Smart Combiner Box

Installation Manual

SolarBOS, Inc.
310 Stealth Court
Livermore CA 94551-9552
925-456-7744 ph.
925-456-7710 fax
www.solarbos.com

1
Copyright © 2013 SolarBOS, Inc. All rights reserved.
All rights reserved. No part of this document may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photographic, magnetic, or otherwise,
without the prior written permission of SolarBOS, Inc.
SolarBOS makes no representations, express or implied, with respect to this documentation or any of the
equipment and/or software it may describe, including (with no limitation) any implied warranties of utility,
merchantability, or fitness for any particular purpose. All such warranties are expressly disclaimed.
SolarBOS is not liable for any indirect, incidental, or consequential damages under any circumstances.
(The exclusion of implied warranties may not apply in all cases under some statutes, and thus the above
exclusion may not apply.)
Specifications are subject to change without notice. Every attempt has been made to make this document
complete, accurate and up-to-date. Users are cautioned, however, that SolarBOS reserves the right to
make changes without notice and shall not be responsible for any damages, including indirect, incidental
or consequential damages caused by reliance on the material presented, including, but not limited to,
omissions, typographical errors, arithmetical errors or listing errors in the content material.

Revision History
Rev. No. Date By Description
1.0 5 April 2013 AO Preliminary Release
1.1 16 April 2013 JS ETL Release
1.2 9 May 2013 AO Menu Layout
1.3 15 April 2014 AM Reformat TOC, added AFCI section
1.4 17 July 2014 AM Added 24VDC customer input wiring diagram
1.5 24 July 2014 AM Rewrote Appendices 1, 2, and 3
1.6 05 July 2016 JP Updated Menu

SolarBOS, Inc.
310 Stealth Court
Livermore CA 94551
925-456-7744 ph.
925-456-7710 fax
www.solarbos.com

2
 Table of Contents
1. Safety Instructions ....................................................................................................... 5
1.1. Symbols ................................................................................................................................. 5
1.2. Warranty ................................................................................................................................ 6
2. Introduction .................................................................................................................. 7
2.1. Unpacking & Inspection ........................................................................................................ 7
3. Installation .................................................................................................................... 8
3.1. Dimensions & Weights .......................................................................................................... 8
3.2. SMART Combiner Orientation .............................................................................................. 9
3.3. Disconnect Switch Assembly ................................................................................................ 9
3.4. Defeating the Disconnect Handle.......................................................................................... 9
4. Wiring ...........................................................................................................................10
4.1. Input Wiring ......................................................................................................................... 10
4.2. Output Wiring ...................................................................................................................... 10
4.3. Wire Entry Locations & Dimensions .................................................................................... 11
5. Circuit Map ...................................................................................................................12
5.1. PV Fuses ............................................................................................................................. 12
6. The Smart Sensor Module ..........................................................................................13
6.1. Smart Combiner Wiring ....................................................................................................... 13
6.1. 24VDC Input Wiring............................................................................................................. 13
7. AFCI Combiner Box.....................................................................................................14
7.1. Even-String CT Installation ................................................................................................. 14
7.2. Odd-String CT Installation ................................................................................................... 15
7.3. Lexan Guard Installation ..................................................................................................... 16
8. Commissioning the Combiner Box ............................................................................17
8.1. Channel Light Map and Menu Navigation ........................................................................... 18
8.2. Zero Current Calibration ...................................................................................................... 20
8.3. Setting Active Channels ...................................................................................................... 21
8.4. Operating Calibration (Only Required for Modbus Users) .................................................. 22
8.5. Setting Modbus Address ..................................................................................................... 24
8.6. Arc Fault Self-Test............................................................................................................... 26
8.7. Exiting the Menu.................................................................................................................. 26
8.8. Arc Fault Detection and Interruption ................................................................................... 26
8.9. Resuming normal operation after a fault ............................................................................. 26
9. APPENDIX 1 - Sensor Board Operation Quick Guide (Active Channels Version) ...27
9.1. Accessing and navigating the menus.................................................................................. 27
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 9.2. Menu indicators ................................................................................................................... 27
9.3. Entering Modbus address and Operation Calibration values ............................................. 27
10. APPENDIX 2 – Sensor Board Reset Button and Menu/Select Button Clarification 28
11. APPENDIX 3 – Torque Values .....................................................................................29
12. APPENDIX 4 – Factory Provided Control Wire Schematic .......................................30
13. APPENDIX 5 – Previous Menu Version ......................................................................31
13.1. Differences between Versions ........................................................................................ 31
13.2. Sensor Board Functions Menu ........................................................................................ 31
13.3. Setting the report type ..................................................................................................... 32
14. APPENDIX 6 - Sensor Board Operation Quick Guide (Previous Menu Version) .....33
14.1. Accessing and navigating the menus.............................................................................. 33
14.2. Menu indicators ............................................................................................................... 33
14.3. Entering Modbus address and Operation Calibration values ......................................... 33
15. APPENDIX 7 – Dual/Single Control Board Differentiation ........................................34
15.1. Dual Top Board with No Ribbon Cable ........................................................................... 34
15.2. Single Top Board with Ribbon Cable .............................................................................. 34
16. APPENDIX 8 - Troubleshooting ..................................................................................35
16.1. Board will start up, but only Channel 1 light is lit up........................................................ 35
16.2. Board’s green light is solid .............................................................................................. 35
16.3. Board frozen/locked up ................................................................................................... 35

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 IMPORTANT SAFETY INSTRUCTIONS
***SAVE THESE INSTRUCTIONS***

This manual contains important instructions for all SolarBOS Smart Combiner Box models that must be
followed during the installation and use of the Smart Combiner Box.
The Smart Combiner Boxes are designed and tested according to international safety requirements. As
with all electrical and electronic equipment, certain precautions must be observed when installing the
Smart Combiner. To reduce the risk of personal injury and to ensure the safe installation and operation of
the Smart Combiner, you must carefully read and follow all instructions and warnings in this Installation
Guide.

