Protection and isolation of photovoltaic installations 1SDC007099B0203 Technical characteristics and ordering information S800PV-S miniature circuit breakers and S800PV-M switch-disconnectors.............................................pag. 11 OVR PV surge protection devices...................................................pag. 12 OT switch-disconnectors................................................................pag. 13 Europa series wall-mounted control boards....................................pag. 14 Junction boxes...............................................................................pag. 15 Metric gauge cable glands and nuts...............................................pag. 16 Terminal blocks...............................................................................pag. 17 ABB experience serving solar energy The great variety of needs that photovoltaic installations are able to satisfy, both in terms of power and connection to electricity networks (single phase, three phase, low or medium voltages), means that components must be carefully selected by designers and installers to optimise the installations and suit differing needs and installation conditions specific to every application. Protective and isolating switchgear equipment is particularly important and ABB offers a full range of these products both for circuits branched from photovoltaic panels, where the high direct voltages typical of these installations are present, and for those that form the alternating current section downstream of the inverter. ABB product range includes control boards and enclosures suitable for outdoor use with IP65 class protection, circuit breakers and switch-disconnectors, surge protection devices and connection terminal blocks. 3 Equipment for the direct current section 4 4 2 its effects on the panels, often located in isolated places that are particularly exposed to adverse weather conditions, or due to the overvoltages that they generate in the installations. The following pages illustrate a number of examples of options for the choice of suitable components to create the protection and isolation functions, both in modular and in-box versions, depending upon the operating voltages in the photovoltaic field. The examples refer to strings of panels up to 16A. 2 4 3 1 2 4 2 2 2 4 4 4 3 1 1 3 3 3 1 1 3 1 In a typical photovoltaic installation, the direct current section includes the field made up of strings of photovoltaic panels downstream of which isolation and protection may be provided by dedicated circuit breakers, for example S800PV-S miniature circuit breakers, usable in situations where there are very high voltage direct currents. On this side, protection against overvoltages can be provided by suitably sized OVR-PV surge protection devices. This kind of protection avoids the effects of lightning strikes and is essential since lightning is a major hazard either due to = ~ 8 6 4 2 7 5 3 1 Strings up to 500V DC Example of a modular field switchboard to protect and isolate strings with a maximum capacity of 16A up to 500V DC made up of: • Europa series IP65 wall-mounted 12-module control board with IP68 metric gauge cable glands and nuts • miniature circuit breaker S802S UC, 16A • surge protection device OVR PV 40 600 P - Surge protection device for 40kA 600V DC photovoltaic installations with removable cartridges • Screw clamp terminal blocks 4-6-10 mm2, voltage rated up to 800V Example of an IP65 in-box field switchboard to isolate strings with a maximum capacity of 16A up to 500VDC made up of: • IP65 polycarbonate junction box, dimensions 275x220x140 with IP65 cable glands • OT16E 4-pole switch-disconnector + shaft + handle • surge protection device OVR PV 40 600 P - Surge protection device for 40kA 600V DC photovoltaic installations with removable cartridges • 4 Screw clamp terminal blocks 4-6-10 mm², voltage rated up to 800V 5 Strings up to 750V DC Example of an IP65 in-box field switchboard to isolate strings with a maximum capacity of 16A up to 750V DC made up of: • IP65 polycarbonate junction box, dimensions 275x220x140 with IP65 cable glands • OT16E 8-pole switch-disconnector + shaft + handle • surge protection device OVR PV 40 1000 P - Surge protection device for 40kA 1000V d.c. photovoltaic installations with removable cartridges 6 Strings up to 800V DC Example of a modular field switchboard for protection and isolation of strings with a maximum capacity of 16A up to 800V DC made up of: • Europa series IP65 wall-mounted 12-module control board with IP68 metric gauge cable glands and nuts • miniature circuit breaker S802 PV-S, 16A • surge protection device OVR PV 40 1000 P - Surge protection device for 40kA 1000V DC photovoltaic installations with removable cartridges • Screw clamp terminal blocks 4-6-10 mm², voltage rated up to 800V Example of a modular field switchboard for isolation of strings up to 800V DC made up of: • Europa series IP65 wall-mounted 12-module control board with IP68 metric gauge cable glands and nuts • S802 PV-M, 32A switch-disconnector • surge protection device OVR PV 40 1000 P - Surge protection device for 40kA 1000V DC photovoltaic installations with removable cartridges • Screw clamp terminal blocks 4-6-10 mm², voltage rated up to 800V 7 Strings up to 800V DC The figure shows an example of circuit configuration for the DC section for protection and isolation of an installation with strings with a capacity up to 800V, currently one of the most widely used types of installation. 2 4 String 1 800VDC/16A 3 1 S802PV-S16 1 2 4 String 2 800VDC/16A 3 S802PV-S16 S802PV-M125 1 2 1 2 4 3 4 String 3 800VDC/16A 3 S802PV-S16 Protection against overvoltages 2 4 String 6 800VDC/16A 3 1 S802PV-S16 Protection from lightning 8 1 2 4 String 7 800VDC/16A 3 S802PV-S16 Inverter ~ = Strings up to 1000V DC Example of a modular field switchboard for protection and isolation of strings with a maximum capacity of 16A up to 1000V DC made up of: • Europa series IP65 wall-mounted 12-module control board with IP68 metric gauge cable glands and nuts • miniature circuit breaker S804 PV-S, 16A • surge protection device OVR PV 40 1000 P - Surge protection device for 40kA 1000V DC photovoltaic installations with removable cartridges • ADO - screw clamp terminal blocks 4 mm², voltage rated up to 1000V Example of a modular field switchboard for isolation of strings with a maximum capacity of 16A up to 1000V DC made up of: • Europa series IP65 wall-mounted 12-module control board with IP68 metric gauge cable glands and nuts • S804 PV-M, 32A switch-disconnector • surge protection device OVR PV 40 1000 P - Surge protection device for 40kA 1000V DC photovoltaic installations with removable cartridges • ADO - screw clamp terminal blocks 4 mm², voltage rated up to 1000V 9 Switchgear for protection downstream of the inverter In photovoltaic installations with capacities higher than 20kW, inverters should be fitted with an isolation transformer, while for power ratings lower than 20kW the residual current circuit breaker for protection against indirect contacts should be type B when an inverter that does not have at least a simple separation between the AC side and the DC side is used. When, however, the inverter is constructed in such a way that it does not permit injection of direct fault current, a type B residual current circuit breaker is not required. ABB supplies automatic, simple switchdisconnectors and switch-disconnector blocks that guarantee effective