Helio Protection. Solar solutions designed by Ferraz Shawmut. Power generation & distribution.

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1 1 Helio Protection Solar solutions designed by Ferraz Shawmut Transportation Power conversion Power generation & distribution Industrial controls Power quality

2 2 A free, renewable and The boom in renewable energies Known reserves of fossil fuels today the world s main energy resource will be depleted by the end of this century if we don t change our ways. In addition, resolutions aimed at reducing the CO 2 emissions that are responsible for global warming, the Kyoto agreement among others, all encourage the development of environmentally friendly renewable energies: hydropower, wind power, biomass, geothermal, aerothermal and solar. Ferraz Shawmut Any installation, whether it s a stand-alone solar array with a back-up generator set or a grid-connected one, is vulnerable to fault currents or lightning. Today fuses and surge arresters are the most effective ways of protecting the wiring and all the electrical equipment in a PV system. But that protection must be designed, dimensioned, tested and adapted to the specific features of solar applications. At Ferraz Shawmut, the specialist in protection specially designed for power generation and distribution, we are showing our commitment to the development

3 Ferraz Shawmut Solar solutions 3 universal source of energy The beauties of photovoltaics What with rising gas and oil prices on the one hand, and incentives and tax breaks for a technology that is booming on the other, solar energy is on a roll. By 2020 installed capacity in solar power is expected to be near 300 GW, 50 times as much as in 2006! This type of system uses an entirely costfree, globally available energy source to generate electricity for use on the spot, or to sell to the grid. It s an extremely reliable process as long as it s properly protected! is committed of solar power with a dedicated range of products: junction boxes, fuses and surge arresters. Fuses shield the cables between strings of modules from damage. The faulty circuits are isolated and the system can keep on generating power. Ferraz Shawmut is the electrical protection division of the global Carbone Lorraine group, which is also involved in photovoltaics through production of the graphite for the molds used to make PV cells.

4 4 Fuses made to measure for At Ferraz Shawmut, the global specialist in protection for power generation and distribution systems, we have designed fuse solutions specifically for grid-connected PV powered systems. These pages will help you chose the solution that is the best match for your array. Operating principle PV powered systems consist of N number of strings connected in parallel, each string consisting of M modules (solar panels). The modules are series connected to generate the d.c. voltage necessary for operation of the inverter installed at the point of connection to the grid. PV array PV string cable PV string overcurrent protection device PV string disconnection device Power conditioning system Array with 1 to 3 strings of modules In this kind of system fault current is just barely higher than operating current. A fuse is not required. Dimensioning the cables between the strings of modules to withstand the maximum fault current is enough to avoid any fire hazard. Bypass diode PV module PV string Key Helio Box PV array jonction box PV array cable Elements that are not required in all cases Enclosure Boundary of system or sub-system PV array main switch PV solar panels inverter meter power grid Solar array connected to the grid Array with at least 4 strings of modules In this kind of configuration, the fault current which is still of much lower intensity than the short circuit current in classic grid supply systems can reach a level that could cause heating and damage insulation. To ensure the best possible protection for the system and any people working on the equipment, each string of solar panels must be protected with a fuse on each pole (such systems are not grounded).

5 Ferraz Shawmut Solar solutions 5 your solar application (grid-connected) Fuses to meet the specific requirements of photovoltaics Designed to clear low fault currents PV cells and panels are d.c. generators. Fuses used to protect loads powered by the alternating current in large grids react to very high fault currents, but the ones used in photovoltaics are very different. Ferraz Shawmut has taken a position on this fast-growing market with specific products that can clear fault currents as small as 2 to 3 times rated current and that takes cutting edge design and expertise. Tried and tested in real-life conditions Operating conditions for fuses are actually more severe when fault currents are low than when they are high, in a circuit where breaking is required under direct voltage. Melting times are long and breaking is arduous. So it is essential that every factor be checked exhaustively and in detail. Ferraz Shawmut has made that effort through extensive work at our labs in Newburyport (USA) and Saint-Bonnetde-Mure (France). Helio Helio is the brand name of the solar solutions designed by Ferraz Shawmut. The product offering dedicated to this booming market encompasses Helio Fuse, Helio Switch, Surge Trap and Helio Box. Helio Fuse calculation I n (A) 500 DC120 When a fault occurs in a DC circuit, the absence of natural voltage zero makes the interruption of DC faults more difficult than the interruption of AC faults as only the fuse arc will force the current to decrease to zero. The correct interruption depends on three parameters: the value of the DC voltage, the value of the ratio L/R (time constant) of the fault path and the value of the fault current. The possible low level of overload to be eliminated in photovoltaic equipment is a very arduous condition for a fuse! Consequently, special photovoltaic fuses Helio Fuses are designed by Ferraz Shawmut in order to ensure people safety and photovoltaic circuit protection. Necessary information to be collected by the photovoltaic designer: > The number M of modules in series in a chain. > The number N of strings in parallel > The reference values in Standard Test Conditions of the used module* Voc STC: open circuit voltage Isc STC: short circuit current * STC (Standard Test Conditions) = irradiance W/m 2, Air Mass 1.5, Cell temperature 25 C DCNH ATM / ATMR > General rule n 1: Taking the fact that the polarities + and - are never connected to the earth (neither one nor the other in a photovoltaic equipment) into account, each chain of modules has to be fitted with two fuses: one fuse on the positive output and also one fuse on the negative output of each chain. > General rule n 2: The rule n 1 has to be applied when the number N of chains in parallel is upper than or equal to 4. (for 1, 2, 3 parallel chains, the fusing is not necessary). DC10 DCT U DC (V) How to choose the correct range of fuses: The choice is done with the compliance of the subsequent rule: Maximum DC Operating Voltage of the fuse in the leaflet must be higher than or equal to 0 x M x (Voc STC). How to choose the correct rating of the fuse: A) Fuse current rating determination in Europe and others temperate areas. Rated current In of the fuse must be higher than or equal to 7 x Isc STC. B) Fuse current rating determination in Africa and Equatorial or tropical areas. Rated current In of the fuse must be higher than or equal to 1.51 x Isc STC.