1. Safety Instructions
1.1. Symbols
Safety and Hazard Symbols

HAZARD: This symbol appears beside instructions and warnings that deal with
dangerous voltages that can injure people who come in contact with them.

Warnings
WARNING: A warning describes a hazard to equipment or personnel. It calls
attention to a procedure or practice, which, if not correctly performed or adhered to,
could result in damage to or destruction of part or all of the SolarBOS equipment
and/or other equipment connected to the SolarBOS equipment or personal injury.

Warnings may also be accompanied by one or more of the safety and hazard symbols described above
to indicate the type of hazard described therein.

Other Symbols
In addition to the safety and hazard symbols described previously, the following symbol is also used in
the Installation Guide:

ATTENTION: This symbol accompanies notes that call attention to supplementary

information that you should know to ensure optimal operation of the system.

GROUND: This symbol marks the areas in the combiner for connecting equipment
grounds only.

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 1.2. Warranty
All combiners sold in the USA have a five-year warranty. For warranty coverage, or if you have questions
about the combiner warranty, contact SolarBOS at the address, telephone number, or web site listed on
page 1 (to send e-mail, see the contact section of the SolarBOS web site: www.solarbos.com).

WARNING: All electrical installation must be done in accordance with the National
Electrical Code ANSI/NFPA 70, local building codes, and the requirements of the
authority having jurisdiction.
WARNING: To prevent electrical shock or injury, all wiring and commissioning
procedures must be performed by qualified personnel.

WARNING: Before installing or using the Smart Combiner, read all of the
instructions and warnings on the combiner and in this Installation Guide.

WARNING: PV arrays produce electrical energy when exposed to light and thus
create an electrical shock hazard.
WARNING: The Smart Combiner uses an integrated disconnect switch, yet both
the line and load side of the switch may still be energized in the OFF position.
Always test both sides of the disconnect before servicing the combiner.

6
2. Introduction
SolarBOS has introduced a new line of Smart Combiner Boxes designed for use with all module and
inverter combinations.
Combiner features include:
 Listed to UL 1741
 Capable of detecting and interrupting series arcs in the array wiring
 Available in NEMA 3, 3R, 4 powder-coated steel, and NEMA 4X stainless steel or fiberglass
enclosures (others available upon request)
 Integrated load-break disconnect switch (optional)
 Integrated load-break contactor switch (optional)
 Current sensing (optional)
 Arc-Fault Circuit Interruption (AFCI) (optional)

A note on nomenclature:
The solar industry oftentimes refers to a combiner box as a “combiner” or “string combiner” and if these
terms are used within this manual they should be considered to mean a “combiner box.”
Additionally, UL (Underwriters Laboratories) makes a distinction between an Arc Fault Detection (AFD)
device and an Arc Fault Circuit Interruption (AFCI) device. An AFD device detects series arcs per the UL
1699B test standard whereas an AFCI device detects and interrupts series arcs per the UL 1699B test
standard. SolarBOS combiners are AFCI devices, even though they also meet the requirements of an
AFD device.

2.1. Unpacking & Inspection

All SolarBOS Smart combiners are thoroughly checked before they are packaged and shipped. Although
they are shipped in sturdy packaging, damage can still occur during shipping and delivery. It is important
to carefully inspect the shipping container and contents prior to installation. If you detect any external
damage after unpacking, report the damage immediately to SolarBOS and the shipping company that
delivered the unit. Items not rejected within 10 days of delivery are considered accepted without recourse.
If it becomes necessary to return the combiner, please use the original packing material.
If you need assistance in dealing with a damaged unit, contact SolarBOS at 925-456-7744.

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3. Installation
3.1. Dimensions & Weights
Refer to Figure 1 and Tables 1-2 for enclosure dimensions. Use appropriate hardware for the mounting
surface. The dimensions of the unit for each Smart Combiner option and the respective weights are
shown in Table 1 below.

Figure 1. Combiner Enclosure Dimensions

Table 1.Smart Combiner Dimensions

ENCLOSURE # OF WEIGHT (LBS.)

H W D X Y
TYPE CIRCUITS STANDARD CONTACTOR DISCONNECT
N3/N4 8, 12, 16 20 20 6 18 18 35 37 39
N3/N4 24, 32 24 30 8 28 22 42 43 45
4XF 8, 12, 16 21 21 10 19 23 29 30 33
4XF 24, 32 25 31 10 29 27 42 44 47

All dimensions are in inches unless otherwise noted.

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 3.2. SMART Combiner Orientation
NEMA-3/4/4X enclosures may be installed in either the vertical or the horizontal orientation. This applies
to Smart Combiner with the “N3” “N4” “4XF” and “4XSS” designation. If installed horizontally (with the
door facing the sky), they should be supported by appropriate mounts.

WARNING: Do not install the Smart Combiner directly to the roof material. Doing
so will void the warranty.

3.3. Disconnect Switch Assembly

The Smart Combiner includes a handle installed on the enclosure door with clearly marked ON and OFF
positions. The switch handle (located on the enclosure door) allows padlocking in the OFF position
enabling Lock Out/Tag Out procedures.

