PHOTOVOLTAIC SOLUTIONS. Operating instructions. String Connection Box SCB

Transcription

1 PHOTOVOLTAIC SOLUTIONS Operating instructions String Connection Box SCB

2

3 TABLE OF CONTENTS 1 GENERAL INFORMATION General information about this document Features of the device Basic variant Optional equipment variants Type identification - Design code of device Scope of Supply Operator's responsibilities Pictograms and symbols used SAFETY Qualification of personnel Purpose of the SCB Warning information on product Modifications Safety provisions DESCRIPTION OF PRODUCT Arrangement of housings of SCB series Series SCB A Series SCB A Series SCB A The individual housings of SCBs Housing +E Housings +E1, +E2, +E Housing +S Overview of overall PV plant (example) Technical data (800 Volt variant) Technical data (1000 Volt variant) Transport INSTALLATION Mechanical Installation Electrical Installation EMC Information Metric cable glands Connection of protective earth conductor Connection of TCP/IP data cable (option) Connection of auxiliary voltage /10 Operating instructions SCB 1

4 4.2.6 Connection of DC strings Connection of DC main cables COMMISSIONING Fuses Determination of fuses Installation of fuses Switching SCB on TROUBLESHOOTING For all device configurations Additionally, for devices with "Monitoring" option Additionally, for devices with "contact monitoring" option Visual inspection of individual elements Housing +S Housing +E CLEANING MAINTENANCE AND SERVICE STORAGE DISPOSAL Operating instructions SCB 01/10

5 1 General information This documentation describes the device String Connection Box (SCB). The SCB is a "photovoltaic generator connection box" for connecting several strings (solar module strings) to an inverter. Depending on the design, the SCB additionally offers features ports for monitoring the measured values of the individual strings (Monitoring option). In this document, the product SCB is hereinafter referred to the "device". 1.1 General information about this document The present documentation was prepared with great care and it was subjected to extensive and repeated reviews. For reasons of clarity, it is not possible to include all details of all types of the product in the documentation. Neither was it possible to consider all conceivable installation, operation or maintenance situations. If you require further information or if you meet with specific problems which are not dealt with in sufficient detail in the documentation, contact your local BONFIGLIOLI agent. We would also like to point out that the contents of this documentation do not form part of any previous or existing agreement, assurance or legal relationship. Neither are they intended to supplement or replace such agreements, assurances or legal relationships. The manufacturer's obligations are exclusively specified in the relevant purchase contract. This contract also contains all and any warranty regulations which may apply to the relevant scope of supply. These contractual warranty provisions are neither extended nor limited by the specifications contained in this documentation. The manufacturer reserves the right to correct or amend the specifications, product information and omissions in these operating instructions without notice. The manufacturer shall not be liable for any damage, injuries or costs which may be caused by the aforementioned reasons. 1.2 Features of the device Each device consists of a basic variant and optional equipment variants. The design of the device is indicated on the delivery note. Alternatively, refer to the type designation on the rating plate Basic variant All devices feature: String connection terminals Fuse holders in negative and positive pole DC load circuit breaker Overvoltage protection Optional equipment variants In addition to the features of the basic variant, the following options can be selected: Blocking diodes to prevent reverse currents in modules and string lines Current measurement plus Ethernet/analog gateway Current measurement plus Ethernet/analog gateway and monitoring of signal contacts (circuit breakers and protection systems) 01/10 Operating instructions SCB 3

6 1.2.3 Type identification - Design code of device The type identification is indicated on the rating plate. The rating plate is indicated both on the right outside on the housing of the device and inside the housing +E0 (housing of DC circuit breaker) at the bottom of the housing Layout of rating plate For specifications of the different SCB types, refer to chapter "Technical data". 4 Operating instructions SCB 01/10

7 The type identification is made up of 7 elements. SCB A 08 2F D S8S M C Contact survey C = With contact monitoring - = Without contact monitoring Monitoring M = With monitoring - = Without monitoring Design S8S = 800 Volt DC load circuit breaker S1S = 1000 Volt DC load circuit breaker Blocking diodes D = With blocking diodes to prevent reverse currents in modules - = Without blocking diodes to prevent reverse currents in Fuse protection 2F = Two-pole fuse protection Number of strings 08 = 8 strings 16 = 16 strings 24 = 24 strings String Connection Box SCB A = String Connection Box Series A Examples: Rating plate identification SCB A 24 2F D S1S M - SCB A 08 2F - S8S M C Meaning String Connection Box A, 24 strings, two-pole fuse protection, with blocking diodes to prevent reverse currents in modules and string lines, 1000 Volt DC load disconnector, with monitoring, without contact monitoring. String Connection Box A, 8 strings, two-pole fuse protection, without blocking diodes to prevent reverse currents in modules and string lines, 800 Volt DC load disconnector, with monitoring, with contact monitoring. 01/10 Operating instructions SCB 5

8 1.3 Scope of Supply Note Using the delivery note, check the received goods for completeness. Inform the supplier and/or the forwarding agent immediately of any incomplete or damaged deliveries. Damaged devices must not be installed in any case. The scope of supply depends on the design of the device. The design of the device is indicated on the delivery note. Alternatively, refer to the type designation on the rating plate. Included: Design SCB A 08: Design SCB A 16: Design SCB A 24: 2 or 3 housings, connected to each other on installation brackets. All necessary, metric cable glands. 3 or 4 housings, connected to each other on installation brackets. All necessary, metric cable glands. 4 or 5 housings, connected to each other on installation brackets. All necessary, metric cable glands. Not included: Fuses (Rated fuse current depends on the plant and must be calculated specifically, see chapter Commissioning) Installation tools. Auxiliary material for installation. 6 Operating instructions SCB 01/10

9 1.4 Operator's responsibilities The operator of the device must ensure that all persons having access to the SCB have read and understood the following chapter on safety. The documentation must be available to these persons at any time. 1.5 Pictograms and symbols used The following pictograms and signal words are used in the documentation: Danger! Danger refers to an immediate threat. Non-compliance with the precaution described may result in death, serious injury or material damage. Warning refers to a possible threat. Non-compliance with the warning may result in death, serious injury or material damage. Caution! Caution refers to an indirect threat. Non-compliance may result in personal or material damage. Attention! Attention refers to a possible operational behavior or an undesired condition that can occur in accordance with the reference text. Note Note marks information that facilitates handling for you and supplements the corresponding part of the documentation. 01/10 Operating instructions SCB 7

