1

Protection
Helio Solar solutions designed by Ferraz Shawmut

www.helioprotection.com

Transportation Power conversion

Power generation Industrial Power
& distribution controls quality
2

A free, renewable and

The boom
in renewable energies
Known reserves of fossil fuels – today the of environmentally friendly renewable
world’s main energy resource – will be energies: hydropower, wind power, bio-
depleted by the end of this century if mass, geothermal, aerothermal and solar.
we don’t change our ways. In addition,
resolutions aimed at reducing the CO2
emissions that are responsible for global
warming, the Kyoto agreement among
others, all encourage the development

Ferraz Shawmut
Any installation, whether it’s a stand-alone
solar array with a back-up generator
set or a grid-connected one, is vulne-
rable to fault currents or lightning. Today
fuses and surge arresters are the most
effective ways of protecting the wiring
and all the electrical equipment in a
PV system. But that protection must
be designed, dimensioned, tested and
adapted to the specific features of solar
applications.
At Ferraz Shawmut, the specialist in
protection specially designed for power
generation and distribution, we are showing
our commitment to the development
 Ferraz Shawmut • Solar solutions 3

universal source of energy

The beauties of
photovoltaics
What with rising gas and oil prices on the
one hand, and incentives and tax breaks
for a technology that is booming on the
other, solar energy is on a roll. By 2020
installed capacity in solar power is
expected to be near 300 GW, 50 times as
much as in 2006!
This type of system uses an entirely cost-
free, globally available energy source to
generate electricity for use on the spot,
or to sell to the grid. It’s an extremely
reliable process – as long as it’s properly
protected!

is committed
of solar power with a dedicated range
of products: junction boxes, fuses and
surge arresters. Fuses shield the cables
between strings of modules from damage.
The faulty circuits are isolated and the
system can keep on generating power.

Ferraz Shawmut is the electrical protection division

of the global Carbone Lorraine group, which is also
involved in photovoltaics through production
of the graphite for the molds used to make PV cells.
4

Fuses made to measure for

At Ferraz Shawmut, the global specialist in protection

for power generation and distribution systems,
we have designed fuse solutions specifically
for grid-connected PV powered systems.
These pages will help you chose the solution
that is the best match for your array.

Operating principle
PV array

PV string overcurrent
protection device
PV powered systems consist of N number
of strings connected in parallel, each PV string disconnection
device

string consisting of M modules (solar

panels). The modules are series connected
to generate the d.c. voltage necessary
for operation of the inverter installed at
Power
the point of connection to the grid. PV string
cable
conditioning
system

Array with 1 to 3 strings PV array

of modules
main switch

Helio Box
PV array cable
In this kind of system fault current is
PV array
just barely higher than operating current. jonction box

A fuse is not required. Dimensioning the

cables between the strings of modules Bypass diode PV module PV string
Elements that are not required in all cases

to withstand the maximum fault current Key Enclosure

Boundary of system or sub-system

is enough to avoid any fire hazard.

Array with at least

4 strings of modules
In this kind of configuration, the fault
current – which is still of much lower
PV solar panels inverter meter power grid intensity than the short circuit current
in classic grid supply systems – can reach
a level that could cause heating and
damage insulation. To ensure the best
possible protection for the system and
any people working on the equipment,
each string of solar panels must be pro-
tected with a fuse on each pole (such
systems are not grounded).
Solar array connected to the grid

