dc combiner box and ac solutions cs6 - cooper · pdf fileleadership in circuit protection dc...

Leadership in circuit protection

DC Combiner box and AC solutions

We deliver:• Electrical solutions that use less energy, improve power reliability

and make the places we live and work safer and more comfortable

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Discover today’s Eaton.

Powering business worldwide

As a global power management company, we help customers worldwide manage the power needed for buildings, aircraft, trucks, cars, machinery and businesses.

Eaton’s innovative technologies help customers manage electrical, hydraulic and mechanical power more reliably, efficiently, safely and sustainably.

We provide integrated solutions that help make energy, in all its forms, more practical and accessible.

With 2013 sales of $22 billion, Eaton has approximately 100,000 employees around the world and sells products in more than 175 countries.

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Energizing a worldthat demands more.

Eaton and Cooper united.

2 EATON DC Combiner box and AC solutions

Company overviewBussmann, a division of Eaton, is the

leading source of circuit protection

solutions in the global marketplace.

Bussmann products are approved

for use around the world and meet

agency requirements and international

standards: IEC, VDE, DIN, CCC, UL, CSA,

BS and others.

Bussmann global headquarters are in

St Louis, Missouri (US), the European

headquarters are in Burton-on-the-

Wolds, Leicestershire (UK), and Asia-

Pacific based in Shanghai. Bussmann

manufactures over 50,000 unique

parts covering extensive circuit

protection solutions for a wide range

of applications and markets, including:

utility, industrial, renewable energy,

automotive and hybrid electric vehicles

and rail applications.

Drawing on a hundred years of fuse

design and expertise, Bussmann has

been at the forefront of the solar

PV market as it has evolved to

become a mature sustainable and

adaptive technology.

PV systems, as with all electrical

power systems, must have appropriate

protection to ensure safe reliable

operation. Throughout this evolution

Bussmann has worked closely with

solar system manufacturers and through

coordinated research and development

has produced revolutionary new fuse

links, surge protection devices and

integrated solutions to ensure people,

property and payback are protected.

As a leading exponent in the design,

development and manufacture of

overcurrent protection, the Bussmann

team of specialist engineers play

a leading role in international

standardisation of photovoltaic fuse

links, offering comprehensive advice on

selection and applications

With a global manufacturing footprint

and a continual commitment to meet

our customers’ needs Bussmann

continues develop innovative high-

quality products for the PV market,

protecting tomorrows’ future, today.

3EATON DC Combiner box and AC solutions

Due to their small size, system protection is often overlooked within residential PV installations. On the contrary adequate protection of the DC and AC circuits in residential installations is just as critical as in much larger systems. Typically made of one or two strings of eight modules, high voltage DC cables may be run throughout the residential building; here it is critical to protect people and property from fi re and death in the event of accidental damage or system failure.

Residential installations < 50kW

• Combiner box

• SPD

• Switch

• Inline fuse holder

• Fireman’s switch

Residential installations


Residential combiner boxFor residential systems where inline fuses are used a simple two string combiner box with DC isolation and PV surge protection can be custom designed in a convenient compact unit.

Standards IEC 61439-1, IEC 61439-2 and IEC 60363-7-712Number of strings 2*, 3, 4

Voltage up to 1000 Vdc

Fuse Optional 10x38 gPV 8 to 12A*

DC load isolation Recommended 25 Adc* to 63 Adc

Overvoltage protection PV T2*

* Typical confi guration

DC overvoltage protectionIntegrated as part of the residential combiner box or installed separately, the DC surge protection device (SPD) protects against damaging voltage surges typically caused by indirect or direct lightning strikes.

Standards EN 50539-11 EN 50539-11SPD test class PV T2* PV T1/T2

Voltage 600 Vdc*, 1000 Vdc 600 Vdc, 1000 Vdc

Short circuit current rating Iscpv 160 Adc* 1000 Adc

Max discharge current In (8/20)μs 40 kA* 40 kA

Lightning impulse current Iimp (10/350)μs - 5 kA


10x38 mm photovoltaic fuse linksThe Bussmann range of photovoltaic fuse links are specifi cally designed to provide high quality protection and isolation for photovoltaic installations ether at string level or within the combiner box.

