Hardware and Installation Manual
Contents
1. i 5 4 Inverter Communication Connection 5 5 String Supervisor Description 5 6 Overvoltage Protection i COMMISSIONING ss ss sressesenieaaena nane neon e eee nananana zone e agas assa ioni e nie iii iaia iene 6 1 Initial Conditions 6 2 Verniy IMO WV INNO NES TT 63 OWC cesses cece e ee io ae sce cece eet ee TRANSPORT AND HANDLIND 1 iii 7 1 Freesun Weights and dimensions nennen nnn 7 2 Transpor Procedure me YS B Prior to CORMECUON nm M DECLARATION OF CONFORMITY CE 1rrrrrrererezzez zzz nie nhan nana nnne FREESUN INDEX 5 LTO P 0 e m FREESUN POWER ELECTRONICS SAFETY INSTRUCTIONS IMPORTANT Head this manual carefully to maximise the performance of this product and to ensure its safe use n order to use appropriately the FREESUN please follow all instructions described in the installation manual referred to transport installation electrical connection and commissioning of the equipment Power Electronics accepts no responsibility or liability for any and all damage resulting from inappropriate use of the equipment The information contained in the installation guide must be observed when installing the inverter PRIOR TO CONNECTION In the rear side of the solar inverter are located the SECURITY FIXATIONS FOR TRANSPORT in both the transforme2. 1 The maximum PV Power depends on the geographic location and type of installation 12 SAFETY INSTRUCTIONS POWER ELECTRONICS FREESUN 2 TECHNICAL CHARACTERISTICS FREESUN LVT SERIES ov eon DC Voltage Range MPP VDC 450V 820V INPUT Maximum permissible DC current A 52 65 77 90 103 129 155 206 258 Recommended cable section mm 2 Max Efficiency Pac nom n 95 9 96 2 97 1 EFFICIENCY Euroeta n 95 0 95 5 96 5 Standby Operating Consumption Duc lt approx 40W External Auxiliary Voltage 230V 50 60Hz AUXILIARY External Back up Fuse for Auxiliary B16A 1 pole Supply x Dimensions WxHxD mm 840 x 1600 x 755 1040 x 1600 x 755 1440 x 1700 x 1040 CANE Weight kg 1125 I Intake thorough rear lower part and both sides blown out through upper side Outdoor Air Flow Intake thorough rear lower part blown out through upper side Indoor A l IP44 IP54 Outdoor Protection Rating as per EN 60529 IP21 Indoor ENVIRONMENT Permissible Ambient Temperature 3 20 C 50 C Relative Humidity non condensing 10 to 95 Max Altitude above sea level 4 1000m Modbus CAN Ethernet optional GSM GPRS LTO P 0 e m Digital Inputs 2 programmable inputs Galvanically isolated 2 programmable and differential inputs Analogue Inputs Current signal 0 20mA Voltage signal full scale configurable 10mV to 10V CONTROL PT100 Input 1 Input INTERFACE String Superv
3. 24 ELECTRICAL CONNECTION POWER ELECTRONICS FREESUN 5 1 2 PV Generator Power Connection DC Connection A busbar that allows string distribution boxes to be connected is located in the left lower area of the inverter sidewall Cables rated for a minimum of 900V 1000V are required for connecting the DC cables to the fuse inputs of the inverter Suitable cable screw connections must be installed in the busbar plates to provide strain relief for the cable The DC cables are connected directly to the busbar using M10 cable lugs The DC voltage of the PV generator must never exceed the maximum permissible inverter input voltage Otherwise the inverter is in acute danger when connected Upy 900 1000 V FSITP0008A Figure 5 3 View of DC connection area with on load disconnector A and circuit breaker B ELECTRICAL CONNECTION 25 ck H se PF GA e m FREESUN POWER ELECTRONICS 5 1 3 General dimensions for AC and DC connection FRONT SIDE 840 FSDTDOOO4AI Figure 5 4 AC and DC Input Output cable plates Frame 1 FRONT SIDE FSDTDOOOSAI Figure 5 5 AC and DC Input Output cable plates Frame 2 26 ELECTRICAL CONNECTION POWER ELECTRONICS FREESUN FRONT SIDE FSDTDOOOGAI Figure 5 6 AC and DC Input Output cable plates Frame 3 5 2 Disconnect External disconnection of the device must always be done when the inverter is operating under no load conditions
4. FSITG0009A Figure 4 1 FREESUN Frame 1 internal view 22 GENERAL INFORMATION POWER ELECTRONICS FREESUN gt bal D AIR rA LLL LLL LLL LLL LLL LLL Ne FSITG0010A Figure 4 2 FREESUN Frame 3 internal view 4 7 Cooling system maintenance The device is equipped with several fans for cooling To perform any work on the fans is recommended that the equipment is switched off as explained in the previous section This procedure should be taken into account for commissioning maintenance and repair work 4 8 Hearing Protection The device fans and the power unit create significant levels of operating noise In addition to this a fault in the device can lead to very high sound levels For these reasons we recommend the use of hearing protection in its vicinity We recommend the use of ear protection when in the vicinity of the device for extended periods 4 9 Burns Immediately after isolating the device depending on the operating conditions certain components can be very hot e g fuses transformer core sine wave filter heatsinks etc Safety gloves should always be worn when working near components that can be expected to be very hot We recommend that safety gloves be worn during all work on the inverter GENERAL INFORMATION 23 ck H cz rozm FREESUN POWER ELECTRONICS 9 ELECTRICAL CONNECTION The electrical connection can be set up after the inverter has been correctly placed on site
5. FSITG0012AI Figure 5 15 String Supervisor internal view The environmental conditions that should be considered for the correct installation of the string supervisor are o TEMPERATURE RANGE 20 C to 50 C o RELATIVE HUMIDITY 15 to 95 o ALTITUDE 1000m over sea level o POLLUTION DEGREE Type Il The information for the correct electrical connections leds indications and dimensions is provided with the technical specification of the string supervisor Please refer to this specific document for further information 34 ELECTRICAL CONNECTION POWER ELECTRONICS FREESUN 9 6 Overvoltage Protection The Freesun Outdoor model is equipped with internal overvoltage protection as standard Optional in Frame 1 Optionally the inverter can also be equipped with lightning protection This built in overvoltage protectors will provide the corresponding protection for AC connection DC connection and also CAN interface for connecting the String Supervisors The Freesun inverter requires auxiliary internal control voltage of 230VAC In case the user provides this power supply externally as long as permitted by the current legislation of the country where the installation takes place the Freesun will provide the corresponding overvoltage protection for this line The user must consider that before measuring the insulation it is required to remove or disconnect the overvoltage protectors or the existing fuses must be removed ELECTRICAL CO