your solar application
Fuses to meet the specific requirements of photovoltaics
Designed to clear low fault currents
PV cells and panels are d.c. generators.
Fuses used to protect loads powered by
the alternating current in large grids
react to very high fault currents, but
the ones used in photovoltaics are very
different. Ferraz Shawmut has taken a
position on this fast-growing market
with specific products that can clear
fault currents as small as 2 to 3 times
rated current – and that takes cutting
edge design and expertise.
Helio Fuse
calculation
When a fault occurs in a DC circuit, the
absence of natural voltage zero makes
the interruption of DC faults more diffi-
cult than the interruption of AC faults as
only the fuse arc will force the current
to decrease to zero.
The correct interruption depends on
three parameters: the value of the DC
voltage, the value of the ratio L/R (time
constant) of the fault path and the value
of the fault current. The possible low level
of overload to be eliminated in photovol-
taic equipment is a very arduous condition
for a fuse! Consequently, special pho-
tovoltaic fuses – Helio Fuses – are desi-
gned by Ferraz Shawmut in order to
ensure people safety and photovoltaic
circuit protection.
Necessary information to be collected
by the photovoltaic designer:
> The number M of modules in series
in a chain.
> The number N of strings in parallel
> The reference values in Standard
Test Conditions of the used module*
• Voc STC: open circuit voltage
• Isc STC: short circuit current
*STC (Standard Test Conditions) = irradiance 1 000 W/m ,
2 (for 1, 2, 3 parallel chains, the fusing is
Air Mass 1.5, Cell temperature 25°C.
(grid-connected)
Tried and tested in real-life conditions
Operating conditions for fuses are actually
more severe when fault currents are low
than when they are high, in a circuit where
breaking is required under direct voltage.
Melting times are long and breaking is
arduous. So it is essential that every
factor be checked exhaustively and in
detail. Ferraz Shawmut has made that
effort through extensive work at our labs
in Newburyport (USA) and Saint-Bonnet-
de-Mure (France).
In(A)
500
400
300
DCNH
200
100
30
ATM / ATMR
600 700 800
> General rule n°1:
Taking the fact that the polarities + and -
are never connected to the earth (neither
one nor the other in a photovoltaic
equipment) into account, each chain of
modules has to be fitted with two fuses:
one fuse on the positive output and
also one fuse on the negative output of
each chain.
> General rule n°2:
The rule n°1 has to be applied when the
number N of chains in parallel is upper
than or equal to 4.
not necessary).
Ferraz Shawmut • Solar solutions 5
Helio
Helio is the brand name of the solar solutions
designed by Ferraz Shawmut. The product
offering dedicated to this booming market
encompasses Helio Fuse, Helio Switch, Surge
Trap and Helio Box.
DC120
DC10 DCT
UDC(V)
900 1 000 1 100
How to choose the correct range of fuses:
The choice is done with the compliance
of the subsequent rule: Maximum DC
Operating Voltage of the fuse in the
leaflet must be higher than or equal
to 1.20 x M x (Voc STC).
How to choose the correct rating of the fuse:
A) Fuse current rating determination in
Europe and others temperate areas.
Rated current In of the fuse must be
higher than or equal to 1.27 x Isc STC.
B) F
 use current rating determination in
Africa and Equatorial or tropical areas.
Rated current In of the fuse must be
higher than or equal to 1.51 x Isc STC.
6

HelioFuse
Product offering
D
 C10
1 000VDC

Minimum Breaking Capacity = 2 In ; Maximum Breaking Capacity = 50 kA

Maximum operating Rated Current Cat. Number Packaging
voltage
1 050 VDC @ L/R = 5 ms 5 DC10GC11C5 10
8 DC10GC11C8 10
10 DC10GC11C10 10
12 DC10GC11C12 10
1 000 VDC @ L/R = 5 ms 16 DC10GC10C16 10
20 DC10GC10C20 10

P/P0,7In

Drawing 1.40

1.20

1.00

0.80

0.60

0.40

0.20

Electrical characteristics 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 I/In

Corrective factor for power losses vs. ambient temperature

In (A) Cat. Number Losses (W)’@0.7 In 20° C P(T)/P(20)

1.2
8 DC10GC10V8 2.0
1.2

10 DC10GC10V10 2.3 1.1

12 DC10GC10V12 3.0 1.1

16 DC10GC10V16 1.45 1.0

20 DC10GC10V20 1.65 1.0

0.9
0 10 20 30 40 50 60 70 Ta (°C)

Fuse clips
MR10 CI MR10 MR10 without compressor

10.1

Cat. Number Designation Weight (g) Pack

20.5

MR10RESSORTCI MR10 CI 4.5 200

15.5
0.8

9 14
MR10RESSORT MR10 7.0 20 4.2

MR10RESSORTSP MR10 without compressor 5.7 20

 Ferraz Shawmut • Solar solutions 7

HelioFuse
Product offering
D
 CT
1 000VDC

Minimum Breaking Capacity = 2In ; Maximum Breaking Capacity = 50 KA

Maximum operating Rated Current Cat. Number Packaging
voltage
1 000VDC @L/R = 2ms 5 DCT5-2 10
8 DCT8-2 10
10 DCT10-2 10
12 DCT12-2 10
15 DCT15-2 10
20 DCT20-2 10
25* DCT25-2 10
*M
 inimum breaking
30* DCT30-2 10 capacity is 3In.

