Operating Manual MULTICLUSTER BOX 12

Transcription

1 Operating Manual MULTICLUSTER BOX 12 MC-BOX BE-en-10 Version 1.0 ENGLISH

2 Legal Provisions Legal Provisions The information contained in this document is the property of. Publishing its content, either partially or in full, requires the written permission of. Any internal company copying of the document for the purposes of evaluating the product or its correct implementation is allowed and does not require permission. SMA Warranty You can download the current warranty conditions from the Internet at Trademarks All trademarks are recognized, even if not explicitly identified as such. A lack of identification does not mean that a product or symbol is not trademarked. The BLUETOOTH word mark and logos are registered trademarks owned by Bluetooth SIG, Inc. and any use of these marks by is under license. Modbus is a registered trademark of Schneider Electric and is licensed by the Modbus Organization, Inc. QR Code is a registered trademark of DENSO WAVE INCORPORATED. Phillips and Pozidriv are registered trademarks of Phillips Screw Company. Torx is a registered trademark of Acument Global Technologies, Inc. Sonnenallee Niestetal Germany Tel Fax info@sma.de 2004 to All rights reserved. 2 MC-BOX BE-en-10 Operating Manual

3 Table of Contents Table of Contents 1 Information on this Document Validity Target Group Additional Information Symbols Typographies Nomenclature Safety Intended Use Safety Information Scope of Delivery Product Description Multicluster Box Grounding in the Multicluster System Type Label Installation Storing the Multicluster Box Requirements for Mounting Preparing the Mounting Location Transport Transport Options Transporting and Mounting the Multicluster Box Electrical Connection Overview of the Connection Area Components and Terminals Enclosure Openings in the Floor Installing the Multicluster Box without Grid Connect Box or NA Box Connecting the Generator Connecting the Utility Grid Connecting the Loads Connecting the PV System Connecting the Sunny Island Inverters Grounding the Multicluster System Connecting the Control Cables Assignment of Spring-Cage Terminals Connecting the Control Cables of the Sunny Island Inverters Connecting the BatFuse Connecting the Control Cables to the Grid Connect Box Connecting the Control Cables to the NA Box Connecting the Data Cables for Measurement Signals and Communication Mounting the Kick Plates Operating Manual MC-BOX BE-en-10 3

4 Table of Contents 7 Preparing the Multicluster System for Commissioning Disconnecting the Multicluster Box and Multicluster System Periodic Actions Disassembling the Protective Cover Mounting the Protective Cover Inserting the Cables Inserting Power and Control Cables Inserting Data Cables Connection to Spring-Cage Terminals Connecting Power Cables to Spring-Cage Terminals Connecting Control Cables to Spring-Cage Terminals Maintenance Inspection of Residual-Current Devices Maintenance Work every 12 Months Decommissioning Disassembling the Multicluster Box Disposing of the Multicluster Box Technical Data Multicluster Technology Terms Contact MC-BOX BE-en-10 Operating Manual

5 1 Information on this Document 1 Information on this Document 1.1 Validity This document is valid for the device type MC-BOX (Multicluster Box 12). 1.2 Target Group The activities described in this document must only be performed by qualified persons. Qualified persons must have the following skills: Training in how to deal with the dangers and risks associated with installing and operating electrical devices and batteries Training in the installation and commissioning of electrical devices Knowledge of and adherence to the local standards and directives Knowledge of and compliance with this document and all safety information 1.3 Additional Information Links to additional information can be found at Document title GRID CONNECT BOX 12 NA BOX 12 SUNNY ISLAND 3.0M / 4.4M / 6.0H / 8.0H BATFUSE- B.01 / B.03 Document type Operating manual Operating manual (document only available in German) Installation manual Operating manual 1.4 Symbols Symbol Explanation Indicates a hazardous situation which, if not avoided, will result in death or serious injury Indicates a hazardous situation which, if not avoided, can result in death or serious injury Indicates a hazardous situation which, if not avoided, can result in minor or moderate injury Indicates a situation which, if not avoided, can result in property damage Information that is important for a specific topic or goal, but is not safety-relevant Indicates a requirement for meeting a specific goal Desired result A problem that might occur Operating Manual MC-BOX BE-en-10 5

6 1 Information on this Document 1.5 Typographies Typography Use Example bold 1.6 Nomenclature Display messages Parameters Terminals Slots Elements to be selected or entered > Links several elements to be selected [Button/Key] Button on device to be selected or pressed Connect the neutral conductor to the spring-cage terminal N at terminal X102:4. Press the [TEST] button on each residual-current device in the Multicluster Box. Complete designation Multicluster Box 12 Grid Connect Box 12 NA Box 12 Designation in this document Multicluster Box Grid Connect Box NA Box 6 MC-BOX BE-en-10 Operating Manual