10 2 Safety The following information includes important safety instructions to be followed by anybody having access to the SCB. Read this chapter and all safety instructions in the individual chapters completely. Only carry out any work with or at the device once you are certain that you have understood all the information correctly. If in doubt, consult your superior or the manufacturer. Danger! Danger of fatal electric shock! Very high DC voltage of solar panel is present permanently. The load circuit breaker only disconnects the connection to the inverter. Never touch electric contacts. Light arcs may develop if the installation is performed incorrectly or improperly. In any case, only use the specified components and follow the installation instructions exactly. The device carries high voltage according to its degree of protection. Any unauthorized removal of the necessary covers, improper use, wrong installation or operation may result in serious injuries or material damage. In order to avoid such injuries or damage, only qualified technical staff may carry out the transport, installation, commissioning, setup or maintenance work required. The device may only be accessible to authorized staff. Unauthorized opening and improper interventions can lead to personal injury or material damage. Repairs on the SCB may only be carried out by the manufacturer or persons authorized by the manufacturer. Check protective equipment regularly according to chapter Service and Maintenance. Any repair work may only be carried out by qualified electricians. Any repair work may only be carried out using original spare parts. Original spare parts are available through the Bonfiglioli customer service. The technical data, connection specifications and information on ambient conditions are indicated on the rating plate and in the documentation and must be complied with in any case. Anyone involved in any kind of work at the device must have read the instructions carefully and understood them before starting the work. Only use correctly dimensioned fuses. The rated current of the fuses must be calculated for each plant separately. For information on how to calculate the rated current, refer to chapter Installation. The device must be used in accordance with the documentation as well as the applicable directives and standards. It must be handled carefully and protected against mechanical stress. Do not bend any components or change the isolating distances. Do not touch electronic components or contacts. The devices are equipped with components which are sensitive to electrostatic energy and can be damaged if handled improperly. Any use of damaged or destroyed components shall be considered as a non-compliance with the applicable standards. 8 Operating instructions SCB 01/10

11 Do not remove any warning signs from the device. 2.1 Qualification of personnel The personnel must be familiar with the installation, assembly, commissioning and operation of the device and the possible hazard sources, and must have the qualification required for the work. In detail, these qualifications include: Mechanical installation of device: Trained fitter with basic electrical skills Electrical installation of device: Trained electricians Commissioning of device: Trained electricians 2.2 Purpose of the SCB The device may only be used for the purpose and in the way described in this documentation. In accordance with the CE labeling requirements, the device meets the requirements of the Low Voltage Directive 2006/95/EC and the electromagnetic compatibility requirements of 2004/108/EC as per the following standards: Applied standards EN EN EN Description Electronic equipment for use in power installations Electromagnetic compatibility Generic standards - Immunity for industrial environments Electromagnetic compatibility Generic standards - Emission standard for industrial environments The technical data, connection specifications and information on ambient conditions are indicated on the rating plate and in the documentation and must be complied with in any case. Anyone involved in any kind of work at the device must have read the instructions carefully and understood them before starting the work. Any use other than the use described above, will be considered as not in accordance with the specified purpose and may result in the warranty becoming null and void. 2.3 Warning information on product Warning of dangerous electric voltage Don't open unless authorized. Additionally, in SCB with blocking diode: Warning of hot surface 01/10 Operating instructions SCB 9

12 2.4 Modifications Any kind of modifications of the SCB are prohibited. 2.5 Safety provisions Note The device can be switched on and off under load via the load circuit breaker. As a standard, the device features: Fuse holders in negative and positive pole DC load circuit breaker (according to system voltage) Overvoltage protection facility (up to 1000 V) With the Monitoring option, the device additionally features: Overvoltage protection for Ethernet network Overvoltage protection for switching power supply Fuse provision for switching power supply (2 A fuse, semi time-lag) With the Contact Monitoring option, the device additionally features: Auxiliary contact for DC load circuit breaker Auxiliary contact for 1000 V overvoltage protection Auxiliary contact for control voltage overvoltage protection 10 Operating instructions SCB 01/10

13 3 Description of product Each SCB comprises several housings each of which contains different assemblies. Housings (+E0) and (+E1) are standard components of each device of series "SCB A". Housings (+E2) and (+E2) increase the number of available strings. Housing Main assemblies Remarks +E0 DC load circuit breaker DC output Included in all SCBs. +E1 8 DC inputs Included in all SCBs. +E2 8 DC inputs Included in SCB-16 und SCB-24 +E3 8 DC inputs Included in SCB-24 +S1 Monitoring Optional Device series Housing with DC inputs Number of DC inputs SCB-8 +E1 8 SCB-16 +E1 and +E2 16 SCB-24 +E1 and +E2 and +E3 24 In the following the arrangement of the housings in the SCB series is shown, with all components installed. 3.1 Arrangement of housings of SCB series Series SCB A 08 +E0 +E1 +S1 Here: Shown with Monitoring option (Housing +S1). 01/10 Operating instructions SCB 11

14 3.1.2 Series SCB A 16 +E2 +E0 +E1 +S1 Here: Shown with Monitoring option (Housing +S1) Series SCB A 24 +E3 +E2 +E0 +E1 +S1 Here: Shown with Monitoring option (Housing +S1). 12 Operating instructions SCB 01/10

15 3.2 The individual housings of SCBs Housing +E0 A2 A1 A1 DC load circuit breaker A2 Auxiliary contact 01/10 Operating instructions SCB 13

16 3.2.2 Housings +E1, +E2, +E3 B2 B3 B4 + B1 B5 B1 String connection terminals on fuse holder B2 Current measuring transducer board B3 DC busbar system Only in housing +E1: B4 DC overvoltage protection B5 Venting device 14 Operating instructions SCB 01/10

