FRO­NIUS xPrimo GEN24 4.0 Plus User manual

Operating
Instructions
Fronius Primo GEN24
3.0 / 3.0 Plus / 3.6 / 3.6 Plus
4.0 / 4.0 Plus / 4.6 / 4.6 Plus
5.0 / 5.0 Plus / 6.0 / 6.0 Plus
42,0426,0302,EN 018-10072023
EN Operating Instructions

Contents
Safety rules 8
Explanation of safety notices 8
Safety 8
General 8
Environmental conditions 9
Qualified personnel 9
Noise emission values 9
EMC measures 10
Backup power 10
Data protection 11
Copyright 11
Protective earthing (PE) 11
General information 13
Fronius Primo GEN24 15
Device concept 15
Function overview 15
Fronius UP 16
Scope of supply 16
Intended use 16
Thermal concept 17
Fronius Solar.web 17
Local communication 18
The various operating modes 19
Operating modes – Explanation of symbols 19
Operating mode – Inverter with battery 20
Operating mode – Inverter with battery and several Smart Meters 20
Operating mode - inverter with battery, AC-coupled to another inverter 20
Operating mode – Inverter with battery and backup power function 21
Operating mode – Inverter with battery, Ohmpilot and backup power function 21
Operating mode – Inverter with battery, further inverter and backup power function 21
Energy flow direction of the inverter 22
Operating states (only for systems with a battery) 22
Energy saving mode 24
General 24
Switch-off conditions 24
Switch-on conditions 24
Special case 24
Indication of energy saving mode 25
Suitable batteries 26
General 26
Limitations in operation 26
BYD Battery-Box Premium 26
LG RESU FLEX 27
Manual system start 29
Requirements 29
Notification of system shutdown 29
Manual battery start after system shutdown 29
Starting backup power operation after a system shutdown 29
Protection of people and equipment 30
Central grid and system protection 30
WSD (wired shutdown) 30
RCMU 30
Insulation monitoring 30
AFCI - Arc Fault Circuit Interrupter (Arc Guard) 30
Safe state 31
Surge protective device 31
Control elements and connections 32
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Connection area 32
Connection area divider 33
Ground electrode terminal 33
DC disconnector 34
Data communication area 34
Button functions and LED status indicator 36
Internal schematic connection diagram of the IOs 37
Backup power variant - PV Point (OP) 39
General 41
PV Point (OP) 41
Explanation - PV Point (OP) 41
Backup power variant - Full Backup 43
General 45
Prerequisites for backup power mode 45
Transitioning from feeding energy into the grid to backup power mode 45
Transitioning from backup power mode to feeding energy into the grid 45
Backup power and energy saving mode 46
Cabling variants including backup power circuits with 1-pin separation e.g. Austria or Aus-
tralia
47
Functions 47
Transitioning from feeding energy into the grid to backup power mode 47
Transitioning from backup power mode to feeding energy into the grid 47
All-pin separation cabling variant e.g. Germany, France, Spain, UK 48
Functions 48
Transitioning from feeding energy into the grid to backup power mode 48
Transitioning from backup power mode to feeding energy into the grid 49
All-pin separation cabling variant, Italy 50
Functions 50
Transitioning from feeding energy into the grid to backup power mode 50
Transitioning from backup power mode to feeding energy into the grid 51
Installation 53
General 55
Quick-lock system 55
Warning notices on the device 55
System component compatibility 57
Installation location and position 58
Choosing the location of the inverter 58
Choosing the location of third-party batteries 59
Installation position of inverter 60
Install the mounting bracket and hang up the inverter 62
Selecting the fixing material 62
Properties of the mounting bracket 62
Do not deform the mounting bracket 62
Fitting the mounting bracket to a wall 62
Installing the mounting bracket on a mast or beam 63
Attaching the mounting bracket to mounting rails 64
Attaching the inverter to the mounting bracket 64
Prerequisites for connecting the inverter 65
Permissible cables for the electrical connection 65
Permitted cables for the data communication connection 66
Cross section of the AC cable 66
Cross section of the DC cable 67
Maximum alternating current fuse protection 67
Connecting the inverter to the public grid (AC side) 69
Safety 69
Connecting the inverter to the public grid (AC side) 69
Connecting solar module strings to the inverter 72
General comments regarding PV modules 72
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Safety 72
Module array - general information 73
Module array configuration 3 ‑6 kW 73
Connecting the solar module strings to the inverter 74
Connecting the battery to the inverter 78
Safety 78
Connecting the battery on the DC side 78
Connecting the LG RESU FLEX ground conductor 82
Connecting backup power - PV Point (OP) 83
