Technical Information

Photovoltaic application
Switch selection
in IEC installation
by Cyril Carpentier
Technical information
Photovoltaic application: selection of switch in IEC installation

This Technical note helps to answer the following questions for a PV installation:
 What are the functions of a PV switch?
 When is an overcurrent protection needed?
 Comparison PV fuse and circuit breaker
 How to select a PV switch?

Contents
1. Executive summary .......................................................................................................................... 3
2. Glossary ........................................................................................................................................... 3
3. Three main functions of PV switching .............................................................................................. 4
3.1. Isolation ................................................................................................................................... 4
3.2. Emergency disconnection ....................................................................................................... 4
3.3. Functional switching ................................................................................................................ 4
4. Location of PV switch and overcurrent protection ............................................................................ 5
4.1. Combiner box input protection................................................................................................. 6
4.2. Combiner box output protection .............................................................................................. 6
4.3. Recombiner box input protection ............................................................................................. 7
4.4. Recombiner box output protection and inverter input protection ............................................. 7
4.5. PV Fuses advantages vs. PV CB in recombiner box input ..................................................... 8
4.5.1. Risk of using circuit breaker in recombiner box input ...................................................... 8
4.5.2. Advantages of using Fuse in recombiner box input ........................................................ 9
5. PV switch operation........................................................................................................................ 10
5.1. PV inverter emergency stop .................................................................................................. 10
5.2. PV inverter remote controlled operation ................................................................................ 10
5.3. Disconnection for fire fighting operation ................................................................................ 11
5.3.1. A disconnection at the PV sub array level ..................................................................... 11
5.3.2. A disconnection at the PV inverter level ........................................................................ 11
5.3.3. Technical solution .......................................................................................................... 11
5.4. Arc Fault Interruption ............................................................................................................. 12
6. Characterization of a PV switch ..................................................................................................... 12
6.1. In: Nominal current ................................................................................................................. 12
6.2. Vnom: Nominal voltage ............................................................................................................ 13
6.3. Non Polarization of the switch ............................................................................................... 13
6.4. Icw : Short time withstand current ........................................................................................... 13
6.5. Icrit – Critical Current............................................................................................................... 14
6.5.1. What is critical current? ................................................................................................. 14
6.5.2. Why is a switch not able to open the critical current ..................................................... 14
6.5.3. Why is critical current more crucial for PV application than for DC or AC application? 15
6.5.4. How to manage properly Icrit......................................................................................... 15
6.6. PV category ........................................................................................................................... 16

March 2015 2 / 17
Technical information
Photovoltaic application: selection of switch in IEC installation

1. Executive summary
A safety and failure analysis shows that PV load break switches without overcurrent protection are needed
- At the combiner box output
- At the recombiner output (optional if the inverter is nearby)
- At the PV inverter input

Since no overcurrent protection is needed, circuit breaker is not adapted since more expensive.

Overcurrent protections are needed against reverse current:

- At the combiner box input
- At the recombiner box input

For recombiner box input, PV fuse rated is the optimized and cost effective solution, able to interrupt the reverse
current under 1000V on one polarity unlike circuit breaker.

Advanced operation such as tripping or motorization can be required in case in case of shutdown for firefighting
operation.

Important features specific to the PV switches are:

- Non polarization of the switch to handle correctly both direct and reverse currents switching.
- Characterization and routine testing at the critical current to ensure the opening at low irradiance
- A proper derating in temperature and altitude.

2. Glossary
PV Photo Voltaic
LBS Load Break Switch
CB Circuit Breaker
UV Ultra Violet

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Technical information
Photovoltaic application: selection of switch in IEC installation

3. Three main functions of PV switching

We concentrate below on the main functions and features of PV switches. We leave aside the features which are
not impacting the design or which are not “PV specific”.

3.1. Isolation
The purpose of isolation is to ensure the safety of operators during maintenance operation by guaranteeing an
effective separation from the source.

