2 Safety

 

2.1  Intended use  

 

The HISbox® DC Combiner HDCXL is a generator junction box for PV strings between the PV generator and the inverter. The  respective PV strands are switched in parallel and have the option of being safeguarded with overcurrent protective  devices.  Depending  on  the  version,  the  HISbox®  DC  Combiner  HDCXL  is  supplied  with  measuring  systems  for  string  monitoring.  

 

The HISbox®  DC Combiner HDCXL can be used in large PV plants which are operated with a central inverter.  

Please see the technical data of the equipment and ensure that these are not exceeded when the plant is in operation.  

 

The generator junction box has been designed exclusively for the intended use outlined above. Deviating applications or  deviating from the installation, erection, commissioning or maintenance instructions as well as modifications or any other  changes render guarantee claims null and void.  

   

This manual is part of the switchgear combination. It must be accessible at all times.  

2.2   Safety advice  

 

This section gives safety advice which must be followed as a matter of principle and without exception, when working with  the product. Please read the section with care and note fully and at every step all safety advice to prevent personal injury  and damage to property and to guarantee lasting operation of the product.  

 

Danger to life from high voltages!   

 

On conducting elements high voltages can occur. Contact with these live parts can cause death or serious injury  

∙ When working on the assembly wear personal protective equipment  

∙ Do not touch any live components or connected/disconnected conductors 
∙ Before performing any work on the assembly, it must be isolated  

o Switch off the DC load-break switch  

o Switch off the relevant sub-array field conductor at the inverter or the main splitter Remove the DC  

fuses in the central inverter or in the main splitter when de-energised.  

o Only open the DC fuse holders in the generator junction boxes when de-energised.  

o To isolate the supply (string cables), disconnect the solar plugs on the outside of the generator junction  

box  

∙ Secure any isolators to prevent them being switched on again and ensure that the equipment and its  

modules are voltage-free    

∙ Earth and short circuit  

∙ Protective covers must remain in place. Adjoining parts or live parts must be covered.  

 

Danger to life from live conductors!  

The connected DC conductors are live. Contact with live parts can cause death or serious injury.  

 

Danger to life from earthing faults!  

PV plants can become live when there is an earthing fault.  If there is contact with plant parts which have faulty earthing, it  can cause death or serious injury. Before undertaking any work, ensure that there are no earthing faults. Furthermore,  damage to the equipment can cause danger to life! The integrity of the switchgear combination must be inspected regularly  and only be operated in a perfect and safe condition.  

The functionality of all fuse configurations must be ensured.  

 

 

Risk of fatal electric shock from unsecured switchgear combination.   

Contact with live components can cause death or serious injury. The switchgear combination must be secured against entry  by unauthorized persons. On completion of the work, lock the switchgear combination, remove the key from the door and  keep it in a safe place.  

 

Risk of fire from faulty installation of connecting cables and not adhering to torque specifications. 

The current carrying capacity of these connections is reduced if the required torques applied to the conducting connections  are not adhered to. Contact resistances increase and can overload components, and can lead to overheating and the risk of  fire. Furthermore, only appropriate tools must be used. 

 

Attention! Risk of burns!   

Parts or components can reach very high temperatures during operation or in case of a failure.  

 

Danger from incorrectly rated DC fuses.

PV module can be damaged by excessive reverse currents. The optimal current values of the generator junction box and derating  factors of the fuse link must be considered. 

 

Components can be damaged by dust or penetration of moisture.  

Only open the switchgear combination when the environment is dry and dust-free. Always keep the equipment closed and do  not open during a sandstorm, precipitation or extremely high humidity.  

 

Damage to electrical components from electrostatic discharge. 

Electronic components can be damaged or destroyed by electrostatic discharge. ESD regulations must be observed for all  work.  

 

Always observe: 

• ∙ The generally recognized rules of the technology and the legal and official regulations  
• ∙ The rules DIN VDE 0100 standards, in particular the VDE 0100-551 (low voltage generating sets, VDE 0100-520 (wiring  
• systems) as well as VDE 0100-712 (PV power supply systems)  
• ∙ Occupational protection and accident prevention regulations of the trade association responsible  
• ∙ The rules and guidelines of the grid operator as well as the Technical Connectivity terms and conditions  
• ∙ If necessary, it is the responsibility of the erectors to implement additional protection measures subject to the  
• local conditions.  
• ∙ The installation and commissioning of the switchgear combination must only be carried out by qualified electrical  
• specialists!  

