HomeRun Combiner Boxes Installation and Operation Manual 100A 225A 400A PATENT PENDING
TABLE OF CONTENTS 1.0 Overview 2.0 Introduction 3.0 Important Safety Instructions 4.0 Disconnecting Combiner Box Electrical Characteristics 5.0 Non-Disconnecting Combiner Box Electrical Characteristics 6.0 Combiner Box Mounting 7.0 Grounding 8.0 Fuse Selection 9.0 Output Conductor Sizing 10.0 Combiner High Voltage Wiring 11.0 Wiring for Smart Combiner with Monitoring 12.0 Ventilation Consideration 13.0 Check Your Work 14.0 Maintenance & Service 15.0 Operation 16.0 Contact Us HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 1
1.0 Overview SLK Solar s HCB Series Combiner Boxes are the professional solar installer s choice for combining PV Arrays and complying with the National Electrical Code. These boxes include: Compliance with the stringent UL1741 safety listing for continuous rated current operation at 50 C. Installation friendly TYPE 3R, 4 or 4X watertight enclosure for vertical or horizontal mounting. Spacious wiring area for ease of installation and maintenance. Simple, clean and solid construction for years of service. 2.0 Introduction SAVE THESE INSTRUCTIONS - This manual provides important instructions for the HomeRun TM Series Combiner Boxes thatt shall be followed during installation and maintenance. The HomeRun TM Series Combiner Boxes are designed and tested to stringent international safety equirements. However, as with all electrical equipment, specific safety practices must be followed. To reduce the risk of injury, carefully read this instruction booklet in its entirety before installing, wiring, or using this product in any way. 2.1. Disclaimer of Liability The installation techniques, handling and use of this product are beyond company control. Therefore, SLK Solar Corporation does not assume responsibility for loss, damage or expense resulting from improper installation, handling or use of this product. 2.2. Listing Information This product meets or exceeds the requirements set forth by Underwriters Laboratories for components used with PV Modules. This UL Standard is UL1741 for accessories used with inverters. 2.3. Limited Warranty Combiner box limited warranties are for 1 year for materials and workmanship. 3.0 Important Safety Instructions There are NO user-serviceable parts in this enclosure. Modifying this product in any way will void the manufactures warranty. WARNING: PV modules pass direct current (DC) when the module is under load. Direct current will arc across gaps and may cause injury or death if improper connection or disconnection is made. Do not connect or disconnect wires to the combiner box when current from the modules or an external source is present. AVERTISSEME ENT: Les modules photovoltaïques sont chargés de courant continu (DC) quand l appareil est branché. Si le branchement ou le débranchement de l appareil ne sont pas fait correctement, le courant peut «sauter» a travers les interstices, se qui peut causer des blessures graves ou même la mort. Ne branchez pas les fils a la «boite á combiner» si une source de courant est présente. WARNING: Voltage is present in open circuit conditions. Photovoltaic modules create voltage anytime light is present. AVERTISSEME ENT: Un voltage est présent dans les conditionss de circuits ouverts. Les modules photovoltaïques créent un courant tant qu il y a de la lumière. CAUTION: For continued protection against risk of fire, replace fuses with only 600VDC rated, max. 30A fuses. ATTENSION: Pour assurer la protection contre le risque d'incendies, remplacez par les fusibles par d'autres de même type et calibre : 30A, 600VDC. Make connections in combiner box prior to connecting modules. To work on the combiner box after the modules are connected, cover all modules in the PV array with an opaque cloth or material. All US installations must be performed in compliance with the National Electrical Code (NEC), ANSI/NFPA 70 and any applicable local codes. HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 2