Drawing Electrical characteristics

P/P0,7In
1.40

Cat. Number Watt Losses @ 0.7In & 20°C

1.20
DCT5-2 0.143
1.00
DCT8-2 0.528
1-1/2” 13/32” 0.80
(38.1 mm) (10.3 mm) DCT10-2 0.690
DCT12-2 0.714 0.60

DCT15-2 0.909 0.40

DCT20-2 1.51 0.20

0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 I/In
DCT25-2 1.77
DCT30-2 1.80 Corrective factor for power losses vs. ambient temperature

Fuse holders
P(T)/P(20)
1.2

1.2

1.1
Cat. Number Number of poles Indicator Packaging Udc maxi 1.1
operating
1.0
US101 1 No 12 1 000V 1.0

US101I 1 Yes 12 700V 0.9

Ta (°C)
US102 2 No 12 1 000V 0 10 20 30 40 50 60 70

US102I 2 Yes 12 700V

For more than 700VDC operating voltage light indicator for fuse melting operation consult us.

Note: U/L recognized voltage are 800VAC and 1 000VDC

Datas for ambient temperature : 20°C
Wire range: rigid wire = 1-16mm2 (18-6 AWG) Multistrand wire = 0.75 - 10mm2 (18-8 AWG)
Ferraz Shawmut recommands to use screwdrivers PZ 2 or Flat 5.5 x 1mm
(maximum diameter 6mm / maximum tightening torque : 2.5Nm (22Ib-in)
IR for fuses: 120kA @ 500V IEC - 80ka @ 690V IEC - 80kA @ 700V UL

Fuse clips
> Refer to the side page.
> H models for PC mount in option.
8

HelioFuse
Product offering
A
 TMR
600VDC

Minimum Breaking Capacity = 1.35In ; Maximum Breaking Capacity = 100kA

Max.Operating Voltage = Rated Voltage Rated Current Cat. Number Packaging
600VDC 5 ATMR5 10
UL/CSA @ 8 ATMR8 10
L/R = 10ms
10 ATMR10 10
15 ATMR15 10
20 ATMR20 10
25 ATMR25 10
30 ATMR30 10
For UL fuses, the maximum operating voltage is equal to the rated voltage.

Drawing P/P0,7In
1.40

1.20

1.00

0.80

0.60

0.40

0.20

Electrical characteristics 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 I/In

Corrective factor for power losses vs. ambient temperature

Cat. Number Watt Losses @ 0.7In & 20°C
P(T)/P(20)
ATMR5 0.582 1.2

ATMR8 0.673 1.2

ATMR10 0.753 1.1

ATMR15 0.822 1.1

ATMR20 0.980
1.0
ATMR25 1.07
1.0
ATMR30 1.19
0.9
0 10 20 30 40 50 60 70 Ta (°C)

Fuse holders

Cat. Number Number of poles Indicator Packaging Udc maxi operating

USBCC101 1 No 12 600V
USBCC101I 1 Yes 12 600V
USBCC102 2 No 12 600V
USBCC102I 2 Yes 12 600V
 Ferraz Shawmut • Solar solutions 9

HelioFuse
Product offering
A
 TM
600VDC

Minimum Breaking Capacity = 1.35In ; Maximum Breaking Capacity = 100kA

Max.Operating Voltage = Rated Voltage Rated Current Cat. Number Packaging
600VDC 5 ATM5 10
UL/CSA @ 8 ATM8 10
L/R = 10ms
10 ATM10 10
15 ATM15 10
20 ATM20 10
25 ATM25 10
30 ATM30 10
For UL fuses, the maximum operating voltage is equal to the rated voltage.

