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smart string box

1. S 1604240 DB9F 3 SGA 1 Shielding 1 SIG A 60 2 2 SIG B 3 3 SIG A 4 4 SIG B 5 5 6 6 GND 7 7 GND TWIN WIRE LENGTH 80cm EN 9 9 4 POLE SCREENED CABLE WITH AWG26 TWISTED PAIRS DB9F SIGA 1 Shielding GB 2 e 3 e P gt l ue Ue e e uM ue Ue e M ee ets 5 6 GND 7 O O 5 P TWIN WIRE LENGTH 120cm TAA 9 FLYING 9 POLE FEMALE peer D SUB CONN 80 cm viewed from welds DB9F id 120 cm Figure 42 24 input SMART STRING BOX cablet 8 4 4 Bus Communication Installation Procedure Before accessing the area of the JUNCTION BOX which contains the bus communication devices put the box in safety conditions Please refer to section 2 7 Power the board at 12 Vdc using terminal M13 also located on the bracket outside the Lexan safety panel In this way the functions of the SMART STRING BOX card are active the board can communicate but does not constitute a hazard for the user Connect the multidrop cable to DB9 CN3 connector or the M11 terminal board alongside Set the SW2 DIP switch in accordance with the prescriptions provided above for the communication bus terminators MODIFYING THE ADDRESS if necessary act on the Rotary Switches CE1 and CE2 setting the required address between
2. n S A S m U 5 4 S SS So 020303 ooo O0 C005 0000 c gt cc 3 cc y s ol oo JG oo ayo oo oo ol o JUNCTION BOX se ewer FUSE BOX SMART STRING BOX IO o m m 18 5 E Ter r UT TH ET TT SSS BOO SSB So OS T SS esses irs Ts E sg Figure 51 FUSE BOX wall mounting For details on the ambient conditions for installation storage and transport please refer to section 5 2 9 2 Configuration Option without Anti Inversion Diodes 1 NOTE Please contact Elettronica Santerno SpA A configuration without anti inversion diodes and 10 string rated current is also available 9 3 Configuration Option with Terminal Connections A version without quick fit connectors is available which entails connecting the string cables using cable glands and terminals All the necessary information can be found in section 7 and section 12 Rev 02 29 04 2013 71 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 10 MAINTENANCE DANGER Before carrying out any kind of operation please refer to section 2 7 q NOTE In the event of any fault please contact the Elettronica Santerno SoA CUSTOMER SERVICE for instructions on the necessary corrective action to be taken Adequate maintenance ensures conversion performance and inverter reliability is maintained over t
3. 102 Rev 02 29 04 2013 7 106 SMART STRING BOX Z SANTERNO wmsraLLarioN CARRARO GROUP Table 56 Analogue inputs configured in 0 100 mV mode a 102 Table 57 Analogue inputs configured as temperature measurement with PT100 103 Table 58 FUSE BOX Electrical Specifications n u 104 Table 59 FUSE BOX technical data nnne ennt nnns nennen 104 Table 60 FUSE BOX dimensions and weights nennen nennen 105 Table 61 Number of FUSE BOX cables nennen 106 Table 62 FUSE BOX cable connection 106 8 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 1 GENERAL INFORMATION ON THE PRODUCT SMART STRING BOX designed for maximum reliability and life expectancy based on numerous years of experience working with large ground and roof installations comply with the most stringent national and European safety directives Our modular design philosophy and the wide range of products available make it is possible to adapt equipment quickly and successfully to the individual needs of the customer Careful and precise design down to the very last detail and strict quality control guaranteed by standard
4. Figure 11 DC SWITCH BOX electrical diagram Rev 02 29 04 2013 27 106 SMART STRING BOX Z SANTERNO wmsraLLarioN CARRARO GROUP Q Wave OO Too L CN ACOTO 1 Figure 12 DC SWITCH BOX bottom view 91000S Recommended destination of cable glands Key Function 1 Disconnecting switch status and release winding contact output 2 SPD status contact output 3 DC cables output 4 Connection of earth GND cable Table 7 DC SWITCH BOX connectors cable glands 4 1 2 String Connection Section JUNCTION BOX 8 string JUNCTION BOXES are available for the SMART STRING BOX with or without anti theft option String String box type Connection Description Sensors Anti theft Section SMART STRING BOX B SA 8 8 string JUNCTION BOX Yes Yes SMART STRING BOX B S 8 8 string JUNCTION BOX Yes No Table 8 JUNCTION BOX string connection modules 28 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 0 5 NE m lii o CNEE To m wg OM M10 M11 CN3 M13 oe SW1 SW2
5. E rupe o o c lt gt c O o 1 I 3 String 5 4 String 4 5 String 5 6 String 6 o o o MEE 2 Sting 2 O EE 3 String 3 O 4 String 4 O 5 String 5 O 6 String 6 O ss 73 String 7 Gmm B String 8 gt o o o D D o 9 7 String 7 B String 8 lt 6 O if 8 214 acd ari UI r1 0 m 6 3 p 0 Figure 13 JUNCTION BOX internal view P000887 B The figure above shows a drawing of the appliance s interior when the upper cover has been removed by unscrewing the 6 screws
6. 30 Table 10 JUNCTION BOX internal connections nnne ns 32 Table 11 Environmental requirements for storage and 34 Table 12 SMART STRING BOX accompanying materials a 37 Table 13 SMART STRING BOX accompanying materials per model 38 Table 14 Power supply input output terminals M13 connector 46 Table 15 230 Vac power supply connections connector M12 46 Table 16 Environmental measures terminals M10 0 47 Table 17 DIP switch configuration of analogue input ACH0 a a 47 Table 18 DIP switch configuration of analogue input ACH1 48 Table 19 Environmental measures factory settings u 48 Table 20 Anti theft function terminals connector 9 1 mener 51 Table 21 Terminals for DC SWITCH BOX auxiliary contacts 52 Table 22 Communication 55 Table 23 Connection cable nirisan aa aiaiai ai eaa aaia asbl aba 59
7. Box 12 6 2 Connection Output Cables Min Max No of cables Tightening Max cable external cable per pole torque Nm section mm diameter mm Output cables to inverter from DC SWITCH BOX 2 18 2x150 12 24 Table 46 Power cables connection No of cables Serer Cable gland manufacturers reference embre 2 1 x positive 1 x negative 35 PG29 adapter A7 M10 2 1 x positive 1 x negative 50 PG29 adapter A10 M10 2 1 x positive 1 x negative 70 PG29 A14 M10 2 1 x positive 1 x negative 95 PG29 A19 M10 2 1 x positive 1 x negative 150 PG29 A24 M10 4 2 x positive 2 x negative 35 PG29 adapter A7 M10 4 2 x positive 2 x negative 50 PG29 adapter A10 M10 4 2 x positive 2 x negative 70 PG29 A14 M10 4 2 x positive 2 x negative 95 PG29 A19B M10 15 5 4 2 x positive 2 x negative 150 PG29 A24B M10 19 Table 47 Power cables connection ferrule 12 6 3 Connection of Earth Cables Description US DIES S Rar mas E ferrule glands Nm diameter mm r Yes 1x PG16 10 35 9 14 Table 48 DC SWITCH BOX earth cable Rev 02 29 04 2013 97 106 SMART STRING BOX Z SANTERNO CARRARO GROUP INSTALLATION GUIDE 12 6 4 Connection of Signal Cables Min Max external Description No of cable glands cable diameter Cable section mm mm DC SWITCH BOX auxiliary terminal
8. Applicable voltage interval 8 12 14 5 Vdc Power absorbed from the battery 7 5 W Absorbed current 300 mA 625 mA 1 6 A 60 V resettable fuse and 15 Vdc Zener Protection diode Table 38 Nominal power supply specifications 12 3 1 Maximum Voltage Derating When equipment is installed at a high altitude the maximum DC voltage i e the maximum Voc value applicable to the product in accordance with section 12 3 must be derated as indicated in the table Altitude m Maximum DC voltage max Voc 0 2000 Unchanged 2001 3000 Do not exceed 846 V Table 39 Maximum DC voltage based on altitude If the equipment is to be installed at over 3000 m please contact Elettronica Santerno SpA Rev 02 29 04 2013 89 106 CARRARO GROUP SMART STRING BOX Z SANTERNO wsraLLariON 12 3 2 Rated Current Derating To calculate the nominal current coefficient Kt is assigned to temperature while coefficient Ka is assigned to altitude 8820005 Figure 57 Coefficient Kt for temperature derating at sea level 90 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO SMART STRING BOX CARRARO GROUP x 1 060000S 0 95 0 9 0 85 0 9 0 8 0 75 0 7 0 65 0 6 0 1000 2000 3000 4000 m Figure 58 Coefficient Ka for altitude derating To calculate nominal current derating the followin
9. CARRARO GROUP 8 COMMUNICATIONS AND REMOTE MONITORING o WARNING To carry out the following operations check that the parallel string box is in safety conditions Please refer to section 2 7 8 1 General Information The SMART STRING BOX is equipped with a communication port which allows for local and remote connection to a remote monitoring system This provides the following advantages Full integration with the Santerno remote monitoring system for checking production performance and detecting alarms Complete remote monitoring accessibility in both local and remote mode from PC and SunwayPortal web portal By using a PC as a Master device it is possible to adopt Elettronica Santerno s Remote Sunway software package This software offers tools such as image capture keyboard emulation oscilloscope and multifunction tester functions operating data history tables compiler parameter setup and reception transmission saving of data to and from PC and scan functions for automatic recognition of connected devices Consult the specific Remote Sunway manual for use of the software package with Elettronica Santerno products 54 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 8 2 Communication Ports and Protocol Used The SMART STRING BOX serial ports use the 2 wire RS485 electric standard plus a 0 volt reference wire and standard Modbus RTU protocol The SMART STRING BO
10. STRING DETECT Figure 2 SMART STRING BOX one line diagram The SMART STRING BOX is made up of the following function blocks String Connection Section JUNCTION BOX This section is for the parallel connection of the PV generator strings and includes safety fuses and anti inversion diodes There are also current sensors and the control board for detecting mismatch loss and executing the algorithms of the anti theft system Serial communication ports are also available Output disconnecting switch section DC SWITCH BOX This section includes a suitable disconnect under load device and a surge protective device 10 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box Medium and high power PV generator systems are made up of a high number of strings To optimize the connection topology and enhance the protection and monitoring systems the parallel connection of the strings is carried out on more than one level usually a first parallel level and a second parallel level Elettronica Santerno offers a complete range of products for string parallel connections STRING BOX and SMART STRING BOXES for creating the first parallel level and the Sunway DC Parallel for creating the second parallel level P001124 B E LL 7279 1st parallel level 2nd parallel level Figure 3 Block diagram of the first and second parallel levels 1 2 Main Inte
11. common anti tampering and theft signalling cumulative anti tampering and theft signalling for multiple SMART STRING BOX up to a maximum of 4 JUNCTION BOX modules ANTI THEFT CABLE THEFT ALARM 9 COMMON 9 a TAMPER ALARM ov ir L 824951 TO 7 TAMPER ANTI THEFT NO SWITCH SYSTEM Figure 28 Anti theft connection with separate anti tampering and theft signalling TO ANTI THEFT ALARM ALARM SYSTEM COMMON COMMON ov ov 12V 12V Y Y Y Y 654321 M9 654321 M9 NC TAMPER NC TAMPER SWITCH SWITCH NO NO Figure 29 Anti theft connection with cumulative signalling for more than one SMART STRING BOX 50 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc The table below list the types of signal connections and details on the relative connector terminal board No of Name of terminals signal Sea POWER 1 SUPPLY 12 Vdc power supply input from central alarm battery 2 0V Common power supply zero volt signal circuits 3 ALR TAMPER Anti tampering contact opens in relation to ALR COM for box opening or forcing 4 ALR COM Common alarm signalling 5 ALR NG Alarm relay NC contact closes follow
12. CARRARO GROUP Index of Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 SMART STRING BOX 9 SMART STRING BOX one line diagram 10 Block diagram of the first and second parallel levels 11 16 input SMART STRING BOX iiaiai 12 JUNCTION BOX for SMART STRING BOX with transparent lexan panel 22 DC SWITCH BOX with opaque Lexan panel eene enne 22 Packaging of SMART STRING BOX 23 SMART STRING BOX serial number entrent nnne nens 24 Composition of a SMART STRING l treten rennen nennen nenas 25 DC SWITCH BOX internal view
13. CARRARO GROUP q NOTE Check that all relative accompanying materials are present Please refer to section 6 1 1 3 2 Product Part Number The product Part Number identifies the parallel string box and is indicated on the relevant dataplate The dataplate also holds all the necessary technical data please refer to section 12 1 The product Part Number is made up of the following elements CS XX X Y ZZ V XX Model SP for SMART STRING BOX X Anti theft A Anti theft Y No of strings No of strings ZZZ Field Voltage 600V Class 600V 800V Class 800V 900V Class 900V 1000V Class 1000V Examples CS SP 8 800V CS SPA 8 800V 3 3 Product Revision Index The product revision index is indicated on the dataplate Please refer to section 12 1 3 4 Serial Number The serial number of each individual module can be found on the lower section of the module itself near the connectors and on the inside 9910008 Figure 8 SMART STRING BOX serial number 24 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smart strine CARRARO GROUP 4 PRODUCT CONFIGURATION 4 1 Composition of a SMART STRING BOX The parallel string boxes are made up of one or more string connection sections JUNCTION BOX and an output section with relative disconnect under load device DC SWITCH BOX Number of inputs JUNCTION BOX DC SWITCH BOX 8 1 1 16 2 1 24 3 1 Table 3 SMART STRING BOX
14. Please refer to section 1 9 Standard EN50110 1 governs the way work in a plant is carried out and the relationship between the aforementioned persons who may work on the plant to maintain the electrical safety conditions stipulated by European Directives This standard and its national equivalents must therefore be adhered to whenever it is necessary to access a PV system Rev 02 29 04 2013 19 106 SMART STRING BOX Z SANTERNO wsraLLariON CARRARO GROUP 2 6 Personal Protective Equipment Maintenance technicians must be provided with the following personal protective equipment as envisaged by European Directives and relative implementation of the same on national territory SYMBOL DESCRIPTION Safety glasses face shield Throughout operations 1000 V high voltage insulated gloves Throughout operations Dielectric helmet Throughout operations Safety footwear dielectric boots Throughout operations Insulated tools Throughout operations Operators must also be provided with a suitable means of communication for contacting the emergency services if necessary Q NOTE It is always advisable to work on the electrical cabinets with THE POWER SUPPLY SWITCHED OFF and the equipment in safety conditions please refer to section 2 7 20 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 2 7 Electrical Connections