Safety 83
Installation 83
Connecting backup power - Full Backup 88
Safety 88
Cabling variants including backup power circuits with 1-pin separation e.g. Austria or Aus-
tralia
88
All-pin separation cabling variant e.g. Germany, France, Spain 89
All-pin separation cabling variant, e.g. UK 90
All-pin separation cabling variant, e.g. Italy 91
Testing backup power mode 92
Connecting the data communication cable 93
Modbus participants 93
Routing data communication cables 94
Connecting the battery communication cable 96
Terminating resistors 96
Installing the WSD (wired shutdown) 98
Closing and commissioning the inverter 99
Closing the inverter's connection area/housing cover, and commissioning 99
Starting the inverter for the first time 99
Installation with the app 100
Installation using the web browser 100
Switching off current supply and restarting the inverter 102
De-energising the inverter and switching it on again 102
Settings - user interface of the inverter 103
User settings 105
User login 105
Selecting the language 105
Device configuration 106
Components 106
Functions andI/Os 107
Demand Response Modes (DRM) 108
Inverter 108
Energy management 111
Energy management 111
Examples - Time-dependent battery control 112
Allowed battery control rules 114
PV power reduction 116
Load management 116
System 118
General 118
Update 118
Setup wizard 118
Restoring the factory settings 118
Event Log 118
Information 118
License Manager 119
Support 120
Communication 121
Network 121
Modbus 122
Remote control 123
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Fronius Solar API 124
Internet Services 124
Safety and grid requirements 125
Country setup 125
Feed-in limitation 125
Dynamic power regulation with several inverters 127
I/O power management 129
Connection diagram - 4 relay 130
I/O power management settings - 4 relays 131
Connection diagram - 3 relay 132
I/O power management settings - 3 relays 133
Connection diagram - 2 relay 134
I/O power management settings - 2 relays 135
Connection diagram - 1 relay 136
I/O power management settings - 1 relay 137
Autotest (CEI 0-21) 137
Options 139
Surge protective device (SPD) 141
General 141
Safety 141
Scope of supply 141
De-energising the inverter 142
Installation 143
Commissioning the inverter 148
DC Connector Kit GEN24 150
General 150
General comments regarding PV modules 150
Safety 150
Scope of supply 151
De-energising the inverter 151
Installation 152
Commissioning the inverter 156
Appendix 157
Care, maintenance and disposal 159
General 159
Cleaning 159
Maintenance 159
Safety 159
Operation in dusty environments 159
Disposal 160
Guarantee provisions 162
Fronius manufacturer's warranty 162
Components for automatic Full Backup backup power changeover 163
Components for automatic Full Backup backup power changeover 163
Status codes and remedy 165
Display 165
Status Codes 165
Technical data 167
Fronius Primo GEN24 3.0 / 3.0 Plus 167
Fronius Primo GEN24 3.6 / 3.6 Plus 170
Fronius Primo GEN24 4.0 / 4.0 Plus 174
Fronius Primo GEN24 4.6 / 4.6 Plus 177
Fronius Primo GEN24 5.0 / 5.0 Plus 181
Fronius Primo GEN24 6.0 / 6.0 Plus 185
WLAN 188
Technical data of surge protective device DC SPD type 1+2 GEN24 189
Explanation of footnotes 189
Integrated DC disconnector 190
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Circuit diagrams 191
Circuit Diagram - PV Point (OP) 193
Circuit Diagram 193
Circuit Diagram - PV Point (OP) Australia 194
Circuit Diagram 194
Fronius Primo GEN24 and BYD Battery-Box Premium HV 195
Circuit Diagram 195
Fronius Primo GEN24 with two BYD Battery-Box Premium HV connected in parallel 196
Circuit Diagram 196
Fronius Primo GEN24 with three BYD Battery-Box Premium HV connected in parallel 197
Circuit Diagram 197
Fronius Primo GEN24 and LG RESU FLEX 198
Circuit Diagram 198
Automatic switch to backup power 1-pin double separation - e.g. Austria 199
Circuit Diagram 199
Automatic switch to backup power 1-pin single separation - e.g. Australia 200
Circuit Diagram 200
Automatic switch to backup power 2-pin double separation - e.g. Germany 201
Circuit Diagram 201
Automatic switch to backup power 2-pin single separation - e.g. France, Spain 202
Circuit Diagram 202
Automatic switch to backup power 2-pin double separation - e.g. UK 203
Circuit Diagram 203
Automatic switch to backup power 2-pin double separation with ext. grid and system protec-
tion - e.g. Italy
204
Circuit Diagram 204
Fronius Primo GEN24 with Enwitec Box 205
Circuit Diagram 205
Wiring diagram - surge protective device SPD 206
Circuit Diagram 206
Dimensions of the inverter 207
Fronius Primo GEN24 3 - 6 kW 209
Fronius Primo GEN24 3 - 6 kW 209
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Safety rules
Explanation of
safety notices WARNING!
