Bentek Solar 1000V BUSS Series User manual

Installation and Operating
Instructions
1000V Breaker Universal
Safety System
125A to 400A, Grounded
Important Safety Instructions
Save These Instructions

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1000V BUSS, Grounded (125A to 400A)
Installation and Operating Instructions
Part 950-003342-000 Rev B
March 2014

Installation and Operating Instructions - 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 3
Table of Contents
About This Book 5
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Notation Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Manual Organization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Document Revisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1: Safety Instructions 7
Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Information for Technicians . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chapter 2: Product Description 11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Explanation of Symbols Used on Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 3: Installation Procedure 21
Required Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Preparing to Install the BUSS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Opening the Enclosure Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Removing the Dead Fronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Circuit Breaker Dead Fronts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Mounting the Breaker Universal Safety System . . . . . . . . . . . . . . . . . . . . . . . . 25
Preparing the Entry Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting Wires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connecting Conductors from Source Circuits . . . . . . . . . . . . . . . . . . . . . . . . . 36
Attaching Conductors to the Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connecting the Fan and Zone Monitoring System Power Supply . . . . . . . . . . . 39
Connecting the Power for the Fan and Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Using the Fan, Vent, and Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Replacing the Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Using the Heater and Hygrostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Finalizing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix A: Bentek Zone Monitoring System using an Ethernet Interface 47
Data Format and Addressing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
The Analog Input Module Web-Based Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Setting Up the Ethernet Port on the PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Connecting the Ethernet Cable to the Analog Input Module . . . . . . . . . . . . 49
Appendix B: Bentek Zone Monitoring System using an RS-485 Interface 51
The DCON Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Installation and Operating Instructions - 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 4
Contents

Installation and Operating Instructions - 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 5
About This Book
This manual provides information on installing the Bentek Breaker Universal
Safety System. Information is included on mounting the equipment onto a
prepared base and connecting the wires to the proper locations.
Intended Audience
This manual is for those qualified to deal with the dangers and hazards involved
in installing electric devices. Those using this manual should be trained
professionals performing work consistent with local regulations. Users should be
skilled in reading site plans and electrical wiring schematics and should be
familiar with meeting requirements contained in UL 50, “Standard for Enclosures
for Electrical Equipment,” UL 514B, “Standard for Safety Conduit, Tubing and
Cable Fittings,” National Electrical Code, ANSI/NFPA 70, and other applicable
standards documents.
Notation Conventions
This manual uses the following notation conventions:
WARNINGWARNING
Warns you of something that could result in physical injury or death.
AVERTISSEMENT
Vous avertit de quelque chose qui pourrait avoir comme conséquence des
dommages corporels ou la mort.
CAUTIONCAUTION
Cautions you against anything that may damage equipment.
ATTENTION
Attentions vous contre tout ce qui peut endommager l'équipement.

Installation and Operating Instructions - 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 6
About This Book
NOTE
Provides information of special interest or importance.
Manual Organization
This manual is organized as follows:
Chapter 1, “Safety Instructions,” provides information on warnings and
guidelines for installing the product safely.
Chapter 2, “Product Description,” describes the Breaker Universal Safety
System and provides specifications.
Chapter 3, “Installation Procedure,” describes how to install the Breaker
Universal Safety System.
Appendix A, “Bentek Zone Monitoring System using an Ethernet Interface,”
describes how to use the optional Current Monitoring System through an
Ethernet interface.
Appendix B, “Bentek Zone Monitoring System using an RS-485 Interface,”
describes how to use the optional Current Monitoring System through an
RS-485 interface.
Document Revisions
Revision Description Date Author Approval
A Initial Release. 10/17/13 GLB JW
B Added trip button information. 3/19/14 GLB JW

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 7
Chapter 1
Safety Instructions
This manual contains important safety instructions for the Bentek grounded
BUSS equipment with the following model numbers.
In model numbers:
BTK10 indicates a 1000V system manufactured by Bentek;
BUSS indicates a Breaker Universal Safety System;
GC (default) indicates a grounded system with a common grounded busbar;
xx specifies the number of circuit breakers;
yyy specifies the amperage of the circuit breakers (an M after the amperage
indicates mixed breaker sizes);
zzz indicates the enclosure type—CS (default) for the standard carbon steel
and CS1 for the tall carbon steel enclosure;
Exspecifies the fan and heater configuration—E1 (default) is fan only and E4
is fan and heater;
Sxindicates the presence of the Bentek Zone Monitoring System—S1 for an
Ethernet connection and S2 for an RS-485 connection.
Model # BTK10-BUSS-GC-xxyyy-zzz-ExModel # BTK10-BUSS-GC-xxyyy-zzz-Ex-Sx

