VOPV1000-1/1 Solar Combiner Box

Product Overview

VIOX Electric is a leading manufacturer of renewable energy electrical equipment, specializing in high-quality solar photovoltaic solutions for the global market. Our VOPV1000-1/1 Solar Combiner Box represents the next generation of solar protection technology, designed specifically for modern DC1000V solar systems that demand higher efficiency and enhanced performance.

The VOPV1000-1/1 is a professional-grade DC combiner box engineered for high-voltage solar PV systems operating at DC1000V. This advanced 1-input, 1-output configuration is optimized for next-generation solar installations featuring high-efficiency modules, bifacial panels, and high-power string configurations. With its 45A current rating and 1000V voltage capability, this combiner box enables reduced system current, lower cable losses, and improved overall system economics.

Key Features & Benefits

• DC1000V High Voltage Rating: Purpose-built for modern high-efficiency solar systems with extended string configurations
• 45A Current Capacity: Higher current rating compared to standard 600V models, suitable for high-power module strings
• Enhanced System Efficiency: Higher voltage operation reduces current, minimizing cable losses and improving ROI
• Comprehensive Protection: Integrated 1000V-rated switch disconnector, dedicated surge protection, and dual-pole fuse protection
• Cost-Effective Solution: Lower current requirements enable reduced cable cross-sections, lowering installation costs
• Robust Construction: IP65-rated ABS enclosure (VOAT-9) provides excellent protection in harsh environments
• Compact Design: Space-efficient dimensions (218 x 200 x 100mm) suitable for residential and commercial installations
• Easy Installation: Wall-mountable with clear labeling and accessible terminal blocks
• Certified Quality: Complies with EN50539 Type 2 standards for high-voltage photovoltaic applications
• Future-Proof Technology: Compatible with latest generation solar modules (500W+ panels, bifacial technology)
• Maintenance-Friendly: Quick-access design allows easy inspection and component replacement

Technical Specifications

General Data

Parameter	Specification
Model	VOPV1000-1/1
Rated Voltage	DC1000V
Maximum Output Current	45A
Configuration	1 Input / 1 Output
Degree of Protection	IP65
Operating Temperature	-25°C to +60°C
Maximum Altitude	2000m (standard), >2000m on request
Standard Compliance	EN50539 Type 2
Insulation Voltage	DC1500V

Enclosure Specifications

Parameter	Value
Model	VOAT-9
Material	ABS (Acrylonitrile Butadiene Styrene)
Protection Rating	IP65
Dimensions (H x W x D)	218mm x 200mm x 100mm
Mounting Type	Wall-mounted
Color	Light Gray (RAL 7035)
Fire Rating	Self-extinguishing, UL94 V0 flame-retardant material
UV Resistance	UV-stabilized for outdoor applications
Cable Entry Points	Multiple M16/M20 knockouts
Weight	Approximately 2.2kg (with components)

PV Switch Disconnector

Parameter	Specification
Model	VOD1-63/4B
Type	DC Load Break Switch
Rated Voltage	DC1000V
Rated Current	45A
Number of Poles	2-pole (positive and negative)
Breaking Capacity	According to EN50539
Operation	Manual rotary operation with clear ON/OFF indication
Mounting	DIN rail compatible (35mm)
Handle Type	Red/Green rotary handle with padlock facility
Contact Material	Silver alloy for DC switching
Electrical Life	>10,000 operations at rated current
Mechanical Life	>100,000 operations

DC Surge Arrester (SPD)

Parameter	Specification
Model	VO-PV1000
Type	Type 2 DC Surge Protection Device
Maximum Continuous Operating Voltage (Uc)	DC1000V
Nominal Discharge Current (In)	20kA (8/20μs)
Maximum Discharge Current (Imax)	40kA (8/20μs)
Voltage Protection Level (Up)	≤3.5kV
Number of Poles	2-pole + PE
Response Time	<25ns
Status Indication	Visual indicator window (green = OK, red = replace)
Standard	EN50539 Type 2, IEC 61643-31
Mounting	DIN rail compatible
Follow Current Extinction	Self-extinguishing design
Thermal Disconnector	Integrated for end-of-life protection

