YASKAWA DCR-1500 User manual

DCR-1500 RE-COMBINER
User’s Manual
www.solectria.com
Copyright 2021 Yaskawa Solectria Solar 10-05-2021

Yaskawa Solectria Solar DOCR-071068-E age 2 of 18
CONTENTS
1. IM ORTANT SAFETY INSTRUCTIONS ...........................................................................................................3
2. RODUCT OVERVIEW ......................................................................................................................................4
3. RATINGS AND S ECIFICATIONS ....................................................................................................................6
3.1 Specifications ..............................................................................................................................................6
3.2 Temperature De-Rating ..............................................................................................................................7
Safe Design and Operation Guidelines...................................................................................................................7
4. MECHANICAL DETAILS ....................................................................................................................................8
5. INSTALLATION and WIRING .......................................................................................................................... 10
6. O ERATING INSTRUCTIONS ....................................................................................................................... 16
7. WARRANTY & RMA INSTRUCTIONS ............................................................................................................ 17
8. A ENDICES .................................................................................................................................................. 17
FI URES
2.1 Illustrated Usage of the DCR-1500 Re-Combiner in the SOLECTRIA VS-500 Energy Storage System
2.2 The DCR-1500 DC Re-Combiner Components
3.1 DCR-1500-500 Temperature De-Rating Curve
4.1 Front and Back of the VS-500 Rack-Mounted Equipment: AC Combiner, DC Re-Combiner, and three
XGI 1500 Inverters (factory wiring not shown)
4.2 Front and Back of the VS-500 Rack-Mounted Equipment: AC Combiner, DC Re-Combiner, and three
XGI 1500 Inverters (factory wiring not shown)
5.1 Specs for Field Wiring to the DCR-1500 Re-Combiner
5.2 Bottom face of the Re-Combiner, showing the area for conduit connections for the V circuits, the factory-
wired Communications Cable, and the Inverter and DC/DC Converter conduits (all dimensions in
millimeters)
5.3 V Output Circuit Conductors Terminations
5.4 Single and Dual Conductor Terminations
5.5 Dyna ower DC/DC Converter Conductor Terminations
5.6 Dynapower DC/DC Converter Conductor Termination
6.1 Re-Combiner Switches On/Off ositions
TABLES
3.1 DCR-1500 Re-Combiner Ratings and Specifications
5.1 Specs for Field Wiring to the DCR-1500 Re-Combiner

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1. IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
The SOLECTRIA DC Re-Combiners come in two models: DCR-1500-500 and DCR-
1500-250. They are referred to here as the DCR 1500 Re-Combiners, and are
exclusively compatible with the SOLECTRIA VS-500 Energy Storage System. The
DCR-1500 Re-Combiner is only sold as a component part of the VS-500 DC-Coupled
Energy Storage System and is not for use in any other application.
opulate the DC Re-Combiner with 2 - 5 V Circuits.
Before using the DCR-1500 Re-Combiner, please read all instructions and caution
markings in this manual and on the Re-Combiner, as well as all other instructions and
warnings for associated equipment.
This manual contains important instructions that must be followed during installation and
operation of the DCR-1500 Re-Combiner. To reduce the risk of electrical shock and to
ensure the safe installation and operation of the Re-Combiner, the following safety
symbols are used to indicate dangerous conditions and important safety instructions.
WARNIN
Could Injure
Personnel or
Damage Equipment
Instructions
for Qualified
Personnel Only
Positive
Connection
Point Symbol
Negative
Connection
Point Symbol
round
Connection
Point Symbol
DC Electrical
Connection
Point Symbol
WARNIN : Disconnect all V modules or completely cover the surface of all V
modules with opaque (dark) material before wiring. V arrays produce dc voltage when
exposed to light and could create a hazardous condition. Always verify the absence of
voltage before performing work on the Re-Combiner.
WARNIN : Connecting V output circuits to the input of the Re-Combiner and making
the connection to the Dynapower DC/DC Converter (D S-500 or D S-250) and battery
subsystem, must only be done after receiving approval from the utility company and
AHJ, and should only be performed by qualified persons.
WARNIN : The DCR-1500 Re-Combiner is designed and listed for use exclusively as a
component in the SOLECTRIA VS-500 DC-Coupled Energy Storage System; the DCR-
1500 Re-Combiner must not be used in any other application.