6. The cables are inserted from below through the pedestal and the base of the cabinet opening the base grilles in the front of the cabinet or in the rear part of the cabinet according to installation requirements In this way it is possible the access to the bottom plates Required glands must be installed in these bottom plates to let the correct installation of input and output cables 5 1 External Connections 5 1 1 Electrical Connections to the AC Grid Power The AC grid connection is made at the TN C TN S TT grid connection type which must be provided by the customer using a 3 phase system equipped for 400V In addition it is also necessary to verify that existing rotary field on L1 L2 and L3 is the same than inverter phase sequence on the contrary a trip will be generated The grid connection must be installed in a way such that a right hand rotary field lies at the input of the cabinet In case of a left hand rotary field is present the inverter will generate a trip Ensure the grid connection cable is fused at the nominal current indicated on the name plate If the specified nominal current differs from the nominal current of the fuse plug the fuse plug having the next highest nominal current may be used The cables for AC connection will be fixed using M8 cable lugs Figure 5 1 View of the base plates for cable routing and the FREESUN electrical connections FSITP0007A Figure 5 2 AC connection terminals
7. reesun SOLAR INVERTER Solar Inverter Hardware and Installation Manual f POWER ELECTRONICS reesun LVT SERIES Solar Inverter Hardware and Installation Manual Edition March 2011 FSMTHWO1HI Rev H FREESUN POWER ELECTRONICS POWER ELECTRONICS FREESUN SAFETY SYMBOLS Always follow safety instructions to prevent accidents and potential hazards from occurring WARNING This symbol means improper operation may results in serious personal injury or death be given because dangerous voltage may be present Maintenance Identifies shock hazards under certain conditions Particular attention should CAUTION operation should be done by qualified personnel Identifies potential hazards under certain conditions Read the message and follow the instructions carefully be given because dangerous voltage may be present Identifies shock hazards under certain conditions Particular attention should Edition of October 2010 This publication could present technical imprecision or misprints The information here included will be periodically modified and updated and all those modifications will be incorporated in later editions To consult the most updated information of this product you might access through our website www power electronics com where the latest version of this manual can be downloaded SAFETY SYMBOLS TO rozm FREESUN POWER ELECTRONICS Revisions Date Revision Description 30 03 2010 A
8. H WIDTH W DEPTH D 1600 FREESUN FSDTD0002A Figure 7 2 Freesun Frame 2 dimensions FS0080 Dimensions mm HEIGHT H WIDTH W DEPTH D FS0100 1440 1700 Figure 1700 1440 1040 7 3 Freesun Frame 3 dimensions 1125 FSDTD0003A TRANSPORT AND HANDLING 39 LOr GA e m FREESUN POWER ELECTRONICS 7 2 Transport Procedure Transport Using a Pallet Truck Crane The inverter is properly labelled with instructions for handling with the packaging and must be respected at all times This also applies to the proper signalling of gravity symbol Figure 7 4 The plinth panels must be unscrewed to transport the cabinet without a palette This allows the fork of a pallet truck forklift or crane to be inserted under the cabinet To avoid damage or accidents during transport and on the installation site the following measures have been introduced he transport markings stipulate that forklift or pallet trucks must always load the switch cabinets by their long sides front and rear sides of the FREESUN It is forbidden to lift them by their sort sides Figure 7 5 Transport by crane is allowed if a suitable crane fork is used which is pushed through the Openings in the base of the cabinet Figure 7 6 The cabinets must not be tilted To perform this manipulation is recommended that the inverter is left as close as possible to their final locat
9. 82 01 Declares under its own responsibility that the product Solar Inverter Brand Power Electronics Model name Freesun Series Is in conformity with the following European Directives References Title 2006 95 CE Electrical Material intended to be used with certain limits of voltage 2004 108 CE Electromagnetic Compatibility References of the harmonized technical norms applied under the Low Voltage Directive References Title EN 50178 1997 Electric devices to be used in power installations References of the harmonized technical norms applied under the Electromagnetic Compatibility Directive References Title EN 61000 6 2 2005 Electromagnetic compatibility EMC Part 6 2 Generic standards Immunity for industrial environments EN 61000 6 4 2007 Electromagnetic compatibility EMC Part 6 4 Generic standards Emission standard for industrial environments Electromagnetic compatibility EMC Part 3 12 Limits Limits for harmonic currents produced by equipment connected to public low voltage systems with input current gt 16 A and lt 75 A per phase Electromagnetic compatibility EMC Part 3 4 Limits Limitation of emission of harmonic currents in low voltage power supply systems for equipment with rated current greater than 16 A Electromagnetic Compatibility EMC Part 3 11 Limits Limitation of voltage changes voltage fluctuations and flicker in public low voltage supply systems Equipment with rate
