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PV Combiner Box Buyer's Guide Last Updated: Jan 17, 2012 Published In: August / September 2009 Combiner boxes are an integral part of many PV installations, serving as the “meeting place” where the wiring from array series strings come together in parallel connections. 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. Many installers used to build their own combiner boxes for lack of availability, but now there are plenty of commercial products to choose from. Some manufacturers will custombuild combiner boxes to meet specific system requirements. Article 690.4(D) of the 2008 National Electrical Code includes PV combiner boxes as equipment that must be identified for appropriate use and listed by an approved testing laboratory, such as Underwriters Laboratories (UL) or ETL labs. The days of “homemade” combiner boxes are quickly disappearing. If you live in a locale where the 2008 NEC is in effect, your electrical inspector will likely require one that is listed by an approved testing laboratory, as mandated by NEC Article 690.4(D). GridDirect Systems Every inverter and charge controller, whether in a utilityinteractive or standalone system, has a DC input voltage window that must be adhered to. In batteryless gridtied systems, inverters require relatively high DC input voltages, from 150 to 600 V (typically 7 to 13 modules wired in series). Small gridtied PV systems (less than 5 kW) often have only one or two series strings of modules. With few wires and no need for series fusing, a PV combiner box isn’t necessary: Strings can be terminated directly in the inverter (see the “Why Series Fusing?” sidebar). However, larger residential systems (between 5 and 10 kW) often have three or more series strings, and will likely need fusing. Systems above 5 kW also typically have more wires to deal with, which can mean more installation time, larger conduit, and increased wire costs if all the wires need to be run to the inverter. 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 griddirect 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. GridDirect Systems Let’s look at a gridtied PV system with three series strings of 10 modules each. Three series strings mean three sets of wires—three positives and three negatives, with one ground wire—coming from our PV array. Even though some inverters have multiple DC inputs, they may not include series fusing capability. Then it’s likely that series fusing will be needed. Even if all the necessary input fusing is provided within the inverter, a combiner can be used to eliminate running seven wires all the way from the PV array to the inverter—possibly reducing wiring costs and installation time. BatteryBased Systems Batterybased systems (offgrid and gridtied with battery backup) have lower DC system voltages than griddirect systems (although highervoltage charge controllers are expected to hit the market soon). Historically, this voltage ranged from 12 to 48 V nominal to match battery voltages, but stepup/down MPPT charge controllers now allow arrays with higher voltages to charge lowervoltage battery banks, making higher array voltages more common (with open circuit voltages usually limited to 150 V). Even with the use of stepup/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 offgrid systems, it’s often wise By: Lena Wilensky Published In: Issue #132, August / September 2009

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  • 7/13/2015 PVCombinerBoxBuyer'sGuide|HomePowerMagazine

    http://www.homepower.com/articles/solarelectricity/equipmentproducts/pvcombinerboxbuyersguide?v=print&print=true 1/3

    PV Combiner Box Buyer's Guide

    LastUpdated:Jan17,2012PublishedIn: August/September2009

    CombinerboxesareanintegralpartofmanyPVinstallations,servingasthemeetingplacewherethewiringfromarrayseriesstringscometogetherinparallelconnections.

    InallbutthesmallestPVsystems,modulesarewiredtogetherinseriesstrings,wherethepositiveleadsofonemoduleareconnectedtothenegativeleadsofthenextmodule.Thisresultsincumulativevoltageoutput,withcurrent(amps)stayingthesame.Theboxwheretheoutputwiresfrommultipleseriesstringsarejoinedisthecombinerbox.Ratedforoutdooruse,itcontainsovercurrentprotectiondevices(OCPDs)andthenecessarybusbarsandterminalsforcombiningtheinputs.

    Manyinstallersusedtobuildtheirowncombinerboxesforlackofavailability,butnowthereareplentyofcommercialproductstochoosefrom.Somemanufacturerswillcustombuildcombinerboxestomeetspecificsystemrequirements.Article690.4(D)ofthe2008NationalElectricalCodeincludesPVcombinerboxesasequipmentthatmustbeidentifiedforappropriateuseandlistedbyanapprovedtestinglaboratory,suchasUnderwritersLaboratories(UL)orETLlabs.Thedaysofhomemadecombinerboxesarequicklydisappearing.

    Ifyouliveinalocalewherethe2008NECisineffect,yourelectricalinspectorwilllikelyrequireonethatislistedbyanapprovedtestinglaboratory,asmandatedbyNECArticle690.4(D).

    GridDirectSystems

    Everyinverterandchargecontroller,whetherinautilityinteractiveorstandalonesystem,hasaDCinputvoltagewindowthatmustbeadheredto.Inbatterylessgridtiedsystems,invertersrequirerelativelyhighDCinputvoltages,from150to600V(typically7to13moduleswiredinseries).

