SunSynk BB-300 User manual

v.7(11/29/23) PLEASE RETAIN FOR
FUTURE REFERENCE
SUNSYNK BUSBAR
USER MANUAL
SUNSYNK-BB-300
www.sunsynk.com
[email protected]
[email protected]

SUNSYNK-BB-300 | User Manual2
SAFETY PRECAUTIONS 3
Safety Warnings 3
Transport and Storage 3
INTRODUCTION 3
Sunsynk Busbar 3
Sunsynk Busbar System 4
FEATURES 4
Internal Parts and Wiring Diagram 4
SYSTEM DESIGN 5
Interconnecting Sunsynk Busbar 5
Orientation of Sunsynk Busbar 6
System Example 7
System Sizing 8
Current Rating 8
Fusing 8
Cabling 8
INSTALLATION 8
Mechanical Connections 8
Connection Features 8
Mounting and Interconnecting 9
Electrical Connections 10
Connecting DC Wires 10
Ground and Negative Connections 10
Positive Connections 12
COMMISSIONING THE SUNSYNK BUSBAR 12
TROUBLESHOOTING AND SUPPORT 12
Cabling Issues 13
WARRANTY 13
TECHNICAL SPECIFICATIONS 13
Table of Contents

SUNSYNK-BB-300 | User Manual3
SAFETY PRECAUTIONS
Safety Warnings
WARNING
Do not work on live busbars. Ensure that the busbar is unpowered by disconnecting all positive
battery poles prior to removing the Sunsynk Busbar front cover.
Work on batteries should be carried out by qualied personnel only. Observe the battery safety
warnings as listed in the battery manual.
Transport and Storage
Store this product in a dry environment.
The storage temperature should be: -40°C to +65°C.
No liability can be accepted for damage in transit if the equipment is not transported in its
original packaging.
INTRODUCTION
Sunsynk Busbar
The Sunsynk Busbar contains a positive and negative busbar with 4 connections for batteries, loads or
chargers and a ground connection.
Sunsynk Busbar with and without cover.

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Sunsynk Busbar System
The Sunsynk Busbar system is a modular busbar system that incorporates DC connections and distribution
for energy.
Sunsynk Busbar - A positive and negative busbar with 4 connections for batteries or DC equipment.
FEATURES
Internal Parts and Wiring Diagram
The internal physical parts and the wiring diagram of the Sunsynk Busbar indicating the following parts:
Positive busbar
Negative busbar
Positive connections
Negative connections
Ground connection
The internal physical parts of the Sunsynk Busbar.

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+
-
+
-+ -+ -+ -
GND
The internal wiring diagram of the Sunsynk Busbar.
SYSTEM DESIGN
Interconnecting Sunsynk Busbar
Each Sunsynk Busbar can connect to other Sunsynk Busbar's on both sides using the links and M8
bolts provided.
If the Sunsynk Busbar is the rst in line, the last in line or is used by itself, it is possible to connect batteries,
loads or chargers directly by adding/exposing the link. However, we do not generally recommend this
because additional insulation and fusing is needed.
Sunsynk Busbar connections: the arrows indicate where the other Sunsynk Busbar's can connect.

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The Sunsynk Busbar can be mounted in any orientation. However, IP22 suggests it is mounted as above.
Orientation of Sunsynk Busbar
Example of Sunsynk Busbar mounted upside down.

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System Example
In this system a Sunsynk Busbar is used by itself.
Single Phase Example
The Sunsynk Busbar does not contain fuses. All connected load, chargers or batteries need to be
fused externally.
Multiple Sunsynk Busbar's can be connected to each other thus creating a longer busbar with more
connections for batteries and/or loads.
3 Phase Example
L2 L3
L1

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System Sizing
Current Rating
The Sunsynk Busbar is rated for a nominal current of 800A, for 12, 24 or 48 system voltages.
To give an idea of how much power the Sunsynk Busbar is rated at dierent voltages, see the below table.
The power rating will give you an indication how big the connected inverter/charger system can be.
System Voltage 12V 24V 48V
800A 12kW 24kW 48kW
Fusing
The Sunsynk Busbar does not have fuses, fusing needs to be done externally.
Always use fuses with the correct voltage and current rating. Match the fuse rating to the maximum voltages
and currents that potentially can occur in the fused circuit.
The total value of the fuses of all circuits should not be more than the current rating of the
Sunsynk Busbar.
Cabling
The current rating of the wires or cables used to connect the Sunsynk Busbar to batteries and/or the DC
loads has to be rated for the maximum currents that can occur in the connected circuits. Use cabling with a
sucient core surface area to match the maximum current rating of the circuit.
INSTALLATION
Mechanical Connections
Connection Features
The Sunsynk Busbar can be opened up by unscrewing 2 cover screws.

