HomeRun Combiner Boxes
Installation and Operations Manual
TABLE OF CONTENTS Notices and Safety Precautions Page 1 Combiner Box Electrical Characteristics Pages 2‐3 Combiner Box Mounting Page 4 Grounding, Fuses and Wiring Pages 5‐6 Maintenance, Service and Operation Page 7 Install Confidence
1010 B Street, Suite 4100 – San Rafael, CA 94901
415-925-9650 – www.sunlink.com
1 SunLink’s HCB Seriies Combiner Boxes
B
are the professional
p
so
olar installer’s cchoice for comb
bining PV Arrayys and complying with the
C
These bo
oxes include:
National Electrical Code.

Complianc
ce with the strin
ngent UL1741 safety
s
listing for continuous ra
ated current op
peration at 50°C
C.

Installation friendly TYPE
E 3R, 4 or 4X watertight
w
enclosure for vertica
al or horizontal mounting.

Spacious wiring
w
area for ease
e
of installa
ation and mainttenance.

Simple, cle
ean and solid construction for years of servic
ce.
SAVE
E THESE INST
TRUCTIONS - This
T
manual prrovides importa
ant instructionss for the HomerrunTM Series C
Combiner Boxess that shall be
TM
follow
wed during insta
allation and ma
aintenance. The Homerun Series
S
Combin er Boxes are d
designed and te
ested to stringe
ent internationa
al
safetyy requirements
s. However, as with all electric
cal equipment, specific safetyy practices musst be followed. To reduce the risk of injury,
carefu
ully read this in
nstruction book
klet in its entiretty before installing, wiring, or using this prod
duct in any wayy.
1..1. Disclaimer of Liability
Th
he installation techniques,
t
handling and use
e of this product are beyond ccompany contro
ol. Therefore, S
SunLink Corporration does nott
asssume respons
sibility for loss, damage or exp
pense resulting
g from imprope
er installation, h
handling or use
e of this producct.
1..2. Listing Infformation
Th
his product meets or exceeds
s the requireme
ents set forth by
y Underwriters Laboratories ffor componentss used with PV
V Modules. This
s
UL
L Standard is UL1741
U
for acc
cessories used with inverters.
1..3. Limited Warranty
W
Co
ombiner box lim
mited warrantie
es are for 1 yea
ar for materials and workmansship.
Impo
ortant Safetty Instructio
ons
There
e are NO user-serviceable parts in this enclo
osure. Modifying this productt
in anyy way will void the manufactures warranty.

WARNING
G: PV modules pass direct currrent (DC) whe
en the module iis under load. D
Direct current w
will arc across g
gaps and may
cause injurry or death if im
mproper connec
ction or disconnection is mad e. Do not conn
nect or disconn
nect wires to the
e combiner box
x
when curre
ent from the mo
odules or an ex
xternal source is present.

WARNING
G: Voltage is present in open circuit
c
condition
ns. Photovolta
aic modules cre
eate voltage an
nytime light is p
present.


CAUTION:: For continued
d protection aga
ainst risk of fire
e, replace fusess with only 600
0VDC / 1000V rated, max. 30
0A fuses.
Make conn
nections in com
mbiner box priorr to connecting
g modules. To work on the co
ombiner box affter the module
es are
connected,, cover all modules in the PV array with an opaque
o
cloth o r material.

All US insta
allations must be performed in compliance with
w the Nation
nal Electrical Co
ode (NEC), AN
NSI/NFPA 70 and any
applicable local codes.

Installation, maintenance & servicing sh
hould be performed only by au
uthorized perso
onnel.

Remove all metallic jewellry prior to insta
alling this product to reduce th
he chance of a
accidental expo
osure to live cirrcuits.

Use insulatted tools to red
duce your risk of
o electric shoc
ck.

Do not insttall or handle th
he combiner bo
ox if it is wet.

Maximum 95%
9
humidity during
d
use.

Contact Su
unLink Corpora
ation if the combiner box enclo
osure is damag
ged or its conte
ents are comprromised.

