INSTALLATION AND OPERATIONS MANUAL:

DC 1500V AFCI COMBINER

REV. 0669-00-A
Innovative Solar Inc.
224 Airport Pkwy Suite 190 - San Jose, CA 95110

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INSTALLATION AND OPERATIONS MANUAL Innovative Solar Utility
1.0 Product Overview 6.0 Warranty and RMA Instructions
2.0 Ratings Table 7.0 Appendices
3.0 Installation 8.0 UL1741 / CSA Certification Letter
4.0 Operating Instructions

IMPORTANT SAFETY INSTRUCTIONS INSTRUCTIONS IMPORTANTES

SAVE THESE INSTRUCTIONS CONCERNANT LA SÉCURI
Before installing or using the String Combiner Box, please read all instructions and caution markings in this manual as well as on the string
combiner, on the PV modules and PV inverter or Charge Controller.

This manual contains important instructions that shall be followed during installation and operation of String Combiner Boxes. To reduce the
risk of electrical shock and to ensure the safe installation and operation of the combiner, the following safety symbols are used to indicate
dangerous conditions and important safety instructions.

CONSERVER CES INSTRUCTIONS. CETTE NOTICE CONTIENT DES INSTRUCTIONS

IMPORTANTES CONCERNANT LA SÉCURITÉ.

Instructions for Positive Negative Ground DC Electrical

WARNING Qualified Connection Point Connection Point Connection Connection
Could Injure Personnel or Personnel Only Symbol Symbol Point Symbol Point Symbol
Damage Equipment

All electrical installations, including the wiring method, shall be performed in accordance with all local and national electrical codes, including NFPA
70 and the Canadian Electric Code Part 1.

WARNING – The fused string combiner contains no user serviceable parts. For maintenance, please
contact Innovative Solar or an authorized installer by visiting www.innovativesolarinc.com or by
calling +1-888-315-6551.

WARNING – Disconnect all PV modules or follow your site specific instructions when connecting the
array. PV arrays produce electrical energy when exposed to light and could create a hazardous condition.

AVERTISSEMENT – Couper Toutes Les Sources d’alimentation Avant Le Dépannage.

WARNING – Connection of the String Combiner Box to PV modules as well as PV inverter to the electric
utility grid must be performed only by qualified personnel.

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 1.0 Product Overview

The String Combiner is a disconnecting fused string combiner designed for combining multiple strings of photovoltaic (PV) modules for
connection to an inverter. In a large PV array, each string of PV modules must be fused before being paralleled and connected to an inverter.
The String Combiners are available with up to 32 source inputs and each source circuit is designed to utilize a fuse that is rated at least 156% of
the short circuit current rating of the respective PV string source circuit. The fuse value for any source circuit should not exceed the PV module
fuse rating.

1.1 Switch Operation

The String Combiner contains a user-operable switch. The switch is 2-poles and interrupts both the positive and negative legs simultaneously.
When the switch is in the ON position, the circuit is closed between the source conductors and the output conductors. In the OFF position, the
circuit is open between the source conductors and the output conductors. The switch is full load-break rated and can be safely operated under
normal operating conditions when installation is per this guide and all warnings and ratings are observed.

1.2 AFCI and RSD Versions

In Arc-Fault and Rapid Shutdown versions the user-operable switch can also be tripped electronically. Control power must be available to the
combiner box for the switch to be tripped in response to an Arc-Fault. In Rapid Shutdown (RSD) configurations, loss of control power will also
trip the switch. When “TRIPPED”, the switch handle will move to an intermediate position and both main contacts will open in the same manor
as if the switch were turned off manually. Returning control power after an Arc-Fault or Rapid Shutdown will not reset the switch. Whenever
tripped, the switch must be reset manually. To do this, turn the switch handle full CCW to the “Reset” position. Only then may it be turned CW
to the “ON” position.

1.3 Surge Suppression

The combiner box is rated for a maximum voltage of 1500VDC, but can also be used on 1000v systems. In order to better support 1000VDC
systems using surge protection, all models can also be ordered with 1000v surge protection.

2.0 Ratings Table

Ratings
Size Standard Size Enclosure Over-Size Enclosure
Operating Voltage Range 0 - 1000 VDC 0 - 1500 VDC 0 - 1000 VDC 0 - 1500 VDC
Max Output Current 400 A
# of Fused Inputs 6 to 24 (up to 32A) 6 to 32 (up to 32A)
Fuse Size Range (A) 3 - 32, 40, 50, 63 A (1 leg only, per NEC2017)
Non-fused leg Switched (per NEC2017)
Input Conductor Size 10 - 8 awg (up to 32A)
# of Output Conductors 1 or 2 (per polarity)
Output Connection Dual M12 (1/2") Studs, 1.75" Spacing (Optional Mechanical Lugs)
Max Output Conductor Size 1000 MCM (dual 600 MCM)
Ground Connections (2) 2/0 + (10) 14 - 4 awg
Ambient Operating Temp -40°C to +50°C (-40°F to +122°F)
Ambient Storage Temperature -40°C to +85°C (-40°F to +185°F)
Certifications UL 1741 (2nd Ed.) (R2015) __ CSA C22.2 No. 290-15
Enclosure, Fiberglass (Standard) NEMA 4X
Dimensions H x W x D 24"x30"x10" n/a
Net weight (approx.) 75 lb. n/a
Enclosure, Powder coated CRS (Optional) NEMA 3R/4
Dimensions H x W x D 24"x30"x10" 30"x30"x10"
Net weight (approx.) 80 lb. 90 lb.