This isolation must fulfil the three following requirements:

Requirements Characteristics Value according IEC
1
IEC 60947-3
Ensure disconnection distance in the air Impulse voltage (Uimp) 5 x Uoc
Guarantee the creepage distance values Isolation voltage (Ui) 1.2 Uoc
Provide safe indication of the open position Positive break indication 3 F or visible breaking
and ensure insulation

Note: Voltage measurement before working on active electrical parts is not enough since the voltage depends on
the sun irradiation that evolves within the time.

3.2. Emergency disconnection

The purpose of emergency disconnection is to ensure the safety of operators and installations in case of
immediate danger such as electrical shock burns or fire on or in the equipment.
The functional switching requires an on-load disconnection.
The controls for these devices must be quickly and easily accessible.

This disconnection must fulfil the four following requirements:

Requirements Characteristics Value according IEC IEC

60947-3
Guarantee on-load Operating voltage (Ue) 1.2 Uoc
disconnection Operating current (Ie) From 0 to 1.25 Isc (non-
This characteristic requires the manufacturer to standard)
respect the current values (low current, critical
current of the device), as well as the data set
out in standard IEC 60947-3
Time constant (L/R) 1 ms
Ensure omnipolar Simultaneous
disconnection Galvanic isolation Air gap
Allow access to the controls Directly, for domestic applications Direct manual operation /
Directly or by remote control in all fields other remote operation
than domestic via pneumatic control with shunt trip or
undervoltage release /
motor / pneumatic actuator
Centralization of controls DC and AC controls are possible if gathered in
the same place

3.3. Functional switching

The Functional switching is used by the end-user to start/stop a device such as the inverter.
The functional switching requires an on-load disconnection.

1
The IEC 60947-3 is under process of revision to take into account the PV issues. The version taken here is the
60947-3 / Ed3 / A2 (Amendment 2 to Edition 3). It is cited as IEC 60947-3 in this document.

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Technical information
Photovoltaic application: selection of switch in IEC installation

4. Location of PV switch and overcurrent protection

Figure 1 - synthesis location of PV switch and over current protection

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Technical information
Photovoltaic application: selection of switch in IEC installation

4.1. Combiner box input protection

Overcurrent protection against reverse current:

Overcurrent protection is needed to protect against reverse current

that appears in case of failure like in Figure 2.

In this case, one string is short-circuited in (1). The other strings

inject current into the default.
We see in (2) and (3) that 3 x Isc is going through the external
string.
Cable and PV modules shall be protected against reverse current
by over current protection on each polarity.

Figure 2– current paths in case of failure in the on PV string

Isolation provided by fuse disconnect switch

For fuse servicing, isolation is provided by a fuse disconnect switch.

The PV fuse standard is IEC 60269 part 6 Ed 1.

Figure 3 – example of PV fuse disconnect

4.2. Combiner box output protection

Load break switch ….
A switch shall be installed at the combiner box output with
the following capability:
- Isolation in order to isolate the sub-array from the rest of
the PV plant or to maintain the combiner box isolated from
the other sub-array
- Load break capability to disconnect the load in case of
emergency or before fuse servicing, since most of the fuse
holder can’t be open under load.

…without overcurrent protection

No overcurrent protection is needed within the switch or
through fuse as shown in Figure 4.
Figure 4 – current path in case of short circuit
In case of short circuit on sub-array cables:
in sub-array cable
- The PV cells delivers a short circuit current of 1.25*In max
(if the irradiation is maximum). No protection can act on this
current level.
- The cables are dimensioned for more than this value (Ib =
1.45 In).

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Technical information
Photovoltaic application: selection of switch in IEC installation

4.3. Recombiner box input protection

Disconnector switch ….
For maintenance (disconnection from the PV source, fuse servicing), an isolation switch can be required.

…and overcurrent protection

Over current protection is needed within the switch or through fuse to protect against reverse current as we can
see in Figure 5.

Figure 5 – current path in case of short circuit in sub-array cable

The fault (1) is supplied by short-circuit currents from the other strings of the installation. The current in the
recombiner box input cable and switch will reach the value on (N-1)*Is/c (N= number of strings).
The wiring system and devices must be protected by an over current protection at the recombiner box to protect
against reverse current.