    SmallgridtiedPVsystems(lessthan5kW)oftenhaveonlyoneortwoseriesstringsofmodules.Withfewwiresandnoneedforseriesfusing,aPVcombinerboxisntnecessary:Stringscanbeterminateddirectlyintheinverter(seetheWhySeriesFusing?sidebar).However,largerresidentialsystems(between5and10kW)oftenhavethreeormoreseriesstrings,andwilllikelyneedfusing.Systemsabove5kWalsotypicallyhavemorewirestodealwith,whichcanmeanmoreinstallationtime,largerconduit,andincreasedwirecostsifallthewiresneedtoberuntotheinverter.Acombinerboxoffersaplacetohouseseriesfusesandparalleltheseriesstringinputs,reducingthenumberofarrayoutputwiresneededtoruntotheinverterlocation.

    Somegriddirectinvertermanufacturersincludeseriesfusingwithintheinverteroritsattacheddisconnectbox,whichmayeliminatetheneedforaseparatecombinerbox.However,usingaPVcombinerboxlocatedclosetothePVarraygivesyoueasyaccesstothewiresforeachseriesstring.ThiscanbehandyfortroubleshootingamalfunctioningPVarraywithouthavingtorunbackandforthtotheinverterarea.

    GridDirectSystems

    LetslookatagridtiedPVsystemwiththreeseriesstringsof10moduleseach.Threeseriesstringsmeanthreesetsofwiresthreepositivesandthreenegatives,withonegroundwirecomingfromourPVarray.EventhoughsomeinvertershavemultipleDCinputs,theymaynotincludeseriesfusingcapability.Thenitslikelythatseriesfusingwillbeneeded.Evenifallthenecessaryinputfusingisprovidedwithintheinverter,acombinercanbeusedtoeliminaterunningsevenwiresallthewayfromthePVarraytotheinverterpossiblyreducingwiringcostsandinstallationtime.

    BatteryBasedSystems

    Batterybasedsystems(offgridandgridtiedwithbatterybackup)havelowerDCsystemvoltagesthangriddirectsystems(althoughhighervoltagechargecontrollersareexpectedtohitthemarketsoon).Historically,thisvoltagerangedfrom12to48Vnominaltomatchbatteryvoltages,butstepup/downMPPTchargecontrollersnowallowarrayswithhighervoltagestochargelowervoltagebatterybanks,makinghigherarrayvoltagesmorecommon(withopencircuitvoltagesusuallylimitedto150V).Evenwiththeuseofstepup/downchargecontrollers,typicallyonlyonetosixmodulesareplacedinaseriesstring,whichmeanscombiningmorestringsinparalleltogetthedesiredpoweroutput,whichnecessitatesacombinerbox.

    Inaddition,chargecontrollerstypicallyhaveonlyasinglesetofinputwireterminals.Foroffgridsystems,itsoftenwise

    By:LenaWilensky

    PublishedIn: Issue#132,August/September2009

  • 7/13/2015 PVCombinerBoxBuyer'sGuide|HomePowerMagazine

    http://www.homepower.com/articles/solarelectricity/equipmentproducts/pvcombinerboxbuyersguide?v=print&print=true 2/3

    tohaveenoughroominthecombinerforaddingmorestringsofmodulesinthefuture.Ifthecombineranditsoutputwiresaresizedaccordingly,andthechargecontrollerhasbeensizedtohandletheadditionalamperage,wiringmorePVmodulesintothesystemcanbeaseasyasterminatingthenewwiresinthePVcombinerbox.

    TheSpecs

    TheSpecificationstableonthefollowingpagessummarizesthemainfeaturescommontomostPVcombinerboxes.WeincludedproductsthatarecurrentlyavailabletoconsumersintheU.S.market.

    MaximumDCVoltage(Max.VDC)

    EachcombinerisratedtoaccommodateuptoaspecificDCvoltage.ResidentialgriddirectsystemsgenerallyaccommodateDCvoltagesupto600V,whilemostbatterybasedPVsystemDCvoltagesarelower,typicallymaxingoutat150V.

    MaximumNumberofPVInputCircuits

    CombinerboxescomewithacertainnumberofterminalswherePVsourcewirescanbeattachedandanequivalentnumberofOCPDspaces.ResidentialPVcombinersusuallyneednomorethan12inputs.Griddirectsystemsrequirefewerinputs,whilebatterybasedsystemscanrequiremore.Additionally,batterybasedPVsystemscommonlyhavemultiplechargecontrollers,andeachmayhaveitsowncombinerbox.