protection in all types of photovoltaic installation. The range also includes type B switch- 10 disconnector devices (for alternating and/ or pulsating currents with direct and direct fault current components) and modular automatic circuit breakers from 4.5kA to 50kA (up to 125A) with a wide choice of accessories to protect against overload and short circuit currents on the AC side. For equipment manufacturers (OEMs) ABB offers contactors suitable for making interface devices which must guarantee intrinsic safety (with the relay coil powered directly from the power network). The ideal solution for outdoor installations, is the Gemini IP66 switchboard which, by virtue of the co-injected moulding technique used, maintains excellent characteristics of mechanical sturdiness and resistance to adverse weather conditions and aggressive substances. The products: technical characteristics and ordering information S800PV-S miniature circuit breakers and S800PV-M switch-disconnectors The S 800 PV range includes S 800 PV-S circuit breakers and S 800 PV-M modular switch-disconnectors that can be used in networks of up to 1200 V DC (four poles version); these products and their very wide range of accessories (auxiliary contacts, release coils) permit the creation of countless installation setups as described in the previous pages. The main characteristics of S800PV circuit breakers and switchdisconnectors are: - interchangeable terminal blocks - lever in a central position for S 800 PV-S miniature circuit breakers - contact status display by single pole - no constraints for polarity and power direction in cabling Connection S800PV-S miniature circuit breakers Networks of photovoltaic panels in earther systems Poles Rated current In [A] Type Order code 2 2 2 2 2 2 2 2 2 2 4 4 4 4 4 4 4 4 4 4 10 13 16 20 25 32 40 50 63 80 10 13 16 20 25 32 40 50 63 80 S802PV-S10 S802PV-S13 S802PV-S16 S802PV-S20 S802PV-S25 S802PV-S32 S802PV-S40 S802PV-S50 S802PV-S63 S802PV-S80 S804PV-S10 S804PV-S13 S804PV-S16 S804PV-S20 S804PV-S25 S804PV-S32 S804PV-S40 S804PV-S50 S804PV-S63 S804PV-S80 2CCP842001R1109 2CCP842001R1139 2CCP842001R1169 2CCP842001R1209 2CCP842001R1259 2CCP842001R1329 2CCP842001R1409 2CCP842001R1509 2CCP842001R1639 2CCP842001R1809 2CCP844001R1109 2CCP844001R1139 2CCP844001R1169 2CCP844001R1209 2CCP844001R1259 2CCP844001R1329 2CCP844001R1409 2CCP844001R1509 2CCP844001R1639 2CCP844001R1809 1200 V c.c. 800 V c.c. 1 3 1 3 5 7 2 4 2 4 6 8 Connection Networks of photovoltaic panels in earther systems S800PV-M switch-disconnectors 1200 V c.c. 800 V c.c. Poles Rated current In [A] Type Order code 2 2 4 4 32 125 32 125 S802PV-M32 S802PV-M125 S802PV-M32 S802PV-M125 2CCP812001R1329 2CCP812001R1849 2CCP814001R1329 2CCP814001R1849 1 3 1 3 5 7 2 4 2 4 6 8 11 OVR PV surge protection devices ABB offers a wide range of surge protection devices specific for photovoltaic installations. The main characteristics of OVR PV surge protection devices are: - integral thermal protections with breaking capacity of 25A DC* - removable cartridges, for easy maintenance with no need to isolate the line - remote signal contact to monitor the operating status (TS versions) - no subsequent short circuit current - no risk if poles are inverted OVR PV surge protection devices Type OVR PV 40 600 P OVR PV 40 600 P TS OVR PV 40 1000 P OVR PV 40 1000 P TS OVR PV 40 600 C OVR PV 40 1000 C Order code 2CTB803953R5300 2CTB803953R5400 2CTB803953R6400 2CTB803953R6500 2CTB803950R0000 2CTB803950R0100 * Note: for surge protection devices installed at points in the network where the short circuit current is higher than 25A DC, suitable protection must be provided 12 OT switch-disconnectors OT series switch-disconnectors are available with rated currents from 16A to 125A in the 4P version (maximum voltage 500V DC) and 8P version (maximum voltage 750V DC). OT switchdisconnectors are suitable for installation in switchboards with 45mm slots The main characteristics of OT switch-disconnectors are: - fast opening and closing mechanism with independent trip function (in OT 45...125 versions) - accessories are snap mounted onto the circuit breakers - OT 45 ... 