17 3.2.3 Housing +S1 C2 C3 C4 C1 C6 C5 C1 Connection terminals for auxiliary voltage, including fuse C2 Overvoltage protection for control voltage C3 Switching power supply for generation of auxiliary voltage C4 Ethernet gateway with extensions (e.g. digital interfaces, analog interfaces) C5 Connection terminals for network C6 Overvoltage protection for network 01/10 Operating instructions SCB 15

18 3.3 Overview of overall PV plant (example) 16 Operating instructions SCB 01/10

19 3.4 Technical data (800 Volt variant) DC input Max. permissible DC input voltage I MPP per string (recommended) for variants without blocking diodes I MPP per string (recommended) for variants with blocking diodes Max. I SC per string for variants without blocking diodes Max. I SC per string for variants with blocking diodes Type SCB A 08 2F-S8S-- SCB A 16 2F-S8S-- SCB A 24 2F-S8S-- Unit 800 V 11 (in case of 20A fuse; otherwise depending on chosen rated fuse current) 8,8 (in case of 16A fuse; otherwise depending on chosen rated fuse current) 14 (in case of 20A fuse; otherwise depending on chosen rated fuse current) 11,2 (in case of 16A fuse; otherwise depending on chosen rated fuse current) Number of DC inputs per pole max. 8 max. 16 max. 24 String fuses PV fuses gr Rated fuse current Calculation according to design, see chapter Determination of fuses A Rated string fuse current 2 20 A Fuse dimensions 10x38 mm Grounding terminal 16 mm² String input terminal, crosssection 1-10 mm² Outer diameter of connecting cable see chapter min. 4.5 / max mm Torque of string connection 1,5 Nm DC output Max. U DC 800 V Max. output current A A A A A Output terminal, copper link with hole diameter Max. connectable tubular cable lug Outer diameter of connecting cable Torque of DC output cable mm M8 x 16, not insulated, (M8 at DC circuit breaker up to 200 A) M8 x 16, not insulated, 150 min / max (M8 at DC circuit breaker up to 200 A) M8 x 16, not insulated, (M10 at DC circuit breaker up to 315 A) mm² mm Nm 01/10 Operating instructions SCB 17

20 AC input auxiliary voltage Input voltage range 100 (-15%) 240 (+10%) V Frequency range Hz max. input current <2 A Device protection fuse Size 5 x 20, AC 250 V Rated fuse current 2A M (semi time-lag) Outer diameter of connecting cable min. 9,0 / max. 17,0 mm Communication Protocol type Specification of network cable Length of network cable (at 100 MBit/s) Outer diameter of connecting cable TCP/IP CAT5, Twisted-pair, shielded max. 100 min. 6,0 / max. 13,0 m mm Dimensions Width incl. installation bracket Height incl. installation bracket Depth incl. installation bracket mm mm mm Weight kg Ambient conditions Permissible ambient temperatures General information Housing Load circuit breaker Overvoltage protection Degree of protection as per EN Protection class as per EN Cable entry C UV-resistant, weather-proof, glass fiber reinforced polycarbonate, RAL 7035 (light grey) Use category DC 21B DC side: Class II C Low voltage 230 V: Class II C LAN interfaces according to Class D (Cat 5) IP 65 without blocking diodes: 2 with blocking diodes: 1 Metric cable glands 18 Operating instructions SCB 01/10

21 3.5 Technical data (1000 Volt variant) DC input Max. permissible DC input voltage I MPP per string (recommended) for variants without blocking diodes I MPP per string (recommended) for variants with blocking diodes Max. I SC per string for variants without blocking diodes Type SCB A 08 2F-S1S-- SCB A 16 2F-S1S-- SCB A 24 2F-S1S-- Unit 1000 V 11 (in case of 20A fuse; otherwise depending on chosen rated fuse current) 8,8 (in case of 16A fuse; otherwise depending on chosen rated fuse current) 14 (in case of 20A fuse; otherwise depending on chosen rated fuse current) A A A Max. I SC per string for variants with blocking diodes 11,2 (in case of 16A fuse; otherwise depending on chosen rated fuse current) Number of DC inputs per pole max. 8 max. 16 max. 24 String fuses PV fuses gr Rated fuse current Calculation according to design, see chapter Determination of fuses A Rated string fuse current 2 20 A Fuse dimensions 10x38 mm Grounding terminal 16 mm² String input terminal, crosssection 1-10 mm² Outer diameter of connecting cable see chapter min. 4,5 / max. 13,0 mm Torque of string connection 1,5 Nm DC output Max. U DC 1000 V Max. output current A A Output terminal, copper link with hole diameter Max. connectable tubular cable lug Outer diameter of connecting cable Torque of DC output cable mm M8 x 16, not insulated, (M8 at DC circuit breaker up to 200 A) M8 x 16, not insulated, 150 min / max (M8 at DC circuit breaker up to 200 A) M8 x 16, not insulated, (M10 at DC circuit breaker up to 315 A) mm² mm Nm 01/10 Operating instructions SCB 19

22 AC input auxiliary voltage Input voltage range 100 (-15%) 240 (+10%) V Frequency range Hz max. input current <2 A Device protection fuse Size 5 x 20, AC 250 V Rated fuse current 2A M (semi time-lag) Outer diameter of connecting cable min. 9,0 / max. 17,0 mm Communication Protocol type Specification of network cable Length of network cable (at 100 MBit/s) Outer diameter of connecting cable TCP/IP CAT5, Twisted-pair, shielded max. 100 min. 6,0 / max. 13,0 m mm Dimensions Width incl. installation bracket Height incl. installation bracket Depth incl. installation bracket mm mm mm Weight kg Ambient conditions Permissible ambient temperatures General information Housing Load circuit breaker Overvoltage protection Degree of protection as per EN Protection class as per EN Cable entry C UV-resistant, weather-proof, glass fiber reinforced polycarbonate, RAL 7035 (light grey) Use category DC 21B DC side: Class II C Low voltage 230 V: Class II C LAN interfaces according to Class D (Cat 5) IP 65 without blocking diodes: 2 with blocking diodes: 1 Metric cable glands 20 Operating instructions SCB 01/10