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2. PRODUCT OVERVIEW
The DCR-1500 Re-Combiner functions as the DC bus in the SOLECTRIA VS-500 DC-
Coupled Energy Storage System and is designed and listed exclusively for use in the
SOLECTRIA VS-500. Refer to the illustration in Figure 1.1 showing its general usage
within the SOLECTRIA VS-500.
Figure 2.1 – Illustrated Usage of the DCR-1500 Re-Combiner in the
SOLECTRIA PVS-500 Energy Storage System
The DCR-1500 Re-Combiner (see Fig 2.2) performs the following basic functions:
(1) PV Output Circuit Connections:
 Disconnect switches for 5 separate V Output Circuits (originating in Solectria
CR1500-400 V Source Circuit Combiners located in the V array field)
 rovisions on the disconnect switches for field-wired connections
 Overcurrent protection fuses
 Connection from all V Output Circuits to the DC bus in the Re-Combiner
(2) Solectria X I 1500 Inverter Connections:
 Connection from the main DC bus to overcurrent protection sized expressly
for the three XGI 1500 inverters.
 Terminal blocks for the factory wiring connections from the Re-Combiner to
the three XGI 1500 inverters.
(3) Dynapower DC-DC Converter (DPS-500 or -250) Connections:
 Factory pre-made internal connections.
 Overcurrent protection and a connection to the main DC bus. Note that a dc
switch is located between the Dynapower DC-DC Converter and the storage
subsystem.
(4) IMI Functionality: the DC Re-Combiner contains
 Sensors and circuitry for the XGI 1500 inverters’ Isolation Monitor Interruptor
functionality
 Factory-wired communications cable from the IMI circuitry to each of the XGI
1500 inverters

Yaskawa Solectria Solar DOCR-071068-E age 5 of 18
Figure 2.2 - The DCR-1500 DC Re-Combiner Components
400A DC DISCONNECT SWITCHES
FOR V OUT UT
CIRCUITS
V OUT UT CIRCUIT
400A DC DISCONNECT
SWITCHES 5x
400A FUSE
5x
250A FUSES 3x
FOR INVERTERS
800A FUSE* for
DC/DC equipment
COMMS
CBA
IMI SENSORS
5x
V CIRCUIT
EQUI MENT
GROUND 5x
INVERTERS &
DC/DC
EQUI MENT
GROUND
TERMINALS
INVERTER CONNECTIONS COM LETED IN
THE FACTORY
(*400A fuse used with D S-250. Single fuse
is standard; features included for parallel-
connection of fuses)
NEGATIVE WIRING
TO INVERTERS
WIRING TO
INVERTERS

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3. RATIN S AND SPECIFICATIONS
3.1 Specifications
DCR-1500-500, DCR-1500-250 SPECIFICATIONS
PV OUTPUT CIRCUITS (FIELD WIRED from PV Source Circuit Combiners)
Maximum Wire Size Compatibility
Cu: 1 or 2 cond, 500 kcmil; 1 cond, 750 kcmil
Al: 1 or 2 cond, 500 kcmil; 1 cond, 750 kcmil
EGC: 14 AWG – 2 AWG
Overcurrent rotection 400A Fuse, positive polarity only
Maximum Voltage 1500 VDC
Maximum Current
(Maximum Current per circuit depends on
the number of V Output Circuits
connected)
DCR-500 DCR-250
Combined 1,093 A 609.1 A
Indiv Ckt (5) 219 A 122 A
Indiv Ckt (4) 273 A 152 A
Indiv Ckt (3) 273 A 203 A
Indiv Ckt (2) 305 A 305 A
ositions 5 V Output Circuit ositions (switch & fuse)
DC Disconnect Switch Integrated 400A, 2-pole, 1500 VDC
X I 1500 INVERTERS (F CTORY PRE-WIRED and tested)
Wire Size Conductors: 4/0 AWG Cu
EGC: 4 AWG Cu
Overcurrent rotection 250A fuse; positive polarity only
Maximum Voltage 1500 VDC
DC-DC CONVERTER (FIELD-WIRED)
Maximum Wire Size Compatibility
Note: 2 conductors per pole (+ & -)
Cu: 2 cond, 500 kcmil
Al: 2 cond, 500 kcmil
EGC: 1/0 AWG Cu, or 3/0 AWG Alum
Overcurrent rotection
D S-500: 800A
D S-250: 400A
ositive polarity only
DC-DC Converter: DC Disconnect Switch Located on the DC-DC Converter
MECHANICAL, ENVIRONMENTAL, SAFETY
Ambient Temperature Range -40°F to 140°F (-40C to +60C)
Safety Certification & Listing / Certification
Agency Intertek, UL1741
Standard Warranty 5 Years standard; 10 Year optional
Enclosure Dimensions
Height: 43.3 in. (1100 mm)
Width: 74.8 in. (1900 mm)
Depth: 6.65 in. (169 mm)
Enclosure Rating, Material, Weight Type 3R, olyester owder-Coated Aluminum
192 lbs (87 kg)

