VOPV1000-3/1 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 VOPV1000-3/1 Solar Combiner Box represents an advanced multi-string solution designed specifically for medium to large-scale DC1000V solar systems that require flexible design and efficient power consolidation.

The VOPV1000-3/1 is a professional-grade DC combiner box engineered for high-voltage solar PV systems operating at DC1000V. This versatile 3-input, 1-output configuration enables efficient consolidation of three independent solar strings into a single output feed, making it ideal for complex roof layouts, multi-orientation installations, and phased solar projects. With its 45A current rating and comprehensive protection for each string, this combiner box delivers optimal performance for 10-15kW solar installations.

Key Features & Benefits

• Triple-String Capability: 3 independent input strings combined into 1 output for streamlined system architecture
• DC1000V High Voltage Rating: Optimized for next-generation solar systems with high-efficiency modules
• 45A Output Current: Sufficient capacity for high-power multi-string configurations
• Individual String Protection: Dedicated fuse protection for each string (6 fuses total) enables precise fault isolation
• Design Flexibility: Perfect for complex roof layouts with multiple orientations (east-west, split arrays)
• Centralized Protection: Single surge protection device and switch disconnector after combining reduces component costs
• Cost-Effective Architecture: Reduces wiring complexity to inverter with single consolidated output
• Robust Construction: IP65-rated ABS enclosure (VOAT-13) withstands harsh environmental conditions
• Phased Installation Ready: Allows gradual system expansion by activating strings sequentially
• Simplified Inverter Connection: Single output feed reduces installation time and material costs
• Easy Troubleshooting: Individual fusing per string simplifies fault diagnosis
• Certified Quality: Complies with EN50539 Type 2 standards for high-voltage photovoltaic applications

Technical Specifications

General Data

Parameter	Specification
Model	VOPV1000-3/1
Rated Voltage	DC1000V
Maximum Output Current	45A
Configuration	3 Inputs / 1 Output
Maximum String Current	15A per string
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
Recommended System Size	10-15kW

Enclosure Specifications

Parameter	Value
Model	VOAT-13
Material	ABS (Acrylonitrile Butadiene Styrene)
Protection Rating	IP65
Dimensions (H x W x D)	296mm x 230mm x 120mm
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/M25 knockouts
Weight	Approximately 3.5kg (with components)
Internal Layout	Optimized for 3-string configuration with clear labeling

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 optimized for DC switching
Position	After string combining point (common disconnection)
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
Quantity	1 unit (common protection after combining)
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
Configuration	6 fuse holders (2 per string: positive and negative)
Fuse Links Included	6 pieces (15A DC gPV fuse)
Protection Scheme	Individual protection for each string
Mounting	DIN rail compatible
Standard	IEC 60269-6
Indicator	Visual fuse status indicator per holder
Contact Material	Copper, tin-plated
Operating Temperature	-40°C to +85°C

Electrical Configuration

The VOPV1000-3/1 features a sophisticated multi-string electrical design optimized for DC1000V systems with enhanced flexibility and safety:

VOPV1000-3/1 Solar Combiner Box Diagram

Input Configuration:

• Three independent string inputs (String 1, String 2, String 3)
• Each string has dedicated positive (+) and negative (-) terminals
• Individual dual-pole fuse protection for each string (6 fuses total)
• Terminal blocks rated for 4-6mm² cable per string
• Clear identification labels for each string input
• Supports different string configurations and module orientations

String-Level Protection:

• Primary Protection: DC fuses (15A gPV type, 30kA breaking capacity) on both poles of each string
• Individual Fault Isolation: Each string can be isolated independently without affecting others
• Overcurrent Protection: Prevents damage from string-level faults or module failures

Combining Point:

• Internal busbar combines three strings after individual fuse protection
• Parallel connection of all three strings to single output feed
• Optimized busbar design minimizes voltage drop and heating

Common Protection (After Combining):

• Secondary Protection: Type 2 DC surge arrester (VO-PV1000, 20kA nominal discharge)
• Isolation: 2-pole DC switch disconnector (45A rated) for complete system disconnection
• Single Point Control: One switch controls all three strings simultaneously

Output Configuration:

