Mastervolt SUNMASTER XL-10 User manual

INSTALLATION MANUAL / INSTALLATIEHANDLEIDING
INSTALLATIONSANLEITING / MANUEL D’INSTALLATION
DC Connection kit
for solar electric applications
TRIPLE OUTPUT MODEL FOR SUNMASTER XL-10 AND XL15
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com v 2.0 January 2011
ENGLISH: PAGE 1
NEDERLANDS: PAGINA 13
DEUTSCH: SEITE 25
FRANÇAIS: PAGINA 37

TABLE OF CONTENTS
2Copyright © 2011 Mastervolt / January 2011 / DC Connection kit for solar electric applications / EN
Copyright © 2011 Mastervolt. All rights reserved.
Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written
permission of Mastervolt is prohibited.
TABLE OF CONTENTS: v 2.0 January 2011
1GENERAL INFORMATION.............................................................................................................................................. 3
1.1 Product description.............................................................................................................................................3
1.2 Use of this manual..............................................................................................................................................3
1.3 Validity of this manual ........................................................................................................................................3
1.4 Guarantee specifications....................................................................................................................................3
1.5 Liability ............................................................................................................................................................... 3
1.6 Changes to the DC Connection kit.....................................................................................................................3
1.7 Identification label...............................................................................................................................................3
2SAFETY GUIDELINES AND WARNINGS....................................................................................................................... 4
2.1 Warnings and symbols.......................................................................................................................................4
2.2 Use for intended purpose...................................................................................................................................4
2.3 Organisational measures ...................................................................................................................................4
2.4 Installation, maintenance and repair................................................................................................................... 4
2.5 Warning of special dangers................................................................................................................................4
3SPECIFICATIONS ........................................................................................................................................................... 5
3.1 Technical specifications ..................................................................................................................................... 5
3.2 Outline drawings................................................................................................................................................. 5
4INSTALLATION............................................................................................................................................................... 6
4.1 General ..............................................................................................................................................................6
4.2 Unpacking ..........................................................................................................................................................6
4.3 Installation environment .....................................................................................................................................6
4.4 PV modules and strings .....................................................................................................................................6
4.5 Use of the spring-cage terminals........................................................................................................................ 6
4.6 Wiring instructions..............................................................................................................................................7
4.6.1 Things you need:...............................................................................................................................7
4.6.2 Wiring between PV-modules and the DC Connection kit................................................................... 7
4.6.3 Wiring between the DC Connection kit and inverter.......................................................................... 7
4.6.4 Connection to the safety ground (PE)................................................................................................7
5START-UP AFTER INSTALLATION............................................................................................................................... 9
5.1 Commissioning...................................................................................................................................................9
5.2 Decommissioning...............................................................................................................................................9
5.3 Maintenance.......................................................................................................................................................9
6TYPICAL INSTALLATION............................................................................................................................................. 10
7SCHEMATICS................................................................................................................................................................ 11
8EC DECLARATION OF CONFORMITY ........................................................................................................................ 12

GENERAL INFORMATION
EN / DC Connection kit for solar electric applications / January 2011 / Copyright © 2011 Mastervolt 3
1 GENERAL INFORMATION
1.1 PRODUCT DESCRIPTION
The Mastervolt DC Connection kit for solar electric
applications is a DC switch between photovoltaic modules
and the Solar inverter on buildings, as required by the
international standard IEC60364-7-712. In this manual it
will be mentioned as “DC Connection kit”.
1.2 USE OF THIS MANUAL
This manual serves as a guideline for the safe and
effective installation of the Mastervolt DC Connection kit:
•The electrician will find in this manual directions for the
installation, operation and commissioning.
•The end-user finds directions for the operation,
maintenance and possible correction of minor
malfunctions of the DC Connection kit.
•Both the installer and the end-user must be completely
familiar with the contents of this manual, and must
carefully follow the instructions contained herein.
•The manual must be accessible to the user
immediately.
This English manual has 12 pages.
1.3 VALIDITY OF THIS MANUAL
All of the specifications, provisions and instructions
contained in this manual apply to standard versions of the
DC Connection kit delivered by Mastervolt solely.
This manual is valid for the following models:
Part number Description
130506000 XL connection kit +DC-switch 600V
30A 6p
1.4 GUARANTEE SPECIFICATIONS
Mastervolt assures the product guarantee of the DC
Connection kit during two years after your purchase, on
the condition that all instructions and warnings given in this
manual are taken into account during installation and
operation.
Among other things, this means that installation is done by
a qualified electrician, that installation and maintenance
are executed according to the stated instructions and
correct working sequence and that no changes or repairs
may have been executed on the DC Connection kit other
than by Mastervolt.
The guarantee is limited to the costs of repair and/or
replacement of the product by Mastervolt only. Costs for
installation labour or shipping of the defective parts are not
covered by this warranty.
For making an appeal on guarantee you can directly
contact your supplier, mentioning your complaint,
application, date of purchase and part number / serial
number.
1.5 LIABILITY
Mastervolt can accept no liability for:
•consequential damage due to use of the DC
Connection kit;
•possible errors in the manuals and the results thereof.
•loss of energy revenues due to possible defects
1.6 CHANGES TO THE DC CONNECTION KIT
Changes on the DC Connection kit may be carried out
only after the written permission of Mastervolt.
1.7 IDENTIFICATION LABEL
Important technical information required for service,
maintenance & secondary delivery of parts can be derived
from the type number indication plate and may therefore
not be removed!
CAUTION!
Never remove the identification label.