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3.2 Temperature De-Rating
The DC Recombiner, DCR-1500-500, has a combined current rating of 1,093 Amps.
This rated combined current is subject to temperature de-rating as in Figure 3.1 below.
Fig. 3.1 DCR-1500-500 Temperature De-Rating Curve
Safe Design and Operation uidelines
 Design the V subarrays to be identical: same V modules, same number of modules in a
source circuit, and the same number of source circuits in parallel.
 opulate the DC Re-Combiner with 2 - 5 V Circuits.
 When shutting down the V Array for any reason, turn off all five V subarrays at the Re-
Combiner. DO NOT disconnect a single subarray at any time.
To maintain safe operation of the DC Re-Combiner, users should
follow these guidelines.
0
200
400
600
800
1000
1200
0 10 20 30 40 50 60 70
Combined Current Rating (A)
Ambient Temp (C)
Temperature De-Rating Cur e

Yaskawa Solectria Solar DOCR-071068-E age 8 of 18
4. MECHANICAL DETAILS
The DCR-1500 Re-Combiner comes pre-integrated as a component in the Solectria
VS-500 DC-Coupled Storage System. See Figures 4.1 – 4.3. The VS-500 comprises
an engineered rack that holds the DCR-1500 Re-Combiner, three XGI 1500 inverters,
the AC anel, and a lant Master Controller (not shown). Except for the required field-
wiring connections, the components on the rack are pre-wired and tested in the factory.
AC COMBINER
Fig. 4.1 Front and Back of the VS-500 Rack-Mounted Equipment: AC
Combiner, DC Re-Combiner, Controller and ower Supply, and three
XGI 1500 Inverters (factory wiring not shown)

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1940
1900
225
V CIRCUIT
SWITCHES
5x
1100
9 x 20 SLOT
3x
510.5
781
1940
LIFTING EYE
2X
Fig. 4.2 Re-Combiner Dimensions (mm), Front, Side and Bottom Views

Yaskawa Solectria Solar DOCR-071068-E age 10 of 18
5. INSTALLATION and WIRIN
Completing the installation of the Re-Combiner (see Figure 5.1) requires: (1) field wiring from
the (up-to-five) V Output Circuits, originating in CR1500-400 V Source Circuit Combiners in
the V array field, to the terminals in the Re-Combiner and (2) field wiring from the terminals in
the DCR to the terminals in the Dynapower DC/DC Converter. In addition, the Re-Combiner has
two factory pre-wired connections: DC power from the Re-Combiner to the DC input of the XGI
1500 inverters, and the communications wiring harness that also connects the Re-Combiner to
the XGI 1500 inverters. Figure 5.1 shows the maximum wire compatibility for the field-wired
connections, and the as-delivered factory-wired conductor specifications.
Figure 5.1 – Specs for Field Wiring to the DCR-1500 Re-Combiner
STEP 1: Disconnect all Equipment Before Wiring to the Re-Combiner
BEFORE removing the Re-Combiner’s covers:
 Open all five DC switches on the Re-Combiner, and
 Open the DC switch between the Dynapower DC/DC Converter and the Battery
Subsystem, to disconnect the batteries from the system.
Do not attempt to make connections to the Re-Combiner if not qualified for
electrical work.
FACTORY
PRE
-
WIRED
To XGI 1500 inverters
4/0 AWG Cu conductors
EGC: 4 AWG Cu
FIELD
-
WIRED
From D S-500 (or -250)
Max 500 kcmil Cu conductors
2 per pole
EGC: 1/0 AWG Cu
FIELD
-
WIRED
From V Source Circuit Combiners
Max: 2 cond x 500 kcmil per pole, Cu or Alum or
1 cond x 750 kcmil per pole, Cu or Alum
EGC: 3 AWG Cu, or 1 AWG Alum
FACTORY
PRE
-
WIRED
Comms wiring harness
to XGI
1500 inverters

