Standalone Grid System SMA

INSELNETZ-PL-UEN105010 | Version 1.
0 EN
Stand-alone Grid Systems
Installing a Stand-alone Grid System
Planning Guidelines
SMA Solar Technology AG Table of Contents
Planning Guidelines INSELNETZ-PL-UEN105010 3
1 Normative Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Grid Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 Installation and Mounting Locations . . . . . . . . . . . . . . . . 10
3.1 Distribution Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 PV Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 PV Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Wind Turbine System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Designing Cable Cross Sections . . . . . . . . . . . . . . . . . . . . 12
5 Installation Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Laying the Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1 General Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2 Installing Cables of a PV Plant . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.3 Installing Cables of a Battery System . . . . . . . . . . . . . . . . . . . . 19
7 Lightning Protection in Off-Grid Systems . . . . . . . . . . . . . 20
7.1 Physical Basis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7.2 Types of Lightning Strike Risks. . . . . . . . . . . . . . . . . . . . . . . . . . 24
7.3 Practical Lightning Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SMA Solar Technology AG
4 INSELNETZ-PL-UEN105010 Planning Guidelines
SMA Solar Technology AG Normative Framework
1 Normative Framework
As with every electrical plant, dangers can arise from off-grid systems for both people and property.
To largely eliminate these dangers, a qualified installation taking current standards into account is
indispensable. For this reason, the installation of such plants may only be performed by qualified
personnel. These instructions are intended for electrically skilled persons who apply fundamental
normative standards in daily practice.
One of the most important standards for the installation and operation of electrical systems is the
German standard DIN VDE 0100 "Erection of power installations with nominal voltages up to
1 000 V". The following table contains parts of this standard which must be adhered to during the
installation of a stand-alone grid.
DIN VDE 0100 "Erection of power installations with nominal voltages up to 1 000 V"
Protective measures (Group 400)
Part 410 Protection against electric shock
Part 430 Protection of cables and lines against overcurrent
Part 440 Protection against overvoltage
Part 470 Application of protective measures for safety
Selection and erection of electrical equipment (Group 500)
Part 510 Common rules
Part 520 Wiring systems
Part 540 Grounding, protective conductors and protective bonding conductors
Part 551 Low voltage generating sets
Verification (Group 600)
Part 610 Initial verification
Requirements for special installations or locations (Group 700)
Part 705 Agricultural and horticultural premises
Part 731 Electrical locations and locked electrical locations
Part 7-712 Low-voltage systems
Requirements for special installations or locations - Solar photovoltaic (PV) power
supply systems (IEC 60364-7-712:2002, modified);
German implementation HD 60364-7-712:2005 + Corrigendum:2006
Normative Framework SMA Solar Technology AG
Relevant standards also apply outside Germany, which are contained in the international standard
IEC 60364 "Electrical Installation of Buildings". When erecting the stand-alone grid, the following
standards must be considered, too:
DIN VDE 0298 Part 4 for sizing cables and lines
DIN EN 50272 Part 2 for installing batteries
DIN VDE 0100-712 for PV plants
Standards dealing with coupling generator systems to the public grid are understandably irrelevant
for off-grid systems.
The above-named standards have the status of the year 2008.
SMA Solar Technology AG Grid Forms
2 Grid Forms
A stand-alone grid has generally several feed-in generators, depending on the energy sources
available, including diesel generators or PV plants with PV inverters (e.g. Sunny Boy) along with
stand-alone grid battery inverters (Sunny Island). All these generators and inverters feed into the AC
grid and constitute the source for the consumer's energy supply as a replacement for the main power
grid.
The AC grid forms the core area of the off-grid system to be installed. It collects the energy of the feed-
in generators and distributes and transfers it to the consumers. To allow optimal use of the energy
being fed in, transmission losses should be reduced to a minimum. The size (greatest distance between
the consumers and sources) of off-grid systems with a nominal voltage of 230 V (single-phase) or
3 x 230 V/400 V (three-phase) is naturally very limited. Large amounts of power can only be
economically transmitted over large distances if voltage levels are high.
The required transformers, high-voltage lines and the necessary protective technology cannot be
covered in this document.
Parts of the installation must be constructed as a DC grid, for example the battery system or the PV
circuits. These circuits should be kept as small as possible, in particular the battery system with its 48 V
maximum nominal voltage, which is low compared to the AC system voltage.
Please note that the actual operating voltage of the battery circuit varies across a wide range around
the nominal voltage, depending upon whether the battery is being charged or discharged. Battery
inverters with 48 V nominal voltage can develop charging voltages of up to 63 V.
Regardless of whether the grid is an AC or DC grid, a distinction is made between different grid forms
based upon
the type of connection to ground of the sources, and
the type of connection to ground of the consumers.
The grid form and the nominal voltage determine which protective measures you can or must use.
The grid form of the AC circuits in a plant connected to the utility grid is largely predetermined, since
the sources lie under the control of the grid operator. This is different for a stand-alone grid where the
sources and consumers are independent.
