Instruction Manual for BYD models including: CB-03A03S-A Core Battery Combiner Box 3, CB-03A03S-A, Core Battery Combiner Box 3, Combiner Box 3
Wintersun Core Combiner Box 3 Türme | Wintersun (by BYD) | Zubehör & Elektro | Memodo
CombinerBox ShenzhenBYDElectronicsCo,.LTD 2 InstallationManualV1.0 LegalProvisions AlltheinformationinthisdocumentisthepropertyofShenzhenBYDElectronicsCo,.LTD ...
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DocumentDocumentCombiner Box Installation Manual Model: CB-03A03S-A / CB-03A06S-A V1.0 1 Combiner Box Shenzhen BYD Electronics Co,. LTD Legal Provisions All the information in this document is the property of Shenzhen BYD Electronics Co,. LTD. No part of this document could be reproduced in any way for business use. Internal use is allowed. Shenzhen BYD Electronics Co,. LTD. makes no representations or warranties express or implied, with respect to this document, including (with no limitation) any implied warranties of utility, merchantability, or fitness for any particular purpose. All such representations or warranties are expressly disclaimed. Neither Shenzhen BYD Electronics Co,. LTD. nor its distributors or dealers shall be liable for any indirect, incidental, or consequential damages under any circumstances. The exclusion of implied warranties may not apply in all cases under some statutes, and thus the above exclusion may not apply. This document does not replace and is not intended to replace any local, state, provincial, federal, or national laws, regulations, or codes applicable to the installation, electrical safety, and use of the battery system. Shenzhen BYD Electronics Co,. LTD. assumes no responsibility for the compliance or noncompliance with such laws or codes in connection with the installation of the battery system. Specifications are subject to change without notice. Every effort has been made to make this document complete, accurate, and up-to-date. However, Shenzhen BYD Electronics Co,. LTD. may need to make some improvements under certain circumstances without advance notice. Shenzhen BYD Electronics Co,. LTD. shall not be responsible for any loss caused by this document, including, but not limited to, omissions errors, typographical errors, arithmetical errors, or listing errors in this document. All trademarks are recognized. Shenzhen BYD Electronics Co,. LTD Address: No.1, Yan'an Road, Kuichong, Dapeng, Shenzhen, Guangdong Province, 518118, P.R. China. 2 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD Combiner Box Content Legal Provisions ......................................................................................................................................... 2 1. Information on this Document .......................................................................................................... 5 1.1. Validity ..........................................................................................................................................5 1.2. Target Group .............................................................................................................................. 5 1.3. Symbols ....................................................................................................................................... 5 2. Safety ........................................................................................................................................................6 2.1. Instructions and Warnings ......................................................................................................6 2.2. Position and securing ...............................................................................................................7 2.4.Safety Precautions ..................................................................................................................... 7 3. Scope of delivery ................................................................................................................................... 9 4. Product Description ........................................................................................................................... 10 4.1. Circuit Diagram ........................................................................................................................10 4.2. Type Label .................................................................................................................................11 4.3. Symbols on the Type Label .................................................................................................. 11 5. Assembly ...............................................................................................................................................12 5.1. Wall Mounting ..........................................................................................................................12 5.1.1. Selecting the Mounting Location ............................................................................ 12 5.1.2. Mounting the Combiner Box ....................................................................................13 6. Electrical Connection ......................................................................................................................... 