Technical solution: Load break switch and 1000V fuse or 2000 V circuit breaker
The over current protection shall be a fuse on each polarity rated for 1000V DC or a circuit breaker rated for
2xUoc max (typically 2000V with 1000V system) as explained in § 4.5.1.

4.4. Recombiner box output protection and inverter input protection

Disconnector switch ….
For PV inverter servicing, an isolation switch is required.
For emergency disconnection and functional disconnection, a load break switch is required.

…without overcurrent protection

For the same reason than for the combiner box output § 4.2, there is no need of over current protection.
In case of short circuit at the array cables or inside the PV inverter:
- The PV cells delivers a short circuit current of 1.25*In max (if the irradiation is maximum). No protection
can act on this current level.
- The cables are dimensioned for more than this value (Ib = 1.45 In).

When the recombiner box is installed nearby the PV inverter, a single load-break switch is required, typically at
the PV inverter input.

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Technical information
Photovoltaic application: selection of switch in IEC installation

4.5. PV Fuses advantages vs. PV CB in recombiner box input

A switch and an overcurrent protection are required in the recombiner input.

It can be fulfilled with 2 technical solutions:
- A fuse on each polarity and a load bread switch
- A circuit breaker

4.5.1. Risk of using circuit breaker in recombiner box input

Double ground fault can occur in PV installations, especially when a negative polarity is grounded.

A first ground fault can appear in the

negative polarity and will not be
detected as we can see in , unless
an expensive ground fault detection
system is installed.

Figure 6 – a first fault appears, undetected.

If later a second ground fault appears

on the positive polarity in , the circuit
breaker  will see two times the
reverse current and will try to open.

Figure 7 – later a second fault appears

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Technical information
Photovoltaic application: selection of switch in IEC installation

At the opening, the circuit breaker

will see a 2000 V potential
developing across and won’t be able
to interrupt the arc. This will lead to
important damage of the recombiner
box.

Instead of a circuit breaker, a 1000V

fuse will be able to interrupt the
reverse current.

Figure 8 - the CB will try to trip under 2000 V

4.5.2. Advantages of using Fuse in recombiner box input

The fuse offer several advantages compared to the option circuit breaker

- The fuse sees 1000V on one polarity and is rated to interrupt overcurrent over 1000V.

Figure 9 – 1000V fuse used in recombiner box input

- The fuse will have the advantage of no false tripping, creating production losses at high temperature. This
event is likely to occur in PV applications as the over current setting is minimum and the temperature range
maximum (-20°C to 70°C).
- The fuse will allow a simple and cost effective installation with the fuse directly mounted on the bus bar.

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Technical information
Photovoltaic application: selection of switch in IEC installation

5. PV switch operation
By default, most of the PV load break switches are manually operable.
But some functionality requires advanced operation.

5.1. PV inverter emergency stop

The Load-Break Switch at the PV inverter input can be used for the emergency stop in case of internal failure. In
this case, the load break switch shall have a tripping function.

5.2. PV inverter remote controlled operation

PV switches at the PV inverter input need to be remotely controlled for opening and reclosing for functional
reasons in the following cases:

- Preventive disconnection during storm in highly exposed areas.

- Disconnection of the PV field to operate inverter at night to manage reactive power only.
- Disconnection of the PV field at night with storage application, to avoid the discharge of the battery in the
PV cells (PV cells without light are only loads).

The switching functions being unchanged, the choice of a motorized PV switch allows to optimize the costs.

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Technical information
Photovoltaic application: selection of switch in IEC installation

5.3. Disconnection for fire fighting operation

5.3.1. A disconnection at the PV sub array level
A disconnection at the PV sub array level for the intervention of fire-fighters can be required for PV installations
on buildings.
- The objective of this disconnection is to ensure few seconds after activation that the fire-fighters won’t be
in contact with cables dangerous voltage while operating inside the building.
- The disconnector should be as close as possible of the PV cells: it is generally in the combiner box ().
- The actuation of the switch should be in the common disconnection area, at the bottom of the building ().
- A positive feedback of the disconnection should also be in the same area () to indicate to the fire-fighters
that the installation is safe.