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 8
Chapter 1: Safety Instructions
You must follow the instructions in this manual during maintenance of the
inverter or combiner box. Save these instructions.
WARNINGWARNING
Disconnect both AC and DC power prior to doing any work on this equipment.
AVERTISSEMENT
Déconnecter toute la puissance avant d'effectuer n'importe quel travail sur cet
équipement.
WARNINGWARNING
The installation, adjustment, or repair of Bentek BUSS equipment involves risk of
contact with potentially lethal voltages and currents. These servicing instructions
are for use by qualified personnel only. To reduce the risk of electric shock, do
not perform any servicing other than that specified in the operating instructions
unless you are qualified to do so.
Refer servicing to qualified personnel.
The enclosure door should remain closed while the BUSS is operational.
Servicing or adjustments should not be performed while the circuits are
energized.
AVERTISSEMENT
L'installation, l'ajustement, ou la réparation de l'équipement de combinateur de
Bentek implique le risque de contact des tensions et des courants
potentiellement mortels. Ces instructions de service sont à l'usage du personnel
qualifié seulement. Pour réduire le risque de décharge électrique, ne pas assurer
l'entretien autre que celui spécifique dans les consignes d'utilisation à moins
que vous soyez qualifié faire ainsi.
Il n'y a aucune partie utilisateur-utile à l'intérieur de l'équipement de
combinateur. Se référer l'entretien au personnel qualifié.
La porte de clôture devrait rester fermée tandis que le combinateur est
opérationnel. L'entretien ou l'ajustement ne devrait pas être effectué tandis que
les circuits activent.

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 9
Chapter 1: Safety Instructions
Important Safety Instructions
The following important safety instructions must be understood and followed.
Save these instructions.
Familiarize yourself with warning and hazard precautions for this BUSS so that
the dangers of this device and its components are understood.
CAUTIONCAUTION
Ensure the unit is properly secured at all times. It may be a tipping hazard in the
shipping container as well as after packaging is removed. Mounting the unit on
the prepared base eliminates the tipping hazard.
ATTENTION
Assurerquel'unitéestcorrectementfixéeàtoutmoment.Elleestlourdeavantetpeut
êtreunrisquedeemboutagedanslerécipientd'expéditioncommeaprèsempaquetage
estenlevé.Lemontagedel'unitésurlabasepréparéeéliminelerisquedeemboutage.
WARNINGWARNING
Inputs from the field panel and outputs to the inverter may be hot! Do not touch
components or parts associated with these connection points. Severe burns or
death can occur.
AVERTISSEMENT
Les entrées du panneau de champ et les sorties à l'inverseur peuvent être
chaudes! ! Ne pas toucher les composants ou les pièces liés à ces points de
raccordement. Les brûlures graves ou la mort peuvent se produire.
Install the BUSS enclosure so that it conforms to national and local safety
and operational codes (NEC and CSA).
The enclosure must only be opened and serviced by authorized and
knowledgeable service and/or contract personnel.
Read this manual and understand all safety, installation, and operational
information before opening or working on this device or any of its
connections or components.
If you have questions that are not answered in this document, contact Bentek
Support at 1-888-202-5009 or at www.benteksolar.com.

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 10
Chapter 1: Safety Instructions
Information for Technicians
When you request assistance, you need the Bentek model number and serial
number of the equipment you are calling about. This information is located on
the top right corner of the front door. The model and serial numbers of installed
equipment should be maintained in a project log for the site.
It is your responsibility as the installation technician to follow these instructions
during installation and/or maintenance of Bentek BUSS equipment.
WARNINGWARNING
Risk of electrical shock exists from energy stored in the inverters. The inverters
contain energy storage devices that require 15 minutes in order to safely
discharge their lethal voltages after disconnecting all sources of supply.
AVERTISSEMENT
Le risque de décharge électrique existe de l'énergie stockée dans les inverseurs.
Les inverseurs contiennent les dispositifs de sorage d'énergie qui ont besoin de
15 minutes afin de décharger sans risque leurs tensions mortelles après
déconnexion de toutes les sources d'approvisionnement.
You are advised that:
Upon connection, this unit is under voltage. At this point, the equipment
contains lethal DC voltages.
When the photovoltaic (PV) array is exposed to light, it supplies DC voltage
to this equipment.
As the installer, you must reference the National Electric Code (NEC) sections
250 and 690 to ensure proper system wiring and grounding compliance. In
addition, all state and federal Occupational Safety and Health Administration
(OSHA) guidelines and regulations must be followed.
Unless otherwise specified, wiring methods must be in accordance with the
National Electrical Code, ANSI/NFPA 70.
Installations in Canada shall be in accordance with the Canadian Electrical
Code, Part I.
Torque tightening information is located on a label inside the front door.
Follow the torque specifications.
Units must be disconnected and isolated from the load at the inverter prior
to servicing breakers or disconnecting cables.