If an operator modifies the switchgear combination unilaterally, the operator is deemed to be a manufacturer and must  therefore provide proof of compliance with DIN EN 61439-1 standards.

 

2.3  Qualification of the electrical specialists   

 

All  the  functions  described  must  be  carried  out  only  by  qualified  electrical  personnel  who  must  have  the  following  qualifications:  

- The ability to recognize risks and avoid possible dangers of electricity due to training and experience.  

- Knowledge of the risks and dangers which can arise during the installation, service and maintenance of DC  

generator junction boxes in photovoltaic plants.  

- Comprehensive knowledge of relevant standards and guidelines.  

- Knowledge of the content of this document and observance of all safety advice.  

 

2.4  Nomenclature of the type label 

 

Designation  

 

• The switchgear combination must be disposed of in accordance with the current regulations for the disposal of electronic waste  
• The switchgear combination complies with the relevant EU guidelines.  
• The switchgear combination conforms to the requirements of IEC 61439  
• The switchgear combination has protective isolation and conforms to the requirements in protection category II.  
• The switchgear combination is protected against the ingress of water and foreign bodies in accordance with DIN EN 60529  
• The degree of protection  can be found in our article description    

3 Scope of supply 

 

  A 1x GRP enclosure with installed cable entry points and pressure equalization element 
  B 1x key set  (2-Bit keys)  

  C 1x set of wall fixing brackets  SS304 (4pcs)  

  D 1 x multiple entry gasket for M32 with 4 cable entries (5-7mm)  

  E Installation manual  

* The product supplied can differ from the image 

 

4 Installation  

 

Do not carry out any work on the switchgear combination in rainy, foggy or very humid conditions (>95%), in environments with high dust development in close proximity or other adverse external conditions.  

 

4.1  Choice of installation site 

Danger to life from fire and explosion. Do not  

- install the switchgear combination on flammable materials  

- install the switchgear in areas where there are easily combustible materials  

- install the switchgear combination in areas where there is a danger of explosion  

 

4.2  Requirements 

 

∙ The installation site must be accessible at all times, emergency exits must not be blocked and must not be located in residential or office spaces  

∙ The installation site must be solid  

∙ The installation site must be suitable for the weight and measurements of the product supplied   

∙ Protection from extreme temperatures: climatic conditions must be complied with (see data sheet)  

∙ The installation site must not be in direct sunlight and must be protected from rain and splashing water. A protective  cover must be provided if necessary  

∙ Connecting cables and wiring systems must be selected and erected so that damage from condensation, water penetration or other damaging effects does not occur  

∙ The connecting cables face downwards and the switchgear combination must not be installed horizontally or at an angle.  

∙ The technical data of the generator junction box such as rated current, rated voltage must never be exceeded during operation.  

∙ Technical Connectivity terms and conditions of the grid operators must be complied with.  

∙ The minimum spacing (see Section „Minimum spacing “) must be observed  

 

4.3  Minimum spacing  

 

Please note the required spacing for optimum air circulation: HIS generally recommends minimum spacing of at least 30 cm  WARNING between all parts which could prevent heat dissipation or could generate heat themselves.

 

4.4  Installing the switchgear combination  

 

Cable glands and plug connectors can be damaged by incorrect transport, storage or installation.  

Any additional installation material required is not included in the scope of supply. (For all necessary information on the  wall mounting brackets provided, see our article description)  

 

Procedure:  

1. Affix the wall mounting brackets supplied to the switchgear combination  

2. Fix the switchgear combination with suitable screws and washers on the mounting supports  

3. Check that the switchgear combination has been mounted firmly and ensure that the screws have been  

sufficiently tightened  

 

4.5  Cabinet Dimensions  

 

For the cabinet dimensions, please see our article description.  

 

5 Electrical connection  

 

Danger to life from high voltages!

 

There can be high voltages on the conducting components Contact with these live parts can cause death or serious injury.  

∙ Ensure that the main load-break switch is switched off (OFF position)  

∙ Ensure that all string fuse holders are open and that the string fuses are removed. Warning: never operate  

string fuses under load!  

