Sungrow SunBox PVS-8M User manual

SunBox PVS-8M/PVS-16M
PV Array Combiner Box
User Manual

Contents
1About This Manual ...................................................................1
1.1Contents....................................................................................................................1
1.2Target Readers ........................................................................................................1
1.3How to Use this Manual.......................................................................................1
1.4Other Information .................................................................................................2
1.5Symbol Explanation..............................................................................................2
1.6Picture Explanation ...............................................................................................3
2Safety Instructions...................................................................4
3Product Description.................................................................8
3.1System introduction .............................................................................................8
3.2Demonstration of the type.................................................................................9
3.3Identifying the PVS............................................................................................. 10
3.4Fuse rating............................................................................................................. 11
3.5DC switch rating.................................................................................................. 11
4Installation Guide ..................................................................12
4.1Checking before installation........................................................................... 12
4.2Mechanical installation..................................................................................... 12
4.2.1 Dimensions............................................................................................................... 12
4.2.2 Installation site requirements............................................................................ 13
4.2.3 Preparation before Installation......................................................................... 13
4.2.4 Installation Method............................................................................................... 14
4.3Electrical installation.......................................................................................... 16
4.3.1 Internal structure.................................................................................................... 16
4.3.2 Water-proof terminals and wirings.................................................................. 17
4.3.3 Wiring preparations............................................................................................... 18
4.3.4 Input wiring and connections........................................................................... 19
4.3.5 Output wiring and connections....................................................................... 22
4.3.6 Ground wiring and connections ...................................................................... 24

4.3.7 Communication Connections ........................................................................... 24
4.3.8 Installation of fuses................................................................................................ 27
4.3.9 Bottom wirings........................................................................................................27
4.4Communication address settings................................................................. 28
4.5Start/Stop of operation .................................................................................... 31
5Commissioning.......................................................................32
6Routine Maintenance.............................................................33
6.1Replace the Fuse................................................................................................. 33
6.2Replace the sealing strip.................................................................................. 34
7Troubleshooting.....................................................................35
7.1Before troubleshooting.................................................................................... 35
7.2Common faults and troubleshooting ......................................................... 35
8Appendix ................................................................................38
8.1Technical data...................................................................................................... 38
8.2Cable requirements ........................................................................................... 39
8.3Quality Assurance............................................................................................... 39
8.4About us................................................................................................................. 41

1
1 About This Manual
1.1 Contents
Safety instructions
Safety instructions for the installation, operation, commissioning and
maintenance of PVS.
Product description
Location of PVS in the PV system, structure, function and classification.
Installation guide
The installation methods and electrical connections of PVS.
Routine maintenance
How to replace the fuses of PVS.
Others
Technical data of PVS, exclusion of liability and the way to contact us.
1.2 Target Readers
This manual is for users who operate the PVS or conduct the maintenance work. The
operators must be trained and qualified personnel.
1.3 How to Use this Manual
Read this manual and other related documents before installation of the PVS.
Documents must be stored in a convenient place for future reference.
The contents of the manual will be periodically updated or revised due to the
product development. It is probably that there are changes of manual in the
subsequent converter edition.

1 About This Manual User Manual
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1.4 Other Information
To satisfy your requirements, we have also provided PVS-6M and PVS-12M with a DC
input string number of 6 and 12 respectively. Their electrical structure, installation
and use are the same with those of SunBox PVS-8M/PVS-16M.
This manual takes SunBox PVS-8M/PVS-16M for example. For installation and
operation of combiner box with other inputs, please refer to this manual.
In actual application, if the PV string input numbers are not 8, 12, or 16,
user needs to set related parameters from the monitoring board of the
PVS to ensure its normal operation. For detailed setting methods, please
refer to “chapter 4.4”.
1.5 Symbol Explanation
This manual contains important safety and operational instructions that must be
accurately understood and followed during the installation and maintenance of the
equipment.
To ensure optimum use of this manual, note the following explanations of symbols
used.
DANGER indicates a hazard with a high level of risk which, if not avoided,
will result in death or serious injury.
WARNING indicates a hazard with a medium level of risk which, if not
avoided, will result in death or serious injury.
CAUTION indicates a hazard with a low level of risk which, if not avoided,
will result in minor or moderate injury.

User Manual 1 About This Manual
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NOTICE indicates a situation which, if not avoided, will result in equipment
malfunction or property damage.
NOTE indicates additional information, emphasized contents or tips to
help you solve problems or save time.
The following symbols on the device enclosure must be paid attention to.
Symbols Explanation
Risk of electric shock! If not avoided, lethal hazard can be caused.
Hot surface! Do not touch!
The symbol represents protective conductor terminal. The terminal
should be connected firmly to avoid potential injury or property
damage.
1.6 Picture Explanation
Pictures used in this manual all take the PVS with standard configuration for
example.
The real PVS you received may differ from the example pictures in the numbers of
the installation hangers and etc. please refer to the actual product you receive.