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 11
Chapter 2
Product Description
The Bentek Solar Breaker Universal Safety System (BUSS) is a floor-mounted
recombiner. It is designed for large PV solar systems (250KW or greater) and is
intended for installation next to the inverter. It is comprised of multiple UL-rated
1000VDC circuit breakers contained in one easy-to-install compact enclosure.
The BUSS provides an unmatched safe and convenient means of isolating and
diagnosing individual DC portions of a PV system for routine maintenance and
troubleshooting.
Maximum current through each circuit of the BUSS is determined by the size of
the circuit breaker and the proper application of deration factors consistent with
NEC code.
Each source circuit is protected separately from overcurrent limits through circuit
breakers according to the requirements of the National Electric Code (NEC). Each
circuit breaker has a switch that can be used to disconnect that breaker.
The circuit breakers provide maximum performance and safety with UL489
breakers. The breaker itself serves as a disconnect in addition to providing circuit
protection.
The 1000V BUSS is designed for up to fourteen circuit breakers that are installed
in two banks. Circuit breakers are available in the following sizes: 125A, 150A,
175A, 200A, 225A, 250A, 300A, 350A, and 400A. Multiple sizes of circuit breakers
can be installed in the same BUSS.
When the BUSS contains twelve or fewer circuit breakers, it is housed in a
79-inch high enclosure. When the BUSS contains thirteen or fourteen circuit
breakers, it is housed in a 87-inch high enclosure.

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 12
Chapter 2: Product Description
Figure 1 Outside of enclosure
Vent
Fan
Eyelets for lifting (4)
Front door
with handle

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 13
Chapter 2: Product Description
Components
NOTE
Figure 2 and show the arrangement of the components for a unit containing 12
circuit breakers. Units with fewer than 12 circuit breakers do not have the top
circuit breakers. Units with 13 or 14 circuit breakers are in the taller cabinet and
are arranged similarly.
The free-standing Breaker Universal Safety System is a floor-mounted NEMA-3R
electrical enclosure that contains the following components:
Circuit Breakers (CB)—1000VDC-rated integral unit are designed to open a
circuit automatically on a predetermined overload of current. The circuit
breakers are installed in two banks. Each circuit breaker has a lock out/tag
out to accommodate a tag or padlock with a shackle up to 1/4-inch.
Dead Fronts—Steel circuit breaker dead fronts inside the door provide access
to the circuit breakers while providing a barrier to prevent unintentional
contact with live parts.
Circuit Breaker Dead Fronts—Covers over each bank of circuit breakers
provide additional protection. The covers do not need to be removed to wire
the BUSS.
Equipment Ground Busbar—Aluminum bar used to combine individual
source circuit grounds to system ground.
Grounded Busbar—Aluminum bar used to combine circuit breakers. The
busbar provides for 16 lug locations or 32 back-to-back connections.
Ungrounded Busbar—Aluminum bar used to connect ungrounded outputs.
Insulators—Plastic standoffs used to isolate the electricity between the
busbars, weldments, and the enclosure.
Fan, Vent, and Thermostat—Provide cooling to the BUSS when the inside
reaches a set temperature (recommended temperature setting is 40oC).
Heater and Hygrostat (optional)—The hygrostat monitors humidity in the
enclosure and controls heat to the BUSS when the humidity reaches a certain
level. Recommended for environments of -20oC and below.
The Bentek Zone Monitoring system or the Current Sense feature
(optional)—Uses an Ethernet or RS-485 interface to provide a method for
monitoring individual source circuits from a PV array. The system is described
in more detail in Appendix A, “Bentek Zone Monitoring System using an
Ethernet Interface,” or Appendix B, “Bentek Zone Monitoring System using an
RS-485 Interface.” The system consists of:
Analog Input Module.
Current Sensors.
Power Supply.

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 14
Chapter 2: Product Description
Wiring Harness.
Plinth (optional)—A base attached at the bottom of the enclosure. The plinth
may be 4 or 8 inches high.
NOTE
Bentek assemblies may use components that are silver plated. This plating may
oxidize (tarnish) over time as a result of natural exposure to standard
atmospheric conditions and become brownish, yellow, off-color or mottled in
appearance. This process is normal and should not be mistaken for indications of
overcurrent. The oxidation of the silver plating will not affect the performance of
the assembly in any way.

