User’s Manual TRISOLAR™ String Combiner Box (SCB) with Monitoring Device for PV Solar Solutions For Solar Plants TRINITY? eae an2 Sen nnn Sn EER HH TOUCH mmm lecmeennel-eGnememlceTRISOLAR" Contents CHAPTER -1 Introduction to the manual CHAPTER -2 What is String Combiner Box CHAPTER -3 Installation of String Combiner Box CHAPTER -4 Electrical Connection CHAPTER - 5 Communication CHAPTER -6 Monitoring Device CHAPTER -7 Technical Specification CHAPTER -8 Pre Commissioning Test CHAPTER -9 Maintenance CHAPTER - 10 Do's & Don'ts CHAPTER - 11 Circuit DiagramTRISOLAR" CHAPTER - 1 Introduction to the manual Chapter Contents : This chapter introduces this manual. Be Ci SCB String Combiner Box oo PPE Personal Protection Equipment Applicability : . PV Photo Voltaic This manual applies to String Combiner Box with Monitoring Device. Pp Ingress Protection SCADA Supervisory Control and Data Acquisition RTU Remote Terminal Unit P Ingress Protection Important Safety Instructions This instruction manual contains important instructions for all SCB that must be followed during the installation and use of the SCB. To reduce the risk of personal injury and to ensure the safe installation and operation of the SCB, you must carefully read and follow all instructions and warnings in this installation guide. Only qualified personnel are allowed to install the junction box! Never work on the junction box or its cabling when the box is connected to the solar modules or inverter, or to the 230 V AC auxiliary power supply. Always disconnect all possible power sources and prevent their accidental reconnection before starting the work. ‘AWaning describes a hazard to equipment or personnel. It calls attention to a procedure or practice, which, if not correctly performed or adhered to, could result in damage of parts of string /\ combiner box. Warning PY modules pass direct current (OC) when the module is under load. Direct current will arc across gap and may cause injury or death itimproper connection or disconnection is made. Do not connect or disconnect wires to the SCB when current from the modules or an external source is present. This ground symbol marks area in the SCB for connecting equipments grounds only, Important Safety Features : + Use insulated tools to reduce the risk of electric shock. + Do not install the SCB if itis wet + Make connection in the SCB prior to connecting modules. + Remove all metallic accessories prior to installing SCB to reduce the chance of accidental exposure to live circuits. TRINITY TOUCH PVT. LTD. 1Introduction to the manual TRISOLAR" Contents of the manual The manual consists of the following chapters: + Introduction to the manual introduces this manual. + What is String Combiner Box introduces SCB. + Mechanical installation describes the mechanical installation procedure of the SCB. + Electrical installation describes the electrical installation procedure of the SCB. + Communication describes the communication procedure of the SCB with the help of monitoring device installed in the SCB Monitoring device describes the functions & features of the monitoring device. ‘Technical specifications contains the technical data of the SCB & monitoring device Pre Commissioning Test Do's & Don'ts. TRINITY TOUCH PVT. LTD. 2TRISOLAR" CHAPTER - 2 What is String Combiner Box Chapter Contents :This chapter describes about the SCB with Monitoring with its Construction The SCB enables you to enjoy a high level of system performance monitoring, while providing exceptional system safety. The SCB is an electrical distribution box where the DC fuses or circuit breakers are placed for safety concern The SCB combines the multiple DC input coming from the panel termination and converts these into one DC output. The output of the SCB is connected to the charge controller or the inverter, depending on the type of system installed. Replaceable fuses are used per string input in the SCB. The SCB featuring (8,16,24 & 32) string inputs, each of which is separately monitored through