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Compact Generator‐Junction‐Box with Monitoring
IInnssttaallllaattiioonn GGuuiiddee aanndd
OOwwnneerr’’ss MMaannuuaall
SSIINNUUSSSSTTRROOMM SSPPIIDDEERR
1
Inhaltsverzeichnis1. Introduction ..................................................................................................................................... 3
2. Brief Description .............................................................................................................................. 4
3. safety instructions ........................................................................................................................... 5
3.1. General Safety Instructions ..................................................................................................... 5
3.2. Installation ............................................................................................................................... 5
3.3. Service and Modification ......................................................................................................... 5
3.4. Danger of Burning ................................................................................................................... 5
3.5. Functional Safety ..................................................................................................................... 6
3.6. Electric Shock and Arcing ........................................................................................................ 6
3.7. Fire Development .................................................................................................................... 6
3.8. Toxin Development ................................................................................................................. 6
4. General Description ......................................................................................................................... 7
5. Installation Guide and Owner’s Manual .......................................................................................... 8
5.1. SINUSSTROM SPIDER ............................................................................................................... 8
5.1.1. Mounting ......................................................................................................................... 8
5.1.2. Connection ...................................................................................................................... 8
5.2. Data Cable (RS485 – field bus) ................................................................................................ 9
5.3. Data Plug ................................................................................................................................. 9
5.4. Base ....................................................................................................................................... 10
5.5. Overvoltage Bus Protection ................................................................................................... 10
5.6. Bus Topology ......................................................................................................................... 10
6. General Technical Data ................................................................................................................. 12
7. Electrical Protection ...................................................................................................................... 13
7.1. Back Current Protection ........................................................................................................ 13
7.2. String Protection .................................................................................................................... 13
7.3. Overvoltage Protection ......................................................................................................... 13
8. String Monitoring .......................................................................................................................... 14
8.1. Sinusstrom – Control ............................................................................................................. 14
8.2. Cover Page ............................................................................................................................. 14
8.3. Visualization .......................................................................................................................... 14
8.4. Channel Overview ................................................................................................................. 15
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8.5. Temperature .......................................................................................................................... 15
8.6. Realtime................................................................................................................................. 15
8.7. Export .................................................................................................................................... 15
8.8. Import .................................................................................................................................... 16
8.9. Alerting .................................................................................................................................. 16
8.10. Email Notification .............................................................................................................. 16
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1. Introduction
This document contains information on the installation and safe operation of the generator
junction box – SINUSSTROM SPIDER.
The compliance of all provisions and advices contained in this manual does not release from
the consideration of the valid regulations and guidelines as requested by the BGV and the
VDE.
The implementation of safety relevant regulations can also strong vary from each other so
that a planning by an electro technical specialized company is necessary.
4
2. Brief Description
The SINUSSTROM SPIDER is a generator junction box for large‐scale photovoltaic systems,
which are based on the central inverter concept.
With this product the strings, or a number of strings, can be brought together.
In addition the built‐in measurement technology enables the monitoring of the individual strings. This function is realized by the integrated day and night‐active string monitoring. This includes a highly accurate measurement of the input currents of the SINUSSTROM SPID‐ER. The measured values are recorded and stored centrally. An alarm function, which is implemented through a web portal, serves the immediate error detection. An alarm function, which is implemented through a web portal, serves the im‐mediate error detection. As another function the SINUSSTROM SPIDER protects the modules and thus ultimately the
entire photovoltaic system through the integrated diodes from reflux and the related dan‐
gers and losses.
The Installation Guide and Owner’s Manual encompasses the instructions to the installation
of the singular SINUSSTROM SPIDERs and the monitoring system. The communication sys‐
tem between the SINUSSTROM SPIDER and the web portal www.sinusstrom.com is illu‐
strated in a graphic in chapter 4.
5
3. Safety Instructions
3.1. General Safety Instructions
Attention! Before using the SINUSSTROM SPIDER, read the safety instruc‐
tions carefully!
3.2. Installation
Prior to installation check whether the packaging or the SINUSSTROM SPIDER is dam‐
aged. If in doubt contact your supplier before you install the SINUSSTROM SPIDER.
All persons employed with the installation of the SINUSSTROM SPIDER, have to be
trained in relation to the general safety instructions concerning electrical equipment and
have to have the necessary experience. They must also be familiar with local require‐
ments, regulations and guidelines and safety regulations.
Make sure during the installation, that the SINUSSTROM SPIDER is mounted vertically in
each case. Vertically means, that the data cable plug is directed downward.
Make sure during the installation of the SINUSSTROM SPIDER, that the de‐
vice in general duty is always out of direct sunlight.
