AEC TOUGH Series User manual

Allis Electric Co., Ltd.
Installation Manual
Single-Phase Grid-Connected
Photovoltaic Inverter
TOUGH - Series

All specifications are subject to change without prior notice. Ver. 1.1

These applied symbols are important for human safety. Violation of
warnings may result in injury to persons or cause death.
WARNING！
RISK OF ELECTRIC SHOCK
WARNING！
RISK OF ELECTRIC SHOCK, ENERGY STORAGE TIMED
DISCHARGE
WARNING！
RISK OF DANGER
WARNING！
HOT SURFACE
REFER TO THIS OPERATIONAL MANUAL
THIS MANUAL IS COPYRIGHT PROTECTED.
Copyright©2012 TOUGH-series Products. All rights reserved
by ALLIS Electronic Co., Ltd. Unless otherwise specified, no
part of this manual may be reproduced or utilized in any form
or by any means, including electronic, mechanical or
photocopying, without permission in writing from either Allis
or Allis's legal representative.

Safety Notes
General Cautions
Read and follow all instructions in this manual. Failure to comply
with the warnings in this manual may violate safety standards. The
manufacturer assumes no liability for the customer’s failure to
comply with these requirements.
Installation of the device must be in accordance with the relevant
safety regulations. Correct grounding and over-current protection
must be provided to ensure operational safety.
Pay attention to the high temperature components and sharp edges.
The temperature of the heat sinks on the outside of the device can
reach over 70°C in normal operation. There is the risk of burn injury
when these parts are touched.
Warning, Risk of electric shock
Personnel must remove all conductive jewelry or personal
equipment prior to installation or service of the device, parts,
connectors, and/or wiring.
Only the licensed and qualified electricians are allowed to perform
the installation, wiring, maintenance or modification on the device.
Switch off the circuit breakers before installation and wirings. Never
stand on a wet location when working on installation and wirings.
Even when no external voltage is presented; the inverter can still
contain high voltages and the risk of electrical shock. Allow 5 minutes
for the inverter to discharge completely after disconnecting the AC
and DC sources from the inverter.
The inverter must be provided with an equipment-grounding
conductor connected to the AC ground.
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Maintenance and Clean
Each inverter is well calibrated before shipment and needs no
additional maintenance during normal operation.
Alterations are not to be made and no tampering with the assembly
in the inverter without the manufacturer’s authorization unless
specified elsewhere in this manual. They may result in injury, electric
shock, or fire and void the warranty.
The inverter contains no user serviceable parts inside. Only trained
staff is authorized to repair the unit. Please contact the specialized
dealer or system technician for further examination.
Wipe the enclosure and display lens with a soft cloth. Do not use
aggressive detergent or cleaning solvents.
Switch the DC disconnect on and off at least once per month in order
to clean the contacts of switch.
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Contents
1 INTRODUCTION ............................................................................ 1
1.1 GENERAL ........................................................................................ 1
1.2 SPECIFICATIONS ............................................................................. 2
1.3 FUNCTIONS AND FEATURES ............................................................ 7
1.4 ACCESSORIES .................................................................................. 8
2 INSTALLATION .............................................................................. 9
2.1 PLACEMENT ................................................................................... 9
2.2 MOUNTING ................................................................................... 10
2.2.1 SAFETY NOTES ............................................................................................. 10
2.2.2 INSTALL INVERTER ON WALL .................................................................... 11
2.2.3 CHECK INSTALLATION STATUS ................................................................... 14
2.3 WIRING THE INVERTER ................................................................ 15
2.3.1 SAFETY NOTES ............................................................................................. 15
2.3.2 INTRODUCTION ............................................................................................ 15
2.3.3 DC INPUT WIRING ...................................................................................... 16
2.3.4 COM LINE CONNECTION ........................................................................... 19
2.3.5 AC OUTPUT WIRING................................................................................... 23
3 OPERATION ................................................................................. 25
3.1 OVERVIEW.................................................................................... 25
3.2 LED INDICATION .......................................................................... 26
3.3 BUTTONS ON PANEL ..................................................................... 27
3.4 LCD DISPLAY ............................................................................... 27