15. 18 2 4 Specific Dangers Linked to Photovoltaic PV Systems 18 2 5 Execution Ol Work u OE E 19 2 6 Personal Protective Equipment a 20 2 7 Electrical Connections Safety 21 2 7 1 Lexan Protective COVER 22 3 PRODUCT IDENTIFICATION 23 3 1 Checking the Product on Delivery r FER 23 3 2 Product Part Uer Mete t 24 3 3 Product Revision Index 24 3 4 Serial 24 4 PRODUCT CONFIGURATION 25 4 1 Composition of a SMART STRING 25 4 1 1 Output Section DC SWITCH BOX L 26 4 1 2 String Connection Section JUNCTION BOX 28 4 1 3 SMART STRING BOX Connection Diagram sse 32 4 2 Measuring the Current and Performance of the Individual Strings 33 4 3 24 hours a day Anti theft Function 33 4 4 Environmental Measures a nene nnn 33 4 5 Monitoring the State of the SPD Disc
16. 18 PT100 EXC1 Excitation output for PT100 thermistor channel 1 19 ACH1 Configurable measure input channel 1 20 OV Common measure 0 Zero volt signal circuits Table 16 Environmental measures terminals M10 connector Please refer to the following table for setting the DIP switch taking into account that contacts 1 3 are relevant to channel ACHO and contacts 4 6 are relevant to channel ACH1 SW1 Configuration of analogue input ACHO 0 10 V f s mode Default configuration Temperature reading 0 100 mV f s mode 0 20 mA f s mode with PT100 thermistor 5510005 7210005 92 0005 210005 Table 17 DIP switch configuration of analogue input ACHO Rev 02 29 04 2013 47 106 SMART STRING BOX Z SANTERNO SW1 CARRARO GROUP Configuration of analogue input ACH1 INSTALLATION GUIDE 0 10 V f s mode Default configuration 0 100 mV f s mode 0 20 mA f s mode Temperature reading with PT100 thermistor Table 18 DIP switch configuration of analogue input ACH1 Configuration of the channel and the measurement unit must be set to correspond by programming the relative board parameters To carry out correct configuration please refer to the Programming Guide Type of acquisition set in the Mode set on SW1 Full scale and notes Temperature thermistor parameters Voltage 0 10 V 0 10 V f s mode 0 10 V V
17. Key to connectors DIP switches and fuses installed on the board CN3 DB9 connector for RS485 with Modbus protocol also repeated on terminal board M11 CN4 Connector for cablet from the cover s microswitch CN5 Connector for cablet from the SPD and or disconnecting switch status signalling contacts M9 Connector for connection to the external anti theft control unit M10 Connector for external sensors solarimeter PT100 Two 3 pole inputs M11 RS485 connection on terminal board M13 Connector for connection of 10 V input output power supply Also indicated on the bracket outside the Lexan panel SW1 DIP switches for analog inputs configuration SW2 DIP switches for insertion of RS485 connection termination resistors FU9 Protection for power supply circuit from PV field FU22 Protection for 230 V mains power supply circuit PE Earth connection screws Rev 02 29 04 2013 29 106 SMART STRING BOX Z SANTERNO INSTALLATION GUIDE CARRARO GROUP 7910008 NA I I 1 ku I I I _ E P _ REN M o Q 0 6 I i ami Figure 14 JUNCTION BOX bottom view Key Description No of cables 1 RS485 input output 2 shielded two twisted pai
18. T o ejr oJ abs g i S T Q i UJ o 9 o u B LI T aw O Ox O O PE 5 i JE TE T 1 T 1 9 Figure 10 DC SWITCH BOX internal view Connections Function A Terminals for auxiliary contacts B Connection bars for power cables to the Inverter PE Earth cable connection screws Table 5 DC SWITCH BOX connections Key 26 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP Terminal Function 4 2 Disconnecting switch status N O contact contact closed when disconnecting switch is closed 3 4 SPD status N C contact contact open if SPD is broken 5 6 Disconnecting switch release winding Table 6 Terminals for auxiliary contacts Up to 2 conductors per pole are envisaged for the DC output power cables If connection is carried out using just one cable per pole only 2 of the 4 cable glands present on the connections side will be used For power cable connections please refer to section 12 6 296000d B SEZ AUT P OVERVOLTAGE 2 5 sqmm DISCHARGER TERMINALS LIMITER ON DIN BAR
19. 0 CS SPA 8 600V CS SPA 8 S00V EZ AUT P 100A 600 800V YO AUX T NE AA DREN OVERVOLTAGE L DISCHARGER 12 ile LIMITER 115 device to the CN5 connector the control board 52 106 GROUND Figure 30 SPD status signalling connection diagram Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 16 and 24 string configuration P001093 0 CS SP 16 600V CS SP 16 800V CS SPA 16 600V CS SPA 16 800V DB9F 1 B SEZ AUT P 160A 600V 800V YO oS OVERVOLTAGE DISCHARGER 12 LIMITER 115 GROUND ES889 B S A 8 Figure 31 SPD and disconnecting switch status signalling connection diagram Key to the cablets shown and numbered in the figure Cablet 1 connects the NC contact terminal 3 and 4 of the DC SWITCH BOX surge protection device to the CN5 connector on the control board Cablet 2 connects the NO contact terminal 1 and 2 of the DC SWITCH BOX disconnecting switch to the CN5 connector on the control board 7 8 Disconnect Switch Release Coil Connections Connection to the release winding is made via terminal 5 and 6 and the relative cable gland in the DC SWITCH BOX Please refer to Table 7 Rev 02 29 04 2013 53 106 SMART STRING BOX Z SANTERNO installation
20. 0 000000000000000000000000000000000000000 a 1600 s TOL m na E a TL I a IT e Ol re e e lt O O S 0 Top 47 I II 1000 107 ie m E A 18 5 6 5 30 amp Slots 6 5x18 5 mm In bet I diss Figure 60 16 string SMART STRING BOX 2218 MAX 600 400 600 600 g eeeeeeeoeeeoo OO 0966000000000 amp CS SP A 24 E eeeeeeeeeeco 0066666086600 2200 Ian 25 gp whey 9 jJ LIE SEIT TH 2 30 Slots 6 5x18 5 mm In between distance 6 5 mm Figure 61 24 string SMART STRING BOX Rev 02 29 04 2013 93 106 INSTALLATION GUIDE CARRARO GROUP SANTERNO SMART STRING BOX 600 519 4 y BH HEXT uni y o TA Ur 175 P001019 0 00 Figure 62 JUNCTION BOX Rev 02 29 04 2013 94 106 CARRARO GROUP SANTERNO suanrsrnic Box INSTALLATION GUIDE P000889 0 Figure 63 DC SWITCH BOX 95 106 Rev 02 2
21. 1 3 Internal View Electrical and Connections Diagram 67 9 1 4 FUSE BOX Assembly Instructions essent 69 9 1 5 Mechanical Dimensions Specifications sse 70 9 1 6 Product Installati nz lll Lee Lora dete entere re 71 9 2 Configuration Option without Anti Inversion 71 9 3 Configuration Option with Terminal Connections 71 10 MAINTENANGE c 72 10 1 ur s her ci DC 72 10 1 1 Box Visual Inspection and Cleaning sse 73 10 1 2 Checking the Connector Status 73 10 1 3 Checking the Cable Glands Status eee 73 101 4 Eee eau mS 73 1071 5 Checking the iieri the iin etd a A eed 74 10 1 6 Checking Tightening U 75 11 TROUBLESFIOOTING u l U T uuu assasasasasamasaanan 76 76 1 2 Current Measurement Malfunction 77 112 1 No Gurrentis oreet teet trece nea tt 77 11 2 2 The Expected Current is not Measured eene 77 11 3 Anti theft System Malfunction 77 11 3
22. 392 300 6 5 6 5 92 106 A i Slots 6 5x18 5 mm In between distance tanti Figure 59 8 string SMART STRING BOX 18 5 _ 6 5 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 1618 MAX 600 400 600 P eeeeooo amp CS SP A 16 ORR EEKE EEE ER ee eee onmmmmmmmummmnuognuuuguuuuo o o
23. ISO 9001 are the strong points of a reliable product which is able to maintain its features unaltered over time Designed to last in even the most arduous environmental conditions Elettronica Santerno string boxes guarantee wide safety margins during daily use These and other design features are what position SMART STRING BOX at the highest level of reliability and performance for photovoltaic field energy production q NOTE The images and photos in this manual may be modified at the manufacturer s discretion both from a technical point of view and in appearance hence the illustrations provided herein are not binding Sd300 8LL000S Figure 1 SMART STRING BOX Line Rev 02 29 04 2013 9 106 SMART STRING BOX Z SANTERNO instalation CARRARO GROUP Medium and high power PV generator systems are made up of a high number of strings To optimize the connection topology and enhance the protection and monitoring systems parallel connection of the strings is carried out on string boxes distributed over the field The SMART STRING BOX line includes string boxes with between 8 and 24 inputs The range offers the following versions 600V version for field voltages up to 750 Vdc maximum 800V version for field voltages up to 880 Vdc maximum 900V version for field voltages up to 900 Vdc maximum 1000V version for field voltages up to 1000 Vdc maximum 1 1 Operating Principles Sd300 vLL000S
24. Table 24 Serial port aiaia 60 Table 25 CN3 connector terminals iaaii a 60 Table 26 M11 connector terminals 60 Table 27 DIP switch for RS485 line terminator 61 Table 28 FUSE BOX configurations rere tere aeternae Care ee xe eda aquqa 64 Table 29 Accompanying Materials sse nennen nn nnne nennen enne 66 Table 30 Key to FUSE BOX connectors cable glands sss 67 Table 31 Negative pole connection diagram 69 Table 32 Mainteriance Sheet nete ceteri Do eti uerb aeta Cate de 72 Table 33 Installation specifications for SMART STRING BOX sss enne 86 Table 34 SMART STRING BOX electrical specifications with anti inversion diodes 87 Table 35 SMART STRING BOX electrical specifications with anti inversion diodes 87 Table 36 SMART STRING BOX power supply ratings esseeneneeenene nnns 87 Table 37 SMART STRING BOX technical data a 88 Table 38 Nominal power supply specifications U U U U U u u uu 8
25. a 26 DC SWITCH BOX electrical diagram sse eene nennen nennen 27 DC SWITCH BOX bottom view nennen ennt sn treten rennen 28 JUNCTION BOX internal view I nn nnns tenen 29 JUNCTION BOX bottom view enemies nennen ren nnn sn nnne nennen 30 JUNCTION BOX electrical diagram eee nennen nennen 31 SMART STRING BOX positioning and connection diagram 32 Unpackaging of SMART STRING BOX sss ener aaa senten en 34 PSMART STRING BOX rere erste ree ise eR 36 Incorrect SMART STRING BOX installation esses 36 SMART STRING BOX with spacers for heat dissipation 37 Cabling recommended for the parallel string modules eene 40 Installation of cables with ferrule on terminal 41 Fitting the string connection connector U U 42 String CISCONNECHON E 43 DC SWITCH BOX position of cable glands I a 44 Short circuit located downstream from the SMART STRING 45 Connection of the 3 wire PT100 thermistor eee nene 48 Anti theft connection with separate anti tampe
26. anti theft system only Version with clamp connectors no quick fit connectors 24 hour a day anti theft with measurement of impedance string 1510005 Figure 4 16 SMART STRING BOX 1 4 Scope of this Manual This manual covers e all SMART STRING BOX for PV applications o JUNCTION BOX Revision 1 and lower version with quick fit PV connector o DC SWITCH BOX Revision 1 and lower e all fuse expansion boxes o FUSE BOX Revision 1 and lower To identify the product version please refer to section 12 1 1 12 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 1 5 For Whom this Manual is Intended This manual must be read by Installers Operators Plant manager Please refer to section 1 9 1 6 Attached Documentation SMART STRING BOX and any FUSE BOXES are supplied with the following documents Name of the document Scope Contains all the information necessary for the Installation Guide assembly installation and maintenance of the product Contains the product operating measurements and Programming Guide programming parameters Table 1 Documentation supplied with the product 1 6 1 Preservation of the Documentation All documents must be kept for the entire life span of the equipment together with the system documentation They must be kept in a place where they are readily available Rev 02 29 04 2013 13 106 SMART STRI
27. are 2 6 V between line A D1 and Common 2 4 V between line B D0 and Common 8 4 3 Internal Bus RS485 Cables In the case of 16 and 24 string SMART STRING BOX a RS485 cable is used to ensure continuity of the multidrop chain This cable fitted with DB9F connectors multidrop connects the RS485 interfaces of each control board CN3 connector SMART STRING BOX with 16 inputs cablet code PC1604160 SMART STRING BOX with 24 inputs cablet code PC1604240 Both cablets are included as part of the supply with each SMART STRING BOX PC1604160 Deer 4 POLE SCREENED CABLE Das ica 1 e auis WITH AWG26 TWISTED PAIRS e 2 2 SG B 3 e 3 gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt 4 e e 4 5 e 5 gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt 6 e 6 7 e 7 GND TWIN WIRE LENGTH 80 o e 80 cm 1 1 606 o o 0 5 sLoooo s FLYING 9 POLE FEMALE D SUB CONN viewed from welds Figure 41 16 input SMART STRING BOX cablet 62 106 Rev 02 29 04 2013 9210008 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box
28. communication fails for a time exceeding the set threshold an alarm message is sent to the user For the configuration of this function please refer to the Programming Guide Rev 02 29 04 2013 49 106 CARRARO GROUP SMART STRING BOX Z SANTERNO installation 7 5 2 Small scale Systems For small scale systems designed to use up to a maximum of four JUNCTION BOX modules it is possible to use an internal relay This can be connected to an anti theft system with a commercial siren and can be monitored in remote mode This relay opens in co ordination with the anti tampering switch the contacts of which are available on terminal board M9 The anti tampering switch is normally closed and opens if someone tries to open the box cover This signal is usually wired to an immediate alarm input of the anti theft system coupled to the system The relay signals the theft of one or more panels in the range of a string It envisages a combination of both NC and NO contacts It usually remains excited NC contact closed and goes into a standby status in the event of an alarm It is normally wired to a delayed input of the anti theft system To obtain a single cumulative signalling of both alarm conditions it is possible to use terminals 3 and 6 of connector 9 thus obtaining a connection of the two alarm contacts in series The figure below indicates the wiring details of three common cases separate anti tampering and theft signalling
29. cover has been removed by unscrewing the 4 screws CN 0 S80100d f 9 9 A Figure 45 B F 8 module internal view Key Function A Negative pole inputs of strings from the PV field B Negative pole outputs of strings to SMART STRING BOX C Safety fuses D Earth terminal E Earth cable input Table 30 Key to FUSE BOX connectors cable glands P001086 0 O Figure 46 FUSE BOX module bottom view Rev 02 29 04 2013 67 106 CARRARO GROUP SMART STRING BOX Z SANTERNO wmsraLLarioN 1410008 OUT _ _ _ _ _ _ _ _ GND Figure 47 FUSE BOX electrical diagram Q WARNING Before accessing the terminal boards check that the box is in safety conditions Please refer to section 2 7 68 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 9 1 4 FUSE BOX Assembly Instructions The FUSE BOX must be mounted alongside the SMART STRING BOX on the brackets provided Then proceed with connecting the cables 0 0 Q 9910005 C Figure 48 Diagram of negative pole connection of the strings to the FUSE BOX Key Description A Earth cable Negative pole of string from the PV field Negative pole of string to JUNCTION BOX Ta