• Single consolidated output to inverter with clear polarity marking
• Terminal blocks rated for 6-16mm² cable (larger to accommodate combined current)
• PE (Protective Earth) connection provided with dedicated terminal
• Output labeled for connection to inverter DC input

Circuit Architecture Benefits:

• Independent string monitoring capability
• Simplified troubleshooting with per-string fusing
• Reduced component count (single SPD and switch for all strings)
• Lower installation cost to inverter (single cable run)
• Enhanced system reliability through fault isolation

Bill of Materials

Item No.	Component	Model/Specification	Quantity
1	ABS Enclosure	VOAT-13, 296x230x120mm, 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	6
5	DC Fuse Link (gPV)	15A, DC1000V, 10x38mm, 30kA	6
6	Input Terminal Block	4-6mm², Red/Black, 1000V rated	6
7	Output Terminal Block	6-16mm², Red/Black, 1000V rated	2
8	PE Terminal Block	6-16mm², Yellow/Green	1
9	DIN Rail	35mm standard, zinc-plated	2
10	Busbar	Copper, tin-plated, 1000V rated, combining	1 set
11	Cable Glands	M16/M20/M25, IP65 rated, 1000V	8
12	Mounting Brackets	Stainless steel 304	2
13	String Labels	String 1/2/3 identification labels	1 set
14	Warning Labels	DC1000V safety labels, multilingual	1 set
15	Installation Manual	English/Multi-language, 3/1 configuration guide	1

Applications

The VOPV1000-3/1 Solar Combiner Box is specifically designed for multi-string high-voltage photovoltaic applications:

Residential Solar Systems

• Large residential installations (10-15kW systems)
• Homes with complex roof layouts requiring multiple orientations
• Split-array configurations (east-west, north-south combinations)
• Properties with multiple roof sections or buildings
• Premium residential projects with high-efficiency 500W+ modules

Commercial Installations

• Small to medium commercial rooftop arrays (15-25kW)
• Building-integrated photovoltaic (BIPV) systems with multiple zones
• Industrial facility solar installations with varied roof orientations
• Multi-tenant buildings with consolidated metering
• Carport and canopy solar structures

Complex Roof Scenarios

• Multiple roof pitches requiring separate string configurations
• East-west facing arrays optimizing morning and evening generation
• Partial shading management with string-level optimization
• Historic buildings with architectural constraints
• Mixed tilt angles for optimal year-round performance

Multi-Orientation Benefits

• East-West Systems: Combine east-facing and west-facing strings for extended generation profile
• Split Arrays: Connect strings from different roof sections efficiently
• Azimuth Optimization: Independent strings maximize energy capture from various orientations
• Tilt Variation: Accommodate different mounting angles in single system

Phased Installation Projects

• Stage 1: Install and connect first string, reserve capacity for expansion
• Stage 2: Add second string when budget allows or demand increases
• Stage 3: Complete system with third string for full capacity
• Flexibility: Allows customers to start small and grow over time

System Architecture Applications

• Connection point for three strings to single-input inverter
• Distribution hub for multi-MPPT inverter systems
• Centralized protection and isolation for string-level maintenance
• Simplified wiring to inverter reduces installation complexity
• Ideal for systems requiring string-level monitoring integration

Benefits of 3-to-1 Configuration

Design Flexibility

Complex Roof Layouts

• Accommodates up to three different roof sections or orientations
• Eliminates need for multiple combiner boxes in distributed arrays
• Simplifies system design for challenging installation sites
• Enables creative solutions for architectural constraints

Multi-Orientation Systems

• Optimize energy production across different sun exposure patterns
• Balance morning, midday, and evening generation profiles
• Compensate for shading at different times of day
• Maximize annual energy yield in suboptimal conditions

Cost Efficiency

Installation Savings

• Single output cable to inverter reduces material costs by 50-70%
• Simplified conduit runs and cable management
• Reduced labor time for inverter connection
• Single entry point at inverter simplifies termination

Component Optimization

• One surge protection device instead of three (cost reduction)
• Single switch disconnector for all strings (simplified operation)
• Fewer components reduce failure points and maintenance needs
• Consolidated protection reduces overall system cost