SAFETY GUIDELINES AND WARNINGS
4Copyright © 2011 Mastervolt / January 2011 / DC Connection kit for solar electric applications / EN
2 SAFETY GUIDELINES AND WARNINGS
2.1 WARNINGS AND SYMBOLS
Safety instructions and warnings are marked in this
manual by the following pictograms:
A procedure, circumstance, etc which
deserves extra attention.
CAUTION!
Special information, commands and
prohibitions in order to prevent damage.
WARNING
A WARNING refers to possible injury to the
user or installer or significant material damage
to the DC Connection kit if the installer / user
does not (carefully) follow the stated
procedures.
2.2 USE FOR INTENDED PURPOSE
The DC Connection kit is constructed as per the applicable
safety-technical guidelines. Use the DC Connection kit
only in installations that meet the following qualifications:
•in permanent installations;
•in a closed cabinet, protected against rain, moist, dust
and condensation;
•the electrical installation must meet the applicable
regulations and standards, must be carried out
correctly and must be in a good condition;
•installed according to the instructions stated in this
manual;
•according to the technical specifications as stated in
chapter 3.
WARNING
Never use the DC Connection kit in situations
where there is danger of gas or dust explosion
or potentially flammable products!
Use of the DC Connection kit other than as mentioned in
this section is not considered to be consistent with the
intended purpose. Mastervolt is not liable for any damage
resulting from the above.
2.3 ORGANISATIONAL MEASURES
The installer / user must always:
•have access to this manual;
•be familiar with the contents of this manual. This
applies to Chapter 2, Safety Guidelines & Warning
particularly.
2.4 INSTALLATION, MAINTENANCE AND
REPAIR
As lethal voltages exist, allow installation, maintenance
and repair of the DC Connection kit and changes in your
electrical system to be carried out by qualified electricians
only.
Connections and safety features must be executed
according to the locally applicable regulations.
In case of decommissioning and/or demounting follow the
instructions as stated in section 5.2.
If such are required, use only original spare parts.
2.5 WARNING OF SPECIAL DANGERS
•High voltages up to 600V DC may exist. Therefore the
DC Connection kit may only be accessible for qualified
electricians.
•Voltages present at the cabling to the photovoltaic
modules are not safe to touch and cannot be switched
off.
•Do not work on the DC Connection kit and/or the
electrical installation if it is still connected to the solar
panels and/or the inverter.
•Only allow changes in your electrical system to be
carried out by qualified electricians.
•Check the wiring at least once a year. In case of loose
connections, burned cables etc: switch off the AC-grid
immediately. Defects must be corrected immediately
by a qualified electrician.

SPECIFICATIONS
EN / DC Connection kit for solar electric applications / January 2011 / Copyright © 2011 Mastervolt 5
3 SPECIFICATIONS
3.1 TECHNICAL SPECIFICATIONS
Model DC Connection kit for solar electric applications
Article no. 130506000
Configuation and Power Rating 4 x 2 pole; 600V / 30A
Over voltage protection: Yes, by means of varistors
Type: Overvoltage arrester, 1-pole, Plug-in P-VMS 600
Max. operating voltage: 600 V AC / 50 Hz
Nominal discharge current: 20 kA (8/20)
Maximum discharge current: 40 kA (8/20)
Protection level Up: < 2,3 kV
Pröpster order nr.:206 602 (see www.proepster.com)
Connections 3 inputs with each 4 string connections (add fuses needed for > 3 strings)
3 output connections to inverter
Mounting Din Rail
Ambient condition –20°C up to +70°C
Max wire diameter 6mm²
Dimensions (HxWxD) 94 x 390 x 185 mm (see figure 1)
Weight Approx. 2.2 kg
Applications Sunmaster XL-10
Sunmaster XL-15
3.2 OUTLINE DRAWINGS
Dimensions are in mm
Figure 1: DC Connection kit for solar electric applications
DEPTH: 195mm

