Protection and isolation of photovoltaic installations

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

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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 experience serving solar energy

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.

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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

Equipment for the direct current section

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.

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Example of an IP65 in-box field switchboard to isolate strings with a maximum capacity of 16A up to 500VDC made up of:

• IP65polycarbonatejunctionbox,dimensions 275x220x140 with IP65 cable glands

•OT16E4-poleswitch-disconnector+shaft+handle

• surgeprotectiondeviceOVRPV40 600 P - Surge protection device for 40kA 600V DC photovoltaic installations with removable cartridges

•4Screwclampterminalblocks 4-6-10 mm², voltage rated up to 800V

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:

•EuropaseriesIP65wall-mounted 12-module control board with IP68 metric gauge cable glands and nuts

•miniaturecircuitbreakerS802SUC,16A


•Screwclampterminalblocks 4-6-10 mm2, voltage rated up to 800V

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• IP65polycarbonatejunctionbox,dimensions275x220x140withIP65cableglands

• OT16E8-poleswitch-disconnector+shaft+handle

• surgeprotectiondeviceOVRPV401000P-Surgeprotectiondevicefor40kA1000Vd.c.photovoltaic installations with removable cartridges

Example of an IP65 in-box field switchboard to isolate strings with a maximum capacity of 16A up to 750V DC made up of:



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:


•miniaturecircuitbreakerS802PV-S,16A


•Screwclampterminalblocks 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:


•S802PV-M,32Aswitch-disconnector• surgeprotectiondeviceOVRPV40

1000 P - Surge protection device for 40kA 1000V DC photovoltaic installations with removable cartridges

•Screwclampterminalblocks 4-6-10 mm², voltage rated up to 800V

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S802PV-S16

String 1 800VDC/16A

String 2 800VDC/16A

String 3 800VDC/16A

String 6 800VDC/16A

String 7 800VDC/16A

Protection from lightning

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S802PV-S16

S802PV-S16

S802PV-S16

S802PV-S16

S802PV-M125

Protection against overvoltages

Inverter

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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.


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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:


•miniaturecircuitbreakerS804PV-S,16A


•ADO-screwclampterminalblocks 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:


•S804PV-M,32Aswitch-disconnector• surgeprotectiondeviceOVRPV40

1000 P - Surge protection device for 40kA 1000V DC photovoltaic installations with removable cartridges

•ADO-screwclampterminalblocks 4 mm², voltage rated up to 1000V

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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 switch-disconnectors and switch-disconnector blocks that guarantee effective protection in all types of photovoltaic installation.The range also includes type B switch-

Switchgear for protection downstream of the inverter

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

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S800PV-S miniature circuit breakers

PolesRated current

In [A]Type Order code

2 10 S802PV-S10 2CCP842001R11092 13 S802PV-S13 2CCP842001R11392 16 S802PV-S16 2CCP842001R11692 20 S802PV-S20 2CCP842001R12092 25 S802PV-S25 2CCP842001R12592 32 S802PV-S32 2CCP842001R13292 40 S802PV-S40 2CCP842001R14092 50 S802PV-S50 2CCP842001R15092 63 S802PV-S63 2CCP842001R16392 80 S802PV-S80 2CCP842001R18094 10 S804PV-S10 2CCP844001R11094 13 S804PV-S13 2CCP844001R11394 16 S804PV-S16 2CCP844001R11694 20 S804PV-S20 2CCP844001R12094 25 S804PV-S25 2CCP844001R12594 32 S804PV-S32 2CCP844001R13294 40 S804PV-S40 2CCP844001R14094 50 S804PV-S50 2CCP844001R15094 63 S804PV-S63 2CCP844001R16394 80 S804PV-S80 2CCP844001R1809

S800PV-M switch-disconnectors

PolesRated current

In [A]Type Order code

2 32 S802PV-M32 2CCP812001R13292 125 S802PV-M125 2CCP812001R18494 32 S802PV-M32 2CCP814001R13294 125 S802PV-M125 2CCP814001R1849

ConnectionNetworks of photovoltaic panels in earther systems

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800 V c.c.

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1200 V c.c.

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800 V c.c.

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1200 V c.c.

S800PV-S miniature circuit breakers and S800PV-M switch-disconnectorsThe 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 switch-disconnectors 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

ConnectionNetworks of photovoltaic panels in earther systems

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OVR PV surge protection devicesABB 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 devicesType Order code

OVR PV 40 600 P 2CTB803953R5300OVR PV 40 600 P TS 2CTB803953R5400OVR PV 40 1000 P 2CTB803953R6400OVR PV 40 1000 P TS 2CTB803953R6500OVR PV 40 600 C 2CTB803950R0000OVR PV 40 1000 C 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

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OT switch-disconnectorsOT 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 switch-disconnectors are suitable for installation in switchboards with 45mm slotsThe 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-disconnectorsPoles Ith (open) Type Order code