30. filter cut off frequency low pass first order filter 1 Hz Table 56 Analogue inputs configured in 0 100 mV mode 102 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO 3s smartstrinc CARRARO GROUP Analogue inputs configured as temperature measurement Rating with PT100 Min Typ Max Unit Type of probe 2 wire connection PT100 thermistor Measurement range 50 125 C PT100 element polarization current 0 67 mA Temperature measurement coefficient 50 Digital resolution 12 bits Maximum cumulative measurement error over 40 C 50 temperature range Ws s Mean value of temperature LSB SW linearization function 0 098 C LSB Permanent overload on the inputs without causing damage 10 10 V Input filter cut off frequency low pass first order filter 1 Hz Table 57 Analogue inputs configured as temperature measurement with PT100 Rev 02 29 04 2013 103 106 SMART STRING BOX Z 12 10 Fuse Box SANTERNO CARRARO GROUP INSTALLATION GUIDE For the installation specifications please refer to section 12 2 for the SMART STRING BOX 12 10 1 FUSE BOX Electrical Specifications U M CS BF 8 CS BF 16 CS BF 24 INPUT Maximum DC input voltage V 1000 Vdc DC string fuses positive A x 2 ipn ie pole Additional fuse sizes available to be defined when ordering the equipment Input c
31. modifications and management involves all persons responsible for production and maintenance It must be carried out in observance of the health and safety regulations described in section 2 5 11 6 1 Fault Containment The following prescriptions are of a general nature Place the equipment affected by the fault in safety conditions This operation may involve stopping and disconnecting all the up and downstream devices Please refer to section 2 4 If the fault has occurred inside an inverter press an emergency stop button to cut the inverter off up and downstream Open the disconnecting switches of all the string boxes so that the entire DC input section is safe including the DC Parallel if installed In multi inverter systems it is usually sufficient to cut off the inverter affected by the fault both up and downstream so that the other inverters can remain in operation If the fault has occurred in one of the components downstream from the inverter AC parallel cabinet external transformer metering cabinet etc STOP all the machines and then press the emergency stop button to cut off the inverter both up and downstream If the fault has occurred in one of the components upstream from the inverter DC parallel String Box etc STOP all the machines and then press the emergency stop button to cut off the inverter both up and downstream Open the disconnecting switches of all the String Boxes so that the entire DC i
32. sized for the maximum fault current If the PV plant is made up of just one SMART STRING BOX the problem does not exist Rev 02 29 04 2013 45 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 7 3 Power Supply Configuration and Connections Each JUNCTION BOX holds a measurement and supervisory circuit which needs a power supply The power supply source of the circuit is based on the product model SMART STRING BOX without anti theft system versions 600V 800V and 900V PV field with a voltage exceeding 200 Vdc SMART STRING BOX without anti theft system version 1000V 230 Vac 10 grid also with UPS backup DC power supply unit via the dedicated terminal M13 equipped with an 8 15 Vdc input This terminal can also be found on the bracket outside the Lexan safety panel SMART STRING BOX with anti theft system 230 Vac 10 grid also with UPS backup 12 Vdc 20 anti theft central battery DC power supply unit via the dedicated terminal M13 equipped with an 8 15 Vdc input This terminal can also be found on the bracket outside the Lexan safety panel 9 WARNING Before accessing the terminal boards check that the box is in safety conditions Please refer to section 2 7 The table below list the types of signal connections and details on the relative connector terminal board Es zs Eus 2 Description terminals signal 7 10V I O Power supply input output 8 OV Com
33. switches in the other JUNCTION BOX modules must remain on OFF If multiple SMART STRING BOX are multidrop connected it is necessary to enter and leave with a RS485 cable which is why there are two input and output cables glands on the box In 8 string SMART STRING BOX made up of a single junction module it is necessary to enter leave with the RS485 cable in the same JUNCTION BOX 56 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 2910005 JUNCTION DC SWITCH vA M11 ece CN3 ES889 Y A Figure 34 8 string SMART STRING BOX connection diagram 8810005 5889 M11 2 10 9 14 GND B A GND B A Figure 35 Details of 8 string SMART STRING BOX connection terminals In 16 and 24 string SMART STRING BOX made up of two or three junction modules it is necessary to enter with the RS485 cable in one of the end boxes leaving the internal route to the internal RS485 bus cable and leave the box from the other end 8910008 JUNCTION DC SWITCH JUNCTION BOX Y A A
34. this manual The DC power supply must come from the PV field only Any use other than that described in this manual is to be considered inappropriate and therefore improper Rev 02 29 04 2013 17 106 CARRARO GROUP SMART STRING BOX Z SANTERNO instalation 2 3 Qualified Technical Personnel All work on SMART STRING BOX products must be carried out by skilled technical personnel only By skilled personnel it is intended persons who have been suitably trained to carry out the work in question To commission and use the SMART STRING BOX personnel must know and understand the instructions for installation and use In particular all safety warnings must be strictly observed 2 4 Specific Dangers Linked to Photovoltaic PV Systems PV systems have certain characteristics which are the source of additional hazards and are described below A live current source is connected Depending on the operating conditions there may be live voltage from the PV generator or from the electrical grid This must be taken into consideration particularly when disconnecting parts from the system Very high DC voltages are involved with no periodic zero crossings hence failure or the incorrect use of fuses or plugs may cause electric arcs The short circuit current of the PV generator is only slightly higher than the maximum operating current and furthermore is linked to radiation This means that fuses may not always blow in the e
35. tightened in the right position 11 3 Anti theft System Malfunction 11 3 1 String Opening is not Indicated Check that the minimum number of strings selected in the SMART STRING BOX parameters are disconnected 11 3 2 False String Opening is Indicated Check that string polarity has not been inverted Rev 02 29 04 2013 77 106 SMART STRING BOX Z SANTERNO wmsraLLarioN CARRARO GROUP 11 4 Malfunction of Communication Ports 11 4 1 Serial Communication Problems Check that all the programming parameters are correct Check the voltage values for the bus in standby please refer to section 8 4 2 11 5 Safety Devices Tripped 11 5 1 Output Disconnecting Switch Tripped Check for short circuits Check the polarity of the PV field poles Check that the release winding is not excited 11 5 2 SPDS Tripped or Fuses Blown If the SPD has tripped and or relative fuse have blows replace them Please refer to section 12 8 78 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 11 5 3 String Fuse Blown This section describes faults relevant to one or more SMART STRING BOX fuses blowing If a fuse blow procedures cannot be limited to simply replacing the fuse Suitable analysis of the fault which caused the problem must be also carried out q NOTE Should the fuse blow again please contact the Elettronica Santerno SpA CUSTOMER SERVICE Bef
36. 1 RS485 Bus Main Principles The MODBUS IDA organization http www modbus org defines the connection for Modbus communication on RS485 serial link used by the inverter as 2 wire cable type For this type of cable the following specifications are recommended Connection cable Shielded cable made up of a balanced pair known as D1 D0 common Type of cable conductor Recommended cable Belden 3106A Paired EIA Industrial RS485 PLTC CM Minimum section for AWG23 corresponding to 0 258 mm For long lengths it is advisable to use conductors a larger section up to 0 75 500 metres with reference to the maximum distance measured between the Maximum length two stations furthest apart Impedance specifications Recommended over 100 usually 120 Table 23 Connection cable It is advisable to connect all the equipment connected to the multidrop connection network to the earth by means of a common conductor In this way any differences in earth potential between different equipment which may interfere with communications is reduced to a minimum The common terminal OV connection is necessary An 0V connection which is common to all equipment in the multidrop communication network minimizes possible differences of reference potential between the equipment which could interfere with communication The common reference of control board power supply is isolated in relation to earth By connecting on
37. 1 String Opening is not Indicated 77 11 3 2 False String Opening is Indicated seen 77 11 4 Malfunction of Communication Ports 78 11 4 1 Serial Communication Problems 78 11 5 Safety Devices Tripped eene enn n nicis ennn 78 11 5 1 Output Disconnecting Switch Tripped a 78 11 5 2 SPDS Tripped or Fuses 1 78 11 5 9 String Fuse BloWnr 79 11 6 General Principles in the Event of Failure 81 11 6 1 Fault Containment U 81 1162 Fault ANALYSIS se e orte E u ERE Ede RC ERE NERO Habe E Ps 82 11 7 Revision of String with Inverted 83 11 8 How to Contact the CUSTOMER SERVICE 84 12 TEGHRINIGAL DATA uu uu u uu onu 85 2ds 85 123 1 Product Revision Label iicet een ae eee nee e uada pad 86 12 2 Installation Specifications m 86 123 Electrical SpecifiGali nS u uu 87 Rev 02 29 04 2013 3 106 SMART STRING B
38. 1 and 99 Figure 32 illustrates the position of the rotary switches which are outside the Lexan safety panel near the CN3 connector and identified with the code MODBUS ADDRESS The left hand rotary switch CE1 is for the tens and the right hand switch CE2 is for the units It is also possible to set addresses above 99 For further information please refer to the Programming Guide Wait for 15 seconds before interrogating the board at the new address In the event of serial communication problems please section 11 Rev 02 29 04 2013 63 106 SMART STRING BOX Z SANTERNO wsraLLarioN CARRARO GROUP 9 OPTIONALS 9 1 Fuse Box vZL000S Figure 43 FUSE BOX 9 1 1 Product ID Code SMART STRING BOX do not have safety fuses installed on the negative pole of the strings If fuses are also required on the negative pole a supplementary FUSE BOX can be connected The FUSE BOX is available in three configurations for 8 16 and 24 strings These configurations are obtained by putting together 8 string FUSE BOX modules Product ID Code Product composition CS 8 1 x B F 8 CS BF 16 2 x B F 8 CS BF 24 3 x B F 8 Table 28 FUSE BOX configurations Product ID codes are as follows CS BF Y Y No of strings No of strings 64 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc 9 1 2 CARRARO GROUP Checking the Product on Delivery The equipment
39. 12 Vdc battery id V gt 200 From DC 8 15 From DC 8 15 power supply power supply unit unit Table 36 SMART STRING BOX power supply ratings Rev 02 29 04 2013 87 106 SMART STRING BOX 9n SANTERNO installation CARRARO GROUP CS SP A 8 XXXV CS SP A 16 XXXV CS SP A 24 XXXV INPUT Max number of strings Oo gt gt 2 UNIT OF MEASURE OUTPUT Nominal output current 45 C ambient temperature G in 198 Output disconnect switch 160 200 250 rating Table 37 SMART STRING BOX technical data 9 CAUTION The maximum number of strings connected to the product shall be calculated based on the allowable output rated power as well as on the ambient temperature and the product configuration 88 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP Features Min Typ Max Power supply from PV field Operating voltage range 200 Vdc Udc max Power absorbed from PV field 6 5 W Protection FU9 2 A 1000 Vac fuse dimensions 6 3x32 mm Power supply from grid Applicable voltage interval 200 Vac 230 Vac 250 Vac Frequency 45 Hz 50 Hz 65 Hz Power absorbed from the grid 6 5 W Peak inrush current 1ms 7A 1 A 250 V fat fuse dimensions 5x20 mm and Protection FU22 250 Vac varistor Power supply from DC or battery source
40. 542 489722 santerno com sales santerno com CARRARO GROUP SMART STRING BOX Z SANTERNO wmsraLLariON Table of Contents TABLE OF CONTENTS uo usu e Rene etae Deb vetare aar nq eR Det tton 2 INDEX OF FIGURES 5 INDEX TABES mr 7 1 GENERAL INFORMATION ON THE PRODUCTI 9 Tel Operating Principles sss 10 1 2 Main Integrated Standard 5 11 1 3 Optional uut usb iie sup Od tte 12 1 4 Scope of this Manual e 12 1 5 For Whom this Manual is Intended 13 1 6 Attached Documentation eene ad nigra 13 1 6 1 Preservation of the Documentation a 13 1 7 References for the Electronic Board ID 14 1 8 14 1 9 u a 15 2 GAUTION STATEMENTS L uuu uuu u uuu fabu tiu endet utn RU DRM 16 2 1 Precautions for Use and Prohibitions r 17 2 2 WHOS HN u uuu 17 2 3 Qualified Technical
41. 7 32 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 4 2 Measuring the Current and Performance of the Individual Strings The SMART STRING BOX makes it possible to accurately read the current of each individual connected string The measurements are processed by the internal control board in order to obtain Mean measurements of the currents for each JUNCTION BOX for the purpose of integration with the Santerno remote control service Detection of string opening Detection of performance loss For further information please refer to the Programming Guide 4 3 24 hours a day Anti theft Function The anti theft function is designed to detect removal of modules from the system When a theft is detected the event is transmitted to the supervision system which immediately sends an alarm message to the user To ensure security the supervision system also known as LDR strategy is designed to check communication signals continuously If communication fails for a time exceeding the set threshold an alarm message is sent to the user The anti theft function also envisages an anti tampering switch The anti tampering switch is normally closed and opens if someone tries to open the box cover This signal is usually wired to an immediate alarm input of the anti theft system coupled to the system The relay signals the theft of one or more panels in the range of a string It usu
