elgris ZERO Export User manual

ZERO Export
“Universal ZERO export controller”
Manual
ZERO and ZEROplus
Version 1.3
elgris GmbH
Langerweher Str. 10
D-52459 Inden
Germany
www.elgrispower.com
[email protected]

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Table of Contents
1. INTRODUCTION___________________________________________________________________________ 4
2. INSTALLATION____________________________________________________________________________ 5
2.1 Safety instructions____________________________________________________________________ 5
2.2 Device overview______________________________________________________________________ 5
2.3 Pin description _______________________________________________________________________ 6
2.4 Wiring diagram ______________________________________________________________________ 6
2.5 ZEROplus ___________________________________________________________________________ 7
2.5.1 Electrical rating ____________________________________________________________________ 7
2.5 RS 485 pin out _______________________________________________________________________ 8
2.6 Dipswitches _________________________________________________________________________ 8
3COMMISSIONING__________________________________________________________________________ 9
3.1 First time power on ___________________________________________________________________ 9
4GRAPHICAL USER INTERFACE ________________________________________________________ 10
4.1 Overview __________________________________________________________________________ 10
4.1.1 Header __________________________________________________________________________ 10
4.1.2 Main area ________________________________________________________________________ 11
4.1.3 Daily chart _______________________________________________________________________ 11
4.2 Inverter settings_____________________________________________________________________ 12
4.3 System settings _____________________________________________________________________ 13
4.3.1 Change the static IP settings _________________________________________________________ 13
4.3.2 Change the time zone ______________________________________________________________ 13
4.3.3 Setting the serial baud rate __________________________________________________________ 14
4.3.4 Broadcast ________________________________________________________________________ 14
4.3.5 SMA Smart Meter _________________________________________________________________ 14
4.3.6 SMA turbo _______________________________________________________________________ 14
4.3.7 VT value _________________________________________________________________________ 14
4.3.8 CT value _________________________________________________________________________ 14
4.3.9 Setpoint _________________________________________________________________________ 15
4.4 elgris cloud _________________________________________________________________________ 16

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4.5 Live chart __________________________________________________________________________ 17
4.6 Data logger_________________________________________________________________________ 18
4.7 Performance________________________________________________________________________ 18
4.8 ZEROplus __________________________________________________________________________ 19
5ADJUSTING THE PID SETTINGS_______________________________________________________ 20
5.1 Manual tuning ______________________________________________________________________ 20
5.2 Ziegler–Nichols method ______________________________________________________________ 21
6FIRMWARE UPDATE ___________________________________________________________________ 22
6.1. Introduction ________________________________________________________________________ 22
6.2 Connecting with the controller_________________________________________________________ 22
6.3 Start of the boot loader_______________________________________________________________ 22
6.4 Login ______________________________________________________________________________ 23
6.5 Select new firmware _________________________________________________________________ 23
6.6 Reset the controller__________________________________________________________________ 23

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1. Introduction
Dear customer, thank you for purchasing this product. The ZERO export controller is the first
controller available on the market which can control up to 10 PV inverters with ZERO export
functionality. Further the ZERO can also act a general PV output controller by limiting the production.
The ZERO export controller has the following features
•Full 3 phase power measurements
•MODBUS RTU control
•MODBUS TCP control
•USB 2.0 flash drive support for data storage
•Multi-colour user LED for status information
•Integrated webserver for intuitive configuration and parametrisation
The following versions or modules are available:
•ZERO EXPORT
•MONITORING AND DATALOGGER
•POWER MANAGEMENT
•LOAD MANAGEMENT
This manual covers all versions. Version specific information is marked on version specific chapters.
Specializing in products for renewable energy, Diesel generators and hybrid power solutions, the
ZERO export offers the following features standard:
•Wide range power supply input from 85 - 265 VAC (50 - 60 Hz)
•Small footprint.
•Intuitive software.
•Wide temperature range of -40° –+85°.
•Industrial PUR protection coating for extra rugged environment.
•IP-68 on request.
If you have any questions or if something is unclear, you can contact us in several ways:
Per E-Mail : [e-mail]
By Phone : [phone]

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2. Installation
2.1 Safety instructions
Before installing the product in the end-installation, ensure that the device is not damages during
transport and everything looks in a normal way.
All the connecting cables must not be bent or squeezed. This can result in malfunctions, short circuits
and defects in the device and/or sensor connected.
Make sure that cables are not damaged when drilling or bolting in place.
The module may only be commissioned after it has been installed contact-free in a casing. This
product generates high frequency. Never operate it in the vicinity of medical devices (e.g.
pacemakers) and/or medical equipment (e.g. in hospitals). Look for a suitable installation site.
2.2 Device overview
Before wiring the device, be sure that the voltage is switched off.
on
1234
1 2 3 4
5 6 7 8 9 10
RS-485
Ethernet
USB

