FRO­NIUS Power Control Box User manual

Fronius Power Control Box Operating instructions
Data communication
EN
/ Battery Charging Systems / Welding Technology / Solar Electronics
42,0426,0081,EN 002-15012013

ud_fr_st_et_00493 01/2012
EN
Dear Reader
Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
Introduction

ud_fr_se_sv_00923 022009
I
EN
Safety rules
DANGER!
WARNING!
CAUTION!
“NOTE!” indicates a situation which implies a risk of impaired results and
damage to the equipment.
NOTE!
This equipment has been manufactured in accordance with the state of the
art and general safety-engineering principles. Nevertheless, incorrect opera-
tion or misuse may still endanger
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/operator,
- working efficiently with the equipment.
All persons involved in any way with starting up, servicing and maintaining
the equipment must
- be suitably qualified
- have good knowledge of dealing with electrical installations and
- read this instruction manual thoroughly and follow the instructions to the
letter.
The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, it is important to comply with both the
generally applicable and local accident prevention and environmental protec-
tion regulations.
All the safety instructions and warning signs on the machine itself:
- must be kept in a legible condition
- must not be damaged, must not be removed
- must not be covered, pasted or painted over
General Remarks
Important!
“DANGER!” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word must be
limited to the most extreme situations. This signal word is not used for
hazards relating to property damage unless there is also a risk of personal
injury appropriate to this level.
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for hazards relating to property damage unless there is also a risk of perso-
nal injury appropriate to this level.
“CAUTION!” indicates a potentially hazardous situation which, if not avo-
ided, may result in minor or moderate injury. It may also be used to draw
attention to unsafe practices that may cause damage to property.
“Important!” indicates practical hints and other particularly useful informati-
on. It is not a signal word for a harmful or dangerous situation.
Whenever you see any of the symbols shown above, pay close attention to
the contents of the manual!

ud_fr_se_sv_00923 022009 II
The machine may only be used for jobs as defined by the “intended purpose”.
Utilisation for any other purpose, or in any other manner, shall be deemed "not
in accordance with the intended purpose". The manufacturer shall not be
liable for any damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises
- thorough reading of and compliance with all the instructions, safety in-
structions and warnings given in this manual
- performing all stipulated inspection and servicing work
- installation in accordance with the instruction manual
Where appropriate, the following guidelines should also be applied:
- regulations of the power supply company for input to the grid
- information provided by the manufacturer of the solar modules
Utilisation for
Intended Purpose
Only
For information about where the safety instructions and warning signs are
located on the machine, please refer to the section of your machine’s in-
struction manual headed “General Remarks”.
Any malfunctions which might impair machine safety must be remedied
immediately before the machine is switched on.
Your safety is at stake!
General Remarks
(continued)
Operation or storage of the machine outside the stipulated range is deemed
“not in accordance with the intended use”. The manufacturer shall not be
liable for any damage resulting therefrom.
Please refer to the technical data in your instruction manual for accurate
information about the permissible ambient conditions.
Ambient
Conditions
Qualified Staff The servicing information provided in this instruction manual is only intended
for qualified staff. An electric shock can be fatal. Please do not carry out any
activities other than those referred to in the documentation. This also applies
even if you are suitably qualified.
All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Have loose connections, scorched,
damaged or under-dimensioned cables and wires repaired immediately by
an authorised specialist company.
Maintenance and repair may only be carried out by an authorised specialist
company.
There is no guarantee in the case of parts sourced from other suppliers that
these parts have been designed and manufactured to cope with the stresses
and safety requirements that will be placed on them. Use only original spare
parts (this also applies to standard parts).
Do not carry out any alterations, installations or modifications to the machine
without first getting the manufacturer’s permission.
Replace immediately any components that are not in perfect condition.

ud_fr_se_sv_00923 022009
III
EN
Safety Precauti-
ons at the Machi-
ne Location
Ensure when installing machines with cooling-air vents that the cooling air can flow freely
through the air vents without obstruction. Only operate the machine with the degree of
protection specified on the rating plate.
Mains connection High-performance devices (> 16 A) can affect the voltage quality on the mains
network because they can feed powerful current into the main supply.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance *)
- criteria with regard to minimum short-circuit power requirement *)
*) at the interface with the public mains network
see Technical Data
In this case, the plant operator or the person using the device should check
whether or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.
EMC device
classifications
Devices with emission class A:
- are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.
Devices with emission class B:
- satisfy the emissions criteria for residential and industrial areas. This
also applies to residential areas in which power is supplied from the
public low-voltage grid.
EMC device classification as per the rating plate or technical specifications
EMC measures In certain cases, even though a device complies with the standard limit
values for emissions, it may affect the application area for which it was
designed (e.g. when there is sensitive equipment at the same location, or if
the site where the device is installed is close to either radio or television
receivers).
If this is the case, then the operator is obliged to take appropriate action to
rectify the situation.
Information on
noise emission
values
The inverter generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when operating under full load in accordance with IEC 62109-1.
The device is cooled as quietly as possible with the aid of an electronic tempe-
rature control system, and depends on the amount of converted power, the
ambient temperature, the level of soiling of the device, etc.
It is not possible to provide a workplace-related emission value for this device
because the actual sound pressure level is heavily influenced by the installati-
on situation, the power quality, the surrounding walls and the properties of the
room in general.