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 Control Power for AFCI and RSD Versions
Version Non-AFCI AFCI RSD AFCI & RSD
Control voltage n/a 120 or 230vac, 24vdc, ±10% 120 or 230vac,
±10%, 50-60Hz ±10%, 50-60Hz
Power consumption n/a 2W 1.6 W 4W
Inrush consumption, <10ms n/a 170 W 1.6 W 4W

3.0 Installation

WARNING – These installation instructions are for use by qualified personnel only. To reduce the risk of
electric shock, do not perform any installation unless you are qualified to do so.

WARNING – This manual contains important instructions for all String Combiner models that shall
be followed during installation of the String Combiner Box.

The necessary steps to installing the String Combiner are unpacking, inspecting, mounting, conduit installation, wiring, testing, and commissioning.

3.1 Unpacking and Inspection

The String Combiners are thoroughly inspected and rigorously tested before they are shipped. Even though the units are delivered in cardboard
packaging, it is possible that the units may become damaged during shipment. Inspect the combiner thoroughly after it is unpackaged. If damage is
noticed, document the damage with digital photos and immediately report the damage to the shipping company. If there is any question about
potential shipping damage, contact Innovative Solar. If it is determined that the unit must be returned, an RMA number must be obtained from
Innovative Solar prior to returning the unit. Take care not to set the combiner on a gravel surface that might scratch the finish.

3.2 Mounting
The String Combiner enclosure is Type 4 or 4X rated and will maintain the rating with appropriate installation methods. For personnel safety, the
String Combiner box should not be installed with the door angled downward at any angle. See mounting option graphic for further understanding.

Be sure to verify load capacity of the mounting area. Mount the combiner using the mounting holes provided.

Install the combiner in an accessible location following NEC codes for

enclosure and switch clearances and proximity to other equipment.

Although not required, the combiner and fuses will stay coolest
if the combiner is located in shade or partial shade from the
array, equipment vault, or other equipment at the site.

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 3.3 Install Conduits
The use of UL514B or equivalent conduit fittings and UL50 installation methods are required to maintain the Type 4 or 4X rating of the enclosure.
Failure to follow these standards may result in water intrusion into the unit through conduit connections and may void the warranty.

Output conduits and source circuit conduits must be installed on the bottom.

Figure 1 –Dimensions (Fiberglass 24x30)

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 Figure 2 –Dimensions (Steel 24x30)

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3.4 Wiring
The String Combiner must use copper source circuit conductors only. For the PV output circuit feeders, either copper or aluminum conductors may
be used. As with any aluminum wiring, follow best industry practices to ensure a reliable connection; thoroughly clean the conductor just prior to
making the electrical connection and use an oxide inhibitor to prevent the formation of aluminum oxide.

All output conductor terminations are rated and have been tested for 90°C wire sizing.

All wiring must be in accordance with local and national electrical codes.

3.4.1 Remove Fuses

WARNING– Removing fuses from a live circuit may create dangerous arc-flash and shock hazards.
1. Confirm that the switch is in the OFF position.
2. Remove each fuse from the touch-safe fuse holder for each source circuit. Store the fuses for later reinstallation.

3.4.2 Shield Removal

WARNING – Removing the plastic shield(s) exposes the installer to dangerous voltage and shock hazards.
WARNING– Remove all fuses before proceeding with Sections 3.4.3 through 3.4.7.
1. Loosen, but do not remove the screw using a screwdriver.
2. Gently remove the plastic shield and store for reinstallation.
3. Leave the screw in place for reinstallation of the plastic shield.

3.4.3 Grounding
See NEC Article 250 and 690 for grounding requirements. A ground bar has been provided for Equipment Grounding Conductors (EGCs).
Torque each EGC accordingly. The String Combiner Box EGC terminal should be used to connect the enclosure to the inverter EGC circuit.

Equipment Grounding Terminals PV Output Circuit Equipment Grounding Terminals

10 positions, 14AWG – 4AWG (2) 6AWG – 2/0AWG

Torque to 35 in-lb, use slotted driver Torque to 50 in-lb, use 3/16” Allen wrench
Cu or Al Conductors Cu or Al Conductors

3.4.4 Source Conductors

See NEC Articles 310 and 690 for proper source circuit conductor sizing. Note that the conductor size ranges given here and on the labels in the
product are the overall allowed ranges that fit in the terminals but the minimum size conductor that can be used must be determined using NEC
and is likely larger than the minimum shown in the ranges.

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 Acceptable source circuit conductor inputs are restricted to copper for the fused source circuit inputs.