Grid Forms SMA Solar Technology AG
The most common grid form used in public utility grids is the so-called TN grid. where the neutral point
or center point of the source is grounded. The neutral conductor of the plant is connected to this
neutral point. The exposed conductive parts of the connected consumers are grounded via protective
conductors in the consumer system, and they are connected to the grounded neutral point of the
source. A distinction is made between PEN conductors (TN-C system), which are a combination of
protective conductor and neutral conductor, and separate PE and N conductors (TN-S system).
A hybrid form of TN-C system, which is used from the source, and TN-S system, which is used in the
consumer system, is common especially in extended grids. This form is known as a TN-C-S system. The
PEN conductor in the TN-C area of the grid is usually grounded again in the house installation and
included in the equipotential bonding before the TN-S area begins, where it is split up into separate
N and PE conductors. The N conductor must not be grounded after PEN is split up into N and PE.
Advantages of the TN system are the low-resistance protective connections, which make a reliable
execution of simple protective measures possible (automatic disconnection of the power source using
fuses in case of error), as well as the fact that only one ground electrode is necessary. A disadvantage
is the somewhat more expensive installation due to the protective conductor in every cable. This,
however, should be no problem in a stand-alone grid, as it is comparatively small. The TN-S or
TN-C-S system therefore is the preferred grid form for a new off-grid system.
In a TT system, the neutral point of the source is grounded, as it is in TN systems. However, the
exposed conductive parts of the consumers are connected to separate ground electrodes of the
system using protective conductors. The N conductor must not be grounded in the consumer system.
This grid form has no direct protective conductor connection between the exposed conductive parts
of the equipment and the neutral point of the source, as have TN systems. The protective conductor
connection is only provided by a connection to ground, which has consequences for the protective
measures to be used (use of residual current breakers). Due to the small size of stand-alone grid
systems, the TT system has no notable advantages for stand-alone grids.
SMA Solar Technology AG Grid Forms
In an IT system, the neutral point of the source is insulated against ground or has a highly resistive
connection to ground. The exposed conductive parts of the consumers are connected to separate
ground electrodes of the system using protective conductors, as they do in TT systems. Certain highly
sensitive application areas, such as medical rooms, require IT systems, as the consumer system must
remain operable in case of a ground fault. This, however, causes additional expense (for example,
constant isolation monitoring or all-pole fusing of the cables). Since not all devices are suitable for
ungrounded grids for reasons of electromagnetic compatibility (EMC) in particular PV inverters,
Sunny Island Chargers (charge controllers) and stand-alone grid inverters must be checked the
installation of a stand-alone grid as IT system is not generally recommended.
The complete installation of protective conductors in a stand-alone grid, which is generally a small
system, does not significantly increase cost. Due to the advantages in carrying out the necessary
protective measures, the TN-S system is recommended for stand-alone grids. If feed-in generators are
spatially separated and must be connected using long lines, a TN-C area with combined N and PE
conductors can be created for cost reasons.
All grid forms share the characteristic that at least one ground electrode must be present. This is in any
case necessary for the equipotential bonding of the electrical system. Very well suited are, for
example, building foundation earth electrodes. If such a ground electrode is unavailable, a ground
rod can be installed. It is important to achieve the lowest possible transmission resistance to the
ground to ensure the greatest possible effectiveness of the protective measure against electric shock
(i.e. fast and safe disconnection in case of error).
Installation and Mounting Locations SMA Solar Technology AG
3 Installation and Mounting Locations
3.1Distribution Room
The distribution system is the central disconnection point of an off-grid system. The individual
components of the off-grid system are electrically connected to the distribution system. Fuses for the
individual consumer circuits are also installed here. A counter specified by the network operator is
generally not necessary for off-grids. It is only necessary if the operator desires separate settlement
from individual consumer groups.
The distribution should be located in a dry, well-lighted room. Make sure that there is free access to
the distribution system. Ideal is a dedicated room for the distributor that includes space for the
inverters. This is also a good location for at least the Sunny Island inverters, as long as the distance to
the batteries is not too great. If the PV plant is mounted in the same building and there are no great
distances to the PV array, you can also install the PV inverters (e.g. Sunny Boy) here.
3.2PV Inverter
Power loss during transmission is one of the most important factors in selecting the mounting location
for the PV inverters. It is given by the square of the current which passes through the cable resistance.
The higher the voltage in a circuit, the lower the loss with constant transmission power. From the PV
array to the consumers, the energy passes through two circuits: the PV circuit (from the array to the PV
inverter) and the AC grid. The voltage in the AC grid is except for load-dependent fluctuations
relatively constant. By contrast, the DC voltage in the PV circuit is subject to large fluctuations. It is
therefore not clear if the current is higher on the AC or DC side of the PV inverter.
In principle, there must be a small distance between inverter and PV modules. This ensures that the
DC cables, which are not protected by fuse, are not too long. SMA offers a large selection of models
suitable for outdoor installation (degree of protection: IP 65).
