Weidmüller PV DC COMBINER BOX User manual

PV DC COMBINER BOX
Operating instructions

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Contents
1 About this documentation 4
1.1 Target group and contents 4
1.2 Symbols and notes 4
2 Safety 5
2.1 General safety notice 5
2.2 Intended use 5
2.3 Personnel 5
2.4 Legal notice 5
3 Device description 6
3.1 Product overview 6
3.2 Enclosure 8
3.3 DC Switch 8
3.4 Surge protection device (SPD) 8
3.5 Fuse holders 8
3.6 Fuses 9
3.7 Terminals 9
3.8 Conductors 9
3.9 Input terminals 9
3.10 String monitoring device (optional) 10
3.11 Power supply for string monitoring 10
3.12 General technical data 11
4 Transport and storage 12
4.1 Transporting 12
4.2 Unpacking the delivery 12
4.3 Storage 12
4.4 Establishing connections 12
5 Installation 13
5.1 Installation site 13
5.2 Positioning of the combiner box 13
5.3 Fixation 14
5.4 Installing the combiner box 14
5.5 Inserting the fuses 18
5.6 Connection of the inputs 18
5.7 Connection of the outputs 19
5.8 Connection of the grounding cable 20
6 Connection of the communications (optional) 21
6.1 Wiring the communications 22
6.2 Connecting the RS485 to the Transclinic 22
6.3 CongurationoftheModbusaddressandtheRS485serial
settings 25
6.4 Recommendations when using serial converters 25
6.5 RecommendationswhenconguringtheSCADA 26
7 Commissioning 27
7.1 Mainindicationsandchecks 27
7.2 Start up 28
8 Accessories and replacing parts 29
8.1 Replacing fuses 29
8.2 Replacing a switch disconnector 29
8.3 Replacing string monitoring devices 29
8.4 Replacing surge protection arresters 29
9 Cleaning 31
10 Maintenance and Service 32
10.1 Maintenace 32
10.2 Service 33
Manufacturer
Weidmüller Interface GmbH & Co. KG
Klingenbergstraße 26
32758 Detmold, Germany
T [phone]
F [phone]
www.weidmueller.com
Document no. 4000001903
Revision 00/April 2020

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1.1 Target group and contents
This user manual is intended to personnel that is involved
in mechanical and electrical installation of a Weidmüller
PV DC COMBINER BOX and moreover to service and
maintenance personnel.
This user manual gives the general overview about the
complete range of PV DC COMBINER BOX, the individual
components, their function as well as their correct handling.
An individual datasheet providing the specic information
is attached to each combiner box. These information speci-
es the original features of each combiner box.
1.2 Symbols and notes
The warnings in this documentation are structured di󰀨er-
ently depending on the severity of danger.
DANGER
Imminent risk of life!
Notices with the signal word "DANGER" warn
you of situations which will result in serious
injury or death if you do not follow the instruc-
tions given in this manual.
WARNING
Possible risk of fatality!
Notices with the signal word "WARNING"
warn you of situations which may result in
serious injury or death if you do not follow the
instructions given in this manual.
CAUTION
Risk of injury!
Notices with the signal word "CAUTION"
warn you of situations which may result in in-
jury if you do not follow the instructions given
in this manual.
ATTENTION
Material damage!
Notes with the signal word "ATTENTION" warn you about
hazards which may result in material damage.
The situation-dependant safety notices may contain the
following warning symbols:
Symbol Meaning
Warning against hazardous electrical voltage
Warning against explosive atmospheres
Warning against electrostatically charged
components
Instruction: observe the documentation
Additional formatting is used in the rest of the text which
has the following meaning:
Text items next to this arrow constitute informa-
tion which is not related to safety, but which pro-
vides important information regarding correct and
e󰀨ective work.
► You can recognise handling instructions from the black
triangle in front of the text.
– Lists are indicated with dashes.
Before start working with the product, read the
documentation completely!
Keep the manual as well as the attached data
sheet stored so that it can be inspected by op-
erating personnel at any time.
The document is available to download from
the Weidmüller website.
1 About this documentation

