Kyocera KD135GX-LPU Model Vehicle User Manual
Contents
1. 7 l Cala L l q i lt L jm lt x BES SIE jip A a a a a a a 1 1 b b N 4 b D o b N GROUND HOLE y a AF a i N b ap N MARKED i v o p T N crouno Hole A la E Dp x rus ail j B Nme y o NEZ f l BY ig ak r N pi 0 41 0 47 GR 7 To Sa oO co j 7 0 47 0 79 1 18 ae SECTION a a SECTION b b2. gt KYOCERA INSTALLATION MANUAL FOR THE KD135GX LPU KD245GX LPB OF SOLAR PHOTOVOLTAIC POWER MODULES Please read this manual carefully before installing the modules KYOCERA 6C 208590 1 INTRODUCTION As the world leader in the development and application of high technology ceramic silica materials Kyocera offers a wide range of highly efficient and reliable crystalline silicon solar photovoltaic PV power modules Kyocera began to extensively research PV technology in 1975 and commenced manufacturing operations in 1978 Since then Kyocera has supplied millions of cells and modules throughout the world With years of experience and state of the art technology Kyocera provides the highest quality PV power modules in a range of sizes designed to meet the requirements of the most demanding energy and power users worldwide 2 APPLICATIONS KDxxxGX LPx series modules are a reliable virtually maintenance free direct current DC power source designed to operate at the highest level of efficiency KDxxxGX LPx series modules are ideal for remote home water pumping utility tied telecommunications and many other applications either with or without using storage batteries 3 WARNINGS amp SAFETY PV modules generate electricity when exposed to light Arrays of many modules can cause lethal shock and burn hazards Only authorized and trained personnel should have access to these modules To reduce the risk of electrical
3. E SELECTION In most applications KDxxxGX LPx series modules should be installed in a location where they will receive maximum sunlight throughout the year In the Northern Hemisphere the modules should typically face south and in the Southern Hemisphere the modules should typically face north Modules facing 30 degrees away from true South or North will lose approximately 10 to 15 percent of their power output If the module faces 60 degrees away from true South or North the power loss will be 20 to 30 percent When choosing a site avoid trees buildings or obstructions which could cast shadows on PV modules especially during the winter season when the arc of the sun is lowest over the horizon 5 MODULE TILT ANGLE KDxxxGX LPx series modules produce bigger power when they are pointed directly at the sun For grid tie installations where the PV modules are attached to a permanent structure PV modules should be tilted at an angle equal to the site s latitude This will typically result in the highest annual energy output 6 INSTALLING KDxxxGX LPx SERIES MODULES To install the module use bolt and nut on installation holes which are opened in the module frame and install the module by following the instruction below The minimum spacing of 2 50 mm is required between PV module and the mounting surface around the perimeter of PV module KDxxxGX LPx series modules may be installed in various applications utilizing a vari
4. OCERA Solar do Brasil Ltda Av das Americas 20007 Bloco 2 Salas rooms 105 to 108 Rio de Janeiro 22790 851 Brazil Phone 55 21 3724 3900 Fax 55 21 3724 391 1 http www kyocerasolar com br E KYOCERA Fineceramics GmbH Fritz Mueller Strasse 27 73730 Esslingen Germany Phone 49 711 93934 999 Fax 49 711 93934 950 http www kyocerasolar de E KYOCERA Asia Pacific Pte Ltd 298 Tiong Bahru Road 13 03 05 Central Plaza 168730 Singapore Phone 65 6271 0500 Fax 65 6271 0600 http www kyocera com sq E KYOCERA Asia Pacific Ltd Room 801 802 Tower 1 South Seas Centre 75 Mody Road Tsimshatsui East Kowloon Hong Kong Phone 852 2723 7183 Fax 852 2724 4501 m KYOCERA Asia Pacific Pte Ltd Taipei Branch 10 FI No 66 Nanking West Road Taipei Taiwan Phone 886 2 2555 3609 Fax 886 2 2559 4131 mE KYOCERA Tianjin Sales amp Trading Corporation Room 1509 Tower A Gemdale Plaza No 91 Jianguo Road Chaoyang District Beijing 100022 China Phone 86 10 8528 8838 Fax 86 10 8528 8839 http www kyocera com cn E KYOCERA Korea Co Ltd Diplomatic Center Room 406 1376 1 Seocho 2Dong Seocho Ku Seoul 137 072 Korea Phone 82 2 3463 3538 Fax 82 2 3463 3539 12 SPECIFICATIONS Under certain conditions a photovoltaic module may produce more voltage and current than reported at Standard Test Conditions STC Refer to Section 690 of the National Electrical Code for guidance in series string sizing and c