6 6 Product offering HelioFuse DC VDC Minimum Breaking Capacity = 2 In ; Maximum Breaking Capacity = 50 ka Maximum operating Rated Current Cat. Number Packaging voltage L/R = 5 ms 5 DC10GC11C DC10GC11C DC10GC11C DC10GC11C L/R = 5 ms 16 DC10GC10C DC10GC10C20 10 Drawing P/P0,7In Electrical characteristics I/In In (A) Cat. Number Losses In 20 C 8 DC10GC10V DC10GC10V DC10GC10V DC10GC10V DC10GC10V Corrective factor for power losses vs. ambient temperature P(T)/P(20) Ta ( C) Fuse clips MR10 CI MR10 MR10 without compressor Cat. Number Designation Weight (g) Pack MR10RESSORTCI MR10 CI MR10RESSORT MR MR10RESSORTSP MR10 without compressor

7 Product offering HelioFuse DCT 1 000VDC Ferraz Shawmut Solar solutions 7 Minimum Breaking Capacity = 2In ; Maximum Breaking Capacity = 50 KA Maximum operating Rated Current Cat. Number Packaging voltage 1 = 2ms 5 DCT DCT DCT DCT DCT DCT * DCT * DCT * Minimum breaking capacity is 3In. Drawing Electrical characteristics P/P0,7In 1-1/2 (38.1 mm) 13/32 (10.3 mm) Cat. Number Watt 0.7In & 20 C DCT DCT DCT DCT DCT DCT DCT I/In DCT Corrective factor for power losses vs. ambient temperature Fuse holders P(T)/P(20) Cat. Number Number of poles Indicator Packaging Udc maxi operating US101 1 No V US101I 1 Yes V US102 2 No V US102I 2 Yes V For more than 700VDC operating voltage light indicator for fuse melting operation consult us Ta ( C) Note: U/L recognized voltage are 800VAC and 1 000VDC Datas for ambient temperature : 20 C Wire range: rigid wire = 1-16mm 2 (18-6 AWG) Multistrand wire = mm 2 (18-8 AWG) Ferraz Shawmut recommands to use screwdrivers PZ 2 or Flat 5.5 x 1mm (maximum diameter 6mm / maximum tightening torque : 2.5Nm (22Ib-in) IR for fuses: 500V IEC - 690V IEC - 700V UL Fuse clips > Refer to the side page. > H models for PC mount in option.

8 8 Product offering HelioFuse ATMR 600VDC Minimum Breaking Capacity = 1.35In ; Maximum Breaking Capacity = 100kA Max.Operating Voltage = Rated Voltage Rated Current Cat. Number Packaging 600VDC 5 ATMR ATMR8 10 L/R = 10ms 10 ATMR ATMR ATMR ATMR ATMR30 10 For UL fuses, the maximum operating voltage is equal to the rated voltage. Drawing P/P0,7In Electrical characteristics I/In Cat. Number Watt 0.7In & 20 C ATMR ATMR ATMR ATMR ATMR ATMR25 7 ATMR30 9 Corrective factor for power losses vs. ambient temperature P(T)/P(20) Ta ( C) Fuse holders Cat. Number Number of poles Indicator Packaging Udc maxi operating USBCC101 1 No V USBCC101I 1 Yes V USBCC102 2 No V USBCC102I 2 Yes V

