User Manual Nubbel_1-0-en _2010_9_15

gehrtec NUBBEL
EFFICIENT PREFABRICATED CABLE SYSTEM
Cabling system for outdoor and roof-mounted photovoltaic systems of all sizes.
The economical and safe option for connecting PV modules
with inverters for large-scale outdoor or roof-mounted systems
USER MANUAL
Introduction
Thank you for choosing the gehrtec-Nubbel system.
This product has been designed to meet the highest quality requirements. The product has also been used
in large-scale systems that we have constructed and operated, meaning that numerous improvements have
been integrated into the product, based on previous experience. We are convinced that we are therefore
able to provide you with an especially high-quality product.
We constantly endeavour to offer our customers the best products at the best prices. For this reason we
continually strive to further improve our products for the benefit of our customers.
We would be delighted if this product entirely fulfils or even exceeds your expectations.
We would be grateful to receive your qualified feedback, in order that we can further optimise our products.
Dr. T. Naebauer
Head of product development
Gehrlicher Solar AG
2
90310056--8.2010
Email: Toni.Naebauer@Gehrlicher.com
Table of contents
1. Safety instructions and general information................................................................. 4
Duty of care on the part of the operator...................................................................................................... 4
Basic safety instructions................................................................................................................................ 4
Requirements of persons installing, using and maintaining gehrtec products............................................... 5
Special types of hazards.............................................................................................................................. 5
Safety and information signs........................................................................................................................ 5
Safety instructions for installation................................................................................................................. 6
Rules and regulations................................................................................................................................... 6
Lightning protection...................................................................................................................................... 7
General information:.................................................................................................................................... 7
Exclusion of liability ..................................................................................................................................... 7
Danger electrical current! ............................................................................................................................ 7
2. Nubbel ........................................................................................................................ 8
The Nubbel types:........................................................................................................................................ 8
Polarities and colours................................................................................................................................... 9
Strings .......................................................................................................................................................... 9
Parallel connection of strings ....................................................................................................................... 9
3. Typical interconnection options for roof-mounted modules ......................................... 10
Example for interconnections with Nubbel double-strand.......................................................................... 10
Module type............................................................................................................................................... 11
Tools........................................................................................................................................................... 11
4. Insulate the ends of the strands.................................................................................. 12
Insulation of open strand ends ................................................................................................................... 12
5. Extension................................................................................................................... 13
6. Routing of the cable................................................................................................... 14
7. Supply coding............................................................................................................ 14
8. Guarantee................................................................................................................. 14
9. Contact ...................................................................................................................... 15
Addresses in Germany............................................................................................................................... 15
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1. Safety instructions and general information
1. Safety instructions and general information
Duty of care on the part of the operator
The Nubbel cabling system has been developed and manufactured under consideration of a risk analysis
and careful selection of materials and further technical specifications. It corresponds to the state-of-the-art
and guarantees highest safety levels.
However, this level of safety can only be realised in the field if all of the necessary measures have been
undertaken. It is part of the duty of care on the part of the installation firm and the operator of the system
to plan for and check the realisation of these measures.
It is especially important for the installer and operator to ensure that:
•
The Nubbel system is always installed and operated in accordance with the regulations for proper
use
•
The Nubbel system is only operated if it is in an optimal, functional condition.
•
The special installation instructions of the module manufacturer and the corresponding auxiliary
component manufacturers are observed.
•
That all installation and maintenance work is undertaken by qualified and trained staff, all of
whom must have fully and carefully read and understood these installation instructions and who
must observe them during execution of all such work.
•
That all applicable laws, directives and regulations to be observed by the installer or operator are
maintained.
Basic safety instructions
•
The area must be secured before beginning with the installation.
•
Biological hazards from plants and animals must be evaluated. If necessary, undertake additional
safety measures, for example, vaccinations.
•
All persons who will be present during operations must have been previously trained.
•
Modifications to the Nubbel system may only be carried out by qualified electricians.
•
Required personal protective gear must be made available.
•
Danger electrical current! The solar modules can generate voltages of up to 1,000 VCD in the
cables (in certain cases, even higher voltages can be produced). For this reason, protective
measures must be taken in relation to these voltages as soon as the solar modules are exposed to
solar radiation.
4
1. Safety instructions and general information
Requirements of persons installing, using and maintaining gehrtec
products
•
All persons must be qualified and authorised.
•
General and installation-specific safety training must be undertaken with all such persons before
beginning any tasks.
•
All persons must be acquainted with and understand these cabling instructions.
Special types of hazards
•
Third-party adaptations to the Nubbel system may only be used after approval / release by the
manufacturer of the system.
•
Sharp profile ends which come into contact with the cable system must be equipped with edge
protection, in order to avoid the risk of damaging the cable.
Safety and information signs
Sign
5
Meaning
Explanation
DANGER
"DANGER" designates safety information which can lead to death or
serious injury if it is not observed.
CAUTION
"CAUTION" designates safety information which can lead to injuries and
/ or property damage if it is not observed.
NOTE
Notes contain information which are necessary for ensuring optimal
installation and operation of the product.
1. Safety instructions and general information
Safety instructions for installation
Read these instructions carefully before commencing with the installation work and observe the information contained herein during the installation process, as well as all applicable safety regulations and other
applicable national regulations in the country of installation.
Prior to undertaking the installation, the installer is obliged to check for conformity of the specified safety
measures with the current editions of such regulations and to observe any new regulations that may be
applicable. The applicable work safety laws and regional national regulations of the relevant country are
to be maintained for states outside of the European Union.
All general safety and relevant accident prevention regulations, especially relating to work outdoors, as
well as all applicable environmental protection regulations are to be observed and maintained, in addition to the work safety measures detailed in these instructions.