42. 9 Table 39 Maximum DC voltage based on altitude 89 Table 40 Calculation of the rated current reduction coefficient sse 91 Table 41 SMART STRING BOX dimensions and weights a 92 Table 42 Clearance Values etre tt eset Lane EE ERR 96 Table 43 Fastening the Cover esses eene ennemis u u a 96 Table 44 String cable connection with cable gland and terminal essen 96 Table 45 String cable connection with quick fit PV connector sse 96 Table 46 Power cables U U enne enn erinnern nnne 97 Table 47 Power cables connection ferrule sess nnne 97 Table 48 DC SWITCH BOX earth cable n nnne ens 97 Table 49 Auxiliary terminals cable section 98 Table 50 Connection of signal cables 98 Table 51 Tightening torques recited recedere Foe 99 Table 52 Output disconnect switch release coil n 99 Table 53 SPD technical specifications L n 100 Table 54 Analogue inputs configured in 0 10 V mode sse enne nens 101 Table 55 Analogue inputs configured in 0 20 mA mode
43. 9 04 2013 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 12 4 2 Clearance Values It is necessary to observe the following minimum distances from walls other equipment and objects in order to ensure safety of access and adequate heat dispersion SMART STRING BOX Front mm RH LH side mm Back mm Bottom mm With anti inversion diodes 800 120 50 250 Without anti inversion diodes 800 120 250 Table 42 Clearance Values See section 6 12 5 Fastening the Cover Description Tightening torque of screws Nm JUNCTION BOX 2 2 5 DC SWITCH BOX 2 2 5 Table 43 Fastening the Cover 12 6 Connection of Power and Signal Cables 12 6 1 DC Connection String Cables VERSION WITH CABLE GLAND AND TERMINALS Tightening Min Max Min Max String cable header torque of conductor external cable terminals Nm section mm2 diameter mm Pipe ferrule manufacturer s reference Cembre 4 mm2 cables PKD 412 1 2 2 5 4 6 5 10 6 mm2 cables PKD 612 Table 44 String cable connection with cable gland and terminal VERSION WITH QUICK FIT PV CONNECTORS Min Max conductor section Min Max external cable String cable header mm diameter mm Quick fit PV connectors 4 6 5 10 Table 45 String cable connection with quick fit PV connector 96 106 Rev 02 29 04 2013 INSTALLATION GUIDE 2 CARRARO GROUP SANTERNO 5
44. CARRARO GROUP 7 1 1 Version with Cable Gland and Terminals The JUNCTION BOX for the SMART STRING BOX does not come assembled with cable glands The cable glands are supplied with the product The procedure for installing the cable gland and connection to the board is described below Screw the cable gland onto the box without tightening it Pass the cable with ferrule through the cable gland Wire the cable to the terminal board From M1 to M4 connect the positive pole of the strings from M5 to M8 connect the negative pole of the strings please refer Figure 15 Tighten the terminals please refer to section 12 6 1 Correctly tighten the cable gland All the cable glands which are not used must be closed with the special plugs WARNING Always use cables with ferrules Please refer to section 12 6 Check the correct position of the ferrule so as to avoid tightening onto the plastic section as shown in the figure To carry out the following operations check that the switch on the DC SWITCH BOX of the parallel string box in question is open Always wear the PPE required by law for working in the presence of live voltage dielectric gloves with at least 1000V high voltage insulation ON URN SERM ROR SSS 7777777727 NNUS SNR E SENS Figure 22 Installation of cables with ferrule on terminal 7 1 2 Version with Quick fit Conne
45. EP2H0600 Integrated Anti theft System Max String Number Voltage Max 750 V dc Current Max 8 A dc x string Short circuit Current 10 A dc x string Anti Reversal Diodes YES IP degree IP65 EMC Immunity EN61000 6 1 Emission SAFETY EN50178 SANTERNO CARRARO GROUP www santerno com MADE IN ITALY Sd300 90000S SMART STRING BOX CS SPA 8 600V 64 Alde EN61000 6 3 Figure 55 SMART STRING BOX dataplate Rev 02 29 04 2013 85 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 12 1 1 Product Revision Label To identify the version of the product supplied simply refer to the revision label on the cover and inside the box LrL000S ZZES5G0610 Rev 2 Figure 56 Product revision label 12 2 Installation Specifications Installation specifications for SMART STRING BOX Operating ambient temperature 25 50 From 5 95 1 g m 25 g m with no Operating ambient humidity condensation or ice formation category 3k3 in compliance with EN50178 Up to 2000 m ASL Altitude For higher altitudes please refer to section 12 3 1 and 12 3 2 Do not install the equipment where it is exposed to direct sunlight Installation site or where it is exposed to conductive dust corrosive gases vibrations water spray or dripping Do not install in salty environments Degree of protection IP 65 Degree of pollution Class 3S2 or higher acc
46. GROUP 8 3 Connection Topologies The SMART STRING BOX is usually multidrop connected The multidrop connection entails the chain connection of multiple devices In this case each device is a JUNCTION BOX The RS485 multidrop line to multiple devices must be wired using a linear and not a star topography each device connected to the line must be connected by an incoming cable from the previous device and have an outgoing cable to connect the next device The exceptions are obviously the first and last devices in the chain which will have only an outgoing line and an incoming line respectively The reference diagram recommended by the MODBUS IDA association for the connection of 2 wire devices is illustrated in the figure below P000534 B D1 Pull Down Figure 33 Recommended multidrop connection diagram The network is made up of the termination resistor and the polarization resistors incorporated for convenience in each JUNCTION BOX and which can be turned on by DIP switch SW2 located next to connector CN3 The figure shows the termination network only for the devices at the ends of the chain In fact these are the only ones which need a terminator Being as one end of the chain is constituted of the Master device only both contacts of dip switch SW2 must be set to ON see Figure 32 in the JUNCTION BOX located the furthest away in electrical terms from the Master i e the one at the end of the multidrop chain All the dip
47. ING BOX 93 Fig ure 62 JUNGTION BOX uuu klnaa 94 Figure 63 DG SWITCH BOX uu u uuu 95 Figure 64 SMART STRING BOX view nnne 99 Figure 65 FUSE BOX CS BF 8 dimensions 105 6 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP Index of Tables Table 1 Documentation supplied with the product esee enne 13 Table 2 Electronic board U U eene enn 14 Table 3 SMART STRING BOX models and relative composition esee 25 Table 4 DC SWITCH BOX by current and voltage size ssssssssssssseeseeeneeeenen nennen 26 Table 5 DC SWITCH BOX connections eene 26 Table 6 Terminals for auxiliary contacts U U U nn 27 Table 7 DC SWITCH BOX connectors cable glands sse 28 Table 8 JUNCTION BOX string connection modules sse nennen 28 Table 9 JUNCTION BOX cables sitis e
48. N 3 1 Checking the Product on Deliver On receiving delivery of the equipment make sure that the packaging shows no signs of damage Check that it complies with your order by referring to the dataplates described below In the event of any damage please contact the relative insurance company or the supplier If the delivery does not match your order contact the supplier immediately Sd300 00000S Figure 7 Packaging of SMART STRING BOX e NOTE The labels indicating the codes and product description and any optionals selected may differ in colour to the ones shown in the figure If the equipment is to be stored before installation make sure that the ambient conditions in the warehouse meet the necessary specifications please refer to section 5 2 The warranty covers manufacturing defects The manufacturer shall not be held liable for any damage which may have occurred during transport and unpacking Under no circumstances shall the manufacturer be held liable for damage or faults caused by incorrect use misuse incorrect installation or inadequate temperature or humidity conditions or exposure to corrosives nor for faults caused by operation outside the rated values Nor shall the manufacturer be held liable for consequential or accidental damage e NOTE For the terms of warranty please refer to the warranty certificate supplied with the product Rev 02 29 04 2013 23 106 SMART STRING BOX Z SANTERNO installation
49. NG BOX Z SANTERNO wmsraLLarioN CARRARO GROUP 1 7 References for the Electronic Board ID Codes The table below indicates the electronic board ID codes used in the electrical and mechanical diagram ID code Description ES889 CONTROL BOARD ES851 DATA LOGGER BOARD Table 2 Electronic board references 1 8 Symbols used KEY DANGER Indicates an operating procedure which if not carried out correctly may lead to injuries or even death caused by electric shock WARNING Indicates an operating procedure which if not carried out correctly may cause serious damage to equipment NOTE Indicates important information concerning use of the equipment gt gt PROHIBITION Strictly forbids the execution of operating procedures 14 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 1 9 Definitions Installer Technician responsible for setting up positioning and installing the equipment in compliance with the system diagram and in accordance with first class professional criteria Operator Worker who has been suitably trained and informed on the risks and relative safety procedures to be adopted The operator can carry out routine maintenance on the equipment Plant manager Person who co ordinates or manages system management activities and is responsible for ensuring health and safety standards are adhered to Technical room Place us
50. O CARRARO GROUP INSTALLATION GUIDE Furthermore depending on the SMART STRING BOX model the following items are supplied Quantity BIRDUIS 16 24 Description p inputs inputs Version with cable gland and terminals 16 8 32 16 48 24 PG11 cable glands 16 32 48 PG11 screw plugs for closing any unused inputs These are to be inserted on the box during the wiring phase 8 16 24 Fuses Version with quick fit connectors 8 16 24 PG11 cable glands 8 16 24 PG11 screw plugs for closing any unused inputs These are to be inserted on the box during the wiring phase 8 16 24 Fuses Table 13 SMART STRING BOX accompanying materials per model Crimpers The quick fit flying connectors must be crimped onto the string cables on site Make sure that suitable crimpers are available 38 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 7 COMMISSIONING 9 WARNING To carry out the following operations check that the parallel string box is in safety conditions Please refer to section 2 7 A DANGER The heat sink at the back may reach very high temperatures during operation DO NOT touch with unprotected hands Burning hazard The following paragraphs provide information on power and signal cable connection and commissioning Each string must be made up of the same number of panels All panels must have the same nominal characteristics Failure to obs
51. OX Z SANTERNO wmsraLLariON CARRARO GROUP 12 3 1 Maximum Voltage Derating LLL Lu ee R A 89 12 3 2 Rated Current Derating sse einn ntn 90 12 4 Dimensions and Weights 92 12 4 1 Mechanical Dimensions sese enemies 92 12 4 2 Clearance Values abc e SE EIE HE DE Ca DR adraia 96 12 5 Fastening the Cover P 96 12 6 Connection of Power and Signal 96 12 6 4 DC Connection String Cables a 96 12 6 2 DC Connection Output Cables 97 12 6 8 Connection of Earth nennen 97 12 6 4 Connection of Signal Cables sse 98 12 6 5 Connection of Internal Components rss 99 12 7 Output Disconnect Switch Release 99 128 n 100 12 9 Environmental Sensors Acquisition r 101 REI 104 12 10 1 FUSE BOX Electrical Specifications 104 12 10 2 Dimensions and Weights u uuu uu 105 12 10 3 Cable Ia aqasha enne n enisi aasawa aqa 106 4 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box
52. P Table 25 CN3 connector terminals in accordance with the MODBUS IDA association nomenclature bud De scripuon 9 A D1 RS485 Signal D1 10 B D0 RS485 Signal DO 11 5 VM OUT 5 V Isolated max 50 mA for powering external optional devices 12 0 VM OUT RS485 signal OV 13 N C Not connected 14 EP Shield Cable braid shield connected to earth EP Table 26 M11 connector terminals in accordance with the MODBUS IDA association nomenclature To connect up to the serial line use the M11 terminal board as described in section 8 2 60 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box DIP SWITCH FOR RS485 LINE TERMINATOR DIP switch Function Factory setting Notes ON 120 Q resistor between A D1 and B DO 1500 resistor between A D1 and 5 VE 1500 _ i Both ON resistor between B D0 and SW2 1 SW2 2 RS485 terminator rminators enabled on 20 OFF no termination and polarization resistor Table 27 DIP switch for RS485 line terminator The factory settings of the DIP switches are indicated in the following figure 9210005 Figure 40 Communication line terminator DIP switch q NOTE Incorrect setting of the terminators in a multidrop line may inhibit communication and lead to communication difficulties particularly at high baud rates If more than the t
53. Safety Procedure Before carrying out any kind of operation inside the box always place the equipment in safety conditions To do this follow the instructions provided below Make sure that the inverter connected to the SMART STRING BOX is not running i e that it is STOPPED Open the switch on the DC side of the converter Remove the cover from the DC SWITCH BOX and open the disconnecting switch there is NO need to remove the Lexan safety panel Disconnect all the strings from the JUNCTION BOXES which make up the SMART STRING BOX without removing the cover see section 11 TROUBLESHOOTING If there are other auxiliary power supply sources at network voltage proceed to open the relative switches and check that the terminals in question are in fact disconnected Proceed to open the JUNCTION BOX modules remove the Lexan safety panel and use a multimeter to check that there is no voltage between and on the copper bars Proceed with the operation in question DANGER The RS485 serial and the environmental sensors input circuit found in the JUNCTION BOXES of the SMART STRING BOX which is not protected by the Lexan safety panel must be considered an ELV Extra Low Voltage circuit galvanically isolated from the PV field circuits but with insulation which has no reinforced insulation or double insulation properties Therefore it cannot be treated as a SELV circuit The RS485 serial communication line an
54. TRING BOX Connection Diagram CS SP 8 600V CS SP 8 800V CS SPA 8 600V CS SPA 8 800V 200 ow B SEZ AUT P 100A 600V 800V 54300 2 110008 OVERVOLTAGE Set DISCHARGER LIMITER TOES z GROUND had ere ES889 B S A 8 asi a CS SP 16 600V CS SP 16 800V CS SPA 16 600V CS SPA 16 800V DB9F 1 2 DB9F E BSEZAUTyP 160A 600V 800V PEN AUX ABB S3 SERIES OVERVOLTAGE DISCHARGER za LIMITER H a GROUND CS SP 24 600V CS SP 24 800V CS SPA 24 600V CS SPA 24 800V DB9F 1 2 DB9F DB9F 4le amp mgoe amp BSEZAUT P 250A 600VI800V peang Eos 4 PEN 3 AUX ABB S3 SERIES OVERVOLTAGE DISCHARGER s LIMITER E GROUND Figure 16 SMART STRING BOX positioning and connection diagram Cables Function 1 Cablet for signalling SPD status 2 RS485 internal bus connection cablet 3 Cablet for signalling disconnecting switch status Table 10 JUNCTION BOX internal connections For the position of the connectors inside the JUNCTION BOX please refer to Figure 13 The figure also highlights the bus communication daisy chain connection which is created using pre wired connectors See section