23 3.6 Transport Attention! Don't turn device upside down. The device may only be transported in horizontal position and in an appropriate way. During transport and storage the device must remain in its original packaging. If the device shows visible signs of transport damage, it must not be installed nor commissioned. Please check the received goods for correct quality, material and type immediately. Obvious defects such as exterior damage of the packing and/or the unit must be notified to the sender within seven days for insurance reasons. Caution! The device is heavy. At least two persons are required for transport. If the device is to be transported over longer distances, use appropriate lifting tools and transport equipment. 01/10 Operating instructions SCB 21

24 4 Installation The device is installed in two work steps: First, the mechanical installation, then the electrical installation. To avoid serious physical injury or considerable material damage, only qualified people may install the devices. During assembly, make sure that no foreign particles (e.g. chips, dust, wires, screws, tools) can get inside the device. Otherwise there is the risk of short circuits and fire. The device complies with the specified degree of protection only if the covers, components and terminals are mounted properly. 4.1 Mechanical Installation The device is exclusively designed for permanent vertical installation on a bearing wall or a special installation panel. Attention! During installation, both the installation and the safety instructions as well as the device specifications must be complied with, refer to chapter 3.4 Technical data (800 Volt variant) and chapter 3.5 Technical data (1000 Volt variant). The device must not be installed in residential and office rooms. Existing escape routes must not be blocked, and there must be escape routes to enable withdrawing from the device quickly. The device must not be installed near combustible materials. Caution! The device is heavy. At least two persons are required for transport and installation. Caution! Mount the devices with sufficient clearance to other components so that the cooling air can circulate freely. Avoid soiling by grease and air pollution by dust, aggressive gases, etc. Caution! Devices equipped with blocking diodes have a heat sink mounted on the outside. Ensure that no mechanical loads act on the heat sink. The device may only be mounted on a hardly inflammable base. Overhead installation is not permissible. Install the device such that all cables and lines are at the bottom. 22 Operating instructions SCB 01/10

25 Ensure sufficient protection against wind, moisture, snow load and direct sun impact. If necessary, build a roof over the device. Note In case the device is installed in closed rooms, we recommend installing smoke detectors. The mechanical installation must always be completed before the electrical installation, taking the following steps: 1. Identify place of installation, considering the following points: - Device must be installed at working height. - Ensure good accessibility and safe foothold near the device. - Ensure sufficient protection against wind, moisture, snow load and direct sun impact. SCB SCB SCB SCB 2. Transport device to place of installation. 3. Screw installation bracket (A) of the device on rails with 9 mm holes as shown in the drawing. Fix the device exclusively using all fixing points provided. For the dimensions of the SCBs and the holes, refer to the following illustrations. Recommendations for bolts: M8 x 25. A A 01/10 Operating instructions SCB 23

26 SCB A 08 SCB A Operating instructions SCB 01/10

27 SCB A Mount external strain relief / cable clamp rail. Note Cable clamp rail not included in scope of supply. 01/10 Operating instructions SCB 25

28 4.2 Electrical Installation Danger! Danger of electric shock Before starting any installation work: Use personal protective equipment. Some components may be hot during operation. Switch off load circuit breaker and then open all fuse holders additionally. Before any assembly or installation work, disconnect the device from power supply. Verify safe isolation from power supply. In any case, ensure that no moisture (rain, snow) may enter into the device; take appropriate protective measures, if necessary. The electrical installation must be performed in the following order: 1. Connection of protective earth conductor, refer to chapter4.2.3 Connection of protective earth conductor. 2. Connection of TCP/IP data cable (option), refer to chapter Connection of TCP/IP data cable (option). 3. Connection of auxiliary voltage, refer to chapter Connection of auxiliary voltage. 4. Connection of DC strings, refer to chapter4.2.6 Connection of DC strings. 5. Connection of DC main cables, refer to chapter Connection of DC main cables. The electrical installation must be carried out by qualified electricians according to the general and regional safety and installation directives. The documentation and device specification must be complied with during installation. Before any assembly or connection work, disconnect the device from power supply. Verify safe isolation from power supply. Do not touch live terminals. Only connect suitable voltage sources. The nominal voltage of the device must correspond to the supply voltage. The device must be connected to ground potential. Housing +E0 (load circuit breaker) may only be opened when all other housings are fully closed EMC Information The devices are designed according to the requirements of generic standard EN with an interference immunity factor for operation in industrial applications. Electromagnetic interference is to be avoided by expert installation and observation of the specific product information. Measures Keep the cables as short as possible, make sure that cables are installed properly using appropriate cable clamps, etc Metric cable glands General information In order to ensure the protection class and tightness of the device all cables entering the device housings must be sealed at the cable entry point using metric cable glands. 26 Operating instructions SCB 01/10

29 Attention! Only use the supplied cable glands. Use of other cable glands may result in the cable entry points not being sealed properly and loss of protection class. Attention! Each cable must be provided with its own cable gland. Never direct more than one cable through a cable gland. This may result in the cable entry points not being sealed properly and loss of protection class. Attention! Never open more cable entry points than required for feeding the necessary cables into the device. Never leave openings at the flange plate open. This may result in the cable entry points not being sealed properly and loss of protection class. Any cable entry points which are not needed must be sealed tightly using filler plugs (not included in scope of supply) Specifications of metric cable glands Purpose Type Tightness range/ strain relief mm Hex. wrench width mm Length of thread mm String cable (variant 1) M16 x 1.5 4, String cable (variant 2) M20 x 1.5 6, Data cable M20 x 1.5 6, Aux. voltage M25 x 1.5 9, DC circuit breaker M40 x /10 Operating instructions SCB 27

30 Installation of metric cable glands 1. Open the perforation on the flange plate provided for the relevant cable. 2. Insert gland body (B) in the housing. 3. Screw gland body (B) and inner nut (C) together. 4. Slip cap nut (A) over cable end. 5. Thread cable through gland body and fix it at relevant contact. Note the relevant torques, see chapter "Technical data". 6. Tighten cap nut (A). A B C 28 Operating instructions SCB 01/10

