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Aurora PVI-6000 User Manual - Solar Energy Products Australia

1. AC PVinput21 7 z 1 Output Input2 H Input22 f oe i inverter o PV Input 2 2 SPERARE MPPT2 5000 00 0 Pvnputi Switch MPPT 1 PVinputta PV Input 1 2 3 1 1 a d P rpuii 1 PV Input t i P PVinpiti 2 BS d i Input2 PV input22 m Inverter 75 Z E MPPT2 PVingut2d PV Input2 2 Fig 3B Integrated switch models power one 70 hanging the Shape of Power Page 16 of 89 PVI 6000 OUTD xx AU Rev 1 0 DC Switch A PV Input 1 4 i D a PV Input 2 o _ gt PViputii 2 n T PV Input I PVinputi 2 PV rut A es M D T 7 1 Output Input24 PV Input22 d mil P DC AC Inverter 4 gee PV input 22 Bap MPPT2 Fig 3C Integrated switch and diodes models power one AvA hanging the Shape of Power Page 17 of 89 PVI 6000 OUTD xx AU Rev 1 0 2 3 Data Transmission and Check When more than one inverter is used remote monitoring can be implemented through a sophisticated communication system b
2. 34 3 9 REPLACING THE MEMORY 35 MONITORING AND DATA TRANSMISSION 38 5 1 USER S INTERFACE 38 AVAILABLE DATA 40 5 2 1 Real time operational 40 9 2 2 Internally logged data siiis aee HR 41 3 9 LED INDICATORS 42 5 4 MESSAGES AND ERROR CODES 47 5 3 LCD DISPLAY CT 50 5 5 1 Connection of system to the 50 35 9 2 Error siiis etit e Rie Hte Per tc pee ap Ue pera doe boda 51 Power one 0 hanging the Shape of Power Page 9 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 3 First phase electric parameter check eee BST By 5 9 5 58 5 3 5 2 Partial iir 59 Dd TodaY 59 Last 60 5 5 5 5 Last 60 352 0 Last 30 Days 60 1 Last 365 DAS aeo stores bei n 60 52 86 WISER p 61 SINT EIC 63 5010 2 Display Sel Me 63 9 5 0 S SEL 64 5 5 6 4 New Password eese senes 64 5 9 6 5 Pm 64 3 9 6 0 IDHTIO 65 53 6 7 Langues
3. 0 hanging the Shape of Power Page 58 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 5 Statistics Select the STATISTICS menu to display the following submenu Lifetime Partial Today Last 7 days Last Month Last 30 Days Last 365 Days User period The display has 2 lines use the keys at the side of the display to scroll through items or open the corresponding submenus as described in section 5 5 3 A FEW POINTERS ON DISPLAY KEY OPERATION An arrow on the left side of the display highlights your current selection as shown in the following figure Lifetime Partial am 5 5 5 1 Lifetime Select Lifetime to view the following information Time Lifetime operation time E tot Lifetime energy output Val Money earned CO2 CO2 saving compared to fossil fuels power one 0 hanging the Shape of Power Page 59 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 5 2 Partial Select Partial to view the following information Time Total operation time since counter was last reset E par Total energy output since counter was last reset PPeak Maximum peak power measured since Partial counter was activated Val Money earned since counter was last reset CO2 CO2 saving compared to fossil fuels since counter was last reset Hold the ENTER key 4th key from display depressed for over 3 seconds to reset all counters in this submenu After 3 seconds a warning sound is repeated 3 times 5 5 5 3 Today Select T
4. 65 5 5 6 8 START Voltage 65 5 5 6 9 entente nnn 65 5 5 6 10 icit ev YR ex eee 66 5 5 6 11 Remote essere 67 5 5 6 12 UM Prot time e sene io hene a 68 5 5 6 13 MPPT scan eene nnne 68 5 5 6 14 Scan 68 6 DATA CHECK AND COMMUNICATION 71 6 1 CONNECTION THROUGH RS 485 SERIAL PORT OR RJ12 CONNECTORS 6 1 1 RS 485 serial port sett ttes t curet uo Pe eive Pues ep 0 1 2 RI T2 COMME CONS cie ee E Dg UN 6 2 SERIAL CONNECTION WITH USB 6 3 MEASUREMENT en nennen nene seen tenen nennen nes power one 0 hanging the Shape of Power Page 10 of 89 PVI 6000 OUTD xx AU Rev 1 0 7 TROUBLESHDOOTIN 78 8 TECHNICAL 02 22 80 8 1 INPUT VALUES Rm 82 OUTPUT VALUES Em 8 3 GRID PROTECTION CHARACTERISTICS ccessessscecececsessnsececececeesensecesecessessensaeees 8 4 GENERAL CHARACTERISTICS cscsssssecececesseaececececsessaeseceeeceesenaeseeeeeesessaeaeees 8 5 POWER 1 0010 000000000000000000000000 power one 0 hanging the Shape o
5. A key consideration in cable selection is cable loss as exceeding loss will lead to derating The maximum cross section area allowed for the conductors to be assembled to the terminal blocks for grid connection is 16 sq mm The supplied M32 cable gland accepts wires up to 19 sq mm Inverter bottom features see Fig 10 from right to left gt 2 holes blanked with waterproof caps Remove the caps to gain access to the connectors for data serial transfer via RS485 port One hole is for the input serial cable and the other for an output cable if fitted output cable is required when several inverters are connected in a daisy chain configuration see Section 6 gt Cable gland for AC grid connection gt 4pairs of Multi Contact connectors for the two photovoltaic arrays power one 0 hanging the Shape of Power Page 29 of 89 PVI 6000 OUTD xx AU Rev 1 0 Fig 10 Connectors found on inverter bottom and their labels WARNING When making the electrical connections follow this exact AN procedure to avoid exposure to dangerous voltages Each step of the procedure is explained in the following paragraphs To disconnect AURORA perform steps 1 5 and 2 5 and then disconnect the AC and DC connectors power one Changing the Shape of Power Page 30 of 89 PVI 6000 OUTD xx AU Rev 1 0 3 6 Electrical Connections Step 1 5 Open the AC grid disconnect switch Step 2 5 Open the photovoltaic field D
6. Type in the correct password and press ENTER to access all information of this section Address Display Set Service New Password Cash Time Language Vstart Autotest Alarm Remote Control UV Prot time MPPT scan EN DIS Scan Period The display has 2 lines use the keys at the side of the display to scroll through items or open the corresponding submenus as described in section 5 5 4 A FEW POINTERS ON DISPLAY DATA READING An arrow on left side of the display highlihghts your current selection When chosen item is selected press ENTER to open the submenu power one 0 hanging the Shape of Power Page 63 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 6 1 Address This function is used to set addresses for communication of the single inverters connected in the system on RS485 line You can assign numbers from 2 to 250 Press UP and DOWN to scroll numbers If you do not want to manually set the address of each inverter select the AUTO function and they will be distributed automatically NEW ADDRESS NEW ADDRESS 248 Auto 5 5 6 2 Display Set This function is used to set display features Light Contrast Buzzer 1 Light display light setting r Mode Intensity Use the MODE key to set display backlighting Select the Mode item with the arrow and press ENTER to open the relevant submenu The following screen is ON OFF Auto ON Light always on OFF Light always off AUTO Automatic light setti
7. The equipment is provided with several labels some of them with a yellow background which are related to safety issues Make sure to read the labels and fully understand them before installing the equipment The labels utilize the following symbols PE Alternate Current AC value a Equipment grounding conductor Main grounding protective earth Direct Current DC value Grounding Earth t Phase ne power one 0 hanging the Shape of Power Page 4 of 89 PVI 6000 OUTD xx AU Rev 1 0 USEFUL INFORMATION AND SAFETY STANDARD FOREWORD The installation of Aurora must be performed in full compliance with national and local standards and regulations AURORA has no spare parts to replace For any maintenance or repair please contact the nearest authorized repair center Please contact your reseller if you need to know the nearest authorized repair center Read and understand all the instructions contained in this manual and become familiar with the safety symbols in the relevant paragraphs before you install and commission the equipment The connection to the distribution grid must be done only after receiving approval from the distribution utility as required by national and state interconnection regulations and can be done only by qualified personnel Cover the photovoltaic panels with dark opaque sheets before they are connected to avoid any chance of high v
8. This feature measures energy saving during a period selected by the user Press ENTER from the User period screen to access the following submenu Start 23 June End 28 August Use the display keys to set the start and end date of the period as follows gt Use ENTER to move from one field to the next from left to right gt Use ESC to go back to the previous field from right to left gt Press ESC repeatedly to go back to the previous menus as described in sect 5 5 3 To set days Press DOWN to scroll numbers backwards from 31 to 1 gt Press UP to scroll numbers from 1 to 31 To set the month gt Press DOWN to scroll months from December to January gt Press UP to scroll months from January to December If set dates are inconsistent the display alerts the user to the problem Data err power one 0 hanging the Shape of Power Page 62 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 6 Setting Select SETTING from the Main menu sect 5 5 4 to display the first screen that refers to the password Password Default password is 0000 It can changed using the keys on display as usual gt Use ENTER to move from one figure to the next from left to right gt Use ESC to go back to the previous figure from right to left gt Press ESC repeatedly to go back to the previous menus as described in sect 5 5 3 Press DOWN to scroll numbers backwards from 9 to 0 gt Press UP to scroll numbers from 0 to 9
