Cooper Crouse-Hinds CCB Series Setup guide

Solar Combiner Solutions - CCB Series
Installation & Maintenance Information
SAVE THESE INSTRUCTIONS FOR FUTURE REFERENCE
IF 1598
IF 1598 • 12/10 Copyright © 2010, Cooper Industries, Inc. Page 1
SAVE THESE INSTRUCTIONS - This manual contains important instructions for Solar
Combiner Boxes that shall be followed during installation and maintenance for the
CCB Series.
1.0 OVERVIEW
Cover all modules in the PV array with dark, opaque material before making
electrical connections to the combiner box from the panels. All U.S. installations
must be performed in compliance with the National Electrical Code (NEC),
ANSI/NFPA 70 and applicable local codes. Cooper Crouse-Hinds Combiner Boxes
comply with the National Electrical Code.
All Canadian installations shall conform to Canadian Electrical Code Part I.
Installation should be performed only by authorized personnel.
The combiner boxes comply with UL1741 safety listing for continuous rated
current operation at 50°C.
2.0 INTRODUCTION
(PLEASE SAVE THESE INSTRUCTIONS)
This manual provides important instructions for the Cooper Crouse-Hinds (CCH)
Combiner Boxes and shall be followed during installation and maintenance. The
CCH Combiner Boxes are designed and tested to stringent safety requirements.
However, as with all electrical equipment, specific safety practices must be
followed. To reduce the risk of injury, carefully read this instruction booklet in its
entirety before installing, wiring, or using this product in any way.
2.1. DISCLAIMER OF LIABILITY
The installation techniques, handling and use of this product are beyond company
control. Therefore, Cooper Crouse-Hinds does not assume responsibility for loss,
damage or expense resulting from improper installation, handling or use of this
product.
2.2. LISTING INFORMATION
This product meets or exceeds the requirements set forth by Underwriters
Laboratories (UL) for components used with PV Modules. This UL Standard is
UL1741 for accessories used with inverters.
2.3. LIMITED WARRANTY
Combiner box limited warranties are for 1 year for materials and workmanship.
3.0 IMPORTANT SAFETY INSTRUCTIONS
There are no user-serviceable parts in this enclosure, other than the fuses. Do
not alter any portion of this product; otherwise, the warranty will be invalidated.
Storage temperature: - 60ºC to +85ºC
4.0 ELECTRICAL CHARACTERISTICS
The combiner box electrical ratings are indicated on Table 2, see page 4.
5.0 COMBINER BOX MOUNTING
VENTILATION CONSIDERATION
Maintain a minimum clearance of 1” on all 4 sides of the enclosure.
Install the enclosure using the 4 external enclosure mounting tabs only. Drilling
holes in the back plate is not recommended and shall void the product warranty.
Place in desired location on a sturdy frame and use the appropriate hardware to
mount the combiner box.
The steel combiner box may be mounted vertically (door opens out) only. The
fiberglass combiner box may be mounted both horizontally and vertically.
Place the box in areas out of continuous water flow and extreme temperature.
6.0 CONDUIT ROUTING
6.1. CONDUIT HOLES
Please refer to Figure 1 for conduit entry areas on the enclosure for all models.
Cut conduit holes in the desired location. The preferred method is the use of a
Greenlee®cutter of the appropriate size. The punch of the cutter should be
placed on the inside of the enclosure and drawn to the outside. Remove all
shavings and debris from enclosure.
6.2. CONNECTOR TYPE
The use of UL514B or equivalent conduit fittings is required to maintain the
environmental rating of the enclosure. Installation of fittings must comply with
UL50 for USA installations and CSA C22.2 No. 94 for Canadian installations to
maintain rating of the enclosure. See Figure 2 for suitable connectors. For use
with rigid/IMC conduit use of Cooper Crouse-Hinds Myers™conduit hub is
recommended. For non-metallic liquidtight conduit, Cooper Crouse-Hinds Lt-NM
series connector is recommended.