3.3. Service and Modification
It is permitted only authorized staff to make repairs or upgrades on the SINUSSTROM
SPIDER. It may be used exclusively original spare parts available from your supplier to en‐
sure optimal personal safety. If no original spare parts are used, compliance with the
regulations relating to electrical safety, EMC and machine safety is not guaranteed.
3.4. Danger of Burning
Attention – Danger of Burning! The housing of the SINUSSTROM SPIDER
serves as a convection surface to dissipate heat loss. During general duty
temperatures > 60°C can occur.
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3.5. Functional Safety
Unauthorized changes to the SINUSSTROM SPIDER can result injury to functional safety
or damage to persons. Furthermore all operating licenses and certificates of the SINUS‐
STROM SPIDER lose their validity.
3.6. Electric Shock and Arcing
Attention – Electric Shock! After connecting of at least one string to the
SINUSSTROM SPIDER, the device is under electrical voltage. The strings are
connected with the SINUSSTROM SPIDER unless otherwise according to the
customer’s request, by a snap‐lock system (Amphenol H4). To prevent arcing when you
unlock the snap‐lock system, the unlocking is allowed only at current less state. Generally
special tool has to be used to unlock the snap‐lock system. A disconnection of the specif‐
ic SINUSSTROM SPIDER is previously absolutely necessary.
In case of destruction of the insulation in the SINUSSTROM SPIDER e.g. by lightning, the
data plug may be separated only with insulated gloves.
3.7. Fire Development
Attention – Fire Hazard! Despite the most careful manufacturing technolo‐
gy it is not entirely exclude, that in case of error or after lightning arcing
arise in or at the housing. Therefore the SINUSSTROM SPIDER has to be
mounted at least three feet away from combustible or inflammable materials.
The SINUSSTROM SPIDER must not be operated in areas of highly flammable or explosive
substances.
3.8. Toxin Development
Attention! After an error occurs, e.g. fire, the SINUSSTROM SPIDER may be
opened only by trained personal, because the overheating of the sealing
compound can occur toxic and harmful substances.
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4. General Description
The SINUSSTROM SPIDER has eight DC‐inputs, one DC‐output, one data cable plug, one
Earthing bolt (M6 screw joint) and a flange with four mounting holes (Ø 4mm).
The DC‐inputs are individually numbered. The DC‐output is spatially separated from the DC‐
inputs and has normally a different plug connection than the DC‐input. Confusion between
the DC‐inputs and the DC‐output is thus entirely excluded.
The housing has the following dimensions:
Width: 217 mm
Length: 188 mm
Height: 67 mm
On the front of the housing is a sign, that the device in general duty – caused by power
losses – can take temperatures, which can lead to burnings in case of direct contact?
Besides that there is another sign which refers on the internal bus address. The inscription of
the sign can be modified as desired according to the customer’s request.
The following figure shows the connection between the SINUSSTROM SPIDERs and the web
portal www.sinusstrom‐control.com.
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5. Installation Guide and Owner’s Manual
All relevant to installation technical data of the SINUSSTROM SPIDER please refer to the
chapter 6.1.
5.1. SINUSSTROM SPIDER
5.1.1. Mounting
The SINUSSTROM SPIDER has to be
mounted according to the four given
mounting holes (Ø 4mm).
Optionally can the base plate of the SINUS‐
STROM SPIDER be unscrewed and rotated
through 90°, so that the device can be
mounted according to the dashed mark.
Make sure during the installation, that the
SINUSSTROM SPIDER is mounted vertically
in each case. Vertically means, that the da‐
ta cable plug is directed downward.
When choosing the mounting point make
sure, that the SINUSSTROM SPIDER in general duty is always out of direct sunlight. If ne‐
cessary a sun protection has to be installed.
5.1.2. Connection The figure shows all connectivity op‐
tions of the SINUSSTROM SPIDER.
During installation make sure, that all
the snap‐lock connections lock and all
leads are backed up against critical
tensile stresses.
To realize a correct Connection the
DC‐inputs are individual numbered.
In each case the earthing bolt must be
connected.
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By design of the data plug (refer to chapter 5.3) the plug connection between the data
plug and data cable can take place only in one direction. To prevent a bending of the sin‐
gular PINs of the data cable, make sure that the data cable and the data plug are con‐
trolled connected.
The data cable has no snap‐lock and must therefore be backed up against self‐release.
5.2. Data Cable (RS485 – field bus)
As a Data cable is a Twisted–Pair–Cable with the following prescribed Wire‐Attributes to
be used (The wire colors correspond to the figure in chapter 4):
Data Line (2x≥0,14mm²) (RS485A (green wire) und RS485B (yellow wire) )
Signal Line (1x≥0,14mm²) (optional)
Operating Voltage (2x≥1mm²) (0 V (blue wire) und +48 V (rote wire) )
The Data Cable must be permanent isolated against the photovoltaic strings with a vol‐
tage of 1000V (DC).