INSTALLATION
6Copyright © 2011 Mastervolt / January 2011 / DC Connection kit for solar electric applications / EN
4 INSTALLATION
4.1 GENERAL
During installation and commissioning of the DC
Connection kit, the Safety Guidelines & Measures are
applicable at all times (see chapter 2 of this manual), as
well as:
•DIN VDE 0100 (Low-voltage electrical installations);
•IEC60364-7-712 (Electrical installations of buildings –
Requirements for special installations or locations -
Solar Photovoltaic power supply Systems);
•VDI 6012 (Local energy systems in buildings –
Photovoltaics);
•BGV A1 (General regulations);
•BGV A2 (Electrical installations and equipment).
4.2 UNPACKING
In addition to the DC Connection kit the delivery includes:
•this installation manual.
After unpacking, check the contents for possible damage.
Do not use the product if is damaged. If in doubt, contact
your supplier.
4.3 INSTALLATION ENVIRONMENT
The DC Connection kit must be installed in the vicinity of
the solar inverter, in a closed cabinet, protected against
rain, moist, dust and condensation.
4.4 PV MODULES AND STRINGS
The solar or DC side of the system consists of several
photovoltaic (solar) modules, further mentioned as “PV
modules”. The PV-modules are connected in series to
form a so called “string”. These strings consist of a positive
(+) and a negatiev (–) connection which can be connected
directly to the DC Connection kit.
The string voltage should be equal to the open circuit
voltage (Voc) per PV module (refer to the specifications of
the PV-module), multiplied by the number of PV-modules
in each string. Depending on the solar irradiation, this
value should be equal to 70-95% of the calculated string
voltage.
4.5 USE OF THE SPRING-CAGE TERMINALS
The DC Connection kit is equipped with spring-cage
terminal to connect the DC-wiring. Use a maximum wire
diameter of 10mm² to fix to the DC spring-cage
connections. Strip the cable insulation 10mm.
Use an insulated 4mm flat blade screwdriver to open the
spring-cage clamp. See figure 2.
Figure 2: Use of the spring-cage terminals
3Pull back screwdriver
2Place cable into opening
1Push screwdriver firmly into the
indicated slot

INSTALLATION
EN / DC Connection kit for solar electric applications / January 2011 / Copyright © 2011 Mastervolt 7
4.6 WIRING INSTRUCTIONS
WARNING
High voltages (up to 600 VDC) may exist on
the PV-strings! Connection of the DC-cabling
may only be carried out if the DC-cables are
voltage free. Therefore the PV-modules must
be disconnected from the DC-cabling (for
instance by disconnecting the MultiContact
connectors at the PV-modules).
CAUTION!
•Short circuiting, reversing polarity or
interchanging of PV-strings may lead to
damage to the DC Connection kit, the
Solar inverter, the cabling and/or the
terminal connections.
•The maximum output current may not
exceed 30A for each output of the DC-
Switch.
•If two ore more strings are connected to
the same Solar-input, both string lengths
must be equal.
•Follow all steps of the installation
instructions in order of succession as
described.
•During the entire installation the rotary
switch of the DC Connection kit must stay
in the O-position (OFF).
•Do not change the existing wiring of the
DC Connection kit
Refer to chapter 6 for typical installation
examples.
<<<< TEXT REMOVED >>>>
4.6.1 Things you need:
To connect the DC Connection kit to the inverter you need
the following cables, long enough to reach from the DC
Connection kit to the inverter (not included with the
delivery)
•Three double isolated DC cables with positive (+)
marking (e.g. red colour) ,
•Three double isolated DC cables with negative (–)
marking (e.g. black colour)
4.6.2 Wiring between PV-modules and the DC
Connection kit
See figure 3. First make the connections to INPUT 1, and
then make the connections to INPUT 2, followed by INPUT
3.
1 Turn the rotary switch of the DC Connection kit to the
O-position (OFF).
2 Mount the DC Connection kit in a closed cabinet.
3 Strip approx. 10 mm of the DC-cables and connect
the cables as indicated.
4.6.3 Wiring between the DC Connection kit
and inverter
See figure 3. Follow in detail all steps of the installation
instructions in order of succession as described below.
1 Make sure the rotary switch of the DC Connection kit
is still set to the O-position (OFF).
2 Strip approx. 10 mm on both sides of the DC cables
3 Connect the DC cable with positive marking (+)
between the positive (+) connection of the OUTPUT
and the positive (+) DC Solar input of the inverter.
4 Repeat this for the negative (–) connection.
5 Repeat steps 3 and 4 to connect the OUTPUT 2 to
DC Solar input nr. 2 of the inverter.
6 Repeat steps 3 and 4 to connect the OUTPUT 3 to
DC Solar input nr. 3 of the inverter.
4.6.4 Connection to the safety ground (PE)
See figure 3. Connect the earth terminals of the varistors
to the safety ground (PE) as indicated. The wiring of this
connection should have a minimum cross section of 16
mm².