Indicates a potentially hazardous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
If you see any of the symbols depicted in the "Safety rules" chapter, special care
is required.
Safety CAUTION!
Danger from crushing due to the incorrect handling of attachments and con-
nection parts.
Injuries to limbs may result.
▶When lifting up, putting down and attaching the inverter, use the integrated
grips.
▶When fitting attachments, ensure that no limbs are located between the at-
tachment and the inverter.
▶Do not hold onto the individual poles on the terminals when locking and un-
locking.
General The device has been manufactured in line with the state of the art and according
to recognised safety standards. In the event of incorrect operation or misuse,
there is a risk of:
-Serious or fatal injury to the operator or third parties
-Damage to the device and other material assets belonging to the operating
company
All personnel involved in commissioning, maintenance and servicing of the device
must:
-Be suitably qualified
-Have knowledge of and experience in dealing with electrical installations
-Read and follow these Operating Instructions carefully
In addition to the Operating Instructions, all applicable local rules and regula-
tions regarding accident prevention and environmental protection must also be
followed.
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All safety and danger notices on the device:
-Must be kept in a legible state
-Must not be damaged
-Must not be removed
-Must not be covered, pasted or painted over
Only operate the device when all protection devices are fully functional. If the
protection devices are not fully functional, there is a risk of:
-Serious or fatal injury to the operator or third parties
-Damage to the device and other material assets belonging to the operating
company
Any safety devices that are not fully functional must be repaired by an author-
ized specialist before the device is switched on.
Never bypass or disable protection devices.
For the location of the safety and danger notices on the device, refer to the
chapter headed "Warning notices on the device" in the Operating Instructions for
your device.
Faults that could compromise safety must be remedied before switching on the
device.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liab-
ility for any damage resulting from improper use.
Qualified per-
sonnel
The servicing information contained in these operating instructions is intended
only for the use of qualified service engineers. An electric shock can be fatal. Do
not carry out any actions other than those described in the documentation. This
also applies to qualified personnel.
All cables and leads must be secured, undamaged, insulated and adequately di-
mensioned. Loose connections, scorched, damaged or inadequately dimensioned
cables and leads must be immediately repaired by authorised personnel.
Maintenance and repair work must only be carried out by an authorised special-
ist.
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made on them, or that they satisfy safety require-
ments. Use only original spare parts (also applies to standard parts).
Do not carry out any alterations, installations, or modifications to the device
without first obtaining the manufacturer's permission.
Components that are not in perfect condition must be changed immediately.
Noise emission
values
The sound power level of the inverter is specified in the Technical data.
The device is cooled as quietly as possible with the aid of an electronic temperat-
ure control system; this 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 installation
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situation, the grid quality, the surrounding walls and the properties of the room
in general.
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 equipment that is susceptible to interference at the same location, or if
the site where the device is installed is close to either radio or television receiv-
ers). If this is the case, then the operator is obliged to take action to rectify the
situation.
Backup power This system has backup power functions. This enables a replacement power sup-
ply to be established in the event of a failure in the public grid.
Where an automatic backup power supply is installed, a backup power warning
notice (https://www.fronius.com/en/search-page, item number: 42,0409,0275)
must be fitted on the electrical distributor.
Maintenance and installation work in the home network requires both disconnec-
tion on the utility side and deactivation of the replacement power mode by open-
ing the integrated DC disconnector on the inverter.
Depending on the insolation conditions and the battery state of charge, the
backup power supply is automatically deactivated and activated. This can cause
the backup power supply to unexpectedly return from standby mode. Therefore,
installation work can only be performed on the home network when the backup
power supply is deactivated.
Influencing factors on the total power in backup power mode:
Reactive power
Electrical loads with a power factor not equal to 1 also require reactive power in
addition to effective power. The reactive power also loads the inverter. Therefore,
to correctly calculate the actual total power, it is not the rated power of the load
that is relevant, but the current caused by effective and reactive power.