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2 Safety
This section includes general safety instructions for
handling the PV DC COMBINER BOX. Specic warning
notices for specic tasks and situations are given at the ap-
propriate places in the documentation. Failure to observe
the safety and warning notices can result in damage to per-
sons and material.
2.1 General safety notice
Proper transport, storage, installation, commissioning, op-
eration and maintenance are required to ensure that the
products operate safely and without any problems.
The permissible ambient conditions must be observed.
Ensure protection against unauthorised opening. Unauthor-
ised persons must neither open nor operate the combiner
box.
Photovoltaic systems can generate hazardous voltages.
Two di󰀨erent ways of service activities are allowed on
these products:
– "Working under voltage": Only electricians who have a
qualication for working under voltage are allowed to
carry out service activities under voltage. Observe the
local regulations and make use of appropriate personal
protective equipment.
– "Working without voltage": Electricians and trained per-
sons are allowed to carry out work without voltage, when
input and output connections are safely disconnected
and secured against re-connection. Observe the local
regulations and make use of appropriate personal pro-
tective equipment.
Before connecting the cables to the input connectors,
make sure that the fuses are not inserted and that the open
circuit voltage of the corresponding string is equal to the
other strings.
Do not extract or insert fuses under load. Before manipu-
lating a fuse make sure there is no reverse current owing
into the corresponding string.
If the installation regulations are violated, all warranty and
liability claims are void.
If a malfunction on a combiner box cannot be xed after
following the recommended measures, the product in ques-
tion must be sent back to Weidmüller. Weidmüller does not
assume any liability if the product has been tampered with.
2.2 Intended use
The PV DC COMBINER BOX series are intended for use
in photovoltaic (PV) systems. The product joins di󰀨erent
strings of a PV system and contains DC over-current and
over-voltage protections for string level. String monitoring
devices are provided optionally.
Weidmüller products may only be used for the applications
described in the catalogue and in the relevant technical
documentation. If products and components from other
manufacturers are used, these must be recommended or
approved by Weidmüller.
The observance of the documentation is part of the intend-
ed use.
2.3 Personnel
All activities described in this document may
only be carried out by specialists and instruct-
ed persons with the following qualications:
– Knowledge of the functionality and principle
of PV systems
– Training in handling dangers and risks dur-
ing installation and handling electrical devic-
es and systems
– Knowledge of applicable standards and
guidelines
– Knowledge and observance of these oper-
ating instructions and the safety instructions
contained therein
It is a common practise in the sector to apply the ve safety
rules described in the standard EN 50110. Anyway, quali-
ed electricians must analyse case by case on each instal-
lation the best way to proceed with safety.
The ve safety rules are the following:
1. Disconnect completely
2. Secure against re-connection
3. Verify that the installation is dead
4. Carry our earthing and measures against short-cir-
cuiting
5. Provide protection against adjacent live parts
2.4 Legal notice
The PV DC COMBINER BOX is CE-compliant in accord-
ance with Directive 2014/35/EU (Low Voltage Directive)
and with Directive 2014/30/EU (EMC Directive).

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3 Device description
Figure 3.1 Product range
3.1 Product overview
PV DC COMBINER BOX is a complete range of tai-
lor-made Level 1 combiner boxes for utility-scale photovol-
taic systems. The combiner boxes are installed to join and
protect the DC strings that go from the PV panels to the
solar inverter.
The PV DC COMBINER BOX product range o󰀨ers solu-
tions from 8 to 32 inputs and 1 or 2 outputs. These can
be designed for systems with string voltage of 1000 or
1500 V DC.
The necessary string cables (+ and -) are to be connected
at the inputs whereas one or two DC+ and DC- main ca-
bles will be at the output side. The output cables must be
connected to a Level 2 combiner box, which will join DC+
and DC- from other Level 1 combiner boxes, or directly to
the solar inverter.
Parameters inuencing the selection of the optimal
PV DC COMBINER BOX
– Ambient temperature
– Degree of protection needed
– DC voltage range
– ISC of the PV string
– DC earthing system
– Number of inputs
– Number of outputs
– Fuses in one or both poles (by default in both poles)
– Type of surge protection (by default Type II SPD)
– Type of input terminals (by default multivia cable glands)
– String monitoring (if yes: single or pair monitoring)

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Device description
5
1
3
4
2
6
Figure 3.2 Main components of the PV DC COMBINER BOX (exam-
ple)
1 DC Switch
2 String monitoring device Transclinic 16i+ (optional)
3 Output DC+/-
4 Ground terminal
5 Fuse holders
6 InputDC+/-(cableglands,alternativelyWM4Cconnectors)

