TE Connectivity SOLARLOK 1954283-1 User manual

Instruction Sheet
SOLARLOK* Combiner Box Assemblies 408--10271
LOC B
E2011 Tyco Electronics Corporation, a TE Connectivity Ltd. Company
All Rights Reserved
*Trademark
TE Connectivity, TE connectivity (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of their respective owners.
TOOLI NG ASSISTANCE CENTER 1--800--722 -- 1111
PRODUCT INFORMATION 1--800--522--6752
This controlled document is subject to change.
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03 MAY 11 Rev D1954283- 1 and 1954283- 2
Figure 1
Mounting Slot
(4 Places)
Front Top
Front Top
Knockout
(4 Places)
Lock
Tab
Cover Screws
(4 Places)
Cover
Negative SOLARLOK Connector
with Seal Cover (5 Places)
Positive SOLARLOK Connector
with Seal Cover (5 Places)
Hinge
(2 Places)
Box
Front Bottom
Y
B
Ground Assembly
1. INTRODUCTION
SOLARLOK Combiner Box Assemblies 1954283--1
and 1954283--2 are used to combine up to five strings
in a pre--terminated connectorized weather--resistant
enclosure to meet National Electric Code (NEC)
requirements for series fusing of photovoltaic (PV)
modules.
All numerical values in this instruction sheet are
in metric units [with U.S. customary units in
brackets]. Figures are not drawn to scale.
Combiner Box Assembly Specifications
System Voltage (DC): 600 V Maximum
Output Current (DC): 75 A Maximum
Continuous Current (DC): 60 A Maximum
Current Per String (DC): 15 A Maximum
Accepts Fuse Rating (DC): 15 A Maximum
Module Short Circuit Rating (Isc) Per String: 9.6 A Maximum
Weatherability Enclosure Type: NEMA Type 3
Ambient Temperature: 50_C [122_F] Maximum
Torque:
Negative Output Terminal 4 Nm [35 in.--lbs]
Positive Output Terminal
Wire Sizes 14--10 AWG 4 Nm [35 in.--lbs]
Wire Size 8 AWG 4.5 Nm [40 in.--lbs]
Wire Sizes 6--4 AWG 5.1 Nm [45 in.--lbs]
Ground Terminal Block 4 Nm [35 in.--lbs]
NEMA, National Electrical Code, and NEC are trademarks of their respective owners.
The combiner box assemblies meet the standards of
Underwriters Laboratories Inc. (UL) 1741 to be used
as an accessory for inverters.
Reasons for reissue of this instruction sheet are
provided in Section 5, REVISION SUMMARY.
IMPORTANT
SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This instruction sheet contains important instructions
for Assemblies 1954283--1 and 1954283--2 that must
be followed during installation and maintenance of the
power system.
Read and understand the following safety precautions
before installing or working with the combiner box
assembly.
— Wiring methods must comply with the National
Electric Code (NEC) and American National
Standards Institute (ANSI)/National Fire Protection
Association (NFPA).
— The DC input and DC output circuits are isolated
from the enclosure. System grounding, if required
by Section 250 of the NEC and ANSI/NFPA 70, is
the responsibility of the installer.
— The photovoltaic system grounding must be
installed according to the requirements of Sections
690.41 through 690.47 of the NEC, ANSI/NFPA
70, and is the responsibility of the installer.
— DO NOT work with the combiner box assembly
if it is attached to any live electrical source.
NOTE
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408- 10271
Rev D2 of 5
— A DC disconnect switch must be incorporated in
the installation in accordance with Article 690 of
the NEC.
— This non--metallic enclosure DOES NOT
provide grounding between conduit connections.
Use grounding--type bushings and jumper wires for
grounding the equipment.
— ALWAYS use insulated tools.
— ALWAYS disconnect the combiner box
assembly from loads; such as, moving the AC/DC
switches to off position and covering the solar cells
with opaque (dark) material, before connecting or
disconnecting SOLARLOK connectors or installing
or replacing fuses.
— ALWAYS disconnect SOLARLOK connectors
before working with the combiner box assembly.
— DO NOT connect or disconnect wires when
electrical current from SOLARLOK connectors or
external source is present.
— DO NOT work with the combiner box assembly
if it is wet.
— DO NOT alter the combiner box assembly in
any way.
WARNING: PV modules generate electricity when
exposed to light and can cause electrical shock or
burn. Multiple power sources could be present inside
the combiner box assembly, and hazardous voltages
could exist on exposed wiring and disconnected
terminals. Care must be taken not to touch live
terminals or conductive materials without personal
protection.
