Ingeteam INGECON SUN SMART User manual

Installation Manual
Ingecon® Sun Three-Phase Inverter
Pg. 1 de 40
Ref.: AAS2000IKI02
Rev.:_ Dec-2009
Ingeteam Energy S.A.
Rev._
AAS2000IKI02
12/2009
INGECON SUN SMART
Ingecon Sun Three-Phase Inverter – Installation Manual

Installation Manual
Ingecon® Sun Three-Phase Inverter
Pg. 2 de 40 Ref.: AAS2000IKI02
Rev.:_ Dec-2009
Ingecon® Sun Three-Phase Inverter – Installation Manual
Table of Contents
Page
Note: Because of the continuous evolution of its products,
Ingeteam Energy S.A. reserves the right to update
and modify this manual without prior notice.
1. Introduction ...........................................................................................5
1.1 General Remarks on Safety ................................................................................5
1.2 Description of the Activities on the Device...........................................................7
2. Assembly...............................................................................................8
2.1 Delivery and Unpacking.......................................................................................8
2.2 Location ...............................................................................................................9
2.3 Disposal ............................................................................................................. 11
3. Electrical Connection ..........................................................................12
3.1 Opening the equipment and access ..................................................................13
3.2 Earth Fault Contact / Grid Connection Indicator ................................................14
3.3 Access to Auxiliary Connections........................................................................14
3.4 GSM / GPRS - Modem communication connection...........................................15
3.5 RS-485 line - Communication connection .........................................................15
3.6 Ethernet - Communication connection...............................................................15
3.7 Optical Fibre - Communication connection........................................................15
3.8 Ground connections...........................................................................................15
3.9 Connection to the Power Grid............................................................................16
3.10 Connection to the PV array................................................................................17
3.11 Prior to start up ..................................................................................................18
3.12 Hermetic seal.....................................................................................................18
4. Start-up ...............................................................................................19
4.1 Equipment checking ..........................................................................................19
4.1.1 Inspection..........................................................................................................................19
4.2 Power up............................................................................................................20
4.2.1 Adjusting the settings ...........................................................................................20
4.2.2 Starting up............................................................................................................20

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5. Uninstalling the inverter.......................................................................21
6. Preventive Maintenance......................................................................23
6.1 Maintenance Procedures...................................................................................23
7. Using the display and keyboard ..........................................................25
7.1 Keyboard ...........................................................................................................25
7.2 Display ...............................................................................................................26
7.3 Main Menu .........................................................................................................27
7.4 Monitoring ..........................................................................................................27
7.5 Stop reasons......................................................................................................30
7.6 Adjustments .......................................................................................................31
7.7 Inverter data.......................................................................................................31
8. Troubleshooting...................................................................................32
8.1 LED indications..................................................................................................32
8.1.1 Green LED ...........................................................................................................32
8.1.1.1 Flashing slowly................................................................................................................32
8.1.1.2 Flashing quickly...............................................................................................................32
8.1.1.3 LED remains on ..............................................................................................................32
8.1.2 Orange LED .........................................................................................................33
8.1.2.1 Flashing quickly...............................................................................................................33
8.1.3 Green LED ...........................................................................................................33
8.1.3.1 LED remains on ..............................................................................................................33
8.2 List of the Alarms and shutdown reasons ..........................................................35
8.3 Inverter alarms caused by protections...............................................................36
8.4 Disconnection from the Grid ..............................................................................36
8.5 Replacement of the ‘Electronics Block’..............................................................37
8.6 Replacement of the Control Board ....................................................................38
8.7 Replacement of Varistors in the Measure Boards .............................................38

Installation Manual
Ingecon® Sun Three-Phase Inverter
Pg. 4 de 40 Ref.: AAS2000IKI02
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Installation Manual
Ingecon® Sun Three-Phase Inverter
Pg. 5 de 40
Ref.: AAS2000IKI02
Rev.:_ Dec-2009
1. Introduction
Carefully read this manual and carry out the installation in conformity with the instructions
provided.
1.1 General Remarks on Safety
The operations described in this manual must be performed exclusively by duly
qualied operators, especially trained to work on electrical installations and having
a suitable knowledge of this manual and of the wiring diagrams attached to the
switchboard (hereafter the ‘qualied personnel’). Risk of electric shock!
The system voltage is not automatically switched off upon the opening of the com-
partment coverings. Therefore, only qualied personnel is authorised to access
those areas following the safety provisions described in this manual.
The safety provisions described herein represent the minimum level of protection
to be ensured. For a higher safety level we recommend to disconnect the main
power supply and to test for the absence of voltage. The system may be subject
to unexpected current returns. Risk of electric shock!
Beside the safety provisions described in this manual, the user must also comply
with all the applicable regulations related to the type of plant, Country, etc.
Please make sure that the company charged of the installation carries out the
work only with qualied personnel.
Per qualsiasi intervento sul dispositivo, l’impianto deve essere disinserito dalla
tensione.
The system must be disconnected from the power supply any time it is
necessary to work on the device.
Attenzione.
Non aprire. Solo personale autorizzato.
Caution.
Do not open. Only authorized operators