the current/voltage measurements. The SCB also designed for the communication purpose through which it shares the data of monitored string to the PLC/SCADA with the help of monitoring device. leet = ss Ar hore fd ally 4 ik annem £IG)-Cs Oo [=] { 8 elie | 3 TRINITY TOUCH PVT. LTD. 3TRISOLAR" CHAPTER -3 Installation of SCB Chapter Contents : This chapter describes the mechanical installation procedure of the SCB. Installation area must be suitable for the weight and dimensions of the SCB. Ensure that the following conditions are met when selecting a mounting location : + Unpack the shipping box and remove the String Combiner Box + Locate the wall or pole on which the String Combiner Box is to be mounted + String Combiner box should be installed in horizontal position + Mount the String Combiner Box on a solid surface. + The mounting location must be accessible at all times, and should be within connection distance of the PV installation. Do not mount the String Combiner Box with a forward tilt Do not mount the String Combiner Box on its side. Do not mount while the air is highly humid Do not mount the String Combiner Box too close to the ground. / Do not install the SCB in a location where: + Corrosive, Explosive or Flammable materials are used or stored. Warning «There isa risk of mechanical impacts. + There is alot of dust, or any conductive dust. + ‘There is a risk offloading or sand piling. + Junction box will be near to a heat source. Exposure to external heat will shorten the component lifetime. The installation location must be accessible in emergencies and for maintenance The installation location must be out of reach of children, animals and pests. ‘Avoid installing the junction box in direct sunlight Leave enough space for cabling below the box. Install the junction box under cover to avoid rain water, Tools and Accessories Make sure that you have the following tools and accessories available: Screwdriver with a set of screw bits Multimeter PPE's Mounting screws. TRINITY TOUCH PVT. LTD. 4TRISOLAR" CHAPTER - 4 Electrical Connections Chapter Contents : This chapter describes how to connect the external wiring to the SCB. A Connections to be done by authorized person only. See the safety instructions before working on = the SCB, Ignoring the safety instructions can cause injury or death. Warning Connecting the Input / Output cable + Connect the DC inputs from the PV strings to the SCB with required torque as per the data sheet. Inputs consists of two sides, positive & a negative side. + Connect the positive input wire from the source circuit to the touch safe fuse holders / terminals and tighten with the torque value of 2.5Nm to 3.0 Nm + Connect the negative input wire from the source circuit to the negative side fuse holders / Terminals and tighten with the torque value 2.5Nm to 3,0 Nm to hold the wire in one place. * Connect the positive output wire from the inverter (or other destination) into the positive output side of the disconnector switch/MCB with required torque values according to the data sheet. + Connect the negative output wire from the inverter (or other destination) into the negative output side of the disconnector switch/MCB with required torque values according to the data sheet. + Connect the cables to the point as displayed in chapter circuit diagrams. TRINITY TOUCH PVT. LTD. 5Electrical Connections TRISOLAR" Hexagon Nuts (Unit: N'm {ft.lbs, kgt¢m}) Strength | Teeicaion \ Nomina \. | Sandardscrew | Coase seren oe fa diarneter theead tweed ‘Standard screw thread Coarse screw thread M5 [uswiizoen] —— proitiiwan M6 sonatas = _ 2 r eT MB | omaeaator3 es = MAO Bir 715 ~ ~ io 4a M10 | jop'idve27 | wrote rsoa pee iieay 4050 Nos 0 8510 85 7 M12 | awd Sosy | aseddioan modiions ae iBeos 300, 357 Tapia io 100 [Wd [ean] oral Poa5 eee Sia Spt ae 10 The wie ho M16 | eooensioia | penetso 25068, 2 | (1200 eh 02) mie |e |, eae wap i T mem | PATE wy [oR Fn] mesh | we Boao 18010240, 17 ts 220 6 to 450 31010 410 M20 |nsodtBision [nasties Pom pons sem | exw vom |, SSS |e won Ge aaa SB Sem |omeia sem] eames don puss Sem wa | ee | em mace ae ose Soules Ses| woes tna coos Sey Hexagon Flange Nuts (Unit: N-m {ft.lbs, kgfm}) Suengih ‘donilaton symbol Nominat \\ | Slandard serew | ‘Cores eorew dames thvead chreas i ro M6 |powdtitoun| ——- wes MB | capneiwmi9 Zs Ban M10 | crsyo92'31'm29) | f25924,20%.90) Bes ost M12 | owt Botey| powde dese) TRINITY TOUCH PVT. LTD. 6Electrical Connections TRISOLAR" TABLE OF STANDARD TIGHTENING TORQUES fect ths section unless alherwise stated. + Use specified baits and nuts, tightening them to the torques sp% + Threaded portions snd bearing surtaces should De cry + Where the property dass differs between the nul and noi (oF stu bot), use the tightering terque spacifed in the table for the bot Hexagon Headed Bolt, Stud Bolt (Unit: N-m {ftlbs, kgf-m}) Stang aT 7 i jection 1 To sorte C Fowt | fromnat Ww) be loner “ (ues Sug _ are M5 lesndiwen| — - —— [awedtfwon| a sea M6 [pon ssa 009) [p2widarorw AiR OD w 12)| - oer ton eam MB pavdhari:s| (oma ifo2s (aiolt!229) | MIO [oli Foun [asmikisorn | osu SSes1| wm k ow | med Sno [WI2” lasndfosy| aa itean | ewe ious | wet ssoaa| endieadiry | eam et Sian wid ec 5 sae iow ToT oo [tb etonay | wrnseeters | erm liters | gash Hom | amg Sein esete Pore) wis | iz em mp2 woz mn rom7 I | emmadiorn | eset tor: |yusoien trm29| ou ee Hay case haw b27| (98 He sem a tov mp | mmm | amu | swum 2500 30 0528 ion | atte | pasts 2a 9 | (0109, 20] sina Seb | as I oy ‘ioaio mom | owas soe | aapew M20 so Oe |e TN | mea ven | roo BR | RR Te sy | sR a nas Zana mee | _ won esa | son m0 cr (195725 tom wots Bes soe tres| pOreE Ros |MOoes dw ry pend Sow Tost ow | aeSoe Suerm | eso | a [Weds BES ay | PBEM | wo SE Been un SBS Bra pele ae [on Sas Hexagon Headed Flange Bolt (Unit: N-m (ftibs, kg-m}) ‘Sirenath a0 7 8T f eather — - = | | | @ ) (8) be] (4) ag eb S | Ss 4 T = aoe Wm m6 (3.019 44,04 085) - {54 1089, 08s 1.2) - 40 10.10 014) ME Intnl] [ownkSbea| ———[naeiBSeoa | Mid zest abs cro vest ‘Sim AB sien |cseaStoen | ssi bse | muittsess | erate sansa| arose lone | gree sinss M12 310 west 8000 106 Tangs 90 Biod | 2 |uewtiBiasn | pewisisnss simmons | cowie? saan | geen | GIeeetsem TRINITY TOUCH PVT. LTD. 7Electrical Connections TRISOLAR" Power Supply Wire Connection + Power supply needs 100-230V AC input for powering up. After getting input AC power supply gives 24V DC supply. 24 V DC Output Connection connected to the Monitoring card: Power Supply Disconnector Switch Fuses: Monitoring Card Connection + Insert positive input Wires from the source circuit to the Touch Safe fuse holder and tighten to torque specifications. + Insert negative input conductor from the source circuit to the negative collector terminal at the monitoring card. + Insert positive output wire to the inverter (or other destination) into the positive output of disconnector switch + Insert negative output wire to the inverter (or other destination) into the negative output terminal ‘Surge Protection Device TRICHECK 24 TRINITY TOUCH PVT. LTD. 8Electrical Connections TRISOLAR" Power Connection + For positive input connection, connect the one side of wire at the Disconnector switch & connect the other side to the input fuse. + For negative input connection, connect the one side of wire at the Disconnector switch & connect the other side to the negative busbar. + Connect the output cables to the 240 sq mm output terminals. Positive & Negative Output Connecting The Combiner Box: To connect the combiner box: Connect the DC Inputs: Connect the DC inputs from the PV strings to the fuses. Inputs consist of two wires, a plus(+) and a minus(-). The plus connects to the fuse holder for the input and the minus connects to the busbar. Each input is labeled and numbered. Connect the plus wire for each DC input to its fuse holder by loosening the screw on the top of the fuse holder and then inserting the wire through the cable gland. Then set torque to 2.5Nm & tighten the screw to hold the wire in place. Connect the minus