3.4. Defeating the Disconnect Handle

For some applications, it may be necessary to temporarily defeat the
integrated disconnect switch on the Smart Combiner.
With the switch in the ON position, the handle door interlock may be
defeated with a tool, such as a small screwdriver, to allow the door to
be opened. The door interlock may be defeated in the ON position and
will reactivate automatically when the enclosure door is closed. See
item 1 on Figure 2.
With the enclosure door open, it is possible to operate the switch with
an auxiliary handle by defeating the handle interlock without using a
special tool.

Figure 2. Defeating the Disconnect Switch

WARNING: Only qualified personnel should defeat the handle door interlock on
the SMART Combiner.

9
4. Wiring
4.1. Input Wiring
Refer to Figure 2 and Table 2 for the input wiring locations of the SMART Combiner. PV positive and
negative conductors are wired into the positive lug and negative distribution block, respectively. These
terminal locations are clearly marked. All PV safety ground conductors are wired into the ground bus
located at the bottom of the SMART Combiner.

NOTE: The SMART Combiner enclosure is shipped with no entry holes. A knock-
out is required for the appropriate conduit size. SolarBOS recommends wire entry
to be made according to Figure 2.

4.2. Output Wiring

Some SolarBOS SMART Combiners have large fault current ratings. When temperature and voltage drop
adjustments are considered, the output conductor sizes can become quite large (500 MCM or greater)
and difficult to manage. NEC Article 310.4 allows paralleling of conductors greater than AWG 1/0 to
achieve higher ampacities.

NOTE: On units with provision for using crimp lugs use Panduit part number
LAA250-38-5 for 250MCM wire or a UL listed equivalent part from another
manufacturer. Be sure to use the appropriate part number for the intended wire
gauge.
NOTE: Rain tight or wet location hubs that comply with the Standard UL514B must
be used for NEMA 3/3R outdoor applications. NEMA 4 or 4X applications must use
watertight hubs that comply with the StandardUL514B. Use Myers-type, water-tight
conduit fittings such as Thomas & Betts H200TB (for 2” conduit) or H300TB (for 3”
conduit) or equivalent from others. Install fittings per manufacturer’s
recommendations.

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 4.3. Wire Entry Locations & Dimensions

Figure 3. Combiner Wire Entry Locations

Dimension “A”, “B”, “C”, and “D” are for input and output wire locations. These locations are
recommendations only. Care should always be taken to assure there is enough wire bend space for the
desired output wire gauge when choosing a conduit entry location. The wire entry locations for the
standard, contactor and disconnect combiners are shown in Table 2.

Table 2. Wire Entry Dimensions

COMBINER ENCLOSURE # OF
A B C D
TYPE TYPE CIRCUITS
N3/N4 8, 12, 16 20 8 8 7
N3/N4 24, 32 30 12 12 7
STANDARD
4XF 8, 12, 16 21 8 8 8
4XF 24, 32 31 12 12 8
N3/N4 8, 12, 16 20 8 8 7
N3/N4 24, 32 30 12 12 7
CONTACTOR
4XF 8, 12, 16 21 8 8 8
4XF 24, 32 31 12 12 8
N3/N4 8, 12, 16 20 8 8 7
N3/N4 24, 32 30 12 12 7
DISCONNECT
4XF 8, 12, 16 21 8 8 8
4XF 24, 32 31 12 12 8
All dimensions are in inches unless otherwise noted

11
5. Circuit Map
The following figure shows the channel map for the PV string inputs for up to 8, 12 and 16 channels.

(a) (b) (c)

1 3 5 7 9 11 13 15

2 4 6 8 10 12 14 16

Figure 4. Input wire labeling schematic for (a) 8 strings, (b) 12 strings, and (c) 16 strings

The Modbus output will report PV string current readings according to the channel map shown above.

5.1. PV Fuses
All SolarBOS SMART Combiners ship with fuses installed according to the user’s predetermined
requirements. All fuses and connection points are electrically tested prior to shipment. SolarBOS
maintains stock of common fuse sizes if replacements are necessary or spares desired.

WARNING: Never open a fuse holder while it is under load. Electrical arcing and
damage to the fuse holder will occur if a fuse holder is opened under load.

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6. The Smart Sensor Module
Smart Combiners include a sensor module located on top of the bus bar in between the fuse holders as
shown in Figure 5. The unit requires a 24V DC power supply available separately from SolarBOS. The
module measures the current of each circuit. The module is also capable of communicating current
information via Modbus/RS-485.
6.1. Smart Combiner Wiring
The output from the current sensor module is RS-485 serial using the standard Modbus RTU protocol.
The positive data, negative data, and data shield should be wired to the RS-485 network. The 24V DC in
is wired to the power supply. Minimum wire size of 24 AWG is required for RS-485 communications. The
24V DC wire should be sized based on distance and number of combiners.
6.1. 24VDC Input Wiring
The user must apply 24VDC at the provided terminals (600mA for AFCI models, and 100mA for AFD
model combiner boxes).

USER MUST APPLY 24VDC AT

THE PROVIDED TERMINALS

PV IN (-)
PV IN (+)

PV OUT (-)

MENU/SELECT
BUTTON

PV OUT (+)
PV IN (+)

Figure 5. The SolarBOS Smart Combiner connection points. AFCI combiner shown.