All Canadian installations shall conform to Canadian Electrical Code Part II and any applicable local codes. Installation, maintenance & servicing should be performed only by authorized personnel. Remove all metallic jewelry prior to installing this product to reduce the chance of accidental exposure to live circuits. Use insulated tools to reduce your risk of electric shock. Do not install or handle the combiner box if it is wet. Maximum 95% humidity during use. Contact SLK Solar Corporation if the combiner box enclosure is damaged or its contents are compromised. Storage temperature: - 60º C - + 85 º C 4.0 Disconnecting Combiner Box Electrical Characteristics The combiner box electrical ratings are indicated for the following three disconnecting Family IDs: Family ID 100 225 400 Maximum Input Fuse Rating (A) 30 30 30 Maximum Voltage (VDC) 1000* 1000* 1000* Voltage Range (VDC) 0-1000* 0-1000* 0-1000* Maximum Continuous DC Current (A) 100 225 400 SCCR AT 600VDC (KAIC) 10 10 10 Positive Input Wire Size (AWG) 14-6 14-6 14-6 Positive Input Terminal Torque (in-lbs) 14.75 14.75 14.75 Negative Input Wire Size (AWG) 14-4 14-4 14-4 Negative Input Terminal Torque (in-lbs) 40 40 40 Ground Input Wire Size (AWG) 14-4 14-4 14-4 Ground Input Terminal Torque (in-lbs) 40 40 40 Max Positive Output Wire Size (AWG) 250 2 x 300 [2 x 500]** 2 x 750 Max Negative Output Wire Size (AWG) 250 2 x 300 [2 x 500]** 2 x 750 Max Ground Output Wire Size (AWG) 1/0 2 x 250 2 x 250 Positive, Negative and Ground Output Terminal Torque (in-lbs) 250 500 500 Operating Temperature NEMA Rating 3R/4/4X 3R/4/4X 3R/4/4X Maximum # of Inputs for this Family 6-48 6-48 10-48 Switch Position Table 1: Electrical and Mechanical Disconnecting Combiner Box Characteristics *Standard Disconnects are not load break rated at 1000V, specify high voltage disconnect for load break rating above 600V **[2 x 500] - Available on some models HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 3
5.0 Non-Disconnecting Combiner Box Electrical Characteristics The combiner box electrical ratings are indicated for the following three non-disconnecting Family IDs: Family ID 100 225 400 Maximum Input Fuse Rating (A) 30 30 30 Maximum Voltage (VDC) 1000 1000 1000 Voltage Range (VDC) 0-1000 0-1000 0-1000 Maximum Continuous DC Current (A) 100 225 400 SCCR AT 600VDC (KAIC) 10 10 10 Positive Input Wire Size (AWG) 14-6 14-6 14-6 Positive Input Terminal Torque (in-lbs) 14.75 14.75 14.75 Negative Input Wire Size (AWG) 14-4 14-4 14-4 Negative Input Terminal Torque (in-lbs) 40 40 40 Ground Input Wire Size (AWG) 14-4 14-4 14-4 Ground Input Terminal Torque (in-lbs) 40 40 40 Max Positive Output Wire Size (AWG) 250 2 x 300 [2 x 500]* 2 x 750 Max Negative Output Wire Size (AWG) 250 2 x 300 [2 x 500]* 2 x 750 Max Ground Output Wire Size (AWG) 1/0 2 x 3/0 2 x 250 Positive, Negative and Ground Output Terminal Torque (in-lbs) 250 500 500 Operating Temperature NEMA Rating 3R/4/4X 3R/4/4X 3R/4/4X Maximum # of Inputs for this Family 6-48 6-48 10-48 Switch Position Table 2: Electrical and Mechanical Non-Disconnecting Combiner Box Characteristics *[2 x 500] - Available on some models HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 4
Table 3 explains how to interpret the intelligent part numbering system. The part number listed in the table is an example of the combiner box model with the following options: 225A, 16 strings, 1000V Load Break Disconnect Switch, Fiberglass NEMA 4X, String Level Monitoring, and Bulkhead Connectors. The Family ID of the part number is the indicator of what column in Table 1 a particular combiner box falls under to determine its electrical and mechanical characteristics. Table 3: Electrical and Mechanical Combiner Box Characteristics Combiner Box Part Number Derivation Table Family ID # of Strings Disconnecting? Material & NEMA Rating Monitoring Bulkhead Connectors HCB-XXX 6-48 (by 2) D or H or N (Non-Disc.) S, SS, or F** 3R, 4, or 4X M or blank B or Blank HCB-225 16 H F4X M B The resulting part number for this combiner box example with the listed options: HCB-225-16-H-F4X-M-B. *D is disconnect load break rated to 600V, H is disconnect load break rated to 1000V, N is no disconnect **S, SS, and F represent the enclosure materials: Steel, Stainless Steel, and Fiberglass, respectively. 6.0 Combiner Box Mounting Install the enclosure using the external enclosure mounting tabs only. Drilling holes in the back plate is not recommended and shall void the product warranty. Place in desired location and use the appropriate hardware to mount the combiner box. The combiner box may be mounted vertically (door opens out) or horizontally (door opens up). Place the box in areas out of continuous water flow and extreme temperature. If the box has a disconnect switch, do not mount the box such that the switch handle is blocked or difficult to operate. Please refer to the enclosure installation manual for additional mounting instructions. HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 5