55. X usually behaves as a Modbus slave i e it responds to requests made by a Modbus Master device The Master is usually a Sunway series solar inverter fitted with a Data Logger board and a PLC with Modbus interface which accompanies the plant or by a PC equipped with Elettronica Santerno s Remote Sunway software The serial port on the SMART STRING BOX available on connector M11 implements galvanic isolation of the RS485 signals in relation to the external communication devices For specifications concerning the protocol programming of the serial parameters the Modbus address etc please refer to the Programming Guide Protocol and availability relevant to the serial ports are indicated in Table 25 Serial port Connector Protocol RS485 CN3 M11 Modbus Slave Table 22 Communication port MODBUS ADDRESS 93 A3 Ms x a Figure 32 ELV zone dedicated to Modbus RS485 and environmental sensors communication 9 WARNING The board does not recognize Modbus address settings carried out when the board is not powered q NOTE To guarantee correct operation of the communication network the RS485 circuit driver is isolated in relation to the 0V of the control board signalling circuits The isolation test voltage between the common CMD signal of the RS485 interface and the 0V GND is 500 Vac 50 Hz 1 min Rev 02 29 04 2013 55 106 SMART STRING BOX Z SANTERNO wsraLLariON CARRARO
56. Y M11 e Exo M11 o CN3 CN3 1 5889 5889 Y Figure 36 16 string SMART STRING BOX connection diagram Rev 02 29 04 2013 57 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP CN3 CN3 ES889 ES889 M11 M1 12 10 9 14 12 10 9 14 t GND B A GND B A Figure 37 Details of 16 string SMART STRING BOX connection terminals JUNCTION BOX DC SWITCH BOX JUNCTION BOX JUNCTION BOX 8 Y Y Y M11 base M11 cae M11 bese CN3 CN3 CN3 0 5889 5889 5889 Y Figure 38 24 string SMART STRING BOX connection diagram CN3 CN3 CN3 ES889 ES889 ES889 M11 M11 M11 12 10 9 14 12 10 9 14 12 10 9 14 o o o o 9 1 1 T o o o GND B A GND B A Figure 39 Details of 24 string SMART STRING BOX connection terminals 58 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 8 4 Connection 8 4
57. ally remains excited and goes into a standby status in the event of an alarm It is normally wired to a delayed input of the anti theft System 4 4 Environmental Measures It is possible to connect up to two auxiliary sensors to the board for measuring the ambient temperature module surface radiation horizontal radiation wind speed The use of these sensors makes it possible to carry out environmental measures distributed over large scale PV plants Each JUNCTION BOX for SMART STRING BOX has two environmental measure inputs Each input can be connected to solarimeters thermometers with 0 100 mV 0 10 V 4 20 mA PT100 outputs For all the details please refer to section 7 4 4 5 Monitoring the State of the SPD Disconnection Switch The control board can monitor the intervention of the Surge Protection Devices and opening of the disconnecting switch For further information please refer to the Programming Guide 4 6 Emergency Disconnecting Switch Opening Opening of the SMART STRING BOX disconnecting switch may occur in remote mode by means of the shunt opening release If necessary use a minimum voltage winding contact Elettronica Santerno S p A For all the details please refer to section 12 7 Rev 02 29 04 2013 33 106 SMART STRING BOX Z SANTERNO instalation CARRARO GROUP 5 STORAGE AND TRANSPORT 5 1 Conditions for Transport The parallel string boxes are delivered packed to extremely high stand
58. ant dripping All the parallel string boxes must be installed in an upright position To facilitate installation the parallel string boxes come supplied with a special bracket 9710005 0510005 Figure 19 Incorrect SMART STRING BOX installation 36 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box Rear spacers are required if the product is provided with anti inversion diodes 08z000S Figure 20 SMART STRING BOX with spacers for heat dissipation To allow for easy installation and effective air circulation make sure there is enough free space around the equipment Dimensions weights and necessary clearances are indicated in section 12 4 6 1 1 Accompanying Materials The following items are provided in the package with each individual SMART STRING BOX Quantity Description 4 PG29 cable glands 2 PG29 screw plugs for closing any unused inputs These are to be inserted on the box during the wiring phase 4 Reducer rubbers for PG29 1 PG16 cable gland 1 1 6 screw plugs for closing any unused inputs These are to be inserted on the box during the wiring phase 1 Set of 4 screws for the cover 4 PG11 cable glands PG11 screw plugs for closing any unused inputs These are to be inserted on the box during the wiring phase Table 12 SMART STRING BOX accompanying materials Rev 02 29 04 2013 37 106 SMART STRING BOX Z SANTERN
59. ards To avoid damaging the product move the package using a pallet jack or a forklift with a lifting capacity no lower than 100 kg Remove the product from the packaging through the sides keeping it horizontal to the ground Oo Figure 17 Unpacking the SMART STRING BOX 5 2 Environmental Requirements for Storage and Transport Required conditions Ambient temperature for storage and transport 25 C 70 C From 5 95 from 1 g m 25 g m with no condensation or ice Ambient humidity for storage formation category 3K3 in compliance with EN50178 Maximum 95 up to 60 g m Slight condensation may occur when the equipment is not running category 2k3 in compliance with EN50178 Ambient humidity during transport Atmospheric pressure for storage 86 106 kPa categories 3k3 and 1k4 in compliance with EN50178 Atmospheric pressure during transport 70 106 kPa category 2k3 in compliance with EN50178 Table 11 Environmental requirements for storage and transport 34 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 6 HANDLING AND ASSEMBLY PROHIBITION It is strictly forbidden to proceed with product handling and assembly operations in adverse weather conditions in snow rain or persistent fog Always check that there is no water or condensate inside the product It is strictly prohibited to leave the produc
60. ble 31 Negative pole connection diagram Rev 02 29 04 2013 69 106 SMART STRING BOX Z SANTERNO wmsraLLariON CARRARO GROUP CY o 4 JO WY FUSE BOX STRING BOX P001088 B Figure 49 STRING BOX connection with optional fuse expansion box 9 1 5 Mechanical Dimensions Specifications S N 30 6 5 25 6 5 m i 1 Y ERN al 2 ai O 18 5x6 5 g LE 3 ee ese i p e eom c e me c 2 Q h fo 1 L C 300 _ Figure 50 FUSE BOX dimensions 70 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 9 1 6 Product Installation The fuse expansion boxes must be installed in accordance with the prescriptions provided in section 6 1
61. cal remote control are as follows please refer to the Programming Guide Measure and control electronic board power supply indicator LED Output disconnecting switch status SPD status String current verification Alarms history forthe SMART STRING BOX accessible in remote and or local remote control When an alarm occurs the SMART STRING BOX records it in the Alarms history list together with the time of occurrence Supply Time and Operation Time the status of the SMART STRING BOX and the value of certain sampling measurements taken at the time of alarm tripping The stored data is very useful in helping to determine the cause which triggered the alarm and consequent removal of the alarm condition 76 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 11 2 Current Measurement Malfunction 11 2 1 No Current is Measured Check if the disconnecting switch is closed Check that string polarity has not been inverted Check that the strings show no signs of interruption in continuity of the cable q NOTE If the problem persists please contact the Elettronica Santerno SpA CUSTOMER SERVICE 11 2 20 The Expected Current is not Measured If the SMART STRING BOX is equipped with quick fit connectors check that said connectors have been connected in the right position If the SMART STRING BOX is equipped with cable glands check that string cables have been
62. ctors The JUNCTION BOX for the SMART STRING BOX does not envisage PV quick fit connectors as a standard type female connector on the positive pole male connector on the positive pole Rev 02 29 04 2013 41 106 SMART STRING BOX Z SANTERNO wmsraLLarioN CARRARO GROUP o WARNING Always use flying connectors of the same brand as the connectors installed on the string box The use of other connectors may damage the product To carry out the following operations check that the disconnecting switch on the DC SWITCH BOX of the parallel string box in question is open Always wear the PPE required by law for working in the presence of live voltage dielectric gloves with at least 1000 high voltage insulation STRING CONNECTION Join the contacts to fit them together Check that they are correctly joined by pulling on the connectors Figure 23 Fitting the string connection connector Once all the strings have been connected to the parallel string box the switch on the DC SWITCH BOX and the DC side of the Inverter can be closed For all details on power cable connections please refer to section 12 6 42 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP STRING DISCONNECTION Squeeze the two spring tabs together Separate the contacts Figure 24 String disconnection 7 2 Connection to the Inverter Proceed as follows Connect the power cables bet
63. d any environmental sensors must be wired in accordance with all the prescriptions for NON SELV circuits Rev 02 29 04 2013 21 106 SMART STRING BOX Z SANTERNO wsraLLariON CARRARO GROUP 2 7 1 Lexan Protective Cover The parallel string boxes and the DC SWITCH box are fitted with a polycarbonate Lexan safety panel Live parts which are most exposed to possible inadvertent contact are protected by this panel made from Lexan a transparent break proof material which is resistant to high temperatures The panel makes it possible to visually inspect the inside of products in relative safety once the cover has been removed A Lexan safety panel is installed in all the JUNCTION BOX modules of the SMART STRING BOX Sd300 2s1000S Figure 5 JUNCTION BOX for SMART STRING BOX with transparent Lexan panel In the disconnecting modules the Lexan panel is covered by a white protective film with a central hole which makes it possible to carry out manoeuvers on the switch without removing the safety panel A window in the film allows the user to observe the state of the dischargers Furthermore the DC SWITCH BOX cover is transparent so that the state of the disconnecting switch can be observed in total safety P000961 0 Figure 6 DC SWITCH BOX with opaque Lexan panel 22 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO 3s smartstrinc 3 PRODUCT IDENTIFICATIO
64. ductors For the convenience of cabling the DC SWITCH BOXES are provided with 4 separate cable glands for single or double cable outputs for each polarity For information relative to the section and diameter of cables please refer to section 12 Q WARNING The cable glands must be correctly replaced and tightened once the cable has been inserted Cable glands which are not used must be plugged The gable glands and covers must be accurately tightened to prevent water insects or small animals from getting inside and causing plant malfunctions as well as fire risks 7 2 1 Protection Devices against Short Circuit The SMART STRING BOX are equipped with a suitable under load disconnect device in output but are not fitted with protection against short circuits such as fuses in output The connection cables between the SMART STRING BOX normally located near the PV modules and the inverter located in the technical room usually carry all the current from the group of strings which belong to an individual SMART STRING BOX Being as the PV field is a current limited generator even in the event of a short circuit the current delivered by this kind of generator cannot exceed the maximum sizing value If the PV plant is made up of more than one SMART STRING BOX this concept is not valid for the current flowing through the cables Take as an example a short circuit which occurs downstream from a SMART STRING BOX but upstream from the connecti
65. e 15POOEPB120 e SMART STRING BOX STRING BOXES FOR PV SYSTEMS USER MANUAL INSTALLATION GUIDE Updated 29 04 2013 Rev 02 English This manual is integrant and essential to the product Carefully read the instructions contained herein as they provide important hints for use and maintenance safety This product is to be used only for the purposes it has been designed to Other uses should be considered improper and dangerous The manufacturer is not responsible for possible damages caused by improper erroneous and irrational uses Elettronica Santerno is responsible for the product in its original setting Any changes to the structure or operating cycle of the product must be performed or authorized by Elettronica Santerno Elettronica Santerno assumes no responsibility for the consequences resulting by the use of non original spare parts Elettronica Santerno reserves the right to make any technical changes to this manual and to the product without prior notice If printing errors or similar are detected the corrections will be included in the new releases of the manual The information contained herein is the property of Elettronica Santerno and cannot be reproduced Elettronica Santerno enforces its rights on the drawings and catalogues according to the law Z SANTERNO CARRARO GROUP Elettronica Santerno S p A Strada Statale Selice 47 40026 Imola BO Italy Tel 39 0542 489711 Fax 39 0
66. e or more inverters to a communication device with a common earth for example a PC a low impedance path between the control board and earth is obtained It is possible that disturbances conducted at high frequency from the power parts of the inverter may transit along this path and this can cause malfunctions to the communication apparatus It is always advisable to equip the communication equipment with a galvanically isolated RS485 communication interface or a galvanically isolated RS485 USB convertor WARNING Cat 5 2 3 or 4 pair data transmission cables cannot be used for the serial connection not even over short sections Wiring operations of the module must be carried out when the inverter is NOT powered Remember to take all the necessary precautions before accessing the connectors and before handling the board Rev 02 29 04 2013 59 106 SMART STRING BOX Z 8 4 2 SERIAL PORT CONNECTION RS485 Port SANTERNO CARRARO GROUP INSTALLATION GUIDE Serial port Optoisolated port Connectors RS485 YES CN3 SMART STRING BOX internal connections M11 RS485 field bus connection Table 24 Serial port connection SS pee SS fel 1 3 A D1 RS485 Signal D1 2 4 B DO RS485 Signal DO 5 7 8 OVM RS485 signal OV 6 N C Not connected 9 5 VM OUT 5 V Isolated max 50 mA for powering external optional devices Shell EP Shield Cable braid shield connected to earth E