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7. AFCI Combiner Box
7.1. Even-String CT Installation
The Current Transducer (CT) is installed in one of two ways: “even-count” and “odd-count”. The terms
“even” and “odd” refer to the total number of string inputs entering a given combiner box. Figure 7 shows
an example of an even-count string input installation.
NOTE: Colored conductors shown for illustrative purposes only. Use appropriately sized conductors.

EVEN HALF OF
EVEN TOTAL STRINGS
NUMBER
OF
TOTAL
STRINGS

EVEN HALF OF
TOTAL STRINGS

Figure 6. CT installation (EVEN-COUNT)

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 7.2. Odd-String CT Installation
Figure 8 shows the top and bottom halves of an example odd-count CT installation. The lower half of the
strings is short one conductor. For the CT electronics to work properly, the number of strings going each
way through the CT must be balanced. For this to work with an odd-stringed system, one string must be
double-wrapped as shown below.
NOTE: Colored conductors shown for illustrative purposes only. Use appropriately sized conductors.

EVEN HALF OF
ODD TOTAL STRINGS
NUMBER
OF
TOTAL
STRINGS ODD HALF OF
TOTAL STRINGS:
Loop only one
conductor twice

Loop only one

conductor twice

Figure 7. CT installation (ODD-COUNT).

15
 7.3. Lexan Guard Installation
Plug in the lead from the MENU/SELECT button to the sensor board header labeled “SW.” Replace the
Lexan guard as shown in the Figure 8. To correctly secure the Lexan guard, insert one side, and then
squeeze the other side into place to fit the guard in between the fuse holders and completely cover the
sensor board.

Figure 8. Lexan Guard installation.

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8. Commissioning the Combiner Box
Previous versions of the AFCI Smart Board use a different commissioning procedure than is listed
here. The procedure listed here requires the user to set all active channels. If your version does not
require you to set active channels please refer to Appendix 5 and 6 – “Previous Menu Versions” for
additional information. If you are unsure of which version you have, compare the label on the inside of
the combiner box with figure 9 and 10 below:

AFCI Calibration Quick Guide

- Hold button 3 seconds to access menu
- Ch. 1 light = Zero Tare (No Current)
- Ch. 2 light = Operating calibration (Detect Active)
- Ch. 3 light = Operating calibration (Use Existing Active)
- Ch. 4 light = Show Active Channels
- Ch. 5 light = Manually Set Active Channels
- Ch. 6 light = Set Modbus Address
- Ch. 7 light = Arc Fault Self Test
- Ch. 8 light = Exit menu
- Enter total current in 3 digit format - 85A enters as '085'
- Use single digits 1- 9, circuit 10 = '0

1 3 5 7 9 11 13 15
Channel / Light Map:
2 4 6 8 10 12 14 16

Figure 9. Current Menu Version

If your combiner box contains this label, please proceed to the commissioning instructions below.

AFCI Calibration Quick Guide

- Hold button 3 seconds to access menu
- Ch. 1 light = zero tare (no current)
- Ch. 2 light = set Modbus address
- Ch. 3 light = operating calibration (enter TOTAL current)
- Ch. 4 light = Report (Inst. / 1 Min. / 15 Min.)
- Ch. 7 light = Arc Fault Self Test
- Ch. 8 light = exit menu
- Enter total current in 3 digit format - 85A enters as '085'
- Use single digits 1-9, circuit 10 = '0

1 3 5 7 9 11 13 15
Channel / Light Map:
2 4 6 8 10 12 14 16

Figure 10. Previous Menu Version

If your combiner box contains this label, please proceed to Appendix 5 and 6 – “Previous Menu Version”.

17
8.1. Channel Light Map and Menu Navigation
1. The menu is accessible only while the board is in RUN mode (green LED flashing).
2. To enter the menu, press and hold the MENU/SELECT button until the LEDs flash, then release
the button.
3. The MENU/SELECT Button (Figure 12) performs two functions in menu mode, momentarily
press the button for scrolling through LED’s or press and hold about 4 seconds for selecting an
option, value, or entering a desired menu choice.
4. To abort from any menu option, power cycle the 24VDC power to the board OR press the on-
board green reset button (Figure 13). The board reboot is completed when the green LED
starts blinking.
5. Figure 11 shows the LEDs with the corresponding channel/menu number.
6. For a list of menu options, see below.
7. For step by step instructions, see sections 8.2 through 8.9
8. For an abbreviated “Quick Start Guide”, see Appendix 1. (Use Appendix 6 for Previous Menu
Version)
9. If you are using a single control board/dual busbar design, refer to Appendix 7.

CHANNEL SENSOR BOARD MENU DESCRIPTION

LIGHT MENU OPTION or SUB-MENU OPTIONs
1 ZERO-TARE Zero current calibration
Enter TOTAL 3-digit current
Ex: 85A = “085”
3 OPERATING CALIBRATION
Note: Only needed for devices
that use Modbus Feature
4 SHOW ACTIVE CHANNELS Lights up all active channels

5 SET ACTIVE CHANNELS See Section 8.3

Address range: 01-99

6 SET MODBUS Enter 00 to Readback Current
Address
Simulates Arc Fault, Causing
7 ARC FAULT SELF TEST Contactor to open. Resume by
holding MENU/SELECT button.
8 EXIT Exit the menu

1 3 5 9 11 13 15

2 4 6 8 10 12 14 16

Figure 11. Channel Light Map

18
 Menu/Select
Button

Figure 12. Lexan Guard installation with MENU/SELECT button

Reset Button

Figure 13. Green Reset Button Location

19
 8.2. Zero Current Calibration (Required for All Devices)

After hardware installation (combiner box completely installed and wired with the PV system fully
operational), it is necessary to calibrate the current sensors.