15 6.1. Connection Instructions ........................................................................................................15 6.1.1. Preliminary Checks ..................................................................................................... 15 6.1.2. Safety during Electrical Connection .....................................................................15 6.2. Inserting the Cables into the Switch Cabinet ...................................................................16 6.2.1. Bottom view of Combiner Box with cable glands ............................................... 16 6.3. Connecting the DC Cables ....................................................................................................17 6.4. Connecting the Grounding Cable ....................................................................................... 19 7. Maintenance ........................................................................................................................................ 20 Installation Manual V1.0 3 Combiner Box Shenzhen BYD Electronics Co,. LTD 7.1. Periodic Maintenance ............................................................................................................ 20 7.2. Extraordinary Maintenance ..................................................................................................20 8. Decommissioning ............................................................................................................................... 21 8.1. Disassembling the Combiner Box ...................................................................................... 21 8.2. Disposing of the Combiner Box .......................................................................................... 21 9. Technical Data ..................................................................................................................................... 22 10. Contact Information ........................................................................................................................ 24 4 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD 1. Information on this Document 1.1. Validity Combiner Box This document is valid for the Combiner Box CB-03A03S-A/CB-03A06S-A. 1.2. Target Group The instructions in this document may only be performed by qualified persons who must have the following skills: · Knowledge of how batteries work and are operated · Knowledge of how an inverter works and is operated · Knowledge of, and adherence to the locally applicable connection requirements, standards, and directives · Knowledge of, and adherence to this document and the associated system documentation, including all safety instructions · Training in dealing with the hazards associated with the installation and operation of electrical equipment and batteries · Training in the installation and commissioning of electrical equipment Failure to do so will make any manufacturer's warranty, guarantee or liability null, and void unless you can prove that the damage was not due to non-compliance. 1.3. Symbols Symbol Explanation Indicates a hazardous situation which, if not avoided, will result in death or serious injury Indicates a hazardous situation which, if not avoided, can result in death or serious injury Indicates a hazardous situation which, if not avoided, can result in minor or moderate injury Indicates a situation which, if not avoided, can result in property damage Packaging instructions Installation Manual V1.0 5 Combiner Box 2. Safety 2.1. Instructions and Warnings Shenzhen BYD Electronics Co,. LTD Failure to follow these instructions may have serious consequences, such as the destruction of the device, personal injury or death due to electric shock. Therefore, the following safety instructions must be read and understood prior to installation and use of the Combiner Box. For any clarifications or additional information, contact the BYD service. Symbol Explanation Once the product has been removed from its original packaging, visually inspect for damage that may have occurred during shipment. If damage is found, contact the distributor or manufacturer. This product must only be used for the purpose for which it has been designed. Any other use is considered improper and therefore dangerous. The manufacturer is not liable for possible damage caused by improper, incorrect or unreasonable use BYD holds itself responsible only for the product in its original configuration. BYD declines all responsibility for consequences deriving from non-original spare parts. Any intervention that alters the structure or the operating cycle of the product must be carried out or authorized by Shenzhen BYD Electronics Co,. LTD. This manual is an integral and essential part of the product. Carefully read the recommendations contained in it since they provide important information on safe use and maintenance. BYD may make technical changes in this manual and to the product at any time without notice. In case of typing errors or other types of errors, the corrections will be included in the new versions of the manual. 