5. allation Do not expose the back of the module to direct sunlight In Canada installation shall be in accordance with CSA C22 1 Safety Standard for Electrical Installations Canadian Electrical Code Part 1 When handle the modules DO NOT HOLD THEM BY SUPPORTING ONLY ONE SIDE OF THE LONG FRAME BECAUSE IT CAN CAUSE SEPARATION OF THE GLASS AND FRAME A CAUTION FIRE RATING In case of roof installation PV module assembly shall be mounted on a fire resistant roof covering rated for the application _KDxxxGX LPx series modules are comprised of a glass front surface polyethylene terephthalate PET backsheet with a Class C fire rating GROUNDING Refer to Grounding section BATTERY When PV modules are used to charge batteries the battery must be installed in a manner which will ensure the performance of the system and the safety of its users Follow the battery manufacturer s safety guidelines concerning installation operation and maintenance recommendations In general the battery or battery bank should be kept away from people and animals Select a battery site that is protected from sunlight rain snow debris and is well ventilated Most batteries generate hydrogen gas when charging which can be explosive Do not light matches or create sparks near the battery bank When a battery is installed outdoors it should be placed in an insulated and ventilated battery case specifically designed for this purpose 4 SIT
6. eg C 2 See module specification sheet for most recent electrical characteristics 3 See module drawing for mounting grounding holes locations MODULE DIMENSIONS MODULE DIMENSIONS MODULE TYPE DIM A DIM B DIMC DIM D DIME DIM F DIM G MODULE TYPE DIMA DIMB DIMC DIMD DIME DIMF DIMG KD135GX LPU 59 06 26 30 25 31 49 10 96 37 13 35 KD205GX LPU KD210GX LPU KD215GX LPU 59 06 38 98 37 99 49 10 96 37 13 35 KD185GX LPU 52 68 38 8971 37 99 49 10 10 32 48 35 KD225GX LPB KD230GX LPB KD235GX LPB KD240GX LPB KD245GX LPB 65 43 38 98 37 99 49 11 067 43 31 35 KD225GX LPB KD230GX LPB aeaee KD235GX LPB S 8 KD215GX LPU poa Tee ee ee ee A i 3 mI T N p oag a 46 9 ii f WIRE JL WIRE i rre 5 i we 4 ae 43 3 fl wN ffo WIRE WIRE LENGTH F i so T NITE a LENGTH a sr m er lH ine daa I WIRE J mem US LENGTH i gt i WRES WIRE f uen LIE LENGTH Z A Saam UO enem E LENH T i f os C P i 8
7. er temperature extremes NOTE Install the maximum number of series connection for the KDxxxGX LPx series modules so that the system voltage is less than 600 V NOTE Do not connect the modules in parallel without maximum over current protection NOTE The minimum diameter that the cable can be bent for the KDxxxGX LPx series modules is 1 93 49mm NOTE In normal conditions PV modules may produce larger current and or voltage than reported in the standard test conditions Therefore when voltage evaluations for components capacity of conductors size of fuses and size of control systems connected to the module output are determined multiply the values of short circuit current Isc and open circuit voltage Voc that are marked in KDxxxGX LPx series modules by the coefficient 1 25 NOTE Refer to Section 690 8 of the National Electrical Code for an additional multiplying factor of 125 percent 80 percent derating which may be applicable 8 GROUNDING Before installation contact the local code authorities to determine the necessary grounding requirements When installing in US market attach all PV module frames to an earth ground in accordance with the National Electrical Code NEC Article 250 Proper grounding is achieved by connecting PV module frames and all metallic structural members contiguously to one another using a suitable grounding conductor The grounding conductor shall be of copper copper alloy or another mate
8. ety of support structure options and attachment methods For optimal performance in all applications clearance between the module frame and the mounting surface is required to allow cooler ambient air to circulate around the back of the module and to avoid the module and or wiring damage A minimum of 13 3 2 mm spacing must also be maintained between module frames to allow for thermal expansion KDxxxGX LPx series modules may be attached to a support structure by the following methods When installing modules in snowy area an appropriate countermeasure has to be taken to prevent possible damages to the lower side frame by slipping snow e g attach supporting parts to the lowest modules Any damage caused by snow or such countermeasure is not covered under warranty BOLTING Utilizing 5 16 or 8 mm steel hardware structure through the existing 35 9 mm diameter mounting holes in the module frame and then through KDxxxGX LPx series module mounting holes on the support structure Tighten the screws with adequate torque usually 132 in lb Support structure should have enough strength to keep the mounting span Refer to the Module Drawings for the position of PV module mounting holes 7 MODULE WIRING KDxxxGX LPx series modules come pre wired with terminals ready for most building attachments or free standing installations Each module has two 12 AWG type PV wire stranded sunlight resistant output cables each terminated wi