Figure 10 - Fire fighting issues

5.3.2. A disconnection at the PV inverter level

A disconnection at the PV inverter level can also be required:

- PV cables can be energized from both sources: by the PV modules and input capacitors of the PV inverter.
- If the PV inverter capacitors maintain a voltage above 60V for more than10 seconds to one minute
(depending on the local legislation) after disconnection of PV module, PV cables shall be also
disconnected from the PV inverter () to reduce the voltage inside the cables between PV modules and
PV inverter below 60 V.

5.3.3. Technical solution

To implement this function, a trippable switch is the optimized solution.

The switch actuation can be electric or even pneumatic to be really independent from the power availability in the
building under fire (generally without power) and coupled with the existing air pressure system used to open sky
domes.

Figure 12 - Example of Figure 11 - Example of

switch SIRCO PA with switch INNOSYS LBS
pneumatic activation with coil activation for
for firefighters firefighters

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Technical information
Photovoltaic application: selection of switch in IEC installation

5.4. Arc Fault Interruption

Defective PV modules, components, faulty cables and connectors can lead to potentially dangerous series arc-
faults.
Series arc fault results from a failure in the intended continuity of current carrying component.
In case of interrupted conductor, the current continues to flow in the air through visible plasma that will burn its
surrounding environment.

Over current protection can’t stop a series arc as the current value value is too
low. Only the load disconnection by opening a load break switch or stopping the
PV inverter can interrupt the arc before it damages the PV plant.

Series arc can be detected at the combiner box level by dedicated arc fault
detector and interrupted by tripping the load-break switch.

Figure 13- Example of

electronic board RESYS
AFD to detect arc fault and
activate a trippable load
break switch

6. Characterization of a PV switch
Among all the PV switches characteristics we’ll focus on a few pertinent ones.
The other features need less attention, as their consequences in safety, reliability and cost are not significant.

6.1. In: Nominal current

The nominal current value of a PV switch depends on the power of the string, group of string or PV generator
connected to this switch
2
- For the IEC standard, the nominal value is In > 1,25 ISCSTC for a temperature of 40 °C. This coefficient
takes into account the possible over current due to over irradiation
- For the UL standard, the nominal value is In > 1,4 ISCSTC

Another parameter to take into consideration is

the real working temperature depending on the
maximal temperature during the day and the
maximum irradiation on the combiner box

Derating coefficient is used to find the nominal

value at a given altitude and temperature. The
manufacturer must supply the temperature
derating ratios.

Figure 14 - Simplified method of temperature derating

2
Isc STC: short circuit current under Standard Test Conditions ( 1000 W/m², 25°C, AM = 1.5)

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Technical information
Photovoltaic application: selection of switch in IEC installation

6.2. Vnom: Nominal voltage

The nominal voltage of a PV switch will be higher or equal to the max PV cell voltage. It occurs at the minimum
temperature in open circuit condition.
The switch Vnom is impacted by the altitude. The cause is the changing dielectric characteristic of the air.
As for the temperature derating on the current, a derating formula or table will be communicated by the
manufacturer. It can be combined with the temperature derating for a better usage by the designer.

Figure 15 – Example of a combined temperature and altitude derating table

6.3. Non Polarization of the switch

A switch must not be polarized to allow switching under all current values in both directions.

If the arc clearance mechanism is polarized, the switch can interrupt the current in one direction and might fail to
do it if the current is flowing in the reverse direction. Both cases can happen in a PV installation

Example where a polarization of the switch can be harmful:

- Installation under low irradiation. ISC << In
- With a cable insulation fault on the PV cell cabling
or in the combiner box.
- The current is too low to blow the PV fuse
protection.
- The polarized switch on the combiner box will not
be able to interrupt the arc.
- If the current is in the range of the Critical Current,
the effect is further amplified.
- Possible consequences: fire, operator death.