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STEP 2: De-Energize the PV Conductors
PV arrays can create hazardous
DC
voltages. Do not attempt to connect
the PV circuits to the Re-Combiner until all PV conductors are confirmed
to be de-energized.
1. Use a multi-meter to check for DC voltage and confirm that the V Output Circuit
conductors, coming from the CR1500-26-20S-400 V Source Circuit Combiners in
the array field, are de-energized.
2. If DC voltage is present, locate the V Source Circuit Combiners and open all DC
disconnect switches, then re-measure.
3. DO NOT ROCEED until the conductors are confirmed to be de-energized.
STEP 3: Prepare the Enclosure for Conduits
1. Remove the left-side cover from the Re-Combiner; save all fasteners for later re-
installation.
2. Note the target area for conduit connections for the V circuits on the bottom face of
the Re-Combiner, as shown in Figure 5.2.
3. Add the necessary holes for the conduits for V Output Circuit entries. The Re-
Combiner accepts up to 5 separate V Output Circuits.
4. Be sure to remove any metal shavings and debris from the inside of the Re-
Combiner.
Figure 5.2 – Bottom face of the Re-Combiner, showing the area for conduit
connections for the PV circuits, and the area with the factory-wired
Communications Cable, and DC +/- to the X I 1500 Inverters. All dimensions in
millimeters.

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SPECIAL INSTRUCTIONS
PRECAUTIONS FOR ALUMINUM WIRE AND CONDUIT SEALIN
Aluminum Conductors
When using aluminum conductors, follow these steps to prepare the conductors.
1. repare one wire at a time.
2. Remove the appropriate insulation from the wire.
3. Using a wire brush, remove the oxidized outer layer from the aluminum
conductors.
4. Immediately apply a neutral dielectric grease, such as Ideal NOALOX
®
anti-
oxidant compound, and connect the aluminum cable to the terminal.
5. If the connection is not made within 30 seconds of applying the compound,
repeat this process, as an oxidized layer may have formed on the conductor.
Conduit Connections
Follow these instructions and best practices when securing conduits to the Re-
Combiner.
1. Use UL514B certified water-tight conduit fittings and proper installation methods
to provide a water-tight connection that will maintain the Type 3R rating of the
enclosure.
2. Use an appropriately-rated sealant and seal the conduits fully to prevent the
exchange of air between the conduit and the enclosure. Sealing the conduit will
help prevent condensation in the enclosure.
Aluminum oxidizes quickly when exposed to the atmosphere. An oxidized
layer is a poor conductor that could lead to thermal issues, production loss,
or damage to the Re-Combiner.
Conduits connected to an outdoor enclosure can introduce water vapor into
the enclosure and lead to the formation of condensation inside. Failure to
follow these guidelines can result in water intrusion into the unit through the
conduit connections and may void the warranty.