wire for each DC input to the negative busbar. Connect the DC Outputs. The Combiner Box has two DC Output plus(+) & minus(-). Insert the positive & negative cable through the DC output cable gland. Connect the plus & minus cables to the UHV 240 terminal TRINITY TOUCH PVT. LTD. 9Electrical Connections TRISOLAR" Connecting the external power supply cable for the monitoring card circuit Connect the cables to the point as displayed in chapter Circuit diagrams Connecting the Modbus link A Connections to the modbus will be done by authorized person only. See the safety instructions before working on the SCB. Ignoring the safety instructions can cause injury or death. Warning The box come completely internally wired. Avoid touching or modifying the internal wiring once installed on site. Only attach the external cables to indicated terminals. Use shielded, twisted pair RS-485 cable suggested by SCADA designers, + Do not connect the RS-485 cable without authorization from Trinity Touch + Make sure that there are no stray voltages over and above the values specified in RS-485 protocols. + Any damage to the services due to over voltage or surge or incorrect external wiring will be on account of the purchaser. TRINITY TOUCH PVT. LTD. 10TRISOLAR" CHAPTER - 5 Communication Chapter Contents : This chapter describes the communication on the Modbus link between the junction box and a PLC/SCADA. Important Information on Bus Connection All bus lines must have cabling to the data logger which is in excellent condition, all shielded and with twisted pairs to guarantee faultless data transmission as suggested by the SCADA designers. SERIAL ARMOURED CABLE TECHNICAL SPECIFICATIONS Conductor ‘Annealed Bare Electrolytic Copper Conductor (As per BS:5308/Part-1V'1986) Cable ype ‘AS per BOM ‘Conductor Insulation Type IV Compound [As per BS 6746] Pair formation. 2 cores twisted to form one pair with 4-6 tums per meter & covered with Mylar tape: Cable lay Al such pairs shall be laid up with suitable lay to form circular cable Core identification ‘As per BOM ‘Screening, ‘Overall screening for all such pairs with aluminium Mylar tape having 0,023 mm min. thickness, 100% coverage with 25% Overlapping, Individual Parr Screening “Annealed tinned copper conductor Material Inner sheath 'ST-2 FRLS (As per IEC 60502) Inner Sheath Thickness (0.80mm(Nom) Inner sheath colour Black, ‘Armouring Galvanised steel ‘round wire"(0 90mm) ‘Outer Sheath 'ST-2 FRLS (As per IEC 60502) ‘Outer Sheath Thickness 4.24mm(mnin) ‘Outer sheath colour Black/Light BUS Make Reputed TRINITY TOUCH PVT. LTD. 1"TRISOLAR" CHARACTERISTICS OF FRLS PVC USED FOR OUTER SHEATH ‘Oxygen index ‘As per ASTM D 2863-77 1.6, 29% minimum at room temperature ‘Temperature index ‘As per ASTM D 2863-77 i.e. 250 C minimum, HCL gas emission ‘As por IEC-754-1 i,¢.20% maximum ‘Smoke rating density ‘As per ASTM D 2843-77 < 60% ELECTRICAL CHARACTERISTICS, Insulation resistance 700M [km at 20 C minimum Mutual capacitance between 250 pfim Adjacent cores at 0.8 kHz (max) Image attenuation at 1 KHz 3.2608/Km HV Test(Core to Core) 2KV for 1 Minute Noise attenuation 60 dB. LR Ratio 25 uH/Ohms [Max] BILL OF MATERIAL Cable Type | Core Identification Application ae) 1": White+Blue, 1.5/2 Pairx | 2™ : White+Orange, RS 485 for Serial As read 0.22-.5 Samm | 3" : White+Green, Communication a 4”: White+Brown TRINITY TOUCH PVT. LTD. 12ge om Communication TRISOLAR Register Mapping DATA.30001 Digital Inputs (in binary format) DATA.30002 Inst Curr Stt_01 (mA [0..30000)) DATA.30003, inst Curr Stt_02 (mA [0...30000) DATA.30004 Inst Curr Stt_03 (mA [0...30000)) DATA.30005 Inst Curr Str_04 (mA (0...30000)) DATA.30006 inst Curr Stt_05 (mA [0...30000) DATA.30007 Inst Curr Stt_06 (mA [0...30000)) DATA.30008 Inst Curr Stt_07 (mA (0...30000)) DATA.30009 Inst Curr Stt_08 (mA [0...30000)) DATA.30010 Inst Curr Str_09 (mA [0.,.30000)) DATA.30011 Inst Curr St_10 (mA [0...30000)) DATA.30012 Inst Curr St_1t (mA [0...30000)) DATA.30013, Inst Curr Str_12 (mA [0...30000) DATA.30014 