10. First edition 16 04 2010 B Data verification String supervisor information 06 05 2010 C Datasheet updating 11 05 2010 D Inclusion of Frame 1 and Frame 2 30 06 2010 E Datasheet updating 16 07 2010 F Communications drawings 02 08 2010 G Figures and configuration table updating 21 03 2011 H Technical characteristics and configuration table updating The equipment and technical documentation are periodically updated Power Electronics reserves the right to modify all or part of the contents of this manual without previous notice POWER ELECTRONICS INDEX SAFET INS TAUG 08 fc T INTRODUCTION EE MES cuo NUMEN T ee VU mme TEGANCGALGHABRALIERSTIOO lalla INSTALLATION Wie E VE 3 1 Requisites for the Installation GENERAL INFORMATION 0000cccccceeseesssnnnnnnseseeeeneeeeeceeeeeseccnnnnnsnsseeseeeeeseneeeesocoaannnsseees dell CONC NERIS mm 4 2 Electrical Connechons eene n nans nnn sc M e SE SUDO NCS MR m did Emergency SiOD RT HE Ai CONCA E E 4 6 Commissioning Maintenance and Repair i 4 7 Cooling system maintenance e ELEGTRICALCONNEGTION ai 51 External EREECHEN m 52 PISCINE Tc 5 3 Sensors and Control Signals for the User
11. dimensions and clearance FREESUN Frame 1 Indoor Lone e r 500 gt I FSTDT0008A L 500 Figure 3 5 General dimensions and clearance FREESUN Frame 2 Indoor 16 INSTALLATION REQUIREMENTS POWER ELECTRONICS FREESUN S uw ba 1040 FSDTD0009A Figure 3 6 General dimensions and clearance FREESUN Frame 3 Indoor 3 1 3 Minimum Workspace Requirements Outdoor DULL RA DOANDO OOOO noO Concrete foundation slab Concrete foundation slab FSDTD0010AI Figure 3 7 General dimensions and clearance FREESUN Frame 1 Outdoor INSTALLATION REQUIREMENTS 17 ck H cz P 0 e m FREESUN POWER ELECTRONICS i 7 Ls ee ee 1 Concrete foundation slab FSDTD0011AI ADAM IDTNALDOD VAL ALNINCOTVLL eC UNA M CODI ODD CPCI TCC LOODAN TTT Concrete foundation slab Figure 3 8 General dimensions and clearance FREESUN Frame 2 Outdoor a 1040 Concrete foundation slab FSDTD0012AI Sinn 8 Concrete foundation slab Figure 3 9 General dimensions and clearance FREESUN Frame 3 Outdoor 18 INSTALLATION REQUIREMENTS POWER ELECTRONICS FREESUN 3 1 4 Inverter Protection Degree EMC Sound Levels The outdoor model of the FREESUN is suitable for outdoor installation according to the IP54 protection degree The control area of the inverter is implemented so that it is separate
12. external internal The solar inverter must receive an internal 230VAC 50 60Hz single phase supply In case of the power supply for control voltage is externally provided as long as permitted by the current legislation of the country where the installation takes place it must be protected with a back up external auxiliary supply fuse B16A 1 pole 6 2 3 DC Power Connections The DC power connections are made over the main DC plates of the inverter Consider that DC connections should be checked to ensure they are mechanically tightened The voltage on each of the main DC cables should be identical and should never exceed the maximum DC voltage level of the inverter It is also important to check not only DC voltage levels but also the polarity of each of the DC main cables because the wrong polarity in one of the DC main cables can damage the PV generator COMMISSIONING POWER ELECTRONICS FREESUN 6 2 4 Serial Interfaces For external communication and string current supervision the data cables have to be connected Detailed information has been above described and specific connection is described in String Supervisor documentation 6 3 Switch On Once all tests and measurements have been performed and all measured values lie within the acceptable range the inverter can be switched on for the first time For this all circuit breakers and overload switches in the Freesun must be switched on At this time the graphic display
13. make up the installation and its interconnection as well as the different lines that may be necessary for both power and communications In case the 230Vac power supply for control is externally provided it will be connected to the elements showed in the scheme The provision of this power supply to the inverters is legislated by the relevant regulatory agency of the country where the installation is located and must therefore be respected 28 ELECTRICAL CONNECTION POWER ELECTRONICS FREESUN To connect and power those elements that are not part of the scope of Power Electronics consider the installation instructions of the respective manufacturers switch router Please consider the following general cable layout LEGEND NETWORK CONFIGURATION 230VAC AUX POWER SUPPLY gt gt gt 24VDC STRING SUPERVISOR POWER SUPPLY CAN COMMUNICATION FE cass ETHERNET COMMUNICATION PC RIPPLE CONTROL RECEIVER ZZZ COMMUNICATION n A ETHERNET CAT 6 nonno o mm o o mm mm mm wm MASTER Freesun Data Center v CAN Y 2x2x0 75mm Y SCREENED Y Iv STRING SUPERVISOR lt INTERNET gt ALZA ELECTRICITY SUPPLIER T BA beem Public Grid vimIIETRT Operator 230VAC AUX 3x2 5mm POWER SUPPLY Ripple Control Receiver Switch 6x0 5mm TWISTED SCREENED ee ee ee ee ee ee eelere I I LI Power Cont
14. present for a longer period of time For these reasons wait a minimum of 10 minutes after switching off before opening the device and wait until the voltage indicator LEDs of the DC bus are off Following this procedure it is possible to work on the solar inverter in a safe way ELECTRICAL CONNECTION 27 ck H cz P 0 e m FREESUN POWER ELECTRONICS 9 9 sensors and Control Signals for the User All required information about digital I O and analogue I O are described below Two analogue sensors and one PT100 temperature sensor can be connected to the Freesun Their connection is made in the connection area of the inverter Factory Settings CONNECTOR X1 CONNECTOR X2 ER 00 ALWAYS OFF AO 00 NONE DO1 2 AO 8 PEN d An 9 E 5 00 ALWAYS ON Alt 2 DO2 8 AI2 1 13 2 14 PT100 a is 24V Usr DI 16 SEES Common Terminal 24Vdc 0 Non used 0 Non used 24V Usr FSDTC0002AI Figure 5 7 Control terminals for the user Further information about setting of each input and output please refer to the Freesun Programming and Software Manual 5 4 Inverter Communication Connection The device can be equipped with various interface cards for the communication between the inverter and a PC or modem The data can be transferred using the following o Ethernet o RS232 RS485 USB o GAN For the String Supervisor o GSM The following control scheme provides information of the different elements that can