9. Before connecting Aurora with the photovoltaic field Power One recommends to check using a proper gauge that the polarity value and the voltage allowed value between positive and negative contacts are correct To connect the arrays follow this procedure for each array 1 Route the positive cable from the Dc disconnect to AURORA 2 Connect the cable to the mating connector of the Multi Contact connector mating connector not included in scope of supply 3 Connect the positive cable to AURORA 4 Route the negative cable from the Dc disconnect to AURORA 5 Connect the cable to the mating connector of the Multi Contact connector mating connector not included in scope of supply 6 Connect the negative cable to AURORA wm power one 0 hanging the Shape of Power Page 32 of 89 PVI 6000 OUTD xx AU Rev 1 0 WARNING Some systems may feature a single array When this is the case the array may be connected to the INI section alone provided that array current is less than the maximum capacity of one AURORA section less than 18Adc To avoid possible problems when determining panel electric insulation parameters short the inputs of the second section IN2 by connecting a cable to the suitable terminals on the inverter board as shown in Fig 12 Remove the panel on Aurora front end to gain access to the board Fig 12B Connections required to short channel 2 power one AvA hanging the Shape of Power
10. Not Used E035 Remote Off Remote power off E036 Vout Avg Average output voltage outside range W012 Il Clock Battery Low No disconnection Clock battery low not operating W013 Clock Failure No disconnection Clock faulty not operating AN Power one 0 hanging the Shape of Power Page 50 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 LCD Display 5 5 1 Connection of system to the grid The two line Liquid Crystal Display is located on the front panel and shows Y Inverter operating status and statistics Y Service messages for operator Y Error messages and fault indications During regular operation the display will cycle through available data The display changes to a different screen every 5 seconds or screens may be scrolled manually by pressing the UP 2nd key from display and DOWN keys 3rd key from display 1 These two screens are displayed upon inverter start up POWER ONE Initialing Please waiting 2 The following screens may appear while waiting for the connection to be established Missing Grid Waiting Sun While the system checks for grid connection to be established Missing Grid the yellow LED next to the display turns on steady while the green LED is flashing When waiting for sun radiation Waiting Sun the green LED turns on steady When the Missing Grid and Waiting Sun conditions are verified the inverter is connected 3 Time
11. also known as PV generator In order to utilize this energy and feed it back to the distribution grid this energy shall be turned into alternating AC current Aurora does this conversion also known as DC to AC inversion in a very efficient way without using rotating parts but just static power electronic devices When used in parallel with the grid the alternate current generated by the inverter is directly fed to the domestic distribution circuit which is in its turn also connected to the public power distribution grid The solar energy system can thus feed all the connected users such as lighting devices household appliances etc When the photovoltaic system is not generating sufficient energy the power required to ensure proper operation of connected users is taken from the public power grid While if the produced energy is too much it is directly fed to the grid thus becoming available to other users According to national and local standards and regulations the produced energy can be sold to the grid or credited to the user against future consumption thus granting a great saving of money 2 1 Key elements of a photovoltaic system STRINGS and ARRAYS The so called STRINGS technology has been developed in order to reduce the installation costs of a photovoltaic system as much as possible These costs are mainly related to the wiring operations on inverter DC side and the consequent distribution on the AC side A
12. green Aurora is powering the Standard machine operation yellow grid search of max power point red or constant voltage green yellow System insulation Ground leakage found device faulty green Defect fault The Fault can be inside or yellow outside the machine See the red alarm appearing on the LCD green Installation phase During installation it refers yellow Aurora is disconnected to set up of the address for red from grid RS 485 communication green Grid disconnection Indicates a missing grid yellow condition red a e fe e NOTE Inverter status is indicated by the corresponding LED turning Ree steady on or flashing and by a display message that provides a description of current operation or fault condition see next sections power one AvA hanging the Shape of Power Page 45 of 89 PVI 6000 OUTD xx AU Rev 1 0 JKA XE RX 1 2 3 4 Nighttime mode AURORA disconnected during night time this occurs when input power is too low to feed the inverter AURORA initialization and grid check Initialization in progress input power sufficient to feed the inverter AURORA is verifying start up conditions for instance input voltage value insulation resistance value etc and grid check routine is launched AURORA is feeding the grid After completing a set of electronics and safety auto test routine
13. Page 33 of 89 PVI 6000 OUTD xx AU Rev 1 0 WARNING If array current exceeds the maximum capacity of one AN inverter input section 18Adc connect the two sections in parallel by jumpering the terminals behind the cover see section 3 7 Jumper wires should have a 6 sq mm cross section area AWGIO0 connect the negative wire across terminals and 2 and the positive wire across terminals IN1 and IN2 as shown in Fig 13 You will also have to set the inverter for parallel connection single string operation by setting the switch shown in fig 13 to PAR EIN2 IN2 mole E Parallel connection of the two Inverter parallel mode configuration Fig 13 Connection configuration for parallel connected sections power one Changing the Shape of Power Page 34 of 89 PVI 6000 OUTD xx AU Rev 1 0 3 7 How to access the internal terminal boards through the front panel WARNING Shock hazard Before removing the front panel disconnect AURORA at both the AC and DC side and allow 5 minutes for the internal capacitors to discharge To remove the front panel unscrew the 4 screws shown in figure 14 using the supplied flat blade screwdriver Fig 14 AURORA with front panel After refitting the front panel tighten the screws to 1 5 Nm 13 2 in lbs as a minimum to ensure proper sealing 3 8 Replacing the CR2032 lithium battery Aurora incorporates a CR2032 lithium batt
14. enough to start up the inverter In this condition the display will read Waiting for sun The yellow FAULT LED indicates that AURORA has detected a fault condition fault description appears on the display The red ground fault LED indicates that AURORA is detecting ground fault in the photovoltaic system DC side When this kind of fault is detected AURORA immediately disconnects from the grid and the corresponding fault indication appears on the display AURORA remains in this condition until the operator presses the ESC key to re start the grid connection sequence If AURORA does not reconnect to the grid call service to have the system troubleshooted Fig 19 LED location Possible LED combinations and their meanings are listed in the following table power one 0 hanging the Shape of Power Page 43 of 89 PVI 6000 OUTD xx AU Rev 1 0 LED on LED blinking LED off 71 Any one of the above conditions power one 0 hanging the Shape of Power Page 44 of 89 PVI 6000 OUTD xx AU Rev 1 0 LEDs Status Operational Status Remarks green Aurora self Input voltage less than 90 1 yellow disconnection during Vdc at both inputs red nighttime 5 Be amp amp ps F tie E green Aurora initialization It is a transition status while yellow settings loading and operating conditions are red waiting for grid check checked
15. is allowed see fig 8 but will worsen heat dissipation and may result in derating WARNING Unit surface may become hot to the touch during operation DO NOT touch unit surface to avoid burns NO Derating Derating Derating Fig 8 Tilted mounting power one A Changing the Shope of Power Page 26 of 89 PVI 6000 OUTD xx AU Rev 1 0 3 5 Before performing the electrical connections A A A A gt gt WARNING The electrical connections can be done only after Aurora is firmly mounted to the wall WARNING The connection of Aurora to the electrical distribution grid must be performed by qualified operators and anyway only after receiving authorization from the utility that operates the grid WARNING For a step by step description of the correct procedure please read and closely follow the instructions provided in this section and its subsections and all safety warnings Any operation no complying with the instructions below can lead to operator installer hazards and to equipment damage WARNING Always respect the nominal ratings of voltage and current defined in Section 8 Technical Characteristics when designing your system Please observe these considerations in designing the photovoltaic system gt Maximum array DC voltage input to each MPPT circuit 600Vdc under any condition Maximum array DC current input to each MPPT circuit 18Adc under any condition WARNING Check the Nati
16. model is equipped with a state of the art anti islanding protection system certified to the following standards and regulations gt 54777 3 2005 2 5 2 Panel Ground Fault This version of AURORA has been designed for use with panels with a floating connection positive and negative terminals not connected to ground A sophisticated ground protection circuit continually monitors the ground connection when it detects a ground fault this circuit shuts down AURORA and turns on a red LED on the front panel to indicate a ground fault condition The AURORA inverter is equipped with a terminal for the system grounding conductor see section 3 6 step 3 for more details 05 NOTE For more details of AURORA shutdown or possible causes of malfunction please refer to sections 5 3 and 5 4 2 5 3 Further Protective Devices Aurora is equipped with additional protections to guarantee safe operation under any circumstances The protections include gt constant monitoring of grid voltage to ensure that voltage and frequency remain within the specified operational limits in accordance with standards automatic power limitation control based on internal temperature monitoring to avoid overheating heat sink temperature lt 70 C 158 Many control devices are fitted to Aurora making its structure redundant but at the same time ensuring a perfect and fully safe operation power one 0 hanging the Shape of Power Page 20 o