7 2 Safety 2 Safety 2.1 Intended Use The Multicluster Box is the main AC distribution board in a multicluster system. The multicluster system forms an AC grid and is made up of several three-phase clusters. Three Sunny Island inverters are connected in parallel on the DC side of each cluster. The multicluster system can be set up with a stand-alone grid (as an off-grid system) or with increased self-consumption and battery-backup function (as a battery-backup system). Figure 1: Circuitry principle of a Multicluster Box The Multicluster Box is not suitable for supplying life-sustaining medical devices. A power outage must not lead to personal injury. Cables with copper wires must be used for the installation of the Multicluster Box. Do not exceed the maximum AC connection power of the Multicluster Box. Regarding interference immunity the product is suitable for EMC environment A, and regarding EMC emissions it is suitable for EMC environment B*. * in accordance with IEC :2011 Operating Manual MC-BOX BE-en-10 7

8 2 Safety Only a generator may be connected directly to the Multicluster Box. To connect the utility grid in addition to the generator, it is necessary to install either a Grid Connect Box or an NA Box between the utility grid and the Multicluster Box (for intended use of the Grid Connect Box / NA Box see operating manual of the Grid Connect Box / NA Box). The Multicluster Box is designed for connection to TN-S, TN-C-S and TT systems: If only the Multicluster Box is used, the multicluster system must be grounded outside the Multicluster Box on the generator side (see Section 6.8, page 23). If the Multicluster Box is used together with an NA Box, the utility grid can be a TN-S, TN-C-S or TT system (see operating manual of the NA Box). No additional grounding measures are required. If the Multicluster Box is used together with the Grid Connect Box, remember that the all-pole disconnection can be deactivated on the Grid Connect Box (see operating manual of the Grid Connect Box). If the all-pole disconnection on the Grid Connect Box is deactivated, the utility grid must be configured as a TN-C-S system (see Section 4.2, page 12). The Multicluster Box must only be operated in conjunction with Sunny Island 6.0H / 8.0H inverters with software release 3.5 or higher. Always take the maximum AC connection power and the permitted inverter combinations into account. Only inverters of the same device type must be installed in a cluster. Different clusters may be equipped with inverters of different device types. All work on the product must only be performed using appropriate tools and in compliance with the ESD protection regulations. Suitable personal protective equipment has to be worn by all persons working on or with the product. The Multicluster Box is designed for use at altitudes of up to 3,000 m above mean sea level. If you wish to use the Multicluster Box at elevations above 3,000 m, contact the SMA Service Line (see Section 14, page 46). The product is suitable exclusively for use in weather-protected outdoor areas and in indoor areas. Only operate the product at temperatures between 25 C and +60 C. Use this product only in accordance with the information provided in the enclosed documentation and with the locally applicable standards and directives. Any other application may cause personal injury or property damage. Alterations to the product, e.g., modifications or conversions, are only permitted with the express written permission of. Unauthorized alterations will void guarantee and warranty claims and in most cases terminate the operating license. shall not be held liable for any damage caused by such alterations. Any use of the product other than that described in the Intended Use section does not qualify as appropriate. The enclosed documentation is an integral part of this product. Keep the documentation in a convenient place for future reference and observe all instructions contained therein. The type label must remain permanently attached to the product. 8 MC-BOX BE-en-10 Operating Manual

9 2 Safety 2.2 Safety Information This section contains safety information that must be observed at all times when working on or with the product. To prevent personal injury or property damage and to ensure long-term operation of the product, read this section carefully and observe all safety information at all times. Danger to life due to electric shock High voltages are present in the Multicluster Box and the multicluster system. Touching live components results in death or serious injury due to electric shock. Disconnect the Multicluster Box and multicluster system from all voltage sources before carrying out any work on the Multicluster Box (see Section 8, page 28). Always operate the Multicluster Box with its protective cover in place. All work on the Multicluster Box must be carried out by qualified persons only. Do not touch any live components in the Multicluster Box or any other devices of the multicluster system. Risk of injury if the Multicluster Box tips over The Multicluster Box is heavy and may tip over if not properly fastened to the support surface. This can result in crushing injuries. After installation, attach the Multicluster Box to the support surface. Risk of burns due to hot components Components and terminals inside the Multicluster Box can get hot during operation. Touching hot components can cause burns. Always operate the Multicluster Box with its protective cover in place. Prior to removing the protective cover, let the Multicluster Box cool down. Operating Manual MC-BOX BE-en-10 9

10 3 Scope of Delivery 3 Scope of Delivery Check the scope of delivery for completeness and any externally visible damage. Contact your distributor if the scope of delivery is incomplete or damaged. Figure 2: Components included in the scope of delivery Position Quantity Designation A 1 Multicluster Box B 1 Data cable for communication (5 m, black) C 3 Data cable for measurement and control signals (5 m, red) D 14 Cable clamp with counter sleeve (22 mm to 28 mm) E 3 LV/HRC size 1 fuse link, 200 A F 1 Set of non-woven adhesive labels for cable designation G 4 Terminal incl. screws for connecting the protective conductors H 3 Fuse link 1 A, tripping characteristics: gg I 1 SD memory card with firmware version 3.5 or higher K 1 Operating manual, circuitry overview, quick reference guide for the Sunny Island inverter 10 MC-BOX BE-en-10 Operating Manual

