RAY-MAX Integrated Solar Power Strip

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1 RAY-MAX Integrated Solar Power Strip , , , , , Owner s Manual NEXTRONEX, INC. Revision Date: 10/27/14

2 Contents 1. Safety Instructions General Equipment Warnings Inspection Upon Receipt Delivery Delivered Bill of Materials Handling Storage Installation Mounting Assembly Wiring Operation Troubleshooting Maintenance and Service Technical Specifications...19 Page 2

3 1. Safety Instructions IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS Read and understand the entire Solar Power Strip Owner s manual before proceeding with any installation or use of the products furnished by Nextronex, Inc. Note all warnings and cautions. Failure to adhere to and implement all prescribed instructions and safety procedures will void all warranties and guaranties and absolve Nextronex, Inc. from all claims of liability whether arising out of contract or allegations of negligence. To reduce the risk of personal injury and ensure safe operation, the following symbols are used throughout the manual to identify important information needed for installation, operation, and maintenance. WARNING A warning identifies a hazard to personnel or equipment. This symbol will be accompanied by specific instructions that must be followed to avoid the hazard. DANGEROUS VOLTAGE This symbol is a specific warning for instructions that deal with dangerous and lethal voltages. FIELD WIRING GROUND This symbol identifies field wiring connections to ground. GROUND This symbol identifies wiring terminations connected to ground. DIRECT CURRENT SUPPLY This symbol identifies a DC circuit Page 3

4 ALTERNATING CURRENT SUPPLY This symbol identifies an AC circuit. SOLAR POWER STRIP OWNER S MANUAL POLYPHASE CIRCUIT This symbol identifies a polyphase circuit. ON POSITION This symbol identifies the on position for switches and controls. OFF POSITION This symbol identifies the off position for switches and controls. 2. General Equipment Warnings WARNING RISK OF ELECTRIC SHOCK. Do not remove lids. Refer to maintenance,section for information regarding user serviceable parts. WARNING - All electrical installations must be done in accordance with local and national electrical codes. WARNING - Connection to the utility grid must be done by qualified personnel. Contact the local utility company prior to installation. WARNING - This unit is rated for operation from -25 C to + 45 C WARNING - System grounding is the responsibility of the installer. Page 4

5 3. Inspection Upon Receipt Immediately upon receipt of the shipment, identify all units and check them against the shipping list. Make a visual examination to detect any damage which may have been incurred during transit. If any damage is discovered, file a claim immediately with the carrier and send notice of the extent of the damage to Nextronex Inc, giving complete identification, carriers name and railroad car number if the shipment was made by rail. The information will enable the company to supply necessary data in support of claim Delivery Each unit is inspected prior to packaging for delivery, however damage can occur during shipment and the unit should be checked before installation. If any damage is noted, first contact your delivery provider. For any other concerns, contact Nextronex, Inc. Customer Service at Delivered Bill of Materials Quantity Description 1 RAY-MAX Integrated Solar Power Strip 1 Owner s Manual 2 Support Stands 1 2 Expansion Joint Kit of Parts: PN for Lite version 2.0 Buss PN for Standard version 2.5 Buss End Caps (ordered seperarately) for each run of Power Strips 4. Handling Expansion Joint Kit of Parts Two people are recommended to lift the Solar Power Strip and set it in place for mounting. If it is necessary to handle the equipment outdoors during inclement weather, it should be thoroughly protected against the entrance of moisture. Page 5

6 5. Storage Any equipment which is not installed and energized immediately should be stored in a clean dry space having a uniform temperature to prevent condensation. Preferably, it should be stored in a heated building having adequate air circulation and protected from cement, plaster, paint, dirt and water. The protective plastic wrapping should be left in place during storage. 6. Installation WARNING - Unit must be installed by a qualified electrician according to the installation instructions provided. WARNING - Do not install or service unit during rain or very damp conditions 6.1. Mounting The Solar Power Strip must be properly located to obtain optimum safety. The unit should be mounted horizontally on a stable, level surface free from standing water and capable of supporting the weight. Recommended use of the support legs as shown below. The Solar Power Strip breaker panel covers are secured after installation but access must be restricted to qualified personnel due to hazardous voltages. Site selection should include consideration of accessibility to non-qualified personnel. Maximum continuous length of Solar Power Strip assemblies is 84 ft. (12, seven foot sections). Power Strip shown mounted on a steel skid with the supplied supports (2 per cabinet) Page 6