17. person who will have to carry out the maintenance operations to fix the fault on the equipment or system See E strings in the table below Message Warning Error Description type Sun Low W001 Il Input Voltage under threshold Input voltage under threshold when off Input OC E001 Input Overcurrent Input UV W002 Input Undervoltage Input OV E002 Input Overvoltage Int Error E003 No parameters No parameters Bulk OV Il E004 Bulk Overvoltage Int Error E005 Communication Error Communication error Out OC E006 Output Overcurrent Int Error E007 IGBT Sat Sun Low W011 Bulk Undervoltage Int Error E009 Internal Error Internal Error power one 0 hanging the Shape of Power Page 48 of 89 PVI 6000 OUTD xx AU Rev 1 0 Message Warning Error Description type Grid Fail W003 Wrong grid parameters Int Error E010 Bulk Low Int Error E011 Ramp Fail DC DC Fail E012 DcDc Error revealed by inverter fault detected by inverter Wrong Mode E013 Wrong Input setting Single instead of dual Wrong input setting single instead of dual channel Over Temp E014 Overtemperature Internal temperature too high Cap Fault 015 Bulk Capacitor Fail Bulk capacitor fault Inv Fail E016 Inverter fail revealed by DcDc Inverter fault detected by DcDc I
18. photovoltaic panel is composed of many photovoltaic cells assembled on the same mount A STRING is composed of a certain number of panels electrically connected in series An ARRAY is composed by one or more strings connected in parallel Larger photovoltaic systems may be implemented by using several arrays connected to one or more AURORA inverters power one 0 hanging the Shape of Power Page 13 of 89 PVI 6000 OUTD xx AU Rev 1 0 The greater the number of panels in each string the lower the cost and the less complex the wiring connections of the system Gell PY Arey Fig 2 Array Composition WARNING String voltage shall not exceed 600 Vdc for any reason so as to avoid damage to the equipment NOTE A minimum input voltage of 200 Vdc is required for Aurora to start the grid connection sequence Once connected Aurora will transfer the maximum power available for any input DC voltage value in a 90V to 580Vdc range to the grid power one Changing the Shape of Power Page 14 of 89 PVI 6000 OUTD xx AU Rev 1 0 The total current of an array must also be within the capability limits of the inverter For AURORA the limit is set at 18 Adc maximum for each input The AURORA model rated 6000W is capable of handling 2 separate arrays The maximum current limit for each input is 18Adc If the output of photovoltaic system exceeds the capacity of a single inverter additional AURORA invert
19. power derating will always consider the lowest value detected power one 0 hanging the Shape of Power Page 88 of 89 PVI 6000 OUTD xx AU Rev 1 0 An Fair Trading Certificate Number CS9220N Certificate of Suitabilit This is to certify that articles of the same type as the article specified below and variations so specified are accepted by the OFFICE OF FAIR TRADING as suitable for connection to public electricity supply in NEW SOUTH WALES in accordance with the provisions of AS NZS 3000 and subject to the condition stated Article Solar Grid Connected Inverter Input Output System Voltage 600Vdc Max Operating Voltage 230V ac Operating Voltage Range 80 580Vdc Continuous Output Current Current 30A Maximum Operating Current 18A Max Cont 50 kW Max Array Short Circuit Current 22A Max Output Overcurrent Protection 35A Trade Name or Mark Aurora Volts Amperes Watts Hertz 50 Other Name Plate Particulars Op Amb Temp 25 C 60 C Degree Of Protection IP65 Protection Class Identification PVI 8000 OUTD S AU Examined for compliance with AS4777 2 amp 3 2005 AS NZS 3100 2002 1 3 ASINZS 60950 2003 A1 3 Issued to Power One Energy Solutions Pty Ltd Nominated Marking CS9220N Conditions 1 This certification will be withdrawn automatically if an article of this type is declared pursuant to the Electricity Consumer Safety Act 2004 This certificat
20. seconds to complete output voltage and frequency check Next connections 2 secs power one 0 hanging the Shape of Power Page 51 of 89 PVI 6000 OUTD xx AU Rev 1 0 4 Shows instant output voltage value and within outside range status Vgrid 197 8 V In range 5 Shows instant output frequency value and within outside range status Fgrid 50 17 Hz In range 6 If measured instant values of voltage step 4 and frequency step 5 are outside the allowed range the following screens are shown alternately Next connections screen 3 Vgrid screen 4 Fgrid screen 5 7 Instant value of insulation resistance 5 5 2 Error messages After the connection is established the inverter runs a test cycle if wrong data is found the cycle is interrupted and an error code is displayed Please look up error codes and their meaning in the table in section 5 4 Until the error is rectified the following screens are shown alternately ERROR Code Type OUTD Part N nod S N Firmware power one 0 hanging the Shape of Power Page 52 of 89 PVI 6000 OUTD xx AU Rev 1 0 Once the error has been removed the inverter resets all functions in progress and re starts the connection Sect 5 5 2 Connection of system to the grid item 2 Missing Grid Waiting Sun power one 0 hanging the Shape of Power Page 53 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 3 First phase electric pa
21. 0 hanging the Shape of Power Page 56 of 89 PVI 6000 OUTD xx AU Rev 1 0 13A Inverter OK Wed 17 May 1123 If all items described above tested are OK the inverter shows a corresponding message in the display top line along with date and time Clock malfunctioning or other non function related faults meaning such faults that do not affect the inverter s ability to generate energy are shown in the bottom line of the display in place of date and time The following error messages are provided CLOCK FAIL indicates clock malfunction contact service BATTERY LOW SET TIME appears the first time the unit is powered up or after the battery has been replaced FAN FAIL contact service MEMORY FAIL Data logging malfunction Contact service power one 0 hanging the Shape of Power Page 57 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 4 Main menu When the grid connection sequence described above and all electrical parameter checks are completed other screens become available These screens let you monitor inverter operation Pressing the ESC key right next to display gives access to 3 new screens A FEW POINTERS ON DISPLAY KEY OPERATION Press the UP 2nd key from display and DOWN keys 3rd key from display to scroll through items Press the ESC key right next to display to go back to the previous session see sect 5 5 3 Press ENTER 4th key from display to open the selected submenu power one
22. 1 Date 17 May 2006 5 5 6 7 Language Itis possible to set the national language or English gt English Italiano 5 5 6 8 START Voltage Start up voltage can be set according to available photovoltaic system Voltage range can be 120V to 350V Default setting for Aurora is 200V This parameter can be changed by means of the display keys VStart 200V 5 5 6 9 Autotest Aurora internal test checking correct operation of the protection and the grid interface device as provided for by national regulations Autotest Press ENTER to access all information of this section UV test OF test UF test DC injection OV Max voltage UV Min voltage OF Max Frequency UF Min Frequency DC injection Output current direct component This component shall not be gt 0 5 with respect to inverter maximum rated current or unit will switch off power one 0 hanging the Shape of Power Page 66 of 89 PVI 6000 OUTD xx AU Rev 1 0 The display has 2 lines use the keys at the side of the display to scroll through items or open the corresponding submenus An arrow on left side of the display highlihghts your current selection When chosen item is selected press ENTER to open the submenu As soon as test is selected the display shows Test in progress During the test the display gives test progress indication If test is passed depending on selected item the display shows V measured voltage T time
23. 1W 2 Frequency Freq Hz 0 01 0 01 0 1 power one 70 hanging the Shape of Power Page 77 of 89 PVI 6000 OUTD xx AU Rev 1 0 Name of Measu Resolution Maximum measure rement error d unit Display Value percentage variable Accumulated energy Energy Wh IWh 4 Time counter Lifetime hh mm ss 15 0 2 Partial time counter Paral hh mm ss 1 0 2 Time power one 70 hanging the Shape of Power Page 78 of 89 PVI 6000 OUTD xx AU Rev 1 0 7 TROUBLESHOOTING Aurora inverters comply with standards set for grid tied operation safety and electromagnetic compatibility Before being delivered the product has been successfully subjected to several tests to check operation protective devices performance and durability these tests together with the system ensuring Power One quality guarantee Aurora optimal operation In case of any possible malfunction of the inverter solve problems as follows Y Work under safe conditions as stated in chapter 3 5 and following check that connections between Aurora photovoltaic field and power distribution grid have been made correctly Y Carefully observe which LED is blinking and read the signal appearing on the display then following the instructions given in chapters 5 3 5 4 and 5 5 try to identify the type of fault found If the malfunction cannot be removed by following these instructions contact the service center or the installer see fo
