Danfoss FLX 17 Pro User manual

www.danfoss.com/solar
SOLAR INVERTERS
Installation Guide
FLX Series
MAKING MODERN LIVING POSSIBLE

Safety and Conformity
Safety Message Types
The following symbols are used in this document:
DANGER
Indicates a potentially hazardous situation which could
result in death.
WARNING
Indicates a potentially hazardous situation which could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which could
result in minor or moderate injury. It may also be used
to alert against unsafe practices.
NOTICE
Indicates important information, including situations
which may result in damage to equipment or property.
General Safety
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.
NOTICE
Before installation
Check for damage to equipment and packaging. If in
doubt, contact the supplier before commencing instal-
lation.
CAUTION
Installation
For optimum safety, follow the steps described in this
document. Keep in mind that the inverter has 2 voltage
carrying sides; the PV input and the AC grid.
WARNING
Disconnecting the inverter
Before starting work on the inverter, switch off AC at the
mains switch and PV using the PV load switch. Ensure
that the device cannot be unintentionally reconnected.
Use a voltage tester to ensure that the unit is discon-
nected and voltage free. The inverter can still be charged
with very high voltage at hazardous levels even when it
is disconnected from AC grid and solar modules. Wait at
least 8 minutes following disconnection from grid and
PV panels before proceeding.
For safe disconnection of DC current, turn off the PV load
switch (1).
Safety and Conformity
L00410568-02_02 / Rev. date: 2013-12-10

CAUTION
Maintenance and modification
Only authorised personnel are permitted to modify the
inverter. To ensure personal safety, use only original
spare parts available from the supplier. If non-original
spare parts are used, compliance with CE guidelines in
respect of electrical safety, EMC and machine safety is
not guaranteed.
The temperature of the cooling racks and components
inside the inverter can exceed 70 ºC. Observe the danger
of burn injury.
DC voltages up to 1000 V are present in a PV system even
when the inverter is disconnected from the AC grid. Faults
or inappropriate use may lead to electric arcing.
WARNING
PV modules generate voltage when exposed to light.
WARNING
Do not work on the inverter while disconnecting DC and
AC.
The short-circuit current of the photovoltaic panels is only
slightly higher than the maximum operating current and
depends on the level of solar irradiation.
Conformity
Go to the download area at www.danfoss.com/solar,
Approvals and Certifications, for information.
See also 5 Technical Data.
CE marking - This symbol certifies the conformity of
the equipment with the requirements of the
applicable EC directives
Safety and Conformity
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Contents
1 Introduction
3
1.1 Purpose of the Manual 3
1.2 Software Version 3
1.3 Spare Parts 4
1.4 Unpacking 4
1.5 Identification of Inverter 4
1.6 Installation Sequence 4
1.7 Return and Disposal 4
1.7.1 Return 5
1.7.2 Disposal 5
1.8 Overview of Installation Area 6
2 Installation 7
2.1 Environment and Clearances 7
2.2 Mounting the Mounting Plate 8
2.3 Mounting the Inverter 9
2.4 Removing the Inverter 10
2.5 Access to the Installation Area 10
2.6 AC Grid Connection 11
2.7 RS-485 or Ethernet Connections 12
2.8 Options 12
2.9 Closure 12
2.10 PV Connection 13
2.10.1 Protection Rating for PV Modules 14
3 Initial Setup and Start 15
3.1 User Interface 15
3.1.1 Operation Modes 15
3.1.2 Security Level 15
3.1.3 Preparation for Master Inverter 16
3.1.4 Manual PV Configuration 16
3.2 Display 16
3.2.1 Initial Setup via Display 17
3.2.2 Turn PV Load Switch On 20
3.2.3 Start-up 20
3.2.4 Autotest Procedure 20
3.3 Web Interface 20
3.3.1 Prepare for Setup 20
3.3.3 Setup Wizard 21
3.3.4 Web Interface 27
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3.3.5 Plant, Group and Inverter Views 28
3.3.6 Autotest Procedure 29
4 Service 30
4.1 Troubleshooting 30
4.2 Maintenance 33
5 Technical Data 34
5.1 Specifications 34
5.1.1 Inverter Specifications 34
5.2 Derating Limits 38
5.3 Conformity 38
5.4 Installation Conditions 39
5.5 Cable Specifications 40
5.6 Torque Specifications 42
5.7 Mains Circuit Specifications 43
5.8 Auxiliary Interface Specifications 43
5.9 RS-485 and Ethernet Connections 44
Contents
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1Introduction
1.1 Purpose of the Manual
The Installation Guide provides information required to
install and commission the FLX series inverter.