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In order to provide a minimum level of safety, the operators must always comply
with the ‘5 golden rules’:
1. Disconnect the power supply
2. Make sure the system cannot be powered on unexpectedly
3. Test for absence of voltage
4. Earth and short-circuit the system
5. Protect yourself against any energised device in close proximity and mark
the working area with safety panels, if necessary.
Before these operations have been carried out, the system is to be considered as
energised and nobody should be allowed to work on it.
To test for absence of voltage it is compulsory to use measuring instruments of Class
III - 1,000 Volt.
Ingeteam Energy, S.A. cannot be held responsible for any damage arising from any
improper use of its products.

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1.2 Description of the Activities on the Device
INSPECTION: This kind of intervention involves opening the covering to carry out a
visual inspection.
MANOEUVRE: Any activity related to software loading, testing of the warming/cooling
systems and corrective maintenance on the system (except on the switchboards) carried
out by means of the operator-machine interface.
MANIPULATION: Any activity of assembly and/or replacement of components, as well
as any change to the calibration settings of the protection devices.
The following provisions must be considered when performing an activity of inspection,
manoeuvre or manipulation:
The Ingecon® Sun devices can be opened exclusively by authorised personnel
during installation and tuning operations.
A serious risk of electric shock exists even after the device has been disconnected
from the electric grid and photovoltaic panels. Wait at least 10 minutes to allow
the system to discharge its natural capacitance.
The use of the following Personal Protection Equipment (PPE) is compulsory:
- Dielectric gloves compliant with the system’s voltage.
- Gloves for protection against mechanical hazards.
- Approved safety goggles for protection against electrical hazards.
- Safety shoes.
Never touch the radiator located behind the system’s Electronic Block, since it
may reach extremely high temperatures.
When handling the device, remember that:
It is forbidden to handle the device when a source of power supply is still connected
to the system.
Always carry out a test to ensure that there are no electric contacts between the
grid or any of the photovoltaic panels and a component of the device.
Always wear safety gloves.

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2 Assembly
General Provisions:
The Ingecon® Sun Inverter must be installed by qualied personnel only, in
conformity with the general provisions on safety described herein. The Inverter
works under currents and voltages that may be dangerous to the operators.
In case of high level of humidity or excess of condensation water inside the device,
dry it carefully before carrying out any electric connection.
2.1 Delivery and Unpacking
Delivery
Upon delivery of the device, check the details on the delivery note, ll out the RECIPIENT
SIGNATURE eld and return it to the sender’s address.
The following table shows the specications of the packing pallets:
Device handling
The following provisions strictly apply to any handling operation of the device
outside the factory premises.
In case of non-compliance with these provisions, the warranty may become null
and void without any responsibility of INGETEAM.
The Inverter must be placed VERTICALLY, even in case it is necessary to return it to
the factory.
Avoid collisions and brisk movements.
Use a fork lift to transport the device.
Follow the basic provisions below:
1. Unscrew the front and rear covers of the base (never unscrew the side ones).
2. Insert the forks at their maximum width under the cabinet.
3. Insert the forks until they come out the opposite side of the cabinet, so as to ensure
the stability of the device.
4. Make sure the forks are correctly levelled to prevent the device from tilting.
5. After placing the device in its denitive position, re-install the base covers.
MODEL PALET TYPE WEIGHT
(Kg)
HEIGHT/WIDTH/LENGTH (mm)
20 kW , 25
kW y 30 kW
Wooden:Bubble
wrap and woo-
den box
340 1300 / 750 / 600