24. AN POWEI DIIE hanging the Shape of Power AURORA Photovoltaic Inverters INSTALLATION AND OPERATOR S MANUAL Model number PVI 6000 OUTD xx AU Rev 1 0 Page 2 of 89 PVI 6000 OUTD xx AU Rev 1 0 REVISION TABLE Document Author Date Change Description Revision 1 0 First release AN SAVE THESE INSTRUCTIONS AN IMPORTANT SAFETY INSTRUCTIONS POWER ONE Reproduction and disclosure even partially of the contents of this manual are strictly forbidden without prior authorization of Power One power one hanging the Shape of Power Page 3 of 89 PVI 6000 OUTD xx AU Rev 1 0 IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety and operational instructions that must be accurately understood and followed during the installation and maintenance of the equipment To reduce the risk of electrical shock hazards and to make sure the equipment is safely installed and commissioned special safety symbols are used in this manual to highlight potential safety risks and important safety information The symbols are WARNING the paragraphs highlighted by this symbol contain processes AN and instructions that must be absolutely understood and followed to avoid potential danger to people US NOTE the paragraphs highlighted by this symbol contain processes and instructions that must be rigorously understood and followed to avoid potential damage to the equipment and negative results
25. ARNING Inverter is provided with a linear output power derating depending on the input voltage starting from 530 Vdc 100 output power to 580 Vdc 0 output power WARNING The open circuit voltage of the photovoltaic panels is affected by the ambient temperature the open circuit voltage increases as the temperature decreases you have to make sure that the minimum temperature estimated for the installation doesn t cause the panels to exceed the maximum upper limit of 600Vdc As an example the following table shows for typical panels of 36 48 and 72 cells the maximum voltage of each panel as a function of the temperature assuming a nominal open circuit voltage of 0 6Vdc per cell at 25 C and a temperature coefficient of 0 0023V C The table shows therefore the maximum number of panels that can be connected in series as a function of the minimum temperature at which the system will operate Consult the panel manufacturer for the correct temperature coefficient of Voc before calculating the maximum voltage of the photovoltaic array power one 0 hanging the Shape of Power Page 81 of 89 PVI 6000 OUTD xx AU Rev 1 0 36 Cells Panels 48 Cells Panels 72 Cells Panels Minimum Panel Panel voltage Max number of panels Panel voltage Panel voltage ax number of panels Panel voltage Table A power one 70 hanging the Shape of Power Page 82 of 89 PVI 6000 OUTD xx AU Rev 1 0 Valu
26. AU Rev 1 0 6 DATA CHECK AND COMMUNICATION 6 1 Connection through RS 485 serial port or RJ12 connectors 6 1 1 RS 485 serial port RS 485 serial port uses a three wire cable two wires are for signals and the third one is for ground connection Cable is routed through the holes located at Inverter bottom which are blanked with waterproof plugs see Fig 23 Supplied cable gland must be installed in the suitable hole 1st PLUG 2nd PLUG FIG 23 Holes for cables necessary for RS 485 port connection or wiring for RJ12 connectors connection For easier installation the inverter features two holes so that input and output cables can be separated in case more units are connected in a daisy chain as described below After passing through cable gland cables are connected inside of the unit to RS 485 terminal blocks that can be reached by removing the front door Refer to par 3 7 for details on front cover correct removal and reassembly procedure gt Signal wires must be connected to T R and T R terminals gt Ground wire must be connected to terminal power one 70 hanging the Shape of Power Page 72 of 89 PVI 6000 OUTD xx AU Rev 1 0 RJ12 No 1 RJ12 No 2 Fig 24 Terminals for connection to RS 485 serial line and S2 switch 6 1 2 RJ12 connectors As an alternative to RS485 serial connection be it as single units or as a daisy chain inverter connection can be performed by means of RJ12 connectors
27. C disconnect switch Step 3 5 Unscrew the 4 captive screws to open the front panel Step 4 5 Connect AURORA to the AC grid disconnect switch WARNING Use suitable low impedance cables to connect AURORA AN to the AC disconnect switch WARNING AURORA must be connected to the AC grid disconnect switch using a three wire cable with a line wire a neutral wire and a yellow green ground PE or protective earth wire 1 Route the cable from AURORA to the Ac disconnect 2 Connect the three pole cable to Aurora using the cable gland on the case 3 Connect the three wires as follows terminal 1 for Protective n earth PE terminal 2 for Neutral N terminal 3 for Line L Fig 11 AC wire terminal block power one AvA hanging the Shape of Power Page 31 of 89 PVI 6000 OUTD xx AU Rev 1 0 WARNING Do not reverse phase and neutral as this might make the system unsafe to run and cause malfunctioning US NOTE If you have installed a meter between the AC disconnect and AURORA follow the same procedure outlined above when connecting the meter Step 5 5 Connect AURORA to the photovoltaic field DC disconnect switches AN Power One strongly recommends using two separate arrays whenever possible Each array should have a current capacity lower than 18Adc and should be connected to one input section of the AURORA inverter WARNING Ensure that photovoltaic field voltage polarity matches the and symbols
28. ased on an RS 485 serial interface with a USB port to facilitate access during installation An optional Aurora Easy Control system is also available for remote monitoring via the Internet analogue modem or GSM digital modem 2 4 AURORA Technical Description Figure 4 shows a block diagram of AURORA The main elements are the input DC DC converters termed boosters and the output inverter Both the DC DC converters and the output inverter operate at high switching frequency to enable a compact design and relatively low weight This is a transformer less version of AURORA i e without galvanic insulation between input and output which further increases conversion efficiency On the other hand AURORA is equipped with the necessary protective devices to ensure safe operation in compliance with applicable regulations without an insulation transformer as discussed in more detail in the relevant section Grid 230V PV Array 600 V max Vom 340 V nom 150 Vmin Inverter DSP control g Fig 4 Aurora block diagram power one 0 hanging the Shape of Power Page 18 of 89 PVI 6000 OUTD xx AU Rev 1 0 The block diagram shows an AURORA PVI 6000 OUTD with two independent input DC DC converters each converter is dedicated to a separate array with independent Maximum Power Point Tracking MPPT control This means that the two arrays
29. can be installed in different positions and orientations Each array is controlled by an MPPT control circuit Thanks to its high efficiency and generously sized heat sink the AURORA inverter provides maximum power operation in a broad range of ambient temperatures The inverter is controlled by two independent DSPs Digital Signal Processors and one central microprocessor This way grid connection is controlled by two independent computers in full compliance with electrical power supply and safety regulations Aurora operative system communicates with the related parts to proceed to data processing This process ensures optimal performance levels of the whole units as well as a high efficiency under all solar radiation and load conditions always in full compliance with the applicable directives standards and regulations power one 0 hanging the Shape of Power Page 19 of 89 PVI 6000 OUTD xx AU Rev 1 0 2 5 Protective Devices 2 5 1 Anti Islanding When the local power distribution grid fails due to a fault or when the equipment is shut down for maintenance operations Aurora shall be physically disconnected under safety conditions so as to protect the people working on the grid in full compliance with the applicable prevailing national standards and regulations To avoid any possible islanding operation Aurora is provided with an automatic disconnection protective system called Anti Islanding The AURORA PVI 6000 OUTD
30. contact active S2 switch 120 TERM set to ON See fig 24 Any AURORA device is supplied with default address two 2 and with the S1 dip switch in the OFF position In order to ensure optimum communication on RS485 line Power One recommends to connect PVI RS232485 adapter in between the first unit of the daisy chain and the computer See fig 25 for further details To this purpose other equivalent devices available on the market can also be used but Power One does not assure correct connection operation since equipment has never been tested with these equivalent devices power one 0 hanging the Shape of Power Page 74 of 89 PVI 6000 OUTD xx AU Rev 1 0 Please note that these commercial devices could require an external termination impedance which is not necessary for Aurora PVI 232485 The following diagram shows you how to connect many multiple units in daisy chain configuration RS 485 1st Unit RTN RTH RS485 ADAPTER TR PVI RS232485 TR OH OFF TR x 2nd Unit 9 1 RS 232 TR 1r 1 3rd Unit e TR orr OFF m x Fig 25 Daisy chain multiple connection NOTE When using RS 485 link there can be up to 248 inve
31. e PVI 6000 OUTD Description Recommended DC power 6200W Nominal input voltage 360Vdc Max absolute input voltage 600Vdc Input voltage MPPT operating 90 Vdc to 580 Vdc range Input voltage MPPT operating 180 Vdc to 530 Vdc range at full power Max short circuit current of 22 Adc each array Max operating input current 18 Adc of each array Max pat power of each 4000 W array PV Ground fault protection Ground fault detector and interruption provided Two independent Input channels configuration MPPT channel with Two channels in array shared negative parallel poles 9 Total DC power input must always be below the recommended DC power NOTE If the input current supplied by the photovoltaic field connected to the inverter is above the max value and the input voltage is within the allowed range the inverter is not damaged power one AvA hanging the Shape of Power Page 83 of 89 PVI 6000 OUTD xx AU Rev 1 0 8 2 Output Values Value PVI 6000 OUTD Description Nominal output power 6000 W Grid voltage maximum range 200 to 270 Vac Grid voltage nominal 230 Vac from 89 to 115 of nominal voltage from 205 to 264Vac for V nom 230Vac Grid voltage operating range as per AS4777 Grid frequency maximum range 45 to 55 Hz Grid frequency nominal 50 Hz operating range as 47 1 to 52 9 Hz Nominal output current 26 Arms Max output current 30 Arms Outpu