Devices with a high reactive power are mainly electric motors such as:
-Water pumps
-Circular saws
-Blowers and fans
High starting current
Electrical loads that need to accelerate a large mass usually require a high start-
ing current. This can be up to 10 times higher than the nominal current. The max-
imum current of the inverter is available for the starting current. Loads with too
high starting currents therefore cannot be started/operated, even though the
nominal power of the inverter suggests that they can. When dimensioning the
backup power circuit, the connected load power and any starting current must
also be taken into account.
Devices with high starting currents are, for example:
-Devices with electric motors (e.g. lifting platform, circular saws, planing
bench)
-Devices with large transmission ratio and flywheel mass
-Devices with compressors (e.g. compressed air compressors, air conditioning
systems)
IMPORTANT!
Very high starting currents can cause short-term distortion or a drop in output
10

voltage. The simultaneous operation of electronic devices in the same backup
power supply system should be avoided.
IMPORTANT!
The inverter may only be operated within the limits of its technical capabilities.
Operation outside of its technical capabilities can cause the inverter to shut
down.
Data protection The user is responsible for the safekeeping of any changes made to the factory
settings. The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
comments.
Protective
earthing (PE)
Connection of a point in the device, system or installation to earth to protect
against electric shock in the event of a fault. When installing a safety class 1 in-
verter (see Technical data), the ground conductor connection is required.
When connecting the ground conductor, ensure that it is secured against acci-
dental disconnection. All the points listed in the chapter Connecting the invert-
er to the public grid (AC side) on page 69 must be observed. It must be ensured
that when using the strain relief devices, the ground conductor is the last to be
disconnected in the event of a possible failure. When connecting the ground con-
ductor, the minimum cross-section requirements specified by the respective na-
tional standards and guidelines must be observed.
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12

General information
13

14

Fronius Primo GEN24
Device concept The inverter transforms the direct current generated by the solar modules into
alternating current. This alternating current is fed into the public grid and syn-
chronized with the grid voltage in use. Moreover, the solar energy can also be
stored in a connected battery for later use.
The inverter is intended for use in grid-connected photovoltaic systems. The in-
verter has backup power functions and switches to backup power mode if it has
been wired accordingly*.
The inverter automatically monitors the public grid. Whenever conditions in the
electric grid are inconsistent with standard conditions (for example, grid switch-
off, interruption), the inverter will immediately stop producing power and inter-
rupt the supply of power into the grid.
The grid is monitored by monitoring the voltage, frequency and islanding condi-
tions.
After installation and commissioning, the inverter's operation is fully automatic;
the inverter draws the maximum possible power from the PV modules.
Depending on the operating point, this power is used in the home, stored in a bat-
tery* or fed into the grid.
As soon as the energy provided by the PV modules is no longer sufficient, the
power from the battery is fed into the home. Depending on the setting, power
may also be obtained from the public grid in order to charge the battery*.
When its temperature gets too high, the inverter automatically reduces the out-
put or charging power, or switches off completely, in order to protect itself.
Reasons for the temperature being too high include a high ambient temperature
or insufficient heat dissipation (for example, inadequate heat dissipation when in-
stalled in switch cabinets).
* Depending on the device variant, suitable battery, appropriate wiring, set-
tings and local standards and guidelines.
Function over-
view Function Primo GEN24 Primo GEN24 Plus
Backup power variant - PV Point
(OP)
Battery connection* Available as an op-
tion**
Backup power variant - Full Backup Available as an op-
tion**
* For suitable batteries, see chapter Suitable batteries.
** The functions are optionally available via Fronius UP (see chapter Fronius
UP).
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Fronius UP With Fronius UP*, the inverter can be expanded by the authorised specialist to
include optionally available functions (see chapter Function overview).
* The availability of Fronius UP varies from country to country. For more in-
formation on Fronius UP and availability, see Installation guide: Fronius
GEN24 & GEN24 Plus.
Scope of supply (1) Housing cover
(2) Inverter
(3) Mounting bracket (illustration)
(4) Quick Start guide
Intended use The inverter is designed to convert direct current from PV modules into alternat-
ing current and feed this power into the public grid. A backup power mode* is
possible provided that appropriate cabling has been installed.
The following are considered improper use:
-Utilisation for any other purpose, or in any other manner
-Alterations to the inverter are not permitted unless expressly recommended
by Fronius
-Installation of components is not permitted unless expressly recommended
or sold by Fronius
The manufacturer is not responsible for any damage resulting from improper use.
All warranty claims are considered void in such cases.