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16. D 6x0 5mm RIPPLE CONTROL RECEIVER Non Used Ei Terminal 5Vdc DIGITAL INPUTS Output Relays FSDTR0003AI Figure 5 11 Connection between the Power Control Interface and the radio ripple control receiver 5 9 String Supervisor Description The main function of the string supervisor is monitoring the strings status to detect quickly their malfunction To do this using a current transducer hall effect the current provided by each string is measured and in this way it is possible to analyse easily the performance of each single one In case of one of the string produces less energy than the others will be detected thanks to the string supervisor The string supervisor is a slave of the solar inverter Its function is to inform the solar inverter and to connect in parallel the panel strings To achieve this the string supervisor is provided with two communication buses already implemented CAN bus to communicate with the inverter and RS485 just in case the user requires to access to the STRING SUPERVISOR via MODBUS Each string supervisor is provided with an overvoltage protector that protects the installation Power Electronics string supervisor detects the status of this overvoltage protector and in case it is out of service as the result of action against a very high energetic value overvoltage it will inform to the solar inverter With this information the maintenance people will have able of managing
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18. NNECTION 35 ck H cz P 0 e m FREESUN POWER ELECTRONICS 36 6 COMMISSIONING Before the first commissioning all work performed on the device should be thoroughly checked Special care with the voltages on the DC and AC sides is required to ensure conformance with the limits allowed on the inverter Nameplate data must be observed 6 1 Initial Conditions Following conditions must be observed to allow a correct commissioning of the solar inverter Before the inverter is put into operation will be required o Ensure an appropriate grounding resistance This is decisive for the safety of the complete system and must therefore be determined before the system is started for the first time o Every circuit breaker and overload switch in the Freesun must be switched off when it is delivered 6 2 Verify the Wiring When performing the cabling checks the connections are first checked for correctness and proper installation 6 2 1 AC Grid Connection The connection made to the feed in cables is 3 phase It must be checked that the inverter is connected to the correct grid connection type TN C TN S or TT In addition it is also necessary to verify that existing rotary field on R S and T is the same than inverter phase sequence on the contrary a trip will be generated The level of the AC voltage should be measured and logged The Freesun feeds into the grid using 3 x 400V 10 6 2 2 Auxiliary Control Voltage Supply
19. ONSIDERATIONS The cable for CAN connection between the solar inverter and the String Supervisor must meet the following specifications to ensure proper operation o Family CAN BUS 2x2x0 75mm VIOLET o Section 0 75mm o Colour code DIN 47100 o Ext cover PVC o Characteristic impedance 1200 The recommended maximum cable length is between 75m and 100m for a data transmission speed of 500Kbps For longer distances please contact Power Electronics Excessive bending of CAN cables can reduce their ability to meet the CAN specification Standard Thick cables shall have a bending radius of greater than 75mm 3 Standard Thin cables shall have a bending radius of greater than 50mm 2 These generic cable types are available in a variety of different offerings such as FLEX HAZ DUTY CLASS I 600V UV RESISTANT etc 30 ELECTRICAL CONNECTION POWER ELECTRONICS FREESUN Case B J900 connector is a screw terminal connector FREESUN PS LVT SERIES POWER ELECTRONICS ni TWISTED _ Jj SHIELDED 2x2x0 75mm 1 TWISTED 4 SHIELDED lei 2x2x0 75mm SHIELDED 3x0 5mme SHIELDED TT 3x0 5mm E LA 3 ERI STRING SUPERVISOR HVDC 124vac Dee 24Vde OVde VDC IN VDC OUT STRING SUPERVISOR YDC IN VDC OUT POWER ELECTRONICS POWER ELECTRONICS EEN ET FEAT FTT TI FTT TI till 1l illl Ll STRING STRING STRING STRING STRING STRING STRING STRING STRING STRING
20. STRING STRING FSDTROOO2BI Figure 5 10 Connection with String Supervisor using a screw terminal connector CONSIDERATIONS The cable for CAN connection between the solar inverter and the String Supervisor must meet the following specifications to ensure proper operation o Family CAN BUS 2x2x0 75mm VIOLET o Section 0 75mm o Colour code DIN 47100 o Ext cover PVC o Characteristic impedance 1200 The recommended maximum cable length is between 75m and 100m for a data transmission speed of 500Kbps For longer distances please contact Power Electronics Excessive bending of CAN cables can reduce their ability to meet the CAN specification Standard Thick cables shall have a bending radius of greater than 75mm 3 Standard Thin cables shall have a bending radius of greater than 50mm 2 These generic cable types are available in a variety of different offerings such as FLEX HAZ DUTY CLASS I 600V UV RESISTANT etc ELECTRICAL CONNECTION 3 1 ck H cz P 0 e m FREESUN POWER ELECTRONICS 5 4 2 Details for connection between Power Control Interface PCI and the Ripple Control Receiver In the following drawing is described the connection of the Power Control Interface to a radio ripple control receiver Please check the manufacture s user manual for more information about the configuration of the radio ripple control device POWER CONTROL INTERFACE f gt POWER ELECTRONICS TWISTED SHIELDE
