YASKAWA SOLECTRIA SOLAR XGI 1500 Attachable Combiner Installation Guide

YASKAWA SOLECTRIA SOLAR XGI 1500 Attachable Combiner Installation Guide

Product Overview

The XGI 1500 Remote Combiner (CR1500) and the XGI 1500 Attachable Combiner (CA1500) are fused PV Source Circuit combiners, designed and listed exclusively for use with the SOLECTRIA XGI 1500 inverter. Refer to the illustration in Figure 1.1 showing their general usage. The Attachable Combiner mates to the SOLECTRIA XGI 1500 inverter and is intended for a Distributed PV System architecture, where the XGI 1500 inverters and the associated Attachable Combiners are located at positions throughout an array field. The Remote Combiners have similar features and models, but are designed for a Centralized or Custered PV System architecture with multiple co-located XGI 1500 inverters and Remote Combiners distributed throughout the PV array field.

The basic functions of the XGI 1500 Combiners are:

1. provide overcurrent protection (1500VDC rated fuses and touch-safe fuseholders) for multiple input PV Source Circuits,
2. bus the PV Source Circuits to form a single, combined PV Output Circuit,
3. provide wiring terminals for field-wired PV Output Circuit conductors,
4. provide the means to isolate the input PV Source Circuits from the PV Output Circuit (CR1500)
5. optionally, provide surge protection for the PV Output Circuit conductors.
   

The Attachable Combiner, CA1500, does not have an integrated DC disconnect, but instead utilizes the DC disconnect switch located on the XGI 1500 inverter. In this case the switch on the XGI 1500 inverter isolates the inverter from the PV Output Circuit conductors terminated in the Attachable Combiner. Both XGI 1500 Combiner types are available in multiple configurations, with fuse protection for 16 to 28 input PV Source Circuits. The part numbers for the CA1500 and CR1500 Combiner models are defined as shown in Table 1.1; a total of 48 part numbers exists. The example is part number CA1500-20-15S, which is an Attachable Combiner, rated for 1500 VDC, with 20 fuse positions (both polarities are fused), 15A fuses pre-installed in the factory, and the optional DC surge protection.

Ratings and Specifications

1500V COMBINERS EXCLUSIVELY FOR USE WITH XGI 1500 INVERTERS| Remote Combiner CR1500 Series| Attachable Combiner CA1500 Series
---|---|---
PV Source Circuit Input WireCompatibility| 14-4 AWG| 1 conductor: 14-6 AWG2 conductors: 14-10 AWG
PV Output Circuit WireCompatibility| Compression Terminal: 1 conductor, 1/0 – 600kcmil; 2 conductors, 1/0 – 600kcmil
Maximum Voltage| 1500 VDC
Fuse Rating Options| 15A or 20A (fuses included)| 25A| 30A| 15A or 20A (fuses included)| 25A| 30A
Fused Positions| 16 / 20 / 24 / 26 / 28| 20| 16| 16 / 20 / 24 / 26 / 28| 20| 16
Fuse Configurations| Both Positive and Negative Polarities Fused
Input PV Source CircuitConfiguration| Ungrounded PV Source Circuits Only
**** DC Disconnect| 2-Pole DC Disconnect, Integrated Positive and Neg. Poles Switched, Rated: 250AMax Continuous Current: 200A| 2-Pole DC Disconnect (on the XGI 1500 inverter), Pos. and Neg. Poles Switched, Rated: 250AMax Continuous Current: 200A
Temperature Range| -40°F to +122°F (-40°C to +50°C)
Mounting Positions| Vertical, Horizontal, or Angled| Vertical orientation, located adjacent to associated XGI 1500 inverter
Safety Certification & Listing /Certification Agency| UL 1741 / Intertek
Standard Warranty| 5 Years
Overall Dimensions(HxWxD)| 29.5 in. x 18.1 in. x 11 in. (750 mm x 460 mm x 280 mm)| 29.5 in. x 15 in. x 10.6 in. (750 mm x 380 mm x 260 mm)
Enclosure Material, Weightand Rating| Polyester Powder Coated Aluminum 85 lbs (38.6 kg); Type 4| Polyester Powder Coated Aluminum 75 lbs (34 kg); Type 4
Option
Surge Protection| Both positive and negative polarities

Installation

Unpacking and Inspection
3.1.1 Check for Damage Yaskawa Solectria Solar thoroughly inspects and rigorously tests each CA1500 and CR1500 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.

Mounting: CA1500 Attachable Combiner
The CA1500 Attachable Combiner is designed to mount to 1⅝-inch strut channel next to the XGI 1500 inverter, as in Figure 3.1. Note that the CA1500 Attachable Combiner comes with factory-installed mounting brackets that mimic those on the XGI 1500 inverter (see also the SOLECTRIA XGI 1500 Users’ Manual). Note also that the front cover of the CA1500 Attachable Combiner faces to the side, relative to the XGI 1500 inverter. The CA1500 enclosure is rated Type 4 and will maintain this rating when the user follows appropriate installation methods.