6 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD 2.2. Position and securing Combiner Box Failure to follow these instructions may have serious consequences, such as the destruction of the device, personal injury or death due to electric shock. Therefore, the following safety instructions must be read and understood prior to installation and use of the Combiner Box. For any clarifications or additional information, contact BYD service. Symbol Explanation If positioning in a closed environment, make sure the area is ventilated and allows regular recirculation of air. If installing in an open environment, position the enclosure in an area that is constantly shaded and protected from exposure to direct sunlight. These measures are important for preventing unnecessary and excessive overheating, which prolonged in time impairs the duration and operation of parts inserted inside. Make sure the wall where the enclosure is to be mounted is suitable to support the weight. The weight is around 8.1kg. 2.4.Safety Precautions This section contains safety precautions that must be observed at all times when working on or with the product. To prevent personal injury and property damage and to ensure long-term operation of the product, read this section carefully and follow all safety precautions at all times. Installation Manual V1.0 7 Combiner Box Shenzhen BYD Electronics Co,. LTD Danger to life from electric shock due to live voltage High voltages are present in the live components of the Combiner Box. Touching live components results in death or serious injury due to electric shock. · Wear personal protective equipment when working on the Combiner Box. · Do not touch live components. · Before performing any work, always disconnect the Combiner Box from voltage sources unless supply voltage is absolutely necessary. · Ensure that the device cannot be reconnected. · Ensure that no voltage is present. · Ground and short-circuit. · Cover or isolate any adjacent live components. Protective covers must always be mounted. Danger to life from electric shock due to live DC cables Touching live DC cables from batteries or an inverter results in death or serious injury. · Prior to connecting the DC cables, ensure that the DC cables are voltage-free. · Wear suitable personal protective equipment when working on the Combiner Box. Danger to life from electric shock if the Combiner Box is damaged If the Combiner Box is damaged, dangerous situations may arise during operation that results in death or serious injury from electric shock. · Only use the Combiner Box when it is in a technically faultless condition and safe to operate. · Regularly check the Combiner Box for visual damage. · Make sure that all external safety equipment is freely accessible at all times. · Make sure that all safety equipment is in good working order. 8 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD Combiner Box 3. Scope of delivery Check the scope of delivery for completeness and any externally visible damage. Contact your distributor if the scope of delivery is incomplete or damaged. 1 - Documents 4 - Positive power cable connector 1 - CB-03A03S-A Combiner Box 4 - Negative power cable connector Figure 1 CB-03A03S-A Combiner Box 8 - Power cable connector unlock protection sleeve 1 - Documents 7 - Positive power cable connector 1 - CB-03A06S-A Combiner Box 7 - Negative power cable connector Figure 2 CB-03A06S-A Combiner Box 14 - Power cable connector unlock protection sleeve Installation Manual V1.0 9 Combiner Box 4. Product Description 4.1. Circuit Diagram Shenzhen BYD Electronics Co,. LTD The CB-03A03S-A Combiner Box is a battery system junction box to an inverter. Up to 3 battery towers could be connected in parallel with this Combiner Box. Figure 3 Block circuit diagram of the CB-03A03S-A Combiner Box The CB-03A06S-A Combiner Box is a battery system junction box to an inverter. Up to 6 battery towers could be connected in parallel with this Combiner Box. Figure 4 Block circuit diagram of the CB-03A06S-A Combiner Box "1-B+", "1-B-" and "PE 1" in the diagram above mean the positive power cable, negative power cable, and grounding cable from the battery tower Number 1. 10 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD Combiner Box 4.2. Type Label There is one type label attached to the Combiner Box. The type label is located on the left upside of the Combiner Box. You will find the following information on the type label: · Manufacturer · Device type · Serial number · Device-specific characteristics · Production date Production date: Year Month Day You will require the information on the type label to use the product safely and when seeking customer support from the BYD local service. The type label must remain permanently attached to the product. 4.3. Symbols on the Type Label Symbol Explanation Beware of electrical voltage. Disposal:Do not dispose of the system together with household waste, please contact BYD service (contact information at the end of this document) to dispose of it in accordance with regulations for electronic waste and used batteries. Indicates a hazardous situation which, if not avoided, will result in death or serious injury. Installation Manual V1.0 11 Combiner Box 5. Assembly 5.1. Wall Mounting 5.1.1. Selecting the Mounting Location Shenzhen BYD Electronics Co,. LTD Fire hazard due to wrong choice of mounting location Under fault conditions electric arcs may occur in the Combiner Box. Electric arcs can cause fires if the Combiner Box is mounted on flammable materials. · Do not mount the Combiner Box on flammable construction materials. · Do not mount the Combiner Box near highly flammable materials. · Do not mount the Combiner Box in potentially explosive atmospheres. Requirements for the