HPL Products Feature

HPL, with its unwavering commitment to the creation of world class quality products, has created a niche for itself in the electrical industry. Nowadays, HPL Electric and Power is regarded as one of the premium manufacturers of reliable Metering Solutions, Switchgears, Lighting Equipment and Wires & Cables. In solar division, it is having an expertise in the manufacturing of junction boxes for the Balance of Systems (BOS).

SOLAR DC DISTRIBUTION BOX (DCDB)

• The DC distribution unit is used to collect the DC output from Array Junction Box (AJB) and supply it to the inverter
• DC Distribution Box provides flexibility for the operator of the solar power plant to disconnect and connect both inward solar supply and battery terminals
• In the HPL DC Distribution Box we have two sections one is the solar section and the other is the battery section
• In each section of our DC Distribution Box there is MCB/MCCB and a fuse of proper rating depending upon the capacity of the power plant and the battery bank are used
• DC Distribution Box isolates battery bank & inverter from any electric surge, while making maintenance easier and enhancing system reliability.
• Our series of PV DCDB is designed to deliver high performance and better reliability of PV Combiner Box attached to access Inverters
• It is added to the inverter for minimizing the system installation time and maximizing the Inverter safety

FEATURES:-

• All of HPL-DC Distribution boxes is tested/certified as per IEC/IS standard
• The enclosure is accessible only via the tools in order to ensure the protection
• Customizable based solution as per customer needs & requirements
• Reliable electric safety to avoid hazard
• Easy and decent Cable management
• Wall mounting design for easy installation and maintenance
• Every terminal is secured and weather proof for outdoor applications also, highly secure wiring, besides being insulated with PG Cable Gland or built-in MC4 terminal connector on demand
• Protects the system if there is any fault during failure in DC side

AC DISTRIBUTION BOX (ACDB) for Solar Application

• The ACDB receives AC power from solar inverter and directs it to AC loads / LT Panel.
• ACDB is an important part of SPV system as it provides extra protection to the system in case of failures on load side
• A provision can also be made in ACDB to monitor the consumption of power from SPV Power Plant
• AC Distribution Box makes maintenance easier and enhances system reliability
• ACDBs from HPL are designed to deliver high performance and added protection by isolating inverter from mains as and when required
• Inclusion of ACDB significantly reduces overall system installation time
• ACDB enables installer to isolate different loads from each other at same location thus making repair and maintenance much safer and faster

FEATURES:-

• All of HPL-AC Distribution boxes are tested/certified as per IEC/IS standard
• The enclosure is available only via the use of designated tools in order to ensure the protection
• Customizable based solution as per customer needs & requirements
• Reliable electric safety to prevent
• Wall mounting design for easy installation and maintenance
• Every terminal is secured and weather proof making it suitable for outdoor applications also, highly secure wiring, besides being insulated with PG Cable Gland or built-in MC4 terminal connector on demand.
• Protects the system if there is any fault during failure in AC side
• Internal Wiring with lugs, ferrules and dressing included

SOLAR ARRAY JUNCTION BOX (AJB)

• Array Junction Boxes (AJB), also referred to as PV combiner boxes, it collects DC power from PV strings with blocking diodes on each string for protecting panels from reverse current flow. The collected power is then transferred to inverter to be converted into AC.
• AJB is meant for combining all the incoming lines from the solar panel strings/arrays and deriving one common string/array output for the multiple array inputs.
• HPL offers highly functional PV Array Junction Box, fabricated with the use of latest technology and is suitable for Solar Power applications of various capacities. Our PV Array Junction Box is tested by the experts under strict industry norms to guarantee flawless functioning and durability.
• HPL array junction boxes are dust, vermin and waterproof and made of Thermoplastic (ABS).
• HPL junction boxes have suitable cable entry points fitted withMC4 connectors of appropriate sizes for incoming and cable glands for outgoing cables (customizable as per customer’s requirements.

FEATURES:-

• HPL array junction boxes are total insulated according to the requirements of IEC 61439-1 as mandate by MNRE and tested up to an operating voltage of 1000 V DC.
• The enclosure is made of high quality polycarbonate.
• IP66 / 67protection.
• The enclosure is accessible only via the use of tools in order to ensure additional protection.
• Can be customized based on customer requirement.
• Blocks the reverse flow of current from battery to solar panels.
• Reliable electric safety to avoid hazard.
• Obstructs sudden surges due to lightening strokes during cloudy and rainy conditions and ground the surges immediately.
• Fuses for overload protection on each string.
• Blocking Diodes for reverse current flow protection (Optional).
• Easy DC-termination.
• Time and money saver Solar String management.
• Space saving and orientation flexibility.

SOLAR MAIN JUNCTION BOX (MJB)

• Main Junction Box is used to combine output from several Array Junction Boxes and connect it to DC Distribution Box OR to Power Conditioning Unit / Solar invertor
• The MJB consists of two sections
• One to combine all the positive terminals
• Second to combine the negative terminals on the other side
• Tested under strict industry norms by experts to guarantee flawless functioning and durability
• HPL Main Junction Boxes are made from high quality Thermoplastic (ABS) with the use of latest technology and is suitable for a range of Solar Power applications such as standalone rooftop systems, Hybrid systems etc.