6.1. Connector Type The use of UL514B or equivalent conduit fittings is required to maintain the TYPE 4 (or 4X) rating of the enclosure. Installation of fittings must comply with UL50 for USA installationss and CSA C22.2 No. 94 for Canadian installations to maintain TYPE 4 (or 4x) rating of the enclosure. See Figure 2 for suitable connectors. Equivalent connectors from other manufactures may be used as long as theyy satisfy citations in this section. Figure 1: Suitable Conduit Connectors 6.2. Install connector 6..2.1. Metallic Conduit Place connector through hole as shown in Figure 3 with the o-ring on the outside of the enclosure. Screw on and tighten the locknut. Next screw on the Grounding Bushing, rotate to desired location and tighten set screws. 6..2.2. Non-Metallic Conduit Place connector through hole as shown in Figure 3 with the o-ring on the outside of the enclosure. Screw on and tighten the locknut. Screw Insulated or plastic bushing onto connector threads to protect conductors from damage. Grounding Bushings are not used with non-metallic conduit. Figure 2: Conduit Connector Exploded View HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 6
7.0 Grounding 7.1. Grounding General A ground bar has been provided for the convenience of combining several grounds into one larger ground wire. Please refer to NEC Article 690 on grounding PV arrays for specific requirements. Models HCB8-D-S, HCB16-D-S & HCB24-D-S have metallic enclosures and have factory installedd ground wiress or straps to bond the enclosure body and door. Note: Do not connect any ground wires to enclosure body bonding location or to door bonding location. 7.2. Grounding with Metallic Conduit When nstalling metallic conduit grounding bushings must be used, refer to section 6.3.1 for installation. A continuous ground conductor must go through the lay-in lug on the grounding bushing with the insulation stripped back on either side of the lay-in lug set screw. Seee Figure 4. Note: Bonding of the Grounding Bushings must comply with the NEC for USA installations and CE Code for Canadian installations. 7.3. Grounding with Non-Metallic Conduit When nstalling non-metallic conduit the grounding conductor is erminated at the ground bar. See Figure 4. Figure 3: Conduit Grounding HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 7
8.0 Fuse Selection Please consult the module manufacturer and/or rating label to selectt the appropriate fuse size. In most cases, the fuse size is determined by multiplying the short circuit current rating by 156% and rounding up to the next standard fuse size. Please consult NEC Article 690 for more information. A maximum of a 30 Amp fuse may be used with this product. 9.0 Output Conductor Sizing The combiner box output design current is determinedd by: (total I sc x 156%) dividedd by a temperature correction factor. Select the appropriate temperature correction factor from the NEC. See NEC Articles 310 and 690 for proper wire sizing. 10.0 Combiner High Voltage Wiring NOTE: USE COPPER OR ALUMINUM CONDUCTORS SUITABLE FOR AT LEAST 75 C Insert positive input conductor from the source circuit into the Touch Safe fuse holder and tighten to torque specifications in Table 1. Insert negative input conductor from the source circuit into the negative collector and tighten to torque specifications in Table 1. Crimp a lug ontoo the positive output wire to the inverter (or other destination ), bolt onto the positive output terminal busbar and secure to the torque requirements in Table 1. Crimp a lug ontoo the negative output wire to the inverter (or r other destination), bolt into the negative output terminal and secure to the torque requirements in Table 1. Make sure all connections are tight, secure and safe for many years of operation. DO NOT INSTALL FUSES! 11.0 Wiring for Smart Combiner with Monitoring If the combiner box includes the option for string level current monitoring, it will have one or more Obvius A89DC-08 DC Current Monitors installed inside the combiner box. It is requiredd that a minimum of ¼ of physical separation be maintained between the wires that connect to the current monitors and the high voltage wires to prevent contactt to the high voltage conductors. The following diagram of the A89DC-088 monitor is for reference only, please refer to the A89DC-08 Installation Manual for proper wiring and configuration of the current monitors. HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 8