Follow all of the instructions given in this document fully and unconditionally!
All generally accepted codes of practice must be applied in any case.
Caution!
Always observe the applicable standards and regulations at the site of installation.
Rules and regulations
The industrial safety act and subsequent directives as well as the rules and regulations set out by the professional trade association and fund for accidents at work must be observed for installation and operation
in Germany.
We would like to especially point out the following hazards and measures for the elimination of risks:
General safety regulations
Decide on measures for the elimination of recognised hazards based on the risk assessment
and instruct all persons involved.
Further information is available, amongst others, from: Industrial safety act, BGV A1 "Principles for prevention", BGV C22 "Construction work", occupational safety regulation, regulations for the handling of
heavy loads.
Biological risks due to pathogenic germs
Ensure that industrial medicine checkups and vaccinations are carried out in accordance with
the risk assessment.
Risk of injury!
Tools and materials must be in optimal condition.
Further information is available, amongst others, from: Biological agents regulation.
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1. Safety instructions and general information
Lightning protection
The planning and construction of a lightening protection system must be carried out by experts.
The following directives are to be observed particularly:
DIN V VDE V 0185, 2002: Lightening protection, Part 2: Risk management:
Assessment of risk for structural systems.
DIN V VDE V 0185, 2002: Lightening protection, Part 3:
Protection of structural systems and persons.
General information:
The configuration and commissioning of electrical cabling requires well-founded specialist knowledge.
Exclusion of liability
In accordance with product liability laws, Gehrlicher Solar AG is not subject to liability for loss, miscellaneous loss of assets, miscellaneous property and / or personal loss or costs occurred by yourself, any
third-parties or your customers as a result of improper and therefore impermissible mounting, installation,
commissioning, use or maintenance of the equipment. Improper in this case refers to tasks which, for example: do not comply with the specifications detailed in these installation and maintenance instructions.
For this reason, we wish to recommend once more, in your own interests, that these instructions are maintained.
Danger electrical current!
The solar modules can generate voltages of up to 1,000 VCD in the cables (in certain cases, even higher
voltages can be produced).
For this reason, protective measures must be taken to protect against these voltages.
Only qualified electricians may carry out work on the systems.
7
2. Nubbel
2. Nubbel
The Nubbel types:
Connection double strand
Branch
Connection single strand
Branch
l
Single strand - Nubbel (=single-pole Nubbel strand)
Double strand - Nubbel (=double-pole Nubbel strand)
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2. Nubbel
Polarities and colours
POSITIVE POLE
=
RED
NEGATIVE POLE
=
BLUE
Strings
The strings are connected to the inverter, whereby several strings can be connected in parallel.
A string is a series connection of modules.
Parallel connection of strings
A Nubbel strand serves to make it as straightforward and reliable as possible to connect several strings in
parallel.
If several strings are to be connected in parallel, then it is to be ensured that the same modules are used in
each string and that the same number of modules are assigned within each string.
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3. Typical interconnection options for roof-mounted modules
3. Typical interconnection options for roof-mounted modules
Example for interconnections with Nubbel double-strand
Simple interconnection on a roof surface
Simple interconnection on a roof surface
10
3. Typical interconnection options for roof-mounted modules
Example of a complex interconnection with Nubbel double-strand
Module type
Always use the same module type for use on a single Nubbel strand!
Tools
Standard electrician's tools are used to cable the modules.
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4. Insulate the ends of the strands
4. Insulate the ends of the strands
The open cable ends must be insulated with suitable insulation material (shrinkable caps) by a qualified
electrician.
Possible shrinkable
caps
NOT INCLUDED IN THE SCOPE OF DELIVERY:
Insulation material, cable for connecting various Nubbel strands and cable for connecting the Nubbel
strands with the inverters.
Insulation of open strand ends
Use only suitable shrinkable caps for this purpose!!
Danger high voltages of over 1,000 volts!
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5. Extension
5. Extension
If open cables are to be extended, then plug-and-socket connectors are to be used in accordance with the
regulations.
Any extensions must be realised with approved plug-and-socket connectors!
MC 3 connector (manufactured by Multikontact)
MC 4 connector (manufactured by Multicontact)
The connectors are to be plugged together. They are not intended to be subsequently disconnected from
each other.
In the event that the connectors must be disconnected from each other in exceptional cases (e.g. exchanging of modules), then it is to be ensured that the electrical circuit is first switched off, in order that arcing is
avoided in the area of the plug-and-socket connectors.
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6. Routing of the cable
6. Routing of the cable
It must also be ensured that all of the cables to be laid are routed cleanly and tidily, insofar as the stand is
switched off. Excessively sagging loops of cable are to be avoided.
7. Supply coding
END SECTION BLUE
END SECTION RED
LENGTH FROM NUBBEL TO NUBBEL
(system distance)
2-4 places are possible on every 3 positions, always given in cm !
8. Guarantee
The current terms of guarantee can be downloaded from the Internet under www.gehrlicher.com or you
can request them in written form through the usual distribution channels.
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9. Contact
9. Contact
Addresses in Germany
Munich office (management centre)
Max-Planck-Str. 3
D–85609 Dornach/Munich
Photo 1: The corporate locations
Tel:
+49 89 / 42 07 92 – 0
Fax:
+49 89 / 42 07 92 – 85 40
info@gehrlicher.com
Coburg office (head office)
Gehrlicher Solar AG
Austraße 101b
D–96465 Neustadt near Coburg
Tel:
+49 95 68 / 89 66 09 – 0
Fax:
+49 95 68 / 89 66 09 – 19
coburg@gehrlicher.com
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