4
2 Safety Instructions
This chapter describes some important safety instructions about SunBoxPVS.
Please read the manual carefully before installation. If any device damage occurs
when ignoring the safety instructions, our company has the right to exclude all
warranty claims.
Lethal Voltage!
Death resulting from burning and electric shock upon touching the live
components of the PVS.
Disconnect the end connection of the PV string before cable connection;
Observe all safety instructions required by the PV cell manufacturer.
Device damage or system fault may cause fire and electric shock!
Optical check the device for any possible damages or dangerous states
before operation.
Check if other external devices or circuit connection are in safe state.
Work on the device only when it is safe to do so.
Death or burning hazard by touching the internal terminals of the device!
Do not touch the terminals or conductors in contact to the inverter or PV
string.
Observe all the instructions and safety regulations related to PVS
connection.

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High voltage is present inside the device!
Follow all the warning signs in the device.
Respect all the safety instructions in this manual and other documents.
The ground cable must be grounded properly, otherwise,
lethal electric shock happens to the operator or installer once a fault
occurs.
device may be damaged after lightening stroke.
Incorrect cable connection may cause damages to the PV cells, combiner
box and inverter. Respect the following instructions during cable
connection:
Connect by strictly following the circuit diagram;
Measure and make sure the string open-circuit voltage meets the
requirements of the combiner box before inserting the fuse;
Identify the positive pole and negative pole before connection.
Only qualified personnel or professional electrician can perform the
operation and wiring described in this manual.
All operations and wirings must in full accordance with the national and
local standards and requirements.
All warning marks and labels must be clear and intact. Replace them if any
damages are found.

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Make sure the terminals are firmly connected during wiring. If the cable
copper core and the terminals are not connected firmly, terminals will be
over-heating and burnt. Anti-flaming cables with multi-strand are advisable
and the cable cross-sectional area should be no less than the recommended
value.
The nuts of the water-proof terminals must be firmly screwed to prevent
water leakage and PVS damages.
Pull the fuse out of the fuse holder for personal and device safety.
Watch out during fuse replacement. Do not touch the fuse with bare hands.
Do not bring any metallic materials during fuse replacement. Replace only
one fuse at one time. Once the one fuse is replaced, check to make sure the
new one is installed firmly and then replace the next one.
The fuse is under high voltage both from the inverter and the PV array. Do
not touch the fuse during device operation.
Disconnect the DC circuit breaker before checking or replacing the fuse.
Notice that all terminals of the DC circuit breaker contain high voltage.
Measure by using proper tools that the current of each input is zero before
replacing the fuse.
Lock the cabinet door and seal the water-proof cover of the lock core after
operation. In rooftop horizontal installation site, fix the auxiliary protection
set of the cabinet with bolts.
No not open the cabinet door frequently.

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Touching or improper operation on the PCB or other sensitive components
may damage the device.
Do not touch any parts inside the cabinet other than the connection
terminals.
Respect all ESD related safety regulations and wear antistatic wrist strap.

8
3 Product Description
3.1 System introduction
For a large-scale grid-connected PV system, it is widespread to install a DC
combining device between PV modules and inverters to minimize cable
connections, facilitate maintenance and enhance reliability.
Our SunBox PVS combiner box series (PVS) are designed for meeting these
requirements, which provides a turnkey solution for PV plant systems.
Considering different types of PVS, a certain number of PV strings can be connected
to the input side of PVS. After combining work done, at the output side, there will be
one DC+ and one DC- main line. By using of surge protection device (SPD) and
circuit breakers, the output can be connected to inverters directly.
The PV generation system including a PVS is shown in Fig. 3-1.
Fig. 3-1 Composition of PV generation system
Tab. 3-1 Device in Fig. 3-1
No. Device
A PV arrays
B SunBox PVS-8M/PVS-16M combiner box
C Inverter
D Data acquisition device
E Environment monitoring device
F Grid
For PVS-8M, up to 8 PV strings can be connected to the input side.
And for PVS-16M, up to 16 PV strings can be connected to the input side.

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PVS has the following features:
Meet outdoor installation requirement
Connect to multiple PV inputs with fuse for each input (can be replaced to other
degree)
PV-specific high voltage SPD equipped, lightening protection function for
positive and negative pole
Quadrupole switch with positive and negative pole in parallel connection to
improve DC voltage-withstand value
Current sensor inside to monitor the current of each string; the monitored
information can be displayed by the LED or sent by RS485
Monitor busbar voltage and the monitored information can be displayed by the
LED and sent by RS485
3.2 Demonstration of the type
Type of the PVS is illustrated below：

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3.3 Identifying the PVS
PVS-8M/PVS-16M is shown in the following picture
No. Name Description
A Lockhole -
B INPUT DC+ Positive pole of DC input
(unused terminals must be sealed)
C INPUT DC- Negative pole of DC input
(unused terminals must be sealed)
D Ground terminal Equivalent potential connection terminal
E MONITOR Monitoring input and output
F OUTPUT DC+ Positive pole of DC output
G OUTPUT DC- Negative pole of DC output
H Ingress-protected air valve
——
I Fixing hanger Allow fixing of combiner