31 4.2.3 Connection of protective earth conductor Before any assembly or installation work, disconnect the device from power supply. Verify safe isolation from power supply. For devices with monitoring option 1. Open Housing +S1. 2. Verify safe isolation of device from power supply. 3. Fix metric gland, see chapter Installation of metric cable glands. While doing this, connect protective earth cable to PE terminal. 4. Check correct fit of protective earth cable by pulling the cable gently. 5. Using a continuity tester, verify correct cable connection. 6. Fix cable at cable clamp rail. 7. Continue with chapter "Connection of TCP/IP data cable" or "Connection of auxiliary voltage". PE PE PE 01/10 Operating instructions SCB 29

32 Devices without monitoring option 1. Open Housing +E1. 2. Verify safe isolation of device from power supply. 3. Fix metric gland, see chapter Installation of metric cable glands. While doing this, connect protective earth cable to PE terminal. 4. Check correct fit of protective earth cable by pulling the cable gently. 5. Using a continuity tester, verify correct cable connection. 6. Fix cable at cable clamp rail. PE 7. Continue with chapter "Connection of TCP/IP data cable" or "Connection of auxiliary voltage". 30 Operating instructions SCB 01/10

33 4.2.4 Connection of TCP/IP data cable (option) Connection of TCP/IP data cable is only relevant to devices with monitoring function. Before any assembly or connection work, disconnect the device from power supply. Verify safe isolation from power supply. Attention! Note permissible maximum length of network cable, refer to technical data. 01/10 Operating instructions SCB 31

34 Connection to a network For connection to a network, the SCB is connected to a data logger via a switch. For direct connection, you can use the data loggers of series Bonfiglioli RPSlog (except for RPSlog 500). 1. Fix metric gland, see chapter Installation of metric cable glands. While doing this, connect data cable as shown in the illustration. -X Terminal - x2 Color Function 1 orange white TX+ 2 orange TX- 3 green white RX+ 6 green RX- 2. Connect shield (A). Ensure proper shield contact and tighten shield clamps manually. 3. Check correct fit of TCP/IP cable by pulling the data cable gently. 4. Fix cable at cable clamp rail. 5. If other devices are to be connected, continue with "Looping the TCP/IP signal between string connection boxes". A 6. Continue with chapter "Connection of auxiliary voltage". 32 Operating instructions SCB 01/10

35 Looping the TCP/IP signal between string connection boxes If more than one SCB are used, the network cables of the SCBs must be connected in series. Before any assembly or connection work, disconnect the device from power supply. Verify safe isolation from power supply. 01/10 Operating instructions SCB 33

36 1. Fix metric gland, see chapter Installation of metric cable glands. While doing this, connect data cable as shown in the illustration. -X Terminal - x2 Color Function 9 orange white TX+ 10 orange TX- 11 green white RX+ 14 green RX- 2. Connect shield (A). Ensure proper shield contact and tighten shield clamps manually. 3. Check correct fit of TCP/IP cable by pulling the data cables gently. 4. Fix cable at cable clamp rail. 5. If other devices are to be connected, continue with "Looping the TCP/IP signal between string connection boxes". 6. Continue with chapter "Connection of auxiliary voltage". 34 Operating instructions SCB 01/10

37 4.2.5 Connection of auxiliary voltage If the housing +S1 forms part of the SCB, an external power supply must be connected for operation of the SCB. Before any assembly or connection work, disconnect the device and the external power supply from power supply. Verify safe isolation from power supply. 1. Fix metric gland, see chapter Installation of metric glands. 2. Connect PE conductor (PE) to X1.PE. cable 3. Connect neutral conductor (N) to X Connect phase (L) to X Check correct fit of auxiliary power supply cables by pulling the cable gently. 6. Fix cable at cable clamp rail. 7. Close housing +S1. 8. Continue with chapter "Configuration of gateway". N L PE 01/10 Operating instructions SCB 35

38 Configuration of gateway Network address of gateway The network addresses of the SCBs are pre-configured and do not have to be changed in most cases. Note The preset IP address is indicated on the gateway. For example, the gateway may have the following default settings: IP address (see designation on gateway) Subnet mask Default gateway Changing the IP address via DIP switches 2 0 through 2 7 You can choose addresses from a range from 1 through 254. Addresses 0 and 255 are used for broadcast messages in the subnet. MODE switch must be in "OFF" position. When the gateway is switched on, the "MS" LED will light up (red) briefly. Once the station has been initialized correctly, the LED will be flashing (green) and the station is ready for communication in the network. If several string connection boxes are used, the first IP address of the string Connection box starts with , , up to max Example Table for 11 SCBs Number of SCBs Bus address DIP switch position IP address Operating instructions SCB 01/10

39 Saving the configuration of the station The DIP switch "CFG" on the gateway is used for saving the I/Os on the gateway in the non-volatile memory. Procedure: Turn DIP switch "CFG" from OFF to ON a) Start of saving procedure. b) LED IOs flashes green (1 Hz). c) LED IOs lights up briefly (orange). d) Saving procedure is active. e) Reset DIP switch from ON to OFF. f) Saving procedure completed successfully if LEDs IOs and GW light up continuously (green) Changing the gateway address and subnet mask The gateway address and subnet mask address can only be changed using a PC connected via a LAN cable. Note Changing the gateway address and subnet mask is required only if the SCBs are to be integrated into an existing network. 1. Establish LAN connection between PC and gateway. 2. Enter preconfigured IP address in the address field of your browser and confirm. The page shown on the right will open. 3. Select menu item "Setup". The following page will open. 4. Enter the gateway address and netmask (subnet mask). 5. Enter your password. 6. To save your changes, press the button "Apply changes". Note If the values are not to be accepted directly, the auxiliary power supply must be interrupted once for a short time. 01/10 Operating instructions SCB 37