7 Power Strip Support Mounting Dimensions Page 7

8 6.2. Assembly 1) Use hardware provided in the provided hardware kit to connect power strips together as shown below. Shoulder Bolt M8 X 10 Belleville Washer M10 Nut, Hex ESN M (Self Locking Nylon) Page 8

9 2) Connect the copper buss bars at each Power Strip connection point using hardware provided in the expansion joint kit of parts. TIGHTEN 3/8 INCH HARDWARETO 18.3 N-m (162 in-lb) TIGHTEN 7/16 INCH HARDWARETO 27.6 N-m (244 in-lb) (4) BOLT, HEX (4) WASHER, BELLVILLE (4) WASHER, FLAT (4) WASHER, FLAT (4) WASHER, BELLVILLE (4) NUT, HEX Page 9

10 3) Between every two sections of Power Strip, the provided bonding strap must be connected to the adjoining Power Strip. Use the hardware provided. TIGHTEN TO 84 in-lb The breaker panel ground wire should already be connected to the panel. Page 10

11 4) Field grounding locations are provided on each end of the Solar Power Strip. The hardware is premounted. Only 1 point on all of the connected Power Strips need to be taken to a central ground. System Grounding In the Nextronex solar equipment system, each major component must be taken only to one central ground. There should not be any bonding between this equipment. This helps prevent ground loops and induced noise. The major components to be grounded include: Each Inverter The Smart Controller One point on the Power Strip Assembly The stainless steel plate in the Load Center lower voltage side The copper bar in the Load Center high voltage side This shows a ground cable coming from each major component to a common ground on a typical installation under a steel skid platform. Page 11

12 6.3. Wiring WARNING Observe proper polarity when connecting to the the bussbars. Failure to do so could result in damage or injury. DC Cable Connections Each set of DC cables (POS/NEG) from the Combiner Boxes is connected directly to a breaker inside the Solar Power Strip. The Power Strip is designed for each set of DC cables to come straight up out of a conduit with a watertight connector in the bottom of the enclosure to the lugs on the breakers. The type of lug provided is ALCu #6AWG 350MCM 3/8 for cable attachment. Stud torque 162 in-lbs Lug torque 375 in-lbs DC POS + Cable Input DC NEG - Cable Input Page 12

13 CT Connections SOLAR POWER STRIP OWNER S MANUAL The Integrated Solar Power Strip comes with all breakers installed. Each breaker has a CT (Current Transducer) for monitoring purposes. They should each be connected to the Smart Controller (See the Smart Controller Manual for more detailed information). An outdoor rated 22AWG, shielded twisted pair cable is recommended for CT hook up. The shields are terminated in the Smart Controller. NEG - POS + CT, Current Transducer CT Inside Power Strip I/O Group Assembly Inside Smart Controller Use Outdoor Rated 22AWG Minimum Shielded, Twisted Pair Cable + _ Terminal Blocks 1 16 used for CT Connections Terminal 1 Shield Connections Terminal 2 +24Vdc Connections Terminal ma Connections Page 13

14 Inverter Connections Connections to the inverter(s) can be made through the back of the Solar Power Strip using water-tight fittings. Recommend 313MCM, DLO 2000V, flexible stranded cable with appropriate terminals to make DC connections to the ½ holes provided in the bussbars. Recommended torque for ½ bolt is 162 in-lbs. There are several attachement points available on the copper buss bar. Treat all cabinet cut edges to avoid corrosion. Page 14

15 GFDI coupling device installed within the Solar Power Strip SOLAR POWER STRIP OWNER S MANUAL The GFDI comes mounted and pre-wired to the buss bar. Two wires for data sensing need to be connected to AK1 and AK2 on the GFDI Coupler and ran through the wireway to the Smart Controller. At the Smart Controller they are connected to TB24 pins 3 and 4 respectively. Page 15