Standards IEC 60269-6, UL 2579, CSA, CCC (1-15A), RoHS compliantVoltage 1000Vdc

Operating Class gPV

Current Ratings 1 – 6A, 8A, 10A*, 12A*, 15A, 20A, 25A

Size 10x38mm

* Typical values

Fireman’s switchThe PV Fireman’s switch is a DC switch disconnector that isolates the lines between the solar modules and the inverter. With the option for remote and under-voltage operation the PV Fireman’s switch enables fi refi ghters to safely isolate the DC lines in the event of a fi re.

Standards IEC/EN 60947-3Voltage 1000Vdc

Number of switches 1*

Switch rating 30A

Inputs/Outputs 1 in*/1 out*, 2 in/2 out

Terminal type MC4* or M12 gland

* Typical values

Inline fuse holderIdeal for residential systems of only one or two strings the Bussmann Inline fuse holder is a single pole, non-serviceable PV fuse and fuse holder assembly in an IP67 dust tight and temporary water immersion resistant housing for use in PV wire harnesses.

Standards CE (IEC 60269-6 fuse), UL , CSA Component AcceptanceVoltage 1000Vdc

Fuse gPV 10x38mm

Current Ratings 1 – 6A, 8A, 10A*, 12A*, 15A, 20A, 25A

IP protection IP67

Terminals Crimp connection for single/stranded 12-10AWG PV cable

* Typical values


As PV installations become larger, typically found in commercial rooftop systems, designing the correct PV protection becomes more important. Typically ranging from 50kW to a few Mega Watts these systems require careful consideration to ensure that they have correct protection and meet national and local codes for installation and connection to the grid.

Commercial installations 50kW to 1MW

• Combiner box


• G59 AC Panel 50kW

• Eaton’s engineering services

Eaton’s Electrical Services & Systems team

offers a comprehensive portfolio of services

tailored for every stage of a power system’s life

cycle – whether it’s design, build, or support.

Our services integrate and optimize the elements

of a power system to make sure it’s aligned with

business goals. We can help keep your power

system safe, effi cient, reliable, and up-to-date.

Commercial installations


Commercial combiner boxIn commercial installations a small number of PV strings may be combined before being input into a string inverter, this is particularly the case for thin-fi lm module based systems. Here for example Bussmann by Eaton can confi gure a three or four string combiner box to include gPV string fuses, DC isolation, and T2 or T1/T2 surge protection devices.

Standards IEC 61439-1, IEC 61439-2 and IEC 60363-7-712Number of strings 2, 3, 4*


Fuse 10x38 gPV 8 to 12A*

DC load isolation 25 Adc to 63* Adc

Overvoltage protection PV T2*

Terminal type MC4 connectors*, M16 glands

IP protection IP65

Enclosure GRP* with transparent*/opaque lid and IP65 breather vent


Overvoltage protectionOwing to the increased size and complexity of commercial PV installations it is important to ensure both AC and DC overvoltage protection is carefully considered and the right protection selected to prevent damage in the event of an indirect or direct lightning strike.

Standards EN 50539-11 EN 61643-11/IEC 61643-1SPD test class PV T2*, PV T1/T2 T1, T1/T2, T2

Confi guration 2 pole + PE 1, 2, 3, 4 Pole, 1+NPE, 3+NPE

Voltage 600, 1000* Vdc 75 – 580 Vac, 280* Vac

Short circuit current rating Iscpv 160*, 1000 Adc -

Max discharge current In (8/20)μs 40 kA* 35kA (T1), 50 kA (T1/T2)

40 kA (T2) (30 kA - 75 Vac T2)

Lightning impulse current Iimp (10/350)μs 5 kA (PV T1/T2) 35 kA (T1), 12.5 kA (T1/T2)


Fireman’s switchIn some markets national and local installation requirements may require the installation of a DC isolat-ing Fireman’s switch. In this case the Eaton Fireman’s switch can be confi gured in larger switch-discon-nector combinations necessary for commercial installations. With remote operation and under-voltage release the individual strings can be fed separately into the string inverter helping to optimise inverter performance.