21. To achieve this it is required to switch off the inverter Once the device is switched off both AC and DC contactors will be open and normally there will be no voltage in the internal circuits Nevertheless residual voltage may be present in the DC bus Therefore to disconnect the inverter the following procedure must be followed o Switch off the inverter with the OFF ON switch OFF position or with the graphic display unit when it is in local mode by pressing the STOP RESET button o Thefollowing power supplies must be disconnected AC Grid voltage for the grid feed in by switching off the main AC internal circuit breakers Auxiliary control voltage 230Vac by switching off the circuit breakers DC voltage from the photovoltaic generator disconnection is normally done automatically by the motorized switch In case the disconnection is done manually use the handle attached to the inverter To ensure that we have no voltage on the DC side also will be necessary to switch off the breaker included in each String Supervisor Thus even in case of accident or other unforeseen events it will be possible to disconnect the inverter safely The device contains capacitors on the AC and DC sides that must discharge once the device has been switched off After switching off there are dangerous accidental contact voltages present within the device for several minutes If there is a fault in the device these voltages may also remain
22. abelling L1 L2 and L3 e Check the polarity of DC voltages DV and PV in the connection plates of the inverter e The photovoltaic generator has been checked with an insulation test to ensure that there is no ground fault GENERAL INFORMATION 21 ck H cz P 0 e m FREESUN POWER ELECTRONICS 4 4 Emergency Stop The Freesun inverter outdoor model is not provided with external emergency stop but it can be ordered as an option The emergency stop button will provide the corresponding normally closed contacts free potential to be correspondly wired to the Freesun Each emergency stop must be powered only from the corresponding inverter 4 5 Operation Apart from the FREESUN Control there are no control elements on the device The cabinet doors must only be opened for commissioning maintenance and troubleshooting as well as for data query and parameter setting Please also note the following safety instructions for working on the device 4 6 Commissioning Maintenance and Repair All work on the FREESUN may only be performed when the device is safely disconnected from de PV voltage DC the grid voltage AC and the auxiliary power supply internal or external when these power sources are secured against being switched on again and when it has been checked that the device is voltage free Only qualified technical personnel may undertake any such task JIDD AAMALLHALHAALLHALLALLHALLTLLHALLTLLE ALLE ALLELUEUEI UUNIIN
23. cial hazards An active power source is connected This means that regardless to the operating mode of the inverter there may be voltage present either from the photovoltaic generator and or the FREESUN This is especially important to consider when disconnecting particular parts of the system Very high DC voltages are present no zero crossing which in case of a fault or inappropriate use of fuses or plugs may lead to arcing The short circuit current of the photovoltaic generator is only slightly more than the maximum operating current and is also dependent on the level of a solar irradiation This means that if a short circuit occurs in the system the existing circuit breakers are not guaranteed to switch off A highly branched generator array may be difficult to disconnect if a fault develops e g short circuit We recommend the extra use of external DC circuit breakers for disconnecting the inverter and or the DC main cables String supervisors DC circuit breakers are built in One circuit breaker should be allocated to each input and these should be located near to de FREESUN as described in the standard VDE0100 part 7 712 and the VDI 6012 regulations Power Electronics must be informed of the required AC grid connection type The device contains capacitors on the AC and DC sides The discharge time of the capacitors is longer than 10 minutes For this reason it is required to wait longer than this time before mak
24. d current 75 A and subjected to conditional connection EN 61000 3 12 2005 IEC 61000 3 4 1998 EN 61000 3 11 2000 Note the requirements of the new norm IEC 61209 1 2010 have been considered in the design and test of our range FREESUN Paterna 28 of April 2010 David Salvo Executive Director f POWER ELECTRONICS www powerelectronics es www power electronics com 24 Hours Technical Assistance 365 days a year 34 96 136 65 57 HEADQUARTER VALENCIA SPAIN C Leonardo da Vinci 24 26 Parque Tecnol gico 46980 PATERNA VALENCIA ESPANA Tel 902 40 20 70 Tel 34 96 136 65 57 Fax 34 96 131 82 01 CATALUNA CANARIAS LEVANTE NORTE CENTRO SUR GALICIA GERMANY AUSTRALIA BRAZIL CHILE CHINA KOREA INDIA MEXICO NEW ZEALAND BRANCHES BARCELONA Avda de la Ferrer a 86 88 08110 MONTCADA I REIXAC Tel 34 96 136 65 57 Fax 34 93 564 47 52 LLEIDA C Terrasa 13 Bajo 25005 LLEIDA Tel 34 97 372 59 52 Fax 34 97 372 59 52 LAS PALMAS C Juan de la Cierva 4 35200 TELDE Tel 34 928 68 26 47 Fax 34 928 68 26 47 VALENCIA Leonardo da Vinci 24 26 46980 e PATERNA Tel 34 96 136 65 57 Fax 34 96 131 82 01 CASTELL N C Juan Bautista Poeta 2 Piso Puerta 4 12006 CASTELL N Tel 34 96 434 03 78 Tel 34 96 136 65 57 Fax 34 96 434 14 95 MURCIA Pol Residencial Santa Ana Avda Venecia 17 30319 CARTAGE
25. d from the power area Qe S e nece IK om i FSITG0007A Figure 3 10 Internal view of the FREESUN With regard to the EMC emissions and the noise level the inverter has been designed to be installed in an industrial environment or for outdoor installation INSTALLATION REQUIREMENTS 19 LTO P D e In FREESUN POWER ELECTRONICS 3 1 5 Ventilation In order to cool the inverter the ventilation system must be free of any obstructions to ensure the required inlet ventilation and heat dissipation The specified minimum clearances must be maintained to ensure the proper ventilation and heat dissipation The permissible ambient temperature in order to ensure the correct operation and maximum feed in performance is between 20 C and 50 C The exhaust air waste heat is blown out through the upper cover FSITG0008A Figure 3 11 Ventilation Concept of the FREESUN 20 INSTALLATION REQUIREMENTS POWER ELECTRONICS FREESUN 4 GENERAL INFORMATION 4 1 Correct Use Appropriate use of the equipment includes o Observation of the safety instructions described in the whole manual o Observation of the instructions in the FREESUN user manual o Observation of additional documentation for variants and options such as grounded operation GFDI and the extended voltage range EVR o Observation of the technical data for the device 4 2 AC grid connection The customer must determine t