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 15
Chapter 2: Product Description
Figure 2 BUSS - front view showing dead fronts (with 12 circuit breakers)
Dead fronts
Screws to remove
dead fronts
(10 on the top dead
front and 6 on the
bottom)
Circuit breaker
Circuit breaker
Electronics enclosure

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 16
Chapter 2: Product Description
Each circuit breaker has a trip button that moves the switch from the On position
to the Neutral (middle) position. The button on the breakers of 350A and below
can be depressed with your finger. On the 400A breaker, the button is small and
slightly inset so it requires a small thin tool such as the tip of a pen or
screwdriver.
Figure 3 Location of Circuit Breaker Trip Buttons
400A circuit
breaker -
location of trip
button
Circuit breakers
350A and below -
location of
trip
button

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 17
Chapter 2: Product Description
Figure 4 BUSS - inside view of BUSS from front with dead fronts removed (shown
with 12 circuit breakers installed)
Current sensor
Circuit Breaker
Equipment
ground busbar
Thermostat
for fan
Electronics
enclosure
Grounded
busbar
Ungrounded
Circuit breaker
dead front
Hygrostat
for heater (opt.)
Ungrounded input
connector
output busbar
Grounded
busbar
Ungrounded
output busbar

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 18
Chapter 2: Product Description
Specifications
Table 1 through Table 5 show the specifications for the following equipment:
BTK10-BUSS-GC-xxyyy-zzz-Ex, BTK10-BUSS-GC-xxyyy-zzz-Ex-Sx. See on page 8 for
an explanation of model numbers.
Ta b l e 1 Electrical Specifications of 1000V BUSS
Max. # of
Inputs
CB Capacity per
string (A)
Max. # of
Outputs
Continuous
Current Rating (A)
Max. Voltage
(VDC)
14 125 to 400 8* 3670 1000
* Four connections with two wires per location.
Ta b l e 2 Physical Specifications of 1000V BUSS
Standard enclosure Tall enclosure
Height (of enclosure) 79 inches * 87 inches *
Additional height due to eyebolt 2.5 inches 2.5 inches
Width 39 inches 39 inches
Width including fan and vent covers 43.25 inches 43.25 inches
Depth (excluding handle) 24 inches 24 inches
Weight, approx. (unwired) 900 pounds 1000 pounds
* Depending on the configuration, an optional plinth will add 4 inches or 8 inches to
the height of the enclosure.
Ta b l e 3 Connector and Wire Information
Ungrounded inputs One per circuit breaker
Ungrounded outputs Common bus with 4 lug locations (up to 8
connections using back-to-back lugs).
Grounded inputs and outputs 16 lug locations (up to 32 connections
using back-to-back lugs) on grounded
common busbar.
Max. barrel diameter of lug 1.75 in.
Max. tongue width of lug 2.5 in.
Input and output cable size Max. 1000MCM *
Optional mechanical lugs No
Input and output type Dual 1/2-in. bolt, 1.75-inch hole
center-to-center measurement, 1000 MCM,
Cu/AL
Input and output wire temp rating 90oC.
Equipment ground input wire range 3/8-in. bolt, 1 AWG, CU/AL
Equipment ground input number and size up to 14; 3/8-in. single hole; max. tongue
size .68” x .98”

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 19
Chapter 2: Product Description
Explanation of Symbols Used on Equipment
The following symbols are used to identify parts and provide warnings for the
BUSS.
Equipment ground output number and size 1; dual 1/2-in. bolt, 1.75-inch hole
center-to- center measurement, max.
tongue size 1.78” x 3”, 500 MCM, CU/AL
Auxiliary power input without heater 104-120VAC, <4A, 50/60Hz
Auxiliary power input with heater 104-120VAC, <15A, 50/60Hz
Auxiliary power input TB wire range 18-12 AWG, CU
Communication connector Ethernet RJ-45, RS-485 terminal block
Note: All terminal lugs should be certified to UL486A&B and/or CS22.2 No. 65.
* Minimum gauge is limited by minimum hole center-to-barrel distance of 0.7in.
Ta b l e 4 Environmental Specifications of BUSS
Maximum operating altitude 2000M
Relative humidity range 0 to 95%, non-condensing
Operating temperature range -20o C to +50o C
Operating temperature range with heater -40o C to +50o C
Storage temperature range -20o C to +80o C
If operating temperatures or altitude exceed these specifications, contact your
Bentek representative to determine deratings.
Ta b l e 5 Certifications
ISO 9001:2008 Quality certified
TÜV SÜD Listed to UL1741
Ta b l e 6 Symbols on Equipment
CAUTION: Risk of Electric Shock. Circuits are live. Disconnect
unit before servicing. Do not remove cover. No user
serviceable parts inside. Refer servicing to qualified service
personnel.
GROUND—This symbol identifies the equipment ground points.
“ON”—This symbol identifies that the item is in the “on” position.
“OFF”—This symbol identifies that the item is in the “off” position.
Ta b l e 3 Connector and Wire Information (Continued)

Installation and Operating Instructions – 1000V BUSS, Grounded (125A to 400A)
950-003342-000 Rev B 20
Chapter 2: Product Description