The CA1500 Attachable Combiner must be mounted vertically on the same horizontal 1⅝-inch strut channels that also hold the XGI 1500 inverter, as in Figure 3.2 and Figure 3.3. The CA1500’s vertical dimension matches that of the XGI 1500 inverter. The upper bracket of the Combiner hangs on the upper strut channel; the lower bracket on the Combiner rests against the lower strut channel. After positioning the Combiner, secure the Combiner to the channels using appropriate 5/16-inch (8mm) bolts, washers and locknuts (fasteners are not supplied).

• See also the SOLECTRIA XGI 1500 Users’ Manual for additional information on installing the XGI 1500 inverter.
• A gap of 2.5 in. (63.5mm) between the CA1500 and the XGI 1500 inverter is required to accommodate the Wiring Harness Assembly supplied with the CA1500, and described in Section 3.4.4.
• The CA1500 Attachable Combiner weight ranges from 75 to 85lbs, depending on the model number. Be sure to account for this weight in the design of the structural support.

Mounting: CR1500 Remote Combiner
The CR1500 Remote Combiner is designed to mount in any convenient location. Typically the Combiner is mounted close to the input PV Source Circuits and some distance from the XGI 1500 inverter. The CR1500 is equipped with four integrated mounting tabs (see Fig. 3.4) to facilitate attachment to a variety of surfaces. The CR1500 enclosure is rated Type 4 and will maintain this rating when the user follows appropriate installation methods.

Wiring: CA1500 Attachable Combiner
Do not attempt to make connections to the CA1500 Combiner if not qualified for electrical work.
The CA1500 Attachable Combiner (see Figure 3.6) comprises:

• Fuseholders: Both PV Source Circuit polarities are fused. Terminate the input PV Source Circuit positive conductors on the left side, and terminate the negative PV Source Circuit conductors on the right side.
• Fuses: Provided with the current rating based on the specific model.
• Terminal Plates: For PV Output Circuit field-wiring terminations: one Positive, one Negative.
• Equipment Ground Busbar and Ground Lug: Input equipment ground terminations are made at the ground bus. An output equipment ground conductor should be terminated in the Ground Lug.
• Conduit Plate and Wiring Harness: A removable conduit plate on the bottom, comes specially configured with the supplied Wiring Harness to connect the Attachable Combiner to the XGI 1500 inverter (see Section 3.4.5)
  

Remove Fuses
Removing fuses from a live circuit may create dangerous arc-flash and shock hazards. Remove all fuses before servicing this unit.

1. This is the first step of the installation and at this step no wiring should be present into or out of the Combiner. No input PV Source Circuits conductors should be present, and no PV Output Circuit conductors should be present.
2. If the XGI 1500 inverter is in place, confirm that the disconnect switch on the XGI 1500 is in the OFF position (even though the wiring between the CA1500 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.
3. Remove fuses from the touch-safe fuseholders for each input PV Source Circuit, both positive and negative polarities. Store the fuses for later re-installation (some models may be delivered with fuses separate and uninstalled).

Removing the plastic guard may expose the installer to dangerous DC voltage and shock hazards.

1. Remove the #10 screws holding the plastic guard, using a Phillips #2 screwdriver.
2. Gently remove the plastic guard.
3. Store the plastic guard and screws for later re-installation.

Prepare the Conduit Plate

1. Remove the Conduit Plate (Figure 3.7), located on the bottom of the attachable combiner.
2. The Conduit Plate comes with the large hole required for connecting the Wiring Harness Assembly (see Section 3.4.5), which includes the PV Output Circuit conductors that terminate in the Combiner and the XGI 1500 wiring compartment.
3. The Conduit Plate has space for up to six 9-conductor strain reliefs, and one additional strain relief for two conductors, accommodating up to a total of 28 pairs of conductors from 28 input PV Source Circuits.
4. Add the necessary holes for the intended number of PV Source Circuit strain-relief fittings.
5. Re-install the conduit plate to the Combiner, and attach and secure the strain-relief fittings (not supplied).
   
   

The PV Output Circuit Wiring Harness Assembly is designed to simplify the field interconnection of the Combiner and the XGI 1500 inverter. The Wiring Harness Assembly comprises:

• A straight section of 2-inch PVC about 7 inches in length, with 90-degree elbows and threaded couplings at each end
• Two (2) 250MCM conductors for the PV Output Circuit overall positive (red) and overall negative (black), with lugs crimped on the ends of the wires to facilitate termination on posts in the Combiner and the XGI 1500 inverter, and
• A 4AWG green equipment ground wire, with stripped ends for easy termination at the busbars in the Combiner and XGI 1500 inverter.
  