DC Fuse Holder & Fuse

Parameter	Specification
Model	VOPV-32
Fuse Type	gPV (Photovoltaic fuse)
Rated Voltage	DC1000V
Rated Current	15A
Breaking Capacity	30kA @ DC1000V
Fuse Size	10 x 38mm
Number of Poles	2-pole (positive and negative protection)
Fuse Holders	2 units (one per pole)
Fuse Links Included	2 pieces (15A DC gPV fuse)
Mounting	DIN rail compatible
Standard	IEC 60269-6
Indicator	Visual fuse status indicator
Contact Material	Copper, tin-plated
Operating Temperature	-40°C to +85°C

Electrical Configuration

The VOPV1000-1/1 features a professional electrical design optimized for DC1000V systems with enhanced safety and performance:

Input Configuration:

• Single high-voltage string input with positive (+) and negative (-) terminals
• Integrated dual-pole fuse protection on both positive and negative conductors
• Terminal blocks rated for 4-6mm² cable, suitable for DC1000V applications
• Clear polarity marking and color coding

Protection Sequence:

• Primary Protection: DC fuses (15A gPV type, 30kA breaking capacity) on both poles
• Secondary Protection: Type 2 DC surge arrester (VO-PV1000, 20kA nominal discharge)
• Isolation: 2-pole DC switch disconnector (45A rated) for safe maintenance disconnection

Output Configuration:

• Single output to inverter with clear polarity marking and labeling
• Terminal blocks rated for 4-10mm² cable
• Reinforced insulation suitable for DC1000V
• PE (Protective Earth) connection provided with dedicated terminal

Safety Features:

• Double-pole switching ensures complete circuit isolation
• Fuse protection on both positive and negative conductors
• Surge protection with thermal disconnector
• Visual status indicators for all protection devices
• Padlock facility on switch for lockout/tagout procedures

Bill of Materials

Item No.	Component	Model/Specification	Quantity
1	ABS Enclosure	VOAT-9, 218x200x100mm, IP65	1
2	DC Switch Disconnector	VOD1-63/4B, 2P, 45A, DC1000V	1
3	DC Surge Arrester	VO-PV1000, Type 2, 20kA, DC1000V	1
4	DC Fuse Holder	VOPV-32, 10x38mm, DC1000V	2
5	DC Fuse Link (gPV)	15A, DC1000V, 10x38mm, 30kA	2
6	Input Terminal Block	4-6mm², Red/Black, 1000V rated	2
7	Output Terminal Block	4-10mm², Red/Black, 1000V rated	2
8	PE Terminal Block	4-10mm², Yellow/Green	1
9	DIN Rail	35mm standard, zinc-plated	1
10	Cable Glands	M16/M20, IP65 rated, 1000V	4
11	Mounting Brackets	Stainless steel 304	2
12	Warning Labels	DC1000V safety labels, multilingual	1 set
13	Installation Manual	English/Multi-language, DC1000V safety guide	1
14	Busbar	Copper, tin-plated, 1000V rated	As required

Applications

The VOPV1000-1/1 Solar Combiner Box is specifically designed for next-generation high-voltage photovoltaic applications:

Residential Solar Systems

• High-efficiency residential installations (5-8kW systems)
• Single-string rooftop systems with 500W+ panels
• Bifacial module installations requiring higher voltage
• Modern grid-tied residential PV systems with string inverters

Commercial Installations

• Small to medium commercial rooftop arrays
• High-power module installations (600W+ panels)
• Building-integrated photovoltaic (BIPV) systems
• Distributed solar generation with centralized protection

High-Voltage System Benefits

• Extended string configurations (up to 30+ panels per string)
• Reduced system current for given power output
• Lower cable cross-sections and reduced copper costs
• Improved system efficiency through reduced I²R losses
• Better performance in high-temperature environments

Module Compatibility

• Monocrystalline PERC modules (450-600W)
• Bifacial solar panels (500-700W)
• High-efficiency HJT (Heterojunction) modules
• N-type TOPCon technology panels
• Half-cell and multi-busbar configurations

Specific Use Cases

• Connection point between high-voltage string and 1000V inverter
• Protection hub for DC circuits in DC1000V solar systems
• Isolation and switching point for safe maintenance procedures
• Surge protection for high-value string inverter equipment
• Systems requiring compliance with latest safety standards

Advantages of DC1000V Systems

System-Level Benefits

1. Reduced Cable Costs

• Lower current for the same power output reduces required cable cross-section
• Up to 30% reduction in cable costs compared to 600V systems
• Fewer parallel strings needed, simplifying wiring complexity