WARNING
To avoid the risk of fire or electric shock, this product should be installed, inspected,
and maintained by a qualified electrician only, in accordance with all electrical codes.
IMPORTANT SAFETY INSTRUCTION
WARNING
PV modules produce direct current (DC) when the module is under load. Direct current
will arc across gaps and may cause injury or death if improper connection or
disconnection is made. Do not connect or disconnect wires to the combiner box when
current from the modules or an external source is present.
WARNING
Use insulated tools to reduce your risk of electric shock. Do not install or handle the
combiner box if it is wet. Contact Cooper Crouse-Hinds at
[email protected] if the combiner box enclosure is damaged or its
contents are compromised.
WARNING
To avoid the risk of electric shock, remove all metallic jewelry prior to installing this
product to reduce the chance of accidental exposure to live circuits.

6.3. INSTALL CONNECTOR
6.3.1. METALLIC CONDUIT
Place Myers hub through hole as shown in Figure 3 with the o-ring on the
outside of the enclosure. Screw on and tighten the locknut. Next screw on the
grounding bushing, rotate to desired location and tighten set screws. If ground
hub configuration is used, terminate ground wire to ground screw on locknut. If
standard configuration is used screw on grounding bushing (Cooper Crouse-
Hinds HGLL series recommended). Rotate to desired location, tighten set screw
and terminate ground wire to ground lug.
6.3.2. NON-METALLIC LT CONDUIT
Place connector through hole as shown in Figure 3 with the o-ring on the outside
of the enclosure. Screw on and tighten the locknut. Screw Insulated or plastic
bushing onto connector threads to protect conductors from damage. Grounding
bushings are not used with non-metallic conduit.
6.3.3. PVC CONDUIT
Place Cooper Crouse-Hinds male adapter connector (MA-NM series
recommended) through hole. Secure with steel locknut (Cooper Crouse-Hinds 11,
12 etc. - order separately). Grounding bushings are not used with PVC conduit.
7.0 GROUNDING
A ground bar has been provided for the convenience of combining several
grounds into one larger ground wire. Please refer to NEC Article 690 on
grounding PV arrays for specific requirements.
Surge Protection (if equipped)
Surge Protective Device (Thermally Protected) for PV applications
The Surge-Trap PV provides advanced overvoltage protection to photovoltaic
systems, which does not require additional over-current protection due its high
short circuit withstand.
8.0 FUSE SELECTION
Please consult the module manufacturer and/or rating label to select the
appropriate fuse size. Please consult NEC Article 690 for more information. A
maximum of a 15 Amp fuse may be used with this product. Cooper Crouse-Hinds
Combiners are not shipped with fuses unless ordered with fuses.
9.0 OUTPUT CONDUCTOR SIZING
The combiner box output design current is determined by: (total Isc x 156%)
divided by a temperature correction factor. Select the appropriate temperature
correction factor from the NEC. See NEC Articles 310.16 and 690.31 for proper
wire sizing.
10.0 COMBINER WIRING
DO NOT INSTALL FUSES!
• Make ground connections first. This includes source circuit grounds, conduit
grounds, and enclosure grounds if using a metallic enclosure.
• Insert positive input conductor from the source circuit to the Touch Safe fuse
holder and tighten to torque specifications in Table 1.
• Insert negative input conductor from the source circuit to the negative collector
holder and tighten to torque specifications in Table 1.
• Insert positive output wire to the inverter (or other destination) into the positive
output terminal and secure to the torque requirements in Table 1.
• Insert negative output wire to the inverter (or other destination) into the
negative output terminal and secure to the torque requirements in Table 1.
Figure 2 - Suitable Conduit Connectors
Figure 3 - Conduit Connector Exploded View
WARNING
To prevent injury, death, or damage to your photovoltaic system, extreme caution should
be taken whenever entering the control cabinet due to energized components.