3.4.1 OPERATIONAL STATUS ................................................................................ 28
3.4.2 CHECK ERROR MESSAGE ............................................................................ 30
3.4.3 SETTING BEFORE OPERATION.................................................................... 31
3.4.4 INFORMATION .............................................................................................. 33
3.5 DESCRIPTIONS OF ERROR MESSAGES ........................................... 34
3.6 TROUBLESHOOTING ..................................................................... 38
4 TECHNICAL DOCUMENTATION ............................................... 43
4.1 OUTLINE DRAWING ...................................................................... 43
4.2 EFFICIENCY .................................................................................. 44
4.3 MPP EFFICIENCY ......................................................................... 46
4.4 DE-RATING OPERATION ............................................................... 47

List of Figures
Fig 1: Grid connected solar system overview ............................................. 1
Fig 2: Accessories in the package ..................................................................... 8
Fig 3: Hanging surface ....................................................................................... 10
Fig 4: Clearances required for installation ................................................ 11
Fig 5: Fasten the mounting bracket ............................................................. 12
Fig 6: Hook the inverter on the mounting bracket ................................. 12
Fig 7: Fasten the screws ..................................................................................... 13
Fig 8: Enclosure bottom view .......................................................................... 15
Fig 9: Assemble your DC terminals - step 1 ............................................... 17
Fig 10: Assemble your DC terminals - step 2 ............................................ 17
Fig 11: Assemble your DC terminals - step 3 ............................................ 18
Fig 12: Complete your DC terminals ............................................................ 18
Fig 13: RS485 pins assignment ....................................................................... 19
Fig 14: Remove the RS485 port housing .................................................... 20
Fig 15: Assemble the communication cable gland ................................. 20
Fig 16: Assemble the communication cable .............................................. 21
Fig 17: Lock the RS485 port housing ........................................................... 21
Fig 18: Fasten the waterproof cable gland nut ....................................... 21
Fig 19: Multi-inverter wiring by RS485 ...................................................... 22
Fig 20: Assemble your AC terminals ............................................................. 23
Fig 21: Check the phase and ground terminals ....................................... 24
Fig 22: Fasten the gland nut ............................................................................ 24
Fig 23: Push the connector until the latch is positioned ...................... 24
Fig 24: Overview front panel of the inverter ............................................ 25
Fig 25: Outline drawing ..................................................................................... 43
Fig 26: Euro. Efficiency of the TOUGH-3000 = 95.83% ........................ 44
Fig 27: Euro. Efficiency of the TOUGH-3300 = 96.1% ........................... 44
Fig 28: Euro. Efficiency of the TOUGH-4000 = 96.5% ........................... 45

Fig 29: Euro. Efficiency of the TOUGH-5000 = 96.6% ........................... 45
Fig 30: MPP Efficiency of the TOUGH-SERIES .......................................... 46
Fig 31: DC power curve of the TOUGH-3000 ............................................ 47
Fig 32: DC power curve of the TOUGH-3300 ............................................ 47
Fig 33: DC power curve of the TOUGH-4000 ............................................ 48
Fig 34: DC power curve of the TOUGH-5000 ............................................ 48
Fig 35: Temperature de-rating curve of the TOUGH-3000 ................. 49
Fig 36: Temperature de-rating curve of the TOUGH-3300 ................. 49
Fig 37: Temperature de-rating curve of the TOUGH-4000 ................. 50
Fig 38: Temperature de-rating curve of the TOUGH-5000 ................. 50

1
1 Introduction
1.1 General
The grid-connected inverter converts DC power yielded from solar array
into AC power for household consumption. Furthermore, the remaining AC
power can be transmitted and sold back to the utilities company. The
inverter operates intelligently under normal conditions and provides no
backup power in case of power cut. The configuration is straightforward as
shown below. Connect the PV wires from floating (ungrounded) PV array to
the DC input of the inverter; also, connect the AC output to the service
entrance. Please consult with your installer for PV array ratings and
external protective devices if the electrical codes are stipulated locally.
Fig 1: Grid connected solar system overview

2
1.2 Specifications
Model TOUGH-3000
Output Data (AC)
Maximum AC Output Power 3000 VA
Maximum AC Output Current 14.5 a.c.A
Nominal AC Voltage 230 a.c.V
Grid AC Frequency 50 / 60 Hz, auto-selection
Power Factor > 0.99 @ 20% load
Reactive Power Factor 1 or adjustable from -0.9 to +0.9**
Total Harmonic Distortion < 3%
Max. output fault current (Inrush) 26 Apeak / 200 μs
Max. output overcurrent protection 20 A
AC connection / Grid forms Single-Phase / TN-C, TN-S, TN-C-S
Input Data (DC)
Maximum DC Power 3200 W
Maximum DC Voltage 550 d.c.V
MPP Tracking Voltage Range 150-500 d.c.V
Peak Power Tracking Voltage 200-460 d.c.V
Maximum DC Input Current (IscPV) 16 d.c.A
Max. number of MPP Trackers 1
Efficiency
Maximum Efficiency 96.5%
Euro. Efficiency 95.8%
Consumption:
Operating (standby) / Night < 12 W / < 0.2 W

