Protection and isolation of
photovoltaic installations
1SDC007099B0203
Technical characteristics
and ordering information
S800PV-S miniature circuit breakers
and S800PV-M switch-disconnectors.............................................pag. 11
OVR PV surge protection devices...................................................pag. 12
OT switch-disconnectors................................................................pag. 13
Europa series wall-mounted control boards....................................pag. 14
Junction boxes...............................................................................pag. 15
Metric gauge cable glands and nuts...............................................pag. 16
Terminal blocks...............................................................................pag. 17
ABB experience serving solar energy
The great variety of needs that photovoltaic
installations are able to satisfy, both in
terms of power and connection to electricity
networks (single phase, three phase, low or
medium voltages), means that components
must be carefully selected by designers
and installers to optimise the installations
and suit differing needs and installation
conditions specific to every application.
Protective and isolating switchgear
equipment is particularly important and
ABB offers a full range of these products
both for circuits branched from photovoltaic
panels, where the high direct voltages
typical of these installations are present,
and for those that form the alternating
current section downstream of the inverter.
ABB product range includes control boards
and enclosures suitable for outdoor use
with IP65 class protection, circuit breakers
and switch-disconnectors, surge protection
devices and connection terminal blocks.
3
Equipment for the direct current
section
4
4
2
its effects on the panels, often located in
isolated places that are particularly exposed
to adverse weather conditions, or due to
the overvoltages that they generate in the
installations.
The following pages illustrate a number
of examples of options for the choice
of suitable components to create the
protection and isolation functions, both in
modular and in-box versions, depending
upon the operating voltages in the
photovoltaic field.
The examples refer to strings of panels up
to 16A.
2
4
3
1
2
4
2
2
2
4
4
4
3
1
1
3
3
3
1
1
3
1
In a typical photovoltaic installation, the
direct current section includes the field
made up of strings of photovoltaic panels
downstream of which isolation and
protection may be provided by dedicated
circuit breakers, for example S800PV-S
miniature circuit breakers, usable in
situations where there are very high voltage
direct currents. On this side, protection
against overvoltages can be provided by
suitably sized OVR-PV surge protection
devices.
This kind of protection avoids the effects
of lightning strikes and is essential since
lightning is a major hazard either due to
=
~
8
6
4 2
7
5
3 1
Strings up to 500V DC
Example of a modular field switchboard
to protect and isolate strings with a
maximum capacity of 16A up to 500V
DC made up of:
• Europa series IP65 wall-mounted
12-module control board with IP68
metric gauge cable glands and nuts
• miniature circuit breaker S802S UC,
16A
• surge protection device OVR PV 40
600 P - Surge protection device
for 40kA 600V DC photovoltaic
installations with removable cartridges
• Screw clamp terminal blocks
4-6-10 mm2, voltage rated up to
800V
Example of an IP65 in-box field
switchboard to isolate strings with
a maximum capacity of 16A up to
500VDC made up of:
• IP65 polycarbonate junction box,
dimensions 275x220x140 with IP65
cable glands
• OT16E 4-pole switch-disconnector +
shaft + handle
• surge protection device OVR PV 40
600 P - Surge protection device
for 40kA 600V DC photovoltaic
installations with removable cartridges
• 4 Screw clamp terminal blocks
4-6-10 mm², voltage rated up to
800V
5
Strings up to 750V DC
Example of an IP65 in-box field switchboard to isolate strings with a maximum
capacity of 16A up to 750V DC made up of:
• IP65 polycarbonate junction box, dimensions 275x220x140 with IP65 cable glands
• OT16E 8-pole switch-disconnector + shaft + handle
• surge protection device OVR PV 40 1000 P - Surge protection device for 40kA 1000V d.c.