67. ed for housing the technological systems such as the wiring plumbing heating air conditioning lifting and telecommunications systems It is equipped with suitable forced air ventilation and or air conditioning and is also fitted with appropriate safety devices governing access maintenance and fire prevention Person in charge of running the electrical system System Manager Person with the highest level of responsibility concerning operation of the electrical system If required some of his her tasks may be delegated to others Person in charge of working activities Works Supervisor Person with the highest level of responsibility concerning the execution of work If required some of his her tasks may be delegated to others The Works Supervisor must give all persons involved in the execution of work activities the relative instructions concerning reasonably foreseeable dangers which may not be immediately apparent Skilled electrician Someone who has been trained and has enough technical knowledge or experience to enable him her to avoid the dangers which may be generated by electricity Instructed person Someone who has been adequately advised or supervised by a skilled person to enable him her to avoid the dangers which may be generated by electricity Rev 02 29 04 2013 15 106 SMART STRING BOX Z SANTERNO wsraLLarION CARRARO GROUP 2 CAUTION STATEMENTS This section covers safety statements The non obse
68. erve these specifications will lead to a plant with low yields and possible malfunctions Do not install devices and or components dischargers return or switch terminals joins on the cables on the wiring between the JUNCTION BOXES and the modules As well as lowering the level of plant safety and performance malfunctions may occur or false signals may be generated by the anti theft system Only a single string is to be connected to each input Connecting more than one string in parallel to an input may lead to the maximum allowable current being exceeded and consequent failure If more inputs are needed use a box with a higher number of connections or split the field into subfields each one being served by a connection box Rev 02 29 04 2013 39 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 7 1 Connection with String Conductors The connection of the cables to the panels must be carried out along the shortest possible route in order to minimize loss in resistance in the cables and hence system losses In the following figure A the correct method of cabling is shown in a diagram STRING 1 HH EJS STRING 2 STRING N 000770 Figure 21 Cabling recommended for the parallel string modules 40 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box
69. fications Rated voltage of system 1000 V Maximum voltage of system 1120 V Back up power supply 4A Rated discharge current 20 kA Response time 25 ns Residual current 1 mA Configuration Y connection of three SPDs to varistor UP level of protection L L L PE 3 8 kV L tightening torque 2 8 Nm Remote Signal Contact Type 1 NO NC Minimum range 12Vdc 10 mA Maximum range 250 Vac 1 Cable section 1 5 mm2 Ambient Conditions Operating temperature 40 80 Maximum altitude 2000 General Specifications Removable cartridges Yes UL94 Fire resistance V0 100 106 Table 53 SPD technical specifications Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO 3s smartstrinc CARRARO GROUP 12 9 Environmental Sensors Acquisition The nominal specifications for the environmental measures analogue inputs are indicated in the table below WARNING If the maximum minimum input or output voltage ratings are exceeded irreparable damage to the equipment may occur e NOTE The isolated power supply output and the analogue auxiliary output are protected by a resettable fuse capable of protecting the power supply unit inside the inverter against faults following a short circuit but it cannot be guaranteed that the inverter will temporarily cease operation in the event of a short circuit ANALOGUE INPUTS Rating Analogue inputs confi
70. g method of calculation is used Calculation of the nominal Calculation of coefficients Condition output current Ktot Kt x Ka If Ktot 2 1 Unchanged Ktot Kt x Ka If Ktot lt 1 Rated output current reduced by a Ktot factor Table 40 Calculation of the rated current reduction coefficient Rev 02 29 04 2013 91 106 SMART STRING BOX Z SAN TERNO CARRARO GROUP INSTALLATION GUIDE 12 4 Dimensions and Weights Product name Dimensions WxHxD mm Weight Kg CS SP A 8 600V 1000x300x185 22 5 CS SP A 16 600V 1600x300x185 32 CS SP A 24 600V 2200x300x185 41 5 CS SP A 8 800V 1000x300x185 22 5 CS SP A 16 800V 1600x300x185 32 CS SP A 24 800V 2200x300x185 41 5 CS SP A 8 900V 1000x300x185 22 5 CS SP A 16 900V 1600x300x185 32 CS SP A 24 900V 2200x300x185 41 5 CS SP A 8 1000V 1000x300x185 22 5 CS SP A 16 1000V 1600x300x185 32 CS SP A 24 1000V 2200x300x185 41 5 P001016 A Table 41 SMART STRING BOX dimensions and weights 12 4 1 Mechanical Dimensions 1018 MAX 600 400 165 218 CS SP A 8 1000 370 O 0 oi
71. grated Standard Functions The main integrated standard functions of SMART STRING BOX are listed below Possibility to connect 8 24 strings Measurement of each individual string current Mismatch detection String opening alarm and detection of poor performance Two environmental measurements radiation and temperature Fuses on the positive pole DC disconnect under load device Surge Protection Device Signalling contact for DC disconnecting switch status Signalling contact for SPD status Quick fit PV connectors Release coil at charge release for roof installations in compliance with fire prevention prescriptions Polycarbonate flameproof and UV ray resistant box Degree of protection IP65 Serial communication system completely integrated with the Elettronica Santerno remote control system with alarm indication in the event of communication loss Advanced self diagnostics Complete integration with the Sunway Station Rev 02 29 04 2013 11 106 CARRARO GROUP SMART STRING BOX Z SANTERNO installation 1 3 Optional Functions The main optional functions of SMART STRING BOX are listed below Fuses installed on the negative pole by using the FUSE BOX fuse expansion box Version without anti inversion diodes and 10A string rated current The rated current and the maximum output current is left unchanged Version available for the configuration without
72. gured in 0 10 V mode Min Typ Max Unit Input impedance 40 kQ Cumulative offset and gain error in relation to full scale value 0 5 96 Temperature coefficient of the offset and gain error 200 Digital resolution 12 bits Voltage LSB value 2 44 mV LSB Permanent overload on the inputs without causing damage 30 30 V Input filter cut off frequency low pass first order filter 1 Hz Table 54 Analogue inputs configured in 0 10 V mode Rev 02 29 04 2013 101 106 SMART STRING BOX Z SANTERNO instalation CARRARO GROUP Rating Analogue inputs configured in 0 20 mA mode Min Typ Max Unit Input impedance 40 Cumulative offset gain error relation full scale value 0 5 96 Temperature coefficient of the offset and gain error 200 Digital resolution 12 bits Voltage LSB value 2 44 mV LSB Permanent overload on the inputs without causing damage 3 7 30 V Input filter cut off frequency low pass first order filter 1 Hz Table 55 Analogue inputs configured in 0 20 mA mode Rating Analogue inputs configured in 0 100 mV mode Min Typ Max Unit Input impedance 1 MO Cumulative offset and gain error in relation to full scale value 0 2 96 Temperature coefficient of the offset and gain error 50 ppm C Digital resolution 12 bits Voltage LSB value 24 7 uV LSB Permanent overload on the inputs without causing damage 30 30 V Input
73. ime This heading describes all the activities required to keep machine parts which are subject to wear and deterioration and or components which are essential for guaranteeing safety and optimum performance in good condition Access to products for the purpose of maintenance modifications and management involves all persons responsible for production and maintenance It must be carried out in observance of the health and safety regulations described in section 2 5 The minimum maintenance interval is indicated in Table 32 Equipment installed in an environment where there is a high concentration of dust requires more frequent maintenance than generally indicated The activities described may involve stopping the inverter Once the maintenance procedure has been completed restart the inverter by pressing the START button 10 1 Maintenance Sheet Maintenance tasks Frequency recommended Box visual Inspection and Cleaning Every 6 months Check the state of connectors Every 12 months Check the state of cable glands Every 12 months Check the state of fuses Every 12 months Check the state of the disconnecting switch Every 12 months Check SPDs Every 12 months Check that cables and bars are securely tightened Every 12 months Check the condition of dataplate and warning signs Every 24 months The frequency of scheduled maintenance may need to be increased depending on the location in which the equipment is installed and
74. ing a theft alarm 6 ALR NO Alarm relay NO contact open following a theft alarm Table 20 Anti theft function terminals connector M9 7 6 Bus Communication Configuration and Connections Please refer to section 8 4 Rev 02 29 04 2013 51 106 SMART STRING BOX Z SANTERNO issrALLArTioN CARRARO GROUP 7 7 Disconnecting Switch and SPD Status Connections The SMART STRING BOX makes it possible to acquire disconnecting switch status or SPD status via the terminal present inside the DC SWITCH BOX Terminal Description 1 2 Disconnecting switch status contact NO 3 4 SPD status contact NC 5 6 Disconnecting switch release winding Table 21 Terminals for DC SWITCH BOX auxiliary contacts The CN5 connector on the SMART STRING BOX control board connected to the DC SWITCH BOX terminal signals an alarm condition if the two poles are opened The contacts on terminals 1 and 2 if open identify the open disconnecting switch only valid for the 16 and 24 string configuration The contacts on terminals 3 and 4 if open identify SPD tripping The diagram for the SMART STRING BOX disconnecting switch status signalling connections is illustrated in the figures below 8 string configuration 5 5 8 600 CS SP 8 600v Key to the cablet shown in the figure Cablet 1 connects the NC contact terminal 3 and 4 of the DC SWITCH BOX surge protection p001092
75. models and relative composition CS SP A 8 600V 800V 1 000V of f 8t L000S Figure 9 Composition of a SMART STRING BOX Rev 02 29 04 2013 25 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 4 1 1 Output Section DC SWITCH BOX DC SWITCH BOXES are distinguished by current capacity and PV field voltage class All DC SWITCH BOXES are fitted with a Surge Protective Device SPD DC SWITCH BOX Description B SEZ P 100A 600V DC SWITCH BOX 100 Class 600V B SEZ P 160A 600V DC SWITCH BOX 160 A Class 600V B SEZ P 250A 600V DC SWITCH BOX 250 A Class 600V B AUT P 100A 800V DC SWITCH BOX 100 A Class 800V 900V 1000 V B AUT P 160A 800V DC SWITCH BOX 160 A Class 800V 900V 1000 V B AUT P 250A 800V DC SWITCH BOX 250 A Class 800V 900V 1000 V Table 4 DC SWITCH BOX by current and voltage size 0 0 A O
76. mon power supply zero volt signal circuits Table 14 Power supply input output terminals M13 connector o WARNING For safety reasons terminal M13 can also be found on the bracket outside the Lexan safety panel 2 9 ot 209 Description terminals signal 1 LINE 230 Vac 50 60 Hz power supply input 2 NEUTRAL 3 EARTH EP Safety conductor EARTH Table 15 230 Vac power supply connections connector M12 For the rated power supply technical characteristics please refer to heading 12 2 46 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 7 4 Environmental Measures Confiquration and Connections Each JUNCTION BOX has two configurable analogue environmental measure inputs Each input can be connected to solarimeters thermometers with 0 100 mV 0 10 V 4 20 mA PT100 outputs The M10 terminal board has three terminals for each analogue measure the signal terminal the common terminal and the excitation terminal for a 3 wire PT100 thermistor measure Before connecting the signal conductors it is necessary to set the relative configuration corresponding to the type of input signal on the SW1 dip switch located next to terminal board M10 see Figure 13 rd Pee e 15 PT100 EXC 0 Excitation output for PT100 thermistor channel 0 16 ACHO Configurable measure input channel 0 17 OV Common measure 0 Zero volt signal circuits
77. n the presence of live voltage hence in the daytime A DANGER Correct connection of the strings to the JUNCTION BOX must be checked by expert personnel only using all the necessary safety devices and precautions Make sure that the inverter connected to the SMART STRING BOX is NOT running i e that it is STOPPED Open the switch on the DC side of the converter Make sure that the disconnecting switch on the DC SWITCH BOX is open Remove the cover from the JUNCTION BOX The Lexan safety panel must be left in its seat With the aid of a multimeter check the polarity of the strings between the positive pole input terminal of each individual string and a negative pole input terminal If a string connection error is found Disconnect the inverted string from the JUNCTION BOX connector Correct the wiring of the inverted string invert the connectors of the positive and negative poles from the panels Once the strings have been correctly wired restore all the conditions for plant operation Replace the cover on the JUNCTION BOX Connect the strings to the quick fit connectors Close the disconnecting switch on the DC SWITCH BOX Close the switch on the DC side of the inverter Rev 02 29 04 2013 83 106 SMART STRING BOX Z SANTERNO installation CARRARO GROUP 11 8 How to Contact the CUSTOMER SERVICE Should it be necessary to contact the Elettronica Santerno SpA CUSTOMER SERVICE plea