9 Product offering HelioFuse ATM 600VDC Ferraz Shawmut Solar solutions 9 Minimum Breaking Capacity = 1.35In ; Maximum Breaking Capacity = 100kA Max.Operating Voltage = Rated Voltage Rated Current Cat. Number Packaging 600VDC 5 ATM ATM8 10 L/R = 10ms 10 ATM ATM ATM ATM ATM30 10 For UL fuses, the maximum operating voltage is equal to the rated voltage. Drawing P/P0,7In /2 (38.1 mm) 13/32 (10.3 mm) Electrical characteristics I/In Cat. Number Watt 0.7In & 20 C ATM ATM ATM ATM ATM ATM25 7 ATM30 9 Corrective factor for power losses vs. ambient temperature P(T)/P(20) Ta ( C) Fuse holders Cat. Number Number of poles Indicator Packaging Udc maxi operating US101 1 No V US101I 1 Yes V US102 2 No V US102I 2 Yes V For more than 700 V DC operating voltage light indicator for fuse melting operation consult us.

10 10 Product offering HelioFuse DCNH 600VDC Minimum Breaking Capacity = 2In ; Maximum Breaking Capacity = 50 KA Maximum operating voltage Rated Current Size Cat. Number Packaging 50A 00 DC00GS60V050PV 3 L/R = 2ms 63A 00 DC00GS60V063PV 3 80A 00 DC00GS60V080PV 3 100A 00 DC00GS60V100PV 3 125A 1 DC1GS60V125PV 3 160A 1 DC1GS60V160PV 3 L/R = 2ms 200A 1 DC1GS60V200PV 3 250A 1 DC1GS60V250PV 3 280A 1 DC1GS60V280PV 3 Size A B C H L M N P R T Drawing P/P0,7In I/In Electrical characteristics Cat. Number Watt 0.7In & 20 C DC00GS60V050PV 4.35 DC00GS60V063PV 4.85 DC00GS60V080PV 5.65 DC00GS60V100PV 6.35 DC1GS60V125PV 9.0 DC1GS60V160PV 10 DC1GS60V200PV 11 Corrective factor for power losses vs. ambient temperature P(T)/P(20) Ta ( C)

11 Ferraz Shawmut Solar solutions 11 Accessories Cat. Number Contact Qty of NO-NC separated circuits Packaging MSNH2-B6PRES Mini = 20V 50mA Maxi = 10A 1 3 MSNH2-B2PRES Mini = 20V 100mA Maxi = 5A 1 3 Remote signalling system for fitting on fuses equipped with micro-switch support. Fuse bases Cat. Number Fuse size Nb of poles Packaging Model Udc maxi operating BB001RFS IP2X Finger Safe 690V BB11PPRFS including cover 690V Dimensions (mm) A B C D E F G H I J K L M N O Size Size , , M ,5 146

12 12 HelioFuse Product offering DC VDC Minimum Breaking Capacity = 2In; Maximum Breaking Capacity = 100kA Rated voltage Rated Current Size Cat. Number Packaging 50A 120 DC120GC12C050EF 1 63A 120 DC120GC12C063EF 1 80A 120 DC120GC12C080EF VDC L/R = 1ms 100A 121 DC121GC12C100EF 1 125A 121 DC121GC12C125EF 1 160A 121 DC121GC12C160EF 1 200A 121 DC121GC12C200EF 1 250A 121 DC121GC12C250EF VDC L/R = 1ms 315A 122 DC122GC11C315EF 1 Drawing 97.5 with MC2R 3E 82.5 with MCR 3E 67.5 with MC 3E with MC2R 3E 91 with MCR 3E 76 with MC 3E avec MC2R 3E 87.5 avec MCR 3E 72.5 avec MC 3E 121

13 Ferraz Shawmut Solar solutions 13 Electrical characteristics Cat. Number Watt 0.7In & 20 C DC120GC11C050EF 3.4 DC120GC11C063EF 4.4 DC120GC11C080EF 5.6 DC120GC11C100EF 7.0 DC120GC11C125EF 8.8 DC120GC11C160EF 11.3 DC121GC11C200EF 15.7 DC121GC11C250EF 19.6 DC122GC11C315EF 24.3 P/P0,7In I/In Corrective factor for power losses vs. ambient temperature P(T)/P(20) Accessories Cat. Number Contact Qty of NO-NC separated circuits Packaging MC3E1-5N Mini = 20V 50mA 1 1 & 3 Maxi = 5A MC3E1-5NBS Mini = 10V 10mA 1 1 & 3 MC3E1-9NBS Maxi = 3A 2 1 & Ta ( C) Remote signalling system for fitting on fuses equipped with micro-switch support. P G C* Fuse bases A D B H L F Cat. Number Nb of poles Packaging Insulation Voltage SP N M S R E SE SE VDC P Q G P Q G C* C* D D H H A M B A M B N E N E F S R F S R L L Cat. Number Drawing A B C* D E F G H L M N P Q Ø R Ø S SP SE SE