photovoltaic installations with removable cartridges
6
Strings up to 800V DC
Example of a modular field switchboard
for protection and isolation of strings
with a maximum capacity of 16A up to
800V DC made up of:
• Europa series IP65 wall-mounted
12-module control board with IP68
metric gauge cable glands and nuts
• miniature circuit breaker S802 PV-S,
16A
• surge protection device OVR PV 40
1000 P - Surge protection device
for 40kA 1000V DC photovoltaic
installations with removable cartridges
• Screw clamp terminal blocks
4-6-10 mm², voltage rated up to
800V
Example of a modular field switchboard
for isolation of strings up to 800V DC
made up of:
• Europa series IP65 wall-mounted
12-module control board with IP68
metric gauge cable glands and nuts
• S802 PV-M, 32A switch-disconnector
• surge protection device OVR PV 40
1000 P - Surge protection device
for 40kA 1000V DC photovoltaic
installations with removable cartridges
• Screw clamp terminal blocks
4-6-10 mm², voltage rated up to
800V
7
Strings up to 800V DC
The figure shows an example of circuit configuration for the DC section for protection and
isolation of an installation with strings with a capacity up to 800V, currently one of the most
widely used types of installation.
2
4
String 1 800VDC/16A
3
1
S802PV-S16
1
2
4
String 2 800VDC/16A
3
S802PV-S16
S802PV-M125
1
2
1
2
4
3
4
String 3 800VDC/16A
3
S802PV-S16
Protection against
overvoltages
2
4
String 6 800VDC/16A
3
1
S802PV-S16
Protection from lightning
8
1
2
4
String 7 800VDC/16A
3
S802PV-S16
Inverter
~
=
Strings up to 1000V DC
Example of a modular field switchboard
for protection and isolation of strings
with a maximum capacity of 16A up to
1000V DC made up of:
• Europa series IP65 wall-mounted
12-module control board with IP68
metric gauge cable glands and nuts
• miniature circuit breaker S804 PV-S,
16A
• surge protection device OVR PV 40
1000 P - Surge protection device
for 40kA 1000V DC photovoltaic
installations with removable cartridges
• ADO - screw clamp terminal blocks
4 mm², voltage rated up to 1000V
Example of a modular field switchboard
for isolation of strings with a maximum
capacity of 16A up to 1000V DC made
up of:
• Europa series IP65 wall-mounted
12-module control board with IP68
metric gauge cable glands and nuts
• S804 PV-M, 32A switch-disconnector
• surge protection device OVR PV 40
1000 P - Surge protection device
for 40kA 1000V DC photovoltaic
installations with removable cartridges
• ADO - screw clamp terminal blocks
4 mm², voltage rated up to 1000V
9
Switchgear for protection
downstream of the inverter
In photovoltaic installations with capacities
higher than 20kW, inverters should be
fitted with an isolation transformer, while for
power ratings lower than 20kW the residual
current circuit breaker for protection against
indirect contacts should be type B when an
inverter that does not have at least a simple
separation between the AC side and the
DC side is used.
When, however, the inverter is constructed
in such a way that it does not permit
injection of direct fault current, a type
B residual current circuit breaker is not
required.
ABB supplies automatic, simple switchdisconnectors and switch-disconnector
blocks that guarantee effective protection in
all types of photovoltaic installation.
The range also includes type B switch-
10
disconnector devices (for alternating and/
or pulsating currents with direct and direct
fault current components) and modular
automatic circuit breakers from 4.5kA to
50kA (up to 125A) with a wide choice of
accessories to protect against overload and
short circuit currents on the AC side.
For equipment manufacturers (OEMs)
ABB offers contactors suitable for making
interface devices which must guarantee
intrinsic safety (with the relay coil powered
directly from the power network).
The ideal solution for outdoor installations,
is the Gemini IP66 switchboard which, by
virtue of the co-injected moulding technique
used, maintains excellent characteristics
of mechanical sturdiness and resistance to
adverse weather conditions and aggressive
substances.
The products: technical characteristics
and ordering information
S800PV-S miniature circuit breakers and
S800PV-M switch-disconnectors
The S 800 PV range includes S 800 PV-S circuit breakers and
S 800 PV-M modular switch-disconnectors that can be used in
networks of up to 1200 V DC (four poles version); these products
and their very wide range of accessories (auxiliary contacts,
release coils) permit the creation of countless installation setups as
described in the previous pages.