12.0 Ventilation Consideration Maintain a minimum clearance of 1 on all 4 sides of the enclosure. 13.0 Check Your Work These steps need to be completed with your personal safety in mind. BEFORE INSTALLING FUSES, completee these simple time-saving checks: Note: A multimeter is needed to verify the installation process. Check that the multimeter is capable or reading the maximum string voltage and maximum string current before proceeding. 13.1. Measure Voltage (V oc ) Place the multimeter in DC voltage mode. Check the open circuit positive voltage (V oc ) from each individual solar array string to the negative bus bar. Ensure each V oc is the proper polarity (this means the meter reads a positive DC voltage) and within the intended i range. V oc does not vary much withh irradiance and temperaturee conditions. 13.2. Measure Current (I sc ) Place the multimeter in DC current mode. Check the short circuit current (I sc ) of each individual solar array string to the negative bus bar. Compare the measured I sc to the panel specifications. I sc does vary with irradiance and temperature so be careful to consider the conditions at the time of measurement. 13.3. Check Ground Currents Check the DC current from each individual string (fuse holder) to ground and verify that no current is flowing to ground. If current is present, locate and repair any ground faults. HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 9
13.4. Insert Fuses Insert fuses into fuse holders and secure it in the closed position. 13.5. Final Inspection Check the DC voltage from the combined output lug to the negative bar. Ensure voltage is the proper polarity and within the desired voltage range. Double check that all conduit penetrations are properly sealed against water and pest intrusion. Close and secure the enclosure door. 14.0 Maintenance & Service Read sections 1 through 3 for important safety information before performing any maintenance or service. Please use protective safety equipment and disconnect all sources of supply before working on this product. The only serviceable components in the HomeRun TM Solar Array Combiner box are the fuses. Before changing a fuse(s) check the system for problems and make repairs as needed. Then go through section 12 before installing a new fuse(s). WARNING: - For Continued Protection against risk of fire, replace fuses with same type and rating of fuse (600V DC rated, MAX 30A Midget fuses). AVERTISSEMENT: Pour assurer de la protection continué contre le risque d'incendie, remplacez par un fusible de mêmes type et caractéristiques. UTILISEZ UN FUSIBLE DE MEME TYPE ET CALIBRE de 30A, 600VDC. Please read section 8.0 to confirm the proper fuse selection. If the combiner box has a disconnect switch it must be switched ten times in a row, once a year, with the system off, to clean contacts. Mechanical aspects of the switch handle should be checked for dirt on an annual basis. No more than 3x the force of normal operation should be applied to the switch. If switch does not operate within this capacity, check for blockage or obstruction. Every 6 months inspect and re-torque the wire connections. 15.0 Operation If the combiner box has a disconnect switch the switch may be used to disconnect the combiner box from current coming from other parts of the array and/or to disconnect the voltage and current of the combiner box from an inverter or other equipment that is downstream of the combiner box. To operate the switch simply rotate the handle 90 degrees, the switch contacts will be open if the switch handle is pointing to the off position. Always place the switch of every combiner box that is connected to an inverter in the off position before servicing the inverter. If the combiner boxes do not have a disconnect switch, turn off the inverter and verify that the current from the combiner boxes to the inverter is zero amps, then open all the fuse holders in the combiner boxes before servicing the inverter. Do not open the fuse holders under load. The fuse holders are not load break rated, and may cause damage or injury if opened under load. There are no other operable parts in the combiner box other than the disconnect switch and fuse holders. 16.0 Contact Us SLK Solar 3601 Hwy 7, Suite 400 Markham, ON Canada L3R 0M3 Phone: (905) 475-7000 Fax: (905) 917-0210 info@slk Solar.com HomeRun Combiner Boxes Installation and Operation Manual - Rev A Page 10