Standards IEC/EN 60947-3Voltage 1000 Vdc

Number of switches 2, 3, 4*, 6

Switch rating 30 A each input

Utilization category DC-21A

Inputs/Outputs 2 in/2 out, 3 in/3 out, 4 in*/4 out*, 6 in/6 out

Terminal type MC4* or M12 gland

IP protection IP65

* Typical confi gurations

AC side grid and systems protectionAs PV systems become larger it is important to meet the national and local requirements for export to the grid, here Eaton has a number of customisable solutions to meet these requirements. For the UK a G59 distribution panel can be confi gured with integrated G59 relay and contactor as well as options for power metering and incoming AC MCBs. Similarly for Germany a VDE-AR-N 4105 preconfi gured unit can be supplied in a number of rating classes from 43 to 100k VA.

Standards G59 VDE-AR-N 4105Rated output As required. Typically <500kW 43, 55, 86, 100k VA

Rated operating voltage 230/400 Vac 230/400 Vac

Monitoring relay G59/3 relay Yes

Contactors 4 pole, rated to suit system 2 (DILMP series)

Terminal type Dependent upon cable size

Metering Multi-function energy meter, MID certifi ed with RS485 & pulse o/p

Isolator 4 pole, rated to suit system

* Typical confi gurations


For large scale ground mount utility PV systems the challenges of providing the correct type and level of system protection becomes ever more critical as system voltages and operating currents are typically signifi cantly higher. Spread out over large areas, with export powers typically in the magnitude of 10’s of MW these large scale solar farms represent signifi cant fi nancial investments for the owners and operators. For this reason it is critical to ensure safe and reliable operation of the DC, LV and MV circuits within these systems as well as meeting local and national codes for connection to the grid.

Utility installations

Utility installations > 1MW

• Combiner box


Eaton’s Electrical Services & Systems team

offers a comprehensive portfolio of services

tailored for every stage of a power system’s life

cycle – whether it’s design, build, or support.

Our services integrate and optimize the elements

of a power system to make sure it’s aligned with

business goals. We can help keep your power

system safe, effi cient, reliable, and up-to-date.


Utility combiner box

For utility scale PV systems the fully customisable Bussmann by Eaton combiner box solution comes into its own with numerous options for the number of input strings, gPV fuse ratings, and options for full system monitoring of individual sting currents and system voltage, power supplies and surge protection for DC, AC and communications. Using dedicated design rules the Bussmann by Eaton engineers tailor the solution specifi c to the installation to ensure all levels of protection are covered.

Standards IEC 61439-1, IEC 61439-2 and IEC 60363-7-712Number of strings 2 – 32 strings (20A fuse max), 2 – 16 strings (32A fuse max), 16 string*


Fuse 10x38 gPV 1 to 32A, 16A*

DC load isolation 25 Adc to 500 Adc, 250 Adc*

Overvoltage protection:

DC PV SPD PV T2*, PV T1/T2, remote indication±

AC SPD± 280 Vac T2, 1 pole, 2 pole or 1+NPE, with remote indication

Data line SPD± 24 V D1/C2

Monitoring±

String current 8, 16, 24 string shunt based monitoring

Power supply External 24 Vdc, Internal 240 Vac to 24 Vdc, Internal 1000 Vdc to 24 Vdc

Communication RS-485 2-Wire Modbus

Terminal type Bottom or side entry MC4 connectors*, M16 glands

IP protection IP65*, IP55 with IP55 vents



± Monitored combiner boxes only

XL square body and NH photovoltaic fuse links

The Bussmann range of XL square body and NH photovoltaic fuse links are specifi cally designed to provide reliable DC overcurrent protection needed for the demanding conditions of utility scale PV farms. Typically used in re-combiners and inverters these fuse links are capable of interrupting low overcurrents associated with faulted PV systems.