1. Turn off the contactor by using the manual switch and then opening the fuse holders on each
circuit. Ensure zero current is flowing through the busbar.

2. Enter Menu Mode. Press and hold the MENU/SELECT button for 4 seconds, until all red lights
flash. Release the button and channel 1 LED will light up. See Figure 14.

3. With the channel 1 light lit, press and hold the MENU/SELECT button for 4 seconds (until the
channel 1 light flashes), then release. The sensor board will cycle through all circuits setting the
zero point on each. No additional user action is required.

4. When finished, the board will return to normal operation, indicated by the flashing green light.

Figure 14. Channel 1 Light ON

20
 8.3. Setting Active Channels (Required for All Devices)
STEP INSTRUCTIONS NOTES
Press and hold the MENU/SELECT button
1 for 4 seconds until all channel lights flash This enters the Menu Mode.
ON and then OFF momentarily.

Release the button. Channel 1 LED will

2 light up to indicate that the board has
entered the “menu” mode.

To cycle through different menu options,

simply press and release the button once
per selection. Do not press and hold for
NOTE:
more than a second, as this will select that
3 Only LEDs 1, 3, 4, 5, 6, 7, and 8 have a menu
option.
option associated with them.
Momentarily push the button until the
channel 5 LED is lit.
When LED 5 is selected, press and hold
4
the button until the LED flashes.
Release button
All Channel Lights will Light up, and the
Amber LED will enter one of three states.

State 1: On, This indicates all of the

channels are currently active
5
State 2: Off, This indicates none of the
channels are currently active

State 3: Blinking, This indicates some of the

channels are currently active
If the LED is in State 2 or 3, you can press
and hold the MENU/SELECT button for
about 2 seconds until the amber LED turns
Depending on your setup, it will typically be easier
on. This will set all of the channels active
5a to set all channels active, and (see 8b). Set
and put the LED in state 1. Alternatively, if
inactive chans individually.
the LED is in state 1, pressing and holding
until the amber LED turns off will turn all
active channels off and put it in state 2.
To go to individual selection mode, press
The Channel 1 LED should light up, indicating
5b and release the MENU/SELECT button
individual selection mode.
once, do not hold.
For Individual Selection mode there are two
states for each channel: WARNING: ARCS WILL NOT BE DETECTED
6
State 1: Amber ON, Channel is Active ON INACTIVE CHANNELS
State 2: Amber OFF, Channel is inactive

21
STEP INSTRUCTIONS NOTES
To turn a channel from active to inactive, or
visa versa, press and hold the
MENU/SELECT button until the amber LED
6a switches state.

In the figure to the right, Channel 3 is

active.
To go to the next channel, press and
6b release, do not hold, and the next channel
LED will light up.
The operation will exit automatically after This will be indicated by a blinking green light. If
7 pressing and releasing the button After the the green light does not start blinking, press and
last channel. release the button several times.

8.4. Operating Calibration (Only Required for Modbus Users)

Unlike the Zero Current Calibration, The Operating Calibration procedure involves multiple user inputs. If
during this process a mistake is made, the process can be aborted by power cycling the 24VDC power to
the board or using the reset button.
STEP INSTRUCTIONS NOTES
Ensure that the PV system is ON, and Close all fuseholders. Turn ON main switch. Verify
1
current is flowing through all strings. contactor is ON. Verify load (i.e., inverter) is on.
Use a current clamp to verify each active The current in each string should remain constant
2 string is at a similar current and greater throughout the calibration procedure, therefore
than 4A. calibration is recommended during a clear day.
Measure the total current output of the
3
respective board/busbar.
Press and hold the MENU/SELECT button
4 for 4 seconds until all channel lights flash This enters the Menu Mode.
ON and then OFF momentarily.

Release the button. Channel 1 LED will

5 light up to indicate that the board has
entered the “menu” mode.

To cycle through different menu options,

simply press and release the button once
per selection. Do not press and hold for
NOTE:
more than a second, as this will select that
6 Only LEDs 1, 3, 4, 5, 6, 7, and 8 have a menu
option.
option associated with them.
Momentarily push the button until the
channel 3 LED is lit.
When LED 3 is selected, press and hold
7
the button until the LED flashes.

22
STEP INSTRUCTIONS NOTES

Release button

8 Channel 10 LED will light up to indicate that

the board has entered OPERATION
CALIBRATION mode.

However, this time after each button press, the

Cycle through the various options to select
8a previous LED will stay ON (except for channel 10
current numbers, see 8b.
LED).
In OPERATION CALIBRATION, the board
is ready to accept a 3-digit number. This
NOTE:
number represents the total current value
“0” is indicated by LED 10 only.
measured previously in Step 3.
8b “1” is indicated by LEDs 1.
“2” is indicated by LEDs 1 & 2.
Use a leading 0 for current values < 100A.
“3” is indicated by LEDs 1, 2, & 3 etc.
For the example, 85A wil be entered as
“085.”

Momentarily press the button until the

desired first digit is “displayed”.
9
Here, the digit “0” is shown.

Press and hold the button until the LEDs

10
flash.
The desired first digit will be stored. Channel 10
11 Release the button. LED will light up again. This indicates that the
board is ready for the second digit.

Momentarily press the button until the

desired second digit is “displayed”.
12
Here, the digit “8” is shown.

Press and hold the button until the LEDs

13
flash.
The desired second digit will be stored. Channel
14 Release the button. 10 LED will light up again. This indicates that the
board is ready for the third digit.