40 4.2.6 Connection of DC strings Danger! Perform connection only while the device is isolated from power supply. Switch off power supply before connecting or disconnecting the control inputs and outputs. Otherwise, components may be damaged. The DC input of the device is intended for connection of solar module strings as per chapters 3.4 Technical data (800 Volt variant) and chapter 3.5 Technical data (1000 Volt variant). 1. Open housings +E1 and, if applicable, +E2 and +E3. 2. Open all DC fuse holders (F1 F16). 3. Fix metric gland, see chapter Installation of metric glands. cable 4. Connect PE overvoltage protection, if applicable (depending on configuration). 5. Connect strings as per table. Start by connecting string 1 and continue in consecutive order. If less than 8 strings are to be connected, leave highest string connection pairs open. 6. Using a DC meter (setting VCC +1000V) verify correct polarity at each fuse pair. 7. Fix cable at cable clamp rail. 8. Close housings +E1, +E2 and +E3. 9. Continue with chapter "Connection of DC main cables" F1 F8 F9 F16 F1 F8: Fuses for positive string (+) F9 F16: Fuses for negative string (-) String connection F1 F9 2 F2 F10 3 F3 F11 4 F4 F12 5 F5 F13 6 F6 F14 7 F7 F15 8 F8 F16 Fuse pairs (F1/F9) (F2/F10) (F3/F11) (F4/F12) (F5/F13) (F6/F14) (F7/F15) (F8/F16) 38 Operating instructions SCB 01/10

41 4.2.7 Connection of DC main cables Connection of DC main cable Danger! Before starting any installation work: Switch off load circuit breaker. Before any assembly or connection work, disconnect the device and the external power supply from power supply. Verify safe isolation from power supply. Attention! Comply with the torque specification required for fixing the cable lugs at DC circuit breaker terminals. Torque specifications: Refer to technical data. 1. Open Lid of housing +E0. 2. Switch off load circuit breaker. 3. Pull of load circuit breaker handle (A). 4. Remove screws of cover (B). A 5. Take off cover. 6. Mount cable lugs to connection cables. B 01/10 Operating instructions SCB 39

42 7. Verify safe isolation of device from power supply. 8. Fix cable lugs at DC output terminals. Comply with correct torque, see chapters 3.4 Technical data (800 Volt variant) and 3.5 Technical data (1000 Volt variant). 9. Fix cable at cable clamp rail. 10. Connect inverter. Check all SCB connections at inverter(s) for correct polarity. 11. Replace and fix cover. 12. Fix load circuit breaker handle. 13. Check polarity of each SCB individually Continue with chapter "Checking the DC main cable connections". Note If the device is not commissioned immediately: Close lid of housing +E0 to load circuit breaker Checking the DC main cable connections After connection of DC main cables: 1. Switch on the load circuit breaker of one SCB. All other SCBs must remain off. 2. Using an appropriate meter, verify correct polarity at the output of the SCB load circuit breaker. 3. Using an appropriate meter, verify correct polarity at the input of the inverter. 4. Release inverter (see inverter instructions). 5. Once the inverter and SCB work properly, perform all steps with each of the remaining SCBs. 40 Operating instructions SCB 01/10

43 5 Commissioning The device may only be commissioned by qualified commissioning staff. Damaged or destroyed components must not be put into operation because they may be a health hazard. Attention! Before switching the device on, the internal fuses of the device must be dimensioned and installed. Attention! Defective fuses must always be replaced in pairs (both positive and negative pole). 5.1 Fuses The fuse to be used depends on the technical design of the overall plant Determination of fuses Attention! Only use gr fuses approved for use in PV applications. Attention! The switching voltage of the fuse must correspond to the maximum DC voltage of the plant. Comply with any additional design rules of the manufacturers of the fuses used. Conditions to be met by the selected fuses The fuses of defective strings must be triggered in order to disconnect the defective strings from the DC system. The fuses of the intact strings must not be affected by this. Instructions on implementing the above conditions The fuses must withstand the maximum short circuit currents of their own strings without triggering. In the module data sheets, the short-circuit currents are referred to STC* (1000 W/m 2 and 25 C). However, it is recommended selecting the fuses, assuming the worst conditions, e.g. for 1200W/m 2 and 70 C. This will increase the short-circuit current by approx. 23%. Attention! With the blocking diode option, the rated fuse current must not exceed 16 A. For easy selection, refer to the identification parameters listed in the following table: I mpp, sens. I SC, max (>I SC STC*) Rated fuse current <=1.1 A <=1.4 A 2 A <=2.2 A <=2.8 A 4 A <=3.3 A <=4.2 A 6 A <=4.4 A <=5.6 A 8 A <=5.5 A <=7 A 10 A <=6.6 A <=8.4 A 12 A <=8.8 A <=11.2 A 16 A <=11 A <=14 A 20 A *= Standard Testing Conditions 01/10 Operating instructions SCB 41

44 5.1.2 Installation of fuses The lower fuse terminals are live even if the fuse holder is open. Before installing the string fuses, check the inputs for correct polarity and verify that no earth fault is present. Install/remove fuses only after the load has been disconnected and using your personal protective equipment. 1. Open housings +E1 and, if applicable, +E2 and +E3. 2. Open fuse closures (A). 3. Install fuses. 4. Close fuse closures. A 5. Close housings +E1 and, if applicable, +E2 and +E3. 6. Tighten housing screws. Comply with correct torque, see chapters 3.4 Technical data (800 Volt variant) and 3.5 Technical data (1000 Volt variant). 42 Operating instructions SCB 01/10

45 5.2 Switching SCB on Until complete commissioning, the SCBs may only be switched on individually for checking them. All other SCBs must remain off. 1. Open housing +E0. 2. Turn load circuit breaker (A) of one SCB to "1". All other SCBs must remain off. Now, the device is on. 3. Using an appropriate meter, verify correct polarity at the output of the SCB load circuit breaker. 4. Close housing. 5. Tighten housing screws. Comply with correct torque, see chapters 3.4 Technical data (800 Volt variant) and 3.5 Technical data (1000 Volt variant). 6. Using an appropriate meter, verify correct polarity at the input of the inverter. A 7. Release inverter (see inverter instructions). 8. Once the inverter and SCB work properly, perform all steps with each of the remaining SCBs. 9. Switch on all SCBs consecutively. 10. Release inverter. The plant is in operation. 01/10 Operating instructions SCB 43