Additional resources available:
•
User Guide, for information required in monitoring
and setup of the inverter, via the display or web
interface.
•
Design Guide, for information required for
planning use of the inverter in a diversity of solar
energy applications.
•
CLX GM Quick Guide, for information required to
install and set up power management of the FLX
Pro inverter using the CLX GM device.
•
CLX Home Installation Manual, or CLX Home GM,
CLX Standard, CLX Standard GM Quick Guide, for
information required to install and set up
monitoring of the FLX inverter.
•
Sensor Interface Option Installation Guide, for
installation and commissioning of the sensor
interface option.
•
GSM Option Kit Installation Guide, for information
required to install a GSM option, and set up data
upload or messaging from the inverter.
•
PLA Option Guide, for information required to
install and set up PLA option for connecting radio
ripple control receiver to the inverter.
•
Fan Installation Instruction, for information
required to replace a fan.
These documents are available from the download area at
www.danfoss.com/solar, or from the supplier of the solar
inverter.
Illustration 1.1 FLX Series Inverter
The FLX series inverters feature:
•
IP65 enclosure
•
PV load switch
•
Sunclix connectors for PV input
•
Manual access via the display, for configuration
and monitoring of the inverter.
•
Ancillary service functionalities. Refer to the FLX
Series Design Guide for details.
•
Access via web interface, for configuration and
monitoring of the inverter.
1.2 Software Version
This manual is applicable for inverter software 2.05 and
onwards. To see the software version, via the display or
web interface (inverter level), go to [Status → Inverter →
Serial no. and SW ver. → Inverter].
NOTICE
Software version at manual release is 2.05. Information
about current software version is available at
www.danfoss.com/solar.
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1.3 Spare Parts
Contact Danfoss for information about spare parts, part
numbers, and ordering.
1.4 Unpacking
Contents:
•
Inverter
•
Mounting plate
•
Accessories bag, containing: 3 mounting screws, 2
cable glands, 2 rubber cups, 1 earthing screw,
and 1 security label for France.
•
4 to 6 Sunclix mating parts depending on the
number of MPPT for FLX Pro 5-17.
•
Installation guide, booklet format
•
Quick guide, poster format
The following items are not supplied:
•
Security screws, M5 x 8-12, optional (not available
as product from Danfoss)
1.5 Identification of Inverter
Illustration 1.2 Product Label
The product label on the side of the inverter shows:
•
Inverter type
•
Important specifications
•
Serial number, located under the bar code, for
inverter identification.
1.6 Installation Sequence
1. Pay special attention to 1.1 Safety Message Types.
2. Install the inverter according to 2.1 Environment
and Clearances, 2.2 Mounting the Mounting Plate
and 2.3 Mounting the Inverter.
3. Open the inverter according to 2.5 Access to the
Installation Area.
4. Install AC according to 2.6 AC Grid Connection.
5. Install RS-485 or Ethernet, if used, according to
2.7 RS-485 or Ethernet Connections.
6. Install options, if any, according to the installation
guide supplied with the option.
7. Close the inverter according to 2.5 Access to the
Installation Area.
8. Install PV according to 2.10 PV Connection.
9. Turn on AC at the mains switch.
10. Set language, master mode, time, date, installed
PV power, country, and grid code:
•
For setup via the web interface, refer to
3.3 Web Interface.
•
For setup via the display, refer to
3.2 Display.
11. Turn on PV by turning on the PV load switch.
Refer to 2.10.1 Connection of PV.
12. Verify the installation by comparing with the
autodetection result in the display, as described
in 2.10 PV Connection.
13. The inverter is now in operation.
For installation and setup of multiple FLX Pro inverters in
master-follower configuration:
•
Perform steps 2–9 and 11 for each inverter.