The main characteristics of S800PV circuit breakers and switchdisconnectors are:
- interchangeable terminal blocks
- lever in a central position for S 800 PV-S miniature circuit
breakers
- contact status display by single pole
- no constraints for polarity and power direction in cabling
Connection
S800PV-S miniature circuit breakers
Networks of photovoltaic panels in earther systems
Poles
Rated current
In [A]
Type
Order code
2
2
2
2
2
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
10
13
16
20
25
32
40
50
63
80
10
13
16
20
25
32
40
50
63
80
S802PV-S10
S802PV-S13
S802PV-S16
S802PV-S20
S802PV-S25
S802PV-S32
S802PV-S40
S802PV-S50
S802PV-S63
S802PV-S80
S804PV-S10
S804PV-S13
S804PV-S16
S804PV-S20
S804PV-S25
S804PV-S32
S804PV-S40
S804PV-S50
S804PV-S63
S804PV-S80
2CCP842001R1109
2CCP842001R1139
2CCP842001R1169
2CCP842001R1209
2CCP842001R1259
2CCP842001R1329
2CCP842001R1409
2CCP842001R1509
2CCP842001R1639
2CCP842001R1809
2CCP844001R1109
2CCP844001R1139
2CCP844001R1169
2CCP844001R1209
2CCP844001R1259
2CCP844001R1329
2CCP844001R1409
2CCP844001R1509
2CCP844001R1639
2CCP844001R1809
1200 V c.c.
800 V c.c.
1
3
1
3
5
7
2
4
2
4
6
8
Connection
Networks of photovoltaic panels in earther systems
S800PV-M switch-disconnectors
1200 V c.c.
800 V c.c.
Poles
Rated current
In [A]
Type
Order code
2
2
4
4
32
125
32
125
S802PV-M32
S802PV-M125
S802PV-M32
S802PV-M125
2CCP812001R1329
2CCP812001R1849
2CCP814001R1329
2CCP814001R1849
1
3
1
3
5
7
2
4
2
4
6
8
11
OVR PV surge protection devices
ABB offers a wide range of surge protection devices specific for
photovoltaic installations.
The main characteristics of OVR PV surge protection devices are:
- integral thermal protections with breaking capacity of 25A DC*
- removable cartridges, for easy maintenance with no need to
isolate the line
- remote signal contact to monitor the operating status (TS
versions)
- no subsequent short circuit current
- no risk if poles are inverted
OVR PV surge protection devices
Type
OVR PV 40 600 P
OVR PV 40 600 P TS
OVR PV 40 1000 P
OVR PV 40 1000 P TS
OVR PV 40 600 C
OVR PV 40 1000 C
Order code
2CTB803953R5300
2CTB803953R5400
2CTB803953R6400
2CTB803953R6500
2CTB803950R0000
2CTB803950R0100
* Note: for surge protection devices installed at points in the network where the short circuit current is
higher than 25A DC, suitable protection must be provided
12
OT switch-disconnectors
OT series switch-disconnectors are available with rated currents
from 16A to 125A in the 4P version (maximum voltage 500V
DC) and 8P version (maximum voltage 750V DC). OT switchdisconnectors are suitable for installation in switchboards with
45mm slots
The main characteristics of OT switch-disconnectors are:
- fast opening and closing mechanism with independent trip
function (in OT 45...125 versions)
- accessories are snap mounted onto the circuit breakers
- OT 45 ... 125 switch-disconnector mechanism for installation
on DIN rails can be locked by a blocking adaptor
OT switch-disconnectors
Poles
Ith (open)
Type
Order code
4
4
4
4
4
4
4
8
8
8
8
8
8
8
25
32
40
63
80
115
125
25
32
40
63
80
115
125
OT 16 E4
OT 25 E4
OT 32 E4
OT 45 E4
OT 63 E4
OT 100 E4
OT 125 E4
OT 16 E8
OT 25 E8
OT 32 E8
OT 45 E8
OT 63 E8
OT 100 E8
OT 125 E8
1SCA022352R7170
1SCA022352R7330
1SCA022352R7500
1SCA022352R7680
1SCA022352R7760
1SCA022398R4580
1SCA022373R1880
1SCA022551R4510
1SCA022551R5310
1SCA022551R2990
1SCA022551R3700
1SCA022551R6120
1SCA022551R7790
1SCA022551R8500
13
Europa series wall-mounted control boards
Europa series control boards for wall mounting have IP65
class protection making them particularly suited for installation
outdoors. They can therefore be used to create field switchboards
downstream of the photovoltaic strings.