ud_fr_se_sv_00923 022009 IV
Equipment with the CE mark fulfils the basic requirements of the Guideline
Governing Low-Voltage and Electromagnetic Compatibility. (More detailed
information about this may be found in the Annex or in the section of your
documentation headed “Technical Data”.)
Safety markings
The user is responsible for backing up data relating to changes made to
factory settings. The manufacturer will not accept liability if personal settings
are deleted.
Data security
Copyright to this instruction manual remains the property of the
manufacturer.
The text and illustrations are all technically correct at the time of going to
print. The right to make modifications is reserved. The contents of the
instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. We should be most grateful for your comments if you
have any suggestions for improvement, or can point out to us any mistakes
which you may have found in the manual.
Copyright
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical
equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility Any device that you no longer
require must be returned to our agent, or find out about the approved collec-
tion and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!
Disposal
Danger of damage to electronic components due to electrostatic discharge.
Take appropriate protective measures when replacing and installing the
components.
ESD Protective
Measures
Electrical Installa-
tions
Electrical installations may only be executed in accordance with the relevant
national and regional standards and specifications.
Only operate the machine if all its protective features are fully functional. If
any of the protective features are not fully functional, there is a danger to:
- the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- working efficiently with the equipment.
Have any safety features that are not fully functional repaired by an autho-
rised specialist company before switching the machine on again.
Never bypass or disable safety features.
Safety Precau-
tions in Normal
Operation

1
Contents
General .............................................................................................................................. 2
General .......................................................................................................................... 2
Maximum output power limitation................................................................................... 2
Prerequisites for operation ............................................................................................. 2
Scope of supply ............................................................................................................. 3
Option ............................................................................................................................ 3
Controls, connections and displays .................................................................................... 4
Safety............................................................................................................................. 4
Controls, connections and displays ............................................................................... 4
Installing the Fronius Power Control Box ........................................................................... 6
Choice of location .......................................................................................................... 6
Installation position ........................................................................................................ 6
Fixing the wall bracket to the wall .................................................................................. 6
Attaching the Fronius Power Control Box to the wall bracket ........................................ 7
Connecting the Fronius Power Control Box to a ripple control signal receiver ................... 8
Safety............................................................................................................................. 8
Maximum cable cross-section ........................................................................................ 8
Connecting the Fronius Power Control Box to a ripple control signal receiver ................
with 4 relays ...................................................................................................................9
Connecting the Fronius Power Control Box to a ripple control signal receiver ................
with 2 relays ...................................................................................................................9
Connecting the Fronius Power Control Box to a ripple control signal receiver ................
with 3 relays ................................................................................................................. 10
Integrating the Fronius Power Control Box in the Fronius Solar Net ................................. 11
General .........................................................................................................................11
Integrating the Fronius Power Control Box in the Fronius Solar Net............................. 11
Connecting the external power supply to the Fronius Power Control Box .................... 11
Setting the operating mode on the Fronius Power Control Box ....................................... 12
The operating mode adjusting dial ............................................................................... 12
Operating modes and settings ..................................................................................... 12
Setting the operating mode on the Fronius Power Control Box ................................... 13
Inverter display ................................................................................................................. 14
General ........................................................................................................................ 14
Inverter display ............................................................................................................ 14
Troubleshooting ............................................................................................................... 16
General ........................................................................................................................ 16
Troubleshooting ........................................................................................................... 16
A power limitation is in effect ........................................................................................ 16
Technical data ..................................................................................................................17
Fronius Power Control Box .......................................................................................... 17

2
General
General The Fronius Power Control Box limits the maximum output power of a
photovoltaic system in accordance with power supply company stipulati-
ons.
As and when required, the power supply company can use a ripple control
signal receiver to set 4 different limit levels.
The Fronius Power Control Box forwards the incoming information along
the Fronius Solar Net to the inverters on the photovoltaic system, which
then independently adjust the output power as appropriate.
Maximum
output power
limitations
The power supply company may limit the maximum output power at the
following levels:
Level Limitation Description
1 100 % no power limitation; energy is fed into the grid in
optimum light conditions and at the maximum
possible output power of the inverter
2 60 % power limitation at 60 %; energy is fed into the grid
in optimum light conditions and at 60 % of the
maximum possible output power of the inverter
3 30 % power limitation at 30 %; energy is fed into the grid
in optimum light conditions and at 30 % of the
maximum possible output power of the inverter
4 0 % power limitation at 0 %; no energy is fed into the grid
Prerequisites
for operation
The following components are required to operate the ‘Fronius Power
Control Box’:
- a Fronius Datalogger in the Fronius Solar Net
- a ‘Fronius Com Card’ for each inverter or an inverter with Com Card
function
The Fronius Power Control Box may be used with the following inverters:
- Fronius IG Plus
- Fronius IG Plus V
- Fronius CL
- Fronius IG-TL
- Fronius Agilo
All inverters from serial number 20220769 onwards are compatible with
the Fronius Power Control Box.