2. Enhanced System Efficiency

• Lower I²R losses in cables and connections
• Improved performance ratio, especially in high-temperature conditions
• Better energy yield over system lifetime

3. Installation Savings

• Reduced labor time due to simpler wiring
• Fewer components and connection points
• Easier cable routing with smaller diameter conductors

4. Scalability

• Longer string lengths enable better design flexibility
• Easier expansion of existing systems
• Better suited for large-scale projects

5. Future-Proof Design

• Compatible with latest generation high-power modules
• Supports emerging PV technologies
• Meets evolving industry standards

Technical Advantages

Lower Operating Current

• For a 5kW system: ~5A @ 1000V vs. ~8.3A @ 600V
• Reduced thermal stress on connections
• Enhanced long-term reliability

Improved Safety

• Lower fault currents in properly designed systems
• Better arc fault protection compatibility
• Enhanced isolation characteristics

Better Performance in Hot Climates

• Reduced voltage drop under high-temperature conditions
• Maintained power output during peak sun hours
• Lower temperature rise in cables and connections

Quality & Compliance

Certifications & Standards:

• EN50539 Type 2 – Photovoltaic (PV) systems – DC connectors for 1000V applications
• IEC 60269-6 – Low-voltage fuses for photovoltaic applications (1000V)
• IEC 61643-31 – Surge protective devices for photovoltaic installations (1000V)
• IEC 60947-3 – Low-voltage switchgear – Switches, disconnectors (1000V DC)
• IP65 – Ingress Protection (dust-tight and water jet protected)
• RoHS Compliant – Restriction of Hazardous Substances
• REACH Compliant – EU chemicals regulation
• CE Marking – European conformity

Quality Assurance Testing:

• 100% factory testing before shipment
• High-voltage withstand testing (DC1500V for 1 minute)
• Insulation resistance verification (>200MΩ @ DC1000V)
• High-temperature aging tests (96 hours at 70°C)
• Thermal cycling tests (-40°C to +85°C)
• Mechanical stress testing (vibration and impact per IEC standards)
• Contact resistance measurement (<30μΩ)
• Surge protection device testing per IEC 61643-31
• UV aging test for enclosure materials

Manufacturing Excellence:

• ISO 9001:2015 certified manufacturing facility
• ISO 14001:2015 environmental management system
• Strict quality control procedures at each production stage
• Premium component selection from certified suppliers (UL, TÜV listed)
• Automated and manual assembly processes for optimal quality
• Comprehensive final inspection and functional testing
• Complete traceability system for all components and assemblies
• Continuous improvement programs based on field feedback

Installation & Maintenance

Installation Guidelines:

Site Selection:

• Mount in a well-ventilated location away from direct sunlight exposure
• Ensure protection from rain, snow, and water accumulation
• Minimum clearance of 150mm on all sides for ventilation and maintenance access
• Avoid locations subject to extreme temperature variations
• Ensure accessibility for future maintenance and inspection

Mounting Procedure:

• Use appropriate mounting hardware for wall material (concrete, metal, wood)
• Ensure level installation using spirit level
• Verify enclosure is securely fastened (minimum 4 fixing points)
• Maintain IP65 protection rating after installation

Electrical Connection:

• Use cables rated for DC1000V with appropriate temperature rating
• Follow color-coded terminals: Red (+), Black (-), Yellow/Green (PE)
• Ensure proper cable entry sealing with appropriate M16/M20 glands
• Verify cable cross-section matches expected current (typically 4-6mm² for 15A)
• Apply proper torque to all terminals (1.2-1.5 Nm as specified)
• Double-check polarity before energization
• Label all cables clearly for future maintenance and troubleshooting

Pre-Commissioning Checks:

• Perform insulation resistance test (minimum 200MΩ @ DC1000V)
• Verify continuity of PE connection
• Check all mechanical connections for tightness
• Confirm SPD indicator shows green (operational status)
• Test switch disconnector operation (no-load)
• Verify all cable glands are properly sealed

Safety Precautions:

DC1000V Safety Warning:

• DC1000V systems require enhanced safety procedures
• Qualified personnel only – specialized training required
• Always use appropriate PPE: insulated gloves (Class 2), safety glasses, arc-rated clothing
• Be aware that capacitive charge may remain in cables for several minutes after disconnection
• Use CAT III 1000V rated test equipment only

Operational Safety:

• Always open the switch disconnector before accessing internal components
• Wait minimum 5 minutes after disconnection before opening enclosure
• Use voltage detector to verify absence of voltage on both poles
• Follow lockout/tagout procedures for maintenance
• Never exceed the rated voltage (DC1000V) and current (45A) specifications
• Do not operate the switch disconnector under load without proper training
• Keep the area around the combiner box clear of flammable materials
• Ensure proper grounding of the system PE terminal

Maintenance Recommendations:

Regular Inspection (Every 6 Months):

• Visual inspection for signs of damage, discoloration, or overheating
• Check surge arrester indicator status (green = OK, red = replace immediately)
• Inspect enclosure for cracks, damage, or compromised seals
• Verify cable glands maintain proper seal integrity
• Check for any signs of moisture ingress

Annual Maintenance:

• Verify all connections remain tight (retorque check: 1.2-1.5 Nm)
• Test switch disconnector operation under no-load conditions
• Perform insulation resistance test (should be >200MΩ)
• Clean enclosure exterior with damp cloth
• Inspect internal components for signs of aging or degradation
• Check and clean ventilation openings if present

Component Replacement:

• Replace fuses only with identical specifications (15A gPV, DC1000V, 10x38mm, 30kA)
• SPD replacement: only use VO-PV1000 or equivalent approved model
• Maintain detailed maintenance log for warranty and safety records

Troubleshooting Guide:

Symptom	Possible Cause	Solution
No output	Fuse blown	Check and replace fuse, investigate cause
	Switch in OFF position	Turn switch to ON position
Overheating at terminals	Loose connection	Retorque terminals to specification
	Undersized cable	Verify cable sizing, upgrade if necessary
SPD indicator red	SPD end-of-life	Replace SPD immediately
Frequent fuse failure	Short circuit in string	Inspect string for damaged cables or modules
	Overcurrent condition	Verify string design current < 15A
Switch difficult to operate	Mechanical issue	Contact technical support
	Attempting to switch under load	Only operate under no-load conditions

Technical Comparison: VOPV1000 vs VOPV600 Series

Feature	VOPV1000-1/1	VOPV600-1/1
Rated Voltage	DC1000V	DC600V
Maximum Current	45A	32A
Switch Model	VOD1-63/4B	VOD1-63/4A
SPD Model	VO-PV1000 (20kA)	VO-PV600 (20kA)
SPD Protection Level	≤3.5kV	≤2.5kV
Fuse Breaking Capacity	30kA	20kA
Enclosure Size	218x200x100mm	290x190x110mm
Insulation Voltage	DC1500V	DC1000V
Ideal String Voltage	700-1000V	400-600V
Module Compatibility	500W+ panels	300-450W panels
System Size	5-8kW	3-5kW
Cable Cost Saving	Up to 30%	Baseline
Best Application	Modern high-power systems	Standard residential

Why Choose VIOX VOPV1000-1/1?

Future-Ready Technology

• Designed for next-generation solar modules (500W+, bifacial, N-type)
• Compatible with latest inverter technologies supporting DC1000V input
• Supports industry trend toward higher system voltages

Superior Engineering

• Purpose-built components rated specifically for DC1000V applications
• Enhanced insulation coordination for long-term reliability
• Optimized for lower current, higher voltage operation

Cost-Effective Solution

• Reduced cable costs through lower operating current
• Fewer parallel strings reduce BOS (Balance of System) costs
• Lower installation labor due to simplified wiring

Safety First

• Comprehensive protection: fusing, surge protection, and isolation
• Visual indicators for all critical protection devices
• Lockable switch for maintenance safety procedures

Global Compliance

• Meets stringent international standards (EN50539 Type 2, IEC)
• Certified components from reputable manufacturers
• Suitable for worldwide installation

Technical Support

• Expert engineering support for system design
• Comprehensive installation and commissioning guidance
• Responsive after-sales technical assistance

Get in Touch

Ready to upgrade your solar installation to DC1000V technology with the VOPV1000-1/1 Solar Combiner Box? Contact VIOX Electric today for:

• Detailed technical specifications and CAD drawings
• Competitive pricing and MOQ (Minimum Order Quantity) information
• Custom configuration options for your specific project requirements
• System design support and string configuration calculations
• Technical consultation on transitioning from 600V to 1000V systems
• Sample orders for testing and evaluation
• Bulk order quotations with volume discounts
• Delivery timeline and international logistics support
• Installation training and comprehensive documentation
• Product certifications and compliance documentation