11 4 Product Description 4 Product Description 4.1 Multicluster Box The Multicluster Box is an SMA multicluster technology device for off-grid systems, battery-backup systems and systems for increased self-consumption. The Multicluster Box is a main AC distribution board to which you can connect up to four clusters. Each three-phase cluster is made up of three DC-side, parallel-switched Sunny Island 6.0H / 8.0H inverters with software release 3.5 or higher. Functions of the Multicluster Box include: Main AC distribution board for Sunny Island inverters, one generator, one load and one PV system Load shedding Automatic bypass and reverse current monitoring for the generator Active anti-islanding Figure 3: Multicluster Box with cabinet door open Position Designation Explanation A Protective cover Prevent inadvertent contact with live components during B Protective cover operation and thus protect from electric shocks. When the Multicluster Box is in operation, the protective covers must always be mounted. C Residual-current device Protects against electric shock and is always used in addition to existing protective measures such as insulation or protective grounding. As soon as a dangerous touch voltage occurs, the residual-current device disconnects the loads at all poles. This is achieved by means of a summation current transformer in the residual-current device which detects the electric currents in the conductors L1, L2, L3 and N. In the normal operating state, the sum of these currents equals zero. Under fault conditions a differential current is formed which trips the residual-current device. D Circuit breakers To protect the power cables of the Sunny Island inverters Operating Manual MC-BOX BE-en-10 11

12 4 Product Description Residual-current device Figure 4: Overview of the residual-current device Position Designation Explanation A Test button The functionality of the residual-current device must be tested regularly (see Section 10.1, page 36). B Switch lever Top position: ON - residual-current device is switched on. Bottom position: OFF - residual-current device has tripped or is switched off. 4.2 Grounding in the Multicluster System With TN-S, TN-C-S and TT systems, the neutral conductor must be grounded for protection against indirect contact with live components. The following options for grounding the neutral conductor are available in the multicluster system: If the multicluster system is using a generator as grid-forming source, the multicluster system must be grounded outside the Multicluster Box on the generator side. If the multicluster system is connected to the utility grid, it is grounded via the utility grid when in parallel grid operation. However, in case of grid failure, the multicluster system must disconnect from the utility grid. For this disconnection, either only the line conductors are disconnected, or in case of all-pole disconnection, the line conductors and the neutral conductor. With all-pole disconnection, the multicluster system with line conductors and neutral conductor are disconnected from the utility grid in the event of grid failure. This disconnection does not ground the neutral conductor in the grid of the multicluster system. Therefore, in multicluster systems with all-pole disconnection, the grounding contactor of the Multicluster Box must ground the neutral conductor in the event of grid failure. The grounding contactor ensures the necessary protection in case of indirect contact with live components. The grounding contactor is in fail-safe design. If the neutral conductor of the multicluster system is connected to the utility grid, no further grounding is permitted in the electricity grid of the multicluster system. Therefore, if the multicluster system is connected to the utility grid via NA Box or Grid Connect Box the grounding contactor of the Multicluster Box deactivates the connection between neutral conductor and ground potential. If the Grid Connect Box is used, the all-pole disconnection can be deactivated (see operating manual of the Grid Connect Box). Deactivation of all-pole disconnection is only possible if the utility grid is configured as a TN-C-S system. The multicluster system may not be operated on a TT or TN-S grid. 12 MC-BOX BE-en-10 Operating Manual

13 4 Product Description 4.3 Type Label The type label clearly identifies the product. The type label is located on the right-hand side of the enclosure. You will find the following information on the type label: Address of Device type (Model) Serial number (Serial No.) Device-specific characteristics You will require the information on the type label to use the product safely and when seeking customer support from the SMA Service Line. Symbols on the Type Label Symbol Explanation Danger to life due to high voltages The product operates at high voltages. All work on the product must be carried out by qualified persons only. Risk of burns due to hot surfaces. The product can get hot during operation. Avoid contact during operation. Allow the product to cool down sufficiently before carrying out any work. Wear personal protective equipment such as safety gloves. Observe the documentation. Observe all documentation supplied with the product. WEEE designation Do not dispose of the product together with household waste but in accordance with the locally applicable disposal regulations for electronic waste. CE marking The product complies with the requirements of the applicable EU directives. Degree of protection The product is protected against interior dust deposits and water jets from all angles. Operating Manual MC-BOX BE-en-10 13

