YASKAWA CR1500-xxP Remote Combiner User Manual

YASKAWA CR1500-xxP Remote Combiner

Ratings and Specifications

The CR1500-xxP Combiner is rated for a maximum DC voltage of 1500VDC and a maximum DC current of 20A per input string. The combiner includes fuseholders for up to 16 fuses, with each fuse rated for a maximum DC voltage of 1500VDC and a maximum DC current of 20A. The enclosure is rated for NEMA 4X and IP66 protection. The combiner is available in various models with different fuse configurations, as shown in Table 3.2.

Unpacking and Inspection

1. Check for Damage – Inspect the combiner for any damage that may have occurred during shipping.
2. Remove Packing Material Inside the Combiner – Remove any packing material inside the combiner before installation.

Figures

• Illustrated Usage of the CR1500-xxP Combiner with the SOLECTRIA XGI 1500 Inverter
• The CR1500-xxP Combiner
• CR1500-xxP Combiner front view (left) and side view (right), dimensions and mounting tab locations
• CR1500-xxP Combiner example mounting to struts
• Bottom of the CR1500-xxP Enclosure
• PV Output Circuit Stud Plates (side view, left; top view, right)
• Compression Lug Connections, Single and Dual Conductors
• PV Source Circuit Equipment Ground Terminals
• PV Output Circuit Equipment Ground Terminal
• Switch Handle Positions for OFF (left) and ON (right)

Tables

• CR1500-xxP Combiner Ratings and Specifications
• CR1500-xxP Combiner Model Numbers
• Fuseholder Specifications
• Example 1500VDC Replacement PV Fuse
• PV Output Circuit Terminal Specifications
• Compression Lug Specifications

SYMBOLE

Usage Instructions

1. Read all instructions and caution markings in the manual and on the combiner.
2. Disconnect all PV modules before wiring.
3. Verify the absence of voltage before performing work on the CR1500-xxP Combiner.
4. Mount the combiner to struts using the mounting tab locations shown in Figure 4.1.
5. Connect PV input strings to the PV output circuit stud plates using compression lug connections, as shown in Figure 4.5.
6. Connect the PV input strings’ equipment ground terminals to the PV source circuit equipment ground terminals, as shown in Figure 4.6.
7. Connect the PV output circuit equipment ground terminal to the system ground, as shown in Figure 4.7.
8. Turn the switch handle to the OFF position before wiring.
9. Wire the output circuit according to the system design.
10. Turn the switch handle to the ON position to enable the output circuit.

IMPORTANT SAFETY INSTRUCTIONS

The SOLECTRIA Remote PV Combiner (CR1500-xxP) is compatible with and intended exclusively for use with the SOLECTRIA XGI 1500 Inverters. Before using the CR1500-xxP Combiner, please read all instructions and caution markings in this manual and on the Combiner, as well as all other instructions and warnings for associated equipment. This manual contains important instructions that must be followed during installation and operation of the CR1500-xxP Combiner. To reduce the risk of electrical shock and to ensure the safe installation and operation of the Combiner, the following safety symbols are used to indicate dangerous conditions and important safety instructions.

SAVE THESE INSTRUCTIONS

The SOLECTRIA Remote PV Combiner (CR1500-xxP) is compatible with and intended exclusively for use with the SOLECTRIA XGI 1500 Inverters.
Before using the CR1500-xxP Combiner, please read all instructions and caution markings in this manual and on the Combiner, as well as all other instructions and warnings for associated equipment.

This manual contains important instructions that must be followed during installation and operation of the CR1500-xxP Combiner. To reduce the risk of electrical shock and to ensure the safe installation and operation of the Combiner, the following safety symbols are used to indicate dangerous conditions and important safety instructions.

WARNING

• Disconnect all PV modules before wiring. PV arrays produce dc voltage when exposed to light and could create a hazardous condition. Always verify the absence of voltage before performing work on the CR1500-xxP Combiner.
• Connecting PV Source Circuits to the input of the Combiner and connecting the PV Output Circuit to the XGI 1500 inverter, must only be done after receiving approval from the utility company and Authorty Having Jurisdiction (AHJ), and should only be performed by qualified persons.
• The CR1500-xxP Combiners are intended exclusively for use with the SOLECTRIA XGI 1500 Inverters. The CR1500-xxP Combiners should not be used with any other inverter.

PRODUCT OVERVIEW

The CR1500-xxP Combiner is a remote photovoltaic (PV) combiner box designed to combine multiple PV strings into a single output circuit. The combiner is intended for use with the SOLECTRIA XGI 1500 Inverters. The combiner includes positive and negative PV input terminals, a ground terminal, and a DC output circuit breaker. The combiner also includes a switch handle for manual on/off control of the output circuit. The enclosure is weather-resistant and suitable for outdoor installation.