Momentarily press the button until the

desired third digit is “displayed”.
15
Here, the digit “5” is shown.

Press and hold the button until the LEDs

16
flash.

23
STEP INSTRUCTIONS NOTES
17 Release the button. The desired third digit will be stored.
The board will cycle through each channel one at
18 No further user action is required.
a time.

When the user-action portion of the OPERATION CALIBRATION procedure is completed, the sensor
module will automatically:

1. Read back the stored values by flashing each digit one time.
a. The user should verify that the correct current values were entered.
b. In the example for 85A, the board will flash “0,” then “8,” and finally “5.”
2. Next, the board will calibrate each channel one by one.
3. Then it will light up all active channels simultaneously.
a. The user should verify that all active and inactive channels are correctly identified.
4. When finished, the board will enter RUN mode, indicated by the flashing green LED near the USB
connector.

Note: Calibration steps MUST be performed in order to ensure accurate readings of string
currents. It is recommended that the current be steady during the calibration procedure (i.e. no
clouds or overcast sky).

8.5. Setting Modbus Address

To set the modbus address, enter the menu by pressing and holding the MENU/SELECT button for 4
seconds to enter menu selection mode. Refer to the Channel Light Map. The Modbus Address is set at
the factory, starting at 37 and incrementing upwards (ex. 38, 39, 40...). A Modbus address label is located
near the Modbus connector on each board. These addresses may be changed by performing the
following menu function:
Note: setting the modbus address without computer connectivity allows for address 1-99 only. The board
must be connected to a computer to receive 3 digit modbus addresses.
STEP INSTRUCTIONS NOTES
Press and hold the MENU/SELECT button
1 for 4 seconds until all channel lights flash
ON and then OFF momentarily.

Release button. Channel 1 LED will light up

2 to indicate that the board has entered the
“menu” mode.

To cycle through different menu options,

simply press and release the button once
per selection. Do not press and hold for
more than a second, as this will select that NOTE:
3 option. Only LEDs 1, 3, 4, 5, 6, 7, and 8 have a menu
option associated with them.
Momentarily push the button until the
channel 6 LED is lit.

24
STEP INSTRUCTIONS NOTES
When LED 6 is selected, press and hold
4
the button until it flashes.

5 Release button. Channel 10 LED will light

up to indicate that the board has entered
SET MODBUS ADDRESS mode.

However, this time after each button press, the

Subsequent actuations of the button will previous LED will stay ON (except for channel 10
5a
again scroll through all LEDs. LED). Each additional press of the button will light
up one more LED.
Once in SET MODBUS ADDRESS mode, NOTE:
the board is ready to accept a 2-digit “0” is indicated by LED 10 only.
number. This number represents the “1” is indicated by LEDs 1.
Modbus address. “2” is indicated by LEDs 1 & 2.
5b
“3” is indicated by LEDs 1, 2, & 3 etc.
Use a leading “0” for addresses 01-09. For
this example, address 5 will be entered NOTE:
“05.” To readback current address, Input “00”.

Momentarily press the button until the

desired first digit is “displayed”.
6
The digit “0” is shown.

Press and hold the button until the LED

7
flashes.
The desired first digit will be stored. Channel 10
8 Release the button. LED will light up. This indicates that the board is
ready for the second digit.

Momentarily press the button until the

desired second digit is “displayed”.
9
The digit “5” is shown.

Press and hold the button until the LEDs

10
flash.
Release the button. This will store the This completes the SET MODBUS ADDRESS
11
second digit. procedure.

When the SET MODBUS ADDRESS procedure is completed, the board automatically returns to RUN
mode.

25
 8.6. Arc Fault Self-Test
In order to verify the board is able to detect an arc, an arc fault self-test may be performed. To perform a
self-test:
1. Enter menu mode by holding the MENU/SELECT button for 4 seconds
2. Select channel 7 in the menu mode, then hold the MENU/SELECT button for 4 seconds. This will
cause the board to detect a simulated arc and light up all Red LEDS and open the contactor.
3. Exit the self-test cycle by holding the MENU/SELECT button for 4 seconds. This turns the red
LEDs off, and closes the contactor.

8.7. Exiting the Menu

To exit the menu, select the channel 8 LED (bottom 4th from left) and hold the MENU/SELECT button for
4s seconds. To abort from any menu option, power cycle the 24VDC power to the board OR press the
on-board green reset button (See Figure 13). The board reboot is completed when the green LED starts
blinking.

8.8. Arc Fault Detection and Interruption

In order for Arc Fault Detection to work properly, the calibration steps in the preceding pages must be
completed. Note: if an arc is detected and the contactor shut off, normal operation must be resumed with
the MENU/SELECT button. Arc-fault status is retained by the board if power is lost and will keep the
contactor turned off in the event of a power outage.

8.9. Resuming normal operation after a fault

If an arc is detected, the sensor module will disable the contactor and will light the LED corresponding to
the channel that triggered the fault. To resume operation, hold the MENU/SELECT button for 4 seconds.

26
9. APPENDIX 1 - Sensor Board Operation Quick Guide (Active Channels Version)

9.1. Accessing and navigating the menus

1. The menus are accessible while the board is in RUN mode (green LED flashing). The board
automatically goes into RUN mode when it is powered up with 24VDC.
2. To enter the menu selection mode, press and hold the MENU/SELECT button ~4 seconds, then
release when the LED(s) flash.
3. To select a menu, momentarily press the button to “scroll” through the menus. Scroll until the
desired menu indicator is illuminated.
4. To enter the selected menu, press and hold the button until the LED(s) flash.
a. For menus 3, 5, and 6 additional user input is required, skip to next step.
b. For menus 1, 4, 7, and 8, the function is executed upon button release.
5. For all menus, the board automatically returns to the RUN mode when that menu function is
completed. No further user action is required.

