sunMAX - Install: Module Assembly & Cabling

With the trim covers installed properly, you’re ready to place and install the first row of AC Modules, which will structurally fasten to neighboring modules in the same row.

Jumper & Y-Cables are also connected in this video tutorial.

Use the same techniques described here to install Modules at any row in the array.

AC Module-to-Mount Installation

Begin by hooking the AC Module onto the top lip of the mounting assemblies at a 45 degree angle, then lower the module while pulling its top edge toward you to keep it securely in place at the mount.

As mentioned in the previous video, the remaining roof mount locations should not have mounting assemblies installed yet.

Holding the AC Module in position, insert the mounting assembly hardware into the top edge of the panel (with the arrows facing forward) and line it up over the roof mounts in the next row.

If the AC Module is supported by more than one mounting assembly or connector mount, ensure that each component is inserted into the top edge of the AC Module before securing it to the roof mounts.

While lowering the AC Module into place, continue to pull its top edge slightly toward you to ensure it remains hooked onto the swivel mounts in the previous row.

Secure the AC Module to the roof mount(s) using the mounting hardware. If the AC Module is not seated properly or sitting evenly with the mounting hardware in row one, make the necessary adjustments.

If adjustments need to be made to one or both of the mounting assemblies in row two, turn the Mounting Assembly Base in either direction to adjust its height.

To raise the height, turn the base clockwise.

To lower the height, turn the base counterclockwise.

Once the mounting assemblies are all the same height, secure the AC Module to the roof mounts.

Subsequent AC Modules can be installed in a similar manner as the first module.

Structural Connections & Trunk Cabling

However, be sure to connect AC trunk cables between neighboring modules, before completely lowering and securing each Module to the roof mount(s).

Neighboring AC Modules whose corners sit at a common Mount Point are structurally supported and electrically bonded by the Mounting Assembly.

If the corner edges of the AC Modules do not rest at a common Mount Point, use a Panel Connector to join the AC Modules together.

Panel Connectors hold the AC Modules together structurally, along the frame edges and corners, while also bonding them together electrically.

The final layout of the Array may prevent you from easily accessing the modules later in the install, so after cables and modules are connected, be sure to properly fasten and securely clip cables to the lips on the underside of AC Modules.

This will suspend the cables above the rooftop and keep them from being exposed to the sun and other harsh weather elements.

Continue installing AC Modules, working from side-to-side, until the layout of your solar array is complete.

In a multi-row system, jumper cables are required to connect the second row of AC Modules to the first, as described in detail in Appendix B of the sunMAX User Guide.

In a multi-row system, jumper cables are required to connect sequential rows of AC Modules, as described in detail in Appendix B of the sunMAX User Guide.

Use clips to fasten these jumper cables to the underside of the modules as well.

Once the last AC Module in your array has been installed, locate the open Y-cable in your string of AC Modules and attach it to the End Run-assembly.

Repeat this step for each string of up to 15 AC Modules.

To review:

  • AC Modules hook onto the top lip of the Mounting Assembly.
  • Connect Trunk Cables, then carefully lower the Modules into place, and secure the mount assemblies at the same height across the row.
  • Ensure that neighboring panels are structurally supported at adjacent corners, securing trunk cables to the underside of the modules as you continue to install modules across the array.
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