Kyocera Battery Charger KC 120 1 User Manual

INSTALLATION MANUAL  
FOR THE  
KC-SERIES  
OF  
SOLAR PHOTOVOLTAIC POWER MODULES  
Please read this manual carefully before installing the modules.  
KYOCERA CORPORATION  
1. INTRODUCTION  
As the world leader in development and application of high technology ceramic/silica materials, Kyocera Corporation  
(KC) 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. POWER MODULES  
Kyocera power modules consist of a series of electrically interconnected crystalline silicon solar cells. Which are  
permanently laminated within an ethylene-vinyl-acetate (EVA) pottant and encapsulated between a tempered glass  
cover plate and a poly-vinyl-flouride (PVF) back sheet. The entire laminate is secured within an anodized aluminum  
frame for structural strength, ease of installation, and to protect the cells from the most severe environmental  
conditions.  
3. APPLICATIONS  
Kyocera modules are a reliable, virtually maintenance-free direct current (DC) power source, designed to operate most  
efficiently in sunlight. Kyocera modules are ideal to power remote homes, recreational vehicles, water pumps,  
telecommunication systems and many other applications either with or without the use of storage batteries.  
4. WARNINGS  
Solar 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  
shock or burns, modules may be covered with an opaque material during installation to avoid shocks or burns. Do not  
touch live terminals with bare hands. Use insulated tools for electrical connections.  
PERMIT  
Before installing your solar system, contact local authorities to determine the necessary permit, installation and  
inspection requirements.  
INSTALLATION 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 KYOCERA modules are quite rugged, the glass can be broken (and the module will no longer work  
properly) if it is dropped or hit by tools or other objects.  
Sunlight shall not be concentrated on the module.  
The module frame is made of anodized aluminum, and therefore corrosion can occur if the module is subject to a  
salt water environment with contact to a rack of another type of metal.(Electrolysis Corrosion) If required, PVC or  
stainless steel washers can be placed between the solar module frame and support structure to prevent this type of  
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7. INSTALLING KC MODULES  
The frame of each module has 0.28φ diameter (7 mm) mounting holes (Refer to Module Mounting Specifications).  
These are used to secure the modules to the supporting structure. An example of a ground mounted structure is shown  
in Figure 3. The four holes close to the corners of the module are most often used for attachment. Refer to the  
Mounting Specification Specifications for the position of these holes. Clearance between the module frame and the  
mounting surface may be required to prevent the junction box from touching the surface, and to circulate cooling air  
around the back of the module. If the modules are to be installed on the roof or wall of a building, the standoff method  
or the rack method is recommended.  
STAND-OFF METHOD: The modules are supported  
parallel to the surface of the building wall or roof.  
Clearance between the module frames and surface of  
the wall or roof is required to prevent wiring damage  
MOUNTING HOLE  
ARRAY FRAME  
and to allow air to circulate behind the module.  
The recommended stand-off height is 4.5 in. (about 115  
mm) If other mounting means are employed, this may  
affect the Listing For Fire Class Ratings.  
SUPPORT  
LEGS  
MODULE  
RACK:  
The supporting frame is used to mount  
modules at correct tilt angles. The modules are not  
designed for integral mounting as part of a roof or wall.  
The mounting design may have an impact on the fire  
resistance.  
FOOT ANGLE  
Figure 2. Basic Rack or Standoff Mounting Structure  
8. MODULE WIRING  
As shown in Module Mounting Specifications, all of the KC modules utilize the Type G junction box except the KC-70,  
KC-80 and KC-120-1 modules which utilize the Type M junction box (see J-box details). This junction box, located on  
the back side of the module, is weatherproof and is designed to be used with standard wiring or conduit connections.  
Kyocera recommends that all wiring and electrical connections comply with the 1999 National Electrical Code (NEC).  
Bypass diodes and cable clamps are included with each module when shipped from the factory.  
Figure 3. Standard Wiring Examples  
To wire Kyocera modules:  
A
Determine the nominal system array voltage of your system. Each panel is equivalent to a 12 VDC nominal block.  
Standard array voltages 12, 24 and 48 volt are shown as examples in Figure 3.  
B. Open the "G" or "M" box cover by loosening the screws in the cover.  
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C. The wire used to interconnect the solar modules  
may be single or two conductor, from 14 AWG (2.08  
mm2) up to 10 AWG (5.26 mm2) gauge stranded  
copper wire, in a “SUNLIGHT RESISTANT” jacket  
UF cable. This cable is suitable for applications  
where wiring is exposed to the direct rays of the  
sun. The maximum and minimum outer diameters  
of the cable that may be used with the cable  
connector are 8 mm and 6 mm respectively (Fig. 3).  