SMA Solar Technology PV inverters are designed to be mounted on a solid foundation. Eye level
mounting provides optimal readability of the device's operational indicators or display. Open space
is also important above and depending upon the device type next to the devices to ensure proper
heat dissipation. Information on the required device mounting clearances can be found in the
installation manual of the Sunny Boy and Sunny Mini Central inverters.
The foundation must provide sufficient support. If possible, do not mount the devices on lightweight
walls or on walls that can act as resonance chambers (e.g. thin wooden walls, sandwich type plaster
board, etc.). The slight vibrations which the devices can generate during operation could otherwise
be amplified and cause the wall to emit sound.
Mounting on a flammable foundation (e.g. wood) is not allowed.
3.3PV Plant
PV modules are suitable for roof- or ground-mounted installation. Ground-mounted installation
requires appropriate mounting supports; roof mounting requires suitable brackets. The module
alignment depends on the installation location. It is important that the PV modules are not shaded
not even partially as this reduces energy output.
SMA Solar Technology AG Installation and Mounting Locations
3.4Batteries
Depending on their type, batteries can be dangerous because they conduct electricity and contain
gases or electrolytes. During the planning and installation of the battery system, keep in mind the
European Standard EN 50272 "Safety requirements for secondary batteries and battery
installations", in particular the safety precautions for the handling of batteries.
The installation location of the batteries should be dry, as cool as possible, but also free of frost. Heat
and frost significantly reduce the service life of batteries. The room must also be well ventilated. If
natural ventilation is not sufficient, artificial ventilation must be installed.
Special racks can be used for battery installation, which provide space-saving storage and good
accessibility for maintenance. Note also the battery weight. The floor must be designed to
accommodate the weight. When using batteries with liquid electrolyte, an acid-resistant sealing is
required so that no battery acid can contaminate the ground. As an alternative to sealing, catch
basins can also be used. This problem does not exist with gel or fleece batteries.
3.5Generator
If you would like to integrate a diesel generator into the off-grid system to be installed, please consider
that an installation in potentially flammable rooms is not allowed. The generator should be in a dry
but well-ventilated room. The motor exhaust gases must be vented using an appropriate ventilation
system. You should consider that the ventilation system can become very hot. This is why you must
provide protection against accidental contact.
Good access for maintenance must be considered in the selection of the installation location. Also
ensure good illumination, as this makes maintenance easier.
An important aspect when selecting the installation location is the emission of noise. A diesel
generator does not work silently and can quickly be considered unpleasant. This is why you should
consider if you wish to connect the generator to the electrical system over a short distance or if a
somewhat more distant installation location, further away from living and sleeping areas, would not
be preferable to saving on cable material. Additional noise protection measures must be taken as
needed.
3.6Wind Turbine System
The optimum installation location for wind turbine systems is especially dependent on local conditions.
Before installing a system, long-term wind speed measurements (over at least one year) should be
made at the intended location.
Locations must be far enough away from buildings or trees, as these not only block the flow of air but
also cause turbulence that can have a negative effect on the possible energy yield of close-by wind
turbine systems. If this results in large distances to the distribution system, please consider that the
cable cross section must be large enough to minimize transmission losses.
Designing Cable Cross Sections SMA Solar Technology AG
4 Designing Cable Cross Sections
One frequently asked question which should be answered here in detail is which cable cross section
must be installed for the individual circuits of an off-grid system. As a rule, the smallest possible cross
section is desired, since larger cable cross sections mean increases in
cable costs,
space required for the installed cable (diameter, space in installation ducts or conduits, minimum
bending radius of the cable), and
cable weight.
However, there are also technical aspects which require a minimum cross section for each
application. The key measurements which influence cable size are:
the allowed current capacity of the cable (depending upon the cable insulation material, the
preceding fuse or the attached power source, the type of cable installation and the ambient
temperature); the larger the cable cross section, the higher the allowed current capacity,
the voltage drop on the line (depending on the cable length and the maximum possible
operating current); the larger the cable cross section, the smaller the voltage drop, and
the maximum loop impedance which ensures compliance with the prescribed disconnection
conditions for the applied protective measures (activation of overcurrent protection devices
within the prescribed period of time) (dependent on cable length); the larger the cable cross
section, the lower the loop impedance.
Compliance with the allowed current capacity is particularly important for fire prevention, since an
overloaded cable presents a fire hazard. This must be considered in a stand-alone grid just as in a
customer's system connected to the public utility grid. DIN VDE 0298 Part 4 is used to determine the
allowed current capacity of cables.
The voltage drop along a cable determines which voltage is available at the end of the cable or the
cable network to the consumer. The aspect of supply quality is of primary importance. According to
DIN VDE 0100 Part 520, the greatest voltage drop of a customer's system may not exceed 4 %
relative to the nominal voltage of the grid. This cannot be directly applied to an off-grid system which
includes both the generator and consumer system. It is important that consumers at the end of the line
are supplied with sufficient voltage, without it being necessary at the other end for the feed-in
generator to produce a voltage that is too high.
