AEG Protect PV User manual

Protect PV - Solar Inverters
Installation Manual
AEG Power Solutions GmbH
Revision: 01
Date: 2011-05-25
InstallationManual
8000038781_00_BAL_en

Contents
1. Safety and Conformity 2
Safety Information 2
Hazards of PV Systems 3
PV Load Switch 3
Conformity 4
Approvals and Certifications 4
2. Introduction 5
Introduction 5
Installation Sequence 6
Overview of Inverter 7
3. Installation 8
Installation Dimensions and Patterns 8
Mounting the Inverter 10
Removing the Inverter 11
Opening and Closing the Inverter 12
AC Grid Connection 14
PV Connection 16
Auxiliary Input/Output 17
Autotest Procedure - Italy Only 17
4. Start-up and Check of Settings 18
Start-up and Check of Settings 18
Troubleshooting 21
Master Mode 21
5. Technical Data 23
Technical Data 23
Cable Requirements 25
Wiring Diagram 28
Auxiliary Interface Specifications 29
RS485 Communication Board Connections 31
Contents
8000038781_00_BAL_en / L00410564-01_02 1

1. Safety and Conformity
1.1. Safety Information
All persons installing and servicing inverters must be:
• Trained and experienced in general safety rules for work on electrical equipment
• Familiar with local requirements, rules and regulations for the installation
Safety information important for human safety. Violation of warnings may result in
injury to persons or death.
Information important for the protection of property. Violation of this type of in-
formation may cause damage and loss of property.
Note:
Useful additional information or “Tips and Tricks” on specific subjects.
Read this before installing, operating or maintaining the inverter.
1. Safety and Conformity
2 8000038781_00_BAL_en / L00410564-01_02
1

Before installation:
Check for damage to inverter and packaging. If in doubt, contact the supplier be-
fore installing the inverter.
Installation:
For optimum safety, follow the steps described in this manual. Keep in mind that
the inverter has two voltage carrying sides; the PV input and the AC grid.
Disconnecting the inverter:
Before starting work on the inverter, switch off AC grid at the mains switch and PV
using the PV load switch. Ensure that the device cannot be unintentionally recon-
nected. Use a voltage tester to ensure that the unit is disconnected and voltage
free. The inverter can still be charged with very high voltage at hazardous levels
even when it is disconnected from grid/mains and solar modules. Wait at least 30
min. following disconnection from grid and PV panels before proceeding.
Maintenance and modification:
Only authorised personnel are allowed to repair or modify the inverter. To ensure
optimum personal safety, only original spare parts available from the supplier
should be used. If non-original spare parts are used, the compliance with CE
guidelines in respect of electrical safety, EMC and machine safety is not guaran-
teed.
Also observe the danger of burn injury. The temperature of the cooling racks and
components inside the inverter may exceed 70ºC.
Functional safety parameters:
Never change the parameters of the inverter without authorisation from the local
energy supply company and instructions from AEG PS.
Unauthorised changes of functional safety parameters may cause injury or acci-
dents to people or inverter. Additionally it will lead to the cancellation of all inver-
ter operating approval certificates.
The AEG PS inverters are all designed according to the German VDE0126-1-1
(February 2006) standard, which includes an insulation test between PV array(s)
and Earth, and a type B, RCMU according to DIN VDE 0100-712.
1.2. Hazards of PV Systems
Very high DC voltages are present in the system even when the AC grid is disconnected. Faults
or inappropriate use may lead to electric arcing. Do not work on the inverter while it has cur-
rent connected to it.
The short-circuit current of the photovoltaic panels is only slightly higher than the maximum op-
erating current and depends on the level of solar irradiation.
1.3. PV Load Switch
Illustration 1.1: Protect PV PV Load Switch
The inverter has been equipped with a PV
load switch (1) for safe disconnection of DC
current.
1. Safety and Conformity
8000038781_00_BAL_en / L00410564-01_02 3
1

1.4. Conformity
1.4.1. Approvals and Certifications
For more information, go to the download area at www.aegps.com/solarinverters, Approvals
and Certifications.
CE marking - This certifies the conformity of the equipment with the regula-
tions which apply in accordance with the directives 2004/108/EC and
2006/95/EC.
1. Safety and Conformity
4 8000038781_00_BAL_en / L00410564-01_02
1