The primary function of the CR1500-xxP Combiner is to combine PV Source Circuits from a PV array in parallel, safely, and form a resulting PV Output Circuit for connection to downstream equipment. The CR1500-xxP is intended exclusively for use with the SOLECTRIA XGI 1500 Inverters. They should not be used with any other inverter. Refer to the illustration in Figure 2.1 showing the CR1500-xxP Combiner’s general usage in a system with the SOLECTRIA XGI 1500 Inverter.

Figure 2.1 – Illustrated Usage of the CR1500-xxP Combiner with the SOLECTRIA XGI 1500 Inverter

The CR1500-xxP Combiner (see Fig 2.2) performs the following functions:

• PV Source Circuit Connections:
  • Touch-safe fuseholders with terminals for 16 – 28 positive-polarity PV Source Circuit conductors
  • Overcurrent protection provided by 20A fuses, factory installed for all positive-polarity PV Source Circuit conductors
  • A 30-position bus for termination of the negative-polarity PV Source Circuit conductors
  • Connection from all PV Source Circuit conductors to the internal DC bus
• DC Disconnect Switch:
  • DC disconnect switch, 250A, two-pole, fully integrated and externally operable; separates the combined PV Source Circuits from the PV Output Circuit terminals and conductors
• PV Output Circuit Connections:
  • Terminals accommodating single 750kcmil conductors or dual 600kcmil per pole, for the field-installed PV Output Circuit conductors.
  • Optional type II surge protection, factory installed.

RATINGS AND SPECIFICATIONS

CR1500-xxP SPECIFICATIONS

PV SOURCE CIRCUIT CONNECTIONS
Maximum Voltage| 1500VDC
Fuseholder

·         Wire Compatibility

·         Required Torque

·         Temperature Rating

·         Other

| ****

·         14 – 6AWG, PV-Rated, Copper Wire Only

·         22 in-lb (2.5 N-m)

·         -40C to +125C

·         Touch-safe, lock-out/tag-out feature

Fuse

·         Rating

·         Type

| ****

·         20A, 1500VDC (factory installed)

·         Replace only with Mersen HP15M, or equivalent 1500VDC photovoltaic fuse

Number of Fuse Positions| 16 – 26 Positions
Fuse Configuration| Fusing for Positive Polarity Only
DC DISCONNECT SWITCH
Configuration| 2-pole, 250A, 1500VDC, externally operable
Maximum Continuous DC Current| 200A
PV OUTPUT CIRCUIT CONNECTIONS
Maximum Voltage| 1500VDC

Maximum Wire Size Compatibility

| Cu: 1 or 2 cond, 600 kcmil

Al: 1 or 2 cond, 600 kcmil EGC: 14 AWG – 2/0 AWG

|
MECHANICAL, ENVIRONMENTAL, SAFETY
Enclosure Dimensions (not including mounting tabs, see Fig. 4.1)| Height: 30.0 in (762mm) Width: 24.0 in (610mm) Depth: 8.00 in (203mm)
Enclosure Material & Rating| Polyester Powder-Coated Steel, Type 4
Weight| 85 lbs
Ambient Temperature Range| -40°F to 140°F (-40°C to +60°C)
Surge Protection (Optional)| Type 2, +/-/GND, Common/Differential Modes
Safety Certification & Listing / Certification Agency| Intertek, UL1741
Standard Warranty| 5 Years standard

Models and Model Numbers

The CR1500-xxP Combiners are available in multiple configurations, with fuse protection for 16 to 28 input PV Source Circuits. The standard fuse value is 20A, but two models provide higher amperage fusing (20 positions with 25 amps, 16 positions with 30 amps).
The model numbers for the CR1500-xxP Combiners are defined in Table 3.2; a total of 14 models exist. The example shows part number CR1500-20P-20S, which is the Remote Combiner, rated for 1500 VDC, with 20 fuse positions for the positive polarity conductors only, 20A fuses pre-installed in the factory, and the optional DC surge protection.

INSTALLATION’

Before installing the CR1500-xxP Combiner, carefully unpack and inspect the unit for any damage. Follow the instructions in section 4.1.1 to check for damage and remove packing material inside the combiner. The combiner can be mounted to struts, as shown in Figure 4.2, using the mounting tab locations shown in Figure 4.1. The bottom of the enclosure is shown in Figure 4.3. Connect PV input strings to the PV output circuit stud plates using compression lug connections, as shown in Figure 4.5. Connect the PV input strings’ equipment ground terminals to the PV source circuit equipment ground terminals, as shown in Figure 4.6. Connect the PV output circuit equipment ground terminal to the system ground, as shown in Figure 4.7. The switch handle positions for OFF and ON are shown in Figure 5.1.