Electrical consumers are generally capable of fault-free operation with voltage fluctuations of 10 %
of the nominal voltage.
The voltage drop is associated with a very significant additional variable important for the design of
the cables in a stand-alone grid: the transmission losses of the cables. As the system designer, you will
have difficulty explaining to your customers that a great deal of money must be invested in the largest
possible PV module area and in an advanced and highly efficient inverter, and that, at the same time,
a too small cable cross section means a significant part of the power generated will be lost during
transmission. 4 % voltage drop also means 4 % power loss in the cable.
SMA Solar Technology AG Designing Cable Cross Sections
Cable losses range over all parts of a stand-alone grid. They can occur in the DC cables of the battery
or PV plant, and in the AC cables between the feed-in generators and the distribution, or in the
consumer system. Where the greatest losses occur depends upon local conditions, in particular on the
required cable lengths. They can therefore not be located in general. However, if different voltage
levels are present in a system, the rule applies that with identical cable cross sections, lower losses
occur in areas of higher voltage, as the current is lower with identical power. This is why special focus
must be put on
the cables of the battery circuit (12 V DC, 24 V DC or 48 V DC), and
the DC cables of the PV plant between the generator (i.e. the PV modules) and the inverter.
As a rule, when sizing cable cross sections, the criterion of allowed current capacity is the less
significant requirement for the cable. Although compliance with the allowed current capacity ensures
safe operation, it generally leads to high cable losses. For this reason, larger cross sections must be
installed than are required by the current capacity.
The disadvantage of high cable utilization rates can be presented clearly. Since the square of the
current is used in the calculation of cable losses, a doubling of the current means that the power loss
increases by four times. Therefore, when you reduce the cable load by installing a second cable with
the same cross section and distribute the power to be transmitted across both cables, each of the two
cables has only one fourth of the original power loss, and the total power losses are halved. The same
effect can also be achieved by doubling the cross section of one cable; the power loss is halved,
assuming identical current and length.
The bottom line is that the transmission of power is always associated with losses. There are no ideal,
loss-free cables in actual installations. As the planner and installer of a system, you should keep your
ability to influence cable losses in mind:
Install cables across the shortest possible distances and avoid detours.
Distribute currents across the largest, economically viable cable cross section (larger cable
cross sections or parallel connection of cables).
An aid in determining the AC and DC cable losses for PV plants is the Sunny Design program, which
you can download free from www.SMA.de/en.
Finally, the cable sizing for the battery cables of an off-grid system will be considered as an example.
The basic rule is to keep the battery cables as short as possible. Since the battery voltages of 12 V,
24 V or 48 V are much lower than the AC voltage of the stand-alone grid, these cables carry
correspondingly higher currents.
Additionally, it must also be considered that power is lost twice in the cables from the stand-alone grid
inverter to the battery: once when charging the battery and then later when discharging and using the
power.
It can roughly be assumed that charging the battery is done as quickly as possible and with a high
constant charging current. By contrast, the discharge of the battery depends greatly upon consumer
requirements, but generally occurs with only an average of 10 % of the maximum charging current.
This can largely be disregarded in considerations of cable losses when compared to the losses during
charging.
Since power storage in batteries is also associated with losses, and inverter losses occur twice in the
inverter, high requirements should be placed on minimizing cable losses in the battery cables. This
naturally implies higher installation costs. However, it must be considered that the power lost in the
cables must be generated (e.g. using diesel fuel) or paid for through a larger module area for the PV
plant. Two percent cable losses during battery charging by a Sunny Island 5048 can be calculated
as representing approximately 100 Watt power.
Table 1: Relative cable losses in a copper cable with a charging current of 100 A and a nominal
voltage of 48 V (application: Sunny Island 5048)
The table above lists cable losses relative to charging power with a constant charging current of
100 A for a Sunny Island 5048. For example, if you wish to allow relative cable losses of 1 %, with
a cross section of 16 mm, you must maintain a maximum distance from the inverter to the connection
terminals of the battery (one-way cable length) of approximately 2 m. If the distance is 9 m, a 70 mm
(almost four times larger) cross section must be installed to achieve the same losses.
When selecting the correct inverter, consider the maximum cable cross section that can be connected
to the device. Cables with a cross section of up to 70 mm can be connected to Sunny Island 5048.
Cables of up to 95 mm can be connected to Sunny Island 2012/2224.
The following tables compare the cable losses of a Sunny Island 2224 and a Sunny Island 2012.
The Sunny Island 2224 has a nominal power of 2.2 kW and a nominal battery voltage of 24 V. The
Sunny Island 2012 has a nominal power of 2 kW and nominal battery voltage of 12 V.