3
General Specification
Dimensions (W x H x D) in mm 405 x 442 x 152
Weight 18 Kg
Cooling Concept Free Convection
Acoustic Noise Level < 35 dB(A)
Maximum Operating Temperature -20 to +45 °C (without derating)
Ambient Temperature Range -25 to +60 °C
Storage / Transportation Condition
Relative Humidity 4 to 100%
Storage / Transportation Condition
Operating Altitude 2000 m
Pollution Degree PD3
Protection Class of Enclosure IP65
Protection Class Class I
Overvoltage Category OVCⅡ(PV) / OVCⅢ(Mains)
Topology Transformerless
Features
DC Connection MC4, Tyco
DC Disconnect yes
AC Connection AC connectors
Display LCD 16X2 screen
Communication Interface RS232, RS485；Bluetooth (Option)
EMC & Low Voltage Directives 2004/108/EC & 2006/95/EC
Standards IEC/EN 62109-1/-2, VDE-AR-N 4105
Warranty 5 years

4
Model TOUGH-3300
TOUGH-4000 TOUGH-5000
Output Data (AC)
Maximum AC Output Power 3300 VA 4000 VA 5000 VA*
Maximum AC Output Current 16.5 a.c.A 20 a.c.A 22 a.c.A*
Nominal AC Voltage 230 a.c.V
Grid AC Frequency 50 / 60 Hz, auto-selection
Power Factor > 0.99 @ 20% load
Reactive Power Factor 1 or adjustable from -0.9 to +0.9**
Total Harmonic Distortion < 3%
Max. output fault current (Inrush) 26 Apeak / 200 μs
Max. output overcurrent protection 20 A
AC connection / Grid forms Single-Phase / TN-C, TN-S, TN-C-S
Input Data (DC)
Maximum DC Power 3600 W 4300 W 5300 W
Maximum DC Voltage 650 d.c.V
MPP Tracking Voltage Range 150-500 d.c.V
Peak Power Tracking Voltage 200-460 d.c.V
Maximum DC Input Current (IscPV) 2 x 10 d.c.A 2 x 13 d.c.A 2 x 15 d.c.A
Max. number of MPP Trackers 2
Efficiency
Maximum Efficiency 96.5% 96.8% 96.9%
Euro. Efficiency 96.1% 96.5% 96.6%
Consumption:
Operating (standby) / Night < 12.5 W / < 0.2 W
*
It is limited to 4600VA and 20A in accordance with the Germany
Standard VDE-AR-N 4105.
**
Adjustable from 0.95 overexcited to 0.95 underexcited with
VDE-AR-N 4105.

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General Specification
Dimensions (W x H x D) in mm 405 x 442 x 165
Weight 25.8 Kg
Cooling Concept Free Convection
Acoustic Noise Level < 35 dB(A)
Maximum Operating Temperature -20 to +55 °C (without derating)
Ambient Temperature Range -20 to +60 °C
Storage / Transportation Condition
Relative Humidity 4 to 100%
Storage / Transportation Condition
Operating Altitude 2000 m
Pollution Degree PD3
Protection Class of Enclosure IP65
Protection Class Class I
Overvoltage Category OVCⅡ(PV) / OVCⅢ(Mains)
Topology Transformerless
Features
DC Connection MC4, Tyco
DC Disconnect yes
AC Connection AC connectors
Display LCD 16X2 screen
Communication Interface RS232, RS485；Bluetooth (Option)
EMC & Low Voltage Directives 2004/108/EC & 2006/95/EC
Standards IEC/EN 62109-1/-2, VDE-AR-N 4105
Warranty 5 years