Storage tem
mperature: - 60
0º C - + 85 º C
ation
Posiitive Ground Configura
The H
HomerunTM Serries Combiner Boxes may be installed for us
se with positive
e grounded solar arrays, as re
equired for exa
ample with
M
certaiin SunPowerTM
solar modules
s. If used in a positive
p
ground configuration substitute the w
word “negative
e” for every insttance of the
word “positive” below
w and substitute the word “po
ositive” for everry instance of tthe word “nega
ative” below.
2 2
HomeRun Combiner Box Installation & Operations Manual
Combiner Box Electrical Characteristics
DISCONNECTING COMBINER BOX ELECTRICAL CHARACTERISTICS Family ID 100/250S 250 400 30 30 30 1000* 1000* 1000* Voltage Range (VDC) 0‐1000* 0‐1000* 0‐1000* Maximum Continuous DC Current (A) 100/250 250 400 10 10 10 Positive Input Wire Size (AWG) 14‐6 14‐6 14‐6 Positive Input Terminal Torque (in‐lbs) 14.75 14.75 14.75 Negative Input Wire Size (AWG) 14‐4 14‐4 14‐4 40 40 40 14‐4 14‐4 14‐4 Ground Input Terminal Torque (in‐lbs) 40 40 40 Compression Lug Max Positive Output Wire Size (AWG) 250 2 x 300 [2 x 500]** 2 x 750 Compression Lug Max Negative Output Wire Size (AWG) 250 2 x 300 [2 x 500]** 2 x 750 Compression Lug Max Ground Output Wire Size (AWG) 1/0 2 x 250 2 x 250 Mechanical Lug Max Positive Output Wire Size (AWG) 350 350 N/A Mechanical Lug Max Negative Output Wire Size (AWG) 350 350 N/A Mechanical Lug Max Ground Output Wire Size (AWG) 350 350 N/A Compression Lug Output Terminal Torque (in‐lbs) 250 500 500 Mechanical Lug Output Terminal Torque (in‐lbs) 325 325 N/A Input Terminal Temperature Rating 75°C 75°C 75°C Output Terminal Temperature Rating 90°C 90°C 90°C ‐25°C to 50°C ‐25°C to 50°C ‐25°C to 50°C 3R/4/4X 3R/4/4X 3R/4/4X 6 ‐ 48 6 ‐ 48 10 ‐ 48 Maximum Input Fuse Rating (A) Maximum Voltage (VDC) SCCR AT 600VDC (KAIC) Negative Input Terminal Torque (in‐lbs) Ground Input Wire Size (AWG) Operating Temperature NEMA Rating Maximum # of Inputs for this Family 0 = OFF
0 = OFF 0 = OFF
1 = ON 1 = ON 1 = ON *Standard Disconnects are not load break rated at 1000V, specify high voltage disconnect for load break rating above 600V Switch Position **[2 x 500] ‐ Available on some models Rev 1 Page 3 HomeRun Combiner Box Installation & Operations Manual
Combiner Box Electrical Characteristics
NON‐DISCONNECTING COMBINER BOX ELECTRICAL CHARACTERISTICS Family ID
60
100/250S
250
400
Maximum Input Fuse Rating (A)
20
30
30
30
Maximum Voltage (VDC)
600
1000
1000
1000
0-600
0-1000
0-1000
0-1000
Maximum Continuous DC Current (A)
60
100/250
250
400
SCCR AT 600VDC (KAIC)
10
10
10
10
Positive Input Wire Size (AWG)
14-6
14-6
14-6
Positive Input Terminal Torque (in-lbs)
14.75
14.75
14.75
Negative Input Wire Size (AWG)
14-4
14-4
14-4
40
40
40
14-4
14-4
14-4
Ground Input Terminal Torque (in-lbs)
40
40
40
Max Positive Output Wire Size (AWG)
250
2 x 300 [2 x 500]*
2 x 750
Max Negative Output Wire Size (AWG)
250
2 x 300 [2 x 500]*
2 x 750
Max Ground Output Wire Size (AWG)
1/0
2 x 3/0
2 x 250
Positive, Negative and Ground Output Terminal
Torque (in-lbs)
250
500
500
Maximum Input Fuse Rating (A)
30
30
30
Voltage Range (VDC)
Negative Input Terminal Torque (in-lbs)
Ground Input Wire Size (AWG)
Operating Temperature ‐13°F to 122°F
‐25°C to 50°C ‐13°F to 122°F ‐25°C to 50°C ‐13°F to 122°F
‐25°C to 50°C NEMA Rating 3R/4/4X 3R/4/4X 3R/4/4X Maximum # of Inputs for this Family 6 ‐ 48 6 ‐ 48 10 ‐ 48 Switch Position 0 = OFF
1 = ON 0 = OFF 1 = ON 0 = OFF
1 = ON *[2 x 500] - Available on some models
COMBINER BOX PART NUMBER DERIVATION TABLE
Family ID&Size
HCB-XXX
HCB-250S
# of Strings
Disconnecting?
Material/NEMA Rating
Monitoring
Pre-Wired
6-48 (by 2)
D or H or N (non-disc)
S, SS, or F** – 3R, 4, or 4X
M or blank
B or Blank
16
H
F4X
M
B
The resulting part number for this combiner box example with the listed options: HCB-250S-16-H-F4X-M-B-LTE.
*D is disconnect load break rated to 600V, H is disconnect load break rated to 1000V, N is no disconnect
**S, SS, and F represent the enclosure materials: Steel, Stainless Steel, and Fiberglass, respectively.
Mech. Lugs
LTE or blank
LTE
Rev 1 Page 4 HomeRun Combiner Box Installation & Operations Manual
Mounting