    MaximumOCPDRating

    Theovercurrentprotectiondevices(OCPDsfusesorcircuitbreakers)chosenfortheparticularcombinercannotexceedthisrating.PVmodulenameplateslisttherequiredseriesfuserating.

    OCPDType

    CombinerboxescomewithOCPDs,usuallyeitheraformoftouchsafefuseholdersorDCratedcircuitbreakers.Sincegridtiedsystemscangenerateupto600VDCwellabovethe150VDCratingofmostavailablecircuitbreakersfusesarealmostalwaysnecessary.OCPDsfoundincombinerboxesaregenerallylimitedtobatterybasedsystems.Mostfuseholdersarenotratedtobeopenedunderload,sotheycannotbeusedasaDCdisconnect.ThisisanespeciallyimportantconsiderationforhighvoltageDCsystems:Tryingtoopenafuseholderwithoutfirstopeningthecircuit(whichcanbesafelydoneviathemainDCdisconnect),willlikelydrawanelectricalarcthatcancauseafireandburnand/orshockyou.

    WireRange:SizeofInput&OutputTerminals

    Wireterminalsareratedtofitarangeofwiresizes,inbothbusbarsandtheOCPDs.Becausetheoutputcircuitiscarryingthecombinedampacityofalltheincomingseriesstringsandalsomayhavetobeoversizedduetovoltagedropforlongerwirerunsinlowervoltagesystems,itmaybenecessarytoconnectarelativelylargediameterwiretotheoutputterminals.

    MaximumNumberofOutputCircuits.

    Sometimesitisappropriatetousemultipleinvertersorchargecontrollerswithasinglearrayliketwooffourstringsintooneinverterandtheothertwointoasecondinverter.Forthis,youllneedeithermultiplecombiners,oronecombinerthatcanaccommodatetwoseparateoutputcircuits.Ofallthecombinerslisted,onlyahandfuloffertwooutputcircuits.

    MaximumContinuousOutputCurrent

    Eachcombinerhasaratingfortheamountofoutputcurrentthatitcansafelyhandle.DependingonthesizeandnumberofOCPDsinuse,itmaybepossibletooverloadthecombinersbusbars.Forexample,inacombinerwithsixteen20Acircuitbreakers,320Acouldflowintotheoutputcircuit,overloadingthebusbarifitisratedat100A.Toensurethisdoesnothappen,useacombinerwithahighenoughoutputrating.

    DataMonitoringCapabilities

    Whileindividualstringmonitoringisgenerallyusedincommercial,ratherthanresidentialscale,systems,some

  • 7/13/2015 PVCombinerBoxBuyer'sGuide|HomePowerMagazine

    http://www.homepower.com/articles/solarelectricity/equipmentproducts/pvcombinerboxbuyersguide?v=print&print=true 3/3

    homeownersareinterestedintrackingtheperformanceofeachstringofPVmodulestoensurethesystemisworkingoptimally.Combinerboxeswithdatamonitoringcapabilityareoftenreferredtoassmartorintelligentcombiners,andalloweasy,quickinstallationofdatamonitoringsystems.

    WeatherproofRating

    MostcombinerboxesareinstalledneartheirPVarrays(thatis,intheweather),andrequireappropriateoutdoorratings.InstallationsareexpectedtolastatleastthelifetimewarrantyofPVmodules(about25years),soinstallingdurable,longlivedequipmentthatwillstanduptotheenvironmentinwhichitisplacediscritical.

    EveryapprovedelectricalenclosurehasaNationalElectricalManufacturersAssociation(NEMA)ratingassociatedwithit.TheratingsonPVcombinersincludeNEMA3and3R(ratedforoutdooruseinlimitedorientations)andNEMA4and4X(includesadditionalprotectionsoboxescanbemountedinanyorientation,fromverticaltohorizontal).Wiringmustentertheboxthroughacordgripthatwillproperlysealthepenetrationandupholdtheweatherproofratingofthatcombinerbox.

    Listing

    TheNECrequiresthatallelectricalequipmenthaveavalidsafetytestlistingtoensuresafetyforthegeneralpublic.IntheUnitedStates,mostofthistestingisperformedbyUL,anindependentnonprofit,althoughthereareotherindependentlaboratoriesthatwilltesttoULstandards.OnesuchlabisIntertek,whichofferstheETLlistedmark.AllofthePVcombinerboxesinthetablehaveacurrentorpendinglisting.

    Access

    LenaWilenskyiscoownerofNunatakAlternativeEnergySolutionsinCrestedButte,Colorado.ShemanagestotaketimeoutfromplayinginthemountainstodesignandinstallPVandremotepowersystems,andinstructPVclassesforSolarEnergyInternational.

    lrecinosGreatarticle,thanks!!

    1year3monthsago


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