mounting location: · The mounting location must not be in a living or office area. · The mounting location must not block any escape routes. · The mounting location must be freely and safely accessible at all times without the necessity for any auxiliary equipment (such as scaffolding or lifting platforms). Non-fulfillment of these criteria may restrict servicing. · The mounting location must be suitable for the weight and dimensions of the Combiner Box. · The mounting location must not be exposed to direct solar irradiation. · The recommended height of the location is higher than 1.6 meters from the ground. · Make sure that the Combiner Box enclosure is not mounted in the path of rainwater. Requirements for mounting: · Mount the Combiner Box in such a way that the connection area is facing downwards. · The recommended height of the wall box should not exceed 3000m · Do not mount the Combiner Box in an inclined position. 12 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD 5.1.2. Mounting the Combiner Box Combiner Box Danger of crushing if the Combiner Box is dropped · When mounting the Combiner Box, take the weight of up to 8.1 kg into account. · Installer should use personal protective equipment. Damage to cable glands and plug connections due to improper transport and installation The cable glands and plug connections protrude from the enclosure. · When transporting and mounting the Combiner Box, ensure that the cable glands and plug connections are not damaged. Additionally required mounting material (not included in the scope of delivery): · 2 expansion screws. Take wall properties into account when choosing the screw type. · Three washers. · If necessary, four screw anchors. Take wall properties into account when choosing the screw anchor type. Figure 5 Dimensions of the CB-03A03S-A Combiner Box Installation Manual V1.0 13 Combiner Box Shenzhen BYD Electronics Co,. LTD Figure 6 Dimensions of the CB-03A06S-A Combiner Box Procedure: 1. Mark the position of the drill holes on the wall or stand. 2. Drill holes at the marked positions and fix rack with using suitable screws and washers. 3. If necessary, insert the screw anchors. 4. Put and fasten the Combiner Box on to the wall 5. Ensure that the Combiner Box is securely fixed. 14 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD 6. Electrical Connection 6.1. Connection Instructions 6.1.1. Preliminary Checks Combiner Box Before connecting the Combiner Box to the battery and inverter, make sure that: · The Combiner Box is in good condition and there was no damage during transport. · The Combiner Box is firmly anchored to walls and stable supports. After performing the checks listed in the points above, proceed to wire the cables according to what is shown in the wiring diagram, making sure to use suitable sizes and colors. Make sure that the DC connections are properly secured inside the terminals in order to prevent possible overheating that may lead to dangerous situations. 6.1.2. Safety during Electrical Connection Danger to life due to electric shock High voltages are present in the live components of the Combiner Box. Therefore, work on the Combiner Box is only allowed if the power is disconnected and the guidelines that apply at the installation location are strictly followed. · Disconnect from voltage sources: · Ensure that the device cannot be reconnected. · Ensure that no voltage is present. · Ground and short-circuit. · Cover or isolate any adjacent live components. Protective covers must always be mounted. Installation Manual V1.0 15 Combiner Box Shenzhen BYD Electronics Co,. LTD 6.2. Inserting the Cables into the Switch Cabinet 6.2.1. Bottom view of Combiner Box with cable glands A B CE Figure. 5 Bottom view of Combiner Box CB-03A03S-A with cable glands A D B CE Figure. 6 Bottom view of Combiner Box CB-03A06S-A with cable glands Position Description A Cable entry for connecting positive power cables from battery towers B Cable entry for connecting negative power cables from battery towers C Grounding cables input from battery towers D Output DC cable glands to an inverter E Grounding cable output gland to a common ground point 16 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD Combiner Box 6.3. Connecting the DC Cables Procedure: 1. Open the clamp and hold. Place the contact in the appropriate cross-section range. Turn the crimp lugs upwards. Release the clamp. The contact is fixed. 2. Press the pliers gently together until the crimp lugs are properly located within the crimping die. 3. Insert the stripped cable end until the insulation comes up against the crimp insert. Completely close the crimping pliers. 4. Insert the crimped-on contact into the insulator of the male or female coupler until it clicks into place. 5. Insert the appropriate end of the test pin into the male or female coupler as far as it will go. 6. Screw up the cable gland hand-tight with the tools PV-MS. 7. The tightening torque must be appropriate for the solar cables used. 8. Plug the parts of the cable coupler together until they click in place. Check that they have engaged properly by pulling on the cable coupler. Installation Manual V1.0 17 Combiner Box Shenzhen BYD Electronics Co,. LTD 9. Plug the connectors into the corresponding DC cable ports. 10. Cover each power cable connector with a plastic sleeve. 