2. Introduction
2.1. Introduction
This manual explains the installation and setup of the Protect PV solar inverter, for the installa-
tion technician.
Illustration 2.1: Protect PV 10 kW, Protect PV 12.5 kW, Protect PV 15 kW
CE marking - This certifies the conformity of the equipment with the regula-
tions which apply in accordance with the directives 2004/108/EC and
2006/95/EC.
The Protect PV inverter series comprises:
Protect PV
Protect PV easy
Common features of the Protect PV variants:
• Output rating of 10 kW, 12.5 kW or 15 kW
• IP 54 enclosure
• PV load switch
• MC4 connectors
2. Introduction
8000038781_00_BAL_en / L00410564-01_02 5
2

Protect PV
variant
User interface Ancillary services DC power rat-
ing
Local Web Server Power Level Adjust-
ment,
Primary Frequency
Control
Ride Through Fault Ride Through
Reactive Power
10 kW
12.5 kW
15 kW
Protect PV ✓ ✓ ✓ ✓ ✓
Protect PV
easy
✓ ✓ ✓ ✓ ✓ ✓
Table 2.1: Differing Features of Protect PV Variants
Product Label
Illustration 2.2: Product Label
The product label on the side of the inverter
shows:
• Inverter type
• Important specifications
• Serial number, see (1), for identifi-
cation by AEG PS
2.1.1. Installation Sequence
1. Read the installation manual. Pay special attention to the section Important Safety In-
formation .
2. Install the inverter according to the section
Installation Dimensions and Patterns and
the section Mounting the Inverter .
3. Open the inverter according to the section Opening and Closing the Inverter .
4. Install AC according to the section AC Grid Connection .
5. Install PV. Remember to use the terminal block to establish parallel connection (if re-
quired), as described in the section PV Connection . The inverter has auto-detection.
6. Install Auxiliary input according to the section Connection of Peripheral Units .
7. Close the inverter according to the section Opening and Closing the Inverter .
8. Turn on AC at the mains switch.
9. Set language, time, date, installed PV power and country:
-For setup via the integrated Web Server, see the Protect PV User Manual,Web
Server Quick Guide section
-For setup via the display, see the section Start-up and Check of Settings in
this manual.
10. Turn on PV by turning the PV load switch on.
11. Verify the installation by comparing with the auto-detection result in the display, as de-
scribed in the section PV Connection .
12. The inverter is now ready for operation.
2. Introduction
6 8000038781_00_BAL_en / L00410564-01_02
2

2.1.2. Overview of Inverter
Illustration 2.3: Overview of AEG PS Protect PV inverter
Live Part
1. AC Connection Area
2. DC Connection Area
3. Terminal block for parallel connection
4. Auxiliary output: Potential free relay
PELV (Safe to touch)
5. Auxiliary interface: RS485
6. Auxiliary interface: Temperature, Irradiation, Energy meter (SO)
7. Auxiliary interface: Ethernet
Other
8. DC-switch
The inverter can also be configured via the Web Server . For further information refer to the
Web Server User Manual.
2. Introduction
8000038781_00_BAL_en / L00410564-01_02 7
2

3. Installation
3.1. Installation Dimensions and Patterns
Note:
When choosing the installation place, ensure that all labels are visible at all times.
For details refer to the section Specifications .
Avoid constant stream of water.
Avoid direct sunlight.
Ensure adequate air flow.
Ensure adequate air flow.
Mount on non-flammable surface.
Mount upright on vertical surface.
Prevent dust and ammonia gases.
3. Installation
8 8000038781_00_BAL_en / L00410564-01_02
3

Illustration 3.1: Safe Distances
Observe these distances when installing one or more inverters. One row mounting is recom-
mended. Contact the supplier for information on mounting in more rows.
Illustration 3.2: Wall Plate
Note:
Use of the wall plate delivered with the inverter is mandatory.
Use screws that can safely carry the weight of the inverter. The inverter must be aligned and it
is important that the inverter is accessible at the front to allow room for servicing.
3. Installation
8000038781_00_BAL_en / L00410564-01_02 9
3

3.2. Mounting the Inverter
For the safe handling of the inverter, two people must carry the unit, or a suitable
transport trolley must be used. Safety boots must be worn.
Illustration 3.3: Mounting the Inverter
Tilt the inverter as shown in the illustration
and place the top of the inverter against the
mounting bracket. Use the two guides (1) at
the top plate to control the inverter horizon-
tally.
Illustration 3.4: Secure the inverter
Lift the inverter upwards (2) over the top of
the mounting plate until the inverter tilts to-
wards the wall (3).
3. Installation
10 8000038781_00_BAL_en / L00410564-01_02
3