Standards IEC 60269-6, UL 2579, RoHS compliant,CSA (NH only), CCC pending

Sizes 01XL, 1XL, 2XL, 3L NH1, NH2, NH3

Voltage 1000, 1100, 1200, 1500 Vdc 1000 Vdc

Current rating 50 to 600A 32 to 400A

Operating Class gPV (UL PV) gPV (UL PV)

Indication Top indication Dual indication

Accessories Microswitches, XL fuse holders Microswitches, NH fuse holders

Medium voltage switchgear Xiria ring main unit

The Xiria Ring Main Unit system is metal enclosed and air insulated, equipped with load-break switches and circuit breakers for 12kV-20kA and 24kV-16kA networks.

They operate with a combination comprised of circuit breakers and electronic relays and feature high level of operational safety and a compact design. A variety of options are available including an extensible version.

Eaton’s full range of SF6-free medium voltage switchgear systems provide an opportunity to make an active contribution to reducing the worldwide emissions of SF6-gas.


PV system overviewEaton can offer a comprehensive range of products for safe, reliable and sustainable PV systems within residential, commercial and utility sectors. Drawing on a hundred years of design and expertise the Bussmann by Eaton combiner box can be confi gured as a simple 2 string unit for residential systems, up to 34 strings with monitoring for utility scale systems.

With a focus on reliability and safety the Bussmann by Eaton combiner box solution has been designed with superior thermal characteristic making it suitable for a range of environments with ambient temperatures up to 50°C. Independent, third party testing and certifi cation by TUV Rheinland gives additional peace of mind that the product is fully compliant to IEC standards IEC 61439-1, IEC 61439-2 and IEC 60364-7-712.

With a global manufacturing footprint and local support, Eaton can meet the needs of PV installations large and small throughout the world.

Feature Benefi tCustom design solution Meets the needs any PV installation

TUV Rheinland tested and certifi ed Reassurance in design reliability and safety

Superior thermal design Reliability in harsh environments up to 50°C

Industry leading internal components Confi dence from 1000’s MWh of global use

Global manufacturing footprint Local support and reduced time frames

Terminal type MC4 connectors*, M16 glands

IP protection IP65





1 Residential combiner box

2 DC overvoltage protection

3 10x38 PV fuse links

4 Single fi reman's switch

5 Inline fuse holder

6 Commercial combiner box

7 AC Overvoltage protection

8 Multiple fi reman's switch

9 AC side grid protection

10 Utility combiner box

11 XL & NH PV fuse links

12 LV & MV switchgear

13 Eaton's Electrical Services & Solutions


Eaton Industries Manufacturing GmbHElectrical Sector EMEARoute de la Longeraie71110 Morges, SwitzerlandEaton.eu

© 2014 EatonAll Rights ReservedPrinted in UKPublication No. BR132004ENOctober 2014

Eaton is a registered trademark.

All other trademarks are property of their respective owners.

Changes to the products, to the information contained in this document, and to prices are reserved; so are errors and omissions. Only order confirmations and technical documentation by Eaton is binding. Photos and pictures also do not warrant a specific layout or functionality. Their use in whatever form is subject to prior approval by Eaton. The same applies to Trademarks (especially Eaton, Moeller, and Cutler-Hammer). The Terms and Conditions of Eaton apply, as referenced on Eaton Internet pages and Eaton order confirmations.

Eaton’s Bussmann Business Cooper Bussmann (UK) LtdMelton RoadBurton-on-the-WoldsLE12 5THUnited KingdomTel: +44 (0)1509 882 600Fax: +44 (0)1509 882 786Email: [email protected]

Customer Support CentreEaton Electric LimitedGrimshaw LaneMiddletonManchesterM24 1GQUnited KingdomTel: +44 (0)8700 545 333Fax: +44 (0)8700 540 333Email: [email protected]

Contact your local Eaton Offi ce

At Eaton, we’re energized by the challenge of powering a world that demands more. With over 100 years experience in electrical power management, we have the expertise to see beyond today. From groundbreaking products to turnkey design and engineering services, critical industries around the globe count on Eaton.

We power businesses with reliable, efficient and safe electrical power management solutions. Combined with our personal service, support and bold thinking, we are answering tomorrow’s needs today. Follow the charge with Eaton. Visit eaton.com/electrical.

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