11. Fix the sleeve with the bundled bolt. 18 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD Combiner Box 6.4. Connecting the Grounding Cable Cable requirement · Conductor cross-section: equal or higher than 10 mm2 · Outer diameter: 6.8 mm Procedure: 1. Unshield the cable, strip conductor in line with insertion depth. 2. Insert the conductor fully into the barrel of the cable lug. (Lug size UL3577 or 9AWG) 3. Ensure that the palm of the cable lug is oriented towards the terminal of the equipment, to which the connection is to be made. 4. Select suitable crimping dies and tools to ensure that the joints made are mechanically strong. 5. Ensure proper crimping series. 6. When the cable lug has been crimped onto the conductor a heat shrink sleeve should be applied. 7. Use appropriate nuts, bolts, washers for a firm and secure electrical connectivity. 8. Loose the original nut and washer on the ground post. 9. Put the grounding cable in the ground post. 10. Tighten the nut and washer. (torque: 5.5 Nm). 11. Ensure that the grounding cable is securely fixed. Installation Manual V1.0 19 Combiner Box 7. Maintenance 7.1. Periodic Maintenance Shenzhen BYD Electronics Co,. LTD It is recommended to periodically inspect the panel and check the following points: · There are no evident signs of rust or corrosion which may impair functioning and safety. (Yearly - Visual inspection) · There are no water infiltrations and excessive dust infiltration. (Yearly - Visual inspection) · The mass grounding and drains are efficient. (Yearly - Visual inspection) · There is insulation between the electrical circuits and masses. (5 Year - Insulation test) · All the DC connections are correctly tightened. (Yearly - Dynamometric torque tool) · There are no burn marks on the terminals. (Yearly - Visual inspection) · The door panel of the enclosure is firmly closed at the end of all the checks and after any maintenance. (Yearly - Visual inspection) 7.2. Extraordinary Maintenance If damaged components need to be replaced only use materials identical to those originally supplied. If the electrical connections are damaged due to mechanical or electrical causes or due to rodents, immediately disconnect the system or at least the damaged part. After verifying that no failures were caused to the equipment, proceed with the replacement of the wires using similar materials. All the maintenance operations must be performed by taking into account all safety instructions, checking beforehand that the components are not powered. 20 Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD 8. Decommissioning 8.1. Disassembling the Combiner Box Combiner Box Danger to life due to electric shock when touching live components of the Combiner Box · Observe the following safety rules when disconnecting: Disconnect from voltage sources. Ensure that the device cannot be reconnected. Check that no voltage or current is present. Ground and short-circuit. Cover or isolate any adjacent live components. Risk of burns from touching hot components · Wear personal safety equipment when working on the device. Requirement: The Combiner Box must be disconnected from voltage sources. Procedure: 1. Remove bolt on the plastic sleeve with a screwdriver. 2. The cable coupler can be disconnected only with the tool PV-MS. 3. Press the latches together with the tool PV-MS and pull the halves of the coupler apart. 4. Disconnect the grounding cables. 5. Put the combiner off the rack. 8.2. Disposing of the Combiner Box Dispose of the Combiner Box in accordance with the applicable disposal regulations for electronic waste. Installation Manual V1.0 21 Combiner Box 9. Technical Data General Data Maximum Operating Voltage (Un) Rated Insulation Voltage (Ui) Rated Impulse Voltage (Uimp) Maximum input current per battery tower Maximum output current Rated Current of the ASSEMBLY (InA): Rated short-time withstand current (Icw) Pollution degree Fuse holder Fuse type Fuse size Shenzhen BYD Electronics Co,. LTD CB-03A03S-A / CB-03A06S-A 1000 V DC 1000 V DC 3.5 kv 30 A 30 A 30 A 45 A 3 Rail Mounting -1,500 VDC 40/22x58 - 1,500 VDC - gPV 40 A MECHANICAL DATA Enclosure Length/ Width/ Height Weight Degree of Protection Type of electrical connection Form of separation 22 SGCC (Galvanized Cold Rolled Steel) 350×300×110 mm /450×350×110 mm IP 55 FFF fixed connection Form1 (no internal separation) Installation Manual V1.0 Shenzhen BYD Electronics Co,. LTD Combiner Box ENVIRONMENT DATA Ambient temperature during normal operation -10~+50 (Note 1) Ambient temperature during storage -10~+50 Humidity 0 % to 95 % non-condensing Altitude up to 3,000 m (Note 2) DC INPUT DATA Maximum number of battery towers Input cable glands entry Input connection Conductor cross-section 3/6 6 / 12 Directly on terminal blocks 6.63 mm² DC OUTPUT DATA Output cable glands entry Input connection Conductor cross-section 2 Directly on terminal blocks 6.63 mm² (Note 1): Derating of 0.5%/K of max. current from 40°C to 50°C. (Note 2): Derating of maximum voltage versus altitude. 1.5 % per 100 m from 2001 m to 3000m. Installation Manual V1.0 23 Combiner Box 10. Contact Information Shenzhen BYD Electronics Co,. LTD Service in Europe desupport@byd.com Telephone: +49 711 25513677 Address: Zettachring 6, 70567 Stuttgart, Germany Global Service Telephone: +86 755 89888888-47175 Address: No.3009, BYD Road, Pingshan, Shenzhen, 518118, P.R. China 24 Installation Manual V1.0WPS 文字