14 14 Product offering Surge Trap Surge Protective Device (Thermally Protected) for PV applications. The Surge-Trap PV provides advanced overvoltage protection to photovoltaic systems by utilizing Ferraz Shawmut s patented TPMOV design, which does not require additional over-current protection due its high short circuit withstand. The Surge-Trap PV is designed to be mounted on 35mm DIN-rail while featuring individual mode visual indication and optional remote indication, providing status to critical control circuits. Technical Features Test Class According to IEC and EN UL 1449 Recognized Component ST600PV ST600PVM* Part Number Type / Class II + III ST1000PV ST1000PVM* UL nd Edition File E Poles 2 3 Technology TPMOV Type of Network Photovoltaic Maximum Continuous Operating Voltage DC U c 670VDC 1 120VDC Nominal Voltage U n 600VDC 1 000VDC Maximum Discharge Current (8/20 µs) I max 50kA Nominal Discharge Current (8/20 µs) I n 20kA Voltage Protection Level U p < < Degree of Protection IP20 Mounting On Wire Range Terminal Torque 35mm DIN Rail #6 to #14 AWG Wire / 16mm 2 to 2.5mm 2 Wire 65 / 70 C Copper Wire Only lb in / 1.67 N m Response Time t A < 25ns Energy Absorption W max 960 J 1820 J Operating Temperature -40 C to +60 C Overcurrent Protection * Built-in microswitch for remote indication No Overcurrent Protection Required Connection / Circuit Diagrams for ST PV, PVM: ST600PV, ST600PVM ST1000PV, ST1000PVM Product Dimensions for ST: ST600PV, ST600PVM ST1000PV, ST1000PVM Connection of Remote Monitoring for ST: Visual Indication Tab Remote Signal Contact Terminal Designations Remote Contact Connection Diagram NO 1 NC 2 Common 3 Subminiature Switch 125 VAC - 3A max -25 C to 85 C Signal Wire Range: #16 to #30 AWG Terminal Torque: 1.8Ib-in

15 Ferraz Shawmut Solar solutions 15 Product offering HelioBox HelioBox Junction Wiring & connecting recommandations Number of string 4 à 6 6 à 8 8 à 12 Nominal Voltage Wire cable section for the strings Closed stuffing box size 1000VDC 4 mm² reinforced isolation PG9 (6 to 10 mm) Finger safe protection (IEC 60529) IP 55 Isolation Class (IEC 60364) Fire and fumes class (UL94 - NFC ) Dimensions (HxLxP) 305x225x129 (mm) Colour RAL 7035 Cable wire recommanded for output 10 mm² (PGxxx) 16 mm² (PGxxx) 25 mm² (PGxxx) Maximum usage temperature - 20 C to + 50 C Maximum storage temperature - 20 C to + 70 C Relative Humidity Weight Labelling All connections must be made by personnel qualified to work at voltages over 50V We recommend wiring the output from the box before the input to the box Max tightening torque = 2.2Nm on output terminals We recommend installing fuses and closing the disconnector handle before making input connections Max tightening torque = 2.2Nm on input terminals All connections must be made under stable weather conditions (no rain or lightning) II V2 95% Maxi ATTENTION: Permanent VOLTAGE higher than 50V Permanent DC voltage equipment Disconnection and Protection DO not open under load Start to connect the outpout Mount fuses and close the fuse holder before input connection Define your catalog number HelioBox Junction (HBJ): Define your Catalogue Number HBJ S Option 1 Option 2 Option 3 Option 4 Option Number Description Cat. Number Example 1 Number of strings connected to your Junction box The Catalogue Number of the selected fuse holder. (in that documentation) 3 Selected the requested surge protection level if any. 1000V or 600V 4 If visual indication requested: > See Through cover and US10I or USBCCI US10 USBC Sxxxx V SXXX (S10C or S60V) For a 6 strings connected application HBJ06 For DCT20 fuses HBJ06US10 For a ST1000PV selected, HBJ06US10S10C 1 HBJ06US10S10CI HelioBox Main: Also available up on request, the Main protection box is connected to the converter. It is composed of DCNH or DC12X fuses together with a switch disconnect presented in next page of this catalogue. Please contact our technical support ( ) for further questions. ts@fr.ferrazshawmut.com

16 16 Product offering Helio Switch Voltage Rating (VDC) Current Rating (A) Catalog Number 63 IT63HEL75VCF IT160HEL75VCF IT200HEL10CCF IT250HEL10CCF IT315HEL10CCF IT400HEL10CCF 1 rue Jean Novel Villeurbanne cedex - France Tél. 33 (0) Fax 33 (0) Merrimac Street Newburyport, MA USA Tél. (978) Fax (978) Tél HE002-05/2008