3
Scope of sup-
ply
1 Fronius Power Control Box
1 wall bracket
1 operating instructions
2 dowels
2 screws
Option Fronius 12 V DC mains adapter for external power supply
15 VA / 1.25 A output power
The following electronic component versions are required on the inverter
to operate the Fronius Power Control Box:
Electronic component Inverter Version
IG-BRAIN Fronius IG Plus V. 4.28.20
Fronius IG Plus V
Fronius CL
PINCI Fronius IG Plus V. 1.4.32
Fronius IG Plus V
CERBO Fronius IG-TL V. 1.1.0.0
TL-5 KW Fronius IG-TL V. 1.1.0.0
MECERCAP Fronius Agilo since the beginning
Power stage set Fronius Agilo since the beginning
Prerequisites
for operation
(continued)

4
Controls, connections and displays
WARNING! Operating the equipment incorrectly can cause
serious injury and damage. Do not use the functions described
here until you have fully read and understood the following
documents:
- these operating instructions
- all the operating instructions for the system components,
especially the safety rules
Safety
Controls,
connections
and displays
Mode
123456789
10 11 12
+
-
GND
GND
(1)
(2)
IN OUT
Info
(3) (4)
12VDC Class
2 Input only
I
(1)(2) (3) (4) (5) (6) (7)
No. Function
(1) Supply LED
- lights up green: there is a sufficient power supply through the
Fronius Solar Net
- does not light up: there is an insufficient or no power supply
through the Fronius Solar Net - an external power supply is
required for the Fronius Power Control Box
(2) LED status indicator
lights up or flashes if an error occurs
An exact description of the LED status indicator is provided in the
„Troubleshooting“ section.
(3) Operating mode adjusting dial
for setting the operating mode of the Fronius Power Control Box
(4) Terminals
for connecting to a ripple control signal receiver

5
No. Function
(5) External power supply connection
for connecting an external power supply when there is not enough
power in the Fronius Solar Net (e.g. if there are too many
DATCOM components in the Fronius Solar Net).
Important! Only use the original Fronius mains adapter to provide
an external power supply to the Fronius Power Control Box.
The supply LED (1) lights up green if there is a sufficient power
supply.
(6) Fronius Solar Net IN connection
Fronius Solar Net input for connecting to other DATCOM
components (e.g. inverter, sensor cards, etc.)
(7) Fronius Solar Net OUT connection
Fronius Solar Net output for connecting to other DATCOM
components (e.g. inverter, sensor cards, etc.)
Controls,
connections
and displays
(continued)

6
The Fronius Power Control Box can be installed horizontally or vertically in
any position. If it is not installed horizontally, the cable entries and outlets
should ideally point downwards.
Installing the Fronius Power Control Box
Choice of
location
Note the following criteria when choosing the location:
- Only install on a firm surface
- The ambient temperature must not fall below 0 °C or exceed +55 °C
- The IP 20 degree of protection of the Fronius Power Control Box
dictates that it be installed exclusively in enclosed spaces, switch
cabinets or containers.
Installation
position
Fixing the wall
bracket to the
wall
1
1
1
3
2
2
2
1
3
2
1
2x
1
2

7
Attaching the
Fronius Power
Control Box to
the wall bra-
cket
1
3
2
1

8
WARNING! If the equipment is used or tasks are carried out
incorrectly, serious injury or damage may result. The Fronius
Power Control Box must only be commissioned by trained
personnel in accordance with the technical regulations. Do not
use the functions described here until you have fully read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components,
especially the safety rules
Safety
Connecting the Fronius Power Control Box to a
ripple control signal receiver
CAUTION! Risk of serious injury from electric shock and risk of
damage to the Fronius Power Control Box.
The ripple control signal receiver contacts must be potential-free.
- Before making the connection, ensure that the ripple control
signal receiver contacts are potential-free.
- Follow the manufacturer’s safety instructions
Maximum
cable cross-
section
The terminals on the Fronius Power Control Box are designed for a maxi-
mum cable cross-section of 1.5 mm².
NOTE! The signals to be connected from the ripple control signal
receiver must be safely isolated from circuits under dangerous
voltages and must not exceed a voltage of 60 V DC.