26. e front cover is removed Handle the solar inverter with care according to its weight nstall the inverter according to the instructions within this manual Do not place heavy objects on the inverter Ensure that the mounting orientation is correct Do not drop the inverter or subject it to impact The Freesun inverters contain static sensitive printed circuits boards Use static safety procedures when handling these boards Avoid installing the inverter in conditions that differ from those described in the Technical Characteristics section TRIAL RUN Verify all parameters before operating the inverter Always apply voltage and current signals to each terminal that are within levels indicated within this manual Otherwise damage to the inverter may result SAFETY INSTRUCTIONS POWER ELECTRONICS FREESUN OPERATION PRECAUTIONS Do not modify or alter anything within the inverter Before programming or operating the Freesun Series initialise all parameters back to factory default values WHO S ABLE TO APPLY THE FOLLOWING INSTRUCTIONS Only trained electricians approved by the responsible energy supply company may install and commission the inverters The instructions assume that you the installer are familiar with electrical installations and know the corresponding rules and regulations SPECIAL HAZARDS OF PHOTOVOLTAIC SYSTEMS Photovoltaic systems have special characteristics that can represent spe
27. h parts missing even if the installation is complete Otherwise you may get an electric shock Do not allow lint paper wood chips dust metallic chips or other foreign matter into the inverter Otherwise fire or accident could occur SAFETY INSTRUCTIONS 7 ck H cz P 0 e m FREESUN POWER ELECTRONICS 8 N WARNINGS RECEPTION he Freesun is carefully tested and perfectly packed before leaving the factory n the even of transport damage please ensure that you notify the transport agency and POWER ELECTRONICS 902 40 20 70 International 34 96 136 65 57 or your nearest agent within 24hrs from receipt of the goods UNPACKING Make sure model and serial number of the solar inverter are the same on the box delivery note and unit Each solar inverter is supplied with a technical manual RECYCLING Packing of the equipments should be recycled For this it is necessary to separate different materials included plastic paper cardboard wood and deposit them on proper banks Waste products of electric and electronic devices should be selectively collected for their correct environmental management SAFETY Before operating the solar inverter read this manual thoroughly to gain and understanding of the unit If any doubt exists then please contact POWER ELECTRONICS 902 40 20 70 34 96 136 65 57 or your nearest agent Wear safety glasses when operating the inverter with power applied and th
28. he required grid connection type for the AC grid connection TN C TN S TT grid and coordinate it with Power Electronics Ensure the grid connection cable for grid feeding is fused at the nominal current indicated on the name plate If the specified nominal current differs front the nominal current of the fuse plug the fuse plug having the next highest nominal current may be used A power switch is used for the optional load disconnecting switch 4 3 Power Supplies Switching on the different power supplies o Connection of main AC grid voltage for the grid feed in o Connection of auxiliary control voltage 230Vac internal power supply There is the option of feeding it externally as long as permitted by the current legislation of the country where the installation takes place o DC voltage connection from the photovoltaic generator must occur in the sequence described and may only be performed when the following conditions are satisfied e Verify that all connections have been made according to the Electrical Connections section e The protective ground connection for grid feed in and for internal power supply is correctly connected e t must be checked that the inverter is connected to the correct grid connection type TN C TN S or TT In addition it is also necessary to verify that existing rotary field on R S and T is the same than inverter phase sequence on the contrary a trip will be generated To this end consider l
29. ightning and V overvoltage protections ck H cz rozm With AC and DC overvoltage protection With AC and DC overvoltage protection and lightning protection From 450 to 820V Transformer connection to 270V From 405 to 820V Transformer connection to 240V Maximum power point range MPP N String Supervisor SI F With auxiliary power supply for String Supervisor connection N Not included Indoor Heating Includes heating resistance Indoor 15kV 20kV 22kV 24kV 30kV 1MPPT 2MPPT Without auxiliary power supply for String Supervisor connection Medium Voltage Output 1 2 MPPT Configuration 10MPPT 1 Option H is only suitable for Freesun HE and Freesun HES series Modular inverter 2 Available for LVT Series 3 Included in the Outdoor model of the Freesun LVT series 4 This option is only suitable for Freesun HES series For other output voltages consult with Power Electronics 5 Onl available for HE and HES series The maximum number of MPPTs depends on the number of modules implemented in each inverter One MPPT per module This is an optional kit configured according to the MPPT number INTRODUCTION 11 FREESUN POWER ELECTRONICS 1 2 Standard Ratings INPUT OUTPUT Max PV Nominal AC Output Operating Grid Voltage Nominal AC REFERENCE Power 1 Power 10 Current Ppv Pac Vac lac nom n FS00200TOO0000 24kWp 20kW 400V