Cable Cost Reduction

• Lower current per string (15A max) allows smaller input cables
• Single larger output cable more economical than three separate runs
• Reduced DC cable losses through optimized architecture
• Less copper required overall compared to separate string runs

Operational Advantages

Simplified Maintenance

• Single access point for all protection devices
• One switch controls entire system for maintenance
• Individual fusing allows string-level troubleshooting
• Clear labeling simplifies fault diagnosis

Enhanced Safety

• Centralized disconnection point reduces arc flash risk
• Single lockout/tagout location for maintenance procedures
• Lower voltage at combining point compared to series connection
• Individual overcurrent protection prevents cascading failures

System Monitoring Integration

• Compatible with string-level monitoring systems
• Individual fuse status enables fault detection
• Simplified data collection point for performance analysis
• Easier integration with smart home or building management systems

Scalability Benefits

Future Expansion Ready

• Start with one or two strings, add third later
• No need to replace combiner box when expanding
• Maintains warranty and certification with expansion
• Protects initial investment while allowing growth

Flexible Capacity Management

• Disconnect individual strings for partial maintenance
• Continue operation with reduced capacity during repairs
• Test new strings before full integration
• Optimize system performance incrementally

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, 100 cycles)
• Mechanical stress testing (vibration and impact per IEC standards)
• Contact resistance measurement on all terminals (<30μΩ)
• Surge protection device testing per IEC 61643-31
• UV aging test for enclosure materials (1000 hours)
• String balancing test to verify current distribution

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 busbar assembly for consistent quality
• Manual inspection of all electrical connections
• Comprehensive final inspection and functional testing
• Complete traceability system for all components and assemblies
• Continuous improvement programs based on field performance data

Installation & Maintenance

Installation Guidelines:

Site Selection:

• Mount in a well-ventilated location accessible for maintenance
• Ensure protection from direct sunlight, rain, and water accumulation
• Minimum clearance of 150mm on all sides for ventilation
• Consider cable entry paths from three different string locations
• Position for easy access to switch and visual inspection of SPD indicator

Mounting Procedure:

• Use appropriate mounting hardware rated for enclosure weight (3.5kg + cables)
• Ensure level installation using spirit level
• Verify enclosure is securely fastened (minimum 4 fixing points)
• Maintain IP65 protection rating after installation
• Consider future expansion access when positioning

String Connection Sequence:

• Label all three strings clearly before connection (String 1, 2, 3)
• Connect strings in numerical order for systematic installation
• Verify correct polarity for each string before termination
• Use cables rated for DC1000V with appropriate temperature rating (typically 4-6mm²)
• Apply proper torque to all terminals (1.2-1.5 Nm as specified)
• Ensure proper cable entry sealing with appropriate glands

Electrical Connection Best Practices:

• Follow color-coded terminals: Red (+), Black (-), Yellow/Green (PE)
• Maintain consistent color coding across all three strings
• Use ferrules on stranded conductors for reliable connection
• Verify cable cross-section matches expected current (15A max per string)
• Double-check polarity before energization
• Keep string cables separated to prevent cross-connection errors

Pre-Commissioning Checks:

• Perform insulation resistance test on each string (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 under no-load conditions
• Verify all cable glands are properly sealed
• Measure open-circuit voltage of each string to confirm correct connection
• Verify string voltages are balanced (within 5% of each other)

Safety Precautions:

DC1000V Multi-String Safety:

• Higher complexity requires enhanced safety procedures
• Qualified personnel only – specialized multi-string 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

Multi-String Specific Hazards:

• Even with one string disconnected, voltage remains from other strings
• Never assume system is de-energized until all strings are verified dead
• Use multi-point voltage testing on all three strings
• Implement proper lockout/tagout procedures with multiple locks if needed

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 all strings
• Test each string individually before proceeding with maintenance
• Never exceed the rated voltage (DC1000V) and current specifications
• Do not operate the switch disconnector under load
• 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
• Inspect each string’s fuse status visually
• Look for any unusual patterns (e.g., one string repeatedly blowing fuses)

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 on each string (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
• Verify string voltage balance (all within 5% of each other)
• Inspect busbar connections for signs of heating