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IIdentifying the equipment
The serial number clearly identies the inverter. All communications with Ingeteam
S.A. should indicate this number..
Damage during transport
Should the equipment sustain damage during transport:
1) Do not install it
2) Immediately notify your distributor of this situation within a 5 day period from the
reception date.
Should it be necessary to nally return the equipment to the manufacturer, the original
packing should be used.
Separate packing waste
All packing waste can be given to an Authorised Manager for not-dangerous disposal.
Anyway, each part of the packing will be:
Wood (box, palets, corners): Authorised Manager for not-dangerous disposal..
Plastics (bag and bubble wrap): Adequated Collection Service container
Cardboard: Adequated Collection Service container.
2.2 Location
Dust free air must be provided in the enviroment of the equipment. Adequqted air quality,
temperature and humidity will be asured.
Leave at least 20 cm of clear space around the equipment to allow the free circulation of air.
The Ingecon®Sun Three-phase inverters are equipped with fans. These fans will rotate
for a few seconds when the grid connection is made.
This routine offers a simple means of allowing the installer to check the fan operation.
It is forbidden to leave any object on the equipment
Locate the equipment in a particle free environment to prevent the ingress of
particles through the vents.
Serial number
Avda. Ciudad de la Innovación, 13
31621 Sarriguren (Navarra)
ESPAÑA
solar[email protected]
Tel [phone]
Fax [phone]
Ingecon®Sun 25 IP 54 2009
Pac: 25 Kw Udc: 405 - 900 Vdc
Uac: 3 X 400 Vac Fac: 50 Hz
S/N 011070411C88
Std:
015070411C88

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Avoid corrosive enviroments.
Due to its considerable weight, the equipment needs to be positioned on a rm and
completely horizontal oor.
If the equipment is seated over a pit to house the cabling conduits, then the equipment
base must rest on the largest possible area of rm ooring without creating any mechanical
stress in the equipment structure.
The inverter should be located in an environment with an ambient temperature of
between -10 to 45ºC.
The equipment is designed for maximum performance in these temperature conditions.
At higher temperatures the equipment will limit its power output.
During operation, the inverter will make a slight buzzing noise.
Do not locate the inverter in an occupied room or on supports that could amplify
this buzzing noise.
Install the equipment in a place that is easily accessible for installation and
maintenance work and which offers sufcient space for personnel to operate the
keypad, read the display and access the inverter interior.
Anchoring
Ingecon®Sun Three-phase inverters can be equipped with an optional sujection system.
This system consist on metal plates that are screwed to the four corners of the plinth
and to the concrete slab where the inverter is located.
In following picture, shape and way of installation of this plates in the enclosures of 10
to 15 kW.
Facilitate the circulation of incoming air through the vents and through the lower
pit, if present, and also the outgoing air through the upper vents.

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Following screwing prescriptions are mandatory:
- Minimun distance between the center of thedrill on the concrete slab to its borders
of 72 mm.
- Diameter of the drill on the concrete slab to its borders of 8 mm.
- Minimun depth of thedrill on the concrete slab of 65 mm.
- Minimun thickness of the concrete slab of 100 mm.
- Torque of 20 Nm.
- Minimun depth of the screw of 45 mm.
45 mm.
65 mm.
100 mm.
72 mm.
2.3 Disposal
At the end of the useful life of the equipment, the waste must be given to an Authorised
Manager for disposal.

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3. Electrical connection
Once the equipment has been mounted in its denitive location, the electrical connections
can be made to the auxiliary equipment, the Power Grid and the PV array.
The Ingecon® Sun inverter electrical connection must be made by qualied person-
nel, observing the general safety conditions set out in this manual. The inverter
operates under hazardous voltages and currents.
The basic inverter connections should be made in the following order:
Connection of the insulation failure detection switch (optional)
Connection of any auxiliary equipment (optional)
Communication line (optional).
Earth connection. See the «Earth connections» section.
Inverter connection to the Power Grid. See the «Power grid connection» section.
Connection to the PV array. See the «PV array connection» section.
Contactor
DC voltage surge
arresters
(OPTIONAL)
Inverter
Transformer
AC voltage surge
arresters
(OPTIONAL)
Fuses
+
-
+
+
+
-
-
-
PV Input
3 X 400 Vac 50 / 60 Hz
L1
L2
L3
filter
N
+
+
-
-
DC Breaker
(OPTIONAL)

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3.1 Opening the equipment and access
Before opening the front door, make absolutely certain that there are no live voltages
inside the cabinet.
For this, the equipment needs to be disconnected from the PV array and from the power
grid.
LIkewise, it is essential to close the equipment before connecting it to the PV array or
power grid.
For Inspection, Operation or Manipulation tasks:
Make an electrical check to ensure that no part of the equipment is in electrical
contact with either the grid or any of the PV panels.
The use of safety gloves and glasses homologued for electrical risk is compulsory
to ensure lack of voltage.
After disconnecting the equipment from the PV array and power grid, wait at least
10 minutes before opening the door. Due to its internal capacitance, the inverter
may maintain hazardous voltage levels.
Whilst the panels are receiving light, the DC cables may be under hazardouse
voltage levels.
Inverter access
All the cables access the unit through the PG cable glands located in the cabinet base
as indicated in the following drawings. If quick connectors option is chosen, they are
located on the base too.
Wire description in following table:
base view
Description Diameter Number of holes Wire section
INPUT DC
INPUT DC C.R.
32
12.5
2
28
11-21
PV quick connector
Type3 or Type 4
OUTPUT AC 1
OUTPUT AC 2
25
40
4
1
9 - 17
19 - 28
GROUNDING 25 1 9 - 17