32. e is issued subject to the article and approved variations being maintained at the standard of the article examined at the time of approval Approved 09 11 2009 This approval expires 09 11 2014 unless suspended cancelled renewed or ext for ende for Fair Trading SIN 5 power on Changing the Shape of Power Page 89 of 89 PVI 6000 OUTD xx AU Rev 1 0 Wt Trading Ref CS9220N ADOENDUM TO CERTIFICATE OF SUITABILITY CS8220N Particulars of Modification s The following Medel Noe being similar to original Model No PVI 8000 OUTD S AU except as follows PVI 8000 OUTD AU Without DC Integrated Switch b PVI 5000 OUTD AU Output rating of 5000W in lieu of 8000W and without the DC Integrated Switch c PVI 5000 OUTD S AU Output rating of 5000W in liau of 8000W and with DC integrated Switch d PVI 4 2 OUTD AU Output rating of 4200W lieu of 8000W and without DC Integrated Switch e PVI 4 2 OUTD S AU Output Rating of 4200W in lieu of G0DOW and with DC integrated Switch f 3 6 Output Rating of 3800W in lieu of 000W and without DC Integrated Switch ig PVI 3 6 OUTD S AU Output Rating of 3800W in lieu of BODOW and with DC Integrated Switch h PV1 6000 OUTD AU W Deeigned for use with Wind Turbines in feu of a Photovoltaic Array z Modal No P VI 3 8 OUTD AU W being similar to Model No PVI 4 2 OUTD S AU except being designed for Wind Turbines in feu of a Photovoltaic A
33. e of Power Page 8 of 89 PVI 6000 OUTD xx AU Rev 1 0 1 2 CONTENTS 1 1 PHOTOVOLTAIC ENERGY 11 DESCRIPTION OF THE 12 2 1 KEY ELEMENTS OF A PHOTOVOLTAIC SYSTEM STRINGS AND ARRAYS 12 2 2 AVAILABLE VERSIONS eene EEE EERE EEO E 15 2 3 DATA TRANSMISSION AND 17 2 4 AURORA TECHNICAL 17 2 5 PROTECTIVE DEVICES eee redet eee e TEE 19 2 5 1 Anti Islanding ed e ORAN 19 2 32 Panel Ground Fault nette rre toe vec tete pea et ee oed ee vob Rs eve a GER 19 2 5 3 Further Protective Devices essent eene eet 19 INSTALLATION eee eee eren anoo nose eese seen sess 3 1 PACKAGE INSPECTION 20 3 2 INSPECTING PACKAGE 8 21 3 3 SELECTING THE PLACE OF INSTALLATION 22 22 3 4 WALL 23 3 5 BEFORE PERFORMING THE ELECTRICAL CONNECTIONS Ree 26 3 6 ELECTRICAL CONNECTIONS 30 3 7 HOW TO ACCESS THE INTERNAL TERMINAL BOARDS THROUGH THE FRONT PANEL 34 3 8 REPLACING THE CR2032 LITHIUM
34. ers can be added to the system each inverter will be connected to an adequate section of the photovoltaic filed on the DC side and to the grid on the AC side Each Aurora inverter will work independent of the others and will push to the grid the maximum power available from its own section of the photovoltaic panels There are several factors and considerations to be taken into account when designing a photovoltaic system such as the type of panels available room location long term target output etc The system configurator available on Power One s web site at www power one com may help in sizing a photovoltaic system PV Array i switch PV Array 2 DC disconnect switch Fig 3 Simplified diagram of a photovoltaic system power one hanging the Shape of Power Page 15 of 89 PVI 6000 OUTD xx AU Rev 1 0 2 2 Available versions PVI 6000 OUTD AU PVI 6000 OUTD S AU PVI 6000 OUTD DS AU The identifier S stands for integrated switch models with a integrated DC switch 600V rated as shown in fig 3B The identifier DS stands for integrated diodes and switch models with a integrated DC switch 600V rated and protection diodes as shown in fig 3C In fig 3A is shown the schematic of the model without integrated switch or diodes PV Input Input 1 PV 2 2 d of PV Input P inputt r4 PVinputt 2
35. ery When the battery is nearing the end of its life a corresponding message appears on the LCD display Remove the front panel see fig 15 to expose the battery Please note that the battery will not fit into its mount from the top down slide the battery into its mount from side A while holding it tilted at a 30 angle The battery will slide into place into the battery mount power one hanging the Shape of Power Page 35 of 89 PVI 6000 OUTD xx AU Rev 1 0 Side A Hold battery at a 30 angle 8250 9 6 54 e143 CoMo wan Fig 15 Battery in place WARNING This component should only be replaced by qualified personnel 3 9 Replacing the memory All energy output logs are stored in this memory If you need to replace the inverter the memory can be removed from the old unit and fitted into the new inverter This way you will retain all system logs and keep saving future daily logs to the memory see fig 16 i Fig 16 Inverter memory SN power one Changing the Shape of Power Page 36 of 89 PVI 6000 OUTD xx AU Rev 1 0 WARNING This component should only be replaced by qualified personnel WARNING Make sure to insert the memory connector pins correctly into the board connector power one 0 hanging the Shape of Power Page 37 of 89 PVI 6000 OUTD xx AU Rev 1 0 4 START UP AN WARNING Do not place any items on AURORA during operation WARNING Do n
36. eved since partial counter was activated Ppk Day Maximum peak power achieved during the day Counter will reset when unit is powered off 7A Verid 197 V Vgrid Avg 0v Vgrid Measured instant grid voltage Vgrid Avg Average grid voltage during the last 10 minutes of operation 8A Igrid 0 8 Fgrid 50 18 Hz Igrid Measured instant grid current Fgrid Measured instant grid frequency power one 0 hanging the Shape of Power Page 55 of 89 PVI 6000 OUTD xx AU Rev 1 0 9A n1 0v Iinl 0 0 A Vinl Instant input voltage measured at channel 1 input Inl Instant input current measured at channel 1 input 10A Vin2 0v lin2 0 0A Vin2 Instant input voltage measured at channel 2 input 1112 Instant input current measured at channel 2 input Or n Iin 0 0A In a configuration with one input connected and a second input connected in parallel the following screen is shown instead of the 2 screens described above 11A Pin1 2 0 Pinl1 Measured instant input power of channel 1 Pin2 Measured instant input power of channel 2 Pin In a configuration with one input connected and a second input connected in parallel the following screen is shown instead of the screen described above 12A Riso Measured insulation resistance Unlike the parameters discussed above this is not an instant value but a one off measurement taken upon inverter start up PoVer ame
37. f 89 PVI 6000 OUTD xx AU Rev 1 0 3 INSTALLATION WARNING The electrical installation of AURORA must be performed in compliance with applicable local and national standards and laws WARNING The connection of Aurora to the electrical distribution grid must be performed only after receiving authorization from the utility that operates the grid 3 1 Package Inspection US NOTE The distributor delivered your AURORA to the carrier safely packaged and in perfect condition Upon acceptance of the package the carrier assumes responsibility for its safe delivery In spite of careful handling transport damage to package or its contents is always a possibility The customer is encouraged to perform the following checks Inspect the shipping box for apparent damage such as holes cracking or any sign of possible damage to its contents Describe any damage or shortage on the receiving documents and have the carrier sign his her full name Open the shipping box and inspect the contents for internal damage While unpacking be careful not to discard any equipment parts or manuals If any damage is detected call the delivering carrier to determine the appropriate action Save all shipping material for the event the carrier sends an inspector to verify damage If the inspection reveals damage to the inverter call your supplier or authorized distributor They will determine if the equipment should be returned for repair T
38. f Power Page 11 of 89 PVI 6000 OUTD xx AU Rev 1 0 1 FOREWORD This document contains a technical description of AURORA photovoltaic inverter so as to provide the installer and user all the necessary information about installation operation and use of AURORA 1 1 PHOTOVOLTAIC ENERGY Industrialized countries greater energy consumers have been experimenting energy saving methods and reduced pollutant levels for many years thanks to the energy conversion process This may be possible through a shrewd and rational consumption of well known resources and also by looking for new forms of clean and not exhaustible energy Regenerating sources of energy are fundamental to solve this problem Under these circumstances solar energy exploitation to generate electrical photovoltaic energy is becoming more and more important worldwide Photovoltaic energy in any case is of great advantage to the environment because the radiated energy we receive from the sun is transformed directly into electrical energy without any combustion process and without producing any pollution power one 0 hanging the Shape of Power Page 12 of 89 PVI 6000 OUTD xx AU Rev 1 0 2 DESCRIPTION OF THE SYSTEM The AURORA inverter is capable of feeding a power grid using the power generated by photovoltaic panels Photovoltaic panels transform the sun radiated energy into electrical energy in the form of direct DC current through a photovoltaic field
39. ff Operation is as follows set to ENABLE to activate manual ON OFF function set to DISABLE to disable manual ON OFF function so that Aurora operation will only depend on external solar radiation Remote ON OFF Remote ON OFF Enable Disable Manual ON and OFF input is read on inverter digital input When set to OFF the display will cycle through the following screens power one Changing the Shape of Power Page 68 of 89 PVI 6000 OUTD xx AU Rev 1 0 Remote OFF 5 5 6 12 UV Prot time This function is used to set inverter connection time after input voltage drops below Under Voltage limit set at 90V For example if UV Prot time is set at 60 seconds and Vin voltage drops below 90V at 9 00 the inverter stays connected to the grid at 0 power up to 9 01 Power One sets this time at 60 seconds The user can change this setting and set it from 1 second to 3600 seconds 5 5 6 13 MPPT scan This function is used to automatically detect input power max multiples MPPTscan En7Dis Enable 5 5 6 14 Scan Interval This function is used to set time interval for system max multiple scan Default setting is 15 minutes Scan Interval 15 min power one 0 hanging the Shape of Power Page 69 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 7 Info This menu is used to display all Aurora data Part No part number gt Serial No Wk Yr serial number week year Fwrel firmware release level