5.3. Data Plug
The Data Plug has the following shape and pin assignment:
The wires 1ge (yellow) and 2gn (green) serve the data communication between the SI‐NUSSTROM SPIDER and the base. Over the wires 3ws (white) and 4br (brown) the ener‐gy supply of the measuring device and the SINUSSTROM SPIDER is realized.
The Signal Line 5rt (red) is currently not used.
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5.4. Base
The base, which operates with an operating voltage of 48V (DC) is an insulated level con‐
verter and gateway, which sends the collected data to a connected local computer.
The base can be mounted on a DIN rail.
The polling interval is depending of the number of connected SINUSSTROM SPIDERs. For
approx. 30 connected SINUSSTROM SPIDERs the polling interval is circa one minute. Are
100 SINUSSTROM SPIDERs connected, the process takes correspondingly about 3 mi‐
nutes.
In addition to the polling of all
devices, is an intensive polling
max. 2 SINUSSTROM SPIDER /
Base possible. The temporal
resolution for these two SI‐
NUSSTROM SPIDER takes in
optimal case two seconds. The
intensive polling interval caus‐
es a slowdown of polling of the remaining SINUSSTROM SPIDER.
5.5. Overvoltage Bus Protection
The Overvoltage Bus Protec‐
tion is a protector which pre‐
vents invalid overvoltage at
the base and the local com‐
puter, e.g. at overvoltage on
the bus through lightning.
5.6. Bus Topology
Over the 5‐pin data plug of the data cable the measuring data is transferred to the base.
The RS485‐Standard guaranties a reliable data transfer to the base. The data transfer
works with a master‐slave half‐duplex procedure. On one base two independent data
cables can be connected. Their length must not exceed 1200 m. Maximal 199 SINUS‐
STROM SPIDER can be administrated by the base and thus connected to the data cable.
11
The data cable has to be terminated with a terminating resistance (120 ohm / ≥0,5W) at
the end of the cable. Otherwise it may cause disorders. Factory‐set one cable end is the
base. The base is thus terminated with a terminating resistance. The other end of the da‐
ta cable must be terminated by the installer.
If the base is installed in the middle of the data cable, or elsewhere between the ends of
the cable, the terminating resistance must be removed through the corresponding jum‐
per. Both ends of the data cable must then be terminated with a terminating resistance.
In the SINUSSTROM SPIDER itself is no terminating resistance installed. The termination
must be set on cable end. For this purpose the termination resistance can be cast directly
to the cable end.
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6. General Technical Data
Generator Junction Box – Specific Values Input (DC) string number (number of measuring channels) 8
max. input current / string 5 A
max. input current / 8 strings 40 A
input voltage (Strings) 675 V
max. input voltage in idle state 1000 V
Input power 27 kWp
DC‐input female cable connector Amphenol H4 (250 µOhm contact resistance) / custom‐made produc‐ tion
Output (DC) max. output current 40 A
nominal load ca. 27 kWp
DC‐output female cable connector Amphenol H4 (250 µOhm contact resistance) / custom‐made produc‐ tion
Power Loss total power loss (SINUSSTROM SPIDER) max. ca. 44 W
Efficiency Efficiency > 99,8 %
String Monitoring SINUSSTROM SPIDERoperating voltage range 22 – 48 V (DC)
current consumption 36 mA
Data Cable twisted‐pair (Ø) 2x ≥ 0,14 mm2
operating voltage (Ø) 2x ≥ 1,00 mm2
data line (Ø) 1x ≥ 0,14mm2
data rate 1200 bit/s
termination resistance 120 Ohm / ≥0,5W
lenght max. 1200 m
Base data rate between base und computer 9600 bit/s
operating voltage 48 V
polling interval (30 connected SINUSSTROM SPIDER)
ca. 1 Min.
Abfrageintervall (100 connected SINUSSTROM SPIDER)
ca. 3 Min.
Intensiv polling interval ca. 2 Sek.
admin SINUSSTROM SPIDER max. 199 St.
Anschlüsse Datenkabel 2 St.
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Overvoltage Bus Protection data rate between overvoltage bus protection and base
1200 bit/s
operating voltage 22 – 48 V (DC)
ports data cable 2 St.
Current Measurement current measurement range / measuring chan‐nel
0 A up to + 6,23 A (with 0,01 A resolution)
measuring inaccuracy (current / measuring channel)
max. 2 %
General Technical Data protection class electronics / connection range (for IEC 60529)
IP 68 / IP 54
surrounding conditions (°C) ‐15 up to +50°C
dimensions with flange wxhxd (mm) 217 x 188 x 67
weight 1,4 kg
serial interface RS‐485
mounting holes Ø 4mm
standards & certifications EN 55011, class A; EN 61326‐1; CE
7. Electrical Protection
7.1. Back Current Protection
Back currents can appear at shadowing of one or more photovoltaic strings as well as at
mismatching. To prevent back currents successfully a back current diode is obstructed
for each DC‐input.