78. nput section is safe including the DC Parallel if installed If the fault has occurred in one of the String Boxes open all the strings connected in input and open the disconnecting switches of all the String Boxes in order to place all the equipment in safety conditions including the cable output section Proceed with analysis of the causes and consequences of the fault q NOTE If necessary please contact the Elettronica Santerno SpA CUSTOMER SERVICE Rev 02 29 04 2013 81 106 CARRARO GROUP SMART STRING BOX Z SANTERNO wsraLLariON 11 6 2 Fault Analysis This section covers the main principles to be observed when analysing the causes and consequences of faults A PV inverter usually operates as part of an overall system All the components adopt various protective measures therefore in general the consequences of a generic fault affecting an upstream component or element does not extend to other components downstream However the causes and the consequences of any faults which may arise need investigating on the plant as a whole Fault investigation and analysis activities represent one of the most hazardous tasks assigned to maintenance technicians This manual only provides indications of an extremely generic nature concerning the precautions which must be adopted when fault investigation and analysis activities need to be carried out on live components In the event of a fault before proceeding to re
79. nufacturer s reference Cembre 2 5 4 6 5 10 4 mm2 cables 412 6 mm2 cables PDK 612 106 106 Table 62 FUSE BOX cable connection Rev 02 29 04 2013
80. off all the unused cable glands 10 1 4 Checking Fuses Routine maintenance entails checking the continuity of the fuses installed in the JUNCTION BOXES of the SMART STING BOXES and STRING BOXES Visually inspect the installed fuses and the fixing springs on the fuse holders inside the JUNCTION BOXES Rev 02 29 04 2013 73 106 CARRARO GROUP SMART STRING BOX Z SANTERNO installation 10 1 5 Checking the SPDs A DANGER Electric shock and burns hazard coming into contact with live PV field or grid components can lead to serious injury and even death NEVER work on the equipment unless it is switched off and disconnected from the power supply Inspect the state of the SPDs Surge Protective Devices by checking the status of the button slot on the discharger The exact position of the SPDs can be seen on the Electrical and Mechanical Diagram P001150 0 Figure 52 Surge Protective Device Button slot status SPD Status Button slot with green indicator visible SPD ready for use Button slot with red indicator visible SPD faulty Please refer to Table 54 74 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 10 1 6 Checking Tightening In order to guarantee correct tightness of the electrical contacts periodical checking of the tightening torques is to be carried out over the equipment s life cycle Pay particular attention to any colo
81. oltage 0 100 mV 0 100 mV f s mode 0 100 mV Current 0 20 mA 0 20 mA f s mode 0 mA 20 mA Current 4 20 mA 0 20 mA f s mode 4 mA 20 mA Temperature reading with PT100 50 120 Table 19 Environmental measures factory settings It is preferable to carry out connection of the environmental sensors with a shielded cable connecting the shield to the GND OV terminal and leaving it free on the opposite side It is preferable to connect the 3 wire PT100 thermistor to eliminate the residual resistance of the wire carrying the excitation current Correct connection is illustrated in the figure below P000907 B PT100 RTD 1 Thermoresistors inputs 0V control board Figure 27 Connection of the 3 wire PT100 thermistor 48 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box If 3 wire PT100 sensors are not used it is still preferable to connect the excitation terminal near the sensor q NOTE It is necessary to set the software parameters to match the dip switch settings Hardware configuration settings which do not correspond with the type of acquisition set in the parameters produce results which do not reflect the values actually acquired A voltage or current value which exceeds the upper full scale value or is less than the lower full scale value produces a saturated acquired value of the maximum and minimum measures respectivel
82. on to the Sunway DC Parallel cabinet see figure below When this happens the current from all the strings bar one is localized in the section of cable between the point where the short circuit has occurred and the connection to the Sunway DC Parallel Rey 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP STRING BOX n 1 DC PARALLEL 2 m 4 2 1 4 x Lex x EN H 5 4 www STRING BOX 2 2 l STRING BOX nN x x AY am mE bl xh oT Figure 26 Short circuit located downstream from the SMART STRING BOX Fault caused by a short circuit on the output cables must be envisaged during the design phase and appropriate protective measures adopted If the PV plant is made up of more than one SMART STRING BOX the Sunway DC Parallel effectively solves this problem If the PV plant is made up of a very small number of SMART STRING BOX a connection directly to the inverter can be envisaged without inserting fuses as long as the cables are
83. onnection Switch 33 4 6 Emergency Disconnecting Switch Opening a 33 5 STORAGE AND TRANSPORT uuu u lz u emite ka citur cet tum pun etum 34 5 1 Conditions for Transport d 34 5 2 Environmental Requirements for Storage and 34 6 HANDLING AND ASSEMBLY 35 6 1 Assembly of the Product on the Installation Site 36 6 1 1 Accompanying Materials ssassn a reet ae E niu o aig 37 7 COMMISSIONING a a 39 7 1 Connection with String Conductors r 40 7 1 1 Version with Cable Gland and Terminals a 41 7 1 2 Version with Quick fit Connectors u a 41 7 2 Connection to the Inverter 43 7 2 1 Protection Devices against Short Circuit sese 44 7 3 Power Supply Configuration and 46 2 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc CARRARO GROUP 7 4 Environmental Measures Configuration and Connections 47 7 5 An
84. ording to IEC 60721 3 3 Table 33 Installation specifications for SMART STRING BOX 86 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 12 3 Electrical Specifications SMART STRING BOX U M 600V 800V 900V 1000V Maximum DC input voltage V 740 Vdc 880 Vdc 900 Vdc 1000 Vdc 12 PV rated 10 38 DC string fuses positive A pole Additional fuse sizes available to be defined when ordering the equipment Input current Impp Impp A 8 Max input current Isc A 10 Uc Pulse withstanding kV 4 kV Strings inputs voltage 4 kV DC output Table 34 SMART STRING BOX electrical specifications with anti inversion diodes SMART STRING BOX without anti inversion U M 600V 800V 900V 1000V diodes Maximum DC input voltage V 740 Vdc 880 Vdc 900 Vdc 1000Vdc 12 A PV rated 10x38 DC string fuses positive pole A Additional fuse sizes available to be defined when ordering the equipment Input current Impp Impp A 10 Max input current Isc A 11 4 kV string i Uc Pulse withstanding sum put voltage 4 kV DC output Table 35 SMART STRING BOX electrical specifications with anti inversion diodes SMART STRING WITHOUT ANTI THEFT SYSTEM WITH 24h 24h ANTI THEFT BOX Versions 600V 800V Version 1000V SYSTEM 900V From 230 Vac grid From 230 Vac Power suppl From PV field From
85. ore replacing a blown fuse all the tasks described in section 11 6 1 and 11 6 2 must be performed PROCEDURE FOR REPLACING STRING FUSES To replace a fuse proceed as follows To extract the blown fuse o Use the special insulated fuse extractor See Figure 53 o Standin front of the fuse holder o Take hold of the fuse with the extractor perpendicular to the electronic card o Give a sharp pull to remove To insert a new fuse o Use the special insulated fuse extractor Please refer to Figure 54 o Standin front of the fuse holder o hold of the new fuse with the extractor o Position the fuse in the fuse holder keeping the extractor perpendicular to the electronic card o Firmly push the fuse into place Rev 02 29 04 2013 79 106 SMART STRING BOX SANTERNO wmsraLLarioN LE 000 Figure 54 Fuse installation using the fuse extractor 80 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box Once the fuse has been replaced restore all the conditions for plant operation Replace the Lexan safety panel Replace the cover Restore the auxiliary power supply if present for SMART STRING BOX only Connect the strings Close the disconnecting switch on the DC SWITCH BOX Close the switch on the DC side of the inverter 11 6 General Principles in the Event of Failure Access to the PV system components for the purpose of maintenance
86. r cables 2 External sensors input 2 three pole cables 3 Strings inputs Up to 16 8 positive amp 8 negative 4 Single phase 230 Vac power supply 2 three pole cables input output 5 Output for signals to anti theft control unit 1 four six pole cable 6 Earth connection EP 1 single pole cable Table 9 JUNCTION BOX cables 30 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z CARRARO GROUP The figure below shows the equipment s internal electrical diagram SANTERNO smartstrinc Box B S 8 Beare VB VB VB VB ot VB 00 90 00 TAI TA2 TA3 TA4 TA5 TA6 TA7 TA8 q N n LC cO 2 gt s S S Ss SG SG SG SG we d E T E F L XL O XL se d XD 0 oO EN E O D Ps 92 pr E D P P P 7 gt gt o m 2 t 38 8 5 B 5 5 da 5 E 5 5 an p eo A Va M e 9 en on Lo gh gt x B b 4 di o 9 a v 0 2000802 B Rev 02 29 04 2013 Figure 15 JUNCTION BOX electrical diagram 31 106 SMART STRING BOX Z SANTERNO instalation CARRARO GROUP 4 1 3 SMART S
87. ring and theft signalling 50 Anti theft connection with cumulative signalling for more than one SMART STRING BOX 50 SPD status signalling connection diagram eee 52 SPD and disconnecting switch status signalling connection diagram 53 ELV zone dedicated to Modbus RS485 and environmental sensors communication 55 Recommended multidrop connection diagram 56 8 string SMART STRING BOX connection 57 Details of 8 string SMART STRING BOX connection 57 16 string SMART STRING BOX connection 57 Details of 16 string SMART STRING BOX connection terminals 58 24 string SMART STRING BOX connection diagram eee 58 Details of 24 string SMART STRING BOX connection terminals 58 Communication line terminator DIP switch 1 enne 61 16 input SMART STRING BOX cablet sse nnne 62 24 input SMART STRING BOX cablet sse ener nnne nennen 63 FUSE BOX Pm 64 B F 8 FUSE BOX 60V r uuu cocer oit ct er nde Feeds rd Dn den POR dco
88. rvance of the safety instructions below may cause serious injury or death and equipment failure Carefully read the instructions below before installing starting and operating the equipment Only competent personnel must carry out the equipment installation SAFETY RECOMMENDATIONS TO FOLLOW DURING USE AND INSTALLATION OF THE EQUIPMENT q NOTE Always read this instruction manual thoroughly before starting the equipment A DANGER ALWAYS EARTH THE EQUIPMENT OBSERVE THE PRESCRIPTIONS CONCERNING CONDUCTOR SECTION INDICATED IN SECTION 12 6 3 Q WARNING Do not connect supply voltages which exceed the rated voltage If voltage exceeding the rated value is applied the internal circuits may be damaged In the event of an alarm please consult section 11 TROUBLESHOOTING Only restart the equipment once the problem has been rectified Do not carry out isolation tests between the power terminals or between the control terminals Make sure that the screws on the connection terminal board have been tightened correctly Observe the ambient conditions for installation The electronic boards contain components which are sensitive to electrostatic charges Do not touch the boards unless absolutely necessary Should this be the case take all the necessary precautions to prevent damages caused by electrostatic charges 16 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 2 1 Precautions for U
89. s 1x PG11 5 10 1 5 Table 49 terminals cable section Min Max external Max cable section Description No of cable glands cable diameter mm mm Power supply terminals cable section M13 power supply input output 1x PG11 5 10 1 Power supply from grid 230 V M12 3 x PG11 5 0 1 5 Environmental measures cable section Environmental Measures M10 2 x PG11 5 10 1 Communication cable section RS485 Modbus M11 2 x PG11 5 10 1 Section of anti theft function cables to the external control unit Anti theft function M9 1x PG11 5 0 1 Table 50 Connection of signal cables 98 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z CARRARO GROUP 12 6 5 Connection of Internal Components 8 rak EE SANTERNO suanrsrniNc 9000 Figure 64 SMART STRING BOX view Key Description Torque Nm A Copper bars for internal power connections 10 Table 51 Tightening torques 12 7 Output Disconnect Switch Release Coil Release coil Voltage Inrush Power Type 220 240V AC AC 100 VA i 1SDA 051342 R1 ABB SACE 220__ 250V DC DC 120 W Shunt opening Rev 02 29 04 2013 Table 52 Output disconnect switch release coil 99 106 SMART STRING BOX Z 12 8 SPD SANTERNO CARRARO GROUP Technical specifications for SPDs are provided in the table below INSTALLATION GUIDE Technical Speci
90. s 65 B F 8 module internal U I u u 67 FUSE BOX module bottom sitne nens 67 FUSE BOX electrical diagram U ener nennen nennen 68 Diagram of negative pole connection of the strings to the FUSE 69 STRING BOX connection with optional fuse expansion box 70 FUSE BOX en tenen 70 FUSE BOX wall Imoa 0ntillg 71 Surge Protective Device nensis nnns sitet 74 Fuse extraction using the fuse extractor U U U u uu uu 80 Fuse installation using the fuse extractor 80 SMART STRING BOX dataplate sss ennemis 85 Rev 02 29 04 2013 5 106 SMART STRING BOX Z SANTERNO wmsraLLariON CARRARO GROUP Figure 56 Product revision label n eere een nece adie canteen eee 86 Figure 57 Coefficient Kt for temperature derating at sea level a 90 Figure 58 Coefficient Ka for altitude Aerating sse entente 91 Figure 59 8 string SMART STRING BOX intres 92 Figure 60 16 string SMART STRING BOX n nus 93 Figure 61 24 string SMART STR
91. s technical specifications are indicated on the box cover 041000S 2 SANTERNO FUSE BOX PERICOLO FOLGORAZIONEI NON RIMUOVERE IL COPERCHIO PARTI PERMANENTEMENTE SOTTO TENSIONE CONSULTARE IL MANUALE DI ISTRUZIONI DANGER ELECTRICAL SHOCK HAZARD DO NOT REMOVE THE COVER PARTS PERMANENTLY UNDER VOLTAGE SEE THE OPERATION MANUALI ZZES9H0000 B F 8 FUSE BOX INPUT 8x 8A 1000 Vdc MAX C OUTPUT 8x 8A 1000 Vdc MAX MADgAM TA Rev 02 29 04 2013 ZZES9H0000 B F 8 FUSE BOX INPUT 8x8A 1000 Vdc MAX OUTPUT 8x8A 1000 Vdc MAX MADE II Figure 44 B F 8 FUSE BOX cover 65 106 CARRARO GROUP SMART STRING BOX Z SANTERNO wmsraLLariON The following items are provided in the package with each individual FUSE BOX No Description 8 PG11 screw plugs for closing any unused cable glands These are to be inserted on the box during the wiring phase 17 PG11 cable glands 8 Fuses Set of 2 screws for the cover Box installation kit made up of 4 stainless steel 6x20 screws 4 stainless steel M6 cage nuts 4 stainless steel M6 flat washers 4 stainless steel M6 split washers plus support bar 66 106 Table 29 Accompanying Materials Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 9 1 3 Internal View Electrical and Connections Diagram The figure below shows a drawing of the appliance s interior when the upper