The steps for successful installation of the CR1500-xxP Combiners are:

1. Unpacking and Inspection
2. Mounting
3. Conduit and Fittings
4. Wiring and Conductor Installation
5. Testing and Commissioning

Unpacking and Inspection

Check for Damage
Yaskawa Solectria Solar thoroughly inspects and rigorously tests each CR1500-xxP Combiner before it is shipped. Even though the Combiners are delivered in rugged packaging, damage could occur to the Combiners during shipment.

• Inspect the Combiner after removing it from its packaging. Take care not to set the Combiner on gravel or other surface that could scratch the paint.
• If damage is observed, take digital photos to document the damage and immediately report the damage to the shipping company.
• If the recipient has any question about the potential shipping damage, contact Yaskawa Solectria Solar (see Section 6 for contact information).
• If Yaskawa Solectria Solar determines that the Combiner must be returned, obtain an RMA number from Yaskawa Solectria Solar and instructions for returning the unit.

Remove Packing Material Inside the Combiner
Remove and properly dispose of all cardboard, tape and other packing material that may be inside the Combiner enclosure.

Mounting

The Remote Combiner is designed to mount in any convenient location. Typically, the CR1500-xxP Combiner will be mounted in the PV array, close to the input PV Source Circuits and some distance from the XGI 1500 inverter. The CR1500-xxP is equipped with four integrated mounting tabsFigure 4.1 – CR1500-xxP Combiner front view (left) and side view (right), dimensions and mounting tab locations

Wiring

Completing the installation of the CR1500-xxP Combiner in the requires: (1) field wiring of the PV Source Circuits (up to 28) — positive polarity conductors to the fuseholders, negative polarity conductors to the 30-position negative terminal block, and equipment ground wires to the equipment ground terminals, and (2) field wiring of conductors from the PV Output Circuit terminals and the equipment ground lug to the XGI 1500 inverter (see the XGI 1500 User’s Manual for further details on those connections).

STEP 1: Confirm That No Wiring is Connected to the Combiner

• This is the first step of the installation and no wiring should be present into or out of the CR1500-xxP Combiner. No input PV Source Circuits conductors should be present, and no PV Output Circuit conductors should be present.
• If the XGI 1500 inverter is in place, confirm that the disconnect switch is in the OFF position (even though the wiring between the CR1500-xxP Combiner and the XGI 1500 inverter is not yet in place). The window on the disconnect switch body will show the “O” (Off) switch status.
• Remove fuses from all of the touch-safe fuseholders in the CR1500-xxP. Store the fuses for later re-installation.

STEP 2: Prepare the Enclosure for Conduits

• Conduit and strain reliefs can be located anywhere suitable on the bottom face of the Combiner as shown in Figure 4.3.
• Add the necessary holes for the conduit and fittings. The Combiner provides adequate space for up to six 9-conductor strain reliefs, readily accommodating up to 28 pairs of conductors from 28 input PV Source Circuits, the maximum allowable.
• Remove all metal shavings and debris from the inside of the Combiner.

warning: Remove all metal shavings and debris from the inside of the CR1500-xxP enclosure.

Conduit Connections

warning: Conduits connected to an outdoor enclosure can introduce water vapor into the enclosure and lead to the formation of condensation inside. Failure to follow these guidelines can result in water intrusion into the unit through the conduit connections and may void the warranty.

Follow these instructions and best practices when securing conduits to the Combiner.

1. Use UL514B certified water-tight conduit fittings and proper installation methods to provide a water-tight connection that will maintain the Type 4 rating of the enclosure.
2. Use an appropriately-rated sealant and seal the conduits fully to prevent the exchange of air between the conduit and the enclosure. Sealing the conduit will help prevent condensation in the enclosure.

STEP 3: PV Source Circuit Connections

warning: Do not attempt to make connections to the CR1500-xxP Combiner if not qualified for electrical work.

See NEC Articles 310 and 690 for proper PV Source Circuit conductor sizing. The rating of the fuseholders and the range of compatible conductor sizes are shown in Table 4.1.

FUSEHOLDER SPECIFICATIONS

Wire Compatibility

| 14 AWG – 6 AWG stranded

14 AWG – 10 AWG solid

90°C Copper Conductors Only

Voltage Rating| 1500 VDC
Ampere Range| Up to 32A
Torque Setting| 22 in-lb, #2 Phillips

Table 4.1 – Fuseholder Specifications

• Verify absence of voltage in PV Source Circuit conductors.
• Run the PV Source Circuit conductors into the Combiner either through conduit or strain-relief connectors.
• Connect the positive conductors to the touch-safe fuseholders, one conductor per fuseholder.
• Connect the negative conductors to the negative polarity terminals (not fused).
• Connect equipment ground conductors to the equipment ground terminals.
• Torque each PV Source Circuit conductor to 22 in-lb with a #2 Phillips screwdriver.