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3.2 Earth Fault Contact / Grid Connection Indicator
The inverter is equipped with a normally-open potential-free contact, which can perform
one of the following two functions:
Insulation failure detection in the DC circuit.
- contact open: no insulation failure in the DC circuit
- contact closed: insulation failure in the DC circuit
Indicator to show that the unit is connected to the power grid by means of its internal
contactor.
- Contact open: the internal grid connection contactor is open, the inverter is not
connected to the power grid.
- Contact closed: the internal grid connection contactor is closed, the inverter is
connected to the power grid.
The equipment always takes measure of the Earth Fault although the contact is used in
Grid connection indicator function.
The equipment is factory congured to perform one or other function; the function
option must be expressly requested when the order is sent to Ingeteam Energy S.A.
The normally open contact admits a voltage of 230 Vac and a maximum current of 10 A.
The contact is accessed through the cabinet side PGs.
3.3 Access to the auxiliary connections
In some PV installations the inverter needs to be connected to auxiliary equipment such
as solar radiation sensors, thermal sensors, anemometers, etc.
Consult the communication accessory installation manual «AAX2002IKI01
Communication accessories Installation Manual.»
For enhanced operation, the cables transporting these auxiliary signals should
be kept at a distance from the power cables.
In these models the auxiliary signals are directly connected to the analogue input card
«AAP0016 Tarjeta de Entradas Analógicas».
Consult the communication accessory installation manual «AAX2002IKI01
Communication accessories Installation Manual.»
N.O.
X1.1 X1.2

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3.4 GSM / GPRS - Modem communication connection
At the installer’s request, optionally, the inverters may incorporate hardware to enable a
GMS / GPRS communication link to be established with the inverter.
Consult the communication accessory installation manual «AAX2002IKI01
Communication accessories Installation Manual.»
3.5 RS-485 line- Communication connection
At the installer’s request, optionally, the inverters may incorporate hardware to enable
communication through an RS-485 serial line.
In all these units, the auxiliary signals are directly connected to card «AAP0022 Com
RS-485»
Consult the communication accessory installation manual «AAX2002IKI01
Communication accessories Installation Manual.»
3.6 Ethernet- Communication connection
At the installer’s request, optionally, the inverters may incorporate hardware to enable
communication through Ethernet.
Consult the communication accessory installation manual «AAX2002IKI01
Communication accessories Installation Manual.»
3.7 Optical Fibre - Communication connection
Upon the installer’s request and as an option, a hardware component for
communication via optical bre can be installed on the Inverter.
On all these devices, the auxiliary signals are connected directly to the ‘AAP0009
bre optics’ board.
3.8 Ground connections
The metal parts of the inverter (equipment ground) are electrically connected to the
ground plate located on the lower right side of the equipment.
To guarantee personal safety, this point must be connected to the installation
ground bar.
Grounding

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3.9 Connection to the Power Grid
The ports for the Power grid connection cables are located either on the cabinet side
or base.
If the distance between the inverter and the Grid connection point requires the use of a
greater cable section, then the use of an external distribution box, located close to the
inverter, is compulsory in order to change from one section to another.
The cable section shall always be based on the equipment power rating.
The inverter protections at the grid connection support a short-circuit current of up to
70 kAmp.
Prior to any manipulation, check that there is no electrical hazard at the power
input from the grid.
The use of safety gloves and glasses homologued for electrical risk is compulsory to
ensure lack of voltage.
These models are equipped with a three terminal bi-metal connector (three phases with
neutral) for connection to the power grid.
The maximum permitted section for these terminals is 50 mm2each phase.

