Solar Combiner Boxes

GEESYS Solar String Combiner Boxes are meant for combining all the incoming lines from the solar panel strings/arrays and deriving one common array output for the multiple array inputs.In a large solar photovoltaic (PV) array, multiple solar modules are connected in series in a string to build the voltage up to proper levels for the inverter. Multiple strings of solar modules are then combined together in parallel to multiply the string output currents to higher levels for input into the inverter.

GEESYS String Combiners (Combiner Boxes) allow the system designer great flexibility in terms of number of circuits, enclosure type and output conductors. GEESYS combiners come in NEMA-3R, 4 and 4X enclosures in either Polycarbonate, powder coated steel, stainless steel, or fibreglass. All enclosures feature complete casketed seals and all output terminals are rated for 90C. GEESYS typically stocks 2 and 32 circuit units in all three enclosures, but other circuit counts can be built to order.

In all but the smallest PV systems, modules are wired together in series strings, where the positive leads of one module are connected to the negative leads of the next module. This results in cumulative voltage output, with current (amps) staying the same. The box where the output wires from multiple series strings are joined is the combiner box. Rated for outdoor use, it contains overcurrent protection devices (OCPDs) and the necessary bus bars and terminals for combining the inputs.

Battery-based systems (off-grid and grid-tied with battery backup) have lower DC system voltages than grid-direct systems (although higher-voltage charge controllers are expected to hit the market soon). Historically, this voltage ranged from 12 to 48 V nominal to match battery voltages, but step-up/down MPPT charge controllers now allow arrays with higher voltages to charge lower-voltage battery banks, making higher array voltages more common (with open-circuit voltages usually limited to 150 V). Even with the use of step-up/down charge controllers, typically only one to six modules are placed in a series string, which means combining more strings in parallel to get the desired power output, which necessitates a combiner box.

In addition, charge controllers typically have only a single set of input wire terminals. For off-grid systems, it’s often wise to have enough room in the combiner for adding more strings of modules in the future. If the combiner and its output wires are sized accordingly, and the charge controller has been sized to handle the additional amperage, wiring more PV modules into the system can be as easy as terminating the new wires in the PV combiner box.

GEESYS provides standard pre-made solutions for Roof Top projects.These include a wide variety of Solar Array Junction boxes and AC Distribution Box. These solutions are customisable.

  • AJB 2in-1out
  • AJB 3in-1out
  • AJB 4in-1out
  • AJB 5in – 1out
  • AJB 6in – 1out
  • AJB 8in – 1out
  • AJB 10in – 1out
  • AJB 12in – 1Out
  • AJB 16in – 1out

Solar String combiner Boxes

 Model  GPRO-OD5X   GPRO-OD10X 
 Maximum Voltage in open Circuit 500V   1000V 

 Input

No of DC inputs 1-6 1-12
Maximum Input Fuse* Rating, A *  6/10/12/15/20/30
Max Input Current in short Circuit  
Max. input current in short circuit at STC  
Maximum string current per fuse holder with all string fuse* Reduction factor 0.55
Conductor Size , Sq.mm  4 — 10 Sq.mm

 

Output

No of DC Outputs 1 - 12 150 Sq.
 Maximum DC Current, A *  Upto 32A   Upto 32A 
 Conductor Size, Sq.mm   4 — 10 Sq.mm   4 — 10 Sq.mm 
Cable gland clamping range,mm 12-32

 

Protection

DC inputs overcurrent protection Protection on both polarities, gPV fuses, size 10 x 38 mm, max. rating 30 A (fuses not provided with product)
Surge Protection Device (SPD)* <=600V DC, Class C/Class B/ Class B+C

1000V DC, Class C/Class B/ Class B+C
Electric shock protection Class II equipment

 

General

Ingress Protection  IP66/65
Enclosure Type  PS*/PC,
Transparent  Top Cover
Wall mounting  Yes
Bus Bar* Yes
 Operating conditions Temp :  -20 to +55 Deg. C , RH : 0 — 95% non cond
 Type of Protections  Short-Circuit,Surge 
 International standards followed  IEC 60364
Design Life  25 years +

 

Every inverter and charge controller, whether in a utility-interactive or stand-alone system, has a DC input voltage window that must be adhered to. In batteryless grid-tied systems, inverters require relatively high DC input voltages, from 90 to 850V (typically 4 to 26 modules wired in series).