14 5 Installation 5 Installation 5.1 Storing the Multicluster Box Store the Multicluster Box in a dry place with an ambient temperature range between 25 C and +60 C. 5.2 Requirements for Mounting Optimum mounting location The ambient temperature influences the tripping threshold of the circuit breakers for the Sunny Island inverters. The higher the temperature, the earlier the circuit breakers will trip. At high ambient temperatures, the derating function of the Sunny Island inverters inhibits premature tripping of the circuit breakers. To ensure optimum operation, mount and install the Multicluster Box and the Sunny Island inverters at the same location. Mounting Location A firm, even support surface, e.g., a concrete foundation, must be available for mounting. The mounting location must be suitable for the weight and dimensions of the Multicluster Box (see Section 12 "Technical Data", page 40). The mounting location must be clear and safely accessible at all times without the need for any auxiliary equipment. The Multicluster Box must be mounted without hindrance of access to the disconnection devices. All local requirements concerning minimum passage widths and escape routes must be observed. Climatic conditions must be met (see Section 12 "Technical Data", page 40). The mounting location must be below 3,000 m above MSL. If you wish to use the Multicluster Box at elevations above 3,000 m, contact the SMA Service Line (see Section 14, page 46). Minimum Clearances SMA 200 mm 200 mm 200 mm Figure 5: Minimum clearances There must be sufficient space at the mounting location to ensure compliance with the minimum clearances. There must be a distance of at least 300 mm between the Multicluster Box and the Grid Connect Box or NA Box. This will ensure adequate heat dissipation. 14 MC-BOX BE-en-10 Operating Manual

15 5 Installation Mounting position Figure 6: Permitted and prohibited mounting positions The mounting location must allow compliance with the permitted mounting position. 5.3 Preparing the Mounting Location Danger to life due to fire or explosion Despite careful construction, electronic devices can cause fires if they are not installed properly. Contact with flammable materials allows the fire to spread. This can result in death or serious injury. Do not install the Multicluster Box on flammable construction materials. Do not install the Multicluster Box in areas containing flammable substances or objects. Do not install the Multicluster Box in potentially explosive atmospheres. Dimensions of the drill holes for fixing the Multicluster Box: Figure 7: Outside base measurements and dimensions of the drill holes Additionally required mounting material (not included in the scope of delivery): 4 suitable screw anchors to fasten the Multicluster Box to the support surface Procedure: 1. On the mounting surface, mark the position of the four drill holes for attaching the base. 2. Drill holes at the marked positions. 3. Insert screw anchors. Operating Manual MC-BOX BE-en-10 15

16 5 Installation 5.4 Transport Transport Options The Multicluster Box is delivered on a Euro pallet. You can use the following means of transport to lift the Multicluster Box off the Euro pallet: Forklift or pallet truck Crane with suitable fork Transporting and Mounting the Multicluster Box Danger of crushing if the raised or suspended Multicluster Box topples or falls The Multicluster Box can topple or fall if it is lifted and transported carelessly or hastily. This can result in death or serious injury. Always transport the Multicluster Box as close to the ground as possible. All means of transport and auxiliary equipment used must be designed for the weight of the Multicluster Box of 200 kg. Transport the Multicluster Box in an upright position. Keep a safe distance from the Multicluster Box at all times during transport. Take the center of gravity of the Multicluster Box into account. The center of gravity of the Multicluster Box is located approximately in the center of the cabinet and is marked on the package with the center of gravity symbol. Damage to the Multicluster Box due to inappropriate transport If the Multicluster Box is set down on an uneven surface, it may warp so that the doors will no longer close properly. This can lead to moisture and dust penetrating the Multicluster Box. Never place the Multicluster Box on an unpaved, uneven surface. Never transport the Multicluster Box with mounted kick plates. Additionally required mounting material (not included in the scope of delivery): 4 suitable bolts to attach the Multicluster Box to the support surface Procedure: 1. Remove all fastening screws from the kick plates at the front and rear (TX 30). 2. Remove kick plates 3. Retain the kick plates and the fastening screws for later use. 4. Slide the means of transport underneath the Multicluster Box and transport the Multicluster Box to the mounting location. 5. Risk of injury if the Multicluster Box tips over The Multicluster Box is heavy and may tip over if not properly fastened to the support surface. This can result in crushing injuries. Attach the Multicluster Box to the support surface using four suitable bolts. 16 MC-BOX BE-en-10 Operating Manual

17 6 Electrical Connection 6 Electrical Connection 6.1 Overview of the Connection Area Components and Terminals Figure 8: Overview of the connection area Position Designation Explanation A Fuse switch-disconnector F101 For LV/HRC size 1 fuse links of the generator terminal B Fuse switch-disconnector F102 For LV/HRC size 1 fuse links of the load terminal C Residual-current device of the Sunny Island inverters D Circuit breakers To protect the power cables of the Sunny Island inverters E Spring-cage terminals X105 To connect the power cables of the Sunny Island inverters F Grounding contactor G Spring-cage terminals X106 - X113 To connect the control cables of Sunny Island inverters, BatFuse, Grid Connect Box or NA Box Operating Manual MC-BOX BE-en-10 17