The main characteristics of the Europa series wall-mounted control
boards are:
- class of protection: II
- manufactured in self-extinguishing thermoplastic material
resistant to abnormal heat and fire-resistant up to 650°C
(incandescent wire test) in conformity with the IEC 60695-211 standard
- installation temperature: -25°C to +60°C
- shock resistance: 6 joules (IK 08 class)
- extractable DIN rail support structure for easy bench wiring,
modular (can be disassembled and reassembled by snap
mechanism) to make wiring of single strings rows
- switchgear can be installed at depths of 53, 68 and 75 mm
- modules with 8 or more modules fitted with rigid bimaterial
flanges to facilitate insertion of pipes and cables
- control boards compliant with CEI 23-48, CEI 23-49 and IEC
60670 standards
Europa Serie
14
Description
Dimensions
WxHxD [mm]
Order code
IP65 CONTROL BOARD, P/SMOKE GREY 4M
IP65 CONTROL BOARD, P/SMOKE GREY 8M
IP65 CONTROL BOARD, P/SMOKE GREY 12M
IP65 CONTROL BOARD, P/SMOKE GREY 18M 1 ROW
140x220x140
205x220x140
275x220x140
380x220x140
12744
12748
12752
12753
Junction boxes
ABB can also supply IP65 polycarbonate junctions boxes that are
particularly suitable for use outdoors.
The main characteristics of the junction boxes are:
- class of protection: II
- manufactured in self-extinguishing polycarbonate, resistant to
abnormal heat and fire-resistant up to 960°C (incandescent
wire test) in conformity with the IEC 60695-2-11 standard
- installation temperature: -25°C to +60°C
- shock resistance: 20 joules (IK 10 class)
- junction boxes compliant with the CEI 23-48 and IEC 60670
standards
Junction boxes
Description
Dimensions
WxHxD [mm]
Order code
BOX IP65 PC
BOX IP65 PC
BOX IP65 PC
140x220x140
205x220x140
275x220x140
12804
12808
12812
15
Metric gauge cable glands and nuts
Main technical characteristics of metric gauge cable glands and
nuts:
- IP68 protection degree
- material: 6.6 polyamide, self-extinguishing material compliant
with the UL94 V2 standard and resistant to abnormal heat
and fire-resistant up to 750°C (incandescent wire test) in
conformity with the IEC 60695-2-11 standard
- usage temperature: from -20°C to +120°C (brief period)
- neoprene seal
- tightening by lamellar crown on the whole diameter of the
cable (prevents possible damage to the cable itself)
- cable glands can be reused without damaging their
effectiveness
Metric gauge cable glands and nuts
Cable gland
METRIC GAUGE M12
CABLE GLAND
METRIC GAUGE M16
CABLE GLAND
METRIC GAUGE M20
CABLE GLAND
METRIC GAUGE M25
CABLE GLAND
METRIC GAUGE M32
CABLE GLAND
Cable gland
order
code
00 951
00 952
00 953
00 954
00 955
METRIC GAUGE M40
CABLE GLAND
00 956*
METRIC GAUGE M50
CABLE GLAND
00 957*
Nut
NUT FOR M12
CABLE GLAND
NUT FOR M16
CABLE GLAND
NUT FOR M20
CABLE GLAND
NUT FOR M25
CABLE GLAND
NUT FOR M32
CABLE GLAND
METRIC GAUGE
NUT FOR M40
CABLE GLAND
METRIC GAUGE
NUT FOR M50
CABLE GLAND
Nut
order
code
Gauge Min Max
M
[mm] [mm]
00 961
12x1,5
3,5
7
00 962
16x1,5
5,5
10
00 963
20x1,5
7
13
00 964
25x1,5
10
17
00 965
32x1,5
12
21
00 966
40x1,5
19
28
00 967
50x1,5
27
35
* M40, M50 and M63 cable glands and nuts are only available on demand
16
Modular terminal blocks
ABB terminal blocks are available in 3 different technologies:
screw-clamp, spring-clamp and ADO system, the most reliable
technology.