•
Perform step 10 on the inverter planned as
master.
•
Perform step 12.
1.7 Return and Disposal
When replacing an inverter, it can either be returned to
your distributor, to Danfoss directly, or disposed of
according to local and national regulations. Danfoss is
committed to its policy of environmental responsibility,
and therefore appeals to end users who are disposing of
inverters to follow local environmental legislation and to
seek safe, responsible means of disposal.
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1.7.1 Return
For return to Danfoss, the inverter should always be in its
original packaging or equivalent packaging. If the product
is returned as a result of inverter failure, contact your
Danfoss inverter supplier.
For return shipment and details, contact Danfoss hotline.
1.7.2 Disposal
In case of end of service life, the inverter can be returned
to your distributor, to Danfoss directly, or disposed of in
the respective country. The shipping to the distributor or
Danfoss is paid by the sender. Recycling and disposal of
the inverter must be done according to the rules and
regulations applicable in the country of disposal. All the
inverter packaging material is recyclable.
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1.8 Overview of Installation Area
PELV (Safe to touch)
1 RS-485 interface
2 Option slot A (can be used for GSM option, optional sensor interface, or PLA option)
3 Ethernet interface
4 Option slot A (can be used for GSM option, optional sensor interface, or PLA option)
Live Part
5 PV connection area
6 Communication board
7ACterminal
Other
8 Security screw position
9PVloadswitch
10 Security screw position
Illustration 1.3 Overview of Installation Area
Introduction
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2 Installation
2.1 Environment and Clearances
Illustration 2.1 Avoid Constant Stream of Water
Illustration 2.2 Avoid Direct Sunlight
Illustration 2.3 Ensure Adequate Air Flow
Illustration 2.4 Ensure Adequate Air Flow
Illustration 2.5 Mount on Non-flammable Surface
Illustration 2.6 Mount Upright on Vertical Surface. Tilt of up to
10 degrees is permitted
Illustration 2.7 Prevent Dust and Ammonia Gases
NOTICE
When planning the installation site, ensure that inverter
product and warning labels remain visible. For details,
refer to 5 Technical Data.
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2.2 Mounting the Mounting Plate
Illustration 2.8 Safe Clearances
NOTICE
Ensure 620 mm base clearance for adequate airflow.
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Illustration 2.9 Mounting Plate
NOTICE
Use of the mounting plate delivered with the inverter is
mandatory.
Mount the mounting plate:
•
Mount in the defined environment.
•
Use screws and rawl plugs that can safely carry
the weight of the inverter.
•
Ensure that the mounting plate is correctly
aligned.
•
Observe safe clearances when installing one or
more inverters, to ensure adequate airflow.
Clearances are specified in Illustration 2.8 and the
mounting plate label.
•
Mounting multiple inverters in a single row is
recommended. Contact the supplier for
guidelines, when mounting inverters in more
than one row.
•
Ensure adequate clearance at the front, for
service access to the inverter.
.
Illustration 2.10 Mounting the Mounting Plate
2.3 Mounting the Inverter
CAUTION
For safe handling of the inverter, 2 people must carry
the unit, or a suitable transport trolley must be used.
Wear safety boots.
Procedure:
1. Lift the inverter. Locate the slots on the side of
the mounting plate.
Illustration 2.11 Position the Inverter
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2. On the inverter, position the side screws against
the mounting plate slots.
3. Push the inverter as shown so the side screws
slide into the 2 lower slots, then the 2 upper
slots. See Illustration 2.12 and Illustration 2.13.
Illustration 2.12 Slide into Slots
Illustration 2.13 Detail of Sliding into Slot
4. Check that the 4 side screws sit securely in the
mounting plate slots.
5. Release the inverter.
Anti-theft Protection (Optional)
To protect the inverter against theft, fasten as follows:
1. Use 2 security screws, M5 x 8-12 (not supplied).
2. Insert screws through the pre-drilled anti-theft
holes (see Illustration 1.3), through the mounting
plate to the wall.
3. Tighten screws.
2.4 Removing the Inverter
Procedure:
1. Perform removal in the reverse order of
mounting.