9
Ripple control signal receiver Fronius Power Control Box
100 %
60 %
30 %
0 %
1
2
3
4
123456789
10 11 12
+
-
GND
GND
(1) (2) (3) (4)
I
Connecting
the Fronius
Power Control
Box to a ripple
control signal
receiver with 4
relays
1. Connect the ripple control signal receiver and Fronius Power Control
Box using a 7-pin cable in accordance with the connection diagram
The cable length must not exceed 10 m.
4-relay mode connection diagram
Connecting
the Fronius
Power Control
Box to a ripple
control signal
receiver with 2
relays
1. Connect the ripple control signal receiver and Fronius Power Control
Box using a 3-pin cable in accordance with the connection diagram
The cable length must not exceed 10 m.
Ripple control signal receiver Fronius Power Control Box
1
2
123456789
10 11 12
+
-
GND
GND
(1) (2) (3) (4)
I
The specified power limitations are as follows:
Power Relay 1 actuated Relay 2 actuated
100 % no no
60 % yes no
30 % no yes
0 % yes yes
2-relay mode connection diagram

10
Connecting
the Fronius
Power Control
Box to a ripple
control signal
receiver with 3
relays
1. Connect the ripple control signal receiver and Fronius Power Control
Box using a 5-pin cable in accordance with the connection diagram
The cable length must not exceed 10 m.
Ripple control signal receiver Fronius Power Control Box
60 %
30 %
0 %
1
2
3
123456789
10 11 12
+
-
GND
GND
(1) (2) (3) (4)
I
If none of the relays are actuated, there is no power limitation.
Important! Lines are not monitored in 3-relay mode. Line breaks are not
identified and displayed as faults.
3-relay mode connection diagram
Connecting
the Fronius
Power Control
Box to a ripple
control signal
receiver with 2
relays
(continued)
Important! Lines are not monitored in 2-relay mode. Line breaks are not
identified and displayed as faults.

11
Mode
10 12
123456789 11
+
-
GND
GND
(1)
(2)
IN OUT
Info
(3) (4)
12VDC Class
2 Input only
I
Integrating the Fronius Power Control Box in the
Fronius Solar Net
If several DATCOM components are connected in the Fronius Solar Net, a
terminating plug must be connected to any free IN or OUT connection on
a DATCOM component.
Important! Observe the inverter and ‘Fronius IG DATCOM Detail’ opera-
ting instructions.
General
Integrating the
Fronius Power
Control Box in
the Fronius
Solar Net
The supply LED will light up green once the data communication cables
have been connected and if there is a sufficient power supply through the
Fronius Solar Net.
If the supply LED does not light up, an external power supply is required for
the Fronius Power Control Box.
Connecting
the external
power supply
to the Fronius
Power Control
Box
Mode
123456789
10 11 12
+
-
GND
GND
(1)
(2)
IN OUT
Info
(3) (4)
12VDC Class
2 Input only
I
12
-
IN
12VDC Class
2 Input only
12 V DC
1. Connect the external mains
adapter to the external power
supply connection
The supply LED will light up
green if there is a sufficient
power supply.
1. Connect the data communication
cables to the Fronius Solar Net
IN and Fronius Solar Net OUT
connections
Only if the Fronius Power Control
Box is the first DATCOM compo-
nent in the Fronius Solar Net:
- connect the terminating plug
to the Fronius Solar Net IN
connection
Only if the Fronius Power Control
Box is the last DATCOM compo-
nent in the Fronius Solar Net:
- connect the terminating plug
to the Fronius Solar Net OUT
connection

12
Setting the operating mode of the Fronius Power
Control Box
Mode
123456789
10 11 12
+
-
GND
GND
(1)
(2)
IN OUT
Info
(3) (4)
12VDC Class
2 Input only
I
Mode
123
(1)
The operating mode adjusting dial
is used to control the inverter func-
tion.
Operating
modes and
settings
The operating
mode adjus-
ting dial
Setting Description
Test mode
10 % of the maximum possible output power is fed into
the grid (irrespective of what is connected to the termi-
nals).
4-relay mode (factory setting)
Depending on the limit set by the ripple control signal
receiver, 100 %, 60 %, 30 % or 0 % of the maximum
possible output power is fed into the grid.
-
0
1
49
Reserved for other operating modes
Settings 4 - 9 are currently assigned to 4-relay mode.
2
3
2-relay mode
Depending on the combination in which the two relays
are actuated on the ripple control signal receiver, 100
%, 60 %, 30 % or 0 % of the maximum possible output
power is fed into the grid.
3-relay mode
Depending on the limit set by the ripple control signal
receiver, 60 %, 30 % or 0 % of the maximum possible
output power is fed into the grid.