125 switch-disconnector mechanism for installation on DIN rails can be locked by a blocking adaptor OT switch-disconnectors Poles Ith (open) Type Order code 4 4 4 4 4 4 4 8 8 8 8 8 8 8 25 32 40 63 80 115 125 25 32 40 63 80 115 125 OT 16 E4 OT 25 E4 OT 32 E4 OT 45 E4 OT 63 E4 OT 100 E4 OT 125 E4 OT 16 E8 OT 25 E8 OT 32 E8 OT 45 E8 OT 63 E8 OT 100 E8 OT 125 E8 1SCA022352R7170 1SCA022352R7330 1SCA022352R7500 1SCA022352R7680 1SCA022352R7760 1SCA022398R4580 1SCA022373R1880 1SCA022551R4510 1SCA022551R5310 1SCA022551R2990 1SCA022551R3700 1SCA022551R6120 1SCA022551R7790 1SCA022551R8500 13 Europa series wall-mounted control boards Europa series control boards for wall mounting have IP65 class protection making them particularly suited for installation outdoors. They can therefore be used to create field switchboards downstream of the photovoltaic strings. The main characteristics of the Europa series wall-mounted control boards are: - class of protection: II - manufactured in self-extinguishing thermoplastic material resistant to abnormal heat and fire-resistant up to 650°C (incandescent wire test) in conformity with the IEC 60695-211 standard - installation temperature: -25°C to +60°C - shock resistance: 6 joules (IK 08 class) - extractable DIN rail support structure for easy bench wiring, modular (can be disassembled and reassembled by snap mechanism) to make wiring of single strings rows - switchgear can be installed at depths of 53, 68 and 75 mm - modules with 8 or more modules fitted with rigid bimaterial flanges to facilitate insertion of pipes and cables - control boards compliant with CEI 23-48, CEI 23-49 and IEC 60670 standards Europa Serie 14 Description Dimensions WxHxD [mm] Order code IP65 CONTROL BOARD, P/SMOKE GREY 4M IP65 CONTROL BOARD, P/SMOKE GREY 8M IP65 CONTROL BOARD, P/SMOKE GREY 12M IP65 CONTROL BOARD, P/SMOKE GREY 18M 1 ROW 140x220x140 205x220x140 275x220x140 380x220x140 12744 12748 12752 12753 Junction boxes ABB can also supply IP65 polycarbonate junctions boxes that are particularly suitable for use outdoors. The main characteristics of the junction boxes are: - class of protection: II - manufactured in self-extinguishing polycarbonate, resistant to abnormal heat and fire-resistant up to 960°C (incandescent wire test) in conformity with the IEC 60695-2-11 standard - installation temperature: -25°C to +60°C - shock resistance: 20 joules (IK 10 class) - junction boxes compliant with the CEI 23-48 and IEC 60670 standards Junction boxes Description Dimensions WxHxD [mm] Order code BOX IP65 PC BOX IP65 PC BOX IP65 PC 140x220x140 205x220x140 275x220x140 12804 12808 12812 15 Metric gauge cable glands and nuts Main technical characteristics of metric gauge cable glands and nuts: - IP68 protection degree - material: 6.6 polyamide, self-extinguishing material compliant with the UL94 V2 standard and resistant to abnormal heat and fire-resistant up to 750°C (incandescent wire test) in conformity with the IEC 60695-2-11 standard - usage temperature: from -20°C to +120°C (brief period) - neoprene seal - tightening by lamellar crown on the whole diameter of the cable (prevents possible damage to the cable itself) - cable glands can be reused without damaging their effectiveness Metric gauge cable glands and nuts Cable gland METRIC GAUGE M12 CABLE GLAND METRIC GAUGE M16 CABLE GLAND