16 7. Operation WARNING When the photovoltaic array is exposed to light, it supplies DC voltage to system. WARNING Before turning on the system all breaker covers must be installed. When DC energy is supplied from the array combiner boxes to the Power strip, there is power available at each breaker input within the Power Strip. Each breaker corresponds to one field combiner box (called a Home Run connection). To fully commission the system, all breakers should be turned to the ON position. This allows the energy from the entire array onto the DC copper buss bars. When the DC voltage reaches a specified level (square root of 2 times the line voltage) and remains above that voltage level for 5 minutes continuous the inverters will go into Wake Up mode. They will warmup for 5 minutes in Wake Up mode. Since all inverters are connected to the DC copper buss bars the youngest inverter (least amount of operating time) will turn on first. The next inverter will be told to turn on when the energy being produced by the entire solar array causes the first inverter to go over 83% of its operating capacity for a short period of time. This continues on until all inverters are on if the solar array is producing enough energy. After the breakers are initially turned to the ON positon the Power Strip is basically a passive component and there is no further operation to it. Power from a combiner box can be stopped from reaching the DC buss bar by turning the breaker associated with it to OFF. Associated with each breaker within the Power Strip is a Current Transducer (CT) that sends a data signal to the Smart Controller. The customer can them monitor the amount of current being produced by each Home Run connection. This is a good way to troubleshoot problem areas within an array. Within a Power Strip cabinet there is one Ground Fault Detector Interrupt (GFDI) sensor per array. If a ground short is detected a signal is sent to the Smart Controller to immediately shut down all inverters. The system will restart automatically when the fault is cleared. Page 16

17 8. Troubleshooting WARNING ARC FLASH AND SHOCK HAZARD All troubleshooting activities should be performed by qualified service personnel only. WARNING When the photovoltaic array is exposed to light, it supplies DC voltage to the breakers within the Power Strip. Each Solar Power Strip System is fully inspected prior to shipment. If there are problems with the operation, ensure that the Solar Power Strip System is installed properly and connections remain intact. For additional assistance, contact Nextronex, Inc. Customer Service at Replacement Table Part Number Description Mfg Mfg# Volts rating Amps rating Breaker ABB 1SDA070470R1 1000VDC 200A 100% Rated Page 17

18 9. Maintenance and Service WARNING RISK OF ARC FLASH AND ELECTRIC SHOCK HAZARD Cleaning is the only user-serviceable activities. All other repair and servicing to be performed by qualified service personnel only The following routine maintenance items should be completed to ensure proper operation. FOR ANY INTERIOR CLEANING AND MAINTENANCE, THE UNIT MUST BE DE- ENERGIZED. Any additional maintenance items must be conducted by qualified service personnel only. Contact a Nextronex authorized service provider for any additional maintenance items or if problems are noted. Nextronex, Inc. Customer Service at Upon Installation All accessories are properly mounted and free from obstructions. Remove all metal shavings from conduit cutouts and other installation debris. Area around the Power Strip is free from debris and construction materials. Covers are securely latched and all connections are tight. Quarterly Inspect unit and surrounding area to ensure that no debris or organic matter is blocking any of the drain areas. Visually inspect outside of unit to ensure all seals and connections are tight. Annually Contact an approved Nextronex service provider for an inspection of the inside of the unit which includes checking all electrical connections. Page 18

19 10. Technical Specifications SOLAR POWER STRIP OWNER S MANUAL INPUT Maximum Array DC Input Voltage 1000 V DC Maximum Number of Inputs 4 Maximum Current per Input 200 A Overcurrent Protection Circuit Breaker, 200 A 100% Rated Maximum Input Wire Size 500 kcmil Minimum Input Wire Size 300 kcmil (optional 2 x 3/0) OUTPUT Maximum Number of Outputs 2 Maximum Current per Output 300 A ENVIRONMENTAL Operating Ambient Temperature Range Storage Temperature Range ENCLOSURE Type Material Finish Dimensions Weight -25 C to +45 C -30 C to +70 C NEMA 3R 16 gauge steel Gloss White Powder coat With E-Coat Primer 254 x 2134 x 406 mm (10 x 84 x 16 in) 91 kg (200 lbs) Questions or Comments? We value customer feedback! If you have any questions, concerns, or comments about this document please contact Nextronex Customer Service. Page 19

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