1. What Is ?
It is a box where many DC inputs are combined electrically from the panels in the system into one DC output connected to the charge controller.
It helps bring the output of several solar strings together; hence, each string conductor is attached to fused inputs and combined into one conductor.
However, the conductor then connects the box to the inverter.
1. PV Combiner Box Function.
The combiner box can reduce the scope of power outages in the event of a PV system failure.
Its central role is to bring the output of several solar strings together from the solar panel into a single box.
It reduces the labour costs since it consolidates the amounts of cables running into the inverter.
1. The combiner box protects the inverter from overvoltage and overcurrent flowing. Types Of PV Combiner Boxes.
PV DC combiner box.
6 String PV combiner box.
Solar PV combiner box.
2 String PV combiner box.
AC PV combiner box.
4 String PV combiner box.
1. PV Combiner Box Vs Junction Box
PV combiner box is where many DC inputs are combined electrically from the panels in the system into one DC output connected to the charge controller.
A junction box is a piece of equipment that unites multiple wires and cables through different ports of entry in the panel system.
1. Choosing Material For PV Combiner Box.
Material selection and lifetime prediction service are essential considerations; hence, two types of material combinations are used to make a combiner box.
PV combiner boxes are made of thermoplastic materials such as polyester or polycarbonate.
A combination of polycarbonate and ABS is more common because it is very cheap compared to using polycarbonate only.
Combiner box enclosures doors are made of gaskets; hence the material is prone to mechanical and thermal degradation.
Poured polyurethane seamless gasket provides a watertight, .
Other materials used are;
Hot compression-moulded fibreglass-reinforced thermoset polyester.
Stainless steel is used on all external hardware.
Ageing allows water to ingress into the junction box and affect the ingress properties of the box; thus, multiple replacements may be necessary over the lifetime.
Combiner boxes occupy disconnect switches exposing the polymeric handle to the elements outside the box.
The polymeric handles are usually prone to UV. Humidity and thermal degradation.
1. Main PV Combiner Box Components
Here are the main components of the PV combiner box;
DC Surge protector device.
When there is lightning, a sudden voltage increase occurs, which may harm the electrical equipment; thus, it protects electrical devices when there is overvoltage.
DC disconnects.
When power is no longer needed, DC disconnect is used to help flow the direct current from the solar system to the device.
Rapid-disconnect contacts.
It reduces the voltage or stops the current by de-energizing a rooftop panel system from a PV array; hence it helps avoid electrical hazards.
Enclosure.
All components of the PV combiner are installed in this physical box.
Fuse.
This typically separates the circuit, causing problems; hence they are not always mechanical since it depends on a tiny wire that burns through when the rating is exceeded.
DC fuse holder.
It is a device that allows the incoming power; thus, it safely helps the fuses integrate into the electrical circuits and helps the current flow through a full path.
Bridge bar.
They mix several inputs into one output; thus, they are mounted on the circuit breaker’s side opposite the positive wires.
Busbar.
It is a , enabling you to integrate many incoming wires into one component and combine them from solar panels.
Circuit breaker.
Circuit breakers usually have one contact for usage with one incoming wire that is used to disconnect or separate a circuit manually.
It can also be used automatically when a short circuit opens or disconnects the circuit.
A terminal strip.
The strip is made of ABS composites; hence, they combine incoming wires into one component from the solar panels.
1. How To Specify PV Combiner Box
When specifying a PV combiner box, the first element is the enclosure since most string combiners are available in outdoor-rated enclosures.
Primarily typical enclosures are; NEMA 3R,4 or4X, but today is NEMA 4 steel or NEMA 4X non-metallic enclosure.
The enclosure is significant because it directly impacts the combiner’s life; hence its mounting position, size, and colour can affect the inner temperatures.
Direct sunlight can increase the internal combiner temperatures and decrease the reliability and life of inner components; hence mounting the combiner in the shade is recommended.
Size can also impact since the combiner in the larger enclosure allows, the larger air volume and surface area inside the enclosure to help fantastic inner equipment.
However, larger enclosures allow more room to work during installation and maintenance, thus making work more accessible.