Illustration 3.5: Place Inverter in Mounting
Bracket
Place the lower part of the inverter against
the mounting bracket.
Illustration 3.6: Fasten screws
Lower (4) the inverter and make sure that
the hook of the inverter base plate is placed
in the lower part of the mounting bracket
(5). Check that it is not possible to lift the
bottom of the inverter away from the mount-
ing bracket.
(6) Fasten the screws on either side of the
wall plate to secure the inverter.
3.3. Removing the Inverter
Loosen the locking screws on either side of the inverter.
3. Installation
8000038781_00_BAL_en / L00410564-01_02 11
3

Removal is performed in the reverse order of mounting. With a firm grip at the lower end of the
inverter, lift the inverter approximately 20 mm vertically. Pull the inverter slightly away from the
wall. Push upwards at an angle until the wall plate releases the inverter. Lift the inverter away
from the wall plate.
3.4. Opening and Closing the Inverter
Remember to observe all ESD safety regulations. Any electrostatic charge must be
discharged by touching the grounded housing before handling any electronic com-
ponent.
Illustration 3.7: Loosen Front Screws
Use a TX 30 screwdriver to loosen the two
front screws. Turn the screwdriver until the
screws pop up. They are secured with a
spring and cannot fall out.
3. Installation
12 8000038781_00_BAL_en / L00410564-01_02
3

Illustration 3.8: Open the Inverter
Push the front cover upwards. When a slight
resistance is felt, give the front cover a tap
on the bottom to snap it into holding posi-
tion. It is recommended to use the holding
position instead of dismounting the front
cover completely.
Illustration 3.9: Close the Inverter
To close the inverter, hold on to the lower
end of the front cover with one hand and
give it a tap on the top until it falls into
place. Guide the front cover into place and
fasten the two front screws.
3. Installation
8000038781_00_BAL_en / L00410564-01_02 13
3

Illustration 3.10: Fasten Front Screws and En-
sure Proper PE Connection.
The two front screws are the PE connection to the front cover. Make sure that
both screws are mounted and fastened with the specified torque.
3.5. AC Grid Connection
Note:
When choosing the installation place, ensure that all labels are visible at all times.
For details refer to the section Specifications .
3. Installation
14 8000038781_00_BAL_en / L00410564-01_02
3

Illustration 3.11: AC Cable Wire Strip
Legend
1 Blue cable - Neutral
2 Yellow/green cable - Earth
The illustration shows the stripping of insulation of all 5 wires of the AC cable. The length of the
PE wire must be longer than the mains and neutral wires.
Illustration 3.12: AC Connection Area
1. Verify the inverter matches the grid-voltage
2. Release main circuit breaker and make precautions to prevent reconnection.
3. Open the front cover.
4. Insert the cable through the AC gland to the terminal blocks.
5. The three mains wires (L1, L2, L3) and the Neutral wire (N) are mandatory and must
be connected to the 4-pole terminal block with the respective markings.
3. Installation
8000038781_00_BAL_en / L00410564-01_02 15
3

6. The Protective Earth wire (PE) is mandatory and must be connected directly to the
chassis PE terminal. Insert the wire and fasten the screw to secure the wire.
7. All wires must be properly fastened with the correct torque. See the section Technical
Data, Torque Specifications for Installation .
8. Close the front cover, and remember to verify that both front screws are applied with
the correct torque to obtain PE connection.
9. Close main circuit breaker.
For safety, check all wiring. Connecting a phase wire to the neutral terminal may
permanently damage the inverter. Do not remove the short circuit bridge at (1).
3.6. PV Connection
Note:
When choosing the installation place, ensure that all labels are visible at all times.
For details refer to the section Specifications .
Do NOT connect PV to earth!
Use a suitable voltmeter that can measure up to 1000 V DC.
1. First verify the polarity and maximum voltage of the PV arrays by measuring the PV
open circuit voltage.The PV open circuit voltage must not exceed 1000 V DC.
2. Measure the DC voltage between the plus-terminal of the PV array and Earth (or the
green/yellow PE cable). The voltage measured should approximate zero. If the voltage
is constant and not zero there is an insulation failure somewhere in the PV array.
3. Locate and fix the failure before continuing.
4. Repeat this procedure for all arrays. It is allowed to distribute the input power on the
inputs unevenly, presuming that:
• The nom. PV power of the inverter is not exceeded (10.3 / 12.9 / 15.5 kW).
• The individual input is not exceedingly loaded, and not more than 6000 W.
• The maximum short circuit current of the PV modules at STC (Standard Test
Conditions) must not exceed 12 A per input.
Illustration 3.13: DC Connection Area
On the inverter turn the PV load switch into
off position. Connect the PV cables by means
of MC4 connectors. Ensure correct polarity!
The PV load switch can now be switched on
when required.
3. Installation
16 8000038781_00_BAL_en / L00410564-01_02
3