Fused Source Conductors Non-Fused Source Conductors

(1) 14AWG – 6AWG 14AWG – 4AWG

Torque to 20 in-lb, use #2 Phillips Torque to 35 in-lb, use 1/8” Allen
75°C Terminations, Cu Conductors Only 90°C Terminations, Cu or Al Conductors

Connect the fused source circuit conductors to the touch safe fuse holders, one conductor per fuse holder. Route all source circuit conductors
such that the installation is neat and orderly.

Connect the Non-Fused source circuit conductors to the negative source circuit terminal block, one conductor per screw terminal; torque each
circuit conductor as described above. Route all source circuit conductors such that the installation is neat and orderly.

3.4.5 PV Output Circuit Conductors

See NEC Articles 310 and 690 for proper output conductor sizing. Innovative Solar provides dual M12 studs (Nema 1.75” pattern) for compression
lugs as standard on utility scale String Combiner Boxes. Combiners can be field configured for mechanical lugs. Simply install the mechanical lug on
the lower stud. Mechanical lugs can be purchased as an accessory.

Output terminals on all Innovative Solar combiners are CU/AL compatible and are approved and tested for 90C sized wire.

A. PV Outputs

600 kcmil– 2 awg

Torque to 550 in-lb (46 ft-lb)
For compression lugs Use 1/2” Allen wrench
2x M12 Studs per bus 90°C Terminations
Torque to 350 in-lb (29.2 ft-lb) Cu or Al Conductors
Maximum lug width 2.40” Strip length 1.4”
Consult factory for alternate lug sizes

NOTE: Only use lugs with aluminum conductors that are explicitly listed for use with aluminum conductors.

3.4.6 Control wiring

For AFCI and Rapid Shutdown versions, control power must be provided to the
control module. Please see the ratings table for power requirements.

Connect L, N, and GND as indicated by terminal block J1 on the control module.

The control module is located in the upper left corner of the enclosure.

The control module also provides an auxiliary contact. The contacts will be in their normal state any time that the switch is tripped or power is lost.

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 Code requires that the control
conductors be segregated from the PV
conductors, if the control conductors
are not also rated equal or higher than
the PV voltage. To support this
segregation, anchor holes have been
provided along the left side perimeter of
the mounting pan. Non-conductive
tubing or conduit may be used on the
conductors if an additional barrier is
needed. A fixed barrier is provided
between the control module and
adjacent bus bar.

If desired the need for this segregation

can be reduced by having the control
conductors enter the enclosure in
proximity to the control module.

The trip coil in the disconnect switch

requires that only specific voltages
be used. For other voltages such as
208vac, a good solution is the use of
a buck-boost transformer. These
transformers are smaller and easier
to implement than isolation
transformers.

3.4.7 Final Steps

WARNING– Verify the proper polarity of each source conductor. Polarity reversal can lead to dangerous
arc-flash conditions capable of harming personnel and equipment.

WARNING– Check the String Combiner Box for tools and ensure the unit is clean and orderly.
1. Verify all connections meet the requirements of this Installation and Operations Guide.
2. Reinstall the plastic shield.
3. Install all fuses.
4. Close the string combiner door.

4.0 Operating Instructions

WARNING– Do not operate the switch with the String Combiner Box door open.
The String Combiner contains a user-operable switch. When this switch handle is in the OFF position, the circuit is open between the source
conductors and the output conductors. Under normal operation, when the switch is in the ON position, the circuit is closed between the source
conductors and the output conductors.

4.1 AFCI Operation

The AFCI function continually monitors all input and output conductors for arcing. If any one of the AFD sensors detects the signature of an arc it
will send a signal to the control module. The control module in turn sends the appropriate signal to the switch in order for it to trip in < 1 sec.

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The AFD sensors each have an LED that indicates status: Flashing = normal, Continuous = fault, Off = power loss.

The control module has a bank of LEDs indicating the status of both inputs and outputs. Green LEDs indicate normal status, while red LEDs indicate
faults.

If an arc-fault is detected the disconnect switch will open and the disconnect handle will move to an intermediate position indicating that it has
been “TRIPPED”. At the same time the control module LEDs will identify that it has tripped as well as the source of the trip. The auxiliary contacts
will also change state providing for an optional remote indication.

In order to reset after a fault, rotate the disconnect handle to its full CCW momentary position “RESET”. This will both recharge the springs in the
disconnect and clear the logic in the electronics.

The disconnect switch may then be turned back on when desired.

AFCI Control Module

6.0 Warranty and RMA Instructions

For all warranty information, please visit: http://www.innovativesolarinc.com/

7.0 Appendices

7.1 Appendix A –Datasheet

Please visit: http://www.innovativesolarinc.com/

7.2 Appendix B – Contact Information

Innovative Solar Inc
224 Airport Parkway
Suite 190
San Jose, CA 95110 USA

Tel: 888-315-6551

Sales/General Info: [email protected]

Customer Support: [email protected]
Website: www.innovativesolarinc.com

7.3 Appendix C – Authorized Distributors

See website for complete and updated listing: http://www.innovativesolarinc.com/

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