RENOGY REC500CB-98 500A Combiner Box User Manual

RENOGY REC500CB-98 500A Combiner Box

Specifications

• Product: Renogy 500A Combiner Box (Standard Version)
• Model: REC500CB-98
• Version: A0
• Compatible with: 12V, 24V, 36V, and 48V batteries, inverters, charge controllers, and battery chargers

Product Usage Instructions

Installation

• Ensure the power source is switched off before installation.
• Mount the combiner box in a suitable location using appropriate hardware.
• Connect the positive and negative busbars to the respective terminals.
• Connect batteries, loads, or chargers to the designated connections.

Expansion

• To expand the system, use the extended terminals to connect additional combiner boxes.
• Ensure proper alignment and secure connections when expanding the system.

Maintenance

• Regularly inspect the combiner box for any signs of damage or loose connections.
• Clean the box periodically to remove any dust or debris that may affect performance.

Frequently Asked Questions (FAQ)

Q: Can the combiner box be used with solar panels?

A: The combiner box is designed to work with batteries, inverters, and chargers but not directly with solar panels. It is used to combine and distribute power from these sources.

Q: Is the combiner box suitable for outdoor installation?

A: Yes, the combiner box is suitable for outdoor installation as long as it is mounted in a weatherproof enclosure to protect it from environmental elements.

Q: What type of fuses are recommended for use with the combiner box?

A: Marine-rated battery (MRBF) fuses are recommended for use with the combiner box to ensure electrical safety and protection.

Before Getting Started

• The user manual provides important operation and maintenance instructions for the Renogy 500A Combiner Box (hereinafter referred to as combiner box).
• Read the user manual carefully before operation and save it for future reference.
• Failure to observe the instructions or precautions in the user manual can result in electrical shock, serious injury, or death, or can damage the combiner box, potentially rendering it inoperable.
• Renogy ensures the accuracy, sufficiency, and applicability of the information in the user manual at the time of printing due to continual product improvements that may occur.
• Renogy assumes no responsibility or liability for personal and property losses, whether directly or indirectly, caused by the user’s failure to install and use the product in compliance with the user manual.
• Renogy is not responsible or liable for any failure, damage, or injury resulting from repair attempts by unqualified personnel, improper installation, or inappropriate operation.
• The illustrations in the user manual are for demonstration purposes only. Details may appear slightly different depending on product revision and market region.
• Renogy reserves the right to change the information in the user manual without notice. For the latest user manual, visit renogy.com.

Disclaimer

• Renogy 500A Combiner Box User Manual © 2023 Renogy. All rights reserved.
• RENOGY and are registered trademarks of Renogy.
• All information in the user manual is subject to copyright and other intellectual property rights of Renogy and its licensors.
• The user manual may not be modified, reproduced, or copied, in whole or in part, without the prior written permission of Renogy and its licensors.
• The registered trademarks in the user manual are the property of Renogy.
• The unauthorized use of the trademarks is strictly prohibited.

Online Manual

Symbols Used

• The following symbols are used throughout the user manual to highlight important information.
• WARNING: Indicates a potentially dangerous condition that could result in injury or death.
• CAUTION: Indicates a critical procedure for safe and proper installation and operation.
• NOTE: Indicates an important step or tip for optimal performance.

Introduction

• The Renogy 500A Combiner Box is equipped with two busbars (a negative and a positive) that offer four connections for batteries, loads, or battery chargers, along with a ground connection.
• It also allows for easy expansion of the system by connecting the box to other combiner boxes through the extended terminals.
• This combiner box is compatible with general batteries (12V, 24V, 36V, and 48V), inverters, charge controllers, and battery chargers.

Key Features

Safety and Stability

• The combiner box is equipped with two busbars and supports the installation of fuses, especially Marine Rated Battery (MRBF) fuses, to ensure electrical safety.
• This also simplifies installation and maintenance with quicker installation and less effort.

Compact and Lightweight Design

• The combiner box is compact and lightweight, making it easy to install in any location, while also providing sufficient internal space to accommodate thick wires and larger terminals.