18 6 Electrical Connection Position Designation Explanation H Grounding busbar X100 To connect the grounding conductors of the generator, the loads and the PV system I Cable support rail K L M N Terminal X104 with spring-cage terminals L1, L2, L3 and N Terminal X103 with spring-cage terminals L1, L2, L3 and N Terminal X102 with spring-cage terminals L1, L2, L3 and N Terminal X101 with spring-cage terminals L1, L2, L3 and N Enclosure Openings in the Floor If a Grid Connect Box or NA Box is installed, the corresponding grounding conductor is also connected here. To connect the line conductors and the neutral conductor of the PV system To connect the line conductors and the neutral conductor of the main distribution for loads To connect the line conductors and the neutral conductor of the generator To connect the line conductors and the neutral conductor of the Grid Connect Box or NA Box If only the Multicluster Box is installed, these terminals are not connected. O SIBUCTRL RJ45 pin connectors for connecting the data cables P Fuses To protect the internal cabling A B Figure 9: Overview of the enclosure openings Position A B Designation Base plate with membranes for inserting the power cables Two-part cable feed-through for inserting the data cables 18 MC-BOX BE-en-10 Operating Manual

19 6 Electrical Connection 6.2 Installing the Multicluster Box without Grid Connect Box or NA Box If the Multicluster Box is installed without Grid Connect Box or NA Box, the terminals of the grounding contactor and the generator contactor must be equipped with a jumper wire. Figure 10: Overview of the provided jumper wires when installing the Multicluster Box without Grid Connect Box or NA Box Position A B Explanation Jumper wire for blocking the grounding contactor Jumper wire for blocking the generator contactor Procedure: 1. Short-circuit X110:1 and X110:2 with a jumper wire to block the grounding contactor. 2. Short-circuit X111:6 and X111:7 with a jumper wire to block the generator contactor. 6.3 Connecting the Generator You can connect a three-phase generator to the Multicluster Box. The line conductors are routed via fuse switch-disconnectors in the Multicluster Box. LV/HRC size 1 fuse links 200 A are installed in the fuse switch-disconnector by default. Generator output fuse influences dimensioning of the PV system power cables Remember that the size of the generator output fuse affects the dimensioning of the PV system cable (see Section 6.6 "Connecting the PV System", page 22). Cable requirements: Conductor material: copper Conductor cross-section: 120 mm² to 150 mm² If the generator does not have an output fuse, the generator connection cables must be ground-fault and short-circuit protected. Procedure: 1. Insert the power cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the grounding conductor to the grounding busbar (AF 17, torque: 15 Nm). To do this, use the screw terminal included in the scope of delivery. Operating Manual MC-BOX BE-en-10 19

20 6 Electrical Connection 3. Connect the neutral conductor to the spring-cage terminal N at terminal X102:4 (see Section 9.4.1, page 34). 4. Connect the line conductors to the spring-cage terminals L1, L2 and L3 at terminal X102: Ensure that a right-hand rotating magnetic field is present at the generator terminal. 6. Provide for strain relief of the power cables by attaching them to the appropriate cable support rail. Use the strain reliefs and counter-troughs provided. 7. According to the type of cable routing and the installation conditions, determine the required fuse link for the fuse switch-disconnector and insert it into the fuse switch-disconnector Generator. 6.4 Connecting the Utility Grid To connect the utility grid in addition to the generator, it is necessary to install either a Grid Connect Box or an NA Box between the utility grid and the Multicluster Box. The grid terminal output fuse influences dimensioning of the PV system power cables Remember that the size of the grid fuse affects the dimensioning of the PV system cable (see Section 6.6 "Connecting the PV System", page 22). Requirements: If using Grid Connect Box: The Grid Connect Box must be properly installed (see operating manual of the Grid Connect Box). If using NA Box: The NA Box must be properly installed (see operating manual of the NA Box). Cable requirements: Conductor material: copper Conductor cross-section: 120 mm² to 150 mm² The power cables must be ground-fault and short-circuit protected. Procedure: 1. Insert the power cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the grounding conductor to the grounding busbar (AF 17, torque: 15 Nm). To do this, use the screw terminal included in the scope of delivery. 3. Connect the neutral conductor to the spring-cage terminal N at terminal X101:4 (see Section 9.4.1, page 34). 4. Connect the line conductors to the spring-cage terminals L1, L2 and L3 at terminal X101: Ensure that a right-hand rotating magnetic field is present at the terminal of the Grid Connect Box / NA Box. 6. Provide for strain relief of the power cables by attaching them to the appropriate cable support rail. Use the strain reliefs and counter-troughs provided. 20 MC-BOX BE-en-10 Operating Manual