Drawing P/P0,7In
1.40

1.20

1.00

0.80
1-1/2” 13/32”
(38.1 mm) (10.3 mm)
0.60

0.40

0.20

Electrical characteristics 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 I/In

Corrective factor for power losses vs. ambient temperature

Cat. Number Watt Losses @ 0.7In & 20°C
P(T)/P(20)
ATM5 0.582 1.2

ATM8 0.673 1.2

ATM10 0.753 1.1

ATM15 0.822 1.1

ATM20 0.980
1.0
ATM25 1.07
1.0
ATM30 1.19
0.9
0 10 20 30 40 50 60 70 Ta (°C)

Fuse holders

Cat. Number Number of poles Indicator Packaging Udc maxi operating

US101 1 No 12 1 000 V
US101I 1 Yes 12 700 V
US102 2 No 12 1 000 V
US102I 2 Yes 12 700 V
For more than 700 V DC operating voltage light indicator for fuse melting operation consult us.
10

HelioFuse
Product offering
D
 CNH
600VDC

Minimum Breaking Capacity = 2In ; Maximum Breaking Capacity = 50 KA

Maximum operating Rated Current Size Cat. Number Packaging
voltage
50A 00 DC00GS60V050PV 3
63A 00 DC00GS60V063PV 3
600VDC @ L/R = 2ms
80A 00 DC00GS60V080PV 3
100A 00 DC00GS60V100PV 3
125A 1 DC1GS60V125PV 3
160A 1 DC1GS60V160PV 3
600VDC @ L/R = 2ms 200A 1 DC1GS60V200PV 3
250A 1 DC1GS60V250PV 3
280A 1 DC1GS60V280PV 3

Size A B C H L M N P R T
00 29.5 47.5 59.5 15 79 13.1 13.1 43.4 50 35
00 1.16” 1.87” 2.34” 0.59” 3.11” 0.52” 0.52” 1.71” 1.97” 1.38”
1 39.5 52.5 64.5 20 135 32.1 32.1 43.4 68 40
1 1.56” 2.07” 2.54” 0.79” 5.32” 1.26” 1.26” 1.71” 2.68” 1.57”

Drawing
P/P0,7In
1.40

1.20

1.00

0.80

0.60

0.40

0.20
0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 I/In

Electrical characteristics Corrective factor for power losses vs. ambient temperature

P(T)/P(20)
1.2
Cat. Number Watt Losses @ 0.7In & 20°C
1.2
DC00GS60V050PV 4.35
DC00GS60V063PV 4.85 1.1

DC00GS60V080PV 5.65 1.1

DC00GS60V100PV 6.35 1.0

DC1GS60V125PV 9.0
1.0
DC1GS60V160PV 10
0.9
DC1GS60V200PV 11
0 10 20 30 40 50 60 70 Ta (°C)
 Ferraz Shawmut • Solar solutions 11

Accessories
Remote signalling
Cat. Number Contact Qty of NO-NC separated circuits Packaging system for fitting on
MSNH2-B6PRES Mini = 20V 50mA • Maxi = 10A 1 3 fuses equipped with
micro-switch support.
MSNH2-B2PRES Mini = 20V 100mA • Maxi = 5A 1 3

Fuse bases

Cat. Number Fuse size Nb of poles Packaging Model Udc maxi

operating
BB001RFS 00 1 3 IP2X Finger Safe 690V
BB11PPRFS 1 1 3 including cover 690V

Dimensions A B C D E F G H I J K L M N O
(mm)
Size 00 32 20 117 100 8 2 14 25 145 21.5 8 56 52 85 84
Size 1 60 32 209 176 10,5 30 20,5 25 250 35 M10 81 71 122,5 146
12

HelioFuse
Product offering
D
 C120-123
1 100VDC

Minimum Breaking Capacity = 2In; Maximum Breaking Capacity = 100kA

Rated voltage Rated Current Size Cat. Number Packaging
50A 120 DC120GC12C050EF 1
63A 120 DC120GC12C063EF 1
80A 120 DC120GC12C080EF 1
100A 121 DC121GC12C100EF 1
1 200VDC IEC @ L/R = 1ms
125A 121 DC121GC12C125EF 1
160A 121 DC121GC12C160EF 1
200A 121 DC121GC12C200EF 1
250A 121 DC121GC12C250EF 1
1 100VDC IEC @ L/R = 1ms 315A 122 DC122GC11C315EF 1