Inst Curr St_13 (mA [0...30000)) DATA.30015 Inst Curr St_14 (mA [0...30000)) DATA.30016 Inst Curr St_15 (mA [0...30000)) DATA.30017 Inst Curr St_16 (mA [0...30000)) DATA.30018 Inst Curr St_17 (mA [0...30000)) DATA.30019 Inst Curr Str_18 (mA [0...30000)) DATA.30020 Inst Curr Str_19 (mA [0...30000}) DATA.30021 Inst Curr Stt_20 (mA (0...30000)) DATA.30022 Inst Curr St_21 (mA [0...30000)) DATA 30023 Inst Curr Stt_22 (mA [0...30000)) DATA.30024 Inst Curr St_23 (mA (0...30000)) DATA.30025 Inst Curr Stt_24 (mA [0...30000) DATA 30034 Digital input 4 DATA.30035 Digital input 2 DATA.30040 inst V_1 (V[0....1000), DATA.30041 Not Used DATA,30042 ‘Aux 4 (0...700mV) [0.1000] DATA.30043 ‘Aux 2 (0...20mA) [0...1000] DATA 30044 Inst T_1(°C [0...100) DATA.30045 Inst T_2 (°C [-22.0..+83.0) DATA.30046 Inst T_3 (°C [22.0..+83,0)) DATA 30047 ‘Sum of all currents (A) DATA.30048 Power (W) (Most significant bit) DATA.30049, Power (W) (Least significant bit) ‘Set up PARITY mode: t:none 2: even DATA.40001 3: odd TRINITY TOUCH PVT. LTD. 3Communication TRISOLAR" Recommendations: Recommendations describes the procedure to avoid the failure of Communication between the SCB and a PLC/SCADA. It calls attention to a procedure or practice, whichif not correctly performed it could result in damage of the monitoring device + Use RS-485 twisted pair cable for communication which should be atleast 4 core. Ideally one should use 6 or 8 core cable for future maintenance reasons. + RS-485 repeaters should be used in the middle of the bus line for better communication where it is. designed in by the network designers. + To avoid voltages on the bus line at the time of inverters ON/OFF the PLC and connection to earth should be established with a 100 ohm resistor minimum 2.5W. + There should be no power cable close to the RS-485 cable. Follow the laying standards for data cables. The length of the data cable should not be more than 1200m + The voltage between the communication line should not be above RS-485 standards, if it does than it will damage the communication drivers of the monitoring device. + For the safety of monitoring device, Trinity Touch recommends RS-485 data line surge suppressor in th SCB so that any surge coming through the data line could not damage the line driver of the device —> FOR MORE INFORMATION, PLEASE REFER TO THE TRICHECK USER’S MANUAL. TRINITY TOUCH PVT. LTD. 14TRISOLAR" CHAPTER -7 Technical Specifications Chapter Contents : This chapter contains the technical data of SCB and the monitoring device. Weeueis cde cous Enclosure material Polycarbonate Cover & Base of Polyster Enclosure dimensions 720x540x201 mm Fuse base Cooper Bussmann Fuse link ‘Cooper Bussmann (12A, 1000V DC) ‘Surge protection device (SPD) Phoenix Contact (30 KA, 1000V DC) Disconnector switch ‘Sacemec (#00A, 1000V DG) Giese Make HES Ingress protection P66 Impact resistance 1k09 Temperature range “50°C to +130°C. Electrical insulation Tngulated Enclosure flammability test ULS+HB Non toxity Halogen free Glow wire test 960°C SPD Specification Make Phoenix Contact re 30kA Network voltage 1000v DC Maximum operating voltage 1060V DC ‘Operating current <0.1mA Nominal discharge current 20KA Maximum discharge current ‘OKA Operating temperature “40°C to 80°C Protection class P20 Housing material Thermoplastic UL 94-V0 Disconnector switch specification Make ‘Socomec Operating current (la) 4008 Votage 000v DC TRINITY TOUCH PVT. LTD. 15Technical Specification TRISOLAR" TRICGHECK24 Technical Specifications Input Curent Number 2% Measuring Range/sting 2A Measuring side Negative FOR MORE INFORMATION, PLEASE REFER TO THE TRICHECK USER’S MANUAL. TRINITY TOUCH PVT. LTD. 7TRISOLAR" CHAPTER - 8 Pre Commissioning Test Inspecting the Combiner Box A For your personal safety, the steps described in this section must be completed before installing fuses Warning Note : A multimeter is required in order to verify the installation process. Check that the multimeter is capable of reading the maximum string volatage and maximum string