9.2. Menu indicators

1. Ch. 1 light = Zero tare (no PV current) Required
2. Ch. 3 light = Operating calibration (enter TOTAL current, 3-digit value) Modbus Users
3. Ch. 4 light = Show Active Channels
4. Ch. 5 light = Set Active Channels (See Section 8.3) Required
5. Ch. 6 light = Set Modbus address (2-digit address) Modbus Users
6. Ch. 7 light = AFCI self-test
7. Ch. 8 light = Exit menu
Commissioning – Perform Zero Tare, Set Active Channels. Modbus Users must perform these steps
in addition to an Operating Calibration and may change the Modbus address if desired.

9.3. Entering Modbus address and Operation Calibration values

1. For Modbus address, enter address as 2-digit number.
2. For Operation calibration, enter known current as 3-digit number.
3. Use leading zeros for address <10 and known currents <100A.
4. To enter a digit, press and hold button until LEDs flash, then release button. Repeat until all digits
are entered.
5. Enter digits one at a time:
a. Channel 1 = “1”
b. Channel 2 = “2”
c. Channel 10 = “0”

Channel Light Map

27
10. APPENDIX 2 – Sensor Board Reset Button and Menu/Select Button
Clarification
The RESET button is a small green button that is directly mounted on to the board. Pushing it will
cause the board to hard restart. (This will open the contactor)
The MENU/SELECT button is mounted to the Lexan guard and connects to the “SW” header pin.
See Figures Below for Clarification:

Reset Button

Menu/Select
Button Input

Reset Button, Menu/Select Button Locations

Menu/Select
Button

Lexan Guard installation with MENU/SELECT button

28
11. APPENDIX 3 – Torque Values

BOX LUG OUTPUTS SMALL CONDUCTORS

CONDUCTOR SIZE TORQUE ITEM TORQUE
1/0 - 2/0 180 in-lbs FUSEHOLDER/SURGE (TVSS) 22 in-lbs
3/0 - 4/0 250 in-lbs NEGATIVE/NEUTRAL INPUTS 25 in-lbs
250 - 350 325 in-lbs SMALL GROUND SCREW 25 in-lbs
400 - 600 375 in-lbs LARGE GROUND SCREW 50 in-lbs
700 - 800 500 in-lbs BOLTED CONNECTIONS &
900 - 1000 600 in-lbs COMPRESSION LUGS

THREAD SOCKET TORQUE

1/4" 7/16" 120 in-lbs

M8 13mm 220 in-lbs

M10* 17mm 275 in-lbs

M10 17mm 550 in-lbs

*For Contactor Combiners M12 19mm 600 in-lbs

29
12. APPENDIX 4 – Factory Provided Control Wire Schematic

AFCI COMBINER
BOXES ONLY

NOTE: For AFCI applications, power to the contactor is controlled by a set of dry contacts on the sensor
board. The dry contacts are accessible at the 2-pin connector labeled “CONT.” The sensor board does
not source power to the contactor.

30
13. APPENDIX 5 – Previous Menu Version
NOTE: It is possible to update the AFCI unit to the most current firmware version. Please
contact SolarBOS if you would like to perform this update.

ONLY USE THIS MENU IF THE LABEL IN YOUR COMBINER BOX LOOKS LIKE THE
FOLLOWING:

AFCI Calibration Quick Guide

- Hold button 3 seconds to access menu
- Ch. 1 light = zero tare (no current)
- Ch. 2 light = set Modbus address
- Ch. 3 light = operating calibration (enter TOTAL current)
- Ch. 4 light = Report (Inst. / 1 Min. / 15 Min.)
- Ch. 7 light = Arc Fault Self Test
- Ch. 8 light = exit menu
- Enter total current in 3 digit format - 85A enters as '085'
- Use single digits 1-9, circuit 10 = '0

1 3 5 7 9 11 13 15
Channel / Light Map:
2 4 6 8 10 12 14 16

13.1. Differences between Versions

The difference between the two menu types is that the user can select and turn off strings which are
considered ‘inactive’. This will stop the AFCI unit from reporting and detecting that string. If an update to
the current firmware is required, please contact SolarBOS. All other functions that are shared between
the two versions, such as zero tare, Modbus address, ect... are the same and section 8 can be referred to
for those functions.

13.2. Sensor Board Functions Menu

CHANNEL SENSOR BOARD MENU DESCRIPTION

LIGHT MENU OPTION or SUB-MENU OPTIONs
1 ZERO-TARE Zero current calibration
Address range:
2 SET MODBUS ADDRESS
00-99
Enter TOTAL 3-digit current
3 OPERATING CALIBRATION
Ex: 85A = “085”
1. Instantaneous
4 SET REPORTING INTERVAL 2. 1-minute average
3. 15-minute average
7 AFCI SELF-TEST Simulates an arc fault
8 EXIT MENU Exits the menu

31
 13.3. Setting the report type
The sensor board can report string level data in one of three intervals:
1. Instantaneous
2. 1-minute average
3. 15-minute average
The sensor Board does not push data. Rather it populates registers available to a gateway device.
SolarBOS offers a gateway device separately or it may be provided by the monitoring provider. SolarBOS
sensor boards default to 1 minute average reporting however some systems only collect data every 15
minutes and setting the report for 15 minute average may be advantageous, however, not required.
STEP INSTRUCTIONS NOTES
1 Ensure that the PV system is ON.
Press and hold the MENU/SELECT button
2 for 3 seconds until all channel lights flash
ON and then OFF momentarily.