Device description
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3.2 Enclosure
The enclosure of the PV DC COMBINER BOX is made
of Glass Fibre Reinforced Polyester (GFRP). The en-
closure provides IP65 and IK07 or higher in accordance
with IEC 62208. Each enclosure is equipped with hinged
door(s).
Figure 3.3 Enclosure
3.3 DC Switch
Figure 3.4 DC switch
The PV DC COMBINER BOX has a DC disconnection
switch by default. The DC voltage of the switch depends on
the voltage of the PV string. The switch disconnector mak-
ing and breaking capacity (according to the IEC 60947-3)
has been selected to assure that it can switch the circuit at
full load at the maximum operating temperature.
3.4 Surge protection device (SPD)
Figure 3.5 Surge protection device
The surge protection device has been selected corre-
sponding to the customers requirements and in accord-
ance with the standard for low-voltage surge protective
devices IEC 61643-32.
Special units for 1 kV or 1.5 kV are used to provide the
best performance in each specic system conguration.
3.5 Fuse holders
Figure 3.6 Fuse holders
The fuse holders provide the interconnection between the
string input cables and other elements inside the combiner
box. The fuse holders ensure that the fuses are placed in
the optimum position to perform their protection function.
Additionally, the type of fuse holders (IP 2X) enable the au-
thorised personnel to operate the fuses in a safe manner.
These products allow multiple setups which helps to build
up specic tailor-made solutions of PV combiner boxes.

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Device description
3.6 Fuses
Figure 3.7 Fuse
The fuses protect the PV strings against over-current situ-
ations. The PV DC COMBINER BOX is provided with gPV
fuses in accordance with IEC 60269-6:2010.
Each design of combiner box contains the most suitable
fuse rating specially selected for each project, depending
on Isc of PV strings, on voltage rating and on ambient tem-
peratures.
To assure the best performance of the complete solution,
PV DC COMBINER BOX is delivered with fuses, optional
without.
ATTENTION
Material damage!
Only use fuses with silver plated end-caps. If you have to
replace a fuse inside a PV DC COMBINER BOX, use the
same type of fuses delivered with the original combiner
box. Pay special attention to the voltage and current rate
as well as the size and material.
3.7 Terminals
Figure 3.8 Terminals
The fuse holder terminals allow to connect the string ca-
bles safely.
3.8 Conductors
To realise the connections regard the following conductor
specications:
Stripping length (regard the tolerances below) 18 mm
Clamping range, min. / max. 0.5 mm2... 16 mm2
WireconnectioncrosssectionAWG,min./max. AWG20...AWG4
Solid H05(07) V-U, min. / max. 0.5 mm2... 16 mm2
Stranded H07V-R, min. / max. 6 mm2... 16 mm2
Flexible H05(07) V-K, min. / max. 0.5 mm2... 16 mm2
Wire end ferrule with plastic collar, DIN 46228-4, min. / max. 0.5 mm2... 16 mm2
Wire end ferrule, DIN 46228-1, min. / max. 0.5 mm2... 16 mm2
Plug gauge acc. to EN 60999 a x b; Ø 5.3 mm (B6)
Conductor cross section Tolerance of stripping length
< 4 mm2± 1 mm
6 – 10 mm2± 1.5 mm
> 16 mm2± 2 mm
In order to assure a reliable connection we re-
commend to use appropriate crimping tools, as
an example PZ 10 HEX (Order No.1445070000).
Please check the Weidmüller product catalogue
to select the appropriate tool.
3.9 Input terminals
A B
Figure 3.9 Cable glands (A) and WMC 4 connectors (B)
The PV DC COMBINER BOX is equipped either with cable
glands or with special photovoltaic connectors WMC 4.
The WMC 4 connectors reduce the installation time as well
as the maintenance time. They fullll the DIN EN 50521
and are TÜV certied.
The cost-e󰀩cient cable glands on the other hand allow the
installer to adjust the necessary number of cables even in
the eld.

Device description
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3.10 String monitoring device (optional)
Figure 3.10 String monitoring device Transclinic 16i+
In case the PV DC COMBINER BOX is equipped with a
string monitoring device, this device is a Transclinic 16i+
1k5 HP with PUSH-IN terminals.
This device simplies the connection work inside the
combiner box and reduces maintenance tasks due to the
PUSH IN terminals. The Transclinic 16i+ can operate at full
load (25 Amps) at maximum temperature range (+70 ºC).
3.11 Power supply for string monitoring
Figure 3.11 Power supply for string monitoring device
The string monitoring device is supplied by a Transclin-
ic BKE DC/DC power supply device. Depending on the
maximum voltage the device is a Transclinic BKE 1k0.4
(≤ 1000 V DC) or a Transclinic BKE 1k5.4 (≤ 1500 V DC).