Small grid-tied PV systems (less than 5 kW @ 600V DC) often have only one or two series strings of modules. GEESYS Team will configure the SJB based on the Inverter’s technical specification and Solar PV modules technical specification. A combiner box offers a place to house series fuses and parallel the series string inputs, reducing the number of array output wires needed to run to the inverter location.

Some grid-direct inverter manufacturers include series fusing within the inverter or its attached disconnect box, which may eliminate the need for a separate combiner box. However, using a PV combiner box located close to the PV array gives you easy access to the wires for each series string. This can be handy for troubleshooting a malfunctioning PV array without having to run back and forth to the inverter area.

  • SJB 1in – 1out
  • SJB 2in – 2out
  • SJB 3in – 3out
  • SJB 4in – 4out
  • SJB 4in – 2out
  • SJB 6in – 2out
  • SJB 6in – 4out
  • SJB 6in – 6out
  • SJB 8in – 4out
  • SJB 8in – 8out
  • SJB 10in – 10out
  • SJB 12in – 12out

Solar String combiner Boxes

 Model  GPRO-GD5X   GPRO-GD10X 
 Maximum Voltage in open Circuit 500V   1000V 

 Input

No of DC inputs 1-6 1-12
Maximum Input Fuse* Rating, A *  6/10/12/15/20/30
Max Input Current in short Circuit  
Max. input current in short circuit at STC  
Maximum string current per fuse holder with all string fuse* Reduction factor 0.55
Conductor Size , Sq.mm  4 — 10 Sq.mm

 

Output

No of DC Outputs 1 - 12 150 Sq.
 Maximum DC Current, A *  Upto 32A   Upto 32A 
 Conductor Size, Sq.mm   4 — 10 Sq.mm   4 — 10 Sq.mm 
Cable gland clamping range,mm 12-32

 

Protection

DC inputs overcurrent protection Protection on both polarities, gPV fuses, size 10 x 38 mm, max. rating 30 A (fuses not provided with product)
Surge Protection Device (SPD)* <=600V DC, Class C/Class B/ Class B+C

1000V DC, Class C/Class B/ Class B+C
Electric shock protection Class II equipment

 

General

Ingress Protection  IP66/65
Enclosure Type  PS*/PC,
Transparent  Top Cover
Wall mounting  Yes
Bus Bar* Yes
 Operating conditions Temp :  -20 to +55 Deg. C , RH : 0 — 95% non cond
 Type of Protections  Short-Circuit,Surge 
 International standards followed  IEC 60364
Design Life  25 years +

GEESYS String Combiner is a junction box which allows several photovoltaic strings (from 8 to 32) to be connected in parallel. The total DC power is then distributed to the photovoltaic inverter. It includes photovoltaic string protection, overvoltage protection and a DC output switch disconnector. They are well adapted for Power plants as well as for photovoltaic large buildings

The Array Box also integrates a monitoring module and communicates through Modbus protocol with the monitoring devices (iRIO, XLRIO) located in the inverter substation. For each string of panels, Array Box realises DC current measurement (0 to 20A per string). The DC voltage (up to 1500Vdc) is also measured and abnormal behaviour or failures are detected.

Array Box can also propose safety opening control and remote control of the switch disconnector.

Having invested huge amount of capital in their solar PV plants, the plant operators want to get the maximum output from their photovoltaic power plants. The solar photovoltaic plant operators want to know the reason behind any / every fall in the PV plants output - whether the fall is due to some known cause [cloudy weather, planned maintenance,... etc.] or the fall is due to a fault in the plant that needs to be rectified. And, in case of fault, they want to know the exact location of the fault.