Cable cross section in mm
2
16 25 35 50 70
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1 0.46 % 0.30 % 0.21 % 0.15 % 0.11 %
2 0.93 % 0.59 % 0.42 % 0.30 % 0.21 %
3 1.39 % 0.89 % 0.64 % 0.45 % 0.32 %
4 1.85 % 1.19 % 0.85 % 0.59 % 0.42 %
5 2.32 % 1.48 % 1.06 % 0.74 % 0.53 %
6 2.78 % 1.78 % 1.27 % 0.89 % 0.64 %
7 3.24 % 2.08 % 1.48 % 1.04 % 0.74 %
8 3.71 % 2.37 % 1.70 % 1.19 % 0.85 %
9 4.17 % 2.67 % 1.91 % 1.34 % 0.95 %
10 4.64 % 2.97 % 2.12 % 1.48 % 1.06 %
11 5.10 % 3.26 % 2.33 % 1.63 % 1.17 %
12 5.56 % 3.56 % 2.54 % 1.78 % 1.27 %
13 6.03 % 3.86 % 2.75 % 1.93 % 1.38 %
14 6.49 % 4.15 % 2.97 % 2.08 % 1.48 %
15 6.95 % 4.45 % 3.18 % 2.23 % 1.59 %
SMA Solar Technology AG Designing Cable Cross Sections
A lower nominal battery voltage means a higher charging current at the same charging power. If you
compare Table 2 with Table 3, you see that Sunny Island 2012 has significantly higher cable losses
resulting from the much higher charging currents.
2
16 25 35 50 70
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1 0.74 % 0.47 % 0.34 % 0.24 % 0.17 %
2 1.48 % 0.95 % 0.68 % 0.47 % 0.34 %
3 2.23 % 1.42 % 1.02 % 0.71 % 0.51 %
4 2.97 % 1.90 % 1.36 % 0.95 % 0.68 %
5 3.71 % 2.37 % 1.70 % 1.19 % 0.85 %
6 4.45 % 2.85 % 2.03 % 1.42 % 1.02 %
7 5.19 % 3.32 % 2.37 % 1.66 % 1.19 %
8 5.93 % 3.80 % 2.71 % 1.90 % 1.36 %
9 6.68 % 4.27 % 3.05 % 2.14 % 1.53 %
10 7.42 % 4.75 % 3.39 % 2.37 % 1.70 %
11 8.16 % 5.22 % 3.73 % 2.61 % 1.86 %
12 8.90 % 5.70 % 4.07 % 2.85 % 2.03 %
13 9.64 % 6.17 % 4.41 % 3.09 % 2.20 %
14 10.38 % 6.65 % 4.75 % 3.32 % 2.37 %
15 11.13 % 7.12 % 5.09 % 3.56 % 2.54 %
2
25 35 50 70 95
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1 1.90 % 1.36 % 0.95 % 0.68 % 0.50 %
2 3.80 % 2.71 % 1.90 % 1.36 % 1.00 %
3 5.70 % 4.07 % 2.85 % 2.03 % 1.50 %
4 7.59 % 5.42 % 3.80 % 2.71 % 2.00 %
5 9.49 % 6.78 % 4.75 % 3.39 % 2.50 %
6 11.39 % 8.14 % 5.70 % 4.07 % 3.00 %
7 13.29 % 9.49 % 6.65 % 4.75 % 3.50 %
8 15.19 % 10.85 % 7.59 % 5.42 % 4.00 %
9 17.09 % 12.21 % 8.54 % 6.10 % 4.50 %
10 18.99 % 13.56 % 9.49 % 6.78 % 5.00 %
11 20.89 % 14.92 % 10.44 % 7.46 % 5.50 %
12 22.78 % 16.27 % 11.39 % 8.14 % 6.00 %
13 24.68 % 17.63 % 12.34 % 8.82 % 6.50 %
14 26.58 % 18.99 % 13.29 % 9.49 % 7.00 %
15 28.48 % 20.34 % 14.24 % 10.17 % 7.49 %
SMA Solar Technology AG Installation Material
5 Installation Material
In principle, the installation of an off-grid system does not require any special materials. Standard
cables, conduits, distribution boxes, circuit breakers, contactors, etc. can be used, as long as they
meet the requirements of the different voltage levels (e.g. 400/230 V AC and 12 V DC, 24 V DC or
48 V DC battery voltage).
For contactors operated with battery voltage, please note the operating range of the Sunny Island.
Devices with a battery voltage of 48 V (e.g. SI 4248 or SI 5048) have an operating range of 41 V
to 63 V. When selecting the contactor coils, you must consider these values, which you will find in the
technical data for the devices. The charging current is also an important criterion.
Example:
You are looking for a contactor coil for an inverter with a nominal voltage of 48 V and an operating
range of 42 V to 63 V. Contactors for applications in battery circuits can generally be ordered with
an "extended voltage range" for the coils, for example 0.7 ... 1.25 * U
N
(U
N
= nominal voltage). This
means that a contactor with a nominal voltage of 48 V could only cover an operating range of 33.6 V
to 60 V. With a longer charging phase at 63 V, the contactor coil would suffer thermal overload and
be destroyed. However, if you select a contactor with a nominal voltage of 60 V, the operating range
under the conditions named above is sufficient (0.7 ... 1.25 * U
N
) from 42 V to 75 V.