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3.10 Connection to the PV array
The cables connecting the equipment to the PV array access the unit through the PG
cable glands located on the cabinet sides or base.
Prior to any manipulation, always check to ensure there is no electrical hazard at
the PV array voltage input.
Never forget that any incident light on the panels generates voltage at the panel
terminals.
Therefore the inverter interior may hold voltages of up to 900 volts even when
not connected to the Grid.
The use of safety gloves and glasses homologued for electrical risk is compulsory to
ensure lack of voltage.
Caution:
Connect the positive pole of the string of panels to the terminals marked +, and
the negative pole to the terminals marked -.
If the distance between the inverter and the PV array connection point requires the use
of a greater cable section, then the use of an external distribution box, located close to
the inverter, is compulsory in order to change from one section to another.
The connection of these models to the PV array is made through 2 terminals with
a maximum section of 50 mm2 .
This type of connection ensures that the installer makes a safe disconnection between
the inverter and PV array.
If the installer decides to take the option of including quick connectors, there will
be 14 pairs of terminals for push-in cables located on the base of the enclosure of
the equipment. When the option is ordered, it has to be especify what type, type 3 or
type 4 quick connectors are required.
If the installer decides to take the PV array directly to this terminal strip (without
using quick connectors) it is highly recommended to install a prior breaker element.

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3.11 Prior to start up
The INGECONSUN SMART inverters are equipped with a series of MT breakers
that protect different parts of the unit. Before the installation can be started up, these
breakers need to be closed.
Prior to manipulating the MT breakers in any way, rst check that there are no
electrical hazards in the unit interior.
The use of safety gloves and glasses homologued for electrical risk is compulsory to
ensure lack of voltage.
Make sure that Q1, Q2 and Q3 MT breakers are in ON position:
3.12 Hermetic seal
During installation, it is important to ensure that the unit’s IP rating is maintained.
For all connections through the PG cable glands, allow sufcient cable length inside the
equipment to ensure that there is no pull on the electric terminals inside.
Check that any unused ports are hermetically sealed.
Safety measures
The front door should be only opened after disconnecting the inverter from the grid and
PV array.
Likewise, it is essential to close the unit before connecting it to the PV array or grid.
If thre is no alarms, after the waiting time, the inverter will begin magnetizing the
transformer producing a soft buzzing. Then, it will connect the grid and search the MPPT.

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4. Start up
The inverter may only be started up once all the connections indicated in the
previous section have been made and once the unit has been perfectly sealed.
4.1 Equipment checking
The INGECONSUN SMART elements are protected by MT brakers. Make sure they
are closed prior to start up.
Prior to any manipulation on MT breakers, check there is not electrical hazard. To
check that no voltage is present, it is mandatory to use: class III - 1000 Volt testing
devices, and recommended protection equipment.
4.1.1 Inspection
Prior to the inverter power-up, a general inspection of the equipment should be made,
primarily consisting in:
· Cabling inspection:
- Check that there are no loose cables
- Check that the cables are in good condition and that there are no nearby hazards
which could lead to the deterioration of the cables, such as intense heat sources,
sharp objects or devices which could impact against or pull on the cables.
- Check that all protection devices are in ON position.
- If AC surge arresters has been ordered, make sure they are correctly inserted
on their base, and that their status indicator is not red..
It’s forbiden remove methacrylate protections to make this inspection.
· DC module:
If DC surge arresters option has been chosen, make sure they are correctly inserted on
their bases and their status indicator is not red.
· Electronic block module:
- Check that MT breakers are closed.
- Check that DC fuses are correctly installed.
· AC module:
Las comprobaciones a realizar en el módulo de salida AC son las siguientes:
- Check that MT breakers are closed.
- Check that AC fuses are correctly inserted on their bases.
- If AC surge arresters has been ordered, make sure they are correctly inserted
on their base, and that their status indicator is not red.

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4.2 Power up
Once you have made a general visual inspection, checked the cabling and ensured that
the unit is sealed correctly, you can then proceed to power up the equipment, whilst
maintaining it in the stop position. Follow the guidelines set out in the equipment-specic
instruction manual.
When performing the tasks indicated in this point, it is mandatory to ensure that the
equipment is sealed, thereby avoiding any possible contacts with live parts without IP5X
protection.
4.2.1 Adjusting the settings
Check that the equipments starts up. Red LED remains on because Manual Stop is
activated.
Check that the values of AC and DC voltages in Monitoring menu. They should be:
340V ≤ Vac1, Vac2, Vac3 ≤ 440V
400 ≤ Vdc ≤ 900
Vdc shows the value of DC actual voltage. Pressing OK while selecting this value it is able
to see the Positive PV array Voltage (PPV) and the Negative PV array Voltage to Earth
(NPV) to check that PV array is correctly balanced, and it don’t has any earth fault contact.
Check there is not any alarm apart of Manual Stop: Alarm 1000H.
4.2.2 Starting up
Once described actions have been completed, proceed to start up the equipment.
- Change to Start Inverter from the display and keyboard. Red LED will switch off, and
green LED will begin flash.
- After one minute, the circuit will be connected authomatically, and the fans will start up
for a few seconds.
Green LED will remain on, and when checking the alarms, there won’t be any of them,
showing 0000H, that means there is no alarm.