40. gt a E a z ESPERE pi lt 4 444 Qo ooo 22222 Nnt X a 2535 i SUN 29 ooaoa 2 zzzz z Q S o HE 8 z o K 5 2 power one AvA hanging the Shape of Power PVI 6000 OUTD xx AU Rev 1 0 Page 70 of 89 gt De 2 NN CUR yt v ago uua G9 oo eae a n S 0 4 9 93 bs J w __ zud 4 MOX matam Jor jar LII mus m nendum m IS 5 a o zw d AXA ZUN oss We T ewan y 2 T gt N 4 Nem E CoG SE d A 5 L 294 NOSSA at mo set sera 0 m em ww one hanging the Shape of Power MAN iMd amp frd CN oin 329 g E on __ our M07 ung oars p 283 A ENS COS ms w Page 71 of 89 PVI 6000 OUTD xx
41. heck system detects an operative malfunction or fault of the monitored system the yellow LED comes on and a message showing the type of problem found appears on the LCD RS 485 address setup indication During installation the yellow LED will keep flashing until the address is acknowledged For further information about address entering refer to section 6 3 Grid disconnection If a grid failure event occurs while the system is regularly operating the yellow LED turns on steady power one 0 hanging the Shape of Power Page 47 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 4 Messages and Error Codes The system status is identified through message or error signals appearing on the LCD The tables below summarize the two types of signals that can be displayed MESSAGES identify current AURORA status so they do not relate to faults and nothing has to be done messages disappears as soon as the system is back to normal operating conditions See W strings in the table below ALARMS identify a possible fault of the equipment or of the connected parts Alarm signals will disappear as soon as the causes are removed except for ground insulation faults in the photovoltaic panels which have to be corrected by qualified personnel Usually when an error signal appears an action is needed This action will be managed as much as possible by Aurora or in case this is not possible Aurora will supply all the necessary helping information to the
42. hey will also provide instructions on how to get the equipment repaired Itis the customer s responsibility to file a claim with the carrier Failure to file a claim with the carrier may void all warranty service rights for any damage Save the original package your AURORA inverter came in should you need to return it for repair in the future power one 0 hanging the Shape of Power Page 21 of 89 PVI 6000 OUTD xx AU Rev 1 0 3 2 Inspecting package contents Description Quantity No AURORA inverter 1 Bag containing 1 3 6 3 70 screws 3 SX10 wall plugs and 1 flat blade screwdriver w bent head 1 M20 cable gland 1 M32 cable gland red cable AWGIO black cable AWGI0 1 seal of the 36A3MDO type cylinder 58 Torx20 wrench 1 6x10 screw 1 d 18 washer 4 positive Multi Contact plugs and 4 negative Multi Contact plugs ready assembled on the inverter One copy of this manual 1 One certificate of warranty 1 CD ROM with communication 1 software power one 70 hanging the Shape of Power Page 22 of 89 PVI 6000 OUTD xx AU Rev 1 0 3 3 Selecting the place of installation Place of installation should be selected based on the following considerations Height from ground level should be such to ensure that display and status LEDs are easy to read Select a well ventilated place sheltered from direct sun radiation Choose a place that allows unobstructed air flow around the uni
43. l be carried out in accordance with the applicable regulations such as conductor sections fuses PE connection power one 0 hanging the Shape of Power Page 6 of 89 PVI 6000 OUTD xx AU Rev 1 0 OPERATION Systems with inverters shall be provided with further control and protective devices in compliance with the corresponding prevailing safety rules such as those relating to the compliance with technical equipment accident preventing regulations etc Any calibration change shall be made using the operational software Once the inverter has been disconnected from the power grid powered parts and electrical connections shall not be touched as some capacitors could be charged Comply with all corresponding marks and symbols present on each device During operation make sure that all covers and doors are closed MAINTENANCE AND SERVICE Comply with manufacturer s recommendations SAVE ALL DOCUMENTS IN A SAFE PLACE power one 0 hanging the Shape of Power Page 7 of 89 PVI 6000 OUTD xx AU Rev 1 0 PVI 6000 OUTD AU PVI 6000 OUTD S AU PVI 6000 OUTD DS AU This document applies to the above mentioned inverters only 77 36039912000 PVI 6000 OUTD SN 0001 WK 19 106 Fig 1 Name plate The name plate affixed to the inverter provides the following information 1 Manufacturing Part Number 2 Model Number 3 Serial Number 4 Week Year of Manufacture power one hanging the Shap
44. llowing page power one 0 hanging the Shape of Power Page 79 of 89 PVI 6000 OUTD xx AU Rev 1 0 Before contacting the service center keep the following information handy INFO Aurora NOTE Information to be found directly on LCD Aurora model Serial number Week of production LED flashing Light blinking or steady Signal displayed Malfunction short description Can malfunction be reproduced If so how Does malfunction appear cyclically If so how frequently Is malfunction present from installation If so has it worsened Description of the atmospheric conditions when the malfunction appeared 55555555 INFO on the Photovoltaic Field Y Make and model of photovoltaic panels v System structure array max voltage and current values number of strings for the array number of panels for each string power one 0 hanging the Shape of Power Page 80 of 89 PVI 6000 OUTD xx AU Rev 1 0 8 TECHNICAL FEATURES 8 1 Input Values A A A WARNING the Photovoltaic field and system wiring must be configured in such a way that the PV input voltage is less than the maximum upper limit independently from the type the number and the operating conditions of the chosen photovoltaic panels As panel voltage also depends on working temperature the number of panels per string shall be chosen according to the min ambient temperature expected in that special area see table A W
45. necessary to take the measurement F measured frequency T time necessary to take the measurement While if test is failed the following will be displayed Vz measured voltage T time necessary to take the measurement F measured frequency T time necessary to take the measurement 5 5 6 10 Alarm The inverter features an alarm function that opens or closes a relay contact access can be gained through front door as indicated in Fig 22 This contact can be used for instance to activate a siren or a visual alarm in case inverter is disconnected from the grid no energy output or for any alarm event generated by the system This function can activate two alarm modes Press ENTER to open the relevant submenu power one 0 hanging the Shape of Power Page 67 of 89 PVI 6000 OUTD xx AU Rev 1 0 C Production Fault An arrow on left side of the display highlihghts your current selection When chosen item is selected press ENTER to confirm activation of chosen mode PRODUCTION Relay is only activated when inverter is connected to the grid contact closing across terminals and FAULT triggers relay activation contact closing across terminals N O and only when an error signal occurs i e when grid is disconnected excluding Input Under Voltage WIND ALARM Fig 22 alarm contacts terminal block 5 5 6 11 Remote Control This function is used to disable inverter manual switch o
46. ng It turns on every time a key is pressed and stays on for 30 seconds then gradually turns off power one 0 hanging the Shape of Power Page 64 of 89 PVI 6000 OUTD xx AU Rev 1 0 2 Contrast display light contrast Available display light tones go from 0 to 9 Press UP and DOWN to scroll numbers and then press ENTER to confirm 3 Buzzer key tone setting Selecting ON keytone on OFF key tone off 5 5 6 3 Service Only installing staff can gain access to this function which is password protected and dedicated code is supplied by Power One 5 5 6 4 New Password This function is used to change the default password 0000 To set your personal code use the display keys as follows gt Use ENTER to move from one digit to the next from left to right gt Use ESC to go back to the previous digit from right to left gt Press ESC repeatedly to go back to the previous menus as described in sect 5 5 3 Press DOWN to scroll numbers backwards from 9 to 0 gt Press UP to scroll numbers from 0 to 9 5 5 6 5 Cash This function is about energy output savings Name EUR Val KWh 00 50 Name set desired currency using keys as usual Default currency is Euro Val KWh it indicates the cost of 1 KWh expressed in set currency Default setting is 0 50 Euro power one 0 hanging the Shape of Power Page 65 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 6 6 Time This function allows time and date setting Time 14 2
47. nt Error 017 Start Timeout Ground F 018 leak fai Leakage current fault Int Error E019 Sensor fail Leakage current fault Int Error E020 DcDc relay fail DcDc relay fault Int Error E021 Inverter relay fail Inverter relay fault Int Error E022 Autotest Timeout Int Error E023 Dc Injection Error Grid OV 004 Output Overvoltage Grid UV W005 Output Undervoltage Grid OF W006 Output Overfrequency Grid UF W007 Output Underfrequency Z Grid HI W008 Z grid out of range Impedance outside range Int Error E024 Unknown Error Internal Error E025 Riso Low Log Only Low insulation resistance Log only Int Error E026 Vref Error Wrong reference voltage VRef Int Error E027 Vgrid Measures Fault Grid voltage VGrid misreading Int Error E028 Fgrid Measures Fault Grid frequency FGrid misreading Int Error E029 Zgrid Measures Fault Grid impedance ZGrid misreading power one 0 hanging the Shape of Power Page 49 of 89 PVI 6000 OUTD xx AU Rev 1 0 Message Warning Error Description type Int Error E030 Measures Fault Leak current ILeak misreading Int Error Il E031 Wrong V Measure Voltage V misreading Int Error Il E032 Wrong Measure Current I misreading Fan Fail W010 Fan No disconnection Fan faulty Log Only Int Error E033 UnderTemperature Internal temperature Il E034 Interlock Fail