• HPL Main Junction Boxes are dust, vermin and waterproof
• Fitted with cable glands of appropriate sizes for both incoming and outgoing cables

 

FEATURES:-

• HPL’s Main Junction Boxes are fully insulated according to the requirements of IEC 61439-1 as mandate by MNRE and tested up to an operating voltage of 1000 V DC.
• The enclosure is made of high quality poly-carbonate.
• Degree of protection IP-66/67
• The enclosure is accessible only via the use of tools in order to ensure the protection
• Customizable based on customer needs
• Blocks the reverse flow of current from battery to solar panels
• Reliable electric safety to avoid hazard
• Obstructs sudden surges due to lightening strokes during cloudy and rainy conditions and ground the surges immediately
• Fuses for overload protection on each string
• Blocking Diodes for reverse current flow protection (Optional)
• Easy DC-termination
• Easy and decent Cable management.
• Time and money saver Solar String management.
• Space saving and orientation flexibility.
• Reliable electric safety to avoid hazard.

SOLAR CABLE

SOLAR CABLE is nervous systems of a Solar power plant from panels to invertor and, therefore, one of the most crucial parts. They are connected on DC side of the system, proper cable sizing and its quality ultimately decides the power delivered to the load and in turn efficiency of the entire system because undersized cable results into heating which may lead further up to hazardous incidents like fire. Also even a small increase in cable resistance resulting into increased I2R losses which is considered as a higher loss of energy and such cable will lose its acceptance.

Further as solar cable has to function in open atmosphere over a long period, it has to withstand all environmental severities like UV radiation, rain, dust & dirt, temperature variations, humidity, insects and microbes etc. frequent failure / replacement of solar cable will lead to decrease in the overall project efficiency resulting in high operational costs. HP Solar cables are made under stringent MNRE parameters to deliver lasting performance throughout the lifetime of the PV system.

Special Properties of HPL Solar Cables

• UV resistance: full protection against ultraviolet rays.
• Outdoor durability: resists extreme temperatures (-40^◦C to 120^◦C) and ozone resistant.
• Halogen-free: Low Smoke Emission & Low Toxicity/Corrosively during fire.
• Properties against fire: flame retardant, fire retardant.
• Flexibility and stripping ability: for fast and easy installation.
• Lifetime and stripping ability: lasts up to 30 years even under tough external conditions.
• Fully recyclable: in accordance with new environmental regulations.
• Suitable to any connector types.
• According to EN/IEC/IS.
  

CONSTITUENTS:-

HPL solar cables are manufactured with the following materials.

• Zero Halogen Polyolefin Compound
• Annealed Tinned Copper Conductor
• Cross Linked Polyolefin Compound

FEATURES:-

HPL Solar Cable has Electrical, Chemical, and Thermal & Mechanical features, detail profile are mentioned below:-

CHEMICAL FEATURES:- Resistant to mineral oils Resistant to acids & alkaline	ELECTRICAL FEATURES:- Voltage Rating : 1.5 (1.8) KV DC High voltage test: 6.5 KV DC for 5 minutes
THERMAL FEATURES:- Maximum conductor temperature of operation- 120◦C during 20000 Minimum operating temperature :- 40◦C	MECHANICAL FEATURES:- Resistant to Impact, tear & abrasion Minimum bending radius- 4 times of overall diameter Safe pulling force – 50 N/sq. mm

TECHNICAL SPECIFICATIONS       :-

SI NO.	PARTICULARS	CABLE SIZES
	Size of Cross Sectional Area in (sq. mm)	2.5	4	6	10	16	25	35	50
1	Max. Conductor D.C. Resistance at 20◦C (Ohm/km)	8.21	5.09	3.39	1.95	1.24	0.79	0.56	0.39
2	Average Diameter of Conductor (mm)	1.88	2.39	2.93	3.9	5.4	6.73	8.08	9.69
3	Approx. Overall diameter of cable (mm)	5	5.8	6.4	7.7	9.4	11.3	12.7	14.9
4	Approx. Overall weight (kg/km)	45	60	80	120	180	275	370	515
5	Minimum Bending radius (mm)	25	29	32	39	47	57	64	75
6	Current rating under continuous operation 90◦C and ambient temperature 40◦C (Amp)	30	42	52	76	95	125	159	185
7	Short circuit current rating for 1 sec. duration	0.32	0.5	0.76	1.3	2	3.15	4.41	6.3
8	HR 105◦C PVC Insulation Thickness-Nominal (mm)	0.7	0.8	0.8	1	1	1.2	1.2	1.4
9	UV HR 105◦C PVC Sheathing Thickness-Nominal (mm)	0.8	0.9	0.9	0.9	1	1.1	1.1	1.2