46 6 Troubleshooting This chapter describes general faults and provides information on how to repair them. If the relevant fault is not included in the tables, please contact the manufacturer. Faults of the device may only be repaired by qualified staff. 6.1 For all device configurations Fault Possible cause Repair Wrong installation Check installation steps. Find out why the fuse was triggered and replace fuse. No voltage at DC Fuse(s) triggered. output Fuse(s) defective Install correct and intact fuses. Solar module(s) defective Replace solar module(s) Check and, if necessary, correct the mechanical installation; in particular, ensure sufficient shadowing Temperature too high and sufficient distances to provide Temporary failures for proper air circulation. Comply with permissible ambient conditions. Loose contact Check and, if necessary, re-tighten all contacts. Note required torques. Sun impact too low Carry out measurement with sufficient sun impact. Clean solar modules and position Solar modules dirty or covered DC output power them correctly. too low At least one of the solar modules defective Replace solar module(s). At least one of the solar modules connected incorrectly Check and, if necessary, correct installation. String fuse triggered Check fuses. Strings not connected correctly in field Check plug connections. 44 Operating instructions SCB 01/10

47 6.2 Additionally, for devices with "Monitoring" option Fault Possible cause Repair No auxiliary voltage Check and, if necessary, correct electrical installation of auxiliary voltage. No data transmission to data gered and replace fuse. Find out why the fuse was trig- Fuse of auxiliary voltage defective logger or web Power supply unit for auxiliary voltage defective server Replace power supply unit. Fuse F34 defective Replace fuse. Analog input module configured incorrectly See Configuration of gateway. Error messages of individual DC strings Various Current metering module(s) defective See data logger or web server monitoring instructions. See 6.4 Visual inspection of individual elements. Additionally, for devices with "blocking diodes" option Fault Possible cause Repair No voltage at DC Have device checked by specialized Blocking diodes defective output workshop. 6.3 Additionally, for devices with "contact monitoring" option Fault Possible cause Repair No data transmission to data logger or web server Auxiliary contact for DC load circuit breaker signals an error Auxiliary contact for 1000 V overvoltage protection signals an error Auxiliary contact for control voltage overvoltage protection signals an error No auxiliary voltage Fuse of auxiliary voltage X.F33 defective Power supply unit for auxiliary voltage defective DC load circuit breaker switched off Auxiliary contact for DC load circuit breaker defective 1000 V overvoltage protection was triggered Auxiliary contact for 1000 V overvoltage protection defective Control voltage overvoltage protection was triggered Auxiliary contact for control voltage overvoltage protection defective Check and, if necessary, correct electrical installation of auxiliary voltage. Find out why the fuse was triggered and replace fuse. Replace power supply unit. Only switch load circuit breaker on again if you know who turned the load circuit breaker off and why it was switched off. Before switching the load circuit breaker on, ensure that nobody is in the hazard zone of the plant. Replace auxiliary contact for DC load circuit breaker Replace 1000 V overvoltage protection. Replace auxiliary contact for 1000 V overvoltage protection. Replace control voltage overvoltage protection. Replace auxiliary contact for control voltage overvoltage protection. 01/10 Operating instructions SCB 45

48 6.4 Visual inspection of individual elements Danger! Switch off load circuit breaker Housing +S Current metering modules 1. Visual inspection of LED indicators of analog input modules. During correct operation, all 8 LEDs of the current metering modules G2, G3 and G4 will light up green. G2 G3 G4 46 Operating instructions SCB 01/10

49 Indicators of overvoltage protection system and switching power supply 1. Visual inspection of overvoltage protection system (A). During correct operation, the inspection field will be green. 2. Visual inspection of functional display of switching power supply (B). During correct operation, the function indicator will light green. -F35 A B Housing +E Lightning protection fuse indicators 1. Visual inspection of lightning protection fuses (A). During correct operation, the inspection fields will be clear. 01/10 Operating instructions SCB 47

50 7 Cleaning Do not clean the device from the inside. In the case of the option with blocking diodes: Clean heat sink using a brush. Remove dust from heat sink gaps. 48 Operating instructions SCB 01/10

51 8 Maintenance and Service The device is maintenance-free. Once every year, a visual inspection is required for maintenance. Inspection object Housing Metric cable glands Cover screws of housing Connection cable Inspection Defect Fit and tightness Fit of screws Fixture Corrosion Insulation Presence, fit and visibility Measure Repair housing / have housing repaired. Check if housing is free from moisture. Check and, if necessary, tighten gland manually. If necessary, tighten screws at the specified torque, replace screws if necessary. If necessary, re-tighten screws at specified torque. Remove corrosion and replace connection cable and cable gland of connection cable. Replace connection cable. Replace if necessary; order through manufacturer. Warning signs (labels) Venting device Dirty Replace Venting device Rating plate Presence, fit and visibility Contact manufacturer. 01/10 Operating instructions SCB 49

52 9 Storage The devices must be stored in an appropriate way. During storage the devices must remain in their original packaging. The devices may only be stored in dry rooms which are protected against dust and moisture and are exposed to little temperature deviations only. Observe the climatic conditions according to EN and the marking on the packaging. 50 Operating instructions SCB 01/10

53 10 Disposal The device must be disposed of properly in accordance with the applicable, national laws and environmental regulations. The device contains raw materials which can be recycled and reused. 01/10 Operating instructions SCB 51