48. oday to view the following information E tod Total energy output during the day Ppeak Peak power achieved during the day Val Money earned during the day CO2 CO2 saving compared to fossil fuels during the day power one 0 hanging the Shape of Power Page 60 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 5 5 4 Last 7 days Select Last 7 days to view the following information E 7d Total energy output during the last 7 days Val Money earned during the last 7 days CO2 CO2 saving compared to fossil fuels during the last 7 days 5 5 5 5 Last Month Select Last Month to view the following information E mon KWh Val EUR Kg E mon Total energy output during the month Val Money earned during the month CO2 CO2 saving compared to fossil fuels during the month 5 5 5 6 Last 30 Days Select Last 30 Days to view the following information E 30d Total energy output during the last 30 days Val Money earned during the last 30 days CO2 CO2 saving compared to fossil fuels during the last 30 days 5 5 5 7 Last 365 Days Select Last 365 Days to view the following information E 365d KWh Val EUR Kg power one 0 hanging the Shape of Power Page 61 of 89 PVI 6000 OUTD xx AU Rev 1 0 E 365d Total energy output during the last 365 days Val Money earned during the last 365 days CO2 CO2 saving compared to fossil fuels during the last 365 days 5 5 5 8 User period User period
49. oltages to appear at the connecting cable terminations power one 0 hanging the Shape of Power Page 5 of 89 PVI 6000 OUTD xx AU Rev 1 0 GENERAL During inverter operation some parts can be powered some not properly insulated and in some cases some parts can move or rotate or some surfaces be hot Unauthorized removal of the necessary protections improper use wrong installation or wrong operation may lead to serious damage to people and objects Transport handling installation commissioning and maintenance must be performed by qualified and trained personnel all accident prevention rules in force in the user s country must be observed According to these basic safety rules qualified and trained people have skills for the assembling start up and operation of the product as well as the necessary requirements and qualifications to perform such operations ASSEMBLY Devices shall be assembled and cooled according to the specifications mentioned in the corresponding documents In particular during transport and handling parts shall not be bent and or the insulation distances shall not be changed There should be no contact between electronic parts and connection terminals Electrical parts must not be mechanically damaged or destroyed potential health risk ELECTRICAL CONNECTION With the inverter powered comply with all prevailing national regulations on accidents prevention Electrical connections shal
50. onal and local standard regulations to make sure your electrical installation design is in compliance with them WARNING Cover the whole surface of the photovoltaic panels using a preferably black material opaque to solar radiation during the installation procedure Remove the protective material when installation is complete power one 0 hanging the Shape of Power Page 27 of 89 PVI 6000 OUTD xx AU Rev 1 0 NOTE In accordance with the typical assembly diagram see Fig 9 3 each array must be connected to a two pole DC disconnect switch An AC disconnect switch with overload cutout must be used to connect AURORA to the grid Recommended ratings for the disconnect switch or the overload cutout are maximum 40A 240V A disconnect Switch DC disconnect Switch Max Rating Max 40A 240Vac DC disconnect Switch Max Rating 25A 600Vdc WARNING When disconnecting AURORA from the grid always open AN the AC disconnect before the DC disconnect Fig 9 Wiring diagram power one 0 hanging the Shape of Power Page 28 of 89 PVI 6000 OUTD xx AU Rev 1 0 A WARNING When selecting the power supply cables for AURORA connection please carefully consider nominal operating voltage insulation voltage maximum operating temperature current density and flammability rating All of these values must comply with the maximum current density ratings required by applicable local rules
51. ot touch the heat sink when the inverter is operating as some parts may be hot and cause burns The start up procedure is as follows 1 Set the external DC disconnect for the photovoltaic panels to ON 2 Set the external AC disconnect for the grid to ON There is no specific order for closing the two disconnects 3 Once both disconnects are closed the inverter starts the grid connection sequence unless the grid voltage and frequency parameters are found to be outside the operating range as per national standards The check routine is indicated by the green LED labelled POWER over the display flashing The check routine may take 30 seconds up to several minutes depending on grid condition Three screens are shown on the display during the check routing e Measuring Riso connection in progress with progress indication e Grid voltage value and status compared to specified values within outside range e Grid frequency value and status compared to specified values within outside range 4 When the connection sequence is completed AURORA starts operating proper operation is indicated by a warning sound and the green LED staying on This means that sun radiation is sufficient to feed the grid 5 If the grid check routine gave a negative result the unit will repeat the procedure until all grid voltage and frequency parameters and grid configuration are found to be in the specified range During this process the green LED
52. part at inverter back The central part of this plate features a seat for fastening the spring Part A Once inverter top end is secured in place you need to secure its bottom end From inverter front use an M6x10 screw and washer to secure the unit to bracket PEM starting the screw in its thread through lower plate centre slot Part A AURORA Part B FRONT BACK power one Changing the Shape of Power Page 24 of 89 PVI 6000 OUTD xx AU Rev 1 0 US NOTE Ensure Aurora is not exposed to direct sun radiation or other external heat sources including the units installed underneath it see fig 7 In the event several inverters are stacked up the heat generated by the inverters placed at the bottom of the stack could cause ambient temperature to rise and affect the operation of the inverters in the upper rows Temperatures exceeding 40 C could result in a derating of the output power of the units placed in the upper rows A combination of high output power and high ambient temperature will make the derating problem even worse For proper cooling make sure to install AURORA so as to allow unobstructed air flow for instance never with the front panel facing a solid surface power one 0 hanging the Shape of Power Page 25 of 89 PVI 6000 OUTD xx AU Rev 1 0 RECOMMENDED ARRANGEMENT Fig 7 Recommended installation of AURORA inverters US NOTE Tilted mounting
53. rameter check A FEW POINTERS ON DISPLAY KEY OPERATION During regular operation the display will cycle through available data The display changes to a different screen every 5 seconds or screens may be scrolled manually by pressing the UP 2nd key from display and DOWN keys 3rd key from display Either way pressing the ESC key right next to the display calls back the previous menu Fig 20 E Fig 21 Auto scroll is indicated by 2 arrows in the top left corner of the display Fig 20 To stop auto scroll press the ENTER key 4th key from display A padlock will appear Fig 21 1A If the measurements taken previously see sect 5 5 1 are found to be correct the system will proceed to the next checks The 12 screens outlined below are shown alternately as mentioned in section FEW POINTERS ON DISPLAY KEY OPERATION 3A E tod 0 Wh tod 0 0 EUR E tod Daily energy output tod Daily energy savings Value is expressed in the set currency power one 0 hanging the Shape of Power Page 54 of 89 PVI 6000 OUTD xx AU Rev 1 0 4A E tot Lifetime energy output since first installation E par Partial energy output during selected period 5A P out EC P out Measured instant output power The second line of the display shows the higher of two temperatures T inv inverter heat sink temperature T boost Heat sink temperature 6A Ppk Maximum peak power achi
54. rray and an Output j for Commissioner for Fair Trading power one Changing the Shape of Power
55. rters connected on the same link Choose any address between 2 and 248 NOTE When using RS 485 link in case one or more inverters are added later to the system please remember to switch back to the OFF position the dip switch of the former last inverter of the system power one hanging the Shape of Power Page 75 of 89 PVI 6000 OUTD xx AU Rev 1 0 6 2 Serial connection with USB port Serial connection through USB port allows connection of a single inverter to a personal computer equipped with a USB 2 0 interface and dedicated software supplied by Power One PC inverter connection cable is a standard USB 2 0 cable 5 metre long with terminals of the A and B type Just remove the waterproof plug located on Aurora side to make the connection see fig 26 Fig 26 USB connection lt Page 76 of 89 PVI 6000 OUTD xx AU Rev 1 0 6 3 Measurement Accuracy Every measure should consider possible errors The following tables show for each reading measurement units gt capacity gt resolution Name of Measu Resolution Maximum measure rement error d unit Display Value percentage variable i TOMBE EY VPI Vdc 1 600mV 2 voltage Ey VP2 Vdc 1 600mV 2 Sr 25mA 2 1 corent Ey IP2 Ade 01 25mA 2 2 power PV Pinl W iw 10W 2 power PV Pin2 w iw 10W 2 Output voltage Vout V IV 296 Output power Pout W