METRIC GAUGE M20 CABLE GLAND METRIC GAUGE M25 CABLE GLAND METRIC GAUGE M32 CABLE GLAND Cable gland order code 00 951 00 952 00 953 00 954 00 955 METRIC GAUGE M40 CABLE GLAND 00 956* METRIC GAUGE M50 CABLE GLAND 00 957* Nut NUT FOR M12 CABLE GLAND NUT FOR M16 CABLE GLAND NUT FOR M20 CABLE GLAND NUT FOR M25 CABLE GLAND NUT FOR M32 CABLE GLAND METRIC GAUGE NUT FOR M40 CABLE GLAND METRIC GAUGE NUT FOR M50 CABLE GLAND Nut order code Gauge Min Max M [mm] [mm] 00 961 12x1,5 3,5 7 00 962 16x1,5 5,5 10 00 963 20x1,5 7 13 00 964 25x1,5 10 17 00 965 32x1,5 12 21 00 966 40x1,5 19 28 00 967 50x1,5 27 35 * M40, M50 and M63 cable glands and nuts are only available on demand 16 Modular terminal blocks ABB terminal blocks are available in 3 different technologies: screw-clamp, spring-clamp and ADO system, the most reliable technology. As far as photovoltaic application is concerned, screw-clamp and ADO system technologies are used. The latest offering the best reliability and long term durability. Screw-clamp blocks for these applications can carry up to 800V DC with 57 A (10 mm²), up to 415A (240mm²) on request, according to IEC 60947-7-1 standard and ADO – clamp can carry up to 1000V DC with 32A (4 mm²). Spring technology is also available on request. Modular terminal blocks Type Application Screw-screw terminal block MA 2,5/5 phase M 4/6 phase M 6/8 phase M 10/10 phase MA 2,5/5.N neutral M 4/6.N neutral M 6/8.N neutral M 10/10.N neutral MA2,5/5.P earth M 4/6.P earth M 6/8.P earth M10/10.P earth ADO-ADO terminal block D 2,5/8.ADO phase D 4/8.ADO phase D 2,5/8.N.ADO neutral D 4/8.N.ADO neutral D 2,5/8.P.ADO earth D 4/8.P.ADO earth ADO-screw terminal block D 6/8.ADO phase D 6/8.ADO3 phase D 6/8.N.ADO neutral D 6/8.N.ADO3 neutral D 6/8.P.ADO earth D 6/8.P.ADO3 earth Section I [A] V [V] Order code 2,5mm2 4mm2 6mm2 10mm2 2,5mm2 4mm2 6mm2 10mm2 2,5mm2 4mm2 6mm2 10mm2 24 32 41 57 24 32 41 57 300A/1s 480A/1s 720A/1s 1200A/1s 800 800 800 800 800 800 800 800 1SNA115486R0300 1SNA115116R0700 1SNA115118R1100 1SNA115120R1700 1SNA125486R0500 1SNA125116R0100 1SNA125118R1300 1SNA125120R1100 1SNA165488R2700 1SNA165113R1600 1SNA165114R1700 1SNA165115R1000 2,5mm2 4mm2 2,5mm2 4mm2 2,5mm2 4mm2 24 32 24 32 300A/1s 480A/1s 1000 1000 1000 1000 1SNA199059R0600 1SNA399244R1400 1SNA199061R2000 1SNA399318R1600 1SNA199091R1700 1SNA399250R2600 2,5mm2 4mm2 2,5mm2 4mm2 2,5mm2 4mm2 24 32 24 32 300A/1s 480A/1s 1000 1000 1000 1000 1SNA199042R2500 1SNA399245R1500 1SNA199044R2700 1SNA399319R1700 1SNA199118R2600 1SNA399251R1300 17 Modular miniature and residual current circuit breakers In addition to S 800 PV circuit breakers, ABB offers a full range of miniature and residual current circuit breakers suited for any application in domestic, industrial and commercial installations. Further information can be found in the “System pro M compact” technical catalogue (cod. 2CSC40002D0206). GEMINI switchboards Due to their IP66 protection degree, Gemini switchboards, made in thermoplastic material by means of the co-injection moulding technique, can be used in any kind of environment, even outdoors, maintaining their high mechanical characteristics and resistance to adverse weather conditions and aggressive substances over time. Further information can be found in the “Gemini. Low voltage insulating switchboards” catalogue (cod. 1SLC805001D0204). Contactors A wide range of contactors, even miniaturised, and thermal relays are available for control and protection functions. Further information can be found in the “Contactors. Motor protection circuit breakers. Thermal relays” catalogue (cod. 1SBC100122C0202). 18 Automation Products Division www.abb.com www.abb.com/lowvoltage © Copyright 2007 ABB. All rights reserved. Preliminary 1SDC007099B0203