∙ Ensure that string cables are not connected to the live PV generator  

∙ Ensure that the main cable of the sub-array is de-energized   

∙ Ensure that the switchgear combination is de-energized  

∙ Personal protective clothing must be worn while working on the switchgear combination   

∙ Do not come into contact with any conducting components or connected /disconnected conductors  

∙ Secure any switches to prevent them being switched on and ascertain that the equipment and parts are de-

energized  

∙ Earth and short circuit  

∙ Do not remove protective covers. Adjoining or energized parts must be covered  

 

When retightening conducting screw connections, observe the specified torque. 

 

5.1  PE conductor  

 

When connecting the surge arrester, please consider the whole over-voltage scheme.  

∙ Pass the earth cable through the glands provided for this purpose (For information on cable diameters please  

see our article description)  

∙ Connect the earth cable to the PE terminal provided for this purpose. (For information on conductor type and  

cross-sectional area as well as applicable torques, please see our article description)  

∙ Tighten the cable gland so that the degree of protection of the switchgear combination and the strain relief is  

ensured. Unused cable glands must be fitted with blanking plugs (For information on the cable gland torques,  please see our article description)  

5.2  Data bus cable/Power supply  

 

∙ Pass the data / power supply cables through the glands provided for this purpose (For information on cable  

diameters see our article description)  

∙ Connect the data / power supply cables to the shield terminals and connection terminals provided for this  

purpose. (For information on terminal connections, conductor type and cross sectional area as well as the  required torques, please see our article description)  

∙ Tighten the cable gland so that the degree of protection of the switchgear combination and the strain relief is  

ensured. Unused cable glands must be fitted with blanking plugs (For information on the cable gland torques  please see our article description)  

 

5.3  PV String cables (Input)

  

Danger  to  life  from  polarity  reversal:  the  switchgear  combination  is  not  protected  against  polarity  reversal.  Polarity  reversals can lead to serious faults.  

∙ Pass the PV string cables through the cable glands provided for this purpose (For information on cable  

diameters, please see our article description)  

∙ Connect the PV string cables to the terminal blocks or fuse holders provided for this purpose. Make sure, that  

the string cable and its active parts show enough gap between conductive materials or active parts of the  junction box (For information on conductor type and diameters and torques to be observed, please see our  article description)  

∙ Tighten the cable gland in order to guarantee the protection degree and the strain relief of the switchgear  combination Fit unused cable glands with blanking plugs (For information on cable gland torques, please see  

our article description)  

 

5.4  Sub-array field cable (Output)  

 

Danger  to  life  from  polarity  reversal:  the  switchgear  combination  is  not  protected  against  polarity  reversal.  Polarity  reversals can lead to serious faults.  

∙ Pass the sub-array field cables through the cable glands provided for this purpose (For information on cable  

diameters, please see our article description)  

∙ Connect the sub-array field cables to the terminal blocks or fuse holders provided for this purpose. Make  

sure, that the sub-array field cable and its active parts show enough gap between conductive materials or  active parts of the junction box. (For information on conductor type and diameters and torques to be  observed, please see our article description)  

∙ Tighten the cable gland in order to guarantee the protection degree and the strain relief of the switchgear  combination. Fit unused cable glands with blanking plugs (For information on cable gland torques, please see  

our article description)  

 

 

6 Commissioning  

 

Danger to life from high voltages!   

 

There can be high voltages on the conducting components. Contact with these live parts can cause death or serious  injury.  

 

∙ Ensure that the main load-break switch is switched off (OFF position)  

∙ Ensure that all the protective covers provided for this purpose are fitted  

∙ Ensure that all string fuse holders are open and that the string fuses are removed. Warning:  never operate  

string fuses under load!  

∙ Ensure that string cables are not connected to the live PV generator  

∙ Ensure that the switchgear combination is de-energized  

∙ Personal protective clothing must be worn while working on the switchgear combination   

∙ Do not come into contact with any conducting components or connected /disconnected conductors  

- Secure any switches to prevent them being switched on and ascertain that the equipment and parts are de-Secure any switches to prevent them being switched on and ascertain that the equipment and parts are de-

energized  

∙ Earth and short circuit  

∙ Do not remove protective covers. Adjoining or energized parts must remain covered 

6.1  Voltage testing  

 

Use only appropriate voltmeters. Ensure that the voltmeter operating and isolating voltmeters are high enough for the  application. The operating voltage can be up to 1500V DC!  