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3.4 Fuse rating
In power system, fuses are used for over-current protection. Choosing right-rating
fuses is very important to ensure safety operation.
The minimum current rating of a fuse can be calculated with short circuit current (Isc)
of PV arrays. Except for some special needs, the recommended rating would be
1.56×Isc.
Users can calculate fuse rating easily. If maximum current of PV arrays=7A, and DC
voltage range of PV arrays=200~1000V, then the fuse rating will be
1000V/(1.56×7A).
3.5 DC switch rating
The DC voltage of the switch is decided by the nameplate. For example, from the
nameplate it can be seen that the maximum DC voltage of the PV array is 1000V, i.e.
DC switch’s withstanding-voltage is at least 1000V. DC switch this product is
equipped meets the required withstanding-voltage degree.

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4 Installation Guide
4.1 Checking before installation
The delivery content of the combiner box is shown below:
PV array combiner box
User Manual
Warranty card
Certificate card
Test report
Check the completeness of the delivery according to the package list inside the
crate.
4.2 Mechanical installation
4.2.1 Dimensions
Fig. 4-1 Dimensions of PVS
Pictures in this manual are indicative only! The real product you receive
may differ.

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4.2.2 Installation site requirements
With IP65 protection degree, the PVS can be installed outdoors. Please meet the
following requirements:
Dimensions and weight of PVS should be considered sufficiently).
Ambient temperature -40℃~+70℃; Relative humidity 0~99%.
Installation site should be as close as possible to PV arrays for minimum cables
and wires usage.
Installation site should be safe venting.
PVS must be installed vertically, including following two types:
−Wall-hung type: Fix the PVS onto a wall (recommended).
−Pillar-mounted type: Fix the PVS onto a pillar.
Never install the device in direct sunlight to guarantee optimal performance.
For big PV plants, it is suggested that the device is installed on the back side of
PV arrays.
For better heat dissipation and convenient maintenance, enough space must be
maintained around the PVS.
For large-scale PV plant, install the PVS on the back of the PV cell installation
bracket
Humidity during installation may damage the PVS. Do not install the PVS
during rainy or humidity days.
Screw the water-proof terminals tightly to prevent moisture penetration no
matter the installation is vertically or horizontally. Seal the unused
terminals after cable connection.
Cover the water-proof lock core. Fix the lock protection device and the
device cabinet tightly by screws when PVS is installed in rooftop
horizontally.
4.2.3 Preparation before Installation
PVS is equipped with plastic buckle on the cabinet before delivery.
The plastic buckle is functioned as a buffer to prevent the sealing strip from
scratches and damages.
Before installing the PVS, please proceed as follows to remove the plastic buckle.

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If this plastic buckle is missing during transport, the normal function of the PVS is
not affected.
4.2.4 Installation Method
PVS has two installation methods: vertical installation and horizontal installation.
Solution 1: Horizontal installation
Horizontal installation is applied to distributed PV plant and on rooftop.
Horizontal installation steps
Step 1 Measure the distances of the hangers of the PVS and mark positions on the
installation surface.
700mm 700mm
290mm
Step 2 Fix the PVS to the surface according to the sequence of bolt, PVS hangers, fix
surface, flat washer, spring washer and nut. Torque:18N.m
Solution 2: Vertical installation
Vertical installation is applied to PV ground plant. PVS is installed in the shadow
place of the PV cells. Wall mounted or column mounted method can be adopted.

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Install PVS upside down is strictly forbidden.
Wall-mounted: fix PVS to the PV array’s installation frame through the mounting
holes of the PVS by 2 or 4 M10×30 bolts
Column-mounted: use hold hoop and steel angle as fixture to fix to the support
column. fix PVS to the steel angle through the mounting holes of the PVS by 2 or
4 M10×30 bolts
Installation steps:
Step 1 Measure the distances of the two hangers of the PVS.
Step 2 Mark positions according to the distances measured on the installation
surface and then drill holes.
Step 3 Fix the PVS to the surface according to the sequence of bolt, PVS hangers,
installation surface, flat washer, spring washer and nut. Torque:18N.m.
Column-mounted steps:
Step 1 The dimensions of the installation holes on the PV cell frame should meet the
requirements in Fig. 4-2.

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Fig. 4-2 Drill holes (unit in mm)
Step 2 As shown in Fig. 4-3, install PVS by hexagon nut and hexagon bolt. From left
to right: bolt, PVS hangers, support, flat washer, spring washer and nut.
Torque: 18N.m.
Fig. 4-3 Installation of PVS
Step 3 Check to ensure PVS is installed correctly and securely.
PVS can also be installed for roof application.
Observe all the instructions in this manual and relevant documents.
4.3 Electrical installation
4.3.1 Internal structure
The internal structure of the PVS is shown below (take PVS-16M for example):