4 25 OT 16 E4 1SCA022352R71704 32 OT 25 E4 1SCA022352R73304 40 OT 32 E4 1SCA022352R75004 63 OT 45 E4 1SCA022352R76804 80 OT 63 E4 1SCA022352R77604 115 OT 100 E4 1SCA022398R45804 125 OT 125 E4 1SCA022373R18808 25 OT 16 E8 1SCA022551R45108 32 OT 25 E8 1SCA022551R53108 40 OT 32 E8 1SCA022551R29908 63 OT 45 E8 1SCA022551R37008 80 OT 63 E8 1SCA022551R61208 115 OT 100 E8 1SCA022551R77908 125 OT 125 E8 1SCA022551R8500

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Europa series wall-mounted control boardsEuropa 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 60695-2-11 standard

- installationtemperature:-25°Cto+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

DescriptionDimensions

WxHxD [mm] Order code

IP65 CONTROL BOARD, P/SMOKE GREY 4M 140x220x140 12744IP65 CONTROL BOARD, P/SMOKE GREY 8M 205x220x140 12748IP65 CONTROL BOARD, P/SMOKE GREY 12M 275x220x140 12752IP65 CONTROL BOARD, P/SMOKE GREY 18M 1 ROW 380x220x140 12753

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Junction boxesABB 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

- installationtemperature:-25°Cto+60°C- shock resistance: 20 joules (IK 10 class)- junction boxes compliant with the CEI 23-48 and IEC 60670

standards

Junction boxes

DescriptionDimensions

WxHxD [mm] Order code

BOX IP65 PC 140x220x140 12804BOX IP65 PC 205x220x140 12808BOX IP65 PC 275x220x140 12812

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Metric gauge cable glands and nutsMain technical characteristics of metric gauge cable glands and nuts:

- IP68 protection degree- material: 6.6 polyamide, self-extinguishing material compliant

withtheUL94V2standardandresistanttoabnormalheatand fire-resistant up to 750°C (incandescent wire test) in conformity with the IEC 60695-2-11 standard

- usagetemperature:from-20°Cto+120°C(briefperiod)- 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

* M40, M50 and M63 cable glands and nuts are only available on demand

Metric gauge cable glands and nuts

Cable gland

Cable glandorder code Nut

Nutorder code

Gauge M

Min[mm]

Max[mm]

METRICGAUGEM12CABLE GLAND

00 951NUTFORM12CABLE GLAND

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


00 956*METRICGAUGENUTFORM40CABLE GLAND

00 966 40x1,5 19 28


00 957*METRICGAUGENUTFORM50CABLE GLAND

00 967 50x1,5 27 35

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Modular terminal blocksABB 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 blocksType Application Section I [A] V [V] Order code

Screw-screw terminal blockMA 2,5/5 phase 2,5mm2 24 800 1SNA115486R0300M 4/6 phase 4mm2 32 800 1SNA115116R0700M 6/8 phase 6mm2 41 800 1SNA115118R1100M 10/10 phase 10mm2 57 800 1SNA115120R1700MA 2,5/5.N neutral 2,5mm2 24 800 1SNA125486R0500M 4/6.N neutral 4mm2 32 800 1SNA125116R0100M 6/8.N neutral 6mm2 41 800 1SNA125118R1300M 10/10.N neutral 10mm2 57 800 1SNA125120R1100MA2,5/5.P earth 2,5mm2 300A/1s 1SNA165488R2700M 4/6.P earth 4mm2 480A/1s 1SNA165113R1600M 6/8.P earth 6mm2 720A/1s 1SNA165114R1700M10/10.P earth 10mm2 1200A/1s 1SNA165115R1000ADO-ADO terminal blockD 2,5/8.ADO phase 2,5mm2 24 1000 1SNA199059R0600D 4/8.ADO phase 4mm2 32 1000 1SNA399244R1400D 2,5/8.N.ADO neutral 2,5mm2 24 1000 1SNA199061R2000D 4/8.N.ADO neutral 4mm2 32 1000 1SNA399318R1600D 2,5/8.P.ADO earth 2,5mm2 300A/1s 1SNA199091R1700D 4/8.P.ADO earth 4mm2 480A/1s 1SNA399250R2600ADO-screw terminal blockD 6/8.ADO phase 2,5mm2 24 1000 1SNA199042R2500D 6/8.ADO3 phase 4mm2 32 1000 1SNA399245R1500D 6/8.N.ADO neutral 2,5mm2 24 1000 1SNA199044R2700D 6/8.N.ADO3 neutral 4mm2 32 1000 1SNA399319R1700D 6/8.P.ADO earth 2,5mm2 300A/1s 1SNA199118R2600D 6/8.P.ADO3 earth 4mm2 480A/1s 1SNA399251R1300

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Modular miniature and residual current circuit breakersIn 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).

ContactorsA 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).

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Protection and isolation of photovoltaic installations