Fuse Rating          Part Number

20A| Mersen HP15M20

Table 4.2 – Example 1500VDC Replacement PV Fuse

Negative PV Source Circuit conductors terminate on the 30-position terminal block, with the following specifications.

STEP 4: PV Output Circuit Connections
The CR1500 Combiner provides stud plates just below the DC disconnect switch body, with 8mm (5/16 in.) studs for customer-supplied compression lugs for both positive and negative PV Output Circuit conductors. See Fig. 4.4. The terminals are rated for 90°C. Refer to NEC Articles 310 and 690 for proper sizing of output circuit conductors. One and two lugs are allowed. Basic specifications are in Table 4.3.

Wire Terminal Temperature Rating|

Number of Terminals

| Number of Wires per Terminal Allowed|

Max Conductor Size Allowed (Copper or Aluminum Conductors)

---|---|---|---
90°C| 1 per pole| 1 – 2| (1 or 2) 600 kcmil

Table 4.3 – PV Output Circuit Terminal Specifications
Compression lugs are NOT provided with the CR1500-xxP Combiner. The lugs must conform to the specifications given in Table 4.4.

Figure 4.4 – PV Output Circuit Stud Plates (side view, left; top view, right)

For the hardware on the stud plate, use the following.

Figure 4.5 – Compression Lug Connections, Single and Dual Conductors

Aluminum Conductors
warning: Aluminum oxidizes quickly when exposed to the atmosphere. An oxidized layer is a poor conductor that could lead to thermal issues, production loss, or damage to the Combiner.

When using aluminum conductors, follow these steps to prepare the conductors.

1. Prepare one wire at a time.
2. Remove the appropriate insulation from the wire.
3. Using a wire brush, remove the oxidized outer layer from the aluminum conductors.
4. Immediately apply a neutral dielectric grease, such as Ideal NOALOX® anti-oxidant compound, and connect the aluminum cable to the terminal.
5. If the connection is not made within 30 seconds of applying the compound, repeat this process, as an oxidized layer may have formed on the conductor.

STEP 5: Equipment Ground Wire Connections

Terminals are provided in the Combiner for all Equipment Grounding Conductors
(EGCs) associated with the PV Source Circuits. Torque each EGC for the PV Source Circuits per the specifications in Fig 4.6.

Fig. 4.6 – PV Source Circuit Equipment Ground Terminals

The output Equipment Ground Conductor should be connected to the 2-position ground lug, with specs as in the specifications in Figure 4.7.

Fig. 4.7 – PV Output Circuit Equipment Ground Terminal

Final Steps
warning: Verify the proper polarity of each conductor. Polarity reversal can lead to dangerous conditions capable of harming personnel and damaging equipment.

• Check the Combiner for tools and debris; ensure that the unit is clean and orderly.
  • Return the fuses to the 26 fuseholders, but do not close the fuse into the fuseholder. That will be accomplished during system commissioning and start-up.
  • Verify that all connections meet the requirements of this User’s Manual.
  • Secure the CR1500-xxP Combiner cover, ensuring that both ¼-turn fasteners are secured.
  • Consult the startup and commissioning procedures for the XGI 1500 inverter before energizing.

OPERATION

warning: Do not operate the disconnect handle switch with the Combiner Box door open.

The CR1500-xxP Combiner contains a user-operable disconnect switch. When this disconnect switch handle is in the OFF position, the circuit is open between the ungrounded PV Source Circuit conductors and the ungrounded PV Output Circuit conductor(s). The disconnect handle can be locked in the off position with user supplied safety locks. The plastic tab on the face of the disconnect handle can be lifted to reveal the locking provisions.
When the disconnect switch is in the ON position, the PV Source Circuit is closed between the ungrounded PV Source Circuit conductors and the ungrounded PV Output Circuit conductors.
The disconnect switch is rated for 250A, is fully load-break rated and can be safely operated under normal operating conditions when installation is per this User’s Manual and all warnings and ratings are observed.

• All Disconnect Switches must be OFF before working on the Combiner.
• See also the User’s Manual for the XGI 1500 Inverter.

WARRANTY & RMA INSTRUCTIONS

For warranty information, please visit: http://solectria.com/support/documentation/warranty-information/grid-tied- inverter-warranty-letter/

APPENDICES

Appendix A – Contact Information

• Address: Yaskawa Solectria Solar 360 Merrimack Street Building 9, Suite 221 Lawrence, MA 01843 USA
• Tel: 978.683.9700
• Fax: 978.683.9702
• Sales/General Info: inverters@solectria.com
• Customer Support: 978-683-9700 x2
• Website: www.solectria.com

References

• Documentation for Yaskawa - Solectria Solar PV Inverters and PV System Products - Yaskawa – Solectria Solar
• Yaskawa Solectria Solar - Leading Commercial PV Inverter Supplier - Yaskawa – Solectria Solar

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