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STEP 4: PV Output Circuit Wiring Terminations in the Re-Combiner
The V Output Circuit conductors terminate on tabs extending from the DC switch. The
tabs are factory-supplied with dual studs to maintain conductor alignment. Figure 5.3
illustrates the terminations and the sections below identify the relevant specifications.
Note that users must supply the Crimp Lug and Fasteners as defined.
Figure 5.3 – PV Output Circuit Conductors Terminations
Lugs
Compression lugs are NOT provided with the DCR Re-Combiner. The lugs must
conform to the specifications given in the table below:
Conductors
Conductor Termination
Lug Type
Plating
&
Material
Max. Tongue
Width Hole Size
Temp
Rating
Two-Hole Tin lated Cu 1.95 in for M8 stud 90C
Max distance from hole center to end of lug 14 mm
Max Allowable Conductor Size
Cu or Alum, 90C temp rating
1 or 2 cond at 500 kcmil
1 cond at 750 kcmil
Fasteners
(Supplied)
A: 8mm flanged nut, SS
Torque: 90 in-lb (10 Nm)
Dual Conductors
Crimp Lugs
Single Conductor
Crimp Lug
A
Fig. 5.4 – Single and Dual Conductor Terminations
ositive polarity conductors (red wires in Fig 5.3) connect to a fuse.
Confirm polarity and fuse connection for positive conductors.
A

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STEP 5: DynaPower DC/DC Converter Conductor Termination
The Re-Combiner provides terminals for the conductors to the Dynapower DC/DC
Converter. The user is responsible to route, secure and properly terminate these
conductors to the Dynapower DC/DC Converter.
Conductors
Max Input / Output
Current
D S-500: 500 A
D S-250: 312.5A
DC Re-Combiner No.
of Terminals
2 per pole
(2 pos, 2 neg)
Terminals
Negative: 2 x 8mm Stud
40mm wide plate
ositive: 2 x 10mm Stud
35mm wide plate
Max Conductor
Recommendation
350kcmil, 90C rated
2 per ole
Fig. 5.
5
–
DynaPower
DC/DC Converter
Conductor
Terminations inside the Re-Combiner
See the Dyna ower DC/DC Converter Installation User Manual for making
connections to that unit.
NE ATIVE
POSITIVE

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STEP 6: Equipment round Wiring
Terminals are provided in the Re-Combiner for all Equipment Grounding Conductors
(EGCs) associated with the V Source Circuits, Dyna ower DC/DC Converter and XGI
1500 inverters. NOTE: the Re-Combiner comes from the factory with the XGI 1500
inverters and Dynapower DC/DC Converter Equipment Ground Conductors pre-wired to
ground lugs. Torque each EGC for the V Source Circuits per the specifications below.
PV Equipment round Lugs (5x)
14 AWG – 2 AWG
Torque to 20 in-lb, Slotted Screw
Cu or Al Conductors
Final Steps
Verify the proper polarity of each conductor. olarity reversal can lead to dangerous
conditions capable of harming personnel and equipment.
Check the Re-Combiner for tools and debris; ensure that the unit is clean and orderly.
1. Verify that all connections meet the requirements of this User’s Manual.
2. Secure the Re-Combiner cover, ensuring that all fasteners are in place.
3. Consult the startup and commissioning procedures for the VS-500 before energizing.

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6. OPERATIN INSTRUCTIONS
Fig. 6.1 – Re-Combiner Switches On/Off Positions
The Re-Combiner contains five user-operable disconnect switches for the V Output
Circuit inputs (see Fig. 6.1). When the disconnect switch handle is in the OFF position, the
circuit is open between the V Output Circuit and the DC bus in the Re-Combiner.
Conversely, when the disconnect switch is in the ON position, the circuit is closed between
the V Output Circuit and the DC Bus in the Re-Combiner.
The disconnect switch is rated for 400A, is fully load-break rated and can be safely
operated under normal operating conditions when installation is per this User’s Manual
and all warnings and ratings are observed.
All Disconnect Switches must be OFF before working on the Re-Combiner.
See also the User’s Manual for the PVS-500 Energy Storage System.
90
°
OFF
ON

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7. WARRANTY & RMA INSTRUCTIONS
For warranty information, please visit: http://solectria.com/support/documentation/warranty-
information/grid-tied-inverter-warranty-letter/
8. APPENDICES
Appendix A – Contact Information
Yaskawa Solectria Solar
360 Merrimack Street
Building 9, Suite 221
Lawrence, MA 01843 USA
Tel: [phone]
Fax: [phone]
Sales/General Info: [e-mail]
Customer Support: 978-683-9700 x2
Website: www.solectria.com

Yaskawa Solectria Solar DOCR-071068-E age 18 of 18
Appendix B - UL1741 Authorization to Mark