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2.3 Pin description
Voltage
input
Pin
Description
Minimum
Maximum
1
Phase 1 voltage input
85 Vac
250 Vac
2
Phase 2 voltage input
85 Vac
250 Vac
3
Phase 3 voltage input
85 Vac
250 Vac
4
Neutral input of voltage
0 Vac
Power input
5
K input current transformer L1
0 Aac
5 Aac
6
L input current transformer L1
0 Aac
5 Aac
7
K input current transformer L2
0 Aac
5 Aac
8
L input current transformer L2
0 Aac
5 Aac
9
K input current transformer L3
0 Aac
5 Aac
10
L input current transformer L3
0 Aac
5 Aac
Dipswitch
1
IP address selection
OFF = DHCP
ON = static
2
System frequency
OFF = 50 Hz
ON = 60 Hz
3
Single or Three phase
OFF = Three phase
ON = Single phase
4
Internal use only
OFF = Default
2.4 Wiring diagram
on
1 2 3 4
L1
L2
L3
N
L
K
KL
GRID
LOAD
N
Please read the manual of the used inverter to check wiring scheme.
Note: Some inverters may need additional hardware

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2.5 ZEROplus
on
1234
The ZEROplus is a ZERO controller equipped with 4 dry contacts to control external loads before
shunting the solar output.
Channel
Pin
Electrical limit
1
11 and 12
1 A at 250 VAC, 1 A at 30 VDC, resistive load
2
13 and 14
1 A at 250 VAC, 1 A at 30 VDC, resistive load
3
15 and 16
1 A at 250 VAC, 1 A at 30 VDC, resistive load
4
17 and 18
1 A at 250 VAC, 1 A at 30 VDC, resistive load
2.5.1 Electrical rating
11 12 13 14
18 17 16 15

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2.5 RS 485 pin out
Pin
Description
1
Not connected
2
RS-232 TX
3
RS-232 RX
4
RS-485 B (D-)
5
RS-485 A (D+)
6
GND
7
Not connected
8
Not connected
2.6 Dipswitches
Dipswitch
Description
OFF
ON
1
DHCP
Static IP
2
50 Hz
60 Hz
3
Three phase
Single phase
4
Not used must be OFF
2.7 LED status
The LED on board informs the user about the internal status.
LED colour
Meaning
Action
Off
No power or internal error
Contact support
Internal Error
Contact support
Date and time not set, no USB data
logging possible
Update date and time or check
internet connection for SNTP
Standby, no inverter online
Check inverter settings
Controller is throttling the PV
Normal operation
Power management active
Normal operation
Controller is not throttling PV
Normal operation

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3 Commissioning
Before starting with the commissioning of the ZERO export controller all safety precautions must be
taken which apply to the rules in your country and general safety rules. Never work on a system with
a running generator or connected grid and short the output of the generator (when available) before
working on the power system.
Only a few settings are needed to commission the ZERO export controller.
Most important is the settings of the current transformer and the setpoint for the limitation of the
power.
3.1 First time power on
Follow the following steps when the system is first time being powered.
Set the dipswitches according to the settings required. Ensure that the IP address is known
when using DHCP.
Switch off the PV inverter, disconnect the PV inverter from the system and start the
controller by applying power to L1 and N in case you use a single-phase system or L1, L2 and
L3 with N for three phase systems. When the ZERO export unit is working properly, the LED is
blinking green or red / green flashing in case there is no internet connection, or the time
server could not be reached.
Connect to the embedded webserver by typing the default address 192.168.1.100 in a web
browser. When using DHCP type the local IP address given by the DHCP server.
On the Menu select Settings and then enable the checkbox “Advanced Settings” to adjust the
CT ratio. The CT ratio is defined as 1: value. For example, when you have a CT 5:200 the value
is 40.
When the CT ratio is changed the power readings on the overview page should match the
actual power. A positive value is consumption from the grid, a negative value means
exporting to the grid. When this is not correct, check the wiring of K and L of the CT.
Detailed readings can be got by typing 192.168.1.100/Meter
Switch on the DC side of the PV system to commission the PV inverters. The steps to add an
inverter to the system is explained on page 9.

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4 Graphical User Interface
The ZERO export controller includes a webserver to adjust the system parameters and see the status
of the system.
By default, the webserver can be reached by typing the IP address 192.168.1.100 in a web browser.
Supported web browsers are Microsoft Edge, Google Chrome and Mozilla Firefox.
4.1 Overview
4.1.1 Header
The header on the integrated webserver gives information about the current status of the ZERO
controller. Besides from the exact type it also shows the firmware version, date and time and informs
the user about the status of the inverter(s).
Icon
Description
The red icon informs about configured inverters which can not be reached
by the controller. Possible causes could be wrong address, wrong wiring or
not active inverter (at night)
The warning icon informs about inverters which are configured and can be
read out by the controller but are not feeding in to the grid. Possible
reason could be not enough PV power available.
The blue information icon informs the user that the configured inverters
are communicating with the controller and are feeding in.
Please note that not all inverters send the status information. In this case the status is
ignored and only the response to the ZERO controller is considered.
Header with status
information and menu
Main area with system
information
Daily chart with load
and PV output