Drawing

106.5 with MC2R 3E

91 with MCR 3E
97.5 with MC2R 3E 76 with MC 3E
82.5 with MCR 3E
67.5 with MC 3E

120 122

102.5 avec MC2R 3E

87.5 avec MCR 3E
72.5 avec MC 3E

121
 Ferraz Shawmut • Solar solutions 13

Electrical characteristics P/P0,7In

1.40

Cat. Number Watt Losses @ 0.7In & 20°C

1.20
DC120GC11C050EF 3.4
DC120GC11C063EF 4.4 1.00

DC120GC11C080EF 5.6
0.80
DC120GC11C100EF 7.0
DC120GC11C125EF 8.8 0.60

DC120GC11C160EF 11.3
0.40
DC121GC11C200EF 15.7
DC121GC11C250EF 19.6 0.20
DC122GC11C315EF 24.3 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 0.8 I/In

Corrective factor for power losses vs. ambient temperature

P(T)/P(20)
1.2

Accessories
1.2

1.1

1.1
Cat. Number Contact Qty of NO-NC Packaging
separated circuits 1.0

MC3E1-5N Mini = 20V 50mA 1 1&3 1.0

Maxi = 5A
0.9
MC3E1-5NBS Mini = 10V 10mA 1 1&3
0 10 20 30 40 50 60 70 Ta (°C)
MC3E1-9NBS Maxi = 3A 2 1&3
Remote signalling system for fitting on fuses equipped with micro-switch support.

P
G

C*

Fuse bases A
B
H

L
F

Cat. Number Nb of poles Packaging Insulation Voltage N E

¿R
M ¿S

SP43-120 1 1
SE43-121 1 1 2 500VDC
P P
Q

SE43-122 1 1
Q
G
G

C* C*

D D

H H

A A
B 10 14 B
10 14 M M

N E N E

14 10 ¿S ¿R 14 10 ¿S ¿R
F F
L L

Cat. Number Drawing A B C* D E F G H L M N P Q ØR ØS

SP43-120 1 194.5 42 125 54.5 26 214.5 134.5 10 234.5 106.5 28 184 8.5 5.5
SE43-121 2 204.5 42 130 54 32 238.5 141.5 10 270.5 116.5 28 191.5 166.5 10.5 5.5
SE43-122 2 230.5 54 140 60 42 260.5 136.5 15 296.5 77.5 35 206.5 171.5 12.5 8.5
14

Product offering
Surge Trap
Surge Protective Device (Thermally Protected) for PV applications. The Surge-Trap PV
provides advanced overvoltage protection to photovoltaic systems by utilizing
Ferraz Shawmut’s patented TPMOV design, which does not require additional
over-current protection due its high short circuit withstand. The Surge-Trap PV
is designed to be mounted on 35mm DIN-rail while featuring individual mode visual
indication and optional remote indication, providing status to critical control circuits.

Part Number
Technical Features ST600PV ST1000PV
ST600PVM* ST1000PVM*
Test Class According Type 2 + 3 / Class II + III
to IEC61643-1 and EN61643-11
UL 1449 Recognized Component UL 1449 2nd Edition 2005 - File E210793
Poles 2 3
Technology TPMOV®
Type of Network Photovoltaic
Maximum Continuous Operating Voltage DC Uc 670VDC 1 120VDC
Nominal Voltage Un 600VDC 1 000VDC
Maximum Discharge Current (8/20 µs) Imax 50kA
Nominal Discharge Current (8/20 µs) In 20kA
Voltage Protection Level Up < 1 500 < 2 400
Degree of Protection IP20
Mounting On 35mm DIN Rail
Wire Range #6 to #14 AWG Wire / 16mm2 to 2.5mm2 Wire
65 / 70°C Copper Wire Only
Terminal Torque 14.75 lb – in / 1.67 N – m
Response Time tA < 25ns
Energy Absorption Wmax 960 J 1820 J
Operating Temperature -40°C to +60°C
Overcurrent Protection No Overcurrent Protection Required