D. Using a flat blade screwdriver, remove only the  
appropriate "KNOCK-OUTS" from the sides of the  
"G" or "M" box .  
TERMINAL SCREW  
SPRING WASHER  
CABLE  
CUP WASHER  
Figure 4.  
Ring or Spade Terminal Connectors  
E. Route wires through the knock-outs and clamps in  
the following steps (see Figure 5):  
a. Insert the nipple (1) of the clamp in a hole in the  
junction box using lock nut (2).  
b. Push the interconnect cable (3) through (1), (2)  
and the cap (4).  
c. Clamp the cable by tightening the cap (4).  
F. Gently hand tighten the terminal screws with cross  
tip (Phillips head) screwdriver. Do not overtighten,  
as the terminal can be damaged.  
G. The output wiring from the final module is generally  
run to a separate array junction box. In commercial  
system, this wiring from the array box to the next  
component (i.e. fuse box. or charge regulator, etc.)  
is generally run in conduit. The maximum electrical  
rating of an acceptable series fuse is 412  
amperes.  
Figure 5. Interconnect Cable Clamp  
H. After checking that module wiring is correct, close and secure all the junction boxes. Use a Phillips head screw driver  
to secure all screws on the junction box cover to ensure a waterproof seal.  
9. GROUNDING  
We recommend you attach all module frames to an earth ground. Attach a separate ground wire to one of the holes  
marked groundon the module frame with a screw and bonding or external tooth washer. This is to ensure positive  
electrical contact with the frame. The racks must also be grounded unless they are mechanically connected by nuts  
and bolts to the grounded modules.  
Grounding is achieved by securing the array frame for both roof and field mounted applications. Additionally, the array  
frame shall be grounded in accordance with NEC Art 250.  
10. BLOCKING DIODES  
Blocking diodes are typically placed between the battery and the PV module output to prevent battery discharge at  
night. Kyocera modules are made of polycrystalline cells with high electrical back flowresistance to nighttime battery  
discharging. As a result, KYOCERA modules do not contain a blocking diode when shipped from the factory. Most PV  
charge regulators do have a nighttime disconnect feature, however.  
11. BYPASS DIODES  
Partial shading of an individual module in a 12 volt or higher source circuit string (i.e. two or more modules connected in  
series) can cause a reverse voltage across the shaded module. Current is then forced through the shaded area by the  
other modules.  
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When a bypass diode is wired in parallel with the series string, the forced current will flow through the diode and bypass  
the shaded module, thereby minimizing module heating and array current losses.  
For 12-volt systems and higher: Each module junction box has a diagram illustrating the proper orientation of the  
bypass diode installed between two of the terminal screws (Figure 11, Figure 12). When the solar modules are  
connected as individual series strings first, and then these strings are connected in parallel, bypass diodes should be  
used in each junction box. This is the simplest wiring arrangement for most installations.  
Diodes that are used as bypass diodes must:  
Have a Rated Average Forward Current [IF(AV)] Above maximum system current at highest module operating  
temperature.  
Have a Rated Repetitive Peak Reverse Voltage [VRRM] Above maximum system voltage at lowest module  
operating temperature.  
12. MAINTENANCE  
Kyocera 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  
THE MODULE TO AVOID PENETRATING THE PVF SHEET. 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 tightness of terminal screws and the general condition of the wiring. Also, check to be sure that  
mounting hardware is tight. Loose connections will result in a damaged module or array.  
13. SPECIFICATIONS  
The electrical and physical specifications can be found at the end of this document (Table 2).  
NOTES  
The electrical characteristics are within ±10 percent of indicated values of Isc, Voc, and Pmax under standard test  
conditions (irradiance of 1KW/m2, AM 1.5 spectrum, and cell temperature of 25).  
Under certain conditions, a photovoltaic module is likely to produce more current and / or voltage than reported at  
standard test conditions. Accordingly, the values of Isc and Voc marked on this module should be multiplied by a  
factor of 1.25 when determining component voltage ratings, conductor ampacities, fuse sizes, and sizes of  
regulators which are connected to the PV output. Refer to Section 690-8 of the National Electrical Code for an  
additional multiplying factor of 125 (80 per cent derating) which may also be applicable.  