Release button. Channel 1 LED will light up

3 to indicate that the board has entered the
“menu” mode.

Subsequent actuations of the button will

“scroll” through LEDs 1-10, one at a time. NOTE:
4 Only LEDs 1, 2, 3, 4, 7, and 8 have a menu option
Momentarily push the button until the associated with them.
channel 4 LED is lit.
When LED 4 is selected, press and hold
5
the button until it flashes.
Release button. The board will enter the
6
SET REPORT TYPE mode.
NOTE:
Subsequent actuations of the button will
LED1 = Instantaneous
6a scroll through LED1, LED1-2, and LED1-3
LED1-2 = 1-minute average
only.
LED1-3 = 15-minute average
Momentarily press the button until the
7
desired report type is selected.
Press and hold the button until the LEDs
8
flash.
Release the button. This sets the desired This completes the SET REPORT TYPE
9
REPORT TYPE. procedure.

When the SET REPORT TYPE procedure is completed, the board automatically enters RUN mode.

32
14. APPENDIX 6 - Sensor Board Operation Quick Guide (Previous Menu Version)

14.1. Accessing and navigating the menus

1. The menus are accessible while the board is in RUN mode (green LED flashing). The board
automatically goes into RUN mode when it is powered up with 24VDC.
2. To enter the menu selection mode, press and hold the MENU/SELECT button ~3 seconds, then
release when the LED(s) flash.
3. To select a menu, momentarily press the button to “scroll” through the menus. Scroll until the
desired menu indicator is illuminated.
4. To enter the selected menu, press and hold the button until the LED(s) flash.
a. For menus 2, 3, and 4, additional user input is required, skip to next step.
b. For menus 1, 7, and 8, the function is executed upon button release.
5. For menu 4, set reporting interval: LED1 = “instantaneous,” LEDs1-2 = “1-minute,” and LEDs1-3
= “15-minute.” Press and hold button when desired interval is indicated, then release when LEDs
flash.
6. For all menus, the board automatically returns to the RUN mode when that menu function is
completed. No further user action is required.

14.2. Menu indicators

Ch. 1 light = Zero tare (there is no PVDC current flowing through busbar)
Ch. 2 light = Set Modbus address (2-digit address, with leading zero if necessary)
Ch. 3 light = Operating calibration (enter TOTAL current, 3-digit value with leading zero)
Ch. 4 light = Set reporting (instantaneous, 1 min. avg., 15 min. avg.)
Ch. 7 light = AFCI self-test
Ch. 8 light = Exit menu

14.3. Entering Modbus address and Operation Calibration values

1. For Modbus address, enter address as 2-digit number.
2. For Operation calibration, enter known current as 3-digit number.
3. Use leading zeros for address <10 and known currents <100A.
4. To enter a digit, press and hold button until LEDs flash, then release button. Repeat until all digits
are entered.
5. Enter digits one at a time:
a. Channel 1 = “1”, Channel 2 = “2”, …
b. Channel 10 = “0”

Channel Light Map

33
15. APPENDIX 7 – Dual/Single Control Board Differentiation
Some AFCI products have more than one control board. When two boards are present each must be
calibrated with the preceding procedures. Note: The right board is “upside down” and menu and string
numbers are accordingly opposite. Units with one control board and two separate fuseholder assemblies
are numbered in the same way. See below. Note: The unit below has “unused” channels.

15.1. Dual Top Board with No Ribbon Cable

Second Top Board

15.2. Single Top Board with Ribbon Cable

16 14 12 10
1 3 5 7

15 13 11 9
2 4 6 8
No Top Board

34
16. APPENDIX 8 - Troubleshooting

16.1. Board will start up, but only Channel 1 light is lit up.
Pull off the lexan cover and pull off all three pin headers from the board (Contactor, button, CT).
Push the green restart button on the board. If the board starts up and goes to normal operation, then plug
in the contactor and CT to the correct pin locations. Do not plug in the button.
If the board is on the left side of the combiner box, place the contactor in the top right pin header
above the relay (black box), named CONT. Place the CT in the pin header right below the relay named
CT.
If the board is on the right side of the combiner box, place the contactor in the bottom left pin header
below the relay (black box), named CONT. Place the CT in the pin header right above the relay named
CT.
Push the green restart button. If the board continues to run and goes to normal operation, plug in the
button.
If the board is on the left side of the combiner box, place the button in the bottom right header named
SW. The three pin connector labeled VT should remain unconnected.
If the board is on the right side of the combiner box, place the button in the top left header named
SW. The three pin connector labeled VT should remain unconnected.
If the board continues operation after plugging in the button, then the pin header connections were
originally incorrect.
If the board goes into the menu after plugging in the button, then the menu button is faulty, please contact
SolarBOS for a replacement button.

16.2. Board’s green light is solid

Unplug anything in the USB connector, wait 15 seconds, and then either power cycle the board or push
the on-board green reset button to restart the board. If the problem persists, contact SolarBOS.

16.3. Board frozen/locked up

If the board appears frozen or locked up and does not respond to button presses, try first holding the
MENU/SELECT button for 5 seconds. If the board does not respond, press the green reset button 5 times
in quick succession. If the board still does not restart, try power cycling the board. If the board’s operation
is still not normal after these steps, please contact SolarBOS.

35