Accessories
Special accessories for Sunny Island can be obtained from SMA Solar Technology. It makes your
selection of such components easier.
The following accessories are available from SMA Solar Technology:
Batteries
Fuse boxes for batteries
Battery shunts (required for installations with DC coupling)
Distribution boxes for generators
Temperature sensors for the battery are included with the Sunny Island. Use only the included
temperature sensors.
Laying the Cables SMA Solar Technology AG
6 Laying the Cables
6.1General Requirements
When installing cables, take care to protect the cables from external influences.
Conversely, the environment of the cables must be protected from possible hazards. For this reason,
only use cables approved for the desired type of installation.
In the area of the distribution system, only surface installations should be used. Compared to flush-
mounted installations, they have the advantage of making it easier to adapt the system, for example
to enhance it.
Make sure to leave sufficient room for later enhancements. Cable channels should therefore not be
sized too small. Cables should also not be bundled too tightly, in order to minimize their mutual
thermal influence.
There are particular requirements for outdoor installations. The cables must be protected against UV
radiation. Standard sheathed cables for moisture-proof installation (NYM) are not suitable. Either
special cable material must be used, or the entire length of the cables must be installed in protective
conduits.
Installing cables in the ground for example to a wind turbine system requires the use of suitable
grounding cables. Installation in flexible protective conduits is only allowed over short distances if the
cables are replaceable. Ensure that the cable path is marked and maintain good documentation. It
helps to avoid damage to the buried cables from later excavation activities.
Installing uninsulated open lines is easier and less expensive than installing an underground cable.
However, special requirements for lightning protection must be met.
SMA Solar Technology AG Laying the Cables
In general, when installing cables, separate the power cables from the control cables (e.g.
communication cables) to prevent mutual influence. The use of cable separators in cable conduits is
advisable.
In regard to the installation technology, AC circuits of off-grid systems do not differ essentially from
systems connected to the public grid. DC circuits of a stand-alone grid are not as familiar to the
installer and will therefore be examined more closely here.
6.2Installing Cables of a PV Plant
There are particular requirements for the cables of a PV plant. They are generally not protected at the
PV array, which means that the cable protection can only be provided by short circuit and ground
fault protected installation, which is allowed within power generation systems according to
DIN VDE 0100 Part 430. The usage of single-core sheathed cables with sufficient insulation
resistance meets these requirements. However, it is essential to ensure that the cables for the plus and
minus poles are laid as close together as possible to prevent the creation of induction loops.
Otherwise, in case of a close-by lightning strike, the highly variable magnetic fields could induce high
voltages which are all the higher, the greater the area of the induction loop.
If a short circuit and ground fault protected installation is not possible, you must secure the DC cables
as close to the PV array as possible.
6.3Installing Cables of a Battery System
The same applies to the DC cables of the battery circuit. Short circuit and ground fault protected
installation is required up to the fuses. You can omit battery fuses if short circuit and ground fault
protected installation is provided throughout, up to the stand-alone grid inverter. When selecting
cable material, ensure that this is approved for short circuit and ground fault protected installation
(e.g. cable type NSGAFu).
Also note that battery acid can corrode the cable insulation. Therefore, use acid-resistant cable
material at least for cables close to the batteries, and adhere to the information of the battery
manufacturer.
Lightning Protection in Off-Grid Systems SMA Solar Technology AG
7 Lightning Protection in Off-Grid Systems
7.1Physical Basis
Lightning is an electric discharge during a storm. The path of the lightning only depends upon the
charge conditions, which also explains the "zig-zag" path of a lightning bolt. The closer the discharge
draws to the surface of the earth, the more influence field concentrations exert on points and curves
which promote an arc. "Positive streamers" are produced, particularly on high buildings and
components. However, the lightning must not necessarily strike there. It can also select a different
path. Since it is impossible to forecast where the lightning will strike, all buildings that one wishes to
protect from lightning strike must be equipped with a lightning protection system.
The lightning strike has several effects:
The acoustic effect is caused by electrodynamic forces. It causes a very tight concentration of the
lightning channel. The quickly decreasing electrodynamic internal pressure in the lightning channel
during lightning current increase is estimated to be several tens of bars. The hot lightning core
implodes. Near by, this is perceived as a bang and at greater distances as rolling thunder.
The thermal effect follows Joule's law W= i t R, where W is heat, i the square of the current, t
duration of current flow and R ohmic resistance. According to the formula above, objects can only be
heated to melting temperature if cable cross sections are small or the specific resistance is high. For
this reason, poor connections are a hazard. A great deal of energy is released in the form of heat
when current flows through poor conductors. The water content of wood and masonry, for example,
is intensely heated and vaporizes. The overpressure of this fast process causes explosion-like blasts.