Photovoltaic panels generate power whenever exposed to ANY light. Cover the panel
entirely prior to wiring or servicing with an opaque cover.
Prior to installation or servicing, switch all disconnects to OFF position and use only
insulated tools and proper P.P.E.
1”
1”
1”
1-1/4”
Recommended combined conduit output for all size enclosures
Figure 1 - Conduit Entry Locations
1”
1”
1”
1-1/4”
TOP VIEW
BOTTOM VIEW
IF 1598 • 12/10 Copyright © 2010, Cooper Industries, Inc. Page 2
1.00
2.38
6.25
1.00
CAUTION
To prevent damage to your photovoltaic system and equipment, the CCB Series Solar
Combiner Box must have fuses installed into each fuse holder in order to operate
properly.
Cooper Crouse-Hinds recommends the use of Cooper Bussmann DCM Series fuses.
TOP VIEW
Recommended photovoltaic string inputs for
all fiberglass enclosures and steel
enclosures sizes 1-6 string and 7-12 string
Recommended
photovoltaic string
inputs for steel
enclosures sizes
13-20 string and
20-24 string

Make sure all connections are tight, secure and safe.
11.0 CHECK YOUR WORK
These steps need to be completed with your personal safety in mind. Before
installing fuses, complete these simple time-saving checks:
11.1. MEASURE VOLTAGE (VOC)
Check the open circuit positive voltage (Voc) from each individual solar array string
to the negative bus bar. Ensure each Voc is the proper polarity and within the
intended range. Voc does not vary much with irradiance and temperature conditions.
11.2. CHECK GROUND CURRENTS
Check the DC current from each individual string (fuse holder) to ground. If current is
present, locate and repair any ground faults.
11.3. INSERT FUSES
Check that the fuses are the proper rating and type and insert fuses into fuse
holders and secure it in the closed position.
11.4. FINAL INSPECTION
Check the DC voltage from the combined output lug to the negative bar. Ensure
voltage is the proper polarity and within the desired voltage range.
Check to ensure that all conduit connections are clean and tight and are properly
sealed against environmental concerns.
Close and secure the enclosure door.
12.0 MAINTENANCE
Please review this manual fully before beginning work on combiner boxes. Follow
all safety guidelines and warnings.
Every 6 months inspect and re-torque the wire connections.
We recommend an Electrical Preventive Maintenance Program as described
in the National Fire Protection Association Bulletin NFPA 70B:
Recommended Practice for Electrical Equipment Maintenance
(www.nfpa.org).
WARNING
To prevent injury, death, or damage to your photovoltaic system, extreme caution should
be taken whenever entering the control cabinet due to energized components.
Photovoltaic panels generate power whenever exposed to ANY light. Cover the panel
entirely prior to wiring or servicing with an opaque cover.
Prior to installation or servicing, switch all disconnects to OFF position and use only
insulated tools and proper P.P.E.
WARNING
To prevent component damage or electric shock, avoid touching any component or any
part of the circuitry while the equipment is operating. Do not place heavy loads on
associated system cables or maneuver them in a manner which may expose personnel
or equipment to current. Do not connect system cables when the terminals are wet or
damp. Do not disconnect cables under load.
IF 1598 • 12/10 Copyright © 2010, Cooper Industries, Inc. Page 3
Number of input circuits 1 through 4 5 through 6 7 through 12 13 through 20 21 through 24
Positive Input Terminal Torque (in-lbs) 16-22 16-22 16-22 16-22 16-22
Negative Input Terminal Torque (in-lbs) 20 35 35 35 35
Positive Output Terminal Torque (in-lbs) 35 35 120 275 120
Negative Output Terminal Torque (in-lbs) 120 500 120 275 120
Ground Output Terminal Torque (in-lbs) 20-35 20-35 275 275 275
Table 1

Cooper Industries, Inc.