Component Replacement:

• Replace fuses only with identical specifications (15A gPV, DC1000V, 10x38mm, 30kA)
• Always replace fuses in pairs (both positive and negative) for same string
• SPD replacement: only use VO-PV1000 or equivalent approved model
• Maintain detailed maintenance log for warranty and safety records
• Record which strings have had fuse replacements for trend analysis

String Balancing and Troubleshooting:

Symptom	Possible Cause	Solution
One string no output	Fuse blown in that string	Check and replace both fuses for affected string, investigate cause
	String disconnected	Verify connections at string input
Unbalanced string voltages	Module mismatch	Verify all modules in string are identical
	Partial shading	Check for new obstructions on specific string
	Module degradation	Investigate module performance in affected string
Frequent fuse failure (one string)	Short circuit in string	Inspect string for damaged cables or modules
	Overcurrent condition	Verify string design current < 15A
All strings affected	Switch in OFF position	Turn switch to ON position
	SPD failure	Check SPD indicator, replace if red
	Inverter issue	Check inverter DC input status
Overheating at terminals	Loose connection	Retorque terminals to specification
	Undersized cable	Verify cable sizing, upgrade if necessary
	High ambient temperature	Improve ventilation or consider shading
SPD indicator red	SPD end-of-life	Replace SPD immediately, do not operate until replaced
Output current imbalance	Different string configurations	Verify all strings have same number and type of modules
	Module degradation	Investigate performance of specific string

Technical Comparison: VOPV1000 Series

Feature	VOPV1000-3/1	VOPV1000-1/1
String Inputs	3	1
String Outputs	1 (combined)	1
Enclosure Size	296x230x120mm	218x200x100mm
Maximum Output Current	45A	45A
Fuse Holders	6 (2 per string)	2 (1 string)
Fuse Links	6 pieces	2 pieces
SPD Units	1 (after combining)	1
Weight	~3.5kg	~2.2kg
Ideal System Size	10-15kW	5-8kW
Best Application	Multi-orientation, complex roofs	Simple single-string systems
String Flexibility	High (3 orientations)	Low (1 orientation)
Expansion Capability	Yes (up to 3 strings)	No
Cost per String	Lower (shared components)	Higher (dedicated components)

Why Choose VIOX VOPV1000-3/1?

Multi-String Versatility

• Handles up to three different roof orientations or sections efficiently
• Ideal solution for complex architectural scenarios
• Enables creative system designs that maximize available space
• Perfect for properties with challenging roof layouts

Superior System Economics

• Lower overall cost compared to three separate 1/1 combiner boxes
• Reduced installation labor through single output connection
• Optimized cable costs with consolidated output feed
• Shared protection components reduce BOS (Balance of System) costs

Design Intelligence

• Individual string protection enables precise fault isolation
• Centralized control simplifies operation and maintenance
• Scalable architecture supports phased installation approach
• Future-proof design accommodates system expansion

Professional Engineering

• Purpose-built components rated specifically for DC1000V applications
• Optimized busbar design for efficient string combining
• Enhanced insulation coordination for long-term reliability
• Comprehensive testing ensures multi-string operation reliability

Installation Excellence

• Clear string identification prevents connection errors
• Systematic layout simplifies complex wiring
• Single output point reduces inverter termination complexity
• Professional documentation includes multi-string configuration guide

Technical Support

• Expert engineering support for complex system design
• String configuration optimization assistance
• Comprehensive installation and commissioning guidance
• Responsive after-sales technical assistance for troubleshooting

Get in Touch

Ready to optimize your multi-string solar installation with the VOPV1000-3/1 Solar Combiner Box? Contact VIOX Electric today for:

• Detailed technical specifications and CAD drawings
• Multi-string system design consultation and optimization
• String configuration calculations and recommendations
• Competitive pricing and MOQ (Minimum Order Quantity) information
• Custom configuration options for specific project requirements
• Technical guidance on complex roof layout solutions
• Sample orders for testing and evaluation
• Bulk order quotations with volume discounts
• Delivery timeline and international logistics support
• Installation training specific to 3/1 configuration
• Product certifications and compliance documentation
• String-level monitoring integration support