Electrodynamic effects occur when parts of the lightning path are arranged in such a way that the
magnetic fields overlap. A force is exerted on the conductor carrying the lightning current that
increases, the smaller the distance. If current flows in the same direction, attractive forces are created.
According to Faraday's law, a lightning charge of 100 As causes 30 mg of iron or a similar amount
of zinc or lead to be decomposed at the current output, which is an electrochemical effect.
However, arresters, which are often struck by lightning, are not expected to develop any
electrochemical decomposition; much more significant is corrosion.
SMA Solar Technology AG Lightning Protection in Off-Grid Systems
The following values are typically associated with lightning:
The grounding system must be connected to the equipotential busbar by the shortest path possible.
For lightning protection systems without lightning protection equipotential bonding, it is required that
the grounding resistance R is less than or equal to five times the smallest distance in meters between
above-ground lightning protection and large metal parts or a high voltage system. A ring-shaped
ground electrode must be laid at least 0.5 m deep and as a closed ring around the outside
foundation. Depending on the discharge, individual ground electrodes must either have a length of
20 m when used as surface ground electrodes, or 9 m when used as deep ground electrodes. Deep
ground electrodes have to be separated by approximately 1 m.
The internal lightning protection includes all measures against the effects of a lightning current and its
electrical and magnetic fields on metal installations and electrical systems. The heart of the internal
lightning protection is the lightning protection equipotential bonding.
This includes bonding of
ducts (not gas lines),
metal installations within the building,
grounded parts of high voltage and IT systems, and
all active wires of power and information technology cables and cords leading into and out of
the building to the grounding system.
Two device types are available to protect live cables connected to the equipotential bonding:
Lightning current arresters (class B arresters) can carry direct lightning currents and lead them
to a grounding system.
Overvoltage arresters (class C arresters) can limit overvoltage and carry the induced surge
currents to a grounding system.
Lightning current values
Maximum value of the lightning
current i
max
This value is decisive for the voltage drop at the grounding resistor
or for the voltage increase compared to the distant environment.
Charge Q This value determines the energy released at the impact point. The
charge results from the product of the lightning current and the
duration of the lightning.
Current squared impulse i t This value determines the heating and the dynamic load. It is
calculated from the product of the square value of the lightning
current and the duration of the lightning.
Rate of lightning current rise
di/dt
This value is decisive for the level of induced (generated) voltage
in all open and closed installation circuits in the vicinity of lightning
conductors.
Another possible protection are shielded cables, where the shielding is connected to the grounding
system. Sufficiently large shielding can both carry the partial lightning currents and prevent the
induction of overvoltages in the cable.
While the external lightning protection is primarily designed to prevent fire hazard, the internal
lightning protection limits the effects of the lightning current and its electrical and magnetic
fields on living creatures, metal installations, electrical consumers and electronic devices. Therefore,
both are necessary for effective lightning protection.
Additional information on protection from the effects of lightning, prepared by the lightning protection
and lightning research committee (Ausschuss fr Blitzschutz und Blitzforschung, ABB) of the VDE
Association for Electrical, Electronic and Information Technologies e.V., can be found in German on
the VDE website, www.vde.com/ABB.
For reasons of standardization, 16 mm coarse Cu wire should be used as a rule.
The decision if and to what extent lightning protection is necessary in a stand-alone grid is largely
determined by the location of the system components and the requirements on the operating safety
of the overall system.
For example, a risk analysis can be made using the software developed by AixThor
(www.aixthor.com) "Risk management: Assessment of risk for structures" (VDE 0185 Part 2:11-2002).
If this analysis reveals that lightning and overvoltage protection measures are necessary, execution
can be planned using the requirements described in Part 3 and 4 of VDE 0185.
The manufacturers of lightning and overvoltage components also offer planning assistance for the
implementation of protective measures. For example, the companies DEHN (www.dehn.de) or
Phoenix Contact (www.phoenixcontact.de) should be mentioned.
When planning off-grid systems, due to the often very exposed locations of the feed-in components
such as wind turbine systems or PV arrays, one will usually come to the conclusion that lightning and
overvoltage protection is necessary.
DIN and VDE standards on lightning / overvoltage protection:
VDE V 0185-1 2002-11 Protection against lightning - General principles
VDE V 0185-2 2002-11 Protection against lightning - Risk Management: Assessment of risk for
structures
VDE V 0185-2 Supplement 1 2004-06 Protection against lightning Part 2: Risk management -
Supplement 1: Calculation assistance for assessment of risk for structures
VDE 0185-3 2004-09 Protection against lightning Part 3: Physical damages to structures and
life hazard
Minimum cross section for protective bonding conductors
Conductor material Required cross section in mm
2
Copper 10
Aluminum 16
Steel 50
VDE V 0185-3/1 2005-06 Protection against lightning Part 3: Physical damages to structures
and life hazard
VDE V 0185-4 2002-11 Protection against lightning - Electrical and electronic systems within
structures
VDE 0845-4-1 2000-07 Lightning protection Telecommunication lines - Fibre optic installations
(IEC 61663-1:1999 + Corrigendum 1999)
Additional interesting/useful publications on lightning protection can be found at the VDE Publishing
House's website, www.vde-verlag.de/english.