The second element is the output wire bend radius; hence the NEC and UL have requirements for wire bend radius spacing inside a string combiner.
We have an adjacent wall bend radius and opposite wall bend radius that is determined by the size of the terminal of the output wire.
AA combiner design that allows a straight shot to the output terminal without a bend can save installation time. It is preferable to bending prominent conductors that often waste material.
A is the last element when specifying a PV combiner box; hence, ensure you maintain and monitor the electrical connections frequently.
This helps with high reliability and lasting field installation.
1. Electrical Enclosure Vs PV Combiner Box
PV combiner box is an equipment where many DC inputs are combined electrically from the panels in the system into one DC output which is connected to the charge controller.
An electrical enclosure is a piece of equipment that prevents shock, mounts switches and displays and protects them from an unfriendly environment.
The combiner box protects the inverter from overvoltage and overcurrent flowing, while the enclosure protects personnel and enclosed equipment against harsh weather.
1. PV Combiner Box Quality Standards And Certifications
UL solutions’ balance of system equipment provides certification of fuses, holders, and combiner boxes.
It is tested and, if applicable, certifies BOS to:
The standard for combiner boxes is UL 1741.
UL 5081 and UL98B for disconnect.
UL subject 4248-19 and UL subject 4248-18 for fuse holder.
UL subject 248-19 and UL subject 2579 for fuses.
UL 489B circuit breakers.
cETLus 1741 listed.
cETLus Listed to CSA standards C 22.2 NO.31 and NO.107.1
NEMA 4 (powder coated)
NEMA 4X (fibreglass and stainless steel)
NEMA 3R (painted steel for vertical mounting positions)
1. Can You Use DC And AC Breakers In One Combiner Box?
No, and yes.
The combiner box is for combining, but it can still be used for breaker, so if you put both DC and AC in the combiner box, it will be strictly for breaker housing and not combining.
Both AC and DC put together in one combiner box help to reduce wiring, and it will not pass code since they cannot be combined this way.
1. How To Choose PV Combiner Box.
A failing combiner box can be hazardous since it can cause smoke and fire; hence when choosing the best combiner box, you should ensure it is UL471 certified.
Ensure it has enough fuse terminals to contain all your panels to handle all voltages for your system.
The combiner box must be able to safeguard the system; thus, you should ensure everything you choose complies with the code standards in your jurisdiction.
It would be best if you considered surveillance since monitoring gives real-time feedback on the inherent benefits of the installation, hence noticing any errors or faults as early as possible.
Ensure you know how the PV combiner box functions since the combiner may need to do more than combine circuits and fuses; hence some can box can handle multiple tasks without issues.
Choose a PV combiner box that you can be able to install; hence it can bring a limited number of strings to one area for convenient installation, disconnect and maintenance in residential applications.
1. PV Combiner Box Mounting Options
If the PV combiner box is installed well, it can function for a very long time without any issues and will require little maintenance.
It is mounted between the solar modules and inverter, and when positioned in the array, it can limit power loss.
PV combiner box can also be installed on the rooftop or other areas where exposure to harsh weather conditions.
1. Benefits Of PV Combiner Box
Here are the benefits of the PV combiner box;
They are not expensive compared to other devices in a solar.
Provides overcurrent and overvoltage protection.
Ensures on-site delivery.
Improves safety of solar panels.
Enhances inverter protection and reliability.
Saves labour and material costs through wire reductions.
Different enclosure sizes.
1. Safety Features In PV Combiner Box
These safety features enable the company to implement solutions that can improve the system performance and capital use.
The safety features are as follows;
Cost-effective monitoring.
String-level monitoring was added to combiner boxes to provide discrete data. Hence the data gives a higher level of monitoring than the inverter alone at a lower cost.
Streamlined installation.
The innovations like whips, quick-connect boxes and pre-punched enclosures have helped to reduce installation time and cost.
Optimized safety.
Combiner boxes were located far from the inverter and without a disconnect switch; thus, the National Electrical Code (NEC) 2011 code changes address safety concerns.
It improved design practices, and a visible means of disconnect was required to be within sight of the fuses.
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