Figure 16 – Example of Reverse current issue in PV

6.4. Icw : Short time withstand current

The second main feature for switches is to accept high short circuits values until the upstream protection clears
the fault.
In PV installation without storage, the Icw is not an issue.
- The use upstream of dedicated fuses gPV, generally at the same value of current ensure easily the correct
protection of the switches.
- For the general switch of the field, the short circuit value of the PV generator is largely under 12 times the
nominal current required by the general standard IEC 60947-3 for switches.

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Technical information
Photovoltaic application: selection of switch in IEC installation

In PV installation with storage, the switch must be coordinated with the battery protection.

- Batteries generate high short circuit currents (typ. 10*In): I SC >> In

- In case of fault “behind” a switch,
- The A²t of the protection (,) immediately “before” the switch
must be lower that the A²t of the switch (,).

Figure 17 - switch/fuse coordination

in storage application

6.5. Icrit – Critical Current

All switchgears interrupt an arc more or less easily depending on the value of the short circuit current. The value
where this interruption is the most difficult is the Critical Current.

6.5.1. What is critical current?

Critical current is defined in §2.1 of the IEC 60947-1 §2.5.16 and the prIEC 60947-3 §2.1
The critical current is the values of current where the arcing time during the opening of a switch is significantly
extended, or when the switch is not able to interrupt the current.
It is typically a low current compared to the nominal rating of the switch.

6.5.2. Why is a switch not able to open the critical current

At the opening, a magnetic field is created by the electrical arc. Due to this magnetic field 𝐵 ⃗ , a resulting
⃗ × 𝐼 . This force is proportional to the current.
electromagnetic force is applied to the arc 𝐹 = 𝐵

If the current is high (nominal value) the resulting force will elongate the arc above the maximal length to interrupt
the arc.

If the current is too low but high enough to be maintained, the resulting force is not able to elongate the arc that
will stay unextinguished.

Figure 18 – Current interruption inside a switchgear

Consequences:
- Risk of electrocution for operators thinking that the installation is disconnected
- Risk of fire of the PV switch inside a combiner box or a PV inverter with propagation to other parts of the
installation.

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Photovoltaic application: selection of switch in IEC installation

6.5.3. Why is critical current more crucial for PV application than for DC or AC application?
In PV applications, the critical current is more crucial than for DC or AC applications for several reasons:
- switches will be mainly operated at the value of the Icrit. Operators prefer to operate and maintain a
PV installation early morning and late evening, when the production is minimum. At this moment, the
current is in the range of the Icrit.

- PV cells are more prone to maintain the arc at low levels:

o They are current generators, instead of batteries, which are voltage generators.
o A current generator will maintain the current and allow the voltage at its terminal to vary, instead
of the voltage generator which will maintain the voltage and allow the current to vary with the
load.

- PV cells current will go naturally towards the Icrit at the switch opening:

in PV application, at the opening of a switch, the voltage will

increase and the current will decrease toward the Icrit value
following the typical U/I curve of a PV cell.

Instead, a voltage generator will try to maintain the voltage

during the opening of a switch.

Figure 19- Critical current of a PV switch shown

on the cell curve

- In addition, the cells voltage at low current is quite higher than the nominal voltage (i.e. 1000 VDC vs.
800 VDC), increasing the difficulty of breaking the arc.

6.5.4. How to manage properly Icrit

AC and DC switch shall not be used for PV application since they are not able to manage Icrit.
In PV application, it is crucial to use switch dedicated to PV, designed to managed Icrit.

Figure 20 – view of arcing chamber of SIRCO PV dedicated to PV

application with special parts to interrupt critical current

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Photovoltaic application: selection of switch in IEC installation

6.6. PV category

The PV category as specified by the IEC 60947-3 is based on the “load” characteristics and as such, where the
switch has to operate.

Figure 21 - IEC 60947-3 definition of PV categories

PV1 is for PV installation with no over current and no reverse current. It’s typically the case for single or dual
string installation in residential buildings.

PV2 is required for all other installations with multiple strings and / or battery storage.

Figure 22 - IEC 60947-3 definition of making and breaking operational performances for PV categories

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