7.2Types of Lightning Strike Risks
Direct strike
The lightning current flows through the PV array, the connected system components and the building
services equipment, which generally is destroyed. Severe mechanical damage can also not be ruled
out.
Indirect strike
A strike occurs close to the generator or the distribution room. Parts of the lightning current can flow
across the PV array and/or enter the cabling. The voltage is boosted in the system cables.
Close strike
Within a radius of approximately 500 m of the lightning discharge channel, magnetic (inductive)
effects influence cable loops of all kinds. With each discharge, large overvoltages develop in the
loops, which can lead to errors or destruction.
Distant strike
At greater distances to the system, capacitive effects occur. This means that an electric field is created
between cloud or lightning channel (high potential) and electrically conductive parts of the plant,
which is separated by an induced charge and therefore creates voltage within the system. Upon a
sudden collapse of the field by the strike, the charges equalize through a surge current. If a surge
current flows through the line, the current and the characteristic impedance cause a surge voltage in
the line.
Two protection goals must be met:
1. Protection from the effects of direct lightning strikes in the system components themselves or the
system buildings.
2. Protection from lightning overvoltages which can also be caused by indirect lightning strikes.
According to VDE 0185 Part 1, two protective measures are available: the installation of an external
lightning protection system (insulated or not insulated, i.e. with or without lightning currents across
system components) and the installation of an internal lightning protection system (overvoltage
protection measures).
7.3Practical Lightning Protection
External lightning protection consists of all of the devices for capturing and discharging the
lightning current to the grounding system:
1. Capture devices
A mesh is installed on the roofing with a mesh size of 10 m x 20 m. No point of the roof surface may
be more than 5 m from the next capture device. Roof structures made of non-conducting material are
considered protected if they do not extent beyond the level of the mesh by more than 0.3 m. If they
extend further out, they must be equipped with a capture point, which is connected with the mesh.
Roof structures made of metal are not connected to the mesh if they
protrude no more than 0.3 m above the level of the mesh,
are at least 0.5 m away from a capture device, and
have no more than a 1 m enclosed area or are max. 2 m long.
2. Dischargers
Dischargers are electrically conductive connections between capture devices and the ground. The
required number of dischargers is given by the circumference of the outer roof edge. Up to
max. 20 m, one discharger is sufficient. For more than 20 m, the roof circumference is divided by 20.
This yields the number of dischargers. Decimals are generally rounded up. The dischargers should be
placed on the corners and junctions of the mesh.
3. Grounding system
A grounding system must be installed for lightning protection if, for example, no foundation earth
electrode is present. The system must be operative without the use of metallic water pipes, ducts or
grounded conductors.
Legal Restrictions SMA Solar Technology AG
The information contained in this document is the property of SMA Solar Technology AG. Publishing its content, either partially or
in full, requires the written permission of SMA Solar Technology AG. Any internal company copying of the document for the
purposes of evaluating the product or its correct implementation is allowed and does not require permission.
Exclusion of liability
The general terms and conditions of delivery of SMA Solar Technology AG shall apply.
The content of these documents is continually checked and amended, where necessary. However, discrepancies cannot be
excluded. No guarantee is made for the completeness of these documents. The latest version is available online at www.SMA.de
or from the usual sales channels.
Guarantee or liability claims for damages of any kind are excluded if they are caused by one or more of the following:
Damages during transportation
Improper or inappropriate use of the product
Operating the product in an unintended environment
Operating the product whilst ignoring relevant, statutory safety regulations in the deployment location
Ignoring safety warnings and instructions contained in all documents relevant to the product
Operating the product under incorrect safety or protection conditions
Altering the product or supplied software without authority
The product malfunctions due to operating attached or neighboring devices beyond statutory limit values
In case of unforeseen calamity or force majeure
The use of supplied software produced by SMA Solar Technology AG is subject to the following conditions:
SMA Solar Technology AG rejects any liability for direct or indirect damages arising from the use of software developed by
SMA Solar Technology AG. This also applies to the provision or non-provision of support activities.
Supplied software not developed by SMA Solar Technology AG is subject to the respective licensing and liability agreements
of the manufacturer.
SMA Factory Warranty
The current guarantee conditions come enclosed with your device. These are also available online at www.SMA.de and can be
downloaded or are available on paper from the usual sales channels if required.
Trademarks
All trademarks are recognized even if these are not marked separately. Missing designations do not mean that a product or brand
is not a registered trademark.
The Bluetooth
word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of such marks by SMA
Solar Technology AG is under license.
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