2. Lift the inverter. 2 people must carry the unit.
3. With a firm grip at the base of the inverter, lift
and slide the inverter out of the mounting plate
slots.
4. Lift the inverter free of the mounting plate.
2.5 Access to the Installation Area
CAUTION
Observe ESD safety regulations. Discharge any electro-
static charge by touching the grounded enclosure,
before handling any electronic component.
Procedure:
1. To open the cover, loosen the 2 lower front
screws using a TX 20 screwdriver. The screws
cannot fall out.
2. Lift the cover 180 degrees. A magnet holds the
cover open.
3. To close the cover, lower it into place and fasten
the 2 front screws.
Illustration 2.14 Loosen Front Screws and Lift Cover
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2.6 AC Grid Connection
Illustration 2.15 Installation Area
Illustration 2.16 AC Cable Wire Strip
On the AC cable, strip insulation on all 5 wires. The PE wire
must be longer than the mains and neutral wires. See
Illustration 2.16.
Illustration 2.17 AC Connection Area
L1, L2, L3 3 mains wires
NNeutralwire
PE1 Primary protective earth
PE2 Secondary protective earth
1. Verify that the inverter rating matches the grid.
2. Ensure that main circuit breaker is released, and
take precautions to prevent reconnection.
3. Open the front cover.
4. Insert the cable through the AC gland to the
terminal blocks.
5. Connect the 3 mains wires (L1, L2, L3), the
neutral wire (N) and the protective earth wire (PE)
to the terminal block with the respective
markings.
6. Optional: Make an extra PE connection at the
secondary PE earthing points.
7. All wires must be properly fastened with the
correct torque. See 5.6 Torque Specifications.
CAUTION
Check that all wiring is correct. Connecting a phase wire
to the neutral terminal may permanently damage the
inverter.
NOTICE
Tighten all screws and glands thoroughly.
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NOTICE
This product may generate DC current exceeding 6 mA,
into the external grounded PE wire. Where a residual
current-operated protective (RCD) or monitoring (RCM)
device is used for protection in case of direct or indirect
contact, only an RCD or RCM of Type B is allowed on the
supply side of this product. When applying an RCD it
must have a 300 mA sensitivity to avoid tripping. IT
systems are not supported.
NOTICE
For fuse and RCD information, refer to 5 Technical Data.
2.7 RS-485 or Ethernet Connections
Before connecting RS-485 or Ethernet cables, refer to
requirements in 5.9 RS-485 and Ethernet Connections.
Procedure:
1. Do not remove the RJ-45 connector.
2. Guide the cables through the base of the inverter
via cable glands. See Illustration 2.18.
3. Plug into the RS-485 or Ethernet connector.
4. Fasten cables with cable ties to ensure a durable
connection over time. See Illustration 2.19.
Illustration 2.18 Guide Through Cable Glands
Illustration 2.19 Fasten with Cable Ties
NOTICE
Tighten all screws and glands thoroughly.
2.8 Options
To install options, refer to the respective option installation
guide.
NOTICE
Tighten all screws and glands thoroughly.
2.9 Closure
1. Close the cover of the inverter installation area.
Fasten the 2 front screws.
2. Turn on AC power.
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2.10 PV Connection
WARNING
PV modules generate voltage when exposed to light.
Do NOT connect PV to earth.
Illustration 2.20 Do Not Connect PV to Earth
Use a suitable voltmeter that can measure up to 1000 V
DC.
1. Mount Sunclix connectors (not supplied) on the
PV cables, according to Illustration 2.21.
2. Verify the polarity and maximum voltage of the
PV arrays by measuring the PV open-circuit
voltage. See Illustration 2.21.
•
The PV open-circuit voltage must not
exceed 1000 V DC. The inverter is
protected against reversed polarity and
will not generate power until the
polarity is correct. Reversed polarity
damages neither the inverter nor the
connectors.
Illustration 2.21 Correct Polarity: Mounting Sunclix Connector
on Cable
1. Measure the DC voltage between the positive
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.
2. Locate and fix the failure before continuing.
3. Repeat this procedure for all arrays. Uneven distri-
bution of input power on the PV inputs is
permitted, if:
•
The individual input is not overloaded.