30. ing any operation or maintenance actions in the unit SAFETY INSTRUCTIONS 9 ck H cz P 0 e m FREESUN POWER ELECTRONICS 1 INTRODUCTION In order to guarantee correct connection and reliable operation of the device it is recommended to read carefully the safety and installation instructions in the following sections FSITG0002A Figure 1 1 FREESUN Frame 1 Outdoor Front View For a safe transport of the unit the internal transformer will be fixed It is important to remove the corresponding fixations once the unit has been correctly placed on site and before starting with electrical connections gt PIT 4 ul PRIM INIHI tI ji wll FSITG0003A Figure 1 2 FREESUN Frame 3 Indoor Front View 10 SAFETY INSTRUCTIONS DAWED CI CRTONMAIC C EDI CI I N POWER ELECTRONICS FHEESUN 1 1 Configuration Table EXAMPLE CODE FS01000TOSAVAFRXXY FS Freesun Series 0100 100kw Output Power 0080 80kw Inverter Location Outdoor TH Isolating Inverter with Low Voltage Transformer LVT Series Transformer H High Efficiency Inverter HE and HES Series Maximum input 09 900VDC voltage 10 1000vDC Adjustable isolation between and earth Monitoring of the i Negative of the photovoltaic installation earth connected isolation Positive of the photovoltaic installation earth connected Without overvoltage protection L
31. ion P uli x an E uat ul pt Figure 7 4 Gravity centre marking Figure 7 5 With forklift pallet truck 40 TRANSPORT AND HANDLING POWER ELECTRONICS FREESUN Figure 7 6 Crane fork 7 3 Prior to connection In the rear side of the solar inverter are located the SECURITY FIXATIONS FOR TRANSPORT in both the transformer and the inductance of the inverter Before making any connections to the inverter is necessary to consider If the inverters are going to be installed side by side it is NECESSARY to REMOVE these SECURITY FIXATIONS BEFORE placing them in their final location It is ESSENTIAL to REMOVE them BEFORE CONNECTING Make sure that all fixations are properly removed and put back the rear covers of the inverter The inverter can now be placed in its final location and the connection procedure can be done as described in the installation manual attached to the inverter J FSITM0002A Figure 7 7 Security fixation for transport Frame 1 TRANSPORT AND HANDLING 41 ck H cz P 0 e m FREESUN POWER ELECTRONICS FSITM0003A Figure 7 8 Security fixations for transport Frame 2 en Y I E i RK FSITM0004A FSITM0005A Figure 7 9 Security fixations for transport Frame 3 42 TRANSPORT AND HANDLING DECLARATION OF CONFORMITY CE The Company Name POWER ELECTRONICS ESPANA S L Address C Leonardo Da Vinci 24 26 46980 Paterna Valencia Telephone 34 96 136 65 57 Fax 34 96 131
32. isor Interface CANopen Modbus RS232 RS485 USB Ethernet BOISE Modbus Protocol Modbus TCP a 2 electrically isolated programmable switched relays She hel Cupue 250VAC 8A or 30 VDC 8A Analogue Outputs 1 Analogue Output galvanically isolated Standard Outdoor Optional Indoor No Outdoor Optional Indoor Standard bed Overvoltage Protectors for Auxiliary POEM Supply yp Lightning Protections Optional Type Certification CE 2006 95 CE 2004 108 CE Safety 7 EN 62109 1 REGULATIONS EMV EN 61000 6 2 EN 61000 6 4 EN 61000 3 4 EN 61000 3 12 Designed according to BDEW MV Guideline Notes 1 Note the possible increase of the panel s voltage Voc at low temperatures 2 For copper conductors The installer must also consider factors such as length of cable for each installation environmental conditions aluminium conductors installation methods and requirements set out in current regulations applicable in the country of installation 3 In case other temperature range is required please contact with Power Electronics 4 For higher altitude consult with Power Electronics 5 In cases where the installation has the positive pole or the negative pole earth connected this protection will be disconnected 6 In T V certification process INTRODUCTION 13 FREESUN POWER ELECTRONICS 3 INSTALLATION REQUIREMENTS 3 1 Requisites for the Installation 3 1 1 Foundation The foundation must guara
33. ntee that the positioning of the inverter is solid and safe It must provide the load carrying capacity necessary to cope with the weight of the inverter Pouring and structural inspection of the foundation slab should be performed on site The inverter cabinet must be installed on a level surface The cables must be routed into the inverter from below where the plates that allows access to the DC and AC terminals The foundation must include access for them To make this possible the foundation must include a pipe or cable carrier Dimensions drawings for this input and output connections are described in Electrical Connection section FSITG0004A Figure 3 1 Installation of the Frame 1 Outdoor with concrete foundation slab 14 INSTALLATION REQUIREMENTS POWER ELECTRONICS FREESUN Cth pt LUUUTIVITTVKKKEKKKKTKKKHEKKCKKKKKKKKKKTKKKKKKKKKKKKKKKKKKKKKKKKKKKKKXK soe FSITG0005A Figure 3 2 Installation of the Frame 2 Outdoor with concrete foundation slab III IIT LT LL PEUT FSITG0006A Figure 3 3 Installation of the Frame 3 Outdoor with concrete foundation slab INSTALLATION REQUIREMENTS 15 Oo bom FREESUN POWER ELECTRONICS 3 1 2 Minimum Workspace Requirements Indoor Please be sure that the installation site meet with the minimum clearances and passage widths as described below when installing the equipment i I 755 a 500 i L FSDTD0007A Figure 3 4 General
34. r and the inductance of the inverter Before making any connections to the inverter is necessary to consider If the inverters are going to be installed side by side it is NECESSARY to REMOVE these SECURITY FIXATIONS BEFORE placing them in their final location It is ESSENTIAL to REMOVE them BEFORE CONNECTING Make sure that all fixations are properly removed and put back the rear covers of the inverter The inverter can now be placed in its final location and the connection procedure can be done as described in the installation manual attached to the inverter WARNINGS AND RECOMMENDATIONS connected the following instructions must be considered The only point in the installation where the positive or the negative pole should be grounded is in the proper inverter through the 4 pole circuit breaker that is added to that effect It is important to note that if there was another grounded connection elsewhere in the installation in the panels themselves in the String Supervisor etc the protection provided by the additional circuit breaker would have NO effect If your device has the positive or negative pole of the photovoltaic system earth Therefore it is recommended to revise periodically the insulation between the pole that is going to be grounded and the earth Like this it will be possible to detect a ground fault unwanted in other points of the installation This will prevent the circuit breaker from providing inappropriate pro