A solar PV plant typically has hundreds / thousands of PV modules spread over a large area. Using conventional means finding answers to both these questions is very difficult and/or time consuming.The string monitoring and diagnostics system offered by GEESYS is a smart solution to above mentioned problems. The string monitoring and diagnostics system provides clear and up to the minute information about the entire generating section of the solar plant. Alarms are displayed locally and on the central monitoring server showing the exact PV module string / array junction box with fault for immediate action by the plant operators.

The string monitoring and diagnostics system offered by GEESYS is affordable and simple to install.

Provides detailed information about the power generated by each string of PV modules.

Provides information about out-of-order or disturbed strings.

Upon occurrence of a fault in the power plant the system gives clear and visible reference points of the place, where the fault is registered and the nature of the fault. Such information is accompanied by a visual alarm in the concerned field array junction box and the central monitoring server.

Monitors the status of the fuses of each string

Each measuring module does a self-check up on power ON.

The system installation is easy and quick as the measuring module comes pre installed in the array junction box provided by Hanut India. Hanut India can customize the array junction box as per plant operator's requirements.

The string monitoring module needs NO additional cabling for power supply and data transmission as it takes power from the PV module strings and transmits data to the central server wirelessly. Absence of power and data transmission wires is a very BIG advantage.

User friendly software is provided for monitoring the performance of all the strings from a central location

  • CB 8in – 1out with SMU
  • CB 12in – 1Out with SMU
  • CB 16in – 1out with SMU
  • CB 24in – 1out with SMU
  • CB 32in – 1out with SMU

Solar String combiner Boxes

 Model  GPRO-D5X   GPRO-D10X 
 Maximum Voltage in open Circuit 1000V   1500V 

 Input

No of DC inputs 1-52 1-52
Maximum Input Fuse* Rating, A *  6/10/12/15/20/30
Max Input Current in short Circuit  
Max. input current in short circuit at STC  
Maximum string current per fuse holder with all string fuse* Reduction factor 0.55
Conductor Size , Sq.mm  4 — 4-10 Sq.mm

 

Output

No of DC Outputs 1 150 Sq.
 Maximum DC Current, A *  Upto 630A   Upto 630A 
 Isolator/MCB A*   4 — 100/250/315/400/500/630   4 —100/250/315/400/500/630 
 Conductor Size, Sq.mm   4 —19*3 to 30*12   4 —19*3 to 30*12 
 Conductor Size, Sq.mm   4 — 10-300 Sq.mm   4 — 10-300 Sq.mm 
Cable gland clamping range,mm 17-50

 

Protection

DC inputs overcurrent protection Protection on both polarities, gPV fuses, size 10 x 38 mm, max. rating 30 A (fuses not provided with product)
Surge Protection Device (SPD)* <<=1000V DC, Class C/Class B/ Class B+C

1500V DC, Class C/Class B/ Class B+C
Electric shock protection Class II equipment
320V AC,SPD 320V AC,40 KA,type-2,Iscpv 100A
48V DC,SPD 48V DC,40 KA,type-2,Iscpv 100A

 

String Monitoring Unit

General

Max Current per String  8-52 Channel, 50A, Hall Effect Based CT
Voltage Measurement  1 Channel (1000V DC Maximum) , Accuracy: 1.5FSD
Internal Temperature Measurement   0 - 100°C, Accuracy ± 2°C for full scales
Data communication (Isolated) RS 485 Modbus RTU Protocol, 2.5KV Isolation, Half Duplex
 I/O's;  DI:2, DO:1; AI:2; Temp Input: 1 RTD PT100 3 Wire
 Auxiliary Power Supply   230V AC, 50Hz, 1-Ph/±15V DC, lA 
Ingress Protection  IP66/65
Enclosure Type  PS*/PC,Transparent Top cover
Wall mounting  Yes
Bus Bar* Yes
 Operating conditions Temp :  -20 to +55 Deg. C , RH : 0 — 95% non cond
 Type of Protections  Short-Circuit,Surge 
 International standards followed  IEC 60364
Design Life  25 years +