The maximum permissible load per
input is 8000 W.
•
The maximum short-circuit current of
the PV modules at STC (Standard Test
Conditions) does not exceed 13.5 A per
input.
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CAUTION
PV installation
Unused PV inputs may not be short-circuited.
Illustration 2.22 DC Connection Area
1. On the inverter turn the PV load switch into off
position.
2. Connect the PV cables using Sunclix connectors.
Ensure correct polarity, see Illustration 2.21.
•
Attach Sunclix mating part to PV cable.
•
Connect to each PV input in the PV
connection area with a 'click'.
Illustration 2.23 Connect to PV Input
2.10.1 Protection Rating for PV Modules
The inverter must only be operated with PV modules of
protection class II, compliant to IEC 61730, application class
A.
Module voltage rating must be more than 480 V (typical
module voltage rating is 1000 V). This does not prevent
the use of strings with lower operating voltage.
Only connect PV modules to the inverter. Other energy
sources are not allowed.
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3 Initial Setup and Start
3.1 User Interface
The user interface comprises:
•
Local display. Enables manual setup of the
inverter.
•
Web interface. Enables access to multiple
inverters via Ethernet.
Choose an interface to set up and start the inverter, either
via
•
Display
3.2 Display
3.2.1 Initial Setup via Display
or
•
Web interface
3.3 Web Interface
3.3.4 Web Interface
Do not touch the other interface during the setup and
start-up processes.
For access and menu information, refer to the FLX Series
User Guide.
3.1.1 Operation Modes
The inverter has 4 operation modes, indicated by LEDs.
For more information on the LEDs, refer to the FLX Series
User Guide.
Off grid (LEDs off)
When no power has been delivered to the AC grid for
more than 10 minutes, the inverter disconnects from the
grid and shuts down. 'Off grid - standby' is the default
night mode. 'Off grid - sleep' is the night mode for lowest
energy consumption.
•
Off grid - standby mode (LEDs off)
The inverter is disconnected from grid. User and
communication interfaces remain powered for
communication purposes.
•
Off grid - sleep mode (LEDs off)
The inverter is disconnected from grid. User,
communication, and option interfaces are
powered down.
Connecting (Green LED flashing)
The inverter starts up when the PV input voltage reaches
250 V. The inverter performs a series of internal self-tests,
including PV autodetection and measurement of the
resistance between the PV arrays and earth. Meanwhile, it
also monitors the grid parameters. When the grid
parameters have been within the specifications for the
required amount of time (depends on grid code), the
inverter starts to energise the grid.
On grid (Green LED on)
The inverter is connected to the grid and energises the
grid. The inverter disconnects when:
•
it detects abnormal grid conditions (dependent
on grid code), or
•
an internal event occurs, or
•
insufficient PV power is available (no power is
supplied to the grid for 10 minutes).
The inverter then enters connecting mode or off grid
mode.
Fail Safe (Red LED flashing)
If the inverter detects an error in its circuits during the self-
test (in connecting mode) or during operation, the inverter
goes into fail safe mode, disconnecting from grid. The
inverter will remain in fail safe mode until power has been
absent for a minimum of 10 minutes, or the inverter has
been shut down completely (AC+PV).
3.1.2 Security Level
3 predefined security levels filter user access to menus and
options.
Security levels:
•
Level [0]: General access. No password is required.
•
Level [1]: Installer or service technician. Password
access required.
•
Level [2]: Installer or service technician. Password
extended access required.
Throughout the manual, a [0], [1] or [2] inserted after the
menu item indicates the minimum security level required
for access.
When logged on to the web interface as Admin, access is
at security level [0].
Access to levels [1] and [2] requires a service logon,
comprising a user ID and a password.
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•
The service logon provides direct access to a
specific security level for the duration of the
current day.
•
Obtain the service logon from Danfoss.
•
Enter the logon via the display, or the web
interface logon dialog.
•
When the service task is complete, log off at
[Setup → Security].
•
The inverter automatically logs the user off after
10 minutes of inactivity.
Security levels are similar on the display and the web
interface.
A security level grants access to all menu items at the
same level as well as all menu items of a lower security
level.