9. hoosing overcurrent protection Kyocera KDxxxGX LPx Series Module Specification Electrical Characteristics STC Module Type KD135GX LPU KD185GX LPU KD205GX LPU KD210GX LPU KD215GX LPU KD225GX LPB KD230GX LPB KD235GX LPB KD240GX LPB KD245GX LPB Series Fuse 15 Rating Physical Characteristics SSCS Physical Characteristics L h 59 06 52 68 59 06 59 06 59 06 65 43 65 43 65 43 65 43 65 43 engt 1500mm 1338mm 1500mm 1500mm 1500mm 1662mm 1662mm 1662mm 1662mm 1662mm Width 26 30 38 98 38 98 38 98 38 98 38 98 38 98 38 98 38 98 38 98 lat 668mm ERs roc Race ao E aca EE E 990mm 990mm Depth 1 81 46mm 1 1 81 46mm 46mm 1 1 81 46mm 46mm 1 1 81 46mm 46mm 1 1 81 46mm 46mm 1 1 81 46mm 46mm 1 1 81 46mm 46mm 1 1 81 46mm 46mm 1 81 46mm 1 81 46mm Weigh 27 6 b 35 3 Ib 39 7 Ib 39 7 Ib 39 7 Ib 46 3 Ib 46 3 lb 46 3 lb 46 3 Ib 46 3 lb eight 12 5kg 16 0kg 18 0 kg 18 0 kg 18 0 kg 21 0 kg 21 0 kg 21 0 kg 21 0 kg 21 0 kg oe Diameter 35 9mm Quantity 4pcs ole Diameter 35 9mm Quantity 4pcs ole Application lass A NOTES 1 The electrical characteristics are within 5 of the installed values of Pmax and within 10 of the installed values of Isc and Voc under standard test conditions irradiance of 1000W m AM 1 5 spectrum and a cell temperature of 25 d
10. me Flat washer Bolt Star washer Aluminum frame Flat washer Bolt 9 BLOCKING DIODES In systems utilizing a battery blocking diodes are typically placed between the battery and PV module output to prevent battery from discharging at night KDxxxGX LPx series modules are made of polycrystalline cells with high electrical back flow resistance to nighttime battery discharging As a result KDxxxGX LPx series modules do not contain a blocking diode when shipped from the factory Most PV charge regulators and inverters incorporate nighttime disconnect feature 10 BYPASS DIODES Partial shading of an individual module in a source circuit string i e two or more modules connected in series can cause a reverse voltage across the shaded cells within the module Module output current is then forced through the shaded area by the remaining illuminated cells and other PV modules in series with the partially shaded module s The current forced through the shaded cells within PV module or modules causes additional module heating and severe loss of power All KDxxxGX LPx series modules are supplied with factory installed non user serviceable bypass diodes The purpose of bypass diodes is to provide a low resistance current path around the shaded cells thereby minimizing PV module heating and array current losses PV modules employ bypass diodes that have Rated Average Forward Current law Above maximum system current a
11. rial suitable for use as an electrical conductor per NEC The grounding conductor must then make a connection to earth using a suitable earth grounding electrode Ensure positive electrical contact through the anodizing on the module frame extrusion by utilizing one of the following methods Attach the grounding conductor 1 to one of the 35 9mm diameter holes marked ground using 5 16 stainless steel hardware Wrap conductor around bolt Tighten the screws with adequate torque usually 132 in lb Avoid direct contact of copper ground conductor to aluminum frame 2 to a ground lug manufacturer ILSCO model GBL 4DBT Tighten the screws with adequate torque usually 62 in lb Use 10 32 stainless steel hardware to attach the lug to the module frame by the torque of 40 in lb A stainless steel star washer positioned between the lug and the anodized surface of the frame must be employed to break through the anodized layer of the frame extrusion and electrically connect the ground lug to the conducting aluminum frame material As a general rule avoid direct contact of copper or copper alloy ground conductors with the aluminum module frame All ground bond securing hardware in contact with either the aluminum module frame and or copper or copper alloy ground conductors must be stainless steel Nut Spring washer Flat washer Nut Ground conductor Spring washer Cup washer Ground lug Star washer Aluminum fra