As far as photovoltaic application is concerned, screw-clamp and
ADO system technologies are used. The latest offering the best
reliability and long term durability.
Screw-clamp blocks for these applications can carry up to
800V DC with 57 A (10 mm²), up to 415A (240mm²) on request,
according to IEC 60947-7-1 standard and ADO – clamp can carry
up to 1000V DC with 32A (4 mm²). Spring technology is also
available on request.
Modular terminal blocks
Type
Application
Screw-screw terminal block
MA 2,5/5
phase
M 4/6
phase
M 6/8
phase
M 10/10
phase
MA 2,5/5.N
neutral
M 4/6.N
neutral
M 6/8.N
neutral
M 10/10.N
neutral
MA2,5/5.P
earth
M 4/6.P
earth
M 6/8.P
earth
M10/10.P
earth
ADO-ADO terminal block
D 2,5/8.ADO
phase
D 4/8.ADO
phase
D 2,5/8.N.ADO
neutral
D 4/8.N.ADO
neutral
D 2,5/8.P.ADO
earth
D 4/8.P.ADO
earth
ADO-screw terminal block
D 6/8.ADO
phase
D 6/8.ADO3
phase
D 6/8.N.ADO
neutral
D 6/8.N.ADO3
neutral
D 6/8.P.ADO
earth
D 6/8.P.ADO3
earth
Section
I [A]
V [V]
Order code
2,5mm2
4mm2
6mm2
10mm2
2,5mm2
4mm2
6mm2
10mm2
2,5mm2
4mm2
6mm2
10mm2
24
32
41
57
24
32
41
57
300A/1s
480A/1s
720A/1s
1200A/1s
800
800
800
800
800
800
800
800
1SNA115486R0300
1SNA115116R0700
1SNA115118R1100
1SNA115120R1700
1SNA125486R0500
1SNA125116R0100
1SNA125118R1300
1SNA125120R1100
1SNA165488R2700
1SNA165113R1600
1SNA165114R1700
1SNA165115R1000
2,5mm2
4mm2
2,5mm2
4mm2
2,5mm2
4mm2
24
32
24
32
300A/1s
480A/1s
1000
1000
1000
1000
1SNA199059R0600
1SNA399244R1400
1SNA199061R2000
1SNA399318R1600
1SNA199091R1700
1SNA399250R2600
2,5mm2
4mm2
2,5mm2
4mm2
2,5mm2
4mm2
24
32
24
32
300A/1s
480A/1s
1000
1000
1000
1000
1SNA199042R2500
1SNA399245R1500
1SNA199044R2700
1SNA399319R1700
1SNA199118R2600
1SNA399251R1300
17
Modular miniature and residual
current circuit breakers
In addition to S 800 PV circuit breakers,
ABB offers a full range of miniature and
residual current circuit breakers suited
for any application in domestic, industrial
and commercial installations. Further
information can be found in the “System
pro M compact” technical catalogue
(cod. 2CSC40002D0206).
GEMINI switchboards
Due to their IP66 protection degree, Gemini
switchboards, made in thermoplastic
material by means of the co-injection
moulding technique, can be used in any
kind of environment, even outdoors,
maintaining their high mechanical
characteristics and resistance to adverse
weather conditions and aggressive
substances over time.
Further information can be found in
the “Gemini. Low voltage insulating
switchboards” catalogue
(cod. 1SLC805001D0204).
Contactors
A wide range of contactors, even
miniaturised, and thermal relays are
available for control and protection
functions. Further information can be found
in the “Contactors.
Motor protection circuit breakers.
Thermal relays” catalogue
(cod. 1SBC100122C0202).
18
Automation Products Division
www.abb.com
www.abb.com/lowvoltage
© Copyright 2007 ABB. All rights reserved.
Preliminary 1SDC007099B0203