Crouse-Hinds Division
P.O. Box 4999, Syracuse, New York 13221 • U.S.A.
Copyright © 2010, Cooper Industries, Inc. • [email protected]
IF 1598
Revision 2
Revised 12/10
All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable. The
accuracy or completeness thereof are not guaranteed. In accordance with Crouse-Hinds “Terms and Conditions of Sale,” and since conditions of
use are outside our control, the purchaser should determine the suitability of the product for his intended use and assumes all risk and liability
whatsoever in connection herewith.
Table 2: Electrical and Mechanical Combiner Box Characteristics
* – Imp Maximum Allowed (Sum of paralleled source circuits)
Number of input
circuits
CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_
01 02 03 04 05 06 07 08 09 10 11 12
Maximum Input
Fuse Rating (A) 15 15 15 15 15 15 15 15 15 15 15 15
Tested current 12 12 12 12 12 12 12 12 12 12 12 10
Max. Continuous
Op Current (A)
Using Max Input
Fuse
12 24 36 48 60 72 84 96 108 120 132 120
SCCR at 600VDC
(A) 7.69 15.38 23.08 30.77 38.46 46.15 53.85 61.54 69.23 76.92 84.62 76.92
Max Voltage (VDC) 600 600
Operating Voltage
Range - Combiner
Only(VDC)
0-600 0-600
Pos Input Wire Size #8-#18 AWG #8-#18 AWG
Neg Input Wire Size #10-#14 AWG #4-#14 AWG
Pos Output Wire
Size 1/0-#10 AWG 350kcmil-#4 AWG
Neg Output Wire
Size 2/0-#8 AWG 500kcmil-#6 AWG 350kcmil-#4 AWG
Ground Output Wire
Sizes #4-#14 AWG 250-#6 AWG
Enc Nema Rating 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R
Enclosure Size 12X10
X06
12X10
X05
12X10
X06
12X10
X05
12X10
X06
12X10
X05
12X10
X06
12X10
X05
12X10
X06
12X10
X05
12X10
X06
12X10
X05
16X14
X06
16X16
X06
16X14
X06
16X16
X06
16X14
X06
16X16
X06
16X14
X06
16X16
X06
16X14
X06
16X16
X06
16X14
X06
16X16
X06
Max # of inputs 6 12
Number of input
circuits
CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_ CCBF_ CCBS_
13 14 15 16 17 18 19 20 21 22 23 24
Maximum Input
Fuse Rating (A) 15 15 15 15 15 15 15 15 15 15 15 15
Tested current 8 8 8 8 8 8 8 8 8 8 8 8
Max Continuous Op
Current (A) Using
Max Input Fuse
104 112 120 128 136 144 152 160 168 176 184 192
SCCR at 600VDC (A) 66.67 71.79 76.92 82.05 87.18 92.31 97.44 102.56 107.69 112.82 117.95 123.08
Max Voltage (VDC) 600 600
Operating Voltage
Range - Combiner
Only(VDC)
0-600 0-600
Pos Input Wire Size #8-#18 AWG #8-#18 AWG
Neg Input Wire Size 14 AWG ONLY 14 AWG ONLY
Pos Output Wire
Size 350kcmil-#4 AWG 350kcmil-#4 AWG
Neg Output Wire
Size 350kcmil-#4 AWG 350kcmil-#4 AWG
Grnd Output Wire Sz 250-#6 AWG 250-#6 AWG
Enc Nema Rating 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R 4X 3R
Enclosure Size 18X16
X08
18X18
X06
18X16
X08
18X18
X06
18X16
X08
18X18
X06
18X16
X08
18X18
X06
18X16
X08
18X18
X06
18X16
X08
18X18
X06
18X16
X08
18X18
X06
18X16
X08
18X18
X06
20X16
X08
20X16
X06
20X16
X08
20X16
X06
20X16
X08
20X16
X06
20X16
X08
20X16
X06
Max # of inputs 20 24