WARNING: There is a risk of electrical shock.
Normally grounded conductors may be ungrounded
and energized when a ground--fault is indicated.
2. DESCRIPTION
Each combiner box assembly consists of a box, cover
(with hinges), transparent dead front lid (under the
cover), and 10 pre--terminated SOLARLOK
connectors each with a removeable seal cover.
The box features 4 knockouts (for output wiring), a
lock tab, ground assembly, and mounting slots. See
Figure 1.
The interior of the box contains 5 fuse blocks
pre--wired to the positive SOLARLOK connectors,
5 terminal blocks pre--wired to the negative
SOLARLOK connectors, and an equipment ground
terminal block used to ground the equipment (if
required). Fuses are not included.
Each combiner box assembly accepts:
Output wire: copper wire sizes 14 through 4 AWG
with a maximum of 19 strands (conductor size
must be determined by the system designer with
respect to the NEC)
Use copper wire rated at 90_C [194_F] minimum
Input wire: (10) SOLARLOK connectors with wire
suitable for application (for field installation of
SOLARLOK connectors onto wire, refer to
instruction sheet 411--18305--1)
Conduit hub (fitting): trade size 21 mm [3/4in.] in
diameter (maximum outside diameter of 44.2 mm
[1.74 in.]) meeting standards of UL 514B —
required to maintain weather resistance for the
combiner box assembly
Use only UL Listed rain--tight or wet--location hubs
for entry into the enclosure
Fuse size: (qty: 5) 10 by 38--mm [13/32 by 11/2-- i n . ]
Midget/5AG form factor — consult with the PV
module manufacturer and refer to NEC Article 690
for appropriate fuse rating
Fuses must be UL Listed and have ratings of
600 VDC (minimum) and 15 A (maximum).
For PV systems, the NEC requires that all fuses
and wiring be sized for a minimum of 1.56 times
the short circuit current rating (Isc) of the PV
module used in the system, then rounded up to
the next standard fuse size. For example, if the
Isc of the PV module is 7.2 A, then the fuse size
would be 11.2 (1.56¢7.2). The next standard
fuse size would be 12 A.
3. INSTALLATION
WARNING: The combiner box assembly must be installed
and serviced by qualified personnel only.
Qualified personnel must be knowledgeable in
safety procedures for working with electricity.
Installation must be performed in compliance with
all applicable building and safety codes including
the NEC, ANSI/NFPA 70, and local utility
interconnection requirements.
3.1. Mount the Combiner Box Assembly
To avoid contact with electricity, DO NOT mount
the combiner box assembly if the combiner box
assembly is attached to any live electrical source.
1. Using a small flat blade screwdriver, remove
one of the knockouts to be used for output wire
(knockout located on the side of the combiner box
is preferred). Take care not to damage any of the
interior components while removing the knockout.
2. Mount the combiner box onto a planar surface
using the mounting slots (DO NOT drill holes into
the combiner box) and appropriate hardware:
stainless steel 1/4-- o r 3/8--in. bolts or screws with
washers. See Figure 2 for mounting dimensions.
NOTE
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408- 10271
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Figure 2
285 mm [11.2 in.]
168 mm
[6.6 in.]
9.6mm[.38in.](4Places)
Mounting Dimensions
90_Vertical
0_Horizontal
M
ou
n
t
i
n
g
A
n
g
l
e
Before system assembly is complete, ensure that:
a. the combiner box assembly and exposed
wiring is located in an area that is NOT readily
accessible, such as a roof top or behind a fence
or barrier, at least 0.914 m [3 ft] above ground
level
b. the location surface ranges from 0_horizontal
to 90_vertical
c. the combiner box assembly is oriented with
the hinges at the top, right, or left
d. there is enough clearance at the front and
above the hinges of the combiner box assembly
to open the cover and below the connectors for
mating and unmating connectors, and
approximately 25.4 mm [1 in.] on all 4 sides of
the combiner box assembly for ventilation
e. the location does not have continuous water
flow or extreme temperature changes
f. the location ambient temperature is a
maximum of 50_C [122_F]
g. the combiner box assembly is in the shade
(this is recommended)
After system assembly is complete, ensure that:
the combiner box and exposed wiring for
connection to the combiner box PV input strings
via the SOLARLOK connectors is located in an
area that is NOT readily accessible, such as a
roof top or behind a fence or barrier
3.2. Ground the Equipment (If Required)
Grounding the equipment is the responsibility of the
installer. Ensure that the ground wire is not nicked,
cut, or scraped.