92. se and Prohibitions AN DANGER RISK OF ELECTRIC SHOCK NEVER carry out operations on the equipment when it is powered EXPLOSION AND FIRE RISKS The risk of explosion or fire may exist if the equipment is installed in a room containing flammable vapours Do not install the equipment where there is a risk of explosion or fire Q PROHIBITION The product described in this manual has not been designed to operate in potentially explosive atmospheres Consequently installation in such an environment is strictly prohibited Q PROHIBITION It is forbidden to make any technical or mechanical modifications to the cabinet even when out of warranty Elettronica Santerno is not responsible for any risks that may arise due to unauthorised alterations modifications or tampering Q PROHIBITION It is strictly prohibited to operate inside the SMART STRING BOX to carry out short circuit tests concerning the strings Any system testing must be carried out on the individual strings only once that have been disconnected from the SMART STRING BOX 22 Intended Use The SMART STRING BOX constitute a modular system for creating parallel strings for PV modules The product envisages a DC SWITCH BOX in output which is capable of excluding connection of the PV field subsection Observe the maximum operating voltage indicated in the product technical characteristics found in section 11 TROUBLESHOOTING The product must only be used as prescribed in
93. se provide the following data Equipment model Serial Number Date of commissioning Order confirmation reference if available It is advisable to recover the following information from the memory Number of operating hours please refer to the Programming Guide Alarms history please refer to the Programming Guide This operation can be carried out using the Remote Sunway program with local or remote connection q NOTE Should it be necessary to send the equipment in for repair or to return the equipment contact the Elettronica Santerno SoA CUSTOMER SERVICE to agree upon the terms 84 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z 12 TECHNICAL DATA Q CAUTION SANTERNO suanr sTrRiNG Box CARRARO GROUP Power supply must be ensured by an external power supply source either the 230 Vac mains or the auxiliary power supply 12 1 Dataplate Each dataplate indicates the product s technical data and identification details Name of the product Part number assigned to the product by Elettronica Santerno Technical data rated input output voltage and current rated power etc CE marking and indications of the relative reference Standards applied in the construction of the equipment CE is a registered collective trademark Product revision index Serial Number identifies the product serial number The dataplate measures 100 x 70 mm and is silver in colour ZZ
94. solve the problem the following tasks must be performed to evaluate The state of components and the system as a whole o Check the state of the contacts o Check the state of cables o Check the status of any interface protection installed in the system o Check the state of all protective elements installed in the system o Check the state of any auxiliary power supplies o Check the level of humidity present on system components If faults have occurred on each box inverter and or the system o Check for any earth faults on the DC side and the AC side o Make sure all prescriptions have been observed relative to the neutral connection or those relative to field configuration floating Positive Earthed Negative Earthed o Check the state of the SPDs and relative fuses Once all the aforementioned steps have been performed proceed with evaluating The causes of faults The consequences of faults on the electrical electromechanical and electronic components The steps to be taken to remove the cause of the fault Once all the aforementioned steps have been performed proceed with rectifying the causes of the fault q NOTE If necessary please contact the Elettronica Santerno SpA CUSTOMER SERVICE 82 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 11 7 Revision of String with Inverted Polarit Correct connection of the strings to the JUNCTION BOX must be checked i
95. t outside without its cover in any kind of weather conditions except for the time strictly necessary to perform the assembly and commissioning operations 9 WARNING The SMART STRING BOX must be installed with the cable input output side pointing downwards Avoid installing the product where it may be exposed to direct sunlight Do not install the SMART STRING BOX upside down or horizontally Make sure that air can circulate freely around the box 9 WARNING Every time the SMART STRING BOX is opened and reclosed it must be done to the highest working standards ensuring that the product remains intact and that no damage is caused to the sealing and fixing elements Before reclosing the cover always check that the inside of the SMART STRING BOX is free from condensate or water residues if this is not the case the product must be placed in safety conditions please refer to section 2 7 and thoroughly dried out Correctly tighten the screws on the closure cover please refer to section 12 5 making sure that the correct degree of watertightness is restored Rev 02 29 04 2013 35 106 CARRARO GROUP SMART STRING BOX Z SANTERNO wmsraLLarioN 6 1 Assembly of the Product on the Installation Site 9 WARNING Being as the ambient conditions significantly affect the life expectancy of the product do not install it where water build up may be created due to dips in the installation surface or where it may be exposed to const
96. the relevant ambient conditions Table 32 Maintenance Sheet 72 106 Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO smartstrinc Box CARRARO GROUP 10 1 1 Box Visual Inspection and Cleaning Visually inspect the state of cables Check that cables show no signs of damage caused by rodents and remove any insects Check to see if any condensation has formed inside the equipment Should this be the case clean with a cloth find out where water is getting in and rectify the problem General box cleaning Check the watertightness of the casing and for any signs of damage Check that the cover is correctly positioned and consequently that IP65 protection is guaranteed Check that no wires clamps or anything else has inadvertently been left under the cover Check that the screws used for securing the cover in place are in good condition If necessary replace with screws supplied with the product or request spares from the Elettronica Santerno SpA CUSTOMER SERVICE 10 1 2 Checking the Connector Status Check the state of the quick fit PV connectors in the JUNCTION BOXES Check that connectors are firmly inserted Check that the cable is correctly crimped on each connector Close off all the unused connectors 10 1 3 Checking the Cable Glands Status Check the state of the cable glands in the JUNCTION BOXES Check that cable glands are securely tightened around the cable Close
97. ti theft System Connections tuens pent ba pH Yao aa DU EGRE 49 7 5 1 Large scale Systems sse enne entes nnns nnne tenens 49 7 5 2 Small scale Systems iridioa esent enitn entres 50 7 6 Bus Communication Configuration and Connections 51 7 7 Disconnecting Switch and SPD Status Connections 52 7 8 Disconnect Switch Release Coil Connections 53 8 COMMUNICATIONS AND REMOTE 54 8 1 apaq 54 8 2 Communication Ports and Protocol Used 55 8 3 Connection Topologies Heu ka has rae REO rsssnnssrssssssssssssssssa 56 8 4 NONE ceca ata ete a d eee 59 8 4 1 RS485 Bus Main Principles eese eene 59 8 4 2 RS9485 POIL iiic SOR dea ope n ba uuu eed auod ae CR n 60 8 4 3 Internal Bus RS485 Gables 2 62 8 4 4 Bus Communication Installation Procedure 63 SMS ID RS IE PP 64 9 1 Quir q R T QC 64 9 1 1 Product BERG m 64 9 1 2 Checking the Product on Delivery I n nan 65 9
98. ur variations or anomalies affecting the terminals and copper bars Replace any damaged connections or corroded contact elements Check the tightness of all the terminal clamps for connecting the power wiring and tighten if necessary The tightening torques can be found in section 12 6 Rev 02 29 04 2013 75 106 CARRARO GROUP SMART STRING BOX Z SANTERNO wmsraLLarioN 11 TROUBLESHOOTING SMART STRING BOX products are completely protected against short circuits and overvoltage caused by system failure or temporary phenomena Furthermore the control system performs complete self diagnosis operations to help personnel solve any problems which may occasionally arise The modular design of Elettronica Santerno inverters makes repair and or reset operations quick and easy to perform This chapter indicates the most likely causes of the most common problems The steps to be taken to remove these causes are also described 9 WARNING To carry out the following operations check that the parallel string box is in safety conditions Please refer to section 2 7 q NOTE If necessary please contact the Elettronica Santerno SpA CUSTOMER SERVICE 11 1 Self Diagnostics The SMART STRING BOX s self diagnostics system detects and records most malfunctions and provides technical support elements which are useful for problem solving The elements providing support for diagnostic functions which are accessible in remote and or lo
99. urrent Impp Impp A 8 Max input current Isc A 10 String cable section 4 6 Uc Pulse withstanding kV 4 kV Strings inputs voltage 4 kV DC output Table 58 FUSE BOX Electrical Specifications U M CS BF 8 CS BF 16 CS BF 24 INPUT Max number of strings No 8 16 24 OUTPUT Maximum output power A 80 160 240 104 106 Table 59 FUSE BOX technical data Rev 02 29 04 2013 INSTALLATION GUIDE Z SANTERNO CARRARO GROUP SMART STRING BOX 12 10 2 Dimensions and Weights Product name Dimensions WxHxD mm Weight Kg CS BF 8 300x341x134 3 CS BF 16 600x341x134 6 CS BF 24 900x341x134 9 Table 60 FUSE BOX dimensions and weights 300 E 18 300 2 341 aco CO je e P0009 16 0 oO Figure 65 FUSE BOX CS BF 8 dimensions For the clearances to be observed see section 12 4 2 for the SMART STRING BOX Rev 02 29 04 2013 105 106 SMART STRING BOX Z 12 10 3 Cable Connection SANTERNO CARRARO GROUP INSTALLATION GUIDE Cable No of cables String cables Earth cable Max 16 8 in input 8 in output 1 Table 61 Number of FUSE BOX cables Tightening torque Min Max Min Max external String cable header of terminals Nm conductor section cable diameter mm mm Pipe ferrule ma
100. vent of a short circuit The PV generator grid is usually an IT type i e it is only earthed in the event of a fault or energy leakage For connection to PV fields with earthing pole connection is of the TN type but the earth connection is protected by a fuse which may trip in the event of a single fault In the event of a fault for example a short circuit cutting off a generator with a high number of branches may prove to be somewhat difficult Take great care to ensure each sub field disconnecting switch has been opened before going near the devices installed in the technical room 18 106 Rev 02 29 04 2013 CARRARO GROUP INSTALLATION GUIDE Z SANTERNO smartstrinc Box 2 5 Execution of Work Maintenance configuration modifications and management operations require the involvement of all production and maintenance personnel These activities must be carried out in observance of health and safety regulations The Standards and Laws governing this aspect vary depending on the personnel involved methods of access and or the tasks which may be carried out on the product and envisage constructive measures aimed at guaranteeing adequate levels of safety Standard EN 50110 1 second edition identifies the people who are granted access to the product Person in charge of running the electrical system System Manager Person in charge of work activities Works Supervisor Skilled electrician Instructed person
101. ween the SMART STRING BOX and the inverter onto the bars in the DC SWITCH BOX Use the special cable glands Connect the cables with suitable cable lugs to the and bars in accordance with the prescriptions in Table 48 Tighten the cable glands Leave the DC SWITCH BOX disconnecting switch open until the string conductors have been connected Rev 02 29 04 2013 43 106 SMART STRING BOX Z SANTERNO CARRARO GROUP 0 0 ol lo e _ _ 18 o Qoo I Wess Vane o He AA X CABLE GLAND CABLE GLAND P001071 B Figure 25 DC SWITCH BOX position of cable glands The conductors in output towards the inverter or the Sunway DC Parallel cabinet for the subfields parallel may be single or double conductors two parallel single pole con
102. wo prescribed terminators have been installed on a line some drivers may enter protection mode for thermal overload thus blocking the communication of some devices Elements participating in a RS485 section are called nodes The maximum number of nodes which can be connected on a section is limited to the following aspects Logic limit of the bus equal to 247 Length of the connection Transmission speed Electronic drivers used The limit set by the line drivers used in Sunway TG models is 30 devices It is not advisable to use section lengths exceeding 500m Should it be necessary to connect more than 30 devices on the same line or over a length exceeding 500 m it is advisable to break the connection up into more than one section using RS485 repeaters q NOTE The RS485 bus default rate is 38400 baud It is not advisable to exceed this value In the event of communication disturbances it is possible to set the rate at a lower value 19200 or 9600 baud For correct communication within the range of the multidrop chain it is necessary to allocate a univocal address to each JUNCTION BOX Rev 02 29 04 2013 61 106 CARRARO GROUP SMART STRING BOX Z SANTERNO installation By default each JUNCTION BOX has a Modbus address composed of the last two digits of the serial number Should it be necessary to change it follow the bus communication INSTALLATION PROCEDURE Q NOTE The voltage values for the bus in standby
103. y 9 WARNING The inputs configured for voltage have a high input impedance and must never be left open if active Isolating a conductor relative to an analogue input configured as a voltage input does not guarantee that the channel reading will be zero Zero is only correctly detected if the input is wired to a low impedance or short circuited signal source Therefore do not put relay contacts in series on the inputs to reset the reading For the technical characteristics please refer to section 12 9 7 5 Anti theft System Connections 9 CAUTION Power supply must be ensured by an external power supply source either the 230 Vac mains or the auxiliary power supply 7 5 1 Large scale Systems The anti theft function in the SMART STRING BOX is perfectly integrated with the Elettronica Santerno remote control system Regular access to instant overall and specific system data Data Logging with analysis of the performance of each individual plant section Management of fault and malfunction situations by means of alarm messages sent via e mail or SMS The anti theft function is designed to detect removal of modules from the system When a theft is detected it is recorded in the control board status JUNCTION BOX then the event is transmitted to the supervision system which immediately sends an alarm message to the user To ensure security the supervision system is designed to check communication signals continuously If

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