56. s the inverter starts the grid connection process As mentioned above during this stage AURORA automatically tracks and analyzes the maximum power point MPPT of the photovoltaic field Ground insulation fault AURORA indicates that insulation resistance was found to be too low This may be due to an insulation fault in the connection between the photovoltaic field inputs and the ground WARNING Shock hazard Do not attempt to correct this fault yourself The instructions below have to be followed very carefully In case you are not experienced or skilled enough to work safely on the machine contact a specialized technician What to do after an insulation defect has been found When the red LED turns on try to reset the fault indication by pressing the multi function ESC key at the side of the display If AURORA reconnects to the grid the fault was due to a transient event such as condensation and moisture getting into the panels If this trouble occurs frequently have the system inspected by a specialized technician If AURORA does not reconnect to the grid open both the DC and AC disconnect switches to place AURORA into a safe condition and contact an authorized service center to have the system repaired power one 0 hanging the Shape of Power Page 46 of 89 PVI 6000 OUTD xx AU Rev 1 0 lt mao Mas MEH 5 7 Malfunction Fault indication Every time Aurora c
57. s depend on many operating parameters other than ambient temperature such as input voltage grid voltage and power available from the photovoltaic panels AURORA can thus decrease power output during certain periods of the day according to these parameters In any case AURORA ensures top power up to 40 ambient temperature as far as it is not directly exposed to the sun Power reduction due to input voltage The graph shows automatic power output derating when input or output voltage is too high or too low power one 0 hanging the Shape of Power Page 86 of 89 PVI 6000 OUTD xx AU Rev 1 0 Output Power two Dc sections operating 9 uano Bureiedo Power W D 600 530 580 Input voltage V 90 FIG 29 SN Power one 0 hanging the Shape of Power Page 87 of 89 PVI 6000 OUTD xx AU Rev 1 0 Output Power one Dc section operating e d Power W 2 8 1 1 o gg m 5 5 gt 5 ot s m Uu S35 w 5 Q oc 2 E 5 5 2 E 90 180 Input 530 580 600 voltage V FIG 30 Necessary conditions for power derating due to environmental conditions and to input voltage can occur at the same time but in this instance
58. see fig 24 Wiring is again routed through the holes located at Inverter bottom which are blanked with waterproof plugs see Fig 23 Input wiring passes through one hole and is to be assembled to one of the RJ12 connectors ti does not matter whether it is no 1 or no 2 since signals are the same considering that they are connected in parallel Output wiring goes out from the other RJ12 connector through the other hole and reaches the next unit power one AvA hanging the Shape of Power Page 73 of 89 PVI 6000 OUTD xx AU Rev 1 0 RJ12 connectors Pin Signal eee Name Description 1 Not Used Data Line TIR Required for RS485 communication Remote OFF 3 R Required or Remote OFF control see chapter 5 5 6 11 for details RIS 4 TR Data Line GPEC Required for RS485 communication 5 Not Used 6 RTN Signal Return Common reference for logical signals 6 1 3 Daisy chain RS 485 terminal block or RJ12 connectors can be used to connect a single AURORA inverter or many AURORA inverters connected in a daisy chain Maximum number of inverters that can be connected in daisy chain is 248 Recommended maximum length of this chain is 1200 metres In case many inverters are connected in a daisy chain it is necessary to assign an address to each unit Refer to paragraph 5 5 6 1 for instructions on how to set addresses Moreover the last inverter of the chain must have line termination
59. t Allow sufficient room around the unit to enable easy installation and removal from the mounting surface A door is provided on unit front to allow for hardware maintenance the USB port for software connection is on right side wall of the inverter protected by a cover Ensure free access to the right side otherwise you will have to remove the unit from its mounting surface The following figure shows the recommended minimum clearances around the inverter 150mm 6 150mm 6 200mm 8 Fig 5 Place of installation Minimum clearances around AURORA power one 0 hanging the Shape of Power Page 23 of 89 PVI 6000 OUTD xx AU Rev 1 0 3 4 Wall mounting AURORA should be mounted in a vertical position as shown in fig 6 The package includes a hardware kit with 3 6 3x70 steel screws and 3 SX10 wall plugs for installation of metal bracket to a masonry wall Screws and wall plugs can be installed using 3 of the 5 holes available on the bracket ref part C WARNING Bracket shall be mounted vertically on wall spring side shall face up while side with M6 PEM shall face down Mounting holes for wall mounting should be 8 mm in diameter and min 70 mm deep For wall of other construction materials it is the installer s responsibility to provide suitable mounting hardware We recommend using stainless steel screws Hang AURORA on the spring at the bracket top by means of the metal mount fastened to the upper
60. t over current protection 40 Arms 8 3 Grid protection characteristics T Complies with Anti islanding protection 4777 3 2005 power one 70 hanging the Shape of Power Page 84 of 89 PVI 6000 OUTD xx AU Rev 1 0 8 4 General characteristics Value PVI 6000 OUTD Description Maximum efficiency 97 gt 96 Euro Internal consumption during stand by 8W Internal consumption during nighttime IW Operating ambient temperature 25 C to 60 Casing protection rating IP65 Nema 4X Audible noise with internal fan on lt 50 dbA Im Size height x width x depth 740 x 325 x 190 mm Weight 27 kg Relative Humidity 0 100 96 condensation point Full power guaranteed up to T amb 40 C as far as unit is not exposed to direct sun radiation Efficiency T 1 1 T 1 a 200 Vdc 1 i esses 5345vdc 480 10 20 30 50 75 100 of Rated Output Power FIG 28 Efficiency plot pover ame 0 hanging the Shape of Power Page 85 of 89 PVI 6000 OUTD xx AU Rev 1 0 8 5 Power Derating In order to ensure inverter operation under safe conditions both from the temperature and electrical point of view the unit automatically decreases power input in the distribution grid Power derating can occur in two cases Power reduction due to environmental conditions Power reduction and temperature at which it occur
61. the following data Lifetime counter of grid connection time Lifetime counter of energy transferred to the grid Energy transferred to the grid every 10 seconds for the last 8640 periods of 10 seconds which on average cover more than 2 days logged data Partial counter of grid connection time counter start time can be reset using the AURORA Communicator software Partial counter of energy uses the same start time of the partial time counter Last 100 fault conditions with error code and time stamp Last 100 changes to grid connection parameters with parameter code and new value The first two types of data are displayed on the LCD and through the RS 485 interface while all other data can be displayed only through RS 485 interface VNN power one 0 hanging the Shape of Power Page 42 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 3 LED indicators There are three LEDs at the side of the display the first LED from the left POWER indicates proper operation of the inverter the LED in the middle FAULT indicates a fault condition whereas the LED on the right GFI indicates a ground fault 1 The green Power LED indicates that AURORA is operating correctly This LED flashes upon start up during the grid check routine If a correct grid voltage is detected and solar radiation is strong enough to start up the unit the LED stays on steady If not so the LED keeps flashing until solar radiation becomes strong
62. u USB Analog inputs Digital Input Output ei RS485 Aurora Easy Control adapter Ethernet SN RS485 du x Dd de hr Telephone or GSM modem End User s computer Fig 18 Data Transmission Options power one Changing the Shape of Power Page 40 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 2 Available Data AURORA provides two types of data that can be collected using the suitable interface software 5 2 1 Real time operational data Real time operational data can be transmitted on demand through the communication lines and are not stored by the inverter The free AURORA Communicator software available on the installation CD may be used to transmit data to a PC please check for the latest updated version at www power one com The following data is available Grid voltage Grid current Grid frequency Power transferred to the grid Voltage of photovoltaic array 1 Current of photovoltaic array 1 Voltage of photovoltaic array 2 Current of photovoltaic array 2 Heat sink temperature Serial Number Part Number Manufacturing week Firmware revision code Daily energy Leakage current of the system Total energy Partial energy Mean grid voltage Insulation resistance Leakage current to ground Date time VVVVVVVVVVVVVVVVVV VV power one 0 hanging the Shape of Power Page 41 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 2 2 Internally logged data Aurora stores internally
63. will keep flashing power one 0 hanging the Shape of Power Page 38 of 89 PVI 6000 OUTD xx AU Rev 1 0 5 MONITORING AND DATA TRANSMISSION 5 1 User s Interface Mode WARNING The RS 485 cable must provide at least 600V protection Normally the AURORA inverter operates automatically and needs no particular supervision When solar radiation is not enough to generate power for the grid for instance at night AURORA disconnects automatically and goes into stand by mode The operating cycle is resumed automatically the moment solar radiation becomes strong enough This is indicated by the LEDs Aurora inverter can provide operational data in the following ways LED indicators gt Operational data on the LCD display gt Data transmission a dedicated serial RS 485 line Data can be collected by a PC or a data logger equipped with an RS 485 port If an RS 485 line is used it may be convenient to use the AURORA RS 485 RS232 Serial Interface Converter model number PVI RS232485 An optional AURORA Easy Control data logger is also available gt Data transmission USB cable This type of connection is typically used when monitoring a single inverter and for maintenance purposes To connect the USB cable remove the waterproof plug at the bottom end of the inverter right wall Fig 17 Fig 17 USB port power one 0 hanging the Shape of Power Page 39 of 89 PVI 6000 OUTD xx AU Rev 1 0 Service u

Aurora PVI-6000 User Manual - Solar Energy Products Australia

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