INSTALLATION
8Copyright © 2011 Mastervolt / January 2011 / DC Connection kit for solar electric applications / EN
ROTARY SWITCH POSITIONS:
0
(
OFF
)
1
(
ON
)
TOP
Figure 3: Connections of the DC-Connection kit:
+ INPUT 3
+ INPUT 3
+ INPUT 3
– INPUT 1
– INPUT 1
– INPUT 1
+ INPUT 3
– INPUT 1
+ OUTPUT 3
– OUTPUT 1
– INPUT 2
– INPUT 2
– INPUT 1
– INPUT 2
– OUTPUT 2
– INPUT 3
– INPUT 3
– INPUT 3
– INPUT 3
– OUTPUT 3
+ INPUT 2
+ INPUT 2
+ INPUT 2 + INPUT 2
+ OUTPUT 2
+ INPUT 1
+ INPUT 1
+ INPUT 1 + INPUT 1
+ OUTPUT 1
PE
– VARISTOR 1
– VARISTOR 2
– VARISTOR 3
PE
+ VARISTOR 1
+ VARISTOR 2
+ VARISTOR 3

START-UP AFTER INSTALLATION
EN / DC Connection kit for solar electric applications / January 2011 / Copyright © 2011 Mastervolt 9
5 START-UP AFTER INSTALLATION
5.1 COMMISSIONING
CAUTION!
Check the polarity of all wiring before
commissioning: positive connected to positive,
negative connected to negative.
Follow the steps described below to switch on the DC
Switch of the DC Connection kit.
1 Connect the PV-modules to the DC-cabling (for
instance by connecting the MultiContact connectors of
the string cabling).
2 Check the voltage and polarity of all connections with
a suitable DC voltage meter. This voltage should be
equal to the open circuit voltage (Voc) per PV module
(refer to the specifications of the modules), multiplied
by the number of modules in each string. Depending
on the irradiation of the PV module, the measured
value should be equal to 70-95% of the theoretically
calculated value. Make sure that the measured
voltage matches the specifications the DC-input of the
inverter.
3 If the voltage and polarity of the strings is OK, turn the
rotary switch of the DC Connection kit to the 1-
postion.
4 Check whether the DC voltage is present at the
inverter (refer to the user’s manuals of the inverter).
5 Connect the solar inverter to the electric grid (refer to
the user manual of the solar inverter).
5.2 DECOMMISSIONING
If it is necessary to put the DC Connection kit out of
operation, follow the instructions in order of succession as
described below:
1 Disconnect the solar inverter form the electric grid
(refer to the user manual of the solar inverter).
2 Turn the rotary switch of the DC Connection kit to the
O-position (OFF).
3 Disconnect the PV-modules from the DC-cabling (for
instance by disconnecting the MultiContact
connectors at the PV-modules).
4 Remove the DC-cables one by one by opening the
spring cage clamps (see figure 3). Insulate the loose
wire end of each DC cable with insulating tape.
Now the DC Connection kit can be demounted in a safe
way.
5.3 MAINTENANCE
The operation of the varistors must be checked regularly.
Varistors indicating a red window must be exchanged by
an identical type (see section 3.1 for specifications).

TYPICAL INSTALLATION
10 Copyright © 2011 Mastervolt / January 2011 / DC Connection kit for solar electric applications / EN
6 TYPICAL INSTALLATION
Figure 4
DC Connection kit with Sunmaster XL-10kW or XL-15kW
PV-strings
OptionalOptionalOptional
DC Connection kit Sunmaster XL10 Sunmaster XL15
SOLAR
INPUT 1 SOLAR
INPUT 2 SOLAR
INPUT 3
A
C