21 6 Electrical Connection 6.5 Connecting the Loads The line conductors L1, L2 and L3 are routed via a fuse switch-disconnector in the Multicluster Box. The maximum permitted 200 A LV/HRC size 1 fuse links are installed in the fuse switch-disconnector by default. Cable Protection The Multicluster Box is not a substitute for the load distribution board. Between the Multicluster Box and the loads, you must install a distribution board with circuit breakers to protect and isolate the loads, as well as a residual-current device. Make sure all standards and directives applicable at the installation site are observed. Cable requirements: Conductor material: copper Conductor cross-section: 120 mm² to 150 mm² The power cables must be ground-fault and short-circuit protected. Procedure: 1. Insert the power cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the grounding conductor to the grounding busbar (AF 17, torque: 15 Nm). To do this, use the screw terminal included in the scope of delivery. 3. Connect the neutral conductor to the spring-cage terminal N at terminal X103:4 (see Section 9.4.1, page 34). 4. Connect the line conductors to the spring-cage terminals L1, L2 and L3 at terminal X103: Ensure that a right-hand rotating magnetic field is present at the load terminal. 6. Provide for strain relief of the power cables by attaching them to the appropriate cable support rail. Use the strain reliefs and counter-troughs provided. 7. According to the type of cable routing and the installation conditions, determine the required fuse link for the fuse switch-disconnector and insert it into the fuse switch-disconnector Load. Operating Manual MC-BOX BE-en-10 21

22 6 Electrical Connection 6.6 Connecting the PV System Connection of other energy sources Instead of a PV system, you can also connect other energy sources (e.g., a small wind turbine system) to the Multicluster Box. Cable protection The Multicluster Box is not a substitute for the distribution board of the PV system (main PV distribution board). Install a circuit breaker and, if necessary, a residual-current device between the Multicluster Box and the PV system for protection and disconnection purposes. Make sure all standards and directives applicable at the installation site are observed. Cable dimensioning: In the event of a short circuit in the PV system cable, short-circuit currents arising in the generator or Grid Connect Box / NA Box will flow via the unprotected cable between the Multicluster Box and main PV distribution. Size the cables to match the fusing of the generator or the Grid Connect Box / NA Box. When planning the short-circuit protection of cables, the PV inverters and Sunny Island inverters may be disregarded, as their construction precludes any danger to power cables in case of short circuits. Cable requirements: Conductor material: copper Conductor cross-section: 120 mm² to 150 mm² The power cables must be ground-fault and short-circuit protected. Procedure: 1. Insert the power cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the grounding conductor to the grounding busbar (AF 17, torque: 15 Nm). To do this, use the screw terminal included in the scope of delivery. 3. Connect the neutral conductor to the spring-cage terminal N at terminal X104:4 (see Section 9.4.1, page 34). 4. Connect the line conductors to the spring-cage terminals L1, L2 and L3 at terminal X104: Provide for strain relief of the power cables by attaching them to the appropriate cable support rail. Use the strain reliefs and counter-troughs provided. 22 MC-BOX BE-en-10 Operating Manual

23 6 Electrical Connection 6.7 Connecting the Sunny Island Inverters Figure 11: Overview of the spring-cage terminals for connecting the power cables Position Explanation A Terminal for the power cables of the main cluster B Terminal for the power cables of extension cluster 1 C Terminal for the power cables of extension cluster 2 D Terminal for the power cables of extension cluster 3 Fusing of the Sunny Island inverter The power cables of each Sunny Island inverter are fused with a 40 A circuit breaker inside the Multicluster Box. Cable requirement: Conductor material: copper Procedure: 1. Insert the power cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the line conductors, the neutral conductors and the grounding conductors of all Sunny Island inverters to the spring-cage terminals X105 for the Sunny Island inverters (see Section 9.4.1, page 34). 6.8 Grounding the Multicluster System The neutral conductors inside the Multicluster Box are not connected to the grounding conductor by default. To ensure safe operation of the multicluster system, you must perform the following action prior to commissioning: Cable requirement: Conductor material: copper Procedure: Ground the multicluster system outside the Multicluster Box on the generator side. To do this, connect the neutral conductor to the grounding conductor, observing all standards and directives applicable at the installation site. Operating Manual MC-BOX BE-en-10 23

24 6 Electrical Connection 6.9 Connecting the Control Cables Assignment of Spring-Cage Terminals Figure 12: Overview of spring-cage terminals for connecting the control cables Position Designation Explanation A X106 Control voltage of the Sunny Island main cluster B X107 DC supply for connection to the BatFuse C X110 Connection of control cables from Grid Connect Box or NA Box D X111 Connection of control cables from Grid Connect Box or NA Box E X112 Connection of control cables to Sunny Island 1 of the main cluster F X113 Connection of control cables to Sunny Island 2 of the main cluster Connecting the Control Cables of the Sunny Island Inverters The Sunny Island inverters of the main cluster must be connected to the Multicluster Box via several control cables. These control cables transmit measurement and control signals between the Sunny Island inverters of the main cluster and the Multicluster Box. Cable requirements: Conductor material: copper Conductor cross-section: 1.5 mm² to 2.5 mm² Procedure: 1. Insert the control cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the cables to the spring-cage terminals X106, X112 and X113 (see Section 9.4.2, page 35): X106: control voltage of the main cluster X112: control cables from Sunny Island 1 of the main cluster X113: control cables from Sunny Island 2 of the main cluster Connecting the BatFuse Cable requirements: Conductor material: copper Conductor cross-section: 1.5 mm² to 2.5 mm² 24 MC-BOX BE-en-10 Operating Manual

