refer to
Instruction sheet issued by Tyco
Electronics.
Additional ground hole –
If needed,
drilling one hole allowed in specified
locations on the frame of the module (see
Figures 4.3(a) and (b)).This hole is for
grounding purposes only. The grounding
hole size should be 0.205” 5.2 mm.
1. Scratch the hole centers of
additional ground hole both side of
frame.
2. Fix a module and Drill the pilot holes
from outside of frame. (hole
diameter: 2 mm)
3. Fix a module and Drill the pilot holes
from inside of frame. (hole diameter:
2 mm)
4. Fix a module and Drill plated
through hole from outside of frame
(hole diameter: 5.2 mm)
5. If barr side of frame outside is more
than 1 mm, remove the barr by
using sandpaper.
WARNING
Do not damage the back side of module
when the holes are drilled.
Junction Box and Terminals
•
Modules are equipped with one
junction box containing terminals for
both, positive and negative polarity,
and bypass diodes.
•
Each terminal is provided with factory
installed lead cables and Multi Contact
MC3 connectors for series and string
connections. Always use these
connectors and do not detach them
from cables.
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