Mounting Overview A. Install the enclosure using the external enclosure mounting tabs only. Drilling holes in the back plate is not recommended and shall void the product warranty. B. Place in desired location and use the appropriate hardware to mount the combiner box. C. The combiner box may be mounted vertically (door opens out) or horizontally (door opens up). D. Place the box in areas out of continuous water flow and extreme temperature. E. If the box has a disconnect switch, do not mount the box such that the switch handle is blocked or difficult to operate. Please refer to the enclosure installation manual for additional mounting instructions. Step 1 – Choose your Connectors A. The use of UL514B or equivalent conduit fittings is required to maintain the TYPE 4 (or 4X) rating of the enclosure. B. Installation of fittings must comply with UL50 for USA installations to maintain TYPE 4 (or 4x) rating of the enclosure. Step 2 – Install Connectors Metallic Conduit A. Place connector through hole with the o‐ring on the outside of the enclosure. B. Screw on and tighten the locknut. Next screw on the Grounding Bushing, rotate to desired location and tighten set screws. Non‐Metallic Conduit A. Place connector through with the o‐ring on the outside of the enclosure. B. Screw on and tighten the locknut. C. Screw Insulated or plastic bushing onto connector threads to protect conductors from damage. D. Grounding Bushings are not used with non‐metallic conduit. Rev 01 Equivalent connectors from other manufactures may be used as long as they satisfy citations in this section. Page 5 HoomeRun Combiner Box Installatiion & Opperationss Manuaal
Grounnding, Fusees and Wirring
Groun
nding Overview
w A
A. A ground b
bar has been provided for the
e convenience of combining several ground
ds into one larger ground wirre. B
B. Please refe
er to NEC Article 690 on grou
unding PV arrayys for specific rrequirements. C
C. Combiner box models wiith metallic encclosures have ffactory installeed ground wirees or straps to bond the enclo
osure body and door. Note: Do not cconnect any grround wires to enclosure boddy bonding locaation or to doo
or bonding loca
ation. Step 1 – Install Grounding nding With Meetallic Conduit Groun
A
A. When instaalling metallic conduit grounding bushings m
must be used, rrefer to section
n 6.3.1 for installation. B
B. A continuo
ous ground conductor must ggo through th
he lay‐in lug on the groundingg bushing wiith the insulation stripped baack on either side
e of the lay‐in lu
ug set screw. N
Note: Bonding of the Groundiing Bushings m
must ccomply with the NEC for USA installations. nding With Non‐Metallic Con
nduit Groun
A
A. When instaalling non‐mettallic conduit th
he grounding conductor is terminated at tthe ground bar. Step 2 – Select Fuse
es A
A. Please con
nsult the module manufacturer and/or ratin
ng label to seleect the appropriate fuse size.. B
B. In most cases, the fuse siize is determin
ned by multiplyying the short ccircuit current rating by 156%
% and roundingg up to the next standard fuse size. C
C. Please con
nsult NEC Articlle 690 for more
e information. D
D. A maximum
m of a 30 Amp fuse may be u
used with this p
product. Step 3 – Output Conductor Sizingg A
A. The combiner box output design curren
nt is determine
ed by: (total Iscc x 156%) divid
ded by a tempeerature correction factor. B
B. Select the appropriate te
emperature correction factorr from the NECC. See NEC Articcles 310 and 690 for proper w
wire sizing. Step 4
4 ‐ Wiring NOTEE: USE COPPER OR ALUMINUM
M CONDUCTO
ORS SUITABLE FFOR AT LEAST 775°C. A
A. Insert positive input cond
ductor from th
he source circuit into the Touuch Safe fuse holder and tightten to torque sspecifications n pages 2 and 3
3. as listed on
B
B. Insert negaative input con
nductor from th
he source circu
uit into the neggative collecto
or and tighten tto torque specifications as listed on pages 2 and 3. C
C. Crimp a lugg onto the output wires to th
he inverter (or other destinattion ), bolt onto the output teerminal busbars and secure to the torq
que requirements in as listed on pages 2 an
nd 3. If the com
mbiner box hass mechanical lu
ugs, use a hex driver to tighten the
e mechanical lu
ug to the torqu
ue requirements as in listed iin pages 2 and 3. D
D. Make sure all connection
ns are tight, seccure and safe ffor many yearss of operation.. EE. DO NOT IN
NSTALL FUSES! Rev 0
01 Page 6
HoomeRun Combiner Box Installatiion & Opperationss Manuaal
Grouunding, Fusses and Wiring
W
Step 5
5 – Wire for Mo
onitoring* *Onlyy if your combin
ner box includess string level currrent monitorin
ng. A
A. If the comb
biner box inclu
udes the option
n for string leve
el current mo
onitoring, it will have one or more Obvius A89DC‐08 or A90DC‐12 C
Current Monito
ors installed inside the combiner box.. B
B. You must m
maintain a min
nimum of ¼” off physical separation
n between the wires that connect to the current mo