* Built-in microswitch for remote indication

Connection / Circuit Diagrams Product Dimensions

for ST PV, PVM: for ST:
ST600PV, ST600PVM ST1000PV, ST1000PVM ST600PV, ST600PVM ST1000PV, ST1000PVM

Visual Indication Remote Signal Terminal Remote Contact Connection Diagram

Connection of Remote Tab Contact Designations
Monitoring for ST: NO 1
Subminiature Switch
NC 2 125 VAC - 3A max
-25°C to 85°C
Common 3
Signal Wire Range: #16 to #30 AWG
Terminal Torque: 1.8Ib-in
 Ferraz Shawmut • Solar solutions 15

Product offering
H
 elioBox

Number of string 4à6 6à8 8 à 12

Nominal Voltage 1000VDC

Wire cable section for the strings 4 mm² reinforced isolation
Closed stuffing box size PG9 (6 to 10 mm)
Finger safe protection (IEC 60529) IP 55
Isolation Class (IEC 60364) II
Fire and fumes class (UL94 - NFC 20-455) V2
Dimensions (HxLxP) 305x225x129 (mm)
HelioBox Junction Colour RAL 7035
Cable wire recommanded for output 10 mm² (PGxxx) 16 mm² (PGxxx) 25 mm² (PGxxx)
Maximum usage temperature - 20°C to + 50°C
Maximum storage temperature - 20°C to + 70°C
Relative Humidity 95% Maxi
Weight
Labelling ATTENTION: Permanent VOLTAGE higher than 50V
Permanent DC voltage equipment Disconnection and Protection
DO not open under load
Start to connect the outpout
Mount fuses and close the fuse holder before input connection
All connections must be made by personnel
qualified to work at voltages over 50V
We recommend wiring the output from the box
before the input to the box
Max tightening torque = 2.2Nm on output terminals
Wiring & connecting
recommandations We recommend installing fuses and closing
the disconnector handle before making input
connections
Max tightening torque = 2.2Nm on input terminals
All connections must be made under stable
weather conditions (no rain or lightning)

Define your catalog number

HelioBox Junction (HBJ):
Define your Catalogue Number
HBJ_ _ _ _ _ _ S _ _ _ _
—— —–——— ———– –
Option 1 Option 2 Option 3 Option 4

Option Number Description Cat. Number Example

1 Number of strings connected to your Junction box 04 For a 6 strings connected
06 application
08 HBJ06…
10
12
2 The Catalogue Number of the selected fuse holder. US10 For DCT20 fuses
(in that documentation) USBC HBJ06US10
3 Selected the requested surge protection level if any. Sxxxx V For a ST1000PV selected,
1000V or 600V SXXX (S10C or S60V) HBJ06US10S10C
4 If visual indication requested: 1 HBJ06US10S10CI
> See Through cover and US10I or USBCCI

HelioBox Main:
Also available up on request, the Main protection box is connected to the converter.
It is composed of DCNH or DC12X fuses together with a switch disconnect presented in next page of this catalogue.

Please contact our technical support (+33 4 26292929) for further questions.
Email : ts@fr.ferrazshawmut.com
16

Product offering
Helio Switch

Voltage Rating (VDC)

Current Rating (A) 750 1 000
Catalog Number
63 IT63HEL75VCF -
160 IT160HEL75VCF -
200 - IT200HEL10CCF
250 - IT250HEL10CCF
315 - IT315HEL10CCF
400 - IT400HEL10CCF

HE002 - 05/2008
- Tél. 04 38 12 44 11 - www.adncom.fr - 5775

1 rue Jean Novel

69626 Villeurbanne cedex - France
Tél. 33 (0)4 72 22 66 11 - Fax 33 (0)4 72 22 67 13

374 Merrimac Street

Newburyport, MA 01950 - USA
Tél. (978) 462-6662 - Fax (978) 462-0181

www.ferrazshawmut.com