Intended use also means:
-Carefully reading and obeying all the instructions, as well as safety
and danger notices in the Operating Instructions
-Installation in accordance with chapter "Installation" from page 53.
When designing the photovoltaic system, ensure that all components of the
photovoltaic system are operated exclusively within their permissible operating
range.
Take into account the grid operator's regulations for energy fed into the grid and
connection methods.
16

The Fronius GEN24 inverter is a grid-connected inverter with a backup power
function – it is not a stand-alone inverter. The following restrictions must there-
fore be observed in backup power mode:
-Backup power mode may be in operation for at max. 2000 hours
-Backup power mode may be in operation for more than 2000 operating hours
if 20% of the duration of the inverter's grid power feed operation is not ex-
ceeded at the relevant time.
* Depending on the device variant, suitable battery, appropriate wiring, set-
tings, and local standards and guidelines.
Thermal concept Ambient air is drawn in by the fan on
the front side and blown out at the
device sides. The even heat dissipation
allows several inverters to be installed
next to each other.
NOTE!
Risk due to insufficient cooling of the inverter.
This may result in a loss of power in the inverter.
▶Do not block the fan (for example, with objects that protrude through the
touch guard).
▶Do not cover the ventilation slots, even partially.
▶Make sure that the ambient air can always flow through the inverter's ventila-
tion slots unimpeded.
Fronius Sol-
ar.web
With Fronius Solar.web or Fronius Solar.web Premium, the PV system can be
easily monitored and analysed by the system owner and installer. If configured
accordingly, the inverter transmits data such as power, yields, load, and energy
balance to Fronius Solar.web. For more information see Solar.web - monitoring &
analysis.
Configuration is carried out via the setup wizard, see chapter Installation with
the app on page 100 or Installation using the web browser on page 100.
Prerequisites for configuration:
-Internet connection (download: min. 512 kBit/s, upload: min. 256 kBit/s)*.
-User account on solarweb.com.
-Completed configuration via the setup wizard.
* The information given does not constitute an absolute guarantee of fault-
less function. High error rates in the transmission, reception fluctuations
or transmission drop-outs can have a negative effect on the data transfer.
17
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Fronius recommends testing the Internet connection on site according to
the minimum requirements.
Local commu-
nication
The inverter can be found via the Multicast DNS protocol (mDNS). It is recom-
mended to search for the inverter by the assigned host name.
The following data can be retrieved via mDNS:
-NominalPower
-Systemname
-DeviceSerialNumber
-SoftwareBundleVersion
18

The various operating modes
Operating modes
– Explanation of
symbols
PV module
generates direct current
Fronius GEN24 inverter
converts direct current into alternating current and charges the bat-
tery (battery charging is only possible with Fronius GEN24 Plus invert-
ers). The integrated system monitoring enables the inverter to be in-
tegrated into a network by means of WLAN.
Additional inverter in the system
converts the direct current into alternating current. However, it can-
not charge a battery, and is not available in backup power mode.
Battery
is coupled to the inverter on the direct current side, and stores elec-
trical energy.
Fronius Ohmpilot
for using excess energy to heat water.
Primary meter
records the system's load curve and provides measurement data for
energy profiling in Fronius Solar.web. The primary meter also controls
the dynamic feed-in control.
Secondary meter
records the load curve of individual loads (e.g. washing machine,
lamps, TV, heat pump, etc.) in the consumption branch and provides
measurement data for energy profiling in Fronius Solar.web.
Loads in the PV system
are the loads connected in the system.
Additional loads and generators in the system
are connected to the system by means of a Smart Meter.
PV Point
is a non-uninterruptible 1‑phase backup power circuit which supplies
electrical devices with up to 3 kW if sufficient power is available from
the PV modules or the battery.
Full Backup
the inverter is prepared for backup power mode. The backup power
mode must be implemented in the switch cabinet by the electrician
performing the installation. The PV system operates in a stand-alone
manner in backup power mode.
Grid
supplies the loads in the system if insufficient power is being gener-
ated by the PV modules or supplied by the battery.
19
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Operating mode
– Inverter with
battery
In order to be able to obtain the highest rate of self-consumption with your PV
system, a battery can be used to store excess energy. The battery is coupled to
the inverter on the direct current side. Multiple current conversion is therefore
not required, and the efficiency is increased.
00 1
6
7
1
Operating mode
– Inverter with
battery and sev-
eral Smart
Meters
00 1
6
7
1
00 1
6
7
2
Operating mode
- inverter with
battery, AC-
coupled to an-
other inverter
+
-
00 1
6
7
1
20