∙ Ensure that the PV inverter is switched off and isolated from the DC side  

∙ Ensure that the main load-break switch is switched off (OFF position)  

∙ Ensure that the fuse holders are open  

∙ Measure the open-circuit voltage of each string  

∙ Note the sign (+ /-) of the reading. Never connect polarity reversed strings  

∙ Establish that the polarity of the strings is the same and ensure that the measured values are the same.  

Never connect largely differing voltage levels together by closing the fuse holders. The fuse holders are not  suitable for load switching purposes. Close the fuse holders only when they are voltage-free and of the same  voltage level.  

 

6.2   Closing the fuse holders  

 

∙ Ensure that the PV inverter is switched off and separated from the DC side  

∙ Ensure that the main load-break switch is switched off (OFF position) 
∙ Ensure that the fuse holders are open  

∙ Wear personal protective clothing  

 When the voltage testing (see 6.1) has been carefully carried out and all the safety rules followed, closing of the fuse  holders can begin.  

 

6.3   Closing the main load-break switch 

∙ Ensure that the PV inverter is ready for operation 
∙ Ensure that the main load-break switch is switched off (OFF position)  

∙ Ensure that the fuse holders are closed 
∙ Wear personal protective clothing  

 

Ensure that generator junction boxes connected in parallel, DC main distribution boards and the inverters are ready for  connection and that all work on the inverters, DC main cables and DC main distribution boards has been completed and  that there is no potential danger to personnel.  

 

7 De-Commissioning  

 

Note the safety advice in Sections 2.2 and 2.3. 

7.1 Fault check  

 

Ensure  that  the  generator  junction  box  is  operating  correctly.  Ensure  that  there  are  no  faults  which  could  lead  to  endangering operating personnel.  

The following describes how to isolate the switchgear combination. 

7.2  Opening the main load-break switch   

 

∙ Ensure that no danger can occur by switching operations   

∙ Units with external handles: please establish that the door is unlocked only after the switch is in the OFF  

position  

∙ Units with internal handles: open the enclosure  

∙ Switch the main load-break switch to the OFF position. Also note that when the DC main switch is switched  

off (OFF position) all active parts still have a voltage which can endanger life  

∙ To isolate the sub-array field cable, open the upstream fuse / switch elements or all generator junction boxes  

connected in parallel. Switch off the inverter 

7.3 Opening the fuse holders  

 

The fuse holders are not suitable for switching when under load. Ensure that there is no current flowing using appropriate  instruments.  

∙ Open all fuse holders and remove the fuse links. Ensure that inadvertent closing cannot occur. Fuse holders  

are not suitable for switching under load  

∙ Warning: both the string cables and the sub-array field cable are still under voltage which can endanger life  

∙ To isolate the string cables, open the solar plug on the outside of the switchgear combination and mark them  

to prevent polarity reversals/ mix-ups  

∙ To isolate the sub-array field cable, open the upstream fuse /switch elements or all generator junction boxes  

connected in parallel. Switch the inverter off 

7.4  Determining voltage free status  

 

Before starting work on the switchgear combination: see the general safety advice in Sections 2.2 and 2.3 and determine  voltage-free status.  

 

7.5  Removal 

Procedure  

 

1. Disconnect all supply input and output cables from the terminals  

2. Isolate the earth cable  

3. Loosen cable glands  

4. Pull out all cables through the cable glands and gland plates. Remove switchgear combination   

 

8  Maintenance  

 

 Note the safety advice in Sections 2.2 and 2.3  

You must check the switchgear combination regularly for function and safety. This means in particular  

 

TABLE  

 

1. There is no sign of corrosion on parts which ensure the function and safety  

Visual inspection  

Annually 

 

2. There  are  no  harmful  amounts  of  water  or  dust  inside  the  switchgear  combination  

Visual inspection  

Annually  

 

3.

Visual inspection  

Annually  

 

4. Insulation properties  

Insulation test  

Every 5 years  

 

5.  Connections are in order and show no signs of heat or burn marks  

Visual inspection  

Annually  

 

6. Internal  covers,  doors,  hinges  and  locking  mechanisms  are  in  order  and  functional  

 

 

Electrical plants and fixed electrical equipment are to be maintained regularly according to the current relevant standards.   Maintenance is the responsibility of the plant operator.  

 

When replacing equipment, only use equipment identical to the original. If you have any questions, please contact the  manufacturer.