12. shock or burns modules may be covered with an opaque material during installation Do not touch live terminals with bare hands Use insulated tools for electrical connections Do not use these modules for solar concentration PERMIT Before installing your PV system contact local authorities to determine the necessary permits installation and inspection requirements hi ae A AND OPERATION Systems should be installed by qualified personnel only The system involves electricity and can be dangerous if the personnel are not familiar with the appropriate safety procedures Do not step on the module Although KDxxxGX LPx series modules are quite durable the glass can be broken and the module will no longer work properly if it is dropped or hit by tools or other objects The module frame is made of anodized aluminum and therefore corrosion can occur if the module is subject to a salt water environment and is in contact with another type of metal electrolytic corrosion If required PVC or stainless steel washers can be placed between PV module frame and support structure to prevent this type of corrosion KDxxxGX LPx series module frame s must be attached to a support structure by one of the methods described in Section 6 Installing KDxxxGX LPx series module s Module support structures to be used to support KDxxxGX LPx series module s should be wind rated and approved by the appropriate local and civil codes prior to inst
13. t highest PV module operating temperature Rated Repetitive Peak Reverse Voltage Vrarm Above maximum system voltage at lowest PV module operating temperature 11 MAINTENANCE KDxxxGX LPx series modules are designed for long life and require very little maintenance Under most weather conditions normal rainfall is sufficient to keep the module glass surface clean If dirt build up becomes excessive clean the glass surface only with a soft cloth using mild detergent and water USE CAUTION WHEN CLEANING THE BACK SURFACE OF PV MODULE TO AVOID PENETRATING BACK SHEET PV modules that are mounted flat 0 tilt angle should be cleaned more often as they will not self clean as effectively as modules mounted at a 15 tilt or greater Once a year check the general condition of the wiring and check to be sure that mounting hardware is tight Loose connections may result in a damaged module or array KYOCERA Solar Group Sales Office E KYOCERA Corporation Corporate Solar Energy Group 6 Takeda Tobadono cho Fushimi ku Kyoto 612 8501 Japan Phone 81 75 604 3476 Fax 81 75 604 3475 http www kyocera com m KYOCERA Solar Inc 7812 East Acoma Drive Scottsdale AZ 85260 U S A Phone 1 480 948 8003 or 1 800 223 9580 Fax 1 480 483 6431 http www kyocerasolar com E KYOCERA Solar Pty Ltd Level 3 6 10 Talavera Road North Ryde NSW 2113 Australia Phone 61 2 9870 3946 Fax 61 2 9888 9673 http www kyocerasolar com au E KY
14. th Multi Contact locking connectors The positive terminal has a male connector while the negative terminal has a female connector The module wiring is solely for series connections only i e male to female interconnections Series and parallel connections shall be made by use of two 10 14 AWG type PV wire stranded sunlight resistant and insulated for 90 C minimum output cables with male and female Multi Contact locking connectors NOTE When making connections with Multi Contact connectors make sure the array is disabled DO NOT MAKE CONNECTIONS WHILE UNDER LOAD Module output connections are marked Do not disconnect under load NOTE MAXIMUM SYSTEM VOLTAGE 600 VDC KDxxxGX LPx series modules and most PV system components have a maximum system voltage rating of 600 volts DC Some grid feed in systems operate at or near this voltage rating Like other polycrystalline the PV modules the open circuit voltage of the KDxxxGX LPx series modules increases as the ambient temperature decreases Maximum system voltage is computed as the sum of the open circuit voltage of the series connected PV modules for the lowest expected ambient temperature Refer to the National Electrical Code Article 690 7 a for determining the maximum number of KDxxxGX LPx series modules that can be placed in series Temperature coefficients specific to the module of use can be used to provide the most accurate prediction of module voltage und
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