7.2. String Protection
It is recommended to provide the SINUSSTROM SPIDER with a string protection on DC‐
output. This string protection should protect the SINUSSTROM SPIDER from inadmissible
fault currents.
7.3. Overvoltage Protection
Besides the string protection we recommend to protect the SINUSSTROM SPIDER on DC‐
output through an overvoltage protection from type 2 of overvoltage, which can be
caused by indirect lightning. The use of additional overvoltage protection devices is rec‐
ommended.
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8. String Monitoring 8.1. Sinusstrom – Control
On the website of the Sinusstrom company
www.sinusstrom.com you will find the menu
named „Sinusstrom Control“
With click on this menu you will attain the web por‐
tal of the string monitoring.
You can sign in with your email address and your
specific password.
8.2. Cover Page
After signing in you will get to the cover page of the
string monitoring.
Here you can see the various locations of your
photovoltaic plants in a list. In addition you see a
current curve of one of your SINUSSTROM SPIDER
of one of your photovoltaic plants as a example.
The graph shows the current curve of the previous
day.
8.3. Visualization
With click on the menu “Visualisierung“ you get to
the corresponding menu. Here you can visualize
the recorded currents of all of your locations.
To visualize the desired graph, choose the date, the
location, the sublevel – “Unterverteiler” and the
second sublevel SPIDER.
15
8.4. Channel Overview
After a successful choice the channel overview of
the selected location opens.
By default all channels of the SINUSSTROM SPIDER
(max. 8 channels) are selected and visualized as a
graph. By clicking on each channel the graph can be
switched on and off.
If you have configured a link to a photo of the selected location under the submenu
„Administration“, a photo of the selected location appears between the calendar and the
selection catalog.
8.5. Temperature
With click on the button the tem‐
perature indicator opens for the chosen date and
location. The temperature profile is visualized as a
graph in the coordinate system. The red line marks
the up to date highest measured temperature at
the location of the selected SINUSSTROM SPIDER.
8.6. Realtime
Below the temperature indicator you find the button . Exists a link e.g.
to a webcam which shows your photovoltaic plant, so opens a window with click on the
button, in which the current recorded pictures are displayed. An arbitrary URL can also
be chosen.
8.7. Export
In the menu item “Export“ you have the possibility
to export all measured and recorded data of your
location in CSV‐Format. Choose therefore the de‐
sired date and location and click on the button
. It then opens a window and you can
save your file as you wish.
16
8.8. Import
In addition to the option Export you have the pos‐sibility to import files in CSV‐Format, which you have saved before on the server. This can be used at repair work for functional check of string cabling.
In this case the notification and the alert about the successful import of the data ensue only to the ex‐ecutive user.
8.9. Alerting
In the menu „Alarmierung“ you have the possibility to visualize the functional state of all of your SI‐NUSSTROM SPIDERs.
First you see your locations of your photovoltaic plants and their status.
With choice of one location a sublevel opens. The individual SINUSSTROM SPIDER and their status are shown.
If you choose a single SINUSSTROM SPIDER, another sublevel opens, which shows the in‐dividual strings and their status.
Depending on the functional state various status symbols are shown. They have the fol‐lowing meaning:
Complete failure. The complete channel is without function or lies under the toler‐
ance threshold.
String failure. One or more strings of one channel are without function.
Function o.k.
8.10. Email Notification
After the daily run of the monitoring algorithm the users are informed via email about
the detected errors. In this email the respective faulty channels and the alert category
are listed. Are no errors detected, ensues no email notification.
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IMPRINT
Sinusstrom GmbH
Ehrenbergstraße 11
98693 Ilmenau
phone: +49 / (0) 36 77 / 66 84 31
fax: +49 / (0) 36 77 / 66 84 39
email: [email protected]
web: www.sinusstrom.com
Disclaimer
The rendered common names, trade names resp. identification and other
designations, can be protected by law even without special labeling (e.g as
marks). SINUSSTROM GmbH assumes no liability or warranty for their free
applicability.
The compilation of texts and illustrations was done with great care.
Nevertheless, errors can not be excluded. The compilation is without
warranty.
© 2011 SINUSSTROM GmbH
All rights, including the photomechanical reproduction and the Storage in
electronic media, remain reserved to the Sinusstrom GmbH. A commercial
use or a passing on of the in this product used texts, shown models, draw‐
ings and photos are not permitted. This manual may not be reproduced in
whole or in parts without prior written consent.
retrieved 03.2011, changes reserved