current before proceeding, To inspect the combiner box: + Make sure that all the wire connections of combiner box are proper. + Measure the Voltage: Set the multimeter to DC voltage mode. Check the open circuit positive voltage from each string to the negative busbar. + Verify that each voltage open circuit is the proper polarity. To do so, place the positive lead of the multimeter on the fuse holder and the negative lead on the terminal block. + Measure the current : Place the multimeter in DC current mode. Check the current of each solar array string to the negative busbar. + Check polarity for all the strings by measuring the voltage differential of the positive end (fused) to ground. Also make sure that all strings are properly labeled indicating polarity and string number + Measure the voltage between the positive and the negative ends at the combiner box. This is the best indicator to know that all strings are wired correctly. TRINITY TOUCH PVT. LTD. 18TRISOLAR" CHAPTER -9 Maintenance Carry out the following maintenance checks atleast once a month. Test Object Test Activity Enclosure Use appropriate screw drivers to avoid damages to the screws of the enclosure. Cable Glands Check the seating and stability of the screw connections and tighten, if necessary, Internal connections (DC connections and if necessary AC connections) Check the seating and stability of the screw connections and tighten, if necessary. External Earth connection Tighten to the prescribed torque, Circuit Breakers/Dis.Connector Switch Press them/ON-OFF Switch handle to make sure they are working properly. External Connection ‘Check connection cables for their condition and mechnical loads and, if necessary, replace. Monitoring Device Check string connections and output power connection and tighten, if necessary, TRINITY TOUCH PVT. LTD. 19TRISOLAR" CHAPTER - 10 SCB Installation “Dos and Don’ts” ‘communication cable Stage Responsibility Precautions Delivery at Site Erection of the SCBs Buyer 1 Erection should be dane as per design drawings Power Terminations: Buyer 11 Terminations shauld be dane as per design drawings Laying of Buyer 1. Communication cable should be of EW4B5 (RS-485) standards. 2. Aminimum aistance of 300 mm should be maintained between the communication Cable and power carrying cables. Preferably a separate table tray should be used. 5, Maximum length of RS485 communication cable loop should be 1200 meters ‘4. Maximum devices on individual loop should be limited to 11 devices for optimal performance. §5, RS485 cable branching should not be done unless a spiter or Hub is used Training by TTPL TIPL, participation by Buyer Termination of ‘communication, ‘earthing cable and Buyer, Supervision by TPL, 11. Separate earth pits) with ohmic value less than 1 Ohm should be ‘made avaliable for electronic and communication equipments 2, Check earth resistance and ensure grounding of earthing terminals ‘communication devices shielding 3. Check or Electrically induced disturbances ar Temporary aver-vollages: fon communication cable 4A. Conduct continuity and loop tests on Communication cable segments 5, Terminate the cable shielding on appropriate ground terminals. powering of Buyer, Supervision by TTPL_| 1. Check the vollage a input terminals 2. Check he vottage of communication cable checking of ‘communication for individual devices. Checking of ‘communication for devices in loop. TIPL, assistance by Buyer Buyer! SCADA vendor, assistance by TPL. 41, Use EINRS-485 compliant communication devices 41. Check and match Baud rate, Stop bits and parity 2, Check correct device addressing TRINITY TOUCH PVT. LTD. 20TRISOLAR" CHAPTER - 11 Circuit Diagram NSH : TOLERANCE ' z 2 TRINITY TOUCH PVT. LTD. 2Trinity Touch Pvt. Ltd. wwnw.trinitytouch.com INDIA (0-10, Defence Colony, New Dah 110024 INDIA mali posimaster@tnsyouchcom Works & Warehouse eryana NDA Toh #91-11. 20808000 E-mail sles@inyecuch com © Gaiis'at” 1800 2000 140 Trinity Touch (EUROPE) Ltd. www.trinitytouch.co.uk mali gosalesar