54

55 INDUSTRY PROCESS AND AUTOMATION SOLUTIONS Bonfiglioli Worldwide & BEST Partners Worldwide AUSTRALIA BONFIGLIOLI TRANSMISSION (Aust) Pty Ltd. 2, Cox Place Glendenning NSW 2761 (Australia) Locked Bag 1000 Plumpton NSW 2761 Tel. (+ 61) Fax (+ 61) sales@bonfiglioli.com.au AUSTRIA BONFIGLIOLI ÖSTERREICH GmbH Molkereistr 4 - A-2700 Wiener Neustadt Tel. (+43) Fax (+43) info@bonfiglioli.at MOLL MOTOR GmbH Industriestrasse Stockerau Tel. (+43) Fax (+43) office@mollmotor.at BELGIUM ESCO TRANSMISSION N.V./S.A. Culliganlaan Machelem Diegem Tel. (+32) Fax (+32) info@esco-transmissions.be BRASIL BONFIGLIOLI REDUTORES DO BRASIL INDÚSTRIA E COMÉRCIO LTDA. Travessa Cláudio Armando Bloco 3 - CEP Bairro Assunção - São Bernardo do Campo - São Paulo (Brasil) Tel. (+55) Fax (+55) bonfiglioli@bonfigliolidobrasil.com.br CANADA BONFIGLIOLI CANADA INC Jane Street - Concord, Ontario L4K 4L6 Tel. (+1) Fax (+1) sales@bonfigliolicanada.com CHILE IMATESA S.A. Santa Rosa San Miguel - Santiago Tel. (+56) Fax (+56) imatesa@imatesa.cl CHINA BONFIGLIOLI DRIVES (SHANGHAI) CO. LTD. 19D, No. 360 Pudong Road (S) New Shanghai International Tower Shanghai (P.R. China) Tel. (+86) Fax (+86) bds@bonfiglioli.com.cn DENMARK BRD. KLEE A/S Gadagervej Albertslund Tel. (+45) Fax (+45) klee@klee.dk FRANCE BONFIGLIOLI TRANSMISSIONS S.A. 14 Rue Eugène Pottier BP 19 Zone Industrielle de Moimont II Marly la Ville Tel. (+33) Fax (+33) btf@bonfiglioli.fr GERMANY BONFIGLIOLI DEUTSCHLAND Gmbh Sperberweg Neuss Tel. (+49) Fax (+49) info@bonfiglioli.de GREAT BRITAIN BONFIGLIOLI UK Ltd Industrial Equipment - Unit 7, Colemeadow Road North Moons Moat - Redditch, Worcestershire B98 9PB Tel. (+44) Fax (+44) uksales@bonfiglioli-uk.com Mobile Equipment 3-7 Grosvenor Grange, Woolston, Warrington - Cheshire WA1 4SF Tel. (+44) Fax (+44) sales@bonfiglioli.co.uk GREECE B.E.S.T. HELLAS S.A. O.T. 48A T.O C.P , Industrial Area - Thessaloniki Tel. (+30) Fax (+30) info@bonfiglioli.gr HOLLAND ELSTO AANDRIJFTECHNIEK Loosterweg, TL Voorhout Tel. (+31) Fax (+31) info@elsto.nl HUNGARY AGISYS AGITATORS & TRANSMISSIONS Ltd 2045 Törökbálint, Tö u.2. (Hungary) Tel. (+36) Fax (+36) info@agisys.hu INDIA BONFIGLIOLI TRANSMISSIONS PVT Ltd. PLOT AC7-AC11 Sidco Industrial Estate Thirumudivakkam - Chennai Tel. +91(0) / / Fax +91(0) / info@bonfiglioliin.com INDONESIA PT. ANEKAMAKMUR TEKNIK NUSAJAYA Pertokoan Glodok Makmur No Jakarta Barat Tel. (+62) Fax (+62) sales@anekamakmur.com ITALY BONFIGLIOLI ITALIA S.p.A. Via Sandro Pertini lotto 7b Carpiano (Milano) Tel. (+39) Fax (+39) customerservice.italia@bonfiglioli.it NEW ZEALAND SAECO BEARINGS TRANSMISSION 36 Hastie Avenue, Mangere Po Box 22256, Otahuhu - Auckland Tel. (+64) Fax (+64) mark@saeco.co.nz POLAND POLPACK Sp. z o.o. - Ul. Polna Torun Tel. (+48) to 37 - Fax (+48) polpack@polpack.com.pl PORTUGAL BT BONFITEC Equipamentos Industriais, Lda. Largo do Colegio de Ermesinde, 70 - Formiga Ermesinde Tel. (+351) /5/6 - Fax (+351) bonfitec@bonfitec.pt RUSSIA FAM 57, Maly prospekt, V.O , St. Petersburg Tel. (+7) Fax (+7) info@fam-drive.ru SPAIN TECNOTRANS BONFIGLIOLI S.A. Pol. Ind. Zona Franca sector C, calle F, n Barcelona Tel. (+34) Fax (+34) tecnotrans@tecnotrans.com SOUTH AFRICA BONFIGLIOLI POWER TRANSMISSION Pty Ltd. 55 Galaxy Avenue, Linbro Business Park - Sandton Tel. (+27) OR - Fax (+27) bonfigsales@bonfiglioli.co.za SOUTH KOREA YOUN HO INDUSTRIAL Room B1, World Plaza Bldg Guro-Dong, Gurd-Gu, Seoul Tel. (+82) Fax (+82) younho@younho.com SWEDEN BONFIGLIOLI SKANDINAVIEN AB Koppargatan Lomma (Sweden) Tel. (+46) Fax (+46) info@bonfiglioli.se THAILAND K.P.T MACHINERY (1993) CO.LTD. 259/83 Soi Phiboonves, Sukhumvit 71 Rd. Phrakanong-nur, Wattana, Bangkok Tel. (+66) / Fax (+66) / / sales@kpt-group.com TURKEY BONFIGLIOLI TURKIYE Atatürk Organíze Sanayi Bölgesi, Sk. No: 17, Çigli - Izmir Tel. +90 (0) (pbx) - Fax +90 (0) info@bonfiglioli.com.tr USA BONFIGLIOLI USA, INC Hargrave Drive Hebron, Kentucky Tel. (+1) Fax (+1) industrialsales@bonfiglioliusa.com - mobilesales@bonfiglioliusa.com VENEZUELA MAICA SOLUCIONES TECNICAS C.A. Calle 3B - Edif. Comindu - Planta Baja - Local B - La Urbina - Caracas 1070 Tel. (+58) / / Fax (+58) Tlx Maica V - maica1@cantv.net VIETNAM BONFIGLIOLI VIETNAM LTD. Lot C-9D-CN My Phuoc Industrial Park 3 Ben Cat - Binh Duong Province - Vietnam Tel. (+84) Fax (+84) salesvn@bonfiglioli.com - HEADQUARTERS BONFIGLIOLI RIDUTTORI S.p.A. Via Giovanni XXIII, 7/A Lippo di Calderara di Reno Bologna (ITALY) Tel. (+39) Fax (+39) bonfiglioli@bonfiglioli.com SPARE PARTS BONFIGLIOLI B.R.T. Via Castagnini, 2-4 Z.I. Bargellino Calderara di Reno - Bologna (ITALY) Tel. (+39) Fax (+39) brt@bonfiglioli.com

56 PHOTOVOLTAIC SOLUTIONS SCB COD. VEC 665 R0