6
Adjustable voltage, Frequency and Reconnection Settings
Setting VDE-AR-N 4105
Range Default
Over-frequency (Hz) 50.05~51.50
(60.05~61.50)*
51.5
(61.5)*
Over-frequency disconnection time (cycle) 1~10 8
Under-frequency (Hz) 47.50~49.95
(57.50~59.95)*
47.50
(57.50)*
Under-frequency disconnection time (cycle) 1~10 8
Over-voltage (Vac) 235~264.5 264.5
Over-voltage disconnection time (cycle) 1~10 8
Under-voltage (Vac) 184~225 184
Under-voltage disconnection time (cycle) 1~10 8
DC injection tripping current (A) 0.1~1.0 1.0
DC injection
disconnection time (cycle) 1~150 8
Insulation resistance trip setting (MΩ) 0.5~10 0.5
PV start voltage (Vdc) 150~500 150
Reconnect delay** (s) 5~300 60
*
This inverter product is compatible on the frequency of 50Hz or 60Hz.
** Once a grid failure occurs, the inverter waits 5~300 seconds before the
next connection to the utility grid. The default setting is 60 seconds for
VDE-AR-N 4105.

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1.3 Functions and Features
 DSP (Digital Signal Processor) makes use of the advanced digital
control technology to enhance the conversion efficiency and the added
functions.
 Conformity to the EMC, Low Voltage Directives and Standards, e.g.
2004/108/EC, 2006/95/EC, IEC/EN 62109-1/-2 and VDE-AR-N 4105.
 Single/Dual MPPT (Maximum power point tracking), the range of
MPPT: 150~500 Vdc.
 Maximum power exports @ 220~240 Vac.
 Maximum efficiency: higher than 96.5%.
 LCD displays the power status and the real-time information.
 Low acoustic noise while the inverter operates.
 Low loss unipolar configuration with high-frequency switching IGBT.
 Waterproof and quickly-installed connectors used.
 Monitor the power information and the system settings via a
computer, the monitoring software and RS232 / RS485 / Bluetooth
(optional) interfaces (please refer to the Installation Manual).
 The power generation system is interactive and complementary to the
utility’s power. When the power generation is insufficient, it can be
supplied by the local utility’s power; when power cut happens,
disconnect the power automatically to maintain the personnel safety.

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1.4 Accessories
Please check the inverter and accessories in the package. If there is some
part incomplete or any pages missing from the manual, please contact the
authorized agent. Please check the following items in the box:
A. Photovoltaic Inverter x 1
B. Mounting Bracket x 1
C. Female Cable Coupler Plus Key x 1 and Minus Key x 1
* For Dual MPPT：Plus Key x 2 and Minus Key x 2
D. AC Female Connector x 1
E. Fixing Screws (bet. the inverter and bracket) x 2
F. Operation Manual (incl. warranty page) x 1
Fig 2: Accessories in the package
A. B.
C.
D. E. F.

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2 Installation
2.1 Placement
Please take the following points into consideration when installing the
inverter and selecting the installation location:
 A solid and vertical wall is essential; not to hand it on a forward-tilting
surface. The backward-tilting angle must be less than 30°.
 The installation location of the inverter must conform to the size and
weight specifications (See the technical information on 1.2.).
 The inverter installation location must have the appropriate amount
of space and be kept clear, and the inverter can be safely operated
without the assistance of auxiliary tools (such as ladder or lift).
 The installation location of the inverter must have at least 20 cm of
space. The environmental temperature must be kept at -25 °C ~ 60 °C.
 To obtain the best conversion efficiency, the DC and AC power
connection prefer the shortest distance. If the distance exceeds 20m,
it’s recommended that the diameter is increased (according to the
specifications of this inverter, the standard diameter of DC and AC
power wires are 12 AWG.).
 In order to select the appropriate installation location for the inverter,
please see the outline drawing.
 The inverters with IP65 rating can be installed outdoors. However, it’s
recommended to avoid direct sunlight and rain. If it can’t be avoided,
please install a rain shield to extend the lifetime of the inverter.
In theory this IP65 unit can be used in pollution degree
4. However, it is suggested to provide with means to
reduce the micro-environment to pollution 1, 2 or 3.

10
Fig 3: Hanging surface
2.2 Mounting
2.2.1 Safety Notes
Don’t remove the external cover of the inverter. No parts inside the
inverter are to be maintained by the user. If necessary, only qualified
maintenance staff can carry out; The
solar panel exposed to sunlight
supplies DC power. Pay attention to electric shock when connecting
the DC power to the inverter.
The inverter (not stand-
alone type) is designed to connect in parallel
with the utility network. In order to avoid damage,
the AC output
can’t be connected to a power generator or the like.
Heat will generate when the inverter operates. Don’t touch the heat
sink or on top of the enclosure to avoid injury due to the hot surface.
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