  

Confirm that the DC Switch and AC switch on the XGI 1500 are in the OFF position, and all fuseholders in the Combiner are in the OPEN position, with fuses removed.

1. Feed the conductors of the Wiring Harness Assembly through the openings in the Combiner and XGI 1500 wiring compartment, and position the conduit up against the bottoms of the enclosures. A slight adjustment of the position of the Combiner may be necessary to align the conduit perfectly.
2. From inside the enclosure, feed the conductors through the mating threaded fitting, then thread the fitting into theconduit coupling to secure the conduit assembly in place, in both enclosures.
3. Proceed to terminate the PV Output Circuit conductors to the lugs, noting carefully the polarity markings on the terminations and insulation color coding: red = POSITIVE, black = NEGATIVE.
4. Terminate the green-jacketed equipment ground wire on the ground terminal in the XGI 1500 wiring compartment and to the equipment ground lug in the Combiner (see Section 3.4.5).
5. Replace the plastic shield in the XGI 1500 wiring compartment. Completed wiring should appear as in Figure 3.10.

Equipment Ground Wiring (both CA1500 and CR1500)
See NEC Article 690 for equipment grounding requirements. A busbar is provided in the Combiner for all Equipment Grounding Conductors (EGCs) associated with the PV Source Circuits. Torque each EGC per the specifications in Table 3. Connect the Equipment Ground Conductor of the Wiring Harness Assembly to the equipment ground lug and torque the lug per Table 3.1.

PV Source Circuit Wiring (both CA1500 and CR1500)
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 3.2.

Fuseholder Specifications

Wire Compatibility| 14 AWG – 6 AWG stranded14 AWG – 10 AWG solid 90C Copper Conductors Only
Voltage Rating| 1500 VDC
Ampere Range| Up to 32A
Torque Setting| 22 in-lb, #2 Phillips

PV Source Ciruit Installation Instructions:

1. Verify absence of voltage in PV Source Circuit conductors
2. Run the PV Source Circuit conductors into the Combiner either through conduit or strain-relief connectors in the Conduit Plate.
3. Connect the conductors to the touch-safe fuseholders, one conductor per fuseholder.
4. Torque each PV Source Circuit conductor to 22 in-lb with a #2 Phillips screwdriver.

PV Source Circuit Fuses
Only replace fuses in the Combiner fuseholders with appropriately-rated 1500Vdc fuses.

PV Output Circuit Conductors (CR1500)
The CR1500 Combiner provides stud plates with 8mm (5/16 in.) studs for customer-supplied compression lugs for both positive and negative PV Output Circuit conductors. The terminals are rated for 90°C. Refer to NEC Articles 310 and 690 for proper sizing of conductors. One and two lugs are allowed.

Number of Fused Inputs| Wire Terminal Temperature Rating| Number of Terminals| Number of Wires per Terminal Allowed| Max Conductor Size Allowed (Copper or Aluminum Conductors)
---|---|---|---|---
16 – 28| 90°C| 1 per pole| 1 – 2| (2) 500 kcmil or (1) 500 kcmil

Compression lugs are NOT provided with the CR1500 Combiner. The lugs must conform to the specifications given in the table below:

For the hardware on the crimp lug, use the following stack-up for each stud. Studs on positive or negative output
plate, crimp lug, 1 flat washer, 1 Belleville washer, and 1 nut.

Final Steps
Verify the proper polarity of each conductor. Polarity reversal can lead to dangerous arc-flash conditions capable of harming personnel and equipment.
Check the Combiner for tools and debris; ensure the unit is clean and orderly.

1. Verify that all connections meet the requirements of this Installation and Operations Guide.
2. Check all PV Source Circuit voltages and polarities.
3. Re-install the plastic guard.
4. Install all fuses and close all fuseholders.
5. Secure the combiner door, ensuring that all fasteners are in place.

Operating Instructions

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

The CR1500 Combiner contains a user-operable disconnect switch. When this disconnect switch handle is in the OFF position, the circuit is open between the ungrounded source conductors and the ungrounded output conductor(s). When the disconnect switch is in the ON position, the circuit is closed between the ungrounded source conductors and the ungrounded output conductor(s). The disconnect switch is fully load-break rated and can be safely operated under normal operating conditions when installation is per this manual and all warnings and ratings are observed.

Warranty & RMA Instructions

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

Appendices

Appendix A – CR1500 and CA1500 Datasheet
Please visit: https://solectria.com/string-combiners/xgi-1500-combiners/

Appendix B – Contact Information
Yaskawa Solectria Solar
360 Merrimack Street
Building 9, 2nd Floor
Lawrence, Massachusetts 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

• Yaskawa Solectria Solar - Leading Commercial PV Inverter Supplier - Yaskawa – Solectria Solar
• How to Buy - Yaskawa – Solectria Solar
• SOLECTRIA XGI 1500 Combiners - Yaskawa – Solectria Solar

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