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Mounting and Interconnecting
This paragraph explains how to attach several Sunsynk Busbar's to each other and how to mount the
Sunsynk Busbar assembly into its nal location.
When mounting onto the wall, please use the drill template and screw pack that are provided. The mounting
positions in the busbar match the drill template guide.
These are the points to take into consideration when interconnecting and mounting the Sunsynk Busbar:
Remove the easy break access windows for linking busbar's shown in the below illustrations.
Connect all Sunsynk Busbar's to each other using the M8 holes, bolts and links provided.
Place the washer and nut on the bolts and tighten the bolts using a torque of 14Nm.
Mount the Sunsynk Busbar in its nal location using the 5mm mounting holes.
Figure 1: easy break access windows and linking position.
BUSBAR BUSBAR
LINK
M8
NUT
M8
BOLT
Figure 2: connection sequence when connecting two Sunsynk Busbar's.
Correct placement of the M8 washer and nut.
EASY BREAK
ACCESS WINDOWS
FOR BUSBAR LINK
FIXING SCREWS
WIRE GUIDES
WALL MOUNT
POSITIONS

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Electrical Connections
Connect DC Wires
For all DC connections the following applies:
All cables and wires connected to the Sunsynk Busbar need to have been tted with M8 cable lugs.
Pay attention to the correct placement of the cable lug, washer and nut on each bolt when attaching the
cable to the bolt.
Tighten the nuts with a torque moment of 14Nm.
M8 BOLT
SUNSYNK
BUSBAR
M8 WASHER
CABLE LUG
Figure 3: correct mounting sequence DC wires.
Correct placement of the M8 cable lug, washer and nut.
Ground and Negative Connections
Connect the ground wire: this only applies if the system requires a ground connection. There should only be
one ground connection per system.
Ground connection.

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Connect the negative wires: remove the relevant access windows if the wire diameters exceed 10mm, as
shown below.
BREAK THIS ACCESS WINDOW
IF THE CABLES EXCEED 10MM DIA
BREAK THIS ACCESS WINDOW
FOR CABLES BELOW 10MM DIA
To reach the negative connections remove the wire guide shown below. The wire guide can be temporary
removed by removing the 4 screws from the Sunsynk Busbar.
FIXING SCREWS
WIRE GUIDES
Negative connection.

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Positive Connections
Before making any positive connections, make sure that the positive wires are not powered.
Disconnect all positive cables from the battery prior to connecting them to the Sunsynk
Busbar. This is to prevent accidental short circuits.
Connect all positive wires.
Power the Sunsynk Busbar system by connecting the positive battery pole(s).
Positive Connection.
COMMISSIONING THE SUNSYNK BUSBAR
Commissioning sequence:
Check polarity of all DC cables
Check cross sectional area of all DC cables
Check if all cable lugs have been crimped correctly
Check if all cable connections are tight (don’t exceed maximum torque)
Tug slightly on each battery cable to check if the connections are tight and if the cable lugs have been
crimped correctly.
TROUBLE SHOOTING AND SUPPORT
Consult this chapter in case of unexpected behaviour or if you suspect a product fault.
The correct troubleshooting and support process is to rst consult the common issues as described in
this chapter.
Should this fail to resolve the issue, contact the point of purchase for technical support.

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Cabling Issues
Cables heat up
This can be caused by a wiring or connection issue. Check the following:
Check if all cable connections are tightened with a torque moment of 14Nm.
Check if all fuse connections are tightened with a torque moment of 14Nm.
Check if the surface area of the cable core is large enough for the current through that cable.
Check if all cable lugs have been crimped correctly and are tight enough.
WARRANTY
This product has a 5 year limited warranty. This limited warranty covers defects in materials and
workmanship in this product and lasts for ve years from the date of original purchase of this product. To
claim warranty the customer must return the product together with the receipt of purchase to the point of
purchase. This limited warranty does not cover damage, deterioration or malfunction resulting from
alteration, modication, improper or unreasonable use or misuse, neglect, exposure to excess moisture, re,
improper packing, lightning, power surges, or other acts of nature. This limited warranty does not cover
damage, deterioration or malfunction resulting from repairs attempted by anyone unauthorised by Sunsynk
to make such repairs. Non-compliance with the instructions in this manual will render the warranty void.
Sunsynk is not liable for any consequential damages arising from the use of this product. The maximum
liability of Sunsynk under this limited warranty shall not exceed the actual purchase price of the product.
TECHNICAL SPECIFICATIONS
Power
Voltage Range 9 - 50Vdc
Current Rating 800A
Connections
Busbar M8
Physical
Enclosure Material ABS
Enclosure Dimensions (HxWxD) 165x245x75mm
Unit Weight 1.8kg
Busbar Material Tinned Copper
Busbar Dimensions (HxW) 8x30mm
Environmental
Operating Temperature Range -40°C to +60°C
Storage Temperature Range -40°C to +60°C
Humidity Max. 95% (Non-condensing)
Protection Class IP22

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Call us: [phone] Email us: [email protected]
HK Address: Room 702-704, 7/F Texwood Plaza, 6 How Ming Street,
Kwun Tong, Kowloon, Hong Kong.
UK Address: Sunsynk, 17 Turnstone Business Park, Mulberry Avenue,
Widnes, Cheshire, WA8 0WN.
SA Address: Globaltech Sunsynk South Africa (Pty) Ltd,
Unit 2 Highview Boulevard, Ferndale 2194.
NL Address: Sunsynk EU, Henri Wijnmalenweg 8,
5657 EP Eindhoven, Netherlands.