When unmated the MC4 connectors are not IP54. The intrusion of moisture may
occur in the following situations:
1. The inverter runs in Master/Slave operation and only one or two PV in-
puts are in use. In this case, the other inputs are not connected to PV
and they are therefore open to intrusion.
2. Not all PV inputs are connected.
3. PV connectors are not fitted; for example in case of disconnection of
parts of a PV plant over a longer period of time.
In situations where the PV connectors are not fitted, a seal cap must be mounted
(included in the scope of the delivery). All inverters with MC4 connections are de-
livered with seal caps on inputs 2 and 3. During installation, the seal caps of those
inputs that are to be used are discarded.
Note:
The inverter is protected against reversed polarity but it will not generate power until the po-
larity is corrected. To achieve optimum production, the open circuit voltage (STC) of the PV
modules must be lower than the max. input voltage of the inverter (see the specifications),
multiplied with a factor of 1.13. UOC, STC x 1.13 ≤ UMAX, inv
3.7. Auxiliary Input/Output
Note:
When choosing the installation place, ensure that all labels are visible at all times.
For details refer to the section Specifications .
The inverter has the following auxiliary input/output:
• 2 x RJ45 for RS485
• 2 x RJ45 for Ethernet
• 1 x 8 pole terminal block for RS485
• 1 x 10 pole terminal block for
-PT1000 temperature sensor input x 3
-Irradiation sensor input
-Energy meter (S0) input
• 1 x 2 pole terminal block for relay outputs
Refer to the specifications for an overview of the communication board and to the inverter user
manual for details regarding auxiliary input configuration via the display.
3.8. Autotest Procedure - Italy Only
An automatic test of the inverter can be initialised by activating the Inverter Autotest Software
in the display. On the display find [Setup → Setup details → Autotest] and press OK. The autot-
est of the inverter will now start.
The inverter autotest manual can be obtained from the inverter manufacturer.
3. Installation
8000038781_00_BAL_en / L00410564-01_02 17
3

4. Start-up and Check of Settings
4.1. Start-up and Check of Settings
Note:
Due to the advanced functionalities of the inverter, it may take up to 10 seconds before the
display becomes available after power up.
Note:
For the version the first start-up and check of settings can also be performed via the integra-
ted Web Server. For further details, refer to the Web Server User Manual.
The inverter is shipped with a predefined set of settings for different countries. All country spe-
cific limits are stored in the inverter and must be selected at installation. It is always possible to
see the applied country limits in the display. The inverter accounts for daylight saving automati-
cally.
After installation, check all cables and then close the inverter.
Turn on AC at the mains switch.
When prompted by the display select language. This selection has no influence on the operating
parameters of the inverter and is not a country selection.
Illustration 4.1: Select Language
The language is set to English at initial start-
up. To change this setting press the OK but-
ton. Press ‘
▼
’ to scroll down through the
languages. Select language by pressing ‘OK’.
Note:
To use the default language (English) simply press the 'OK' button twice to select and ac-
cept.
4. Start-up and Check of Settings
18 8000038781_00_BAL_en / L00410564-01_02
4

Illustration 4.2: Set Time
Set time as prompted by the display. Press
'OK' to select number. Press ‘
▲
’ to scroll up
through the numbers. Select by pressing
'OK'.
The clock is 24-hour format.
Note:
It is very important to set the time and date accurately as the inverter uses this for logging.
If a wrong time/date is accidentally set, correct it immediately in the set date and time menu
[Setup → Inverter details → Set date and time].
Illustration 4.3: Set Date
Set date as prompted by the display. Press
'OK' to select. Press ‘
▲
’ to scroll up through
the numbers. Select by pressing 'OK'.
4. Start-up and Check of Settings
8000038781_00_BAL_en / L00410564-01_02 19
4