onitors and the
e high voltage wires to preve
ent contact to the high voltage conductors. Note:: Diagram of th
he A89DC‐08 m
monitor is for reeference only, please refer to the A
A89DC‐08 or A90DC‐12 installlation manuall nd configuratio
on of the curren
nt monitors. for prroper wiring an
Step 5 – Ensure Pro
oper Ventilatio
on A
A. Maintain aa minimum cleaarance of 1” on
n all 4 sides of the enclosure . Step 6 – Check Your Work ORE INSTALLING
G FUSES, comp
plete these simp
ple time‐saving
g checks. Notee: A multimeterr is needed to vverify the insta
allation processs. BEFO
Checkk that the multtimeter is capa
able or reading the maximum
m string voltagee and maximum
m string curren
nt before proceeeding. A
A. Measure V
Voltage (Voc) a. Place tthe multimeter in DC voltage
e mode. b. Check the open circu
uit positive voltage (Voc) from
m each individ ual solar arrayy string to the n
negative bus bar. e each Voc is the proper polaarity (this mean
ns the meter reeads a positivee DC voltage) aand within the intended c. Ensure
range.. d. Voc do
oes not vary m
much with irradiance and tem
mperature condditions. B
B. Measure C
Current (Isc) a. Place tthe multimeter in DC currentt mode. b. Check the short circu
uit current (Iscc) of each indivvidual solar arraay string to thee negative bus bar. panel specificaations. c. Compare the measured Isc to the p
es vary with irrradiance and temperature so
o be careful to consider the cconditions at th
he time of meaasurement. d. Isc doe
C
C. Check Ground Currents D
D. Check the DC current fro
om each individ
dual string (fuse holder) to grround and veriify that no currrent is flowing to ground. pair any ground faults. a. If current is present,, locate and rep
Step 7 – Insert Fuse
es A
A. Insert fuse
es into fuse holders and securre it in the clossed position. Step 8 – Conduct Fiinal Inspection
n A
A. Check the DC voltage fro
om the combined output lug tto the negativee bar. B
B. Ensure voltage is the pro
oper polarity an
nd within the d
desired voltagee range. C
C. Double che
eck that all con
nduit penetrations are prope
erly sealed agaiinst water andd pest intrusion
n. D
D. Close and ssecure the encclosure door. Rev 1
1 Page 7
HomeRun Combiner Box Installation & Operations Manual
Maintenance, Service and Operation
Maintenance and Service A. Read the Notices and Safety Precautions on pages 1‐2 for important safety information before performing any maintenance or service. B. Please use protective safety equipment and disconnect all sources of supply before working on this product. C. The only serviceable components in the HomerunTM Solar Array Combiner box are the fuses. a. Before changing a fuse(s) check the system for problems and make repairs as needed. b. Then go through Steps 5‐ 6 on page 7 before installing a new fuse(s). D. WARNING: ‐ For Continued Protection against risk of fire, replace fuses with same type and rating of fuse (600V DC rated, MAX 30A Midget fuses). E. If the combiner box has a disconnect switch it must be switched ten times in a row, once a year, with the system off, to clean contacts. F. Mechanical aspects of the switch handle should be checked for dirt on an annual basis. G. No more than 3x the force of normal operation should be applied to the switch. If switch does not operate within this capacity, check for blockage or obstruction. H. Every 6 months inspect and re‐torque the wire connections. Ongoing Operation A. If the combiner box has a disconnect switch the switch may be used to disconnect the combiner box from current coming from other parts of the array and/or to disconnect the voltage and current of the combiner box from an inverter or other equipment that is downstream of the combiner box. B. To operate the switch simply rotate the handle 90 degrees, the switch contacts will be open if the switch handle is pointing to the off position. C. Always place the switch of every combiner box that is connected to an inverter in the off position before servicing the inverter. D. If the combiner boxes do not have a disconnect switch, turn off the inverter and verify that the current from the combiner boxes to the inverter is zero amps, then open all the fuse holders in the combiner boxes before servicing the inverter. a. Do not open the fuse holders under load. E. The fuse holders are not load break rated, and may cause damage or injury if opened under load. F. There are no other operable parts in the combiner box other than the disconnect switch and fuse holders. Rev 1 Page 8