3.1.3 Preparation for Master Inverter
The master mode feature allows 1 inverter to be appointed
as master inverter for the inverter network.
The master inverter accesses the other inverters in the
network, enabling:
•
Settings and data replication to the rest of the
network, enabling easy commissioning and data
management.
•
Control of power at plant level (control of
ancillary services).
•
Data retrieval from the network, for graphical
display on the web interface, upload to a data
warehouse, or export to a PC.
Before enabling master mode, ensure that the following
requirements are met:
•
No other master inverters are present in the
network.
•
Ethernet connection from PC to inverter RJ-45
interface, using a patch cable (network cable
cat5e, crossed or straight through). See 2.7 RS-485
or Ethernet Connections.
•
Installed sensor interface option, with sensors
installed, when sensor data are required.
•
Location closest to the router, in a daisy chain
network topology.
After enabling master mode, perform a network scan to
verify that all follower inverters are connected to the
master inverter. To initiate the scan, go to [Setup →
Inverter details → Master mode → Network].
3.1.4 Manual PV Configuration
Set up the inverter for manual PV configuration:
•
Via the display, security level 1, at [Setup → Setup
details → PV configuration].
•
Via the web interface, security level 0, at [Inverter
level: Setup → Setup details → PV configuration].
When the inverter is set to manual PV configuration, the
autodetection is subsequently overridden.
To set the configuration manually via the display:
1. Turn on AC to start the inverter.
2. Obtain the installer password from the distributor.
Go to [Setup → Security → Password], and enter
the password.
3. Press [Back]. Use the arrows to navigate to [Setup
→ Setup details → PV configuration].
4. Select manual PV configuration mode, at: [Setup
→ Setup details → PV configuration → Mode:
Manual].
5. Set up the PV input configuration to match the
wiring, at: [Setup →Setup details →PV configu-
ration].
•
PV input 1: Individual, Parallel or Off
•
PV input 2: Individual, Parallel or Off
•
PV input 3: Individual, Parallel or Off
3.2 Display
NOTICE
The display activates up to 10 seconds after power up.
The integrated display on the inverter front gives the user
access to information about the PV system and the
inverter.
The display has 2 modes:
1. Normal: The display is in use.
2. Power saving: After 10 minutes of display
inactivity the back light of the display turns off to
save power. Reactivate the display by pressing
any key.
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Illustration 3.1 Overview of Display Buttons and Functionality
Key Function LED
F1 View 1/View 2 - Screen When keys F1-F4 are
selected, the LED above
the key will light up
F2 Status Menu
F3 Production Log Menu
F4 Setup Menu
Home Return to View Screen
OK Enter/select
Arrow up A step up/increase value
Arrow
Down
A step down/decrease
value
Arrow Right Moves cursor right
Arrow Left Moves cursor left
Back Return/de-select
On - Green
LED On/flashing = On grid/
Connecting
Alarm - Red
LED Flashing = Fail safe
The inverter is
configured as master.
This icon appears in the
top right corner.
The inverter is a
follower, connected to a
master. This icon
appears in the top right
corner.
Table 3.1 Overview of Display Buttons and Functionality
NOTICE
The contrast level of the display can be altered by
pressing the arrow up/down button while holding down
the F1 button.
The menu structure is divided into 4 main sections:
1. View - presents a short list of information, read
only.
2. Status - shows inverter parameter readings, read
only.
3. Log - shows logged data.
4. Setup - shows configurable parameters, read/
write.
See the following sections for more detailed information.
3.2.1 Initial Setup via Display
The inverter is shipped with a predefined set of settings
for different grids. All grid-specific limits are stored in the
inverter and must be selected at installation. It is always
possible to see the applied grid limits in the display.
After installation, check all cables and then close the
inverter.
Turn on AC at the mains switch.
IP address can be found in the display during commis-
sioning.
When prompted by the display select language. This
selection has no influence on the operating parameters of
the inverter and is not a grid code selection.
Illustration 3.2 Select Language
The language is set to English at initial start-up. To change
this setting press the [OK] button. Press [
▼
] to scroll down
through the languages. Select language by pressing [OK].
Initial Setup and Start
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