25 6 Electrical Connection Procedure: 1. Insert the control cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the control cables to the spring-cage terminals X107 (see Section 9.4.2, page 35). Make sure that the poling of the terminals is correct Connecting the Control Cables to the Grid Connect Box Cable requirements: Conductor material: copper Conductor cross-section: 1.5 mm² to 2.5 mm² Ground connection at terminals X110 and X111 If the control cable between Multicluster Box and Grid Connect Box contains a grounding conductor, the grounding conductor terminal must not be connected on both sides. Procedure: 1. Insert the control cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the control cables to the spring-cage terminals (see Section 9.4.2, page 35). X110:1,2: block of grounding contactor of Multicluster Box X110:3,4: feedback from grid contactor of Grid Connect Box X111:1-4: voltage measurement of Grid Connect Box X111:6,7: block of generator contactor of Multicluster Box X111:8,9: block of grid contactor of Grid Connect Box 3. Ensure that the insulated conductors are firmly in place Connecting the Control Cables to the NA Box Cable requirements: Conductor material: copper Conductor cross-section: 1.5 mm² to 2.5 mm² Ground connection at terminals X110 and X111 If the control cable between Multicluster Box and NA Box contains a grounding conductor, the grounding conductor terminal must not be connected on both sides. Procedure: 1. Insert the control cables into the Multicluster Box (see Section 9.3.1, page 31). 2. Connect the control cables to the spring-cage terminals (see Section 9.4.2, page 35). X110:1,2: block of grounding contactor of Multicluster Box X110:3,4: feedback from grid contactor of NA Box X111:1-4: voltage measurement of NA Box X111:6,7: block of generator contactor of Multicluster Box X111:8,9: block of grid contactor 2 of NA Box X111:11,12: block of grid contactor 1 of NA Box 3. Ensure that the insulated conductors are firmly in place. Operating Manual MC-BOX BE-en-10 25

26 6 Electrical Connection 6.10 Connecting the Data Cables for Measurement Signals and Communication The data cables for measurement signals and communication are connected on the SIBUCTRL. Figure 13: Overview of the connection area in the SIBUCTRL Position A Procedure: 1. Insert the data cables into the Multicluster Box (see Section 9.3.2, page 32). 2. Connect the data cables for measurement signals (red): for the master of the main cluster to pin connector X30 (Mstr/L1 BackupVtgCur) for slave 1 of the main cluster to pin connector X31 (Slv1/L2 BackupVtgCur) for slave 2 of the main cluster to pin connector X32 (Slv2/L3 BackupVtgCur) 3. Connect the data cable for communication between the Sunny Island inverters and the Multicluster Box (black) to pin connector ComSyncIn. 4. Connect the other end of the data cable to pin connector ComSyncIn of a Sunny Island inverter in the main cluster. Since all Sunny Island inverters of the main cluster (master and slaves) are interconnected via a communication bus, the Multicluster Box can be connected to a slave or to the master of the main cluster (see documentation of the Sunny Island inverter). 5. Ensure that the terminator is plugged into the pin connector ComSyncOut Mounting the Kick Plates Requirement: All installation work must be completed. Procedure: Designation Pin connectors for measurement signals (ComSyncIn, ComSyncOut) B Pin connectors for communication (X30, X31, X32) 1. Ensure that the power cables are retained with a strain relief. 2. Insert the kick plates and attach with the fastening screws (TX 30, torque: 21 Nm). 26 MC-BOX BE-en-10 Operating Manual

27 7 Preparing the Multicluster System for Commissioning 7 Preparing the Multicluster System for Commissioning Load shedding in the first two operating hours The state of charge (SOC) recorded by battery management and the available battery capacity (SOH) of the battery will deviate strongly in a newly connected battery from the actual SOC and SOH values. During operation, the values recorded by battery management will gradually approach the real values. In the first two operating hours using the new battery, these deviations can lead to load shedding. Requirements: If the Multicluster Box is installed without Grid Connect Box or NA Box, the jumper wires for blocking the grounding contactor and the generator contactor must be in place (see Section 6.2, page 19). In a multicluster system with Grid Connect Box / NA Box, all preparations for commissioning the system must have been completed in the Grid Connect Box / NA Box (see operating manual of the Grid Connect Box / NA Box). The Multicluster Box must be properly installed (see Section 5, page 14). The multicluster system must be grounded outside the Multicluster Box on the generator side or via the Grid Connect Box / NA Box (see Section 6.8 "Grounding the Multicluster System", page 23). All power, control and data cables must be correctly connected (see Section 6, page 17). All cables must be tightly enclosed by a membrane or cable feed-through in the floor of the Multicluster Box. All power cables of the generator, loads, PV system and Sunny Island inverters must be retained inside or outside the Multicluster Box. In a multicluster system with Grid Connect Box / NA Box, all power cables must be retained inside or outside the Multicluster Box. The floor of the Multicluster Box must be closed with the base plates. All seals must be correctly fitted. The kick plates on the base of the Multicluster Box must be attached (see Section 6.11, page 26). Procedure: 1. Mount the protective cover (see Section 9.2, page 30). 2. Close the Multicluster Box. 3. Commission the multicluster system (see documentation of the Sunny Island inverter). Operating Manual MC-BOX BE-en-10 27