Refer to Figure 3, and proceed as follows:
A size 8 AWG copper wire is installed between
the grounding assembly and the equipment
ground terminal block.
1. Remove the wire binding hex nut from the wire
grounding assembly.
2. Position the ground wire into the wire slot of the
ground bolt.
3. Thread the wire binding hex nut onto the ground
bolt. Finger--tighten the wire binding hex nut until
the wire is compressed.
4. Using a 9/16--in. open end wrench, hold the hex
body of the ground bolt, and using a 5/8--in. socket
wrench, tighten the wire binding hex nut to a torque
of 5.08 N--m [45 in.--lbs.].
For additional information on the wire grounding
assembly, refer to Instruction Sheet 408--10262.
Figure 3
Wire
Wire Slot of
Ground Bolt
Wire Binding
Hex Nut
Hex Body of
Ground Bolt
Optional Grounding
3.3. Connect Wiring and Install Fuses
1. Using a cross--recessed screwdriver, remove
the two cover screws opposite the hinge, then
remove the two remaining cover screws. Pivot the
cover open.
NOTE
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408- 10271
Rev D4 of 5
2. Using the screwdriver, remove the two screws
securing the transparent dead front lid; then
remove the transparent dead front lid. Refer to
Figure 4.
3. Install the conduit hub onto the conduit; then
install the hub onto the knockout opening of the
combiner box. Push the hub toward the floor of
the combiner box so that it will not interfere with
closing the cover of the combiner box; then tighten
the hub. Dress the output wires through the conduit
and into the combiner box.
The hub must be installed onto the conduit before
the hub is installed onto the knockout opening.
4. Strip the output wires to approximately 12.7 mm
[.50 in.].
5. Insert the positive wire into the positive output
terminal (located on the bus bar of the fuse
blocks); insert the negative wire into position 3
(center) negative output terminal located on the
terminal blocks (the negative wires are commoned
via the terminal block assembly); and, if required,
insert the ground wire into the equipment ground
terminal (located on the equipment ground terminal
block) — then using the screwdriver, tighten each
terminal screw to the torque indicated in Section 1.
SeeFigure4.
DO NOT use the terminal block as a system
ground. Use it only as an equipment ground
pass--through.
6. Install each fuse in the fuse blocks as follows:
pivot the fuse puller until it opens, insert the fuse
into the holder ensuring that the end sits in the
metal clip, then press the fuse puller down until it
snaps into place.
Fuses must be UL Listed and have ratings of
600 VDC (minimum) and 15 A (maximum).
7. Remove the seal covers, and retain. Connect
the SOLARLOK connectors (of input wiring) from
the PV modules to the appropriate SOLARLOK
connectors of the combiner box assembly.
3.4. Inspect and Close the Combiner Box Assembly
1. Inspect the combiner box to ensure the
following:
— all terminations are secure
— conduit hub (fitting)(s) is properly sealed
— connectors are fully mated
Figure 4
Screw (2 Places)
Securing Transparent
Dead Front Lid
Fuse Blocks
(Positive Wires)
Terminal Blocks
(Negative Wires)
Equipment Ground
Terminal
Positive Output
Terminal
Negative Output
Terminal
Equipment Ground
Terminal Block
Fuse Puller (5 Places)
SOLARLOK Connectors
(of Input Wiring) Connected
to SOLARLOK Connectors
(of Combiner Box Assembly)
Connecting Wire and Installing Fuses
Output Wires
Conduit
Ground Wire
NOTE
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408- 10271
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2. Re--install, and secure (using the two screws),
the transparent dead front lid. Tighten the screws
to a torque of 0.5 N--m [4 in.--lbs].
3. Close the cover, and secure it using the four
cover screws. Tighten the screws to a torque of
0.9N--m[8in.--lbs].
4. REPLACEMENT AND REPAIR
Components of the combiner box assembly are not
repairable. DO NOT use a damaged or defective
combiner box assembly. DO NOT alter any
components of the combiner box assembly.
Fuses (not included with the box) can be replaced.
Order replacement combiner box assemblies through
your representative, or call 1--800--526--5142, or send
a facsimile of your purchase order to 717--986--7605,
or write to:
CUSTOMER SERVICE (038--035)
TYCO ELECTRONICS CORPORATION
PO BOX 3608
HARRISBURG PA 17105--3608
5. REVISION SUMMARY
Revisions to this instruction sheet include:
SChanged fuse rating requirement in Section 2
and Step 6 of Paragraph 3.3