35. rol Interface TIERE RN ERE IN 24VDC 3x0 5mm SCREENED Ej E i STRING SUPERVISOR STRING SUPERVISOR STRING SUPERVISOR D wn cceccecccecccecc lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt Al Figure 5 8 General communications layout ELECTRICAL CONNECTION 29 ck H se P GA e m FREESUN POWER ELECTRONICS 5 4 1 Details for connection between Freesun and String Supervisor The Freesun and the String Supervisor are connected by a CAN interface The CAN interface connector is J900 and it is located in the control board of the Freesun Connections of String Supervisor with the Freesun inverter are described in the following drawings Case A J900 connector is a DB9 connector FREESUN een LVT SERIES POWER ELECTRONICS CONTROL BOARD J900 N C NOT CONNECTED CAN L GND N C NOT CONNECTED N C NOT CONNECTED GND CAN H N C NOT CONNECTED N C NOT CONNECTED oo o GoOo m o jN il TWISTED SHIELDED LS 2x2x0 75mm HVDC 24vac OVde 24V dc OVde VDC IN VDC OUT STRING SUPERVISOR STRING SUPERVISOR YDC IN VDC OUT POWER ELECTRONICS POWER ELECTRONICS iili ll iilii Il STRING STRING STRING STRING STRING STRING STRING STRING STRING STRING STRING STRING Trt Tr I INI II TTT TI TTT T FSDTR0002AI Figure 5 9 Connection with string supervisor using a DB9 connector C
36. tection due to eventual uncontrolled ground leakages 6 SAFETY INSTRUCTIONS POWER ELECTRONICS FREESUN In this manual safety messages are classified as follows N WARNING If possible do not remove the solar inverter cover while the power is applied or the unit is in operation Otherwise electric shock could occur If possible do not run the solar inverter with any of the covers removed Otherwise you may get an electric shock due to the high voltage terminals inside the inverter Do not open the inverter doors except when necessary for installation or maintenance even in such cases remove the input power if possible Otherwise you may access the charged circuits and get an electric shock Operate the switches with dry hands Otherwise you may get an electric shock Do not use cables with damaged insulation Otherwise you may get an electric shock Do not subject the cables to abrasions excessive stress heavy loads or pinching Otherwise you may get an electric shock N CAUTION Install the inverter on a non flammable surface Do not place flammable material nearby Otherwise fire could occur Disconnect the input power if the solar inverter gets damaged Otherwise it could result in a secondary accident or fire After the input power is applied or removed the inverter will remain hot for a couple of minutes Touching hot parts may result in skin burns Do not apply power to a damaged inverter or to an inverter wit
37. the situation properly The string supervisor has two fuses for each string that disconnects the panels forming this string in case of overload If the fuse is blown it would be detected by the supervisor string because the current of this string would be zero The string supervisor provides a digital input to detect the theft of panels The string supervisor has one on load disconnector already built in that allows a complete isolation of the string from the installation by switching off both the positive and the negative poles This is very useful when maintenance operations are required but without stopping energy production 32 ELECTRICAL CONNECTION POWER ELECTRONICS FREESUN FSITG0011A Figure 5 12 String Supervisor External View External dimensions for string supervisor are described in the following drawing ck H cz P 0 e m FSDTD0013A Figure 5 13 String Supervisor dimensions ELECTRICAL CONNECTION 33 FREESUN POWER ELECTRONICS In the following drawing main components of the string supervisor are shown HALL EFFECT FUSE TRANSFORMER 1 0 E R TI 8 0 2 OVERVOLTAGE amp PROTECTOR ON LOAD ui PE DISCONNECTOR o0 HVDC CONTROL BOARD O CAN COMMUNICATION O RS485 COMMUNICATION nt HVDC FUSE 1 2 8 FSDTP0001AI Figure 5 14 String Supervisor components CONTROL BOARD TERMINAL TERMINAL BREAKER STRING FUSES STRING FUSES OVERVOLTAGE PROTECTOR
38. unit is connected the LED FAULT is flashing while the inverter is synchronizing Once the inverter is synchronized the LED will turn off In this way the inverter is completely connected in both AC and DC sides After that you can proceed to start the unit by pressing the START button of the graphic display unit if it is in local mode or with the key switch select ON position inside the cabinet The Freesun will now start automatically after checking the grid voltage and frequency parameters Finally the motorized DC breaker is activated automatically and connects the PV generator COMMISSIONING 37 ck H cz P 0 e m FREESUN POWER ELECTRONICS 38 T TRANSPORT AND HANDLING Only the transport methods described in the installation guide are permissible please follow the transport requirements here described Any other transport method or system could damage the unit 7 1 Weights and dimensions Freesun Please note the heavy weight of the inverter To assist with transporting the data sheet of the dimensions and weight must be considered N CAUTION Heavy weight of the cabinet unit Danger of tipping during transport The cabinet must always be transported upright REFERENCE HEIGHT H WIDTH W eee ng FS000 FS0020 FS0025 FS0030 1600 840 FS0035 FSDTD0001A Figure 7 1 Freesun Frame 1 dimensions TRANSPORT AND HANDLING POWER ELECTRONICS FS0040 FS0050 DIMENSIONS mm HEIGHT
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