28 8 Disconnecting the Multicluster Box and Multicluster System 8 Disconnecting the Multicluster Box and Multicluster System 1. Switch all loads off. 2. Stop the multicluster system at the master of the main cluster (see documentation of the Sunny Island inverter). 3. Switch off all Sunny Island inverters (see documentation of the Sunny Island inverter). 4. In the Multicluster Box, switch off all circuit breakers of the Sunny Island inverters. 5. Disconnect the main PV distribution board and secure against reconnection. 6. Shut down the generator and secure against reconnection. 7. If a Grid Connect Box or NA Box is installed, perform the following steps: Open the Grid Connect Box or NA Box. In the Grid Connect Box or NA Box, switch off all circuit breakers and residual-current devices. Switch off the AC voltage supply at the grid-connection point. 8. Open the Multicluster Box. 9. Risk of burns due to hot components Components and terminals inside the Multicluster Box can get hot during operation. Touching hot components can cause burns. Prior to removing the protective cover, let the Multicluster Box cool down. 10. Disassemble the protective cover (see Section 9.1, page 29). 11. Ensure that the Multicluster Box is voltage-free. 12. Ground and short-circuit the main PV distribution board outside the Multicluster Box. 13. Ground and short-circuit the generator outside the Multicluster Box. 14. Cover and isolate any adjacent live components. 28 MC-BOX BE-en-10 Operating Manual

29 9 Periodic Actions 9 Periodic Actions 9.1 Disassembling the Protective Cover Danger to life due to electric shock High voltages are present in the Multicluster Box and the multicluster system. Touching live components can result in death or serious injury due to electric shock. Disconnect the Multicluster Box and multicluster system from all voltage sources before carrying out any work on the Multicluster Box (see Section 8, page 28). Procedure: Risk of burns due to hot components Components and terminals inside the Multicluster Box can get hot during operation. Touching hot components can cause burns. Prior to removing the protective cover, let the Multicluster Box cool down. 1. Release all fastening screws in the protective cover (TX 30). Operating Manual MC-BOX BE-en-10 29

30 9 Periodic Actions 2. Remove the protective cover. 3. Retain the protective cover and the fastening screws for later use. 9.2 Mounting the Protective Cover Procedure: 1. Insert the protective cover in the Multicluster Box. 2. Insert all fastening screws and tighten them (TX 30, torque: 4 Nm). 30 MC-BOX BE-en-10 Operating Manual

31 9 Periodic Actions 9.3 Inserting the Cables Inserting Power and Control Cables Damage to the Multicluster Box due to moisture penetration Dust and moisture can penetrate the Multicluster Box due to overstretched or damaged rubber membranes. Moisture and dust intrusion can cause irreparable damage to the Multicluster Box. When selecting the enclosure opening, match the diameter of the membrane to the diameter of the cable. Choose suitable tools for piercing the membrane. Ensure that the membrane is not ruptured when the cable is inserted. Requirement: The kick plates must be dismantled (see Section "Transporting and Mounting the Multicluster Box", page 16). Procedure: 1. Disassemble the protective cover (see Section 9.1, page 29). 2. Remove all screws of the front and rear base plates on the floor of the Multicluster Box (TX 25) and remove the base plates. 3. Insert each cable into the Multicluster Box as follows: Select a suitable enclosure opening for the given cable. Pierce the membrane of the selected enclosure opening with a pointed object. Make sure that the opening is not too large. Insert each cable through the membrane of the selected enclosure opening into the Multicluster Box. Ensure that the cable is tightly enclosed by the membrane. Strip the insulation of each cable. Cable type Power cable Control cable Stripping length 40 mm 20 mm Ensure that the seal at the edge of the base plate is firmly attached. 4. Insert the base plates and tighten all screws (TX 25 screwdriver, torque: 9 Nm). Operating Manual MC-BOX BE-en-10 31

32 9 Periodic Actions Inserting Data Cables 1. Release the screws of the mounting plate of the two-part cable feed-through inside the Multicluster Box. 2. Remove the mounting plate and set it aside. 3. Remove the cable feed-through from the enclosure. 4. Loosen the screws of the two-part cable feed-through. 5. Remove the half without the T-shaped fastening pieces. 6. Lay the data cables for communication, control and measuring signals into the half with the T-shaped fastening pieces, and secure with cable ties. Ensure sufficient cable length from the cable feed-through to the desired connection point. 32 MC-BOX BE-en-10 Operating Manual