MANUFACTURED IN JAPAN BY KYOCERA CORPORATION  
KFG GROUP  
KSI GROUP  
Kyocera Fineceramics GmBH  
Fritz Müller Strasse 107, D-73730 Esslingen, Germany  
Phone: (49) 711-9393-417  
Kyocera Solar Inc. (Headquarters)  
7812 East Acoma Drive, Scottsdale, AZ 85260, USA  
Tel: (480) 948-8003 or (800) 223-9580  
Fax: (480) 483-6431  
Fax: (49) 711-9393-450  
Kyocera Solar Pty, Ltd.  
KAP GROUP  
36 Windorah St., Unit 6 Stafford 4053 Queensland, Australia  
Tel: (61) 7-3856-5388  
Fax: (61) 7-3856-5443  
Kyocera Asia Pacific Singapore  
Fritz Müller Strasse 107, D-73730 Esslingen, Germany  
298 Tiong Bahru Road, #13-03/05 Tiong Bahru Plaza Singapore  
168730  
Kyocera Solar Argentina S.A.  
Tel: (65) 271-0500  
Fax: (65) 271-0600  
Mejico 2145, 16400 Martinez Prov. de Buenos Aires Argentina  
Tel: (54) 114-836-1040  
Fax: (54) 114-836-0808  
Kyocera Solar Do Brazil  
Rua Mauricio da Costa Faria, 85  
22780-280 Recreio Rio de Janeiro  
Tel: (55) 2-1554-5554  
Fax: (55) 2-1553-4894  
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Table 2. Kyocera KC-Family Module Specifications  
Electrical Characteristics:  
Model Number  
KC-120-1  
120  
KC-80  
80  
KC-70  
70  
KC-60  
60  
KC-50  
50  
KC-45  
45  
KC-40  
40  
KC-35  
35  
Rated Power, Watts (Pmax)  
Open circuit Voltage (Voc)  
Short Circuit Current (Isc)  
Voltage at Load (Vmp)  
21.5  
7.45  
16.9  
7.1  
21.5  
4.97  
16.9  
4.73  
600  
21.5  
4.35  
16.9  
4.14  
600  
21.5  
3.73  
16.9  
3.55  
600  
21.5  
3.1  
19.2  
3.1  
21.5  
2.48  
16.9  
2.34  
600  
18.8  
2.5  
16.7  
3
15  
15  
Current at Load (Imp)  
3
2.33  
N/A  
yes (4)  
6
Maximum System Voc  
600  
600  
yes (4)  
6
600  
yes (4)  
6
Factory Installed Bypass Diode (Qty)  
Series Fuse Rating (Amps)  
yes (6)  
11  
yes (6)  
7
yes (6)  
7
yes (4)  
6
yes (4)  
6
NOTE: The Electrical specifications are under test conditions of irradiance of 1kW/M2, Spectrum  
of 1.5 air mass and cell temperature of 25oC  
Physical Characteristics:  
Model Number  
KC-120-1  
56.1  
KC-80  
38.4  
KC-70  
34.1  
KC-60  
29.6  
KC-50  
25.2  
KC-45  
22.6  
KC-40  
20.7  
KC-35  
18.5  
Length, Inches (mm)  
(1425)  
(976)  
25.7  
(865)  
25.7  
(751)  
25.7  
(639)  
25.7  
(573)  
25.7  
(526)  
25.7  
(471)  
25.7  
Width, Inches (mm)  
25.7 (652)  
(652)  
(652)  
(652)  
(652)  
(652)  
(652)  
(652)  
Depth (frame, Inches (mm)  
Depth (including j-box), inches (mm)  
Weight, Pounds (kg)  
1.42 (36) 1.42 (36) 1.42 (36) 1.42 (36) 1.42 (36) 1.42 (36) 1.42 (36) 1.42 (36)  
2.0 (52) 2.0 (52) 2.2 (56) 2.0 (52) 2.1 (54) 2.1 (54) 2.0 (52) 2.1 (54)  
23.6 (11.9) 21.2 (9.6) 15.4 (7.0) 13.2 (6.0) 11.0 (5.0) 9.9 (4.5) 9.9 (4.5) 8.8 (4.0)  
Mounting Hole Diameter, inches (mm) * 0.28" (7) 0.28" (7) 0.28" (7) 0.28" (7) 0.28" (7) 0.28" (7) 0.28" (7) 0.28" (7)  
*Note: See Module Mounting Specifications for Hole Location on Frame  
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MODULE MOUNTING DIMENSIONS  
DO NOT USE  
DO NOT USE  
KYOCERA KC−SERIES  
MODULE MOUNTING SPECIFICATIONS  
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