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5.3
Electrical installation photovoltaic generator
5.3.1
Electrical wiring safety precautions
•
The sum of Voc of modules in series must not exceed the maximum system volt-
age of the module under any condition. Reverse current applied to the modules
must not exceed 7 A.
•
Do not touch or handle the PV module, terminal box or the end of output
cables with bare hands.
•
Do not carry out installation when PV modules, installation tools or installation
area are exposed to water.
•
Ensure that the connection parts between SF modules and power receiving
devices are isolated and waterproof. Using SF modules with insufficient isola-
tion and waterproofing could result in an electric shock, an electric leak or an
accident.
•
Keep the junction box and connecting cables away from any liquids until the
connectors are mated. Failure to do this may cause faulty wiring.
•
The connecting components between the modules must be compatible
with the connecting system. They must enable them to work perfectly and
completely safely.
•
Inverters must meet the technical requirements of SF modules.
•
Do not connect the PV modules directly to loads such as motors. Variation in
output power may damage the motor.
•
Observe and understand the safety instructions of batteries. Their misuse can
result in serious bodily harm due to high electrical current.
•
Cables should be adequately protected from damage by wildlife.
5.3.2
Cabling
Solar Frontier places great value on delivering as many components as possible
pre-assembled in order to help avoid sources of error.
As each roof and PV installation has its own peculiarities, certain cables have to be
adapted on site to the system and assembled accordingly. For example, the cables
for extending the connecting cables to reach the inverter have to be assembled
on site. In addition, if there are obstructions on the roof (e.g. dormers) it may be
necessary to bridge the increased distance with extension cables. The DC cable,
sockets and plugs which are included in the PowerSet are for this purpose.
An Hosiden crimping tool (HSC2009-530030) is also required for crimping the
contacts. This is not included in the PowerSet. Pre-assembled connecting cables
must not be altered.
Please ensure a clean and proper assembly of the cables to avoid error
sources and to ensure safe cabling.
The DC cables used must comply with the requirements specified in Section 10.5.2
and be compatible with the plug-in connectors provided by Solar Frontier. Solar
Frontier recommends the use of the DC cables as specified in Section 10.5.2. These
are available from Solar Frontier.
The following tools are required to assemble the cables:
- Mounting key (not included in the delivery)
- Crimping tool for twisted contacts (not included in the delivery)
- Insulation stripping pliers (not included in the delivery)
Shortening and stripping the insulation from the DC cable
First, the cable has to be shortened to the proper length. Then the outer insulation
is removed with suitable insulation stripping pliers to a length of 6.5-7.5 mm.
Please take care not to damage the wires in the DC cable. This could reduce
the cross section and cause electrical faults.
Figure 7
Positioning
aid
Figure 8
Adjust the tool:
1. Lift the positioning aid
2. Turn the positioning aid by
±120° in the desired direction
Crimping the twisted contacts
Crimping
pliers
Connector
Contact
Socket
Pin
6
The HSC2010 positioning aid is
used for crimping the pins.
Positioning aid HSC2013 is used for
crimping the contacts.
Figure 9
Place the contact or pin in the posi-
tion for the respective cross-section.
Figure 10
Place the crimping sleeve com-
pletely into the tool as shown in
Figure 11.
Figure 11
Do not close the crimping pliers
completely at first.
Close the tool gently and check
whether the crimping sleeve is
properly positioned in the crimping
die.
Figure 12
Guide the stripped end of the cable
fully into the crimping sleeve.
Then close the tool completely
while holding the cable until the
locking device has been triggered.
Figure 13
Check the crimping result and the
correct fit of all cable strands.
Figure 14
Guide the crimped contact into the
connector until it perceptibly clicks
in and locks.
Gently pull at the cable to check
whether the contact holds firmly
and has locked.
Take note that the pin may not
be inserted into the connector.
Guide the crimped pin into the
socket until it perceptibly clicks in
and locks.
Gently pull at the cable to check
whether the pin holds firmly and
has locked.
Figure 15
Take note that the contact may
not be inserted into the socket.
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