Sturdy Outer Casing

• The combiner box protects the system connections with a sturdy outer casing, which remains intact even when subjected to wire bending or twisting.

Long-Time Stable Running

• The high-quality tin-plated copper busbars inside ensure the system operates reliably for extended periods.

SKU

• Renogy 500A Combiner Box REC500CB-98

What’s In the Box?

Make sure the combiner box is free of any signs of damage.

Required Tools & Accessories

• Before installing and configuring the combiner box, prepare the recommended tools, components, and accessories.
• For how to size bare wires, refer to “How to Size Cables?” in this manual.

Get to Know Renogy 500A Combiner Box

Exterior

Interior (with the cover removed)

Each busbar terminal is equipped with a terminal bolt, a spring washer, and a flat washer.

Wiring Diagram

• The continuous current flowing through the combiner box shall not exceed 500A. The voltage is within the range of 9V to 60V.
• The wiring diagram only shows the key components in a typical DC-coupled residential energy storage system for illustrative purposes.
• The wiring might be different depending on the system configuration. Additional safety devices, including disconnect switches, emergency stops, and rapid shutdown devices, might be required.
• Wire the system under the regulations at the installation site.

Use MRBF Fuse

Use ANL Fuse

Dimensions

Dimension tolerance: ±0.2 in (0.5 mm)

How to Size Cables?

Size wires specific to the operating current of relevant devices. Refer to the table below for copper cable ampacities with different gauge sizes.

• The above values are from the NEC Table 310.15(B)16 for copper cables rated at 167°F (75°C), operating at an ambient temperature of no more than 86°F (30°C).
• Cables longer than 6 feet (1829 mm) may require thicker gauge wires to prevent excessive voltage drop in undersized wiring.

How to Install the 3/8 in Lugs (M10 Ring Terminals)?

How to Connect Energy Devices to the Busbars Safely?

• Ensure that the positive busbar terminal does not come into contact with the negative busbar terminal.
• Short circuits can damage connected batteries and devices.

Step 1. Plan a Mounting Site

Install the combiner box in a clean, cool, and dry place. Keep water, oil, and dirt away from the combiner box, and protect it from direct sunlight.

• The combiner box can be mounted either on a floor or on a wall.

Step 2. Wear Insulating Gloves

Step 3. Remove the Cover

Step 4. Mount the Combiner Box

• Make sure that the combiner box is installed firmly to prevent it from falling off.
• Inspect the combiner box for any visible damage including cracks, dents, deformation, and other visible abnormalities.
• All terminal contacts shall be clean, free of dirt and corrosion, and dry.

Step 5. Ground the Combiner Box

Step 6. Connect Energy Devices to the Combiner Box

• Install wires on energy devices (charge controller, battery, inverter, and more) before connecting them to the combiner box.
• For details on how to install wires on the devices, see the user manual of the specific device.
• Always install the negative terminals before the positive ones.
• The following figure connects a REGO 12V 60A MPPT Solar Charge Controller to the combiner box as an example.
• Ensure the cable lug and the busbar terminal are in contact, and place the washers on top of the lug. Do not place the washers between the busbar terminal and the cable lug to avoid high resistance and excessive heating.
• Ensure that the positive busbar terminal does not come into contact with the negative busbar terminal. Short circuits can damage connected batteries and devices.
• Check the polarity before connecting the cables. Reverse polarity can damage connected batteries and devices.
• To ensure the safe and reliable operation of the system, please follow the torque specifications of relevant devices recommended by the manufacturer to secure cable connections.
• Over-tightening can cause terminal breakage, while loose connections can lead to terminal meltdown or fire hazards.

Use MRBF Fuse Recommended Components

• Components marked with “*” are available on renogy.com.
• Choose proper MRBF fuses (not included) to meet the specifications of the relevant devices.
• For details, see the user manuals of the relevant devices.

1. STEP-1 Install the negative
2. STEP-2 Install the MRBF fuse and positive

Use ANL Fuse Recommended Components

Choose proper ANL fuses (not included) to meet the specifications of the relevant devices. For details, see the user manuals of the relevant devices.

1. STEP-1 Install the negative
2. STEP-2 Install an ANL fuse
3. STEP-3 Install the positive

Step 7. Install the Cover

Interconnecting Combiner Boxes

1. Step 1: Remove the dust covers and extend positive/negative terminals from the first combiner box. Similarly, remove the dust covers from the positive and negative busbars from the second combiner box.
2. Step 2: Align the busbar ports.
3. Step 3 : Install the terminal bolts, spring washers, and flat washers on the busbar ports.

Specifications

263 x 160 x 100 mm

Weight| 5.73 lbs. / 2.6 kg
Busbar Material| Tinned Copper
Busbar Dimensions| 0.16 x 1.18 in 4 x 30 mm
Recommended Terminal Torque| 70.8 in·lbs / 8 N·m
Operating Temperature Range| -4°F to 140°F / -20°C to 60°C
Storage Temperature Range| -40°F to 176°F / -40°C to 80°C
Humidity| 0-99% RH (non-condensing)
Protection Class| IP22

Maintenance

Inspection

Please perform regular inspections following the steps below:

• Examine the external appearance of the combiner box. The casing and terminals of the combiner box shall be clean, dry, and free of corrosion.
• Check the continuity of the fuses. Replace any blown fuses.
• Check the cables and connections. Replace any damaged cables and tighten any loose connections.
• In certain application scenarios, corrosion may occur around the terminals. Corrosion can cause increased resistance and poor contact.
• It is recommended to regularly apply insulation grease to each terminal. Insulation grease can form a moisture-resistant seal and protect the terminals from corrosion.

Cleaning

• Please clean the combiner box at regular intervals following the steps below.
• Disconnect the devices and batteries or battery combiner box from the combiner box.
• Clean the casing and terminals. The household cleaner can be used if the combiner box is extremely dirty.
• Use a clean cloth to dry the combiner box. Ensure that the area surrounding the combiner box remains clean and dry.
• Reconnect the necessary devices to the combiner box.

Important Safety Instructions

General

• Wear proper protective equipment and use insulated tools during installation and operation. Do not wear jewelry or other metal objects when working on or around the combiner box.
• Keep the combiner box out of the reach of children.
• Do not dispose of the combiner box as household waste. Comply with local, state, and federal laws and regulations and use recycling channels as required.
• In case of fire, put out the fire with an FM-200 or CO₂ fire extinguisher.
• Do not expose the combiner box to flammable or harsh chemicals or vapors.
• Clean the combiner box regularly.
• It is recommended that all cables should not exceed 32.8 ft (10 m) because excessively long cables result in a voltage drop.
• The cable specifications listed in the user manual account for critical, less than 3%voltage drop and may not account for all configurations.
• Do not expose the combiner box to strong electrostatic fields, strong magnetic fields, or radiation.

Combiner Box Safety

• Please keep the combiner box away from water, heat sources, sparks, and hazardous chemicals.
• Do not puncture, drop, crush, burn, penetrate, shake, strike, or step on the combiner box.
• Do not repair, tamper with, or modify the combiner box.
• Do not touch any terminals.
• Please make sure all devices have been disconnected before working on the combiner box.
• Do not place tools on top of the combiner box.
• Do not insert foreign objects into the positive and negative terminals of the combiner box.
• Ensure the connected devices are off before connecting them to the combiner box.

Renogy Support

• To discuss inaccuracies or omissions in this quick guide or user manual, visit or contact us at: renogy.com/support/downloads .
• contentservice@renogy.com
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Documents / Resources

| RENOGY REC500CB-98 500A Combiner Box [pdf] User Manual
REC500CB-98 500A Combiner Box, REC500CB